CARB legal 1.8 swap?
 

OK, so I have a 91 with some very minor tweaks, but I'm getting bored and want to start making some power. The eventual goal is to go fully built turbo engine but for now going to start with an engine swap. I live in California so I'm going to need to BAR the engine swap and I'm wondering if I'm missing any required parts. (BTW planning on doing a 1.8 NA)

Off the top of my head I need,
long block
1.8 intake/exhaust manifold
1.8 throttle body
1.8 coil pack
ECU for that year
1.8 down pipe
1.8 catalytic converter
1.8 wiring harness
1.8 intake tract
1.8 AFM
1.8 airbox
o2 sensor for after "cat"
(hoping its just that simple)

Also, do I need to alter the fuel tank or EVAP system to comply with CARB? If so what parts are on the 1.8 that aren't on the 1.6?

Also I already have a 95' trans clutch and fly wheel(from converting auto to manual) and a 99' 4.1 open differential so as far as drive train is concerned I think I'm good to go.

Try to stay with a '94-'95 donor if you can, as that will reduce the complexity of the changes to the cars other wiring harnesses. You also won't have to modify the fuel system or deal with any of the other hassles.

The big question will be whether to replace the entire front harness of the car (which includes the ECU harness) or to modify the one you have. Replacing is more work overall, modifying requires some electrical skills. Either way, the FSM wiring diagrams will haunt you in your sleep. :D

The ECU connector housings are the same for a '90-'93 vs. '94-'95, though the latter has many extra wires. Many things are in the same places as far as the ECU connector is concerned, though you'll have to move a few wires and add some others. The '94-'95 only has one TPS instead of two (meaning the 1.6 ECU has separate wires for the auto vs. manual TPS) for instance, but the '90-'93 lack EGR. That sort of thing.