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GT DOHC into a 97 Geo Metro
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Author:  fainya [ Sat May 02, 2015 12:16 am ]
Post subject:  GT DOHC into a 97 Geo Metro

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.

Author:  me and my metro [ Sat May 02, 2015 12:31 am ]
Post subject:  Re: GT DOHC into a 97 Geo Metro

Sweet, now you can post 12 more pics! :) :lol:

Author:  CAMI Man [ Sat May 02, 2015 12:34 am ]
Post subject:  Re: GT DOHC into a 97 Geo Metro

Very nice !!
Looks like a very clean excellent install , Well done 8)

Author:  fainya [ Sat May 02, 2015 12:39 am ]
Post subject:  Re: GT DOHC into a 97 Geo Metro

Remember, no one has done this swap before.
Engine fired up on the first attempt.
From a standing stop at the bottom of the freeway entrance to
the top of the entrance, 0 to 90 and still in four gear. Only revved it to 6,000 rpm..
New engine that is not broken in yet, so I was easy on the throttle.
4.10 GT gear box. FYI.

Author:  CAMI Man [ Sat May 02, 2015 12:45 am ]
Post subject:  Re: GT DOHC into a 97 Geo Metro

It has been done .
There is a guy in Toronto that has a DOHC GT swap done .
It was on the tv show last car standing .

Author:  geopat [ Sat May 02, 2015 11:58 pm ]
Post subject:  Re: GT DOHC into a 97 Geo Metro

Cami Man wrote:
It has been done .
There is a guy in Toronto that has a DOHC GT swap done .
It was on the tv show last car standing .


With that guys car. my old car and one other that i have heard of there have been at least 3 mk4/5 cars running around in southern ontario with twin cam swaps.
fainya is the first to run it using the mk5 obd2 computer from the sohc 16valve.

Author:  CAMI Man [ Sun May 03, 2015 12:13 am ]
Post subject:  Re: GT DOHC into a 97 Geo Metro

geopat wrote:
Cami Man wrote:
It has been done .
There is a guy in Toronto that has a DOHC GT swap done .
It was on the tv show last car standing .


With that guys car. my old car and one other that i have heard of there have been at least 3 mk4/5 cars running around in southern ontario with twin cam swaps.
fainya is the first to run it using the mk5 obd2 computer from the sohc 16valve.


fainya did a Awesome job !! :!:
Great workmanship :!:
When he gets it broke in maybe he can post a video of a run :D

Author:  Evmetro [ Sun May 03, 2015 8:53 pm ]
Post subject:  Re: GT DOHC into a 97 Geo Metro

Sweet!

Author:  fainya [ Tue May 12, 2015 6:05 pm ]
Post subject:  Re: GT DOHC into a 97 Geo Metro

The new intake air system arrived today and got installed.

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I found soft o ring that would seal the intake tube to the throttle body.
I didn't like the look of rubber hoses and clamps. I used two O rings
72 mm OD, 60 mm ID, 6mm thick, lots of lube an a firm push.
I did the carb cleaner test to see if I had any leaks at the new o ring
Passed with flying colors.

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I added a bracket to keep the air cleaner and the new intake tube secured.

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Tomorrow road test time for brake in, mpg, and performance.
If it get 40mpg I will be happy.

Author:  BV1 [ Thu May 14, 2015 2:28 pm ]
Post subject:  Re: GT DOHC into a 97 Geo Metro

Awesome build, please keep up posted with the results :)

Steve

Author:  fainya [ Thu May 14, 2015 11:17 pm ]
Post subject:  Re: GT DOHC into a 97 Geo Metro

My 1st 200 mile road trip went quite well.
No leaks, no drips, no errors.
I did get it up to 100 mph.
I got 37 mpg at 65 to 68 mph.
The software and the serial to usb cable will be here
Monday and Tuesday.
I will be able to tune the PCM once it all gets here.
If I can get this thing to get 40 mpg at 75 mph I will be happy.

Author:  CAMI Man [ Fri May 15, 2015 10:00 am ]
Post subject:  Re: GT DOHC into a 97 Geo Metro

Nice !! :D
fainya how does it seem to pull so far .

Author:  Teeth [ Wed May 20, 2015 10:35 am ]
Post subject:  Re: GT DOHC into a 97 Geo Metro

I just want to chime in so I make sure I don't miss any updates to this thread =)

I sort of can't believe this works, and the advantages are clear--particularly if you're doing this swap in a Mk4 that already has the wiring you need. I am waiting to see (and assist in any way I can) whether it's possible to alter the fuel/timing maps and rev limiter to something more appropriate for the G13B.

What's most interesting to me is that it's apparently not so crazy to run an engine with substantially different characteristics using a donor ECU, provided the number of cylinders and displacement are roughly the same. Given that I would have to transplant a wiring harness or do a ton of splicing to do this in my 94 GT anyway, this project makes me think that I could use an ECU out of something like a Honda, where all the tuning parameters and methods are well known, as a lower cost alternative to a stand-alone ECU to take advantage of OBDII advances.

Cool stuff :D

Author:  codyb76 [ Wed May 20, 2015 10:36 pm ]
Post subject:  Re: GT DOHC into a 97 Geo Metro

I was kinda waiting to see you comment, as I am under the impression you are our current leader in working with the ecus and chipping etc. I was under the impression that the suzuki obd2 ecu was 'uncracked' as of yet, I actually stopped with my 16v project once I ran into the limitations of the stock ecu.
As far as another ecu like Honda running a Suzuki it is possible, but it would require getting the Honda distributor in the Suzuki and other inputs all from the Honda. But as far as running, most 1.3-1.6L ecus of any make would run a stock engine of that displacement I'm sure, as long as vacuum at idle is sufficient. Think back to the old days, you could set the base timing of a dodge\chev or ford at 6degrees, then bolt the same carb to any of the 350/351/360 engines and they would all run well. Not 'tuned' or completely optimized, but generally run decently. I think fainyas setup will be the same. From my experience with that ecu setup the low rev limit will be the initial hurdle as far as making good power.
This is a neat project for sure. I have both gti(with turbo) and 99 16v with all bolt ons and gt internals, so I've been watching, as this is a conglomeration of both my setups.

Author:  fainya [ Sat May 23, 2015 11:16 pm ]
Post subject:  Re: GT DOHC into a 97 Geo Metro

Since the engine/transmission transplant I have kept the driving to local 10-20 mile runs. Other then a clutch adjustment,
the transmission works great.
As for the engine, I have been chasing the little issues. Water hose to the throttle body split on its end and had to be replaced.
Valve cover gasket got a piece wire insulation caught between the head and the valve cover(oil leak). Removed the valve
cover and the piece of plastic to stop the leak. PCV hose needed hose clamps. Valves rattled on regular grade fuel, I am running midgrade premium to
stop the valves from rattling. Metal wire loom brackets to keep the oil pressure plastic tubing and the front O2 sensor wiring
away from the header. Rubber grommets for the air temp sensor and the pcv breather pipe into the new aluminum air intake.
The twin cam engine runs completely different then any of the other Suzuki engines. I am getting used to it.
So today was 1st long road trip day. 250 miles out and back to see Gokarter. We did chinese buffet for lunch, talked about
going up to GeoPalooza this year, played with cars and generally enjoyed each others company.
So 200 miles at 70-75 with cruise control on, 50 miles around town with the A/C running, car got 40 mpg. (39.871)
Once I got back and the engine cooled down I pulled the plugs to see a nice tan color on all 4 plugs. No glazing on the ceramic
insulators.
So this new engine now has 350-400 miles on it. No leaks on the engine or the transmission. More power and torque then I
ever imagined. And the highway fuel mileage is not that bad. Oh! I did have the car up to 100 mph. The throttle says I can
go faster if I want. Car handled very well with all the new suspension work. I just can't say enough about the Toyo tires.
I am waiting on the new ODB2 to USB cable to arrive on Monday. I can then start monitoring engine parameters and access
what needs to be tuned.
I have a new eprom socket that needs to be installed on the PCM to replace the soldered to circuit board eprom. I have access
to an eprom reader/burner. Once I have a copy of the firmware from the original eprom, I will program a new eprom for
performance and proper low end fuel mixtures. The engine is laggy below 3,000 rpm.
I will post the results as I do the changes.

Author:  fainya [ Sun May 24, 2015 10:13 am ]
Post subject:  Re: GT DOHC into a 97 Geo Metro

On your 94 GT, you would need the engine harness and the PCM off of the 98 doner car.
I would suggest placing the PCM by the glove box like the later car have it.
There will be 2 connectors to the chassis wiring harness. I can give you the pinouts
for the 98 haarness. You would have to come up with the pinouts for the 94 GT.
The cam sensor and the injectors is where you will have to fabricate components to make it work.
The crank sensor is nothing more then swapping the lower timing belt drive pulley. But it will require
a 98 or later oil pump to get the hole for the crank sensor.
I was able to use the 98 engine harness without having to splice or stretch any of the connections.
If you want to use the GT injectors, you will have to change the wiring pigtails from the 98 to
the GT connectors.
The 98 has no EGR, air flow sensor, and will need wiring and another O2 sensor placed behind the CAT.

Author:  Solerpower [ Sun May 24, 2015 11:38 am ]
Post subject:  Re: GT DOHC into a 97 Geo Metro

What Toyo tires did you go with? Proxes r1r, r888, t1r? I know your thread isn't particular to your wheels, but since you brought it up, could you post a picture of them? Thanks

Author:  fainya [ Fri May 29, 2015 3:49 pm ]
Post subject:  Re: GT DOHC into a 97 Geo Metro

The redline on the 98 PCM is supposed to be 6,000. I pushed the
little engine to 7,000 before I got cut out with the 98 PCM and
electronics. I can live with that.

Author:  suprf1y [ Fri May 29, 2015 3:59 pm ]
Post subject:  Re: GT DOHC into a 97 Geo Metro

I believe it's 6750. I shift at 6500 and never hit it

Author:  returntoswift [ Wed Jun 03, 2015 2:42 am ]
Post subject:  Re: GT DOHC into a 97 Geo Metro

I'm very interested in doing this type of setup in my 93 Suzuki. I've been looking at the possibility of running a 2000 Metro or Swift main Harness and ecu but so far I've only been able to score an auto harness. How difficult was it to make the cam sensor/distributer? Is it just the sensor in the dist shell? Im still trying to sort out my wiring but very inspired by your project.

Author:  fainya [ Sat Jun 06, 2015 3:45 am ]
Post subject:  Re: GT DOHC into a 97 Geo Metro

The GT distributor with the 98 cam sensor did not work. I couldn't get the engine to rev past 3,000 rpm.
Link to new cam sensor housing I had to make to cure the problem.
viewtopic.php?f=30&t=59792

The other thing I want to try is the original GT injectors, but I need a set of 92 GT injector pigtails. The
shape of the 98 pigtails will not fit the 92 GT injectors.

The car is sitting right now as I am doing the last two things that need to be finished.
I used the headliner glue that came with the new headliner material. headliner fell down in 6 months and
is out of the car. I will redo the headliner with 3M contact cement.
Front bumper skin is off and at the body shop getting repainted the slate green metalic color of the rest of the car.
Hitting that coyote in West Texas destroyed the original front bumper skin and it had to be replaced with one that
was not painted. The dark grey color does not look as good as the painted ones.

When money permits I am pulling the 2.25" cat and going to the 2.0" cat that I should have put on the car to begin with.

Author:  Dillan03 [ Sat Jun 13, 2015 4:58 pm ]
Post subject:  Re: GT DOHC into a 97 Geo Metro

Could you list the exact modifications that it took to make this happen? I have a 98 Metro and I just ordered a twin cam that I intend on installing very soon. Did all the accessories from the 98 bolt to the twin cam? Any info that you can help with the engine that I got is out of a 91 GT.

Author:  codyb76 [ Sat Jun 13, 2015 5:03 pm ]
Post subject:  Re: GT DOHC into a 97 Geo Metro

Is your metro a 1.3 5spd now or a 3cyl model?

Author:  Dillan03 [ Sat Jun 13, 2015 5:10 pm ]
Post subject:  Re: GT DOHC into a 97 Geo Metro

It's 1.3

Author:  Dillan03 [ Sat Jun 13, 2015 5:13 pm ]
Post subject:  Re: GT DOHC into a 97 Geo Metro

And 5 speed sorry forgot that part

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