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2.5 to 2.7 swap in 2000 Grand Vitara

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Offline stunt

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2.5 to 2.7 swap in 2000 Grand Vitara
« on: February 02, 2005, 04:32:31 AM »
I located a 2.7 out of a 2002 XL-7 w/ only 10k on it for $850 + $250 shipping.

The 2.5 seized up at 80k due to the oil pump failing and the wife not pulling over when the oil pressure light came on.

From my previous thread here, I learned that:

* 2.5 and 2.7 have the exact same external dimensions.

* 2.5 ECU should be able to handle the 2.7

Questions:

1. Will I get more power by installing the 2.7 ECU?

2. Will a 2002 2.7 ECU plug into the connector on my 2000 2.5 equipped ride? (ie no harness change needed)

3. Will the y-pipe and cats and other exhaust components from a 2002 XL-7 fit a 2000 Grand Vitara?

I'm trying to preserve the 2.7's 185 hp rating (or perhaps up it a little), so I want to make sure the exhaust flows as freely as possible.  I understand that the rating of the 2.5 was upped from 155 to 165 in 2002 by simply employing some of the XL-7 exhaust components.

Does the aftermarket offer exhaust pieces that improve upon the flow of the factory XL-7 components?  Any vendor recommendations?  Headers, Y-pipe, high flow cats, mufflers, etc.

Thanks!
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Offline ebewley

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Re: 2.5 to 2.7 swap in 2000 Grand Vitara
« Reply #1 on: February 02, 2005, 04:53:12 AM »
Quote
I located a 2.7 out of a 2002 XL-7 w/ only 10k on it for $850 + $250 shipping.

The 2.5 seized up at 80k due to the oil pump failing and the wife not pulling over when the oil pressure light came on.

From my previous thread here, I learned that:

* 2.5 and 2.7 have the exact same external dimensions.

* 2.5 ECU should be able to handle the 2.7




I'm not sure I would agree with that second bullet. There are control differences between the two V6 engines. Not saying it won't work but I don't think I'd bet the farm on it... Be careful and do more research.

Good Luck, Eric
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Offline the_maplebar

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Re: 2.5 to 2.7 swap in 2000 Grand Vitara
« Reply #2 on: February 02, 2005, 06:36:04 AM »
Quote
I understand that the rating of the 2.5 was upped from 155 to 165 in 2002 by simply employing some of the XL-7 exhaust components.


Hey, I've been wondering about that.  I have a 2002 Tracker, which didn't get bumped to 165hp until 2003.  Do you know what the XL-7 exhaust components were?  Is it just  a more free flowing tubing and muffler or something else?

Calmini has a performance exhaust for both the GV and XL-7.  
[link]http://www.puresuzuki.com/exhaust_system1.htm[/link]

I haven't seen anyone that offers headers for the new engines (although I haven't looked to hard).   So I can't really help you out anymore.    I will be interested to see how your swap goes, I plan on keeping my Tracker around a while and if I ever feel the need to replace the engine I would definitely like to upgrade to the 2.7.
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2002 4DR Tracker V6 ZR2.... 1.5"/2" coil spacers front/rear, BDS Strut Extensions, 235/75R15 Cooper STT... They ROCK!!!
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Offline 99Trackerconv

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Re: 2.5 to 2.7 swap in 2000 Grand Vitara
« Reply #3 on: February 04, 2005, 03:27:29 AM »
Calmini has a performance exhaust for both the GV and XL-7.  
[link]http://www.puresuzuki.com/exhaust_system1.htm[/link]quote]


Yeah but they don't make performance stuff for the 99+ 2dr
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Offline the_maplebar

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Re: 2.5 to 2.7 swap in 2000 Grand Vitara
« Reply #4 on: February 04, 2005, 07:39:26 AM »
Quote
Yeah but they don't make performance stuff for the 99+ 2dr


You had me puzzled there for a while, but then I realized that you are right.  On the site Calmini only lists an exhaust for the GV & XL-7 V6.  Does anyone know if they list more products in their catalog?
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2002 4DR Tracker V6 ZR2.... 1.5"/2" coil spacers front/rear, BDS Strut Extensions, 235/75R15 Cooper STT... They ROCK!!!
http://www.zukiworld.com/forum/index.php?topic=35.msg111575#msg111575[/url]
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Offline stunt

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Re: 2.5 to 2.7 swap in 2000 Grand Vitara
« Reply #5 on: February 04, 2005, 09:48:16 AM »
Thanks for the link to the exhaust system Maple.  Looks nice!

As to the hp ratings, I think the XL-7 must use larger pre-cats and perhaps a larger diameter y-pipe compared to the stuff on the original 2.5.

My 2.7, which shipped today, does include the pre-cats, so hopefully I'll end up w/ close to 185 hp.

So I got started tonight on extracting the old motor.  Here is a shot of the patient in my garage with the hood removed:



At this point, the following has been done:

Air filter disconnected
strut brace removed
radiator and shroud removed
vacuum lines disconnected
heater hoses removed
fuel lines disconnected
exhaust bolts holding y-pipe to cat removed
wiring harness partially disconnected



This is a 4x4, so I'm wondering if it would be easier to unbolt the engine from the tranny before pulling it out?  Looks to me like it will be more work to disconnect the transfer case from the tranny than to disconnect the engine from the tranny.  I'm not sure how easy it will be to deal with the torque converter if I leave the tranny in the car.  Any thoughts?
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Offline HotRod

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Re: 2.5 to 2.7 swap in 2000 Grand Vitara
« Reply #6 on: February 04, 2005, 10:15:09 AM »
Nice garage ;D.
Bigger than my house :-/
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95 2dr Geo Tracker with Calmini 6"inch combo lift, 32'inch BFGs M/Tlocked and loaded--D.D is my 06 Racy RED Aerio SX AWD
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Offline SnoFalls

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Re: 2.5 to 2.7 swap in 2000 Grand Vitara
« Reply #7 on: February 04, 2005, 10:49:31 AM »
Quote
Nice garage ;D.
Bigger than my house :-/


Cleaner than my house ... by far :)
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Offline Cwkick

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Re: 2.5 to 2.7 swap in 2000 Grand Vitara
« Reply #8 on: February 04, 2005, 10:56:55 AM »
Guys,

He has his own lift!  :o

*drool*

Cwkick
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95xl7

Re: 2.5 to 2.7 swap in 2000 Grand Vitara
« Reply #9 on: February 04, 2005, 10:59:12 AM »
You will need the 2.7 ECU and the pins in your dash harness connector that connects to the ECU are in different spots. You can pull them out and move them to match the 2.7 ECU. The two motors have different Maf sensors as well.
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Offline 97TRAKIN

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Re: 2.5 to 2.7 swap in 2000 Grand Vitara
« Reply #10 on: February 04, 2005, 11:25:49 AM »
That garage WOW! :o :o :o :o :o
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Offline stunt

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Re: 2.5 to 2.7 swap in 2000 Grand Vitara
« Reply #11 on: February 04, 2005, 12:38:31 PM »
Quote
You will need the 2.7 ECU and the pins in your dash harness connector that connects to the ECU are in different spots. You can pull them out and move them to match the 2.7 ECU. The two motors have different Maf sensors as well.


Thanks man!

I got the seller to throw in the ECU for 50 bucks.  The engine also includes the entire harness and he claims there isn't a single cut.  I'm pretty sure the Maf sensor will still be attached the to 2.7.

Are the pin changes between 2.5 and 2.7 ECU's documented somewhere?

Thanks for the comments on the garage!  I ordered a kit from Miracle Truss (4 bay 48'x30'x12').  It took a few weekends to setup (once the foundation had been poured).  Hanging the insulation was the only thing that sucked.  I had to rent an extend-a-fork lift to bolt the initial frame together.  Them trusses are heavy!  It was built in 2001.
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Offline HotRod

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Re: 2.5 to 2.7 swap in 2000 Grand Vitara
« Reply #12 on: February 04, 2005, 12:38:58 PM »
I hate you ;) ;D
I guess I can't complain too much.I do have a itty bitty one car garage.
Good thing the zuki is small ;D
Good luck on the repairs.
« Last Edit: February 04, 2005, 12:43:32 PM by trickker »
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95 2dr Geo Tracker with Calmini 6"inch combo lift, 32'inch BFGs M/Tlocked and loaded--D.D is my 06 Racy RED Aerio SX AWD
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95xl7

Re: 2.5 to 2.7 swap in 2000 Grand Vitara
« Reply #13 on: February 04, 2005, 01:16:54 PM »
Quote


Thanks man!

I got the seller to throw in the ECU for 50 bucks.  The engine also includes the entire harness and he claims there isn't a single cut.  I'm pretty sure the Maf sensor will still be attached the to 2.7.

Are the pin changes between 2.5 and 2.7 ECU's documented somewhere?

It isn't documented, but looking at wiring diagrams for the Grand Vitara and the XL7 you will see the different locations. It is the connector coming from your 2000 dash harness to the ECU E61 connector.
On the XL7's,the MAF and IAT sensors are part of the under hood harness,not the engine harness.
But you can run the extra 3 wires for the MAF separately. Should be a easy swap.  8)



Thanks for the comments on the garage!  I ordered a kit from Miracle Truss (4 bay 48'x30'x12').  It took a few weekends to setup (once the foundation had been poured).  Hanging the insulation was the only thing that sucked.  I had to rent an extend-a-fork lift to bolt the initial frame together.  Them trusses are heavy!  It was built in 2001.

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Offline 97TRAKIN

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Re: 2.5 to 2.7 swap in 2000 Grand Vitara
« Reply #14 on: February 05, 2005, 08:17:11 AM »
I see suttle changes in your engine bay as opposed to the "04s. Like my charcole (spell) canister is to the rear under side of the truck right above the gas tank. There is also a plastic splash guard over each bank of cylinders covering the coil packs. Is your MAS sensor built into the throttle body too.
The XL-7 does use high flow pre-cats and the main cat is high flow also. These were carried over to the TrackVits for "04.

Here is a shot of the "04 engine bay.
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