PurpleMystique
Hard-core CEG'er
My 83,000 mile SVT engine spun a bearing, and since it's my DD I need to get it back on the road asap, and as cheaply as possible. If I had a shop, tools, and all the time in the world I'd love to take care of this myself, but those are luxuries that I don't have right now. The mechanic I'm talking with hasn't done a 3.0 swap before, but he does own a V6 Mystique, so he's at least familiar with the car and engine. The best deal he could find on an SVT 2.5 so far was one with 56,000 miles for $1900. I decided that was ludicrous and a 3.0 is the best way to go. I pointed him towards LKQ for a 3.0 and I'm now putting together a list of what needs to be done. Because I'm trying to minimize labor costs, I'd like to do a straight oval-port swap.
So I'm asking for a little help in putting together a complete list to give to a mechanic so that he can get my car running again.
So far I have (assuming an '01-'03 Taurus or Sable engine):
Needed from old engine:
-Throttle cable
-Throttle body
-Throttle cable bracket
-Oil pan
-Dipstick/tube
-Oil pickup (to match oil pan)
-Oil sensors/head coolant crossover tube sensors
-2.5 Timing cover
-Crank pully
-2.5 alternator bracket
-Valve covers
-Timing components (chains, guides, tensioners, etc.)
-Cams
New parts needed:
-Exhaust manifold gaskets (one time use) $6 each, need 2 (Any part number for this?)
-BCA part# 482041N Oil Seal, Front Timing Cover. $8
-2.5 Right Front Timing Cover Gasket F5RZ-6020-A $5
-2.5 Center Front Timing Cover Gasket F5RZ-6020-B $5
-2.5 Left Front Timing Cover Gasket F5RZ-6020-C $5
-2.5 Right Valve Cover Gasket F5RZ-6584-B $11
-2.5 Left Valve Cover Gasket F5RZ-6584-C $11
-2.5 Spark Plug Tube Seals ($2/ea., come in packs of 2)F5RZ-6C527-A
-Engine mount Long Bolts: W704693S309 $5.22/EA. LIST
-Engine mount Short Bolts: W704694S309 $3.53/EA. LIST
Customizations:
-Wire in (or tap) knock sensor
-Wire in oil sensor
-Extend wiring for EGR solenoid and TPS
-Vacuum lines (see this thread for pictures)
-Grind top passenger side engine mount to clear the heads. The newer Cougar engine mount (part #1S7Z3A732AA) requires less grinding, but the current one will work with a little extra time.
-EGR tube must be fitted via brass compression fitting (see previous thread)
-Fuel rail brazing/welding/replacement (see this for replacement, or this for general soldering/welding bs.)
-Trim alternator bracket mounting points off of block (try to install 2.5 alternator bracket to see what needs to be removed
-Trim extra ATX mounting point tab - it blocks SVT Oil cooler lines
-Remove crank pilot bearing (not needed now that it's not ATX) - either cut it flush with a sawsall or cutoff wheel, or cut some notches in the sides of it and use a small gear puller
-Modify throttle cable bracket to fit new angle
-Replace crankshaft pulley bolt as it's a TTY (torque to yield)
-When putting SVT cams on the 3.0, use all of the 2.5 timing components, such as the timing cover, chains, guides, tensioners, and the bolts
After this is all done a tune would be a great idea, I've heard. Warmonger can do that via an XCal2 through the mail, right?
That's what I've put together so far. I'd really like to give him a thorough list so that it's as painless for him as I can make it. Also, would it be worth the extra cost in labor required to swap in the SVT cams/timing components?
So I'm asking for a little help in putting together a complete list to give to a mechanic so that he can get my car running again.
So far I have (assuming an '01-'03 Taurus or Sable engine):
Needed from old engine:
-Throttle cable
-Throttle body
-Throttle cable bracket
-Oil pan
-Dipstick/tube
-Oil pickup (to match oil pan)
-Oil sensors/head coolant crossover tube sensors
-2.5 Timing cover
-Crank pully
-2.5 alternator bracket
-Valve covers
-Timing components (chains, guides, tensioners, etc.)
-Cams
New parts needed:
-Exhaust manifold gaskets (one time use) $6 each, need 2 (Any part number for this?)
-BCA part# 482041N Oil Seal, Front Timing Cover. $8
-2.5 Right Front Timing Cover Gasket F5RZ-6020-A $5
-2.5 Center Front Timing Cover Gasket F5RZ-6020-B $5
-2.5 Left Front Timing Cover Gasket F5RZ-6020-C $5
-2.5 Right Valve Cover Gasket F5RZ-6584-B $11
-2.5 Left Valve Cover Gasket F5RZ-6584-C $11
-2.5 Spark Plug Tube Seals ($2/ea., come in packs of 2)F5RZ-6C527-A
-Engine mount Long Bolts: W704693S309 $5.22/EA. LIST
-Engine mount Short Bolts: W704694S309 $3.53/EA. LIST
Customizations:
-Wire in (or tap) knock sensor
-Wire in oil sensor
-Extend wiring for EGR solenoid and TPS
-Vacuum lines (see this thread for pictures)
-Grind top passenger side engine mount to clear the heads. The newer Cougar engine mount (part #1S7Z3A732AA) requires less grinding, but the current one will work with a little extra time.
-EGR tube must be fitted via brass compression fitting (see previous thread)
-Fuel rail brazing/welding/replacement (see this for replacement, or this for general soldering/welding bs.)
-Trim alternator bracket mounting points off of block (try to install 2.5 alternator bracket to see what needs to be removed
-Trim extra ATX mounting point tab - it blocks SVT Oil cooler lines
-Remove crank pilot bearing (not needed now that it's not ATX) - either cut it flush with a sawsall or cutoff wheel, or cut some notches in the sides of it and use a small gear puller
-Modify throttle cable bracket to fit new angle
-Replace crankshaft pulley bolt as it's a TTY (torque to yield)
-When putting SVT cams on the 3.0, use all of the 2.5 timing components, such as the timing cover, chains, guides, tensioners, and the bolts
After this is all done a tune would be a great idea, I've heard. Warmonger can do that via an XCal2 through the mail, right?
That's what I've put together so far. I'd really like to give him a thorough list so that it's as painless for him as I can make it. Also, would it be worth the extra cost in labor required to swap in the SVT cams/timing components?
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