Nemasys - 2.0L Hatchback -

[WOLFMAN AK907]

I believe it's from a Froenza?

[xiaogary]

What needed to be done for the swap of 2 liter engine and D20 gear box?

1) Engine mounting.
2) Gearboc mounting.
3) Engine accessories (alternator, aircon, coolant piping...)
4) gearbox linkage and speedo cable or sensor
5) ECU (direct plug in using 1.6 ecu, any rewiring needed)
6) Speedometer and instrument panel modification to fit.

[Petrified.Rabbit]

he hasa build thread split between here and it is mostly on aveoclub.net

[Manorness7]

It's so beautiful...

Oh I also have a question about your projector headlights, will the stock bulb work with them (H4), or are they a different bulb size? I would hate to have to buy new HIDs just because the projector headlight housing is a different size.

[WOLFMAN AK907]

Typically they're usually a different bulb I think.

[Manorness7]

Hmm... I wonder how hard it would be to retro fit an H4 in them, jeeze I hate it when they don't keep things the same sometimes. The projector headlights look mean! but disappointing for the fact that it might not be so easy to fit an H4 in them so nicely.

[WOLFMAN AK907]

Well, if you ordered your kit from vvme.com you could just order the new bulbs you need, they all interchange with the same HID harness.

[Manorness7]

I bought the digital slim ones from a different company...I imagine they would make like an adpater kit or maybe it wouldn't be so difficult to retro fit, I just don't know...

[Reddemonx92]

yea the bulb is different
on the projectors they are H1 i believe not H4 like our regular headlights

[Nemasys]

Wow guys thanks so much for all the nice replies!

Yes the projectors are H1 bulbs, they come with the assembly when you buy them. The HID bulbs were slightly bigger then the ones already installed so i had to take a rotary tool to make the hole bigger.

Like Wolfman said, just get a new set of bulbs, you can find some fairly cheap now.

wow, is that a 2.0L from an optra?

That is correct, also known as the Suzuki Forenza in the States.

What needed to be done for the swap of 2 liter engine and D20 gear box?

1) Engine mounting.
2) Gearboc mounting.
3) Engine accessories (alternator, aircon, coolant piping...)
4) gearbox linkage and speedo cable or sensor
5) ECU (direct plug in using 1.6 ecu, any rewiring needed)
6) Speedometer and instrument panel modification to fit.

1) The engine mounts using the stock mounts from the 1.6, no modification required.

2) The gearbox mounts the same as both the d16 and d20 have an identical casing. You need to transfer some parts from your d16 to the d20 tho, all bolt on.

3) You need ALL the engine accessories, including the flywheel, you dont need the clutch.

4) You can use the 1.6 linkage, the speedo cable is an electronic sensor, can be reused, no rewiring needed

5) You need a 2.0L ecu that directly plugs into the 1.6 harness. You need to extend some of the wires from the 1.6 harness tho.

6) The speedo/tach works fine.