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***How to swap a 2nd gen 1.9 LX to a 3rd Gen 2.0 97 SPI.***

Pics http://www.intergate.com/~ttool/swap.html

Cost= $300 for my motor from a junk yard with 30,000 mi. And $175-300 for new clutch.
1.9 is 88 Hp, 2.0 SPI is 110 Hp 125 TQ
Both are SOHC motors, very similar. 1.9 is 9:1 C/R, 2.0 is 9.2:1 C/R. The 2.0 head has larger valves, intake manifold/runners, and a larger throttle body 45mm instead of 40.

It would take some good mod´s and money for a 1.9 to = the output of a stock 2.0. And the good new´s is allmost all the mods on a 1.9 will work on a 2.0, things like ignition coil and wires, UDP, Headers, chips and other´s. The cold air intake would need to be modified because the throttle body on a 2.0 is at a angle.

2 days or less to complete swap.
You will need:
A 97 2.0 SPI, a Cheery Picker, Jack, rachet-it-strap, three but-end connectors, good 1/2 inch wrench socket, a goods set of standard and metric tools. And fuel line remover tool. Also get a repair manual, there only $15 and you should have one by now.

You will have to decide what to do with the secondaries butterflies in the intake manifold (SPI) since the 2nd gen PCM does not have a output to control them. When closed they help out with low end power, when open they add high end power. I don´t suggest cutting them out.
One way would be to hold secondary´s open all the time by removing the set screw that adjusts them and replace it with a 2 inch long screw. Or leave the electric motor on manifold and wire to a push button or Tack shift light w/ a relay, Then set the light to what ever RPM you want them to open at. I found 3000 RPM´s to be the best. 2-6 ohm @ 10-25 watt resister should be used in series with the motor to insure a long life of the motor and gears. Read the "How to" "Adjustable SPI Controller" for more details.

Now would be a good time to do the "motor mount mod", Have some window sealer ready.
And new fuel filter, new exhaust gasket, PVC inlet tube gaskets, t-stat and t-stat gasket ready.

This swap was done to a 96 LX that uses OBDII computer.
Instructions will very a little for 91-95, Mostly sensors, and throttle cable.

Parts that must be used:
Must use 97 Fuel system, Fuel rail, injector, FPR. Just buy a 97 Escort motor (only motor used that year). 98 and up use a different fuel system completely. (A 91-96 fuel system can be made to work on 97, 98-up)

2nd Gen Tranny will bolt up to 2.0, auto or manual

Must use 91-96 fly wheel and clutch, 97-up will not work.
91-96 uses a smaller main shaft on the tranny, and a smaller clutch.

The 91-95 and 96 computer (PCM) will run the 2.0 fine, no need to swap.

Must use 91-96 PVC tube. 97 PVC Tube (attached to block w/3 8mm bolts)will hit tranny clutch hydraulic bracket.

Use 91-96 Coolant temp sensor and fan sensors with housing to the heater core and T-stat housing off the head. Or you will need a heater core hose from 3rd Gen.

Use all 91-96 accessories and bracket: Starter, Alternator.

Power steering, A/C Compressor can be left in car w/bracket during the swap.

Start by:
Take out/off- Hood, Radiator, Alternator, Starter, exhaust manifold (or header), Accessory bracket (push to front,can leave power steering pump and compressor line hooked up)

No need to pull tranny if you have a manual. Remove crank pulley, crank sensor and heater core hose (unless auto). Hook up hoist before unbolting motor mounts or unbolting motor from tranny to not put any stress on main shaft. Then you will have to completely remove the passengers side motor mount. Next use a jack to hold the tranny up. Then remove the front and side tranny mounts. Next unbolt motor from tranny. Then use a rachet-it-strap to gently pull tranny to drivers side, don´t get too rachet happy, you could mess up the back tranny mount or bend clutch lines or shifter linkages (just watch what your doing and you will be OK). Next, push the motor apart from the tranny.
This will give you enough room to remove the motor and clutch. Than remove motor. You must use the alignment tool to properly assemble new clutch on fly wheel before you drop in the new motor.
(5sp. only) The most diffecult part of the entire swap is getting the tranny´s main shaft splines to match up with the clutch disk splines (it not that difficult). You will need to line up the tranny and the motor, I used some longer bolts to help guide the two together, and turned the crank with wrench back and forth to get the two to line up as I was pushing them together. You might need to spend some time on this step.

Note: Automatic Transmissions do not need to unbolt the tranny mounts. Just pull off the plate on the bottom side of the oil pan to unbolt the torque converter. Motor will then remove.

Vacuum Lines:
Unscrew the vacuum line distributor from the 91-96 intake manifold. Make a coupler from a short piece of hose to connect it to the drivers side vacuum port. Then connect the brake booster hose, PCV, FPR hose, EGR if you have it,(use hoses from 91-96). On the passenger side port, plug in the cruse control. (Vacuum lines will vary w/ year.)

All sensors and injectors used on a 97 motor are 100% compatible with a 96 wiring harness, The TPS wire´s will have to be extended about 4 inches. You can use the 97 throttle body and Idel air valve.
91-95 will have to swap sensors as per required.

Throttle cable from a 96 is a direct fit, you will have to use the second hole down to take up the slack. No modifying necessary. 91-95 bracket may need to be modified.

Fuel lines are a direct fit, just need to unclip to split them up,
one on each side.

You will have a left over bolt, one that holds the motor to the tranny. For some reason the bottom rear hole is off. But no problem you will still have like 6 or so holding them together. If your a perfectionist than just swap oil pans, than all bolts will line up.

Good Luck, It easy if your prepared.
This mod is great and cheap. The power band from the SPI it is much better than the 1.9, once you get the secondary intake manifold motor working at the correct RPM.
Gas mileage is just as good as the 1.9.
I´v put about 10,000 mi on mine with no problems of any kind.
 

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Thank you. You have help me in making up my mind. I was thinking of the 1.8 T4 BPturbo from a GTR (believe or not I found 6 of them). But that sounded like it would be more trouble then I wanted to get into. It looks I will be making a few calls to find the 2.0 in the morning. I thing that this little 93 LX wagon will have a new life. And soon
 

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Discussion Starter · #4 ·
<TABLE BORDER=0 ALIGN=CENTER WIDTH=85%>[TR][TD]Quote:

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24-04-2003 at 22:02, wiccansilver wrote:
Thank you. You have help me in making up my mind. I was thinking of the 1.8 T4 BPturbo from a GTR (believe or not I found 6 of them). But that sounded like it would be more trouble then I wanted to get into. It looks I will be making a few calls to find the 2.0 in the morning. I thing that this little 93 LX wagon will have a new life. And soon
[/TD][/TR][TR][TD]

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The SPI swap wont give you near the power can of a GTX, but you can have a SPI swap done in a week end. :)
 

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Discussion Starter · #6 ·
<TABLE BORDER=0 ALIGN=CENTER WIDTH=85%>[TR][TD]Quote:

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26-04-2003 at 23:00, 95EsortSittinLo wrote:
is it worth it?
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25% more power for $300........Hell yeah!!
 
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