The other catch is the intake now goes to the opposite side of the engine bay so need to relocate items. The radiator is from the 2.0L. And a 1in body lift will make fitment easier. I cut a few sections of the underside of the hood. Check the photos in my other thread for where I moved things underhood. Washer reservoir, p/s reservoir and such.

Just another update in the quest for more knowledge about this swap. I exchanged some words with Brent at Trail Tough, specifically regarding the CEL codes and the OBD II plug issues found when using an automatic 2.3 donor. He stated that the codes do not effect the running condition or tail pipe emissions, but will fail if testing in your jurisdiction that plugs in for codes. He also went on to say that you would be able to read any codes with a normal OBD II scan tool with the TT wiring.

Personally this wouldn't be an issue because there is no emission testing where I live, and I use a mounted OBD II enabled trip computer to track my mileage, So I'll know when a new code pops up.

I know BRD HUNTER said they don't have a OBD II plug in their wiring earlier, but they must have changed this. Personally, I wouldn't purchase it without this wired in, so maybe it come from customer demand.

We tore out all the wiring and just installed what was needed, which wasn't much.

I got the TT information from Herman.  We spent a lot time on phone discussing what he needed & what he got.  He bought the motor , wiring conversion , and still got an automatic to match his manual.  He was on a trip to Moab when not having the CEL light or OBDII port made his rig to bad to run trails. 

If you are going to run electric fan, get a good one, these motors run hotter than the 1.6L.  We tried using the Aux fan of our 93, and it was not good enough, so had over heating issues.

I'd like to try using the fans out of the aerio. The rad is only small but it has 2 massive electric fans on it. I believe you when you say they are hotter though. I daily drive an 06 aerio, and even when it's -10 Celsius it reaches opperating temp in about 2 minutes, vs about 5/6 min in the 1.6 tracker.

perryd
You will be pleased with the conversion.
This Tracker has a reputation on the southern Oregon dunes for how fast it is considering it is a full bodied vehicle with a heater.
Steve in post #9 gave the link to the 1.6 to 2.3 conversion I did to a 1997 Tracker 4 door which gives most all details.
I purchased all needed parts and motor mounts from Trail Tough and they also did the wiring harness which requires almost all if not all the wiring from the 2.3 donor.
I have not yet had TT modify the Dash to get the tack working.
TT did not wire in the check engine light for reasons they explained,  but the scan tool still tells you why it is not running correctly.
I had a TPS and a spark plug fail and the scan tool isolated  the problem.
The only negative is that I have an automatic ECU (which most of them apparently are) which apparently does not throttle down as fast as a manual ECU as it has been explained to me.
I wait an extra second when up shifting to give the engine a chance to slow down to make it easier on the Tracker 5 speed synchros.
Herman

Herman, good to see you aboard.
Regarding Tach, we did not have any issue with the tach and did not move needle.  As we stripped wiring down to basics I do not remember where I got the tach signal from.  I did spend a lot of time going over wiring diagrams.
Interesting about Herman's clutch signal, as I am looking at another sweet swap and ECU has a clutch signal that I am guessing does a fast idle down.  Perhaps that function is still in Aerio automatic ECU with no wire or signal going to it.  TT may know, and I do not have Aerio wiring diagrams now.  One of the problems with getting this information is that one has to know what question to ask to get correct answer.

The ECU had an output for running the tach, I remember that much.  We did need to add an inline temp sensor since there was no output for running the stock temp sensor in the dashboard.

Thanks for the words of wisdom herman, the swap is becoming closer to a reality the more I read. Between talking to you guys and trail tough it's proving to be much more well supported than I thought.