@jamnar
Hi, thanks for the write up!
I'm looking into putting a '96 into my '00 sw2.

Curious when you wrote:

"Vapor canister purge valve - different construction.
Solution: Swap"

Can you clarify what swapped to where?

Thanks!

 

@jamnar Now stickied (please forgive me)

 

I just got back from visiting family in Georgia so it'll take a little bit before I can put together an intelligent reply.
Check back in a day or two and I will have details.

 

sounds good thanks @jamnar
i'll be using this as a guide for my swap, i appreciate your write up!

 

And had to go back to Georgia. Then Clifton Forge.
And a whole bunch of other stuff in between.
Been a crazy couple of weeks.
I will get this info posted. Just taking longer than I expected.

 

@gustycrosswinds
Here's the deal with the evap canister purge valve.
First thing to note is I was swapping a 1997 California emissions engine into a 2000 Federal emissions car so this may be the only reason I had to change this part.
The 2000 purge valve had a quick disconnect on one port:


2000 vapor canister purge valve

The 1997 purge valve did not:


1997 Vapor Canister Purge Valve

There may have also been a difference in the electrical connector, I don't really remember.
Regardless, to save trouble with connecting the 2000 plumbing and connector I swapped the 2000 purge valve over to the 1997 block.

2000 purge valve on 1997 block

 

I had previously given a list of items that needed to be altered or swapped to make the 1997 engine work in the 2000 body.
Here's more info on that with pictures.


1997

#1 The 1997 exhaust manifold was different (probably the Cali spec) and down pipe would not bolt up.
Solution was to replace entire exhaust from manifold to resonator with 1997 parts with the exception of the downstream O2 sensor. That needs to be the 2000 version since they are different.
The upstream O2 sensor is identical so no change needed there.

1997 exhaust manifold

2000 exhaust manifold

#2 The 1997 throttle body was different in many ways and the 2000 throttle body is not compatible with the 1997 manifold.
Solution was to replace the throttle body with a 1999 SOHC throttle body and swap over the TPS and vacuum port assembly. The vacuum lines did need to be modified for the new orientation.

#3 1997 DOHC, #2 1999 SOHC, #1 2000 DOHC

#3 EGR valve is different.
Solution was to swap over the 2000 EGR valve since it's the same mounting pattern and electrical connector.

#4 MAP sensor is different, both mounting and electrical connection.
Solution was to swap over the 2000 MAP sensor. It actually would fit in the 1997 port tightly enough that it didn't require the use of mounting bolts.


1997 MAP sensor

2000 MAP sensor in 1997 intake

 

On the back side of the engine:


1997

#1 MAP sensor was covered in previous post.
Solution was to swap the 2000 to the 1997. It fits.

#2 Evap canister purge valve was covered in previous post.
Solution was to swap the 2000 to the 1997.

#3 Knock sensor. The 1997 and 2000 use completely different sensors, connectors and mounting methods/locations.
Solution was to cut off the threaded portion of the 1997 sensor and modify it to create an adapter that would allow the 2000 sensor to be mounted to the 1997 block.
Here's the 1997 sensor before modifications:

1997 knock sensor
[img alt="2000 knock sensor location
"]https://cimg9.ibsrv.net/gimg/www.saturnforum.com-vbulletin/991x623/2000_knock_location_d759408981fa308e0f0a8da9198612 89e7dd46b4.jpg[/img]
2000 knock sensor location "X" shows unthreaded location where 1997 sensor would have gone.

Cutting off the threaded portion of the 1997 sensor:


Cut off the 1997 sensor threads

Threading it for the 2000 sensor mount bolt

Crude but effective adapter created

2000 knock sensor with adapter installed

2000 knock sensor installed on 1997 block

 

Such a valve (whose open/close behavior is controlled by the signal coming through that 2 wire connector) should be unaffected from year to year as the far as the functionality is concerned. The frequency at which it opened and closed may have been different to meet California emissions, I truly have no idea. But to keep the 2000 PCM happy, you needed to use the 2000 purge valve.

 

It's been said that the 2nd Gen aluminum intake manifold can be swapped over to a 3rd Gen head.
The question has been raised as to why I didn't swap the 2000 intake to the 2nd Gen head and save all the trouble I had swapping throttle bodies, modify fuel system etc.
First, here's what we're working with:


1997 head

2000 head

The problem is those last two studs on the left.


2000 stud

If I want to put a 2nd Gen intake on a 3rd Gen head I would relocate that circled stud to the hole below and to the left.
No problem.
However, if I want to swap the 3rd Gen intake to a 2nd Gen head:


Stud hole missing on 1997 head

I can't relocate that stud on the 1997 head since there's no hole for it.
The location of that stud won't work for the 2000 intake since I need this part to seal so as to not leak coolant:


2000 coolant port

Arrow points to stud that would not have a mounting hole in the 1997 head.

This is why I kept the 1997 manifold and made all those modifications to make it work.