Swap A New Hemi Into An Old Mopar

If you buy any parts from... 

   

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If you buy any parts from Bouchillon Performance, be sure to mention this article. JR Bouchillon told us he'd give CC readers a price break.

All measurements are in inches.Power levels vary slightly from model and increased with each model year--the 5.7 in the '09 Challenger makes 375 hp.

Similarities And Differences Between The 5.7 And 6.1
Both engines share a number of features, including the following:
Cast-iron, deep-skirt block with cross-bolted main caps
Aluminum cylinder heads
Roller lifters
Dual plugs--two spark plugs per cylinder
Drive by wire (electronic throttle body)

Externally, the blocks are the same size, however, they are different enough on the inside that they cannot interchange; 6.1 Hemis have the following revisions:
Additional block reinforcement
Bigger bore, 4.10 inches versus 3.92 inches
Revised coolant passages
Forged crankshaft
Floating wristpins
Oil squirters to cool the bottoms of the pistons
Billet steel camshaft
Hollow intake valves, sodium-filled exhaust valves
Revised oil pan to reduce windage
Larger intake and exhaust ports
Cast-aluminum intake manifold (instead of molded plastic)
Factory headers
No MDS (multidisplacement system)