I have committed to a 2.5L swap into my 2009 2.3L manual hatch. Reason for needing an engine is here: https://www.mazda3forums.com/122-stock-issues/766546-oil-filter-cap-failure-leads-seized-engine.html
I sourced a 2012 2.5L from an Escape. I am trying to follow along various DYI's but given that I am not a mechanic some things are over my head. I did brakes, oil changes, suspension, a singe cam swap once on a Golf, but never did any tranny, engine removals, clutches or other engine work. Hoping there are more experienced folks that can help out.
I am using the following resources as the roadmap (No particular order). KUDOS and Thanks to the folks before me. I would not have attempted this if it was not for these fantastic people that documented their knowledge for others.
http://www.happywrenching.com/mazda/6/mazda-6-and-ford-fusion-23l-engine-swap.html
https://www.mazda3forums.com/61-powertrain-2004-2009-mazda3/758761-tonyguns-2-5-swap-experience.html
https://www.mazda3forums.com/61-pow...a3/764362-2-3-2-5-lessons-learned-2019-a.html
https://www.mazda3forums.com/61-powertrain-2004-2009-mazda3/692793-how-mazda-ford-2-5l-swap.html
https://www.mazda3forums.com/61-pow...3/764604-2007-mazda-3-2-5l-swap-question.html
https://www.mazda3forums.com/61-powertrain-2004-2009-mazda3/647562-04-2-3l-swap-2-5l-successful.html
https://www.mazda3forums.com/123-modifications/587650-06-2-3l-10-2-5-engine-swap.html
My notes on Engine removal:
Engine removed:
Random Observations:
[*]Intake Manifold -> Both original and the donor engine intake manifolds are very dirty with oil/exhaust residues.
Mazda 09 2.3L vs 12 Escape 2.5L Observations:
Next up
I sourced a 2012 2.5L from an Escape. I am trying to follow along various DYI's but given that I am not a mechanic some things are over my head. I did brakes, oil changes, suspension, a singe cam swap once on a Golf, but never did any tranny, engine removals, clutches or other engine work. Hoping there are more experienced folks that can help out.
I am using the following resources as the roadmap (No particular order). KUDOS and Thanks to the folks before me. I would not have attempted this if it was not for these fantastic people that documented their knowledge for others.
http://www.happywrenching.com/mazda/6/mazda-6-and-ford-fusion-23l-engine-swap.html
https://www.mazda3forums.com/61-powertrain-2004-2009-mazda3/758761-tonyguns-2-5-swap-experience.html
https://www.mazda3forums.com/61-pow...a3/764362-2-3-2-5-lessons-learned-2019-a.html
https://www.mazda3forums.com/61-powertrain-2004-2009-mazda3/692793-how-mazda-ford-2-5l-swap.html
https://www.mazda3forums.com/61-pow...3/764604-2007-mazda-3-2-5l-swap-question.html
https://www.mazda3forums.com/61-powertrain-2004-2009-mazda3/647562-04-2-3l-swap-2-5l-successful.html
https://www.mazda3forums.com/123-modifications/587650-06-2-3l-10-2-5-engine-swap.html
My notes on Engine removal:
- Entire front end is unbolted - went ok. Some don't do it but I decided I wanted the extra working room. Already paid for itself dealing with all the coolant hoses and electrical clips under the Intake manifold.
- Removal of the coolant hoses -> bit of work as the hose dries onto the plastic ends....I damaged one of the hoses trying to get it off
- Disconnecting the wiring from the engine - that is a pain! Some clips are so hard to get at the release tab! And those clip-in clips that hold the wiring in place are such a royal pain to remove! I spent multiple hours just unclipping. NOT fun at all. Did not count, but I'd guess in total there are about 20 or so connectors, and another 20 of those wire clips to deal with. Under 10 or so grounding wires to remove. I have a few more clips that I have to get to under the engine.
- Shifter linkage -> How exactly do you remove it? I can't see anything that unclips. Do I just force the end of the cable off the little ball? ANSWER: They just pry off.
- Clutch actuator (don't know the proper name) -> Do I remove just the two bolts that hold the actuator in place and remove it off the tranny casing or do I actually have to remove the hard line and keep that part on the tranny case? (Sorry not sure why image rotated 90 deg and how to fix it) ANSWER: Removing the bolts worked, No need to disconnect the line.
- The hose going into top of Manifold (other end into the master cylinder it looks like) -> Is that just a vacuum line and How does that come off - can't figure how that connector works. I can't see any levers or things to push. (Sorry not sure why image rotated 90 deg and how to fix it). ANSWER: Held in by an O-ring, so pulling/prying straight up worked.
- Exhaust manifold -> Do I need to remove any of the heat shields to get at the bolts? Or is all that done from under the car? ANSWER: Yes, Need to remove heatshield to remove the exhaust manifold. No joint exists in the donwpipe that can be undone like other cars (and the donor engine).
Engine removed:
Random Observations:
[*]Intake Manifold -> Both original and the donor engine intake manifolds are very dirty with oil/exhaust residues.
Mazda 09 2.3L vs 12 Escape 2.5L Observations:
- Exhaust manifold - Both heads have the same size ports (was expecting 2.5L to be bigger like the intake). Manifold has different shape & different material.
- Oil Dipstick - longer on Ford.
- The thing on the side of the block Ford does not have a sensor in it and Mazda does. I guess I'll be swapping this. Anyone know what the sensor is?
- Front Engine Cover, other than the engine mount bracket (that has the extra stud on it), I can't find any differences. Not planning on swapping but will remove the extra stud.
- As others have stated, water pulley are different size and need to be swapped.
- Ford's PVC valve and hose is different. Since I'm using the stock 2.3 intake manifold I plan on using the Mazda's hose. I will buy a new valve just in case as it is hard to get to replace later. Purple valve is Ford.
- The thermostat cover pipes are different. Mazda's are longer, Ford is shorter. But I'm not changing them. UPDATE: Ford's won't work as the hose kits the alternator. Turned out the angle is also different. Had to swap out to the Mazda one.
- Oil filters are different. Since the Mazda cartridge cover wrecked my current engine (see https://www.mazda3forums.com/122-stock-issues/766546-oil-filter-cap-failure-leads-seized-engine.html), I'm using the old school can that comes on the Ford. Will use the Mazda sensor.
- VVT Solenoid plug points the other way on the ford (towards center of valve cover). Plan to use Ford's unless existing wiring won't reach, then will swap for the Mazda one.
- Oil Pickup is different (Mazda goes deeper than and in a slightly different location). Mazda is the thin one, Ford is the thick one. Last picture shows a caliper set to the Mazda height, so it shows how much shallower the ford one is.
- Spark plugs look the same but part numbers are different. I'm going to take a chance on the Ford ones (buying new ones). Ford on the left.
- Coil Packs. Mazda is 3-pin square ones, Ford is 2-pin round ones. Plan on using Mazda ones due to existing harness and use of the Mazda valve cover.
- Injectors are different (black on Ford, Blue on Mazda). Plan on using the Ford ones.
- Valve Cover is different, well covered in the above links so not covering here. I am buying a new Valve cover gasket and re-using the Mazda one.
- Oil Pan & Intake manifold is different, well covered in the above links so not covering here.
- Side motor mount was ripped in half - looked at it many times but I guess you can't tell with engine's weight on it. So replacing all the mounts
- Clutch and flywheel look done so might as well replace now
- My front heat shield is completely disintegrated (you can see the insulation-like scrap on the side of the pipe. Will be replacing with new shield.
- Could not stand the salty residue on the block. So spend a day wire wheeling, taping, de-greasing and painting the head, block and oil pan.
Next up
- Move all the components from old engine to new and prep for re-install
Attachments
-
350 KB Views: 132
-
305.2 KB Views: 116
-
383.5 KB Views: 116
-
314.4 KB Views: 113
-
563.7 KB Views: 37