Problem with using a non-intercooled VE engine is, one thing leads to another, which leads to another, which leads to another....
An intercooled VE one works much slicker.
First off, if the '95 is a 4wd, you'll have to swap the oil pan, otherwise if it's 2wd leave it alone.
You'll also need the engine mount brackets from the '95, of course.
On wiring it, everything pretty much plugs in, the oil sender is the same, you'll need the '95s temp sender, the alternator wiring unplugs from the '90 and plugs into the '95.
The RED wire in the '95 start/run solenoid wiring is switched and hot all the time and goes to the VE's FSS.
The white wire is hot only when cranking.
To get your Tach and Charging to work, simply use the crank sensor and the harmonic balancer from the '95, though SOME (Not all) 1990 engines do have the notched balancer for the sensor to read off of.
As far as running the overdrive and lock-up, if you acquired the TPS and it's mounting bracket from a '91.5-'93 and use the 1990 engine's TV cable, it's all bolt on and should work fine.
The TPS shares the same range values, resistancewise.
I don't know how involved you want to get with the Intercooler, but you can swap all of the parts associated with it from the '95 onto the 1990.
Also, the 1990 uses the same pullies and fan support (not the fan) as the '95, but you'll need the '95's A/C mount for the A/C compressor to work and it is a direct swap.
Use the thermostat housing and radiator from the '95, along with the radiator hoses and any other accessories, as mentioned here.
On the intake inlet, since your replacement is non-intercooled, you'll need to remove the accelerator bracket for the '95 airhorn to bolt to the intake, as well as use your '95 intake plate, which has the sensors you'll need for the pre-heaters to work correctly.
The intake plate on a non-intercooled locates the inlet 4" further rearward, but if you install the '95 one as it is on the '95 engine, it corrects the offset.
In reality, if you turn a non-intercooled plate 180*, it puts the inlet in the same place as the Intercooled and '94-up engines.
As outlined above, you will need to at least modify the accelerator bracket to clear the intake horn, which leaves you with modifying the old Non-intercooled bracket (preferable, if you have the tools to do so), or acquire the '91.5-'93 brackets, which will still require mods to install on a Non-intercooled engine.
The accelerator/cable mount assembly itself is the SAME between intercooled or Non-intercooled engines, so that part of the assembly is taken care of.
You will have to modify the fuel inlet and returns, but you could look into the '92-'93 lift pump fittings as a possible solution, as they are a "clip on" design, whereas the pre-'92 versions are hose clamped.
Another solution would be to run the '95 lift pump set-up and regulate it down to under 15 psi.
Of course, you'll likely run the turbo off the '95, if not, use the '95s cast turbo elbow to solve the exhaust issue.
All this being said, since it's a "temporary" engine, I'd just install it with the 1995's radiator and bare necessities and run it non-intercooled.
Mark.
by r.anger » Mon Jan 31, 2011 7:22 pm 
