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Old 04-29-2010, 06:44 AM   #1
sr5guy
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Default 3.5 Swap Parts Differences and Interchanges

Identical Parts

A/C Compressor (93-95 Legend only, 91-92 must use Legend or change manifold)
A/C Belt Tensioner and Bracket
Belts - Alternator, Power Steering and A/C
Camshaft Front Seal
Camshaft Rear Plug
Crankshaft, Rear Main Seal
Crankshaft, Rear Cover (rear main housing) and o-ring
Crankshaft, Front Seal
Cylinder Head Bolts
EGR Valve & Lift Sensor
EGR Bracket (on head)
Flexplate/Flywheel (Automatic only)
Idle Control Valve (IACV/EACV)
Intermediate Shaft & Bearing (shaft that goes through oil pan for driver's side axle to differential)
Orifice, Camshaft Bearing
Orifice, Lifter
PCV Valve
Power steering pump
Power steering upper bracket
Starter (uses slightly different design but 100% compatible)
Sensor, Oxygen
Sensor, Knock
Sensor, Coolant Temperature
Sensor, Coolant Gauge
Sensor, Cam Position (93-95 Legend only, 91-92 must use Legend sensor)
Sensor, Throttle Position (93-95 Legend Type II with TCS only – up facing sensor)
Sensor, Oil Pressure
Sensor, Map (relocated on fuel rail but it’s the same part #)
Thermostat
Thermostat “goose neck”
Valve, Intake (Type I only, type II I 1mm larger)
Valve, Exhaust
Valve, Lifters/Tappets
Valve, Rocker Arms
Valve Seal

Parts that are eliminated

Engine oil cooler (eliminated)
*Deleted, area where this once occupied is now occupied by the balance shaft.

Differential cooling pipes and hoses.
*RL has an un-cooled differential

PAIR System
*When compared to a type I 3.2 motor the pair system is completely eliminated. You must change the driver’s side exhaust manifolds, PAIR pipe and type I 3.2 intake manifold to retain this emission system. Note that type II 3.2’s don’t have the PAIR system.

Air boost valve
*Air boost valve is eliminated.

Oil Temperature Sensor
*eliminated from rear of passenger’s side valve cover, but bung is still there. See valve covers for more info.

Parts that are added

Balance Shaft
*A balance shaft was added to the passenger side of the block.
*It’s inclusion changed the casting of the block significantly.
*It is obviously an engineering after-thought.
*At the rear of the block, one of the mounting ears was extended in a semi-circle to clear the balance weights. Therefore, one of the bell housing bolts on the legend transmission will not line up to it.
*It is driven off a separate cog on the crankshaft pulley and uses a separate belt and tensioner mounted to the oil pump.
*The balance shaft runs external to the block in a tube to from the front gear drive to weights in the rear closest to the flywheel.
*The shaft spins out of sequence with the crank and requires a special method to time it properly.

Block Drain Pipe
*An engine coolant block drain pipe is added on the passenger's side on what used to be the coolant supply line to the differential.
*It is capped off with a rubber cap, simply remove the cap to drain the engine block of coolant.

RL Intake Manifold Notes

*RL Uses a COMPLETELY different upper intake manifold and throttle body base.
*When using the RL intake, it’s recommended to use the RL throttle body it’s redesigned with internally different ports and the EVAP vacuum nipple is facing the wrong way.
*VIS butterfly mid-section has same part number as Legend and is 100% Compatible.
*Lowest section of the intake has a redesigned EGR setup with one hole on the driver’s side instead of 2 and a baffle to prevent debris from entering the intake manifold. Compatible with Legend intake
*Re-designed aluminum billet fuel rail system with different style fuel pressure regulator and addition of muffler to dampen spikes in pressure.
*Elimination of PAIR emissions system.
*Elimination of air boost valve.
*Relocation of air intake temp sensor from front of manifold to rear.
*Relocation of fast idle valve from rear of intake manifold to the top of the throttle body base.
*Relocation of the fast idle valve intake hose from the rear to the front and elimination of the fast idle valve pipe.
*Coolant temperature sensor and gauge sender switch spots on the water bypass. If tearing down the RL manifold, use the Legend water bypass to prevent having to rewire these sensors.
*Requires making extensions and modifications to the wiring harness and vacuum lines to use on the Legend.

When using the RL Intake manifold, use these parts from the RL:
Sensor, air intake (screw in instead of flange)
Fast idle valve (it’s coolant pipes are facing the opposite direction)
Fuel Rails
Fuel Pressure Regulator (different design and fuel pressure)
Throttle Body


Legend Intake Manifold Notes

*Legend manifolds, both the Type I and Type II, bolt directly onto the RL motor when using the RL heads.
*Enables usage of the legend fuel rails and covers for a stealth install and easier parts interchange.
*Does not require modification and elongation of the wire harness.
*In order to use the Legend intake manifolds you must change the pipe under the manifold and the water outlet on the back of the driver’s side head. This is necessary to provide coolant to the fast idle valve.
*When using the Legend intake, it’s recommended to use the Legend Throttle body. The upward facing TPS sensor must be transplanted and calibrated from the RL motor, or a throttle body from a Type II with TCS may be used. The downward facing TPS sensor interferes with the upper timing covers.

Use the following Legend parts with the Legend intake manifold:
Sensor, Air Intake
Fuel Rails
Fuel Pressure Regulator
Fast Idle Valve
Throttle Body
Water pipe (under intake manifold)
Water outlet (at rear of driver’s cylinder head)
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Last edited by sr5guy; 04-29-2010 at 10:19 AM.
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Old 04-29-2010, 06:45 AM   #2
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Parts that are different, but compatible

Alternator Upper Bracket
*Less adjustment is allowed for on the RL’s bracket
*When the Legend bracket is used the taller deck height prevents one of the bolts from lining up properly

Coil Packs
*RL Coil packs were redesigned with a spark detection system for OBD2 misfire detection.
*RL coil packs have 3 prongs versus 2, the extra prong is for the misfire detection.
*Electrically compatible. Can be used on Legend by de-pinning the Legend connectors and installing the pins into the RL connectors with the misfire detection wire cut off.

Differential
*Uses same internal parts and casting as Legend automatic diff.
*Eliminates the use of an internal oil cooler and associated pipes, but the “bungs” for them are still in the casting.
*Compatible with automatic Legends, for M/T use the legend’s cast iron differential.
*Uses different style speed sensor (use Legend)

Exhaust manifolds
*Different part numbers, and shape, but compatible.

Fuel Rails
*Fuel rails are made of billet aluminum.
*Due to different standoffs on the intake manifold they will not bolt to the Legend intake manifold.
*Uses a screw on type fuel pressure regulator instead of a bolt on.

Mount bracket, driver’s side
*Completely different design.
*Uses same bolt pattern as Legend.
*Legend bracket bolts on directly for swap.

Valve covers
*Different design. 3.5 has integrated standoffs cast into the the valve cover. for coil packs, while 3.2 uses screw in standoffs. Same gaskets, bolt locations, shape, etc.
*Passenger’s side valve cover does not have hole drilled and tapped for oil temperature sensor. It does have a bung that can be drilled out and tapped for the sensor.

Parts that are completely incompatible

Alternator
*Same mounting but different electrical connections.

Camshaft pulleys/cogs
*Section width is thinner by 3mm

Crankshaft Pulley/Harmonic Balancer
*Nose and offset of pulley are different due to the presence of the balance shaft drive cog on the crank.
*Belt pulley diameters remain the same
*Belt position remains the same due to the modification of the offset of the pulley
*Pulley is lightened by 2-3lbs when compared with the Legend’s rubber damped pulley

Fuel Injector
*RL uses saturated injectors (12-14ohms) versus the Legend’s peak and hold type (1-2 ohms).
*Different physical electrical connectors.
*RL injectors can be made electrically compatible by removing the injector resistor box.

Mount Bracket, Passenger Side
*The engine mount system was completely changed for the RL, it used a completely redesigned subframe and mount positions were changed.
*The transmission mid-mounts in some RL’s were changed from the bottom of the bellhousing on the transmission to the rear of the engine mount, directly below the starter on the passenger’s side and next to the differential on the driver’s side. The brackets for these motor mounts should be removed for the swap.
*The passenger side front mounting bracket is shaped differently to clear the balance shaft.
*This requires cutting and welding the leg of the Legend’s mount onto the RL mount.
*The driver’s side mounting pattern and location is identical to the Legends and it bolts right on.

Oil pump
*Different by magnitudes. It’s case now supports the tensioner and front drive of the balance shaft.

Oil Pan
*Different design
*Uses different oil filter bung

Oil Filter
*Different shaft size, incompatible

Speed Sensor
*Use Legend Speed sensor

Thermostat housing
*Due to the eliminated port on water pump outlet, the opening is smaller to match.
*Uses a different shaped o-ring gasket.
*Thermostat and gasket remains the same

Timing Belt
*One tooth longer
*Section width is thinner by 3mm

Timing belt drive pulley/cog
*Section width is thinner by 3mm

Timing Covers
*Upper and lower covers are different.

Water Pump
*Does not have hose nipples on passenger side like the 3.2’s where they would interfere with the balance shaft drive
*Overall shorter in length
*Revised and different shape of water passage
*Uses different shaped o-ring gasket.
*Eliminated port to thermostat housing, passage smaller and shaped differently
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Last edited by sr5guy; 04-29-2010 at 10:30 AM.
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Old 04-29-2010, 06:46 AM   #3
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Old 04-29-2010, 06:52 AM   #4
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where did you find the time to post this??? GREAT info
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Old 04-29-2010, 06:58 AM   #5
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great thread!

ps why do u think the RL vss won't work?
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Old 04-29-2010, 07:02 AM   #6
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+1 this might need to be a STICKY.
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Old 04-29-2010, 07:11 AM   #7
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awesome thread matt!!
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Old 04-29-2010, 07:56 AM   #8
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Nice, will come in handy when i'll do my 3.5 swap.
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Old 04-29-2010, 09:05 AM   #9
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Another great post!! Man I didn't know the 3.5 was so different, I actually think I have the wrong injectors in my 3.5 Hummmmm
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Old 04-29-2010, 09:07 AM   #10
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Excellent write up. This obviously took a long time. Stickied.

Quote:
Originally Posted by sr5guy View Post

Fuel Injector
*RL uses peak hold injectors versus the Legend’s saturation type.
*Different electrical connections.
*Electrically incompatible.

Oil Filter
*Different shaft size, incompatible
Two things caught my eye, that I need help understanding.

The Legends stock injectors are peak/hold. The RL are saturated.
*Use Legend injectors for swap*

Oil filter. What shaft are you refering to?



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