Issue Resolved: Backyard Mechanic Replaces Defective BMW X5 Engine with Vintage Ford I6

      Bruce Mowrey

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      Unusual engine replacement. Bruce Mowrey swapped the V8 engine of his BMW X5 for a carbureted Ford inline-six.

      Budget-friendly solution. Mowrey saved thousands on repairs by using a $700 engine and transmission set.

      Innovative engineering. He modified the BMW to accommodate the Ford engine using straightforward yet creative methods.

      Distinct driving experience. Although the vehicle is slower, it is dependable, providing a significantly different driving sensation.

      Many backyard mechanics have found German cars to be quite challenging, often due to their precision and quirks. To tackle this, Bruce Mowrey decided to replace the 4.8-liter V8 in his 2009 BMW X5, which was a gift, with a more familiar yet surprising 240-cubic-inch Ford inline-six engine that's over 50 years old.

      Mowrey captured attention, including mine, when he shared a Facebook video showcasing the BMW with its hood open. The video has garnered over half a million views, and it’s easy to see why. While I’ve witnessed various engine swaps, this one stands out.

      “We took it for a drive, and if you hit a long red light, it would start smoking when you took off,” Mowrey recounted about the car, which was in poor condition when he acquired it. “We discovered it had faulty valve stem seals. The repair would cost $5,200.”

      This followed approximately $9,000 already spent by the previous owner.

      Bruce Mowrey

      Right away, Mowrey's mind began racing with potential engine options for replacement. He shared that he has a background in such projects, with his previous endeavor being the installation of a 3208 Caterpillar diesel engine into a 1969 Ford one-ton frame, complete with a Peterbilt cab.

      “I’ve always leaned towards Ford engines, like a little 289 or 302,” Mowrey recalled. “Then, I came across an ad on Facebook Marketplace for the 240 that came with a transmission that was mated to it since new.”

      During the 1960s and 1970s, Ford had several inline-six engines. The 240-cubic-inch model sat comfortably within that range, nestled between the 170-cubic-inch engine usually found in Econoline vans and the 300-cubic-inch version used in pickups and dump trucks.

      “We got the engine and transmission for $700, then removed the old engine,” Mowrey explained. “I disassembled it, but no one wanted any parts, so we scrapped it and received $60 for the aluminum block.”

      Making the classic Ford engine fit required some cleverness. Mowrey removed the old high-pressure fuel pump while keeping the housing and substituted the stock fuel tank with one from a boat. Now, a low-pressure pump sits beneath the BMW, with a nylon tube extending into the tank to draw fuel. (I doubt anyone from Munich would attempt such a solution. Thankfully, Mowrey hails from Tacoma.)

      He created a multi-step starting process that involves inserting the key fob, flipping the ignition switch, and another switch for the fuel pump. The engine starts with the push of a button. “It’s been quite a puzzle to figure out how to make everything work,” Mowrey humorously noted.

      As expected, the car's electronics didn't initially cooperate with the Ford engine. Mowrey shared that the windshield wipers ran constantly but at a low speed and the turn signals failed to function, with the heater blower also nonoperational.

      “It was simpler to run a power wire and connect it to a main switch,” Mowrey said. “So now, the engine operates on its own circuit.”

      The final challenge was addressing the driveline compatibility. The Ford three-speed automatic was not designed for an independent rear end. Mowrey resolved this by purchasing a 1350 u-joint driveshaft adapter from TF Works, a supplier for BMW drift car parts, which fit perfectly without needing any modifications to the original driveline.

      The vehicle runs smoothly now, though it’s notably slow.

      “You need to adjust to driving with that kind of engine again,” Mowrey remarked. “It’s not simply flooring the gas and taking off. It’s a gradual acceleration—completely different engine dynamics.”

      However, that isn’t an issue since it starts and runs reliably every time. This is the kind of project you undertake when you're given a car for free and find an affordable solution that works. Mowrey clearly enjoyed the process, as evident from his enthusiasm when discussing the project.

      “It’s been a tremendous mental challenge to figure all this out,” Mowrey stated. “I did it all in our driveway in front of our house.”

      Mowrey lost his right hand in a trucking accident in