Grand Am Series
Join Date: Feb 2018
Location: Spring Hill, TN
2.3 to 2.5 modifications
Just wanted to share and show the modifications done to install the 10K miles 2015 Fusion 2.5 into my 2004 3 hatch 5 speed.
- Picture of completed swap with 2.3 cover. Note no oil cap through hole. Used Fusion valve cover so oil cap and dipstick are under the cover. Blocked off 2.3 dipstick at pan by cutting old dipstick 1/2 above block, filling the cut tube with the Toyota engine sealer I used on pan and timing cover, then crimping edge of tube shut and installing it with the sealer into the oil tube hole.
-Picture of engine with cover off showing the Fusion engine with junkyard writing on valve cover. It has their stock number with erroneous 2016 Fusion written. It is actually a 2015 as the identification on their tag on the block as well as running the VIN on the tag verified. Cost $546 out the door with no core at N&S auto parts in Nashville, TN. Came with harness. A plus as I had to splice one connector.
- Picture of VVT solenoid with Fusion connector spliced in. I believe 2013 and up have this different connector. Maybe 2012 also. Bonus if you get harness with engine. If not, you can buy the connector on Rockauto. Also, I plugged the timing cover oil passage for the old VVT setup on the 2.3 timing cover before installing it. It will seal against Fusion block with old seal but I wanted to verify there will never be a issue with pressure loss to the VVT. Just a belt and suspenders mindset.
- Picture of how I modified the purge line. Cut off old connector end and connected it with 1/4 inch fuel hose to 1/4 to 3/8 adapter going to 3/8 hose connected to modified Fusion purge valve.
- Picture of modified Fusion purge valve. Cut off about 1/2 inch of end of purge valve and separated middle of purge valve at the molded union of the purge valve. If you are looking at one you will know what I mean. Gutted the purge valve except for the metal hosing that is left as it is molded into the plastic housing. Drilled and tapped hole where the plunger originally went through and tapped it with a 1/8 npt tap. Installed a 1/8 npt threaded 1/4 inch nipple into hole with JB weld on the threads and then JB welded the two halves back together. Painted black after so it wouldn't look so obvious. Result: 2 vacuum nipples from one vaccum source so I could hook up the Tumble valve solenoid as well as the original purge line as mentioned above. Total cost: some JB weld, black spray paint and a $4.95 nipple from Ebay. Connected 1/4 inch fuel hose to nipple and then 1/4 to 3/16 adapter and then connected the vacuum hose from Tumble solenoid.
- Picture of Variable Intake Air solenoid(left) and Variable Tumble Valve solenoid(right). Notice that the valve on the left is doing nothing as there is no feedback to ECU for the actuator it controls. All the ECU needs to see is that it is hooked up to keep off CEL. I looped a piece of vaccum line to keep water/dust out. Could use caps but didn't have any. The Tumble valve(controlled shutters on 2.3 intake) is hooked up like the 2.3 except that the actuator isn't hooked to anything as the Fusion intake just has nice wide open flowing ports. The CEL stays off though because the actuator still is controlled by the ECU and still sends the on/off signal it looks for although it does nothing in reality.
I know others have done this swap and there is a lot of info on the long "2.3 to 2.5 success" thread. I just wanted to bring these things out as these are the details that I had to think and decide about as I did it. If I need to be clearer about something let me know.
There is a guy that makes adapters for some of these things to the tune of $120 to $135. What I did was almost free and I got the satisfaction of doing the fabricating myself. You can also do 2.5 Mazda intakes that still have the two working systems mentioned with the benefit of having the right port flow between intake and head(You will have to run the 2.3 shutter valve actuator as it has the proper voltage range for the ECU verses the 2.5 actuator. See other threads for the specifics). You can also run the 2.3 manifold with an adapter sold on Ebay that makes it all easy. The drawback is power loss due to the smaller 2.3 intake ports. I was originally going that route until I saw the difference between the ports in person.
Last edited by rickkari; 04-04-2018 at 04:03 PM.