Picked up a 2008 5 for my daughter in law to replace her aging Grand Caravan and wouldnt you know it the HG let loose on the way home from buying it. Maybe the guy knew, maybe he didn't but it is what it is and we got it cheap enough in todays market that its worth putting some time and money into it.
Compression test confirmed the gasket was blown between cylinders 2 and 3 with low compression in 1 and 4 so off came the head. It didnt look too bad but did see some light cylinder scoring on #1 that I wasnt happy with. Decided at that point a lower mileage engine would probably be more cost-effective than fixing this one.
car-part.com indicated the complete engine in our 5 was the same as an '06-09 3 and the best deal around seemed to be a 95K mile engine for $1100. I then found the threads here about the 2.5 swap into the 3. Same engine, so why not? After a lot of research I purchased a 2015 Fusion 2.5 with 21K on it for $450.
Not done yet - new engine is on the stand and reassembly has started. What I have hit so far:
Compression test confirmed the gasket was blown between cylinders 2 and 3 with low compression in 1 and 4 so off came the head. It didnt look too bad but did see some light cylinder scoring on #1 that I wasnt happy with. Decided at that point a lower mileage engine would probably be more cost-effective than fixing this one.
car-part.com indicated the complete engine in our 5 was the same as an '06-09 3 and the best deal around seemed to be a 95K mile engine for $1100. I then found the threads here about the 2.5 swap into the 3. Same engine, so why not? After a lot of research I purchased a 2015 Fusion 2.5 with 21K on it for $450.
Not done yet - new engine is on the stand and reassembly has started. What I have hit so far:
- The intake manifold from the 5 does not fit perfectly on the Fusion head. All the bolt holes line up but the Mazda 5 manifold sits a bit low and the gasket doesnt line up perfectly. I purchased this intake adapter on ebay Mazda 3 6 Fusion 2.3 to 2.5 engine swap 1/8" intake manifold adapter + GASKET | eBay and its just what the doctor ordered. I did paint it black to make it not so obvious when I go in for inspection. It looks factory.
- I was hoping to keep the spin-on oil filter adapter from the Fusion but I cant do that because the 5 has the transmission cooler plumbed into the filter adapter where the Fusion has a seperate transmission cooler located in front of the radiator. Oh well.
- Have to use the 5 valve cover and the VVT solenoid in the Fusion is smaller in diameter than the old Mazda one. The seal in the valve cover is removable - ordered a Mahle replacement and it should be here today. Have to use the VVT connector from the Fusion as well. They cut it pretty short at the salvage yard, I may need to buy a new one - they are available.