I have a 2002 with a blown engine. Would like to replace it with the one from my 1999 model.

I came across the following posts on another forum and am wondering what others may be able to add to this, or the experiences of others who may have done a similar swap.

Any help Greatly Appreciated.


(Here are those other posts)

97-'03 engines will all interchange.

Some things are different in all of these years. Most are minor. Don't change out your ECU.

- 1997-2000 would be the most direct swap but you'll have to deal w/ the timing chain issues all over again. With these years you need to match 2wd/4wd to your vehicle.

- 2001 you need to use your old upper intake, wiring harness, and cam sensor. Timing is still a problem w/ these engines.

- 2002-03 reuses the same parts as '01 but you'll also need to reuse your old fuel rail (including your old injectors). This makes for a little more work but it seems to be worth it b/c '02 is when Ford finally improved the timing cassettes.

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I recently finished my ‘98 to ‘03 swap and everything is working as it should. There are a few more things (other than what’s listed above) that are different about the engines…

You have to use your old exhaust manifolds. The newer manifolds use studs instead of bolts but that’s not a big deal. What is a big deal is that the studs are spaced further apart and they won’t fit the flange. Anything can be modified but it won’t be worth your time and effort to make the new manifolds fit unless your old manifolds are warped or cracked. You also need to use your old EGR valve, bracket, and pipes.

You can save some time if you use your old valve covers. I chose to go with the new covers and I like how it turned out but there was a good bit of modifying necessary to get everything to match back up. The coil pack, upper radiator hose, PCV valve(s) (mine now has two and an extra line), spark plug wires/mounts, DPFE sensor, and the main electrical harness connector bracket all need to be modified. If you use your old valve covers all of these will match up as on the old engine.

The older engine emission system circulates air through a freeze plug knocked out of the block above the crank. The new engine circulates from the rear of the drivers side valve cover. I suspect Ford eliminated the crank breather b/c it clogs over time. I instead set up mine to use both which should make for better circulation and also provide a backup in case one line clogs. If you keep the crank breather (you have to keep it if you use your old valve covers) it would be a good idea to clean it the next time you change out the intake manifold gaskets.

The cam sensor, oil pressure sender, and block ground appear to be the only sensors/connectors you’ll need to use from the older engine. I used all the sensors from the newer engine except for these three.

You need to use your old heater hose bracket/coupling.

The oil filter is different and you need to get filters to fit an '02/'03.