Dont poke beehives!
Join Date: Jan 2005
Location: Raleigh, NC
Feedback: 15 / 100%
Model: Dodge Intrepid
How To: Convert a 2002-2004 3.5HO Engine to Work in a 1998-2001 and vice versa
Heres the list of items you will need to change on a 02-04 3.5HO, to make it work in a 98-01, or vice versa. This applies to 2.7 conversions, as well as 3.2-3.5 swaps. To do this properly, you will need either a good core 3.2 or 3.5 98-01 engine as a parts source, or buy everything used indiviually.
**This process also works when installing a 98-01 engine in a 02-04 vehicle, it is the same process with the exception of the EGR valve. You must remove the EGR valve and install a block off plug in the cylinder head hole, and install a non-egr plenum, all available from 02-04 engines.
If you are doing a 2.7 - 3.5 conversion, and using a 2002-2004 3.5 in a 1998-2001, you have to follow the instructions completely on the conversion itself, as well as these instructions.
You will need to change the following parts on the 02-04 engine with the same parts from a 98-01 engine, or vice versa, if installing a 98-01 into an 02-04:
1. Engine wiring harness
2. EGR valve & tubes (02-04 into 98-01 only, must be removed when going 98-01 into 02-04)
3. Intake plenum-- The plenums can be converted by swapping the following parts:
a. IAT sensor
b. Throttle body
c. MT valve
d. SRV valve actuator-- '04 has an electric one, 01 and older has vacuum, it will bolt right up in place of the electric no problem.
e. You would have to drill out the egr tube holes. They are there on the 04 plenum, just blocked off.
f. You would also have to drill out the vacuum port for the vacuum reservoir and cruise control servo, again the ports are there, just blocked off.
**If going 98-01 engine into 02-04 car, you must obtain an 02-04 plenum. The conversion requires EGR block off plates which are NLA.
4. Engine flywheel
5. SRV Valve Vacuum reservoir and hoses
6. Left camshaft sprocket. To change this, you will need to:
a. Buy the camshaft holding tool, OTC # 7999. 50$ cost roughly. It installs into the back of the camshaft and holds it in place so the camshaft sprocket can be installed in the proper position. Yes a timing belt can be changed without the tools, but it is critical that you use this tool when changing either of the sprockets. Not only is it next to impossible to keep the cam in the proper position, but you have to replace the bolts with new ones, and they have to be torqued to 75ft lbs, which the tools hold the cams in place again to make this possible. If you dont use these tools, you will seriously damage the valvetrain.
8. Coolant Temperature Sensor
All that done, install it, plug it in, and start it up. Good luck.
Found this on the DI Site, From the master himself