1. Compatibility and Parts Sourcing:
* Engine Compatibility: While both are V6 engines, the 2.7L and 3.5L have vastly different architectures. You'll need to determine the exact year and model of both the donor 3.5L engine and the recipient Charger to ensure compatibility. Even within the same engine family, there can be significant differences based on year and trim level. Wiring harnesses, ECU (Engine Control Unit), and transmission compatibility are crucial.
* Transmission: The 3.5L engine likely uses a different transmission than the 2.7L. You'll likely need the transmission from the donor car as well, and it might require modification to fit the Charger's chassis.
* Wiring Harness and ECU: The wiring harnesses are completely different. You'll need the complete harness from the donor vehicle and potentially need to adapt it to work with the Charger's existing system. A standalone engine management system might be necessary.
* Mounting Points and Brackets: The engine mounts and brackets will almost certainly be different. Fabrication or modification of existing mounts will be required.
* Exhaust System: The exhaust system will need to be replaced or significantly modified.
* Cooling System: The radiator, hoses, and possibly the water pump might need to be changed to accommodate the larger engine's cooling requirements.
* Driveshafts: The length and potentially the design of the driveshafts might need modification or replacement.
2. The Swap Process:
* Removal of the 2.7L Engine: This involves disconnecting numerous components, including the wiring harness, fuel lines, cooling system, exhaust system, and transmission.
* Installation of the 3.5L Engine: This requires precise alignment and careful mounting to ensure proper operation.
* Wiring and Computer Integration: This is arguably the most challenging aspect. You'll need extensive electrical knowledge to correctly integrate the donor engine's harness with the Charger's system. Improper wiring can lead to engine damage or vehicle malfunction.
* Transmission Installation: This involves connecting the transmission to the engine and to the driveshafts.
* Exhaust, Cooling, and Other Systems: Reconnect or replace all the necessary components like the exhaust system, cooling system, and any other systems affected by the engine swap.
* Programming and Calibration: The ECU needs to be programmed and calibrated to work correctly with the new engine and transmission. A professional tuning shop might be necessary.
3. Legal and Safety Considerations:
* Emissions Compliance: Depending on your location, the swap might affect your vehicle's compliance with emissions standards. This could require significant modifications and inspections.
* Insurance: Inform your insurance company about the engine swap. They might require an inspection or adjust your premiums.
In Summary:
This is a highly complex and labor-intensive project requiring significant mechanical and electrical expertise. It's not recommended for someone without extensive experience in automotive repair and engine swaps. Unless you're very experienced, this should be handled by a professional mechanic specializing in engine swaps. The cost of parts, labor, and potential unforeseen issues could easily exceed the cost of purchasing a Charger with a 3.5L engine.
