1.5 to 1.6 engine swap

[lecote]

hoeh!
I own a 01 accent gs model in Canada. It has 158000km which is roughly 80000 miles.
I have changed the tranny gaskets and filters twice.
the brakes all around..:sigh: twice
tires, all 4... twice, 13's just don't last long..
All Struts.
Rear sway bar links
Front bearings
Both Front axles,( I learned after that first expensive quote just how easy it is to do it yourself.heheh).
Outer CV Boots X 2 (ice-sand and_-35C and cheap boots)
One MAF Sensor
One windshield wiper transmission,
One thermostat.
One intake Manifold recall, (shortly after the repair I left my smoking Car in the parking lot of the local dealership who did the "repair". What I got after that stunt was nothing less then Amazing Service...!!

This is were my story starts..
After 6 years of almost flawless performance from the the original 1.5 SOHC engine, it started misbehaving a few weeks into the early summer. Then after my wife dropped me off at work I noticed the tell tale cloud of steam from a head gasket failure.:yell:
Not one to phased by mechanical maintenance I decided to challenge my skills and look for an upgrade.
So I thought "Let's do a Beta swap!:becky: Then reality hit me and I thought, how bout the GSi Motor then, it's only a little bigger with one different sensor, how bad can it be?":p
I went out and found a parts car for 400$ running, perfectly. It has the 1.6 DOHC engine as it was a GSI model, A/C and five spoke rims
(finally..A/C It may be winter up here for 10 months but damn does it get hot for the other 2 ;) )
The Physical swap went fairly smoothly over a 3 day period in august.
Being as I brought the Ac over from the donor car, I also brought the Main Engine Harness with it, so as to have the Map sensor harness instead of the MAF and the the Ac button hook up.
I still have both set's of computers, but according to many a forum, they are identical so I left the originals in place.
After a few rust instigated set backs and lot A.D.D. moments, the engine swap is complete with all sensors and plugs accounted for.
I go to turn the key and ....notta.
That's were I am at the moment, I will update in a few days as I trouble shoot the wires!
All said, I'm looking forward to figuring this Egnima out and hopefully before the snow falls.(I think I've got a few day's at least LOL)
I am open to ideas opinions and more then happy to answer questions.
After having done all this work, I am quite impressed with the amount of engineering that goes into making a car, even a cheap one!
Ciao fer now.
lecote.

[lecote]

Heoh,
I have quadruple checked that all harnesses are plugged in, and still have a no start.
There is power going to the ignition and out, but there is no power going to the fuel pump and starter. I have lights, but no windshield wipers? It seems the computer and a few relays aren't talking to each other. Maybe some counseling is in order..LOL Going to check with a buddy who has a better scanner,and some more experience. Gonna be warm here in the 'peg for a few days, so hopefully I can figure this out! Ideas are welcome!
Ciao

[Admin1]

Welcome here! You have got your self a big job!
I just looked through the ETM on the Ign System I would check your fuse link(IGN)30A, If its good check your connection at the outside fuse/relay box. Power goes there to the Ignition Switch, It supplies power to the Coils an much more! its on page SD-42. Im pretty sure I sent you a Shop manual didnt I?
As far as the PCM goes there is a different part number for the DOHC/SOHC.

[lecote]

thanks, for the info, I'll check it out, and yes you did send me a link to d load a manual but it doesn't exist? (The requested URL /01ACCXXXX.zip) does not exist.)
I scanned my 'puter to see if maybe I did and saved it in a weird place but no luck. I'd be really happy if I could get a second chance at it! :thumb:
I'll update soon!

[Admin1]

Not a problem I will resend! :typing:
I PM you the manual!

[lecote]

Heoh,
Having spent the better part of the day,looking through the supplied digital manual(super helpful) armed with a circuit tester I've found a few interesting things.
1. Power seems to be going from the ignition through the engine fuse box to the start relay.
2. The ecm slot in the engine fuse box (15 amp) isn't getting any power.?
3.There is no power going to the fuel pump but no ground (from the ecm)to complete the circuit.
4.No power going to the coils through the connectors but there is power in the fuse box.(ecm again)

I've switched both computers to the one's from the original 1.6 as it was running with them. I'm thinking I may have to plug in the old dash and rear harnesses including the interior fuse box so as to have all the original harness in place. Certainly easier then chasing circuits in that rat's nest.
First I'm gonna dig around that ecm fuse wire to see if it helps.
I'm starting to feel a little :crazy:
ciao

[lecote]

heoh,
Still wire chasing,
Found out that the ecm 2 fuse goes to the idle control actuator. So no power there.
Dont' know how this is all intertwined but still studying all those schematics..:deadhorse: but when it starts .this will be worth it:woot:!

[Admin1]

ECM(2) fuse gets its power from the Engine Control Relay, The Relay is grounded by the ECM. When you turn your key on do you get a MIL light? From what it sounds is the ECM is not powered up!

[Accent Sport]

Are you sure that your lack of power distrubution is not related to the Ignition immoblizer system , maybe the immoblizer unit needs it's original ecu/ecm because they are programmed only to read their mated unit from the factory !.
Just a thought, Good luck.

[Admin1]

Thats a very good point! Here in the States we dont have IMM on Accents! Does all years an Accent models in Canada have IMM on them? or can you get them without IMM?

[lecote]

Heoh,
Unfortunately, no mil light on. I can't even get contact with an OBD II scanner.I'm thinking that one of the two computers isn't getting power. My car/s don't have the etac/immobilizer system. The higher end sedans do though. But the Gsi did have powerlock system..so you might have a good lead for me to follow accent sport.!THX
I'm just about got both cars stripped down to the sheet metal for the rest of the harness change. These car are pretty easy to work on physically when you get the trick harness clips and tie downs mastered. Soon I'll have the original 1.6 harness back to front withthe original computers. I'm hoping this will eliminate some possibilities.
Thanks for the clues guys!!!

[Admin1]

Well with you not having the CEL on means your PCM is not powered up! You need to check out ECU Fuse3 10amp(Memory Power) Also check your grounds, For AT trany G11, Manual trany G10, Also check out Fuse 5 battery power with key on or start( ECM connector C26 pin13) Thats the "P"an"G" that powers the PCM up! You will not have power at ECU fuse1 till the PCM is powered up!

[lecote]

That makes sense! I will go back and check those circuit/s grounds again!! MERCI!(french for thank you):pray2:

[Accent Sport]

As far as I'm aware all cars sold in Canada since about the mid 90's have the immoblizer system on them by law, That's why I was thinking that might be the problem since he is trying to use a different ECU/ECM with his factory imm. unit but I'm not sure how they relate/ communicate to one another. If that is what is happening then that would explain why everything else is operating but the engine won't turn over, he is not sending the right code to the right source !.

[lecote]

Heoh!
Immobilizer or not...after the lengthy task of switching the rear main harness over...the 1.6 starts and runs beautifully.:clap2:
I spent the night celebrating,:party: and now I start the process of buttoning everything up.
I had to remove the dash and the half the carpet to re-run the appropriate harness.( but not the actual dash harness.)
There is one wire that's different from the 2 harnesses that' I'm going to try locate in the manual (so we know why)
Thanks for all the info and help!
I'm sure I'll have some, related issues in the near future as I try to keep this car alive.
I'll post in new forums,
THANKS ALL! :Banane35:

[lecote]

Heoh,

There is power going to the ignition and out, but there is no power going to the fuel pump and starter. I have lights, but no windshield wipers?
Ciao

At this point did notice that harness EM03 was different but thought it wasn't that important.:nono:
Just recently I double checked with a co-workers, who's driving a gs model, the 1.5 has three wires(red blue green) in the harness and the 1.6 has 4 (extra white). This is the wire that gives the ecm/ecu it's power.. I think?.
I'm having a little trouble finding it in the schem's.( it's there I'm pretty sure)
Morale of this story is, If you are planning to do a 1.5 to 1.6 swap, plan to bring the wires with it! Every last one!
You will be very happy you did!
Day 2 and my car is running great, and the power difference between the 2 engines is very significant. This is a like new car! :love:
I'll update this in a month!
Ciao
Kevin

[Admin1]

Kevin thank you for this tread! this will be very helpful for anyone that does a 1.5 to 1.6 I can honestly say I have never heard someone do this! But I have! Cool!! Well done bud!

[jsinton]

You can find complete wiring diagrams at hmaservice.com. It's free and the official site.

[Rsquared]

At this point did notice that harness EM03 was different but thought it wasn't that important.:nono:
Just recently I double checked with a co-workers, who's driving a gs model, the 1.5 has three wires(red blue green) in the harness and the 1.6 has 4 (extra white). This is the wire that gives the ecm/ecu it's power.. I think?.
I'm having a little trouble finding it in the schem's.( it's there I'm pretty sure)
Morale of this story is, If you are planning to do a 1.5 to 1.6 swap, plan to bring the wires with it! Every last one!
You will be very happy you did!
Day 2 and my car is running great, and the power difference between the 2 engines is very significant. This is a like new car! :love:
I'll update this in a month!
Ciao
Kevin

If you like that...ad a short ram and swap out the factory muff. You'll get better performance and sound at both ends.

[lecote]

Heoh,
It's been well over a month,and I've gone through the first oil change.
All is good. The only repair I needed was a new hose clamp for the power steering return hose that blew itself off while I was parking. Messy but no biggie.
Thanks for some of the performance tips..I'll consider them. If the car lasts the year, I'll give it some decent rims and rubber, and maybe even a paint job.:tongue: