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Old 02-28-2021, 10:51 AM   #3
fetchitfido
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Join Date: May 2006
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2001 SC2
Default Re: Engine Swap 1995 Saturn SL2

'91-'92 crankshafts can't be used in '93+, the timing gear is funky. '91-'93ish also have a funky bolt pattern to the valve cover that isn't found on '93ish-'98.

'95 for the easiest swap into '95

'93-'94 are nearly identical to '95 but you'll have to put the vac EGR gasket on the elec EGR and redrill the holes to match the vac egr gasket (or use the adapter found on some '94's)

'96-'98 also has the elec EGR but lacks the 2nd ECTS port so you'll have to drill & tap that (use upper radiator hose if the engine is assembled, head if it's being rebuilt). It's not as scary as it sounds, stuff a rag down the pipe past where you plan on putting the sensor, then vacuum it out. If you get a '98 you'll have to swap the IM from the '95, they changed too much with the fuel system in '98.

'91-'98 exhaust manifolds interchange on the head but there were 3 styles and you have to keep the downpipe with the style. '91-'92 got a 4-2-1 header, '93-'98 Fed emission's are identical and '96-'98 got the option of Cali Emission's with a coffee can sized pre-cat in the manifold.

Try to avoid '99-'02, they could be made to work but you'd really want a rear or t-bone hit full parts car to do it.
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