Shadetree Mechanic Skillfully Swaps Defective BMW X5 Engine with Vintage Ford I6

Countless amateur mechanics have been baffled—astonished, even—by German vehicles. They are simply so… meticulous. And temperamental. Bruce Mowrey decided to tackle this by replacing the 4.8-liter V8 of his 2009 BMW X5, which was a gift to him. In its stead now resides a familiar yet surprising engine: A 240-cubic-inch Ford inline-six that dates back over 50 years.

Mowrey attracted attention, including mine, when he shared a Facebook video showcasing the Bimmer with the hood opened. It’s racked up more than half a million views now, and rightfully so. I’ve observed numerous engine swaps, but never one like this.

“We took it for a spin, and if you had to stop at a long red light, it would start smoking when you took off,” Mowrey remarked about the vehicle, which was in poor condition when he acquired it. “We discovered it had faulty valve stem seals. A repair job would cost $5,200.”

And this was after its previous owner had poured nearly $9,000 into it.

Immediately, he began brainstorming various engines he could install. Mowrey informed me he’s experienced in such projects. His previous endeavor involved fitting a 3208 Caterpillar diesel engine into a 1969 Ford one-ton frame, complete with a Peterbilt cab.

“I’ve always been a fan of Ford; a small 289, 302, or something similar,” Mowrey recollected. “Then an advertisement appeared on Facebook Marketplace for this 240 paired with a transmission it had been coupled with since new.”

Ford produced a series of inline-six engines throughout the ’60s and ’70s. Among them, the 240-cubic-inch variant was quite popular. The 170-cubic-inch engine was commonly found in Econoline vans, while the 300-cubic-inch variant was utilized in pickups and even dump trucks.

“We located [the engine and transmission] for $700 and then removed the old engine,” Mowrey shared. “I disassembled it, but nobody was interested in buying any parts. So, we scrapped it and made $60 for the block since it was entirely aluminum.”

Fitting the classic Ford engine required some creativity. Mowrey eliminated the antiquated high-pressure fuel pump but retained the housing, replacing the stock tank with one from a boat. A low-pressure pump now resides beneath the BMW, accompanied by a nylon tube extending into the tank for fuel extraction. (I suspect a Munich man would never attempt that. Thankfully, Mowrey hails from Tacoma, or nearby.)

He established a multi-step starting procedure involving the key fob, then activating a switch for ignition and another for the fuel pump. Subsequently, the engine starts with a push-button. “It’s been quite a fun challenge figuring out how to make all that function,” Mowrey joked.

As anticipated, the computers initially did not cooperate with the Ford engine. Mowrey stated that the windshield wipers operated continuously at first, but only at a slow speed. The turn signals were also non-functional, and the heater faced issues as the blower refused to activate.

“It was just simpler to connect a power wire to a main switch,” Mowrey clarified. “So, the engine operates on its own dedicated circuit.”

The final challenge was addressing the driveline configuration. The Ford three-speed automatic transmission wasn’t designed with an independent rear-end in mind. What Mowrey did was acquire a 1350 u-joint driveshaft adapter from TF Works, a supplier for BMW drift car components. It fit perfectly and did not necessitate any alterations to the stock driveline.

The old gal runs superbly now—except, it’s sluggish. Like, really sluggish.

“You need to adjust to driving that type of engine once more,” Mowrey noted. “It’s not simply pressing the gas, and away you go. It’s a gradual rise to speed, and then you’re off. It’s an entirely different realm of engine.”

However, that is not overly problematic since it starts and runs every time. That’s precisely what you do when presented with a car for free and find an effective, budget-friendly solution. Mowrey relished the project—you can tell by the way he discusses it.

“It’s been a significant intellectual challenge to figure out how to achieve this,” Mowrey stated. “I accomplished all this in front of our home in the driveway.”

I know one thing: I hold immense respect for him for accomplishing this. And I’m pleased to share the story with all of you. The Ford inline-six is renowned for a reason, and here it is today, still operational—albeit in an unusual vehicle.

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**Amateur Mechanic Skillfully Replaces Defective BMW X5 Engine with Vintage Ford I6**

In an unconventional yet remarkable display of automotive creativity, an amateur mechanic has effectively replaced the defective engine of a BMW X5 with an old Ford inline-six (I6) engine. This endeavor not only highlights the mechanic’s ingenuity but also raises discussions regarding engine compatibility, performance, and the inventive solutions that can emerge within the automotive repair realm.

### Background

The BMW X5, a premium SUV recognized for its performance and luxury, can be costly to maintain, particularly concerning engine troubles. When the original engine of a 2005 BMW X5 failed, the owner was faced with a substantial repair expense that could surpass the vehicle’s worth. Enter the amateur mechanic, who recognized an opening to revitalize the car without incurring significant costs.

### The Engine Replacement

The choice to swap the BMW’s engine with a vintage Ford I6 was influenced by several factors. Firstly, the Ford I6 is celebrated for its toughness and simplicity, making it a trustworthy option for a frugal repair. Moreover, the mechanic had access to a Ford I6 engine from an older model, which was in working order.

The engine replacement process involved several key stages:

1. **Evaluation and Strategy**: The mechanic carefully evaluated the dimensions and mounting points of both engines. This stage was critical in determining how the Ford I6 could be positioned within the BMW’s engine compartment.

2. **Creation of Mounts**: Custom motor mounts were constructed to firmly secure the Ford I6. This necessitated precise measurements and welding abilities to guarantee a suitable fit.

3. **Wiring and Electronics**: One of the most complex components of the swap was integrating the Ford engine’s wiring with the BMW’s electronic systems. The mechanic had to modify the ignition and fuel mechanisms to function with the Ford engine while ensuring the BMW’s dashboard and sensors remained operational.

4. **Exhaust System Adjustments**: The exhaust system was adjusted to fit the different exhaust manifold of the Ford I6. Custom piping was designed to ensure optimal flow and avoid leaks.

5. **Testing and Calibration**: After installation, the mechanic performed comprehensive testing to fine-tune the engine’s performance. This included refining the fuel mixture and ignition timing to extract the best output from the Ford I6.

### Performance and Outcomes

The outcomes of the engine replacement were surprisingly favorable. The Ford I6 delivered smooth and dependable power delivery, albeit offering a different driving experience compared to the original BMW engine. The mechanic reported that the vehicle preserved commendable acceleration and handling traits, with the significant advantage of reduced maintenance costs linked to the simpler Ford engine.

### Community Response

The project attracted attention within car enthusiast communities, receiving a blend of admiration and skepticism. Many commended the mechanic’s ingenuity and ability to think creatively, while others questioned the long-term feasibility of such a swap. Nevertheless, the project’s success has encouraged other DIY enthusiasts to contemplate alternate engine choices for their own vehicles.

### Conclusion

The successful replacement of a BMW X5 engine with an older Ford I6 by an amateur mechanic illustrates the essence of innovation and resourcefulness present in the automotive repair community. While such swaps may not be traditional, they emphasize the potential for inventive solutions in the face of expensive repairs. As more enthusiasts consider unconventional engine swaps, the limits of automotive customization continue to broaden, demonstrating that with sufficient determination and skill, nearly anything is achievable in the automotive repair landscape.