Now for the "meat and potatoes"....... Here are the main things I found that need to be swapped in order to make the 2.0 work
1. Intake Manifold
The intake from the 2.0 will not work in the Escape. There are sensors on the E's intake that the 2.0's does not have. Don't be an idiot like me and figure this out AFTER the new motor is in the car. It is best to do all the swapping while both motors are out of the vehicle. With swapping the intake comes a new challenge. The water pump outlet nipple on the 2.0 is sitting at an angle that will not allow the 2.3 intake to bolt on correctly. You can bend it however you choose but here is what I did. Take a rubber mallet and lightly tap the nipple so it spins towards the block. Get it as close as you can but leave enough room to get the hose on.
Here is a picture of what I am talking about
2. Cylinder head temp sensor
The head temp sensor's have different plugs on each motor (at least for the '08 2.0, earlier years may use the same one). The sensor in the 2.0 will work with the Escape's ECU but you must swap the connector from the 2.0. I did this by cutting the wires and crimping the 2.0's connector onto the Escapes wiring loom.
3. Fuel rail
The 2.0 fuel rail does not have a fuel pressure sensor built into it. You can either just use the whole fuel rail, injectors and all, from the 2.3 or swap the 2.0's injectors onto the 2.3's. I had to swap injectors because I broke 2 of the 2.3 injectors while uninstalling.
4. Oil filter housing
The 2.3 has an oil cooler built into the oil filter housing. It would be wise to use this on the 2.0 since you are running a smaller motor in a bigger car than it was designed for. I had to use the 2.0's filter housing because the 2.3's was cracked (I believe this is what may have caused my engine failure, oil was pouring out of the filter housing). I plan to install a remote oil cooler in the near future. Make sure to get a new gasket for the housing ($12 at autozone). If you do use the 2.0's filter housing, swap the 2.3 oil pressure sensor because the 2.0's will not work with the Escape's ECU and you will have an oil pressure light on.
5. Camshaft position sensor
The '08 motor uses a different camshaft than the '06. The difference is the timing teeth that the sensor used to pick up the timing. You can swap the camshafts by getting the timing kit for the 2.3 motor and setting it at TDC. Then swap out the camshafts and it should be all good. I did not discover this until everything was installed and I was ready to fire it up. I used the 2.3 camshaft sensor in the 2.0 motor and everything seems to run just fine but I have a pending engine code for the camshaft sensor. I took the E out post-swap for a 40 mile drive and it never skipped a beat so I may just have to deal with a check engine light being on in the future.
6. Passenger side halfshaft mounting bracket
There is a bracket on the back of the 2.3's block that the halfshaft mounts to. Don't forget to swap this onto the 2.3.
Other than that, everything was plug and play. I didn't even have to shim the motor mounts woohoo. If you have any question please feel free to ask. If I think of anything else I will edit the write up.
I will have a video up soon of the post-swap engine running