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Discussion Starter #1
Hello everyone, heres the direct question for those of you skimming: Will a 2006-2008 Suzuki Reno or Forenza 2.0L Engine fit in a 2005?? Junk yard says ONLY 2004 - 2005 will fit and 2006 wont???? I call BS after doing research. 2004-2005 is MORE $$$ ????? WHY? I dunno.

Now here's the story, question and reason behind this swap if anyone cares... Its puzzling and any help is appreciated!

I work for a very small power sports shop and we sell used cars as well. We recently had a bad incident where we replaced a head gasket on a 2005 Reno D-TEC 2.0L DOHC with 120K miles (ticked upper end, ran rough, jumped time 1 tooth). Found bad Head Gasket and warped head. We changed timing kit, head gasket, all upper end gaskets, had the head resurfaced (they took off .015") and pressure tested. Put it all together and it ran great for 100 miles or so. Sold it to a customer and it lasted 30 minutes and blew up. Tore the thing down to the last bolt and stripped the block of all parts. Found ALL 4 pistons were seized onto the wrist pins (press fit into rods w/ no circlips) BADLY. Found that when we cranked the engine over we had NO OIL pressure into the head (had TONS b4). Head gasket is very suspect (it was aftermarket) but I cant tell for sure if it was HG failure or something else first (HG is DEF bad now). Cylinders are great, crank is fine, rods are ok, main and rod bearings good. Oil pump didnt heat up and doesn't have any wear. Had a new water pump as well in the timing kit. Any opinions????? We're at a loss here :eek: Motor had no damage except the pistons seized to wrist pins. VERY confused not finding other damage. I noticed this motor only has the 1 oil passage and my theory is it leaked compression from cylinder into oil passage and stopped oil flow. HG has a pattern that looks like this happened but no one believes it.

Thanks!!!! :lol:

Roger
 

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2006 are OBDII and use a different ECU, injectors and emissions controls system to the 2005. Direct swaps are not possible without some serious rewiring. Some engine parts may be interchangeable but the control systems are definitely not.

you might get away with a block and head swap using all the manifolds and injectors off the 2005, but I'm not sure if the manifolds interchange between the 2005 and 2006.

the oil passage is in the front of the gasket, and I've seen them partially occlude the gallery leading to the overhead gear. If its the pins siezed to the conrods, i'd also be looking at other blocked oil holes as well, that quite often gets overlooked with a new gasket, "we found the prob, yay" but a bit of old gasket gets stuck in a gallery, blocking oil to somewhere else.

have a look at this link http://www.suzuki-forums.com/suzuki-jimny-sierra-samurai-forum/140137-its-head-gasket-correctly-pic.html

while its on a samurai, it still shows the partially blocked hole bottom right.
 

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Discussion Starter #3
The pins are always seized to the conn rods... they are press fit. The pins pivot in the pistons not in the top of the conn rod. The pistons actually seized to the pins.

We took the head apart and had it machined and cleaned and blew air through all passages with the oilers removed... But your right it could have been plugged in the block.

However, the oil passages fro the wrist pins are in the conn rods and its a sprayer jet that coats the cylinder and the oil ring scrapes the oil off the cylinder to lube the pin into piston. The jets in the conn rod are fed through the crank and lower conn rod bearings. The cylinders had oil leading me to believe this was working.

I THINK the top end lacked oil causing an overheat condition and the cylinders got hot enough to burn the oil and not lube the pins... this is a THEORY though. This leads me back to your suggestion of the oil passage being obstructed in the block to head area. I did check this after the engine failed and it wasnt plugged but it could have been when it was put together..... you just never know. The HG wasnt in goot shape around the oil passage area at all.

As far aw OBD2 all vehicles after 1996 are obd2.... I think I get what you mean though... they updated the controls of the engine and its a different GM system... I should be able to swap all electronics and make it work.. the manifolds are the same.

Roger
 

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ECU's will be different, but both years are certainly OBD2.

In 2006 they updated a bunch of things, with the most noticeable being the DBW throttle body. Block and head should mostly be the same however.
 

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Discussion Starter #5
Are the reluctor rings on the crankshaft going to be the same? I see they use a different crank sensor between the 2005 and 2006 engines. Other than that ALL parts are the same 2005-2006 (crank, cams, block, pistons, rods, plugs, coils, injectors, etc) The head is different part number and cant figure out why....
 

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^ TBH I don't know why the crank sensors are a different part #. I've never actually compared the two cranks or their reluctor rings in person. I've only worked with the 04-05 motors. Not sure why the head would be different part# either... there must be some small revisional changes. Sorry wish I had more info to share...
 

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i know they changed the head design some for the 06. not really sure why or everything they did though. they did change the design of the oil return hose on the valve cover and also the way the coolant runs through the head behind the egr valve. off hand the only other thing i can think of is the drive by wire system.
 

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Discussion Starter #8
OK, its been a while but this is resolved.

We purchased a 2006 Reno/Forenza motor with 35K on it for $1000 delivered and I made it work.

For the record the ONLY things you need to change to make a 2006+ motor work on in a 2004-2005 reno/forenza are:

1. Throttle Body (easy) - intakes are identical and exhaust as well. Just the TB is different.
2. Wiring Harness (easy)
3. I changed the crank position sensor from my 05 motor into the 06 as part numbers were different (dont know if 06 will work)

THATS IT!

Motor runs perfect and purrrrs like a kitten. The 06+ motors had a different breather tube from the block to the head in the front of the motor by the dipstick. The head/valve cover is different because of this. Whole motor swap is SIMPLE. Every other part is the exact same.

Thanks for the help guys!!!

Roger
 

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really happy you were able to get everything working and fixed. its good to know theres another one back on the road and running!
 

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OK, its been a while but this is resolved.

We purchased a 2006 Reno/Forenza motor with 35K on it for $1000 delivered and I made it work.

For the record the ONLY things you need to change to make a 2006+ motor work on in a 2004-2005 reno/forenza are:

1. Throttle Body (easy) - intakes are identical and exhaust as well. Just the TB is different.
2. Wiring Harness (easy)
3. I changed the crank position sensor from my 05 motor into the 06 as part numbers were different (dont know if 06 will work)

THATS IT!

Motor runs perfect and purrrrs like a kitten. The 06+ motors had a different breather tube from the block to the head in the front of the motor by the dipstick. The head/valve cover is different because of this. Whole motor swap is SIMPLE. Every other part is the exact same.

Thanks for the help guys!!!

Roger
Ok but if I want to put a 2006 head on a 2005 can it be done
 

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Ok but if I want to put a 2006 head on a 2005 can it be done
if they are the same, yes. There were changes 2005 to 2006 but i'm not sure if the head and valves changed. I know the sensors and throttle bodies changed. Only way to tell would be to put them side by side and check.
 
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