The biggest snag you might run in to is that the turbochargers between 1st gen and 2nd gen DSMs were changed up. In the 1st gen the cars used MHI turbos while the 2nd gen used Garret turbos so you may have to custom fab the oil and coolant set up since the 1G head won't be pre-tapped for the lines, and if it is and I'm wrong, it'll be tapped for the MHI turbo. Also the turbo 2nd gen ran an 8.5:1 compression ratio while the non turbo 1g was a 9-9.5:1 ratio so you will definitely want the boost controller between 5-8lbs like you said not so much so you don't have to change the head gasket but more so you don't spin a bearing or blow a rod. Keep in mind the NA doesn't have a knock sensor so you might throw a CEL with that too on your 2G ecu.
Another big problem you might run in to is that 1992 was the year they started the transition from the 6-bolt to 7-bolt crank mid-year. Depending on when your 92 was built you may not be able to transfer over your flywheel and clutch set up and might have to go brand new for those, though the bellhousing and block should still bolt up nicely.
Don't forget injectors and a fuel tune too, the turbo DSMs had 450cc injectors so you will probably want to swap as much of your 2g fuel set up to the 1g as you can. You will need to do a fuel tune for the lower boost since your ECU is programmed to expect around 15lbs of boost and not 8lbs, but they are both 4G63 engines so the fuel system should bolt up nicely.
I can't really think of anything else you might run in to. The two engines are fairly similar and the rest of the systems should connect up nicely.
If you have problems with your turbo system bolting up, I do still have a bunch of parts left over from my 1G auto GSX (1G turbo head, cams, pistons, rods, turbo, intake and exhaust manifolds) that would bolt up and could be set to run on lower boost or built to run on higher boost.
__________________
2001 Chevrolet Monte Carlo SuperSport
|