Ooh wait.....I forgot option #5(you may need a sawzall for clearancing though).

http://beta.atpowerthrottles.com/product_info.php/ford-duratec-itb-ecu-throttle-body-kit-p-93

 

Thanks for finding this. Furthers my thoughts that a regular Mr.Gasket gasket sheet will work.

 

But you were planning on running just a gasket-not the adaptor plate?

 

One of the best things about the 2.5 swap is getting rid of the god awful 2.3 manifold, I couldn't imagine going through any type of 'effort' to keep.

Get Karl's cable throttle body adapter for the 2.5 manifold or put a Cosworth/knockoff on it. A custom manifold will flow significantly greater and also cost a lot more, the Cossie will work fine and with the 2.5 will make for a nice broad torque plateau.

- Drew

 

Well,it appears the guy on the fusion forum was only using his original 2.3 manifold, because his donor engine didn't have the controls on the manifold he needed for emissions.
He apparently didn't feel there was enough sealing surface, with the port mismatch, to seal properly.
So he made the adapter plate.
If you were going to try the Cosworth manifold, maybe before porting you could weld some material to the top of it for additional sealing surface and then have it ground flat again?

 

Karl has some good info all together on his forum about the 2.5 swap.
He has some experience with this swap so should know his stuff.
I thought about going the ported Cosworth manifold way, but I don't know if I want to be the guinea pig there.
Karl is not a fan of this idea.
Apparently if I pick the right donor intake, my wiring plugs will hook up to it to run its flaps etc.

Honestly, other than passing smog I rather get rid of all that crap.
If you could port the Cosworth,I wonder how it would flow compared to the stock 2.5 manifold.....

 

Here's the massive swap info link:

http://massivespeedforums.com/reply/44240952

 

Yeah I've talked to Karl. Its not ideal for the 2.5, but I really don't want a dual stage intake. I'll be the guinea pig in the spring. We'll see how it goes.

 

Hey 408wkash, spring has sprung,and summer is almost over even-any updates?

Wondering if you got the cossie style mani to work with the 2.5...

 

Awesome info. Massive's lowdown on their site is great. Not to dirty this thread, but how do the 2.5 valve diameters compare to the 2.0/2.3?

 

Thats a good question.
2.0 and 2.3 valve head diameters appear to be the same but I'm not finding any valve specs online
for the 2.5 I-4.

 

It is thin, but i think a gasket should still seal. I think back to my dads stock 5.0 intake that was square ported, and its about the same size and it sealed.

 

I really hope you are right.

Hey....it's 10 days till spring!

And Focaljet duratec moderators...can we get an updated title under Duratec tuning?

The 2.3 may be "powerful"...but new it ain't.


And let's get some 2.5 love mentioned in there...
well .....yeah a focus never came with one...

Maybe "....and 2.5 engine swaps" at the end?

 

Rallyrs I've open my 2.5 engine (euro spec) the valve size are the same of the 2.0

 

Boost is the answer.:evilgrin:

 

2.5 gasket,laid on a 2.3 cossie knock off.

 

2.5 gasket,laid on a 2.3 coosie knock off.

Look who's back!

Thanks for the picture, that answers some big questions.

 

I've been around. Just been lying low...lol. But yeah,hope that pic helps out.

 

Hey man sorry ive been so busy trying to get the car done I haven't been paying much attention to the forum lately. The swap is done and together. Not running as of yet, having pats issues from going zetec-duratec.

I made a gasket out of gasket material, laid a bead of black silicone along the intake around the ports, and on the back side of the gasket to the head. Again, has not been tested, but there is no reason why it shoudn't work. I look at a mustang gt40 intake or a stock intake square ported, and there is minimal gasket material there. If the intake was passing fuel and coolant it would be slightly more worried.

 

Hey thanks for the update!

So in that pic you posted, we are looking at a Cossie knock off, ported into the o-ring groove to match up to the
2.5 cylinder head intake ports.. right?

 

Yes correct. Maybe slightly larger than the port itself. Ever so slightly. When I put the intake on the head, you could actually see the outline of the bottom of the port. Saw this online as well. Someone posted a picture on a 2.0/2.3 that is, on a real cosworth. So out of the box it is slightly larger on the bottom and sides. So i made it slightly larger all around. What I did really was just remove the o ring groove, to make the port itself as large as possible, so it does not have to taper. Considering they are small to begin with.

 

Nice..I can't wait to see how your car runs.

What are your zetec to Duratec issues?

 

I was having pats issues, so it would not turn over. Swapped in a matching cluster/ecu/steering column & keys and it turns over. Ran for about 10 seconds lol. I have no communication at the OBDII port so I cant change the previous turbo tune the previous owner of the ECU had. Power at the port but no communication at all. Which sucks lol.

 

That sounds like no fun....

 

I hope ur able to get it to work 408wkash. I decided to go a different route for simplicity and semi plug and play reasons. My car is an 04 with 2.3 PZEV(blown). Got me a 40k'ish 2.5 from a 10' fusion. Using a 10' Mazda6 intake manifold. Removed the tumble flaps from the mazda manifold,used all the port inserts and shaft plug from the fusion manifold. The Mazda manifold has imrc,so that part will be plug and play. I will how ever have to run a remote iac.

 

I believe foxbody 5.0's had a throttle body with built in IAC. I wonder how hard it would be to adapt that

 

I'm running a remote mount idle air control and a throttle body adapter on mine with the stock fusion 2.5L intake that has no tumble flaps. it works

 

Where did you get the throttle body adapter?