i picked up a 02 pi motor from a crown vic for my 96 gt and was wondering what kinda of issues can i expect to run into when doing the swap. for example the 02 has a coil on plug set up. i need to get as good an idea of what to expect so that i can prepare for it seeing as ill only have a weekend to get the car finished so i can drive it to work. also i was thinking of going with an aluminum flywheel any input on that?
swap issues??
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wmburns
SN Certified Technician
This has been covered multiple times. It has also been done by Tons of PPL. I have the motor from a 2004 CV in my 2000 GT now.
Note, performing this entire swap in a weekend is a tall order. IMO, just swapping an exact motor in a weekend is tough enough as it is.
There are some things to swap from the Old Mustang motor to the New CV motor in addition to the normal things. The "little things" are likely to be deal breakers. Especially if you need parts on a Sunday.
In addition, this swap needs to be done using the electrical harness from the original car (Mustang).
If you insist on doing a COP swap, look at the following product. However, give up any chances of completing the job over a weekend.
Plug and Play COP Conversion Harnesses!!!!
Note, performing this entire swap in a weekend is a tall order. IMO, just swapping an exact motor in a weekend is tough enough as it is.
There are some things to swap from the Old Mustang motor to the New CV motor in addition to the normal things. The "little things" are likely to be deal breakers. Especially if you need parts on a Sunday.
In addition, this swap needs to be done using the electrical harness from the original car (Mustang).
If you insist on doing a COP swap, look at the following product. However, give up any chances of completing the job over a weekend.
Plug and Play COP Conversion Harnesses!!!!
wmburns
SN Certified Technician
Parts to re-use.
Fuel injectors
wiring harness
throttle body
air tube.
Ignition.
Front acc
oil pan (if you wish to keep the Mustang's larger capacity).
dip stick (if you swap oil pans).
heater return line. Later MY's use an O-ring. Olders MY's use a barbed fitting.
pilot bearing (if manual)
Flywheel (if manual)
use new motor mounts
Find a suitable location to mount the 2nd temperature sensor. Either drill/tap the intake or use the block drain.
exhaust manifolds
EGR system.
Some adjustment will be required for the PCV system. The later MY's use a larger PCV valve. Gone is the do-nut around the PCV valve.
Fuel injectors
wiring harness
throttle body
air tube.
Ignition.
Front acc
oil pan (if you wish to keep the Mustang's larger capacity).
dip stick (if you swap oil pans).
heater return line. Later MY's use an O-ring. Olders MY's use a barbed fitting.
pilot bearing (if manual)
Flywheel (if manual)
use new motor mounts
Find a suitable location to mount the 2nd temperature sensor. Either drill/tap the intake or use the block drain.
exhaust manifolds
EGR system.
Some adjustment will be required for the PCV system. The later MY's use a larger PCV valve. Gone is the do-nut around the PCV valve.
wmburns
SN Certified Technician
The motor mounts ARE the same. However, there will never be a better time to replace/inspect. Highly recommend replacement if old.
Yes you will need a PI alternator bracket. Or several ppl have reported being able to "modify" the Non-PI bracket to to work.
Yes you will need a PI alternator bracket. Or several ppl have reported being able to "modify" the Non-PI bracket to to work.
mustang_matt
New Member
I just did this swap. you'll need a new intake, one with a coolant fitting. I used a 2001 lincoln town car motor. then I bought professional products intake and had it drilled. You can also use a DORMAN intake for a p.i. engine from any autoparts store or buy a ford racing replacement you'll need to drill this one also, but the DORMAN does not require you to drill it. But, the DORMAN has smaller runners than the Ford. You DONT need a new alternator bracket if you use your 1996 alternator. You DONT need to get a new harness if you want to run C.O.P. you can rewire your current coil pack harness to fire the C.O.P. The front timing cover is different than the 96 4.6. if you keep your coil packs you'll have a small issue with the passenger side coil. The timing cover is missing one of the bolt holes for the coil bracket. (no biggie tho) I would use the plenum off the crown vic it flows a little more cfm than the 96 plenum, you can look on accufabs web site to confirm this.. one other thing the belt routing is different on the 2002 crown vic compared to the 2002 mustang and the 1996 mustang..but you can change the crown vic belt routing by adding a idler pulley to the pass. side and make it a mustang routing. Aluminum flywheel is good if you have gears. I say that b/c the aluminum flywheel revs fast and frees up hp. but the motor has to work harder to keep revs. the weight of heavier flywheel helps keep the motor turning. Great for high performance engines and race cars, but I would be hesitant to put it on a mostly stock car.
since i have the crown vic pi manifold i was going to just drill and tap that for the 2nd temp sensor. i really wanted to try out a aluminum flywheel but im starting to hear more and more ppl say its not a good idea for a daily driver.. as for mods i just orders bbk equal length shorty headers (wanted LT's but california smog laws suck) catted x-pipe, flowmaster 40's (these things drone way to much), 1/2 plenum spacer, and havent decided on a plenum or throttle body so those may stay stock for a little while
fast97gt
Active Member
just replied to your pm you definitly need to swap oil pans, the cv will interfere with the cross member. also the drvers head will have a coolant temp sensor in it, this is what i used when plugged the temp sensor in, not having to "get a new intake". +1 on NEW engine mounts. als STAY away from the 1/2 spacer unless your willing to modify the egr tube.
mustang_matt
New Member
2wheelryder if your gonna do a plenum just get the 78mm BBK plenum intake.. I bought one about 3 months ago, GREAT mod the car pulls so hard from 4500 to 6000. It costs a little more than the macs or professional products or C&L plenums, but its well worth it. I'm running it with a 1/4 inch spacer on a professional products intake. no EGR tube issues but I did have a rubbing issue on my strut tower with my cold air. its a k&n though other brands may not have this problem.
mustang_matt
New Member
also if you dont like the flowmasters (I have these, I know how much they can drone on the inside of your car) try borla pro xs they sound incredible!! I put a set on my buddies 94 GT. You know the mustang in the first Transformers movie? Thats wat his car sounds like.. Also 5.0 mustang magazine did a dyno shoot out on a bunch of mufflers a few years back, and I think the pro xs came in ether First or second on power production.
even bbk doesnt recommend their 78mm TB for a mostly stock stang. they say a stock stang wont benefit from it at all its more for force induction applications
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