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Uzzy 11-10-2006 08:28 PM

S-Series Swap Guide
 
I can't claim responsibility for this, as many of you will immediately recognize it. There have been lots of questions about engine swaps, and compatibility, and since the self-destruction of turbosaturns.net no one has a place to get many of the answers they need. So, in slightly shortened form, I present to you:

[SIZE="6"][B]S-Series Swap Guide[/B][/SIZE]
Updated 3-06-06

[I]Please be aware that this guide is a work in progress. The information contained within this swap guide is believed to be correct but be aware that errors maybe present. [/I]

[COLOR="Red"]Swap Guide[/COLOR]

[B]Intake manifolds and fuel delivery:[/B]
91-94 Intake manifolds interchange.
95-98 Intake manifolds interchange.
99-2k Intake manifolds interchange.

91-94 Throttle bodies interchange.
95-98 Throttle bodies interchange.
99-2k Throttle bodies interchange.

91-94 Fuel rails and injectors interchange.
95-97 Fuel rails interchange however the injectors from 95 and earlier years will not work correctly in the 96-97 years. The injectors are the same size they are just of different impedance.

91-94 fuel pressure regulators where non-adjustable.
95-97 fuel pressure regulators where adjustable.

91-94 aluminum fuel rails will not fit 95-97 intake manifolds due to the bolt pattern and fuel lines being plastic.
95-97 plastic fuel rails w/adjustable fuel pressure regulators will not fit the 91-94 intake manifolds due to the bolt pattern and fuel lines being metal.

Also, the ports on the 93-94 are much cleaner than 91-92, though the 92 seemed to have a wider opening on the mouth of the intake ports. The 95 mics out close to the 93-94, though it is reshaped with a shallower curve leading down to the valve surface. The combustion chambers up to 94 are all identical.

[B]Throttle Bodies:[/B]
95 AND 96-98 TBís are not interchangeable

95 is different than the rest, however the intake manifold is interchangeable.

[B]Injectors:[/B]
91-95 injectors are peak and hold or also known as low impedance.
96-02 are called saturated injectors or also known as high impedance.

set multi-meter to measure resistance.
2-4(ohms) low impedance
4-10(ohms) weird injectors. pretty much only found on old Porsches.
10-14(ohms) high impedance

[B]Cam covers:[/B]
The earlier cam covers seal better, as they have more bolts holding them down.

[B]Camshaft Specifications:[/B]
*not indicative of all years (1991-1998) but close....*

Int. Centerline 107.25*
Exh. Centerline 107.5*

@.050 specs

Int. Opens -7.5 BTDC Int. closes 27.5 ABDC
Duration @.050 200*

Exh. opens 24.5 BBDC Exh. closes -12 ATDC
Duration @.050 192.5*


@.006 specs

Int. Opens 7 BTDC Int. closes 51 ABDC
Duration @.006 238*

Exh. opens 39 BBDC Exh. closes 7 ATDC
Duration @.006 226*

[B]Heads:[/B]
The '91 DOHC head is a freakshow-leave it alone.
91-94 Heads interchange. (compatible with any year block.)
95-98 Gen2 heads - Linear EGR valve, otherwise compatible with 91-94 heads. Compatible with any year block.
99+ Gen3 Heads are NOT compatible with older heads. Completely redesigned. Compatible with any year block.
2000 (or 1999?) - 2002 Have the roller-rocker design with the small ports.

95 Heads do not interchange with any other year correctly. While yes all the heads up to 99 will interchange physically they will not have proper electronics and egr connections. The 95 head is the first year of the electronic egr valve. And the head has two coolant temp sensors. Now the 91-94 had a vacuum controlled egr valve and also had two coolant temp sensors. The egr mount is completely different between the vacuum and the electronic. Now the 96+ heads also came with the electronic egr valve but they only had one coolant temp sensor due to the fact that 96+ years went to the obd II pcm and only called for one coolant temp sensor.

'91-'94 heads can be adapted to later year engines and use the new style EGR valve if you get the adapter from Saturn that was used on 1994 DOHC cars sold in California, Part#21006753

You can use a '95 DOHC head all the way up to '98 all you have to do is buy one extra temp sender and screw it in the "spare" hole. Alternately, you can install the sender from an Autometer electric coolant temp gauge-it's a direct fit.

[B]Valves:[/B]
91-94 Valves; Flatfaced. Compatible with 91-98 cylinder heads.

95-98 Valves; Dished. Compatible with 91-98 cylinder heads.

91-93 had flat faced valves.
94+ had dished valves.
Now what difference does it make? The 91-93 can be used to raise the compression slightly on the 94+ model years. While the 94+ valves can be used on 91-93 years to lower compression slightly.

[B]Exhaust manifold:[/B]
91-92 OEM header is interchangeable for 93-98 DOHC Saturn engines

SOHC are all the same
DOHC switches from 5 to 9 bolt some year 1999?
1992 OEM Header can be used on 1991-199x model DOHCs (the year before they switch to the new bolt pattern).

[B]Oxygen Sensor Bungs:[/B]
1991-1993 Smaller Bung = o2 Sensors/Bungs interswappable between these years but not interswappable w/ newer ones
1994-2002 Larger Bung = o2 Sensors/Bungs interswappable between these years but not interswappable with older ones

[B]Blocks:[/B]
91-02 blocks are compatible with all years

*1991 - 1993 (midway through '93) blocks contain an oil feed restrictor (looks like a freeze plug with a hole in it) present in the right front oil galley beneath the deck. This should be removed to prevent oil starvation to the head, as the newer headgaskets function as the restrictor.

91-99 blocks interchange externally. Now internally itís a different ball game. The 91-92 had a crank all on its own that will not function correctly in the 93-99 years due to the positioning of the crank position sensor reluctor ring notches. 93-99 cranks are interchangable
'92 to '02 blocks are totally interchangeable. The '00 and up blocks are stronger and all the accessories from previous years fit. Also, the internals from previous years will fit in the '00 and up blocks.

There were 2 dipstick tubes used, not entirely sure when they changed, but 91-92 I know for sure had a dipstick tube that positioned itself away from the block, and I know that my 99 & 2000 have a dipstick tube that hugs the block. The actual dipsticks are the same length so you can use either tube to move the dipstick out of the way of the turbo, or supercharger.

Some people are strengthening their bottom ends by using a 2000+ block girdle. Here's all the parts you need to put a Tie Plate(girdle) on a Pre 2000 Block.

Tie Plate # 21008490
10 Main Bolts #21008491
10 Tie Plate Inserts #21008492
10 Washers #21015091
10 Nuts #11516879
Pick up tube #21008572
Oil Pan #21015428

Also the Tie Plate inserts require a special socket SPX#J44057

[B]Rods:[/B]
1991 - 1998 Rods are the same.
1999 - 2002 Rods are the same.
1999 - 2002 Rods are longer than the 91-98 rods, and have to be used with the 99-02 pistons which have the wrist pin moved up.

The 99-02 rods are 5.863" long vs 5.712" for the 91-98 rods.

[B]Crankshafts:[/B]
91-92 Crankshafts only work with 91-92 PCM's. Avoid at all costs.

93-98 Crankshafts are essentially identical; compatible with any year block.

99-02 Crankshafts were redesigned; heavier. Compatible with any year block.

[B]Pistons:[/B]
So 91-93 Pistons + 94-99 valves equal lower compression.
94-99 Pistons with 91-93 vales equal higher compression.
Now with these compression changes they are slight not drastic. It is about a 2-2.5 point change in compression. So do not expect huge gains.

The 91-93 model years came with the lower compression piston than the later years. The way they maintained the 9:5:1 compression was using the flat faced valves. The 91-93 pistons also came with thicker ring lands which is a plus. Now the 94+ years came with a higher compression piston but it also came with thinner ring lands which is not good. The way they maintained the 9:5:1 compression was by using the dished valves to lower the compression down to its 9:5:1 state.

91-94 Pistons; Slight dish, thickest dome of all years. (Yields 9.5:1 compression with 91-94 flatfaced valves) Compatible with 91-98 rods.

[B]ECU/Harness:[/B]
1991-1999 = Manufactured by Delco
2000-2002 = Manufactured by Motorolla
1991-1995 = OBD1
1996-2002 = OBD2

91-92 PCMs are grouped together. The wiring harness for them is slightly different (two wire type oil presssure unit). If using a 93+ block the oil pressure unit must be changed in order for the harness to hook-up.
93-94 PCMs are grouped together.
95 PCMs are year specific.
Years after this, I'm not sure.


[I]To be continued...[/I]

Uzzy 11-10-2006 08:29 PM

Re: S-Series Swap Guide
 
[B]MAP/Pressure sensors:[/B]
There are several varieties of pressure sensors from GM: Map sensors in 3 varieties (1 bar, 2 bar, 3 bar), and a barometric pressure sensor. 1 Bar sensors are good for NA engines, they measure from 0 (vacuum) to approximately atmospheric pressure. A 2 Bar sensor is good for 15 PSI of boost, and a 3 Bar unit is good for 30 psi of boost.
They all share a common pinout, although the connector keying may be different:

Pin A -- Ground
Pin B -- Sensor output
Pin C -- +5 volts

Version Part numbers Description

1 Bar GM part # 2503679
standard part # AS-5
Pretty much any normally aspirated TBI GM car, plus plenty of others

2 Bar GM part # 16009886 ~$49 ([url]http://www.gmpartsdirect.com[/url])
Wells part # SU-129
standard part # AS-4
91-93 GMC Syclone & Typhoon 4.3 turbo
87-90 Pontiac Sunbird Turbo 2.0
84-86 Sunbird (actually any J-car) turbo 1.8

3 Bar GM part # 16040749
1989 turbo Pontiac trans am

When swapping heads from tbi SOHC to DOHC the engine side of the wiring harness needs to be swapped to the same year harness as the PCM/head. The SOHC PCM needs to be changed to the DOHC PCM of the same year grouping as the head (no matter what). If you have an auto, you must swap to the appropriate year DOHC tranny also.

If going from mpfi SOHC to DOHC, the harness doesn't need to be change.

95 used OBD-II style closed loop operation. If you want to boost and plan on having the stock computer be a part of things, pre-95 is better. You can run rich at boost/part throttle. 95 and later you can't, 99+ is even more sensitive.

When doing my swap from 95 SOHC to 96 DOHC I used the same wiring harness, but the 95 DOHC PCM I bought would not connect due to the connectors so I cut the little guide tabs off with some tile nippers and slid the connector in the PCM it snapped in and no service engine. The only problem was the 95 head has 2 temp sensors and the 96 only has one so I left the gauge sensor out.

[B]Clutch:[/B]
1991 - 1999 Have the original clutch design.
2000 - 2002 Have the self-adjusting hydraulic POS.
1991 - 2002 Have the same flywheel and throw-out bearing.


[B]Fuel System:[/B]
1991 - 1997 Have the wonderful fuel return line.
1998 - 2002 Have the returnless fuel system.
1999(?) - 2002 have a plastic test port.
91-94 fuel pressure regulators where non-adjustable.
95-97 fuel pressure regulators where adjustable.
91-94 aluminum fuel rails will not fit 95-97 intake manifolds due to the bolt pattern and fuel lines being plastic.

Return type fuel rail used on 2003-04 Cavalier and Sunfires will convert "returnlees" type fuel rail on 2003-04 ION. You will need to convert/replace tank unit AND route a return line back to the fuel tank as well (or at least as far as the T-fitting at the fuel filter) The 2 line JBody filter can then replace the 3 line version in this mod.

[B]Fuel Pumps:[/B]
98-99
Type: Turbine
G.P.H. 35-45 or L.P.H. 132-170 wide open
Max P.S.I. 70-90

97
Type: Turbine
G.P.H. 30-40 or L.P.H. 114-151 wide open
Max P.S.I. 70-85

91-96
Type: Gerotor
G.P.H. 30-45 or L.P.H. 114-170 wide open
Max P.S.I. 65-75

There is a Walbro pump that fits 97+ Saturns. Look on [url]www.turbosaturns.net[/url] site for the complete write up.

[B]Axles/CV:[/B]
Also, I understand the axles are larger on post '98-'99 cars?

The spline pattern for 98 and up seems different. I know '98 to '93 are different, as I have parts for both. I pulled the '95 axle real quick and it has the same spline pattern as the '93.

Of course, the ABS axles are thicker, and are preferable to the non-abs axles for anyone who's ever launched their car. They should be able to be used w/ or w/o abs, I'll verify that when I go to the parts yard.

[B]Brakes:[/B]
The rear disc brakes from any s-series with abs will fit any non-abs s-series.

[B]Oil pans:[/B]
91-98 oil pans have a clearance problem when installing the windage tray from a 2000+up into your engine so get the oil pan along with the windage tray. The last 2 nuts hold the oil pan up about 1/4" off of the rail


[B]Belt Tensioner:[/B]
The belt tensioners from 91-97 are manufactured by Gates. From í98-í02, they are manufactured by Dayco. The OE Gates tensioners fit any year, the OE Dayco tensioners do not fit 91-94, Iím not sure about the 95-98 blocks though. The tensioner is too deep for the hole it sits in, 98+up have a bigger hole in them to accommodate the new tensioner. The aftermarket Gates tensioner should be avoided if at all possible, OE is best.

"What belt bypasses the P/S and A/C?"
Survey says: Saturn part# 21007093. Gates part# (for SOHC, donít know about DOHC) K050551

[B]Instrument cluster:[/B]
1991-1992 Instrument clusters can't be used with the 93+ wiring harness unless the wires are moved to the proper places in the connector face (some of the wires are in different places).

[B]Disk Brake Conversion:[/B]
For some reason Saturn decided to change the E-brake cables six different times. The models listed below each have their own style E-brake cable. There are two different lengths (short wheelbase, and long).

Also, in '95 Saturn decided to change the connector at the E-brake cable. This continued till midway through '97, then they went BACK to the original style.

91-94 SC/SC1/SC2

91-94 sedans and wagons and all 97-02 cars (97 with VIN#s VZ334256 (sdn) VZ334335 (wgn) and VZ334269 (cpe) & higher

95-96 SC1/SC2

95-96 sdns, wgns, all 97 models with VIN #'s VZ344255 (sedans) VZ344334 (wagons) and VZ334268 (sedans) and prior

[B]Aftermarket:[/B]
Fel-Pro Gaskets & Seals:

1991-1998
Head Gasket: 9968 PT
Intake Gasket: MS 95632
Exhaust Gasket: MS 95630
Throttle Body Gasket: 60998
91-94 Vacuum EGR Valve Gasket: 70978
(94 CA)95-98 Linear EGR Valve Gasket: 70789
Valve Stem Seals: SS 72867
Front Crank Seal: TCS 45958
Rear Main Seal: BS 40615
Water Neck Seal: 35087
Water Pump Seal: 35090

[B]Spring Rates: [/B]
OEM Springs: 126 lb/in front, 129 lb/in rear
Dropzones 450 lb/in front, 350 lb/in rear
H&R Race Springs: 310lb/in front, 250lb/in rear
H&R Sport Springs: 205 lb/in front, 195 lb/in rear
Eibach Pro Kit: 149 lb/in front, 91-159 lb/in rear
Progress Group: 200 lb/in front, 170 lb/in rear
Sprint 2" Springs: 200 lb/in front, 140 lb/in rear
Sprint 2.5" Springs: 200 lb/in front, 140 lb/in rear
KYB GR-2 front: 30% stiffer than stock
KYB GR-2 rear: same as stock

ARP studs from Jegs or Summit.
Main Studs: Part #165-5402
Head Studs: Part #165-4202

[B]Motor Mounts:[/B]
Prothane inserts. They're only $25.99 from Summit. And that will do both dogbones. Part # PTP-7-510. Caution: Engine Vibration may significantly increase over stock.


[I]Turbosaturns.net
Swap Guide
Updated 3-06-06

Please be aware that this guide is a work in progress. The information contained within this swap guide is believed to be correct but be aware that errors maybe present.[/I]

geartooth94 12-12-2006 06:50 PM

Re: S-Series Swap Guide
 
RIP turbosaturns.net :tear:

eljefino 12-12-2006 08:58 PM

Re: S-Series Swap Guide
 
That place was fun, you had to have a spine, and most people were pretty hard core.

That swap guide is 99% DOHC, so if you're reading and get confused, step back and consider the audience.

RangerRover 12-12-2006 09:50 PM

Re: S-Series Swap Guide
 
Sent a PM to Charlie, asking him to make this a sticky..

osxuser 12-13-2006 01:04 AM

Re: S-Series Swap Guide
 
Another ex-TSN guy here, those guys were crazy... :dizzy: Thanks for bringing this over.

Uzzy 12-13-2006 01:05 AM

Re: S-Series Swap Guide
 
[QUOTE=RangerRover;959663]Sent a PM to Charlie, asking him to make this a sticky..[/QUOTE]

So did I when I posted it. Busy guy. :|

wolfman 01-25-2007 10:25 AM

Re: S-Series Swap Guide
 
I only found one error:

1991 - 2002 Have the same flywheel and throw-out bearing.

Sorry but, WRONG. The late 99'-02' flywheels use LARGER clutch disks (with completely different part numbers) and as a result are machined differently to accomodate them.

91'-EARLY 99' use the exact same flywheels.
LATE 99'-02' use the exact same flywheels.

(Oh, and not all DOHC 99's resemble the 00' and up engines with the "new" heads. There are MANY, MANY early 99' DOHC that are the same as the 95'-98's.)

Carlyle 02-05-2007 02:49 AM

Re: S-Series Swap Guide
 
Hey what stock GM injector is best to swap into my 93 DOHC? Like, out of what car?

Shaw18 Racing 02-06-2007 10:58 PM

Re: S-Series Swap Guide
 
I would like to add to list if I may.

[FONT="Arial Black"]Axels/CV[/FONT]
[FONT="System"]91'-94 early models all same(longer smaller splines)
94' later models-at least 00' all the same(shorter larger splines)


[FONT="Arial Black"]Radiators[/FONT] [/FONT]
[FONT="System"]91'-94' early models all same
94' later models- at least 00' all the same[/FONT]

c_dicken 02-14-2007 03:09 AM

Re: S-Series Swap Guide
 
Watch out that shaw guy will give u advice and the next thing ya know your stuff blown up :D lol just playin this mans pretty smart he knows his saturns

sl2clone 02-26-2007 01:39 AM

Re: S-Series Swap Guide
 
Axle discrepancy here.
I stripped SEVERAL saturns in my driveway.
It's 91-93 that are the small axles and small hub holes. 94+ are the larger outer axle stubs. The inner stubs are the same.
Couldn't use my 92 spindle in my 99 until I swapped out the hub. Used a 94 auto in a 92. My 94s were both late production 93s but sold and titled as 94s.

asdf 02-26-2007 06:26 PM

Re: S-Series Swap Guide
 
True, it's not like the differential is different for any year. It's only the 91-93 hubs.

anaverin 03-16-2007 06:09 AM

Re: S-Series Swap Guide
 
I HAVE A 95 sc2. I have used later heads before and modded a new coolant sensor hole. I need to know if i can change to a spare 2000 sc2 head i have. What do i need to change in the timing cover deparment? will the intake manifold and exuast manifold bolt up? just a thought i had. thanks

Uzzy 03-16-2007 07:55 AM

Re: S-Series Swap Guide
 
[QUOTE=anaverin;1020098]I HAVE A 95 sc2. I have used later heads before and modded a new coolant sensor hole. I need to know if i can change to a spare 2000 sc2 head i have. What do i need to change in the timing cover deparment? will the intake manifold and exuast manifold bolt up? just a thought i had. thanks[/QUOTE]

I know for sure, exhaust will not bolt up. As for the rest, I don't know personally.

cyphon21 03-16-2007 10:40 AM

Re: S-Series Swap Guide
 
What about interior wise?

Will the interior panels of the doors fit the SC to SL or opposite? or is it just the seating that can be switched?

madpogue 03-16-2007 12:08 PM

Re: S-Series Swap Guide
 
[QUOTE=cyphon21;1020209]Will the interior panels of the doors fit the SC to SL or opposite? or is it just the seating that can be switched?[/QUOTE] Just look at both cars. The coupe doors are considerably bigger than the sedan doors. Not even close. Sedan and wagon doors are the same, however.

mlt01SC2 03-26-2007 10:51 AM

Re: S-Series Swap Guide
 
Anybody know about interior switches such as the door jam switch or the fog light and dimmer switch? I have an '01 SC2 (hence the user ID) and need both.

Tanro 04-19-2007 01:44 PM

Re: S-Series Swap Guide
 
Hey is the guide orignally from Turbo Saturns?

Uzzy 04-19-2007 09:58 PM

Re: S-Series Swap Guide
 
[QUOTE=Tanro;1043241]Hey is the guide orignally from Turbo Saturns?[/QUOTE]

Yes. In the preamble I said where I stole it from. :yes:


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