Join Date: Apr 2010
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Got car started last night and runs good, no cels so far, ended up using the gutted Mazda 6 pre-cats, putting headers on soon anyway, no cels so far, thanks for all the help. Here's a list of what I swapped and re-used:
-2009 Fusion block didn't change anything internally.
-Air induction system: Using an AEM CAI with original 2006 Mazda 6 MAF sensor, cleaned with MAF cleaner.
-TB swapped from 2006 Mazda 6 after a good cleaning
-Upper intake from 2009 Fusion, the 09 Fusion intake has slight upward angle at the TB compared to the 2006 Mazda 6 intake but with the CAI this was not an issue for me. Used this intake because it was spotless clean and my old one had residue from oil and most likely catalytic material, so I was lazy and used the clean one.
-Lower intake from 2009 Fusion
-Fuel rail and injectors from 2009 Fusion
-Front cover with all sensors and pulleys (timing cover) swapped from 2006 Mazda 6
-Valve Covers swapped from 2006 Mazda 6 only because I wanted engine cover to fit, and I didn't have a complete set of the fusion spark igniters, this is optional and you can keep the fusion valve covers if you wish. Just check the OCV seals and replace them if they are bad
-Oil Pressure sensor swapped from Mazda 6
-OIL PAN kept the 2009 Fusion pan, the 2009 pan looks identical to Mazda 6 pan, cannot speak for other years, exhaust fit perfectly, did put in a new seal and cleaned out pan while I had it off. Did not change oil pick up tube, left Fusion one in place.
-EGR valve 2006 Mazda 6, Fusion one is missing tiny vacuum fitting
-PCV valve 2006 Mazda 6
-Pilot guide for clutch swapped from 2006 Mazda 6 (some refer to this as pilot bearing but actually it's just a round locator guide for your clutch alignment tool, not an actual bearing just a large solid metal insert that fits into the crank end and has a hole centered in it to fit the nose of the clutch alignment tool). Some say it's not needed but I swapped it in anyway to make clutch alignment easier, trans slipped right on without any hassle.
Hope this info can help someone else doing the 09 fusion Swap to an 06 Mazda 6
Note all gaskets were replaced with new Felpro gaskets
Thanks to everyone who contributed information to this project, now off to have some fun before I have to put on my snow tires, ZOOM ZOOM!