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Old 11-16-2012, 12:53 PM   #1 (permalink)
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Default Help-problems with fusion eng. Swap

I bought a 03 Mazda 6S for my son. They told us that they had done an engine swap with an 06 Ford Fusion, and that all was fine, except that the check engine light had been on since the swap. Well, it's more than that..When they did the swap, they said they used the block and heads only from the Fusion and swappped everything else over from the Mazda. The car runs fine, but it will not pass CT emissions, so I can't register it. It has been at a local Mazda dealer for a month now. They are only tinkering with it when they have nothing else to do to keep the cost down, but they can't figure out the problem. I don't know the exact code that is coming up, but the car is showing that it is running lean, so it is using too much fuel. They said that they have done the computer flash and have checked EVERYTHING that could be causing it. They have even been swapping out parts from another car with no success. Has anyone else had this problem? What dumb little thing could we all be missing?
Thanks for your help...
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Old 11-16-2012, 02:46 PM   #2 (permalink)
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Lean is too much air, not enough fuel.

Need code to help, video would be better.

why would a swapped engine not pass emissions? it is the same engine, just different cosmetic stuff (see my sig if you have any more questions beyond that on how "different" they are)
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Old 11-18-2012, 10:37 AM   #3 (permalink)
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Thanks flipper. I'll try to get the codes from Mazda tomorrow. I can't help but believe that this is something simple that is being overlooked.
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Old 11-19-2012, 12:47 PM   #4 (permalink)
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Could very well be. It isn't uncommon that the most simple things (like a crack in an air line) to create all kinds of frustrations.
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Old 11-21-2012, 08:58 AM   #5 (permalink)
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Haven't gotten the codes from Mazda, (not returning calls), but these are the codes that the first, emission approved, repair shop came up with. They didn't know where to start with it, hence taken to Mazda.... V0121 Lost coomunication with anti-lock module, U0073 control module communication BUS AFF. Multi plex communication U1900. Can system communication error. U2516 Can system wiring harness open or shorted. ABS/TCS/HU/CM or instrument cluster or PCM (computer).
It's been 6 weeks now, shoveling against the tide with Mazda, going to pull the car out by Friday unless some miracle happens.
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Old 11-21-2012, 12:20 PM   #6 (permalink)
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Sounds like the wiring harness got damaged during install/removal.
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Old 11-21-2012, 05:12 PM   #7 (permalink)
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Took it home from Mazda dealer today. Also showing codes PO102-mass air flow, and PO113-Intake air temp sensor. Bottom line is that they said they have checked everything but can't find the problem. Check engine light is off now, but will come on soon again I'm sure. They also said that it wouldn;t set parameteres for the emission test after they drove it over 100 miles........
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Old 11-26-2012, 11:34 AM   #8 (permalink)
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check the wiring going to the MAFS would be the first start. may need a full scale engine harness replacement. new they go for ~2k... I had to replace one recently. should fix all of your problems. less you can sort out where the messed up wiring is.

Ps where are you located? maybe a local member could lend you a hand?
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