Best Upgrade Ever: 3L

gamiller · 08-02-2007, 11:22 PM

The 3.0 Duratec is what should have powered the Cougar since its beginning. With the extra displacement, there's plenty of power on tap for passing on the highway or running the AC at idle. I wish I had swapped motors five years ago!

Last week DanG completed installing both my 3.0L engine and my turbo. This thread documents one variation of the rare "straight" swap and its complexities, wherein the donor motor is used in its entirety (i.e. block, heads, lower intake manifold, and upper intake manifold). For better or worse (richer or poorer?), I am using the 3L UIM as well as the heads. Perhaps that's suboptimal for performance, but that's how the motor was built, and I don't want to spend another $1500 on it for an SVT UIM, port-matched heads, gaskets, and reassembly.

The engine was rebuilt by Rick Blackford (a.k.a. Buckshot77) with the following components:

8.5:1 Diamond pistons (.020 overbore)
Pauter rods
Kinger PnP heads
Clevite main bearings
Clevite rod bearings
ARP head studs

gamiller · 08-02-2007, 11:31 PM

To handle the added power, I had a Torsen LSD installed in the transmission as well as a SPEC Stage 3+ clutch.

SPEC Stage 3+ clutch disc vs. SVT clutch disc

The disc is about twice as thick as the SVT disc. It came with a slave cylinder but, unlike other SPEC clutches, no bolts were included! Note that BlackCoog's Stage 3+ looks different because he requested that the clutch be lightened.

jaged · 08-02-2007, 11:32 PM

since youre keeping the 3L uim like me you might want to look into a 04/05 uim. its a dual plenum. i have one, putting it on monday. it looks like itll flow a lot better

im very happy with my straight 3L swap, lots of low end grunt, awaiting turbo numbers....

Topik · 08-02-2007, 11:39 PM

In that case gary, I might have to post a few pictures I took

gamiller · 08-02-2007, 11:46 PM

This motor ran for 107K miles without an issue. I hate seeing things go to waste, so I purchased another Cougar in the region that just so happened to be missing an engine (among other things). We replaced gaskets for the timing cover, valve covers, and oil pan. Good as new!

Note my solvents of choice: PB Blaster and Dr. Pepper!

gamiller · 08-02-2007, 11:48 PM

Quote:

Originally Posted by Topik

In that case gary, I might have to post a few pictures I took

I know not of the incriminating pictures of which you speak.

Topik · 08-02-2007, 11:55 PM

little turbo here and there

gamiller · 08-02-2007, 11:56 PM

Because I went with the 3.0 upper intake manifold (UIM), we had to make a couple modifications.

First up, is my custom EGR tube which was made from two 2.5L EGR tubes. Check out that sweet flange he added at my request to allow for replacing the EGR! Sadly, we forgot to put the sleeve on, so Dan had to cut it and weld it together again.

J-Man · 08-02-2007, 11:58 PM

Should have just gotten rid of the EGR altogether, theres no point for it really on a boosted car. Show some pics of the Nautilus kit, I'd love to see the craftsmanship. . .

gamiller · 08-02-2007, 11:58 PM

Quote:

Originally Posted by Topik

little turbo here and there

You're gonna have to wait for my turbo thread in the FI forum. As Dan once warned me, "Don't mix your berries."

08-02-2007, 11:22 PM	#1 (permalink)
gamiller Got turbine on my mind Join Date: Jun 2001 Location: Fairfax, VA Posts: 2,645 Images: 4 Blog Entries: 3	Best Upgrade Ever: 3L The 3.0 Duratec is what should have powered the Cougar since its beginning. With the extra displacement, there's plenty of power on tap for passing on the highway or running the AC at idle. I wish I had swapped motors five years ago! Last week DanG completed installing both my 3.0L engine and my turbo. This thread documents one variation of the rare "straight" swap and its complexities, wherein the donor motor is used in its entirety (i.e. block, heads, lower intake manifold, and upper intake manifold). For better or worse (richer or poorer?), I am using the 3L UIM as well as the heads. Perhaps that's suboptimal for performance, but that's how the motor was built, and I don't want to spend another $1500 on it for an SVT UIM, port-matched heads, gaskets, and reassembly. The engine was rebuilt by Rick Blackford (a.k.a. Buckshot77) with the following components: 8.5:1 Diamond pistons (.020 overbore) Pauter rods Kinger PnP heads Clevite main bearings Clevite rod bearings ARP head studs __________________ Roush Performance Suspension Nautilus Performance Stage 3 Turbo Kit

08-02-2007, 11:31 PM	#2 (permalink)
gamiller Got turbine on my mind Join Date: Jun 2001 Location: Fairfax, VA Posts: 2,645 Images: 4 Blog Entries: 3	Clutch To handle the added power, I had a Torsen LSD installed in the transmission as well as a SPEC Stage 3+ clutch. SPEC Stage 3+ clutch disc vs. SVT clutch disc The disc is about twice as thick as the SVT disc. It came with a slave cylinder but, unlike other SPEC clutches, no bolts were included! Note that BlackCoog's Stage 3+ looks different because he requested that the clutch be lightened. __________________ Roush Performance Suspension Nautilus Performance Stage 3 Turbo Kit

08-02-2007, 11:32 PM	#3 (permalink)
jaged EFFING MOSQUITOS Join Date: Mar 2003 Location: hebron, in Posts: 13,843 Images: 1	Re: Best Upgrade Ever: 3L since youre keeping the 3L uim like me you might want to look into a 04/05 uim. its a dual plenum. i have one, putting it on monday. it looks like itll flow a lot better im very happy with my straight 3L swap, lots of low end grunt, awaiting turbo numbers.... __________________ BUY COUGARFEST RAFFLE TICKETS SM 86 now with two choices 2.5L or 3L

08-02-2007, 11:39 PM	#4 (permalink)
Topik VADriven Member Join Date: Apr 2004 Posts: 5,386	Re: Best Upgrade Ever: 3L In that case gary, I might have to post a few pictures I took

08-02-2007, 11:46 PM	#5 (permalink)
gamiller Got turbine on my mind Join Date: Jun 2001 Location: Fairfax, VA Posts: 2,645 Images: 4 Blog Entries: 3	Out with the Old... This motor ran for 107K miles without an issue. I hate seeing things go to waste, so I purchased another Cougar in the region that just so happened to be missing an engine (among other things). We replaced gaskets for the timing cover, valve covers, and oil pan. Good as new! Note my solvents of choice: PB Blaster and Dr. Pepper! __________________ Roush Performance Suspension Nautilus Performance Stage 3 Turbo Kit

08-02-2007, 11:55 PM	#7 (permalink)
Topik VADriven Member Join Date: Apr 2004 Posts: 5,386	Re: Best Upgrade Ever: 3L little turbo here and there

08-02-2007, 11:56 PM	#8 (permalink)
gamiller Got turbine on my mind Join Date: Jun 2001 Location: Fairfax, VA Posts: 2,645 Images: 4 Blog Entries: 3	Fabrication: EGR Because I went with the 3.0 upper intake manifold (UIM), we had to make a couple modifications. First up, is my custom EGR tube which was made from two 2.5L EGR tubes. Check out that sweet flange he added at my request to allow for replacing the EGR! Sadly, we forgot to put the sleeve on, so Dan had to cut it and weld it together again. __________________ Roush Performance Suspension Nautilus Performance Stage 3 Turbo Kit

08-02-2007, 11:58 PM	#9 (permalink)
J-Man DPMS/Glock Join Date: Jun 2004 Posts: 11,630 Images: 5	Re: Best Upgrade Ever: 3L Should have just gotten rid of the EGR altogether, theres no point for it really on a boosted car. Show some pics of the Nautilus kit, I'd love to see the craftsmanship. . . __________________ "America is in that awkward phase where it's too late to implement any meaningful change, and too early to start shooting." McCain/Palin 2008!

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