swapping 16v engines, what to expect?

[Crossover Zack]

hello again!

my Girlfriends tracker has some issues with the engine. it shoots out white smoke upon start-up (my guess is the piston rings are gone), it leaks a lot of oil( my guess is the crank shaft seal), and it has a very rough idol ( my guess is the crank pulley loosened up).

Her tracker is a 1997 16v manual tranny 4X4 2 door with AC

we then purchased a parts vehicle, 1995 16v manual tranny 4X4 2 door without AC

my plan was to do an engine swap next summer after i did all my research, but with the way things are going, i want to have all my ducks in a row should her engine die before then.

now the question is, what should i expect to happen when i do a motor swap.

How much of the engine is a direct swap? (please be very descriptive)

What should i expect to buy,(i.e. Gaskets, hardware)?

if i have not provided enough information, please ask and i will do my best to fill in the blanks.

[razor02097]

If the smoke is only on start up my money would be on valve seals not piston rings.

Do you know the condition of the motor you are swapping? You don't want to swap in a motor that is worse than what you have...

[Crossover Zack]

Originally Posted by razor02097

If the smoke is only on start up my money would be on valve seals not piston rings.

Do you know the condition of the motor you are swapping? You don't want to swap in a motor that is worse than what you have...

good point on the valve seals. not 100% on that.

the motor i plan swapping in starts up, runs, and idols smooth. it still runs in the tracker it is currently in.

[razor02097]

That is a good sign. I'm not sure if a 1997 engine is much different than a 1996.... I do know the accessories from a 1996 will bolt to a 1995 block.

While the 95 engine is out that would be the time to dig in and do all the preventative maintenance items that are difficult to get to normally like timing belt, cleaning the EGR system etc...

[Crossover Zack]

Originally Posted by razor02097

That is a good sign. I'm not sure if a 1997 engine is much different than a 1996.... I do know the accessories from a 1996 will bolt to a 1995 block.

While the 95 engine is out that would be the time to dig in and do all the preventative maintenance items that are difficult to get to normally like timing belt, cleaning the EGR system etc...

visually the engines appear to be identical, intake and everything.

if i could get a descriptive list of the "preventative maintenance" including links to "how to" threads that would be wonderful.

thanks!
zack

[razor02097]

EGR cleaning...

http://www.suzuki-forums.com/suzuki-...tml#post285929

http://www.suzuki-forums.com/suzuki-...alve-pics.html

Timing belt changing...

timing belt swap



Other preventative maintenance things like plugs, wires, oil, etc...

[Crossover Zack]

Originally Posted by razor02097

EGR cleaning...

http://www.suzuki-forums.com/suzuki-...tml#post285929

http://www.suzuki-forums.com/suzuki-...alve-pics.html

Timing belt changing...

timing belt swap



Other preventative maintenance things like plugs, wires, oil, etc...

thanks for all the info!

zack

[Bex]

Generations run like this:
89-90 (OBD1)
1991-1995 (OBD1)
1996-1998 (OBD2)
Your 1997 will be OBD2, different harness, ECU, sensors, etc. to the 1995 You will need to swap the 95 engine, harness and ECU into the 1997 essentially making the 1997 into an OBD1 (on board diagnostics) car, with a 'dumber' ECU, less sensors, etc. I believe that the distributor will need to be swapped as well.

However, it may be just as interesting to see what really is wrong with your 1997, rather than assuming its the crank pulley, pistons, seal, etc. For example, the distributor o-rings spew out a lot of oil at the rear of the engine. I was told my 'rear seal' was gone. Pah. It was just the o-rings - a $5.00 fix. It is ver possible that your 97 engine is not nearly as bad as you think.....

[Crossover Zack]

Originally Posted by Bex

Generations run like this:
89-90 (OBD1)
1991-1995 (OBD1)
1996-1998 (OBD2)
Your 1997 will be OBD2, different harness, ECU, sensors, etc. to the 1995 You will need to swap the 95 engine, harness and ECU into the 1997 essentially making the 1997 into an OBD1 (on board diagnostics) car, with a 'dumber' ECU, less sensors, etc. I believe that the distributor will need to be swapped as well.

However, it may be just as interesting to see what really is wrong with your 1997, rather than assuming its the crank pulley, pistons, seal, etc. For example, the distributor o-rings spew out a lot of oil at the rear of the engine. I was told my 'rear seal' was gone. Pah. It was just the o-rings - a $5.00 fix. It is ver possible that your 97 engine is not nearly as bad as you think.....

if i can keep this engine going i would like to, but time and money are against me. so worst case scenario, i would like to be prepped. i would be willing to trade the 95 for a "drop in" in the 97

once i get some time i can do a look over of the engine and enplane my situation a little better. if simple o-rings, gaskets, and an overall tune-up can solve my problems, i'll be a very, very happy man!

thanks!
zack

[xxx]

swapping what.
short block
long block
the whole thing, with manifolds.
the 95 has no CPK sensor , diffr pan and oil pump.
so you most move those from 97 block to 95, all this is on my swap page. http://kickfix.ac-vw.com/SWAPS.html
search swap. and posted it 100s of times here...


the 97
inspect the crank SNOUT, against my bad crank snout page, see if yours is 1, a runner, 2 fixabel, 3 hopeless... post photo? easy huh? make me un blind..... dig?
do the compression test then the leak down.
those 3 simple tests pass, then put in new valve seals.
run it.

if not swap pans pump and CKP like my swap page shows
the 97 is a OBD2 car. and must use the stock setup.
intake, sensors. EGR .
The ECU is tuned for YOUR 97 EGR not the 95s.
the 97 has unique EVAP system and will fail on the 95 setup
so keep the intake system in tact.
the MAF s are the same.

id kill to find a kick motor that ONLY smoked, what deal......


search in my box
tuneup
nets the whole deal
EGR
vast on EGR, for all 4 generating

FYI, in 1995.5 Suz, switch from 4 port EGR to mono port.
in 1196 they went OBD2, and vast changes.
show photos of supected areas

i guess you never notices the EGR changes or the EVAP 2 vsv
the 97 has a new EGR tube on the right side of the pleum , did you miss that?

no lie they are close, but do you expect the CEL to stay out. (you never said, some do ,some have smog stations, or worse in calif)