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Old 05-09-2016, 03:56 PM   #1 (permalink)
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Default Bought myself a 94 sidekick with a 16v

Bought it to take the engine and replace the 1.3 in my samurai.

I'm pretty comfortable with this whole process, although I still haven't found a really good reference on how to redo the wiring harness. I wanted to make a thread about what other stuff might be useful to take from the sidekick.

Axles? Suspension components?

Any pointers or resources I can read?

Thanks guys
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Old 05-09-2016, 04:01 PM   #2 (permalink)
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Old 05-09-2016, 09:04 PM   #3 (permalink)
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Nice Sami!

If I had to do it over again, or if I could offer a helpful hint, take the harness out in all it's glory and send it in to have it done, I think it's like $400 or so and probably well worth it. If you happen to have a ton of time on your hands and would like to go it yourself I have a set of instructions for making it happen. Let me know if you want them.

Your going to love the 16v for sure!
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Old 05-10-2016, 07:19 AM   #4 (permalink)
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Originally Posted by caseyjones955 View Post
Nice Sami!

If I had to do it over again, or if I could offer a helpful hint, take the harness out in all it's glory and send it in to have it done, I think it's like $400 or so and probably well worth it. If you happen to have a ton of time on your hands and would like to go it yourself I have a set of instructions for making it happen. Let me know if you want them.

Your going to love the 16v for sure!

Hey thanks so much Casey, appreciate the advice.

If there is one thing I'm good at when it comes to cars, it's the wires so I'm actually looking forward to making my own harness.

I would absolutely like the instructions.

Do you also happen to have any resources about hacking the ECU?
Thanks, email me [email protected]
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Old 05-10-2016, 07:20 AM   #5 (permalink)
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I might send it in, but I want to at least get a good gauge of exactly what's involved before I do. I've done hot rod harnesses from scratch before, so I'm pretty sure I can pull it off, and I want the bragging rights.
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Old 05-10-2016, 02:50 PM   #6 (permalink)
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Ok, I sent the document, its a PDF and its pretty long. Definitely let me know which way you decided to go. I'm going to use that document to clean up my harness after I get the AC working. Whoever did mine initially was not keeping neatness as a priority but I'm OCD enough to need to go back through it once I get the AC harness integrated properly.

Good luck!
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Old 05-10-2016, 04:11 PM   #7 (permalink)
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Got it! Thanks a ton Casey
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Old 05-12-2016, 03:42 PM   #8 (permalink)
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Quote:
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Do you also happen to have any resources about hacking the ECU?
Thanks, email me [email protected]

Its a One Time Programmable (OTP) processor so it can't be remapped.
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Old 05-12-2016, 06:17 PM   #9 (permalink)
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I had quite a conversation about this with someone before. The 1.6 16v is already around 100hp which is pretty darn good for an efficient NA streetable 1.6L.

They are in a pretty decent state of tune as they sit and even if you could remap there probably wouldn't be much to gain without a different cam and some headwork. Suzuki managed to get solid performance out of these little mills right out of the box. While you have the engine on the stand it's a great time to replace any leaking gaskets, replace timing belt set and do a valve adjust. Pull the EGR valve off and make sure the passages are clear and it functions correctly as they tend to get carbon logged and create drivability issues, other than that it should rock jut fine. It took me years to accept but the Japanese have been light years ahead of us since the 70s when it comes to getting the most out of an engine. They already did a great job of tuning this engine.

Oh, another good read is about the bottom timing pulley and keyway. I removed my lower pulley when I had the engine out and it was fine so I retorqued to the new torque value with red loctite. Just make sure your key and keyway in the crank are not distored. If yours is damaged let me know, I have an extra pulley and key. Even if the crankshaft keyway is buggered theres a trick to make it work. The reason this happens is some techs dont know that you dont need to remove the pulley to replace the timing belt,and they dont get torqued back correctly. If it was never touched it should be fine but definately easier to check now than with the engine in the vehicle. This way when you install the engine you have real peace of mind that it's right. Noteworthy. The 1.3 is a free running engine but the 1.6 is NOT so timing belt health is imperative.

Mines sitting on 35" tires, with a heavy winch bumper and 9k winch, roll cage and other heavy stuff and the bone stock 16v does ok although it wont set you back in the seat or anything. this 16v engine, healthy and in stock trim should do the job just fine. I get fairly decent MPG to boot and I can cruise down the highway at 70 all day long, it holds 5th gear just fine until headwinds or grades, then I just wind her up in 4th and stay the course.

I would probably save some $$ for gearing though as the right gears make ALL the difference. Before I had my gearing correct it would barely move under it's own power, now it leaves a stop light and pulls to speed just fine.

EDIT. Get EGR and valve cover gaskets and a complete timing belt kit. Skip the cheap Chinese ebay stuff and get OEM Suzuki stuff, a little more money but that Chinese stuff is substandard. Fel Pro gaskets are great but the timing components OEM if at all possible.
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Last edited by caseyjones955; 05-12-2016 at 06:20 PM.
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Old 05-13-2016, 03:32 PM   #10 (permalink)
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Thank you for the input Casey, I will definitely put the engine on a stand and take a look at all the components.

I asked my friends engine rebuilding shop for a quote, he said 2k all in. So I might just take it and dump a load of cash in, maybe even see if I can get oversized pistons just for laughs.

I'll start doing some research about the gears. I read so much about it online.

Ive been looking through the document you sent me, its a godsend. Thanks so much for that!
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