2.5L/3.0L Coil On Plug upgrade available!

[buckeyesvt]

I know there are alot of people here that have done 3.0L swaps. Of those, I know some were looking to use the COP setup that came stock on their engines. Doing some research, I discovered the Coil On Plug system could be used on stock 2.5L (with appropriate hardware) and 3.0L Full and Hybrid engines. The only change in hardware would be the valve covers for the non-COP setup engines (like hybrid and 2.5L stock) that aren't designed with the COP bungs and the COP units themselves.

All that is required to make the system work is a redesigned harness that properly reconfigures the coils to work with the Cougar stock DIS system. I am going to offer the harness for sale soon, however I am gauging interest first before I do. This is not a flash in the pan idea - It is proven out and is working on a 2005 Full 3L in a 99 Contour SVT. I will attach a link below to view the video.

To sort out a few questions I will try to answer them all here first and then answer questions as they come up.

Why is COP better? First off, gets rid of the spaghetti bowl on top the motor (worse in the case of straight 3L's due to having the coil up front instead of the rear). Honestly I never wanted to use a standard coil - But my overall understanding of the system was a little green in how to properly convert it to work on standard Non-COP EEC's. Other benefits include: Lifetime serviceable unit - COP has a lifespan of the engine itself... therefore no replacing wires ever again. The COP units also allow for tighter spark control as there is no latency between the coil firing and the spark traveling the cable. This is probably one of the most "usable/felt" benefits as throttle response and torque become a big factor on the bottom end in relation to spark control. Plus, no wires means no breaking down of the internal core of the wire, no misfires and no missing under heavy load from cross talk between the spark plug wires. Plus you can now add COP to the list of items made to work on Cougars with existing electrical hardware. Most of the guys who have newer engines may have these laying around already! Put them to use!

Now, how much do coils cost? Motorcraft New Coil On Plug units (2M2Z-12029-AC) $39.46 each! Bill Jenkins (Team Ford). Valve covers, well - that I didn't check on. I was aiming this more at the 3.0L guys but the 2.5L and 2.0L guys could use this setup as well if they wished. Final harness pricing hasn't been determined yet (looking for less expensive supplier of coil ends), however right now it stands around $165.00. If we source aftermarket coil end replacements the total cost for the harness could come down to $110-$115. This will be a brand new harness, all loomed and sealed up. It will require 4 wires (the factory wires going into your factory coil plug) to be spliced in. It will not be a hard installation as most of it is plug and play.

Is there an interest here for this? Since this morning I have 14 interested people on FCO... Any more? I'll check this thread for updates as I can.

Pic:


Video: Coil on Plug demonstration video

-Dom

[StealthyWeasel]

Awesome man good work, I would def. buy it as long as it works with no flaws. What's the total cost everything considered?

[buckeyesvt]

It works with no flaws. Price depends on if you have coils already or need to buy coils. I posted above about the price of the the coils themselves and the price of the harness at this moment. If I get more orders (interest now sits a 20) the better the price will be.

Perhaps in a week or so I will be able to lay out exact costs. I want to throw the offer out there to see how many people would be interested in buying the harness to do this easily.

-Dom

[cpapashley]

OK so what you are saying is I can change my Cam covers, and get rid of my 2.5l ignition system with the three coil towers, plug in these individual coils make no changes to the pcm and then I have the superior coil on plug system, is that right??

Or is there something I am missing??

That would really appeal to me, and might to those who have the first generation 2.5l MPV's.

Please correct me if I am reading this wrong.

[buckeyesvt]

Originally Posted by cpapashley

OK so what you are saying is I can change my Cam covers, and get rid of my 2.5l ignition system with the three coil towers, plug in these individual coils make no changes to the pcm and then I have the superior coil on plug system, is that right??

Or is there something I am missing??

That would really appeal to me, and might to those who have the first generation 2.5l MPV's.

Please correct me if I am reading this wrong.

Right now the only issue we are researching is the IMRC on the front valve cover. Unfortunately all the covers we've looked at so far (with COP) do not have the IMRC mounting point on the front valve cover. This present a small issue - Because the COP will work without any other modifications (like to the PCM or such) but the IMRC is still needed and the mounting is not there.

So, if anyone else would like to dive into this (I have no idea how the MPV is setup vs. the Cougar).

-Dom

[morbid]

Better to move the imrc off of the head anyways. Just say it has to be relocated and be done with it.

[fordrule]

is the COP adjustable? lets say you have a xcal2 and a PRP. and you can adjust the ecu? will the cop parameters be in there?

[cpapashley]

Originally Posted by buckeyesvt

Right now the only issue we are researching is the IMRC on the front valve cover. Unfortunately all the covers we've looked at so far (with COP) do not have the IMRC mounting point on the front valve cover. This present a small issue - Because the COP will work without any other modifications (like to the PCM or such) but the IMRC is still needed and the mounting is not there.

So, if anyone else would like to dive into this (I have no idea how the MPV is setup vs. the Cougar).

-Dom

Well for me that is not much of an issue as I have already moved the IMRC, just got so sick of the intermittent way it worked, works every time now

So from reading through your first post the COP harness will connect into the existing wiring that goes to the 2.5l coil pack, is that right?

Sounds like this might be a cool little upgrade.

Now the fact I am in Australia means that I would more than likely source my cam covers from somewhere else other than importing from america. So will the 3.0l cam covers from the Mazda Tribute/Ford Escape work?? Other wise I will have to just pass it on to others in NA MPV land as something they may want to follow up as an option. I think that is the only 3.0l cam covers for the duratec that makes its way to Australia, unless the cam covers in the Jaguar Xtype with the 2.5l engine is the same and has the same water pump location, although that may not affect it just thinking aloud...

Oh dear so many questions, I will stop there to wait for some answers.

Thanks in advance.

[fordrule]

any word on the COPs and xcal? is it compatable?

[buckeyesvt]

Sorry, to both of you (Cp and fordrule). I have been completely drained by tanother 3L discussion (I'm sure you're aware of the one I am referring to). I am at work now, but I will sit down and answer all your questions when I have the proper time to do so.

Thanks!

-Dom