The sticky at the beginning of this forum is a wealth of information for the 1.8 guys but it seems to be missing some crutial information for us 2.2 swappers.

I understand that there are better suited donor cars for specific recipients. I don't know if my prospective set up is ideal, but some of my early october will be spent swapping a 2.5 sohc into my 96 obs that currently has a 2.2. It is an obd2 car, has a knock sensor, no egr that I'm able to locate and a cable clutch.

OPTION ONE
I plan to use
the 2.2 ecu
2.2 wiring and engine harness (need to confirm that this is an acceptable option)
2.5 injector plugs spliced to the 2.2 engine harness with 2.5 injectors
2.2 power steering and associated hoses
2.2 A/C and hoses
2.2 alternator
2.5 intake manifold
2.5 exhaust manifold
2.5 coolant temp sensor
2.5 crank sensor
2.2 Maf sensor
2.5 plug wires and coil/ignitor (with a disabled 2.2 ignitor and spliced wiring upstream)

I think I need to use: (but need to confirm this with others who have done it)
1.8 throttle body
1.8 IAC valve and maybe a portion of the harness


Those of you who have done this swap could you please tell me... does this look about right?


MAJOR OPTION TWO... I will have the 2.5 harness and 2.5 ecu. How much more time should I expect to spend on swapping out the 2.5 harness complete to the ecu? (I have a feeling that would be the best option.)

use 2.5 everything except for the ac/alternator/ps pump

what to do?

 

new option...

since there isn't anybody who has any input... I'll try a rigged 92 saab 900 iac valve 2.5 injector plugs on a 2.2 harness

 

option 2 will save u some headache- drop in that sealed engine and its ecu and ur good to go!

 

scratch both options I just mentioned.

I am now done with the swap and did this....

97 EJ25 DOHC to 99 EJ25 SOHC

swapped the engine harnesses, shaved the tabs off of the injectors so that the 97 plugs would mate to the 99 injectors, swapped the throttle body and added a block-off plate between the TB and the intake manifold for the IACV circuit

Major differences.... Cut the EGR mounting body, brake booster vacuum line, and IAC mounting body from the 97 intake manifold and TIG welded them onto the 99 intake manifold modified the throttle cable/cruise control cable bracket. I used the 97 coil pack and ignitor 99 plug wires with the coil side insulators cut off and used some generic ones to cover and insulate the metal

97 alternator
97 PS pump
97 AC compressor
97 flywheel
97
97
97
97 pretty much everything

sohc out of an RS into a Legacy OB

 

I had to weld a flare nut to the exhaust manifold and run a stainless steel natural gas supply line to the egr body.

Looks fine, works as a stock one would. No check engine lights ever and hell... it passes smog to boot!

Cheers!
Bill