I have successfully transplanted a 92 GT DOHC into a 97 Geo Metro using 98 ODB2 engine controls.
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First I did not want to run the early ODB1 computer and engine controls.
Unless you buy a $300+ piggy back chip and connector, you can't read, adjust or modify any of the ODB1 PCM parameters.
With a 98 ODB2 system you have port injection, ability to see engine running parameters, the ability to tune and adjust
the PCM.
So not only did I transplant a 92 GT DOHC into a 97 Geo Metro, I also upgraded the entire wiring harness to the 98 Geo
Metro for the port injection, fuel tank pressure sensor, no EGR, better head lights, heated back glass, and a few other niceties.
I had to replace the 92 distributor with the 98 cam sensor that required me to build a housing for the sensor that replaced the
92 distributor.
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I also used the 98 fuel injectors on the 92 GT fuel rail. The 92 injectors have different wire ends that would not
plug into the 98 injector ends.
The 92 uses three water sensors. The 98 only uses one to do all the work of three. The extra holes where plugged off.
The 92 used and air flow meter. The 98 does not. I am not sure how this will affect the engines performance. To be seen.
The original GT intake was used. Idle air bleed of the GT was removed and the MAP sensor was installed in its place.
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The Idle Air Bleed for the 98 is part of the throttle body. TB was bored out to 47 mm.
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Opening in the GT intake was 46 mm from the factory and was bored out to 47 mm to match the 98 TB. The 98 TB has a wider hole spacing then the GT TB. I could get two apposing holes to line up. The other two holes I made aluminum threaded plugs, JB welded the plugs in place, refaced the intake at the TB opening, drilled and tapped new holes to take the wider 98 TB.
Being that I now had an engine with no distributor, mounting brackets for the two ignition coils had to be made and fitted
to not interfere with any of the other engine components.
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Most of the 98 wiring fitted the GT engine. The only thing I had to make was a rear O2 sensor cable extension.
The 98 air intake tube had to be shortened and clamped where the cut to shorten the tube was made.
Lastly I had to make a new throttle cable bracket as none of the 92 brackets where even close to where they needed to be
for this transplant.
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Engine specs on the rebuild as follows.
Engine bored 0.030 over with Aires forged pistons.
Pistons needed more oil to the wrist pins. I drilled holes to the oil control rings to get the added oil to the wrist pins.
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Wrist pins from Airies where 0.750". Suzuki wrist pins where 0.748" pistons and rods where bored for the 0.750" wrist pins.
Forged GT crankshaft. was reground to 0.010" undersize with a clearance of 0.0008" to 0.0012". Plastigage was right at 0.001"
New oil pump with the machining done to allow the 98 crank sensor to be installed along with the 98 oil pan was used.
The 98 oil pump has better flow rates then the GT.
The lower crankshaft timing bell sprocket was changed over to the 98 for the crank sensor to work.
The head work I did here at my shop as this is very important to be done right.
Ultra sound the head to remove all the internal hard to get grim and varnish.
Glass bead the head to get the rest of the dirt off.
Fixture was made to hold the head and the tank of hot water and be able to use it on my milling machine at the right valve
guild angles.
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16 new guilds where installed. I drilled out the old guilds as to not stress the head at the guild holes. Head was heated in a tank of hot water to 212 degrees, guilds where chilled in dry ice before installing them. guilds pressed in with
about 15 psi. After head was back to room temperature it took 55 psi too move the guilds. This was tested on a 3 cylinder head
before I ever did it to the GT head.
Stainless exhaust valves. Steel intake valves. 3 angle valve job on new guilds was not long or hard to do.
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Vitain valve guild seals. Springs checked out to be the right height, both free standing and at the compressed height.
I am using the stock cams for now. I may change this later as I tune the engine.
I had two bad lifters so I changed them all for new ones.
I got a new unused header for the exhaust system. The blue paint didn't last long. It turned gray.
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Flywheel was cut for weight and to get hard spots out of it. When done it weighted in at less the 9 pounds.
A turbo clutch disk and pressure plate where used. Pressure plate came in at 350 PSI of holding pressure.
Stock 4 cylinder pressure plate only comes in at 300 psi.
Transmission was a GT and I completely went through it and installed a poor mans LSD. Trans was in nice shape to begin with.
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All the mounts and brackets came off the 98.
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Alternator and starter where rebuilt.
I would have added more pictures but the Forum limits me to 12 pictures only.
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