Check out the bottom line of my sig to see the difference compared to the SVT motor (~160hp/135ft-lbs to the wheels stock). In order to get mine to work properly, I have had to install electronics to tune air/fuel ratio, I need to upgrade my fuel injectors, and I am experimenting with colder spark plugs to chase a knock problem I am experiencing. That is with the heads and intake from a 2.5 on a 2001 Taurus 3.0 block, using the stock engine controller.
Terry will most likely do it somewhat differently (if you should decide to go that way), and you'll drive away with a car needing no more work. He is the best - he was in powertrain development for Ford on the Duratech over in the UK. Downside: he is in western Michigan. Not too close to Virginia.
Oh, and you'll spend the same amount, if not more, to tear down your motor and repair it vs. a new one or a 3L conversion. The costs may end up being similar (reman 2.5 vs. Terry doing a 3.0 for you). Besides, do you want to drive around with an engine that has already blown once (if you repair your old 2.5)? Too strong a possibility of hidden damage in there.
I feel for you - I was in your situation this summer.
