I started with a 1108cc Mpi seicento MS,
We decided it was time to upgrade as the 1.1 was showing serious signs that it was ready to fail.
The plan was to buy and turbo a 1.2 over time but the quick spiral of the 1.1 forced us to fit a 1.2
I choose a 1242cc 8v mpi 188.a4.000 from a mk2 punto, it came with all ancillaries except exhaust manifold, it also had aircon.
The removal proved easy enough, we took the gearbox off then took the engine out through the top of the bay.
In hindsight, As we were using a forklift instead of a engine lift. I would have lifted the whole car made a wooden gearbox and engine stand, rested the car, disconnect as much as I could then lift a bit, disconnect a bit more until the car was free of the engine and box.
The engine mount is different on the punto, as well as some of the ECU wiring (sei is over the passenger arch, punto at the back of the manifold), the crank wheel was also too wide and the wrong way round.
So it made sense to strip and swap EVERYTHING from the old engine to the new. Really straight forward. The only sticking point was the crank TDC sensor, for this we had to modify the mount. Because the sensor sits on the other side of the crank pulley.
We cut where the sensor slots in so that it could slide in and out (inline with the engine) . Then using 2 peices of aluminium (I suppose you could you washers)and created a spacer that brought the sensor out to be in line with the point on the pulley.
After this it was all just reverseal fitting back into the car.
Once the engine was back in we refitted the gearbox (remember to grease the spline, we forgot and it was a nightmare to slot in)
Only thing left was the exhaust to do. As the 1.1 exhaust manifold had the Cat directly off it and the fact that it was a sportex exhaust that had already be chopped and messed with (it was rusty and worn as well) , we just dived in and cut/welded away.
The downpipe now caught on the sump of the taller 1.2 but because of the cat we were unable to extend it down so instead chopped 2-3cm from the bottom of the cat placed a smaller 1.5inch S/s pipe in side it at a slight down angle (had to cut a V shape in the end) about 5inch long and welded that on, we then welded a 1.75ich pipe over that (about 10inch long) and a long flexi section on the the end of that.
The other end of the flexi got a 1.75inch pipe welded to it about 12inch long, we also attached an exhaust bracket to it so it went on the original mount.
By this point there was a bend approaching on the original exhaust so we cut before the bend and welded that to the 1.75inch.
Now we used gun gum and a pipe joiner and bolted what we had made and the original exhaust togeather. Not the pritiest but it worked.
The only other sticking points, we lost the cerclip for the throttle cable at the carb end. So it didn't idle correctly at first. Luckily we found it!
The coolant pipe from the header tank to the 4way peice was to close to the engine and was burning so has to modify an existing clip to hold it away.
The clutch was a bitch to get right too (as it was brand new)
And our drivers side ball joints and coilover bolts were all fussed togeather so had to chop it out and order another on (unfortunately the MS has ABS so not easy to find a hub with it on)
We had never attempted an engine swap before, and even with the problems of the drivers hub (we spent a good 6 hours trying to free all of that up)
It took us around 28hrs, we took our time because we didn't want to mess anything up and recon if we were to do it again it would be half that time.
We decided it was time to upgrade as the 1.1 was showing serious signs that it was ready to fail.
The plan was to buy and turbo a 1.2 over time but the quick spiral of the 1.1 forced us to fit a 1.2
I choose a 1242cc 8v mpi 188.a4.000 from a mk2 punto, it came with all ancillaries except exhaust manifold, it also had aircon.
The removal proved easy enough, we took the gearbox off then took the engine out through the top of the bay.
In hindsight, As we were using a forklift instead of a engine lift. I would have lifted the whole car made a wooden gearbox and engine stand, rested the car, disconnect as much as I could then lift a bit, disconnect a bit more until the car was free of the engine and box.
The engine mount is different on the punto, as well as some of the ECU wiring (sei is over the passenger arch, punto at the back of the manifold), the crank wheel was also too wide and the wrong way round.
So it made sense to strip and swap EVERYTHING from the old engine to the new. Really straight forward. The only sticking point was the crank TDC sensor, for this we had to modify the mount. Because the sensor sits on the other side of the crank pulley.
We cut where the sensor slots in so that it could slide in and out (inline with the engine) . Then using 2 peices of aluminium (I suppose you could you washers)and created a spacer that brought the sensor out to be in line with the point on the pulley.
After this it was all just reverseal fitting back into the car.
Once the engine was back in we refitted the gearbox (remember to grease the spline, we forgot and it was a nightmare to slot in)
Only thing left was the exhaust to do. As the 1.1 exhaust manifold had the Cat directly off it and the fact that it was a sportex exhaust that had already be chopped and messed with (it was rusty and worn as well) , we just dived in and cut/welded away.
The downpipe now caught on the sump of the taller 1.2 but because of the cat we were unable to extend it down so instead chopped 2-3cm from the bottom of the cat placed a smaller 1.5inch S/s pipe in side it at a slight down angle (had to cut a V shape in the end) about 5inch long and welded that on, we then welded a 1.75ich pipe over that (about 10inch long) and a long flexi section on the the end of that.
The other end of the flexi got a 1.75inch pipe welded to it about 12inch long, we also attached an exhaust bracket to it so it went on the original mount.
By this point there was a bend approaching on the original exhaust so we cut before the bend and welded that to the 1.75inch.
Now we used gun gum and a pipe joiner and bolted what we had made and the original exhaust togeather. Not the pritiest but it worked.
The only other sticking points, we lost the cerclip for the throttle cable at the carb end. So it didn't idle correctly at first. Luckily we found it!
The coolant pipe from the header tank to the 4way peice was to close to the engine and was burning so has to modify an existing clip to hold it away.
The clutch was a bitch to get right too (as it was brand new)
And our drivers side ball joints and coilover bolts were all fussed togeather so had to chop it out and order another on (unfortunately the MS has ABS so not easy to find a hub with it on)
We had never attempted an engine swap before, and even with the problems of the drivers hub (we spent a good 6 hours trying to free all of that up)
It took us around 28hrs, we took our time because we didn't want to mess anything up and recon if we were to do it again it would be half that time.
