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Old 07-03-2011, 12:46 PM   #1 (permalink)
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Default 88 samurai engine swap with 95 esteem 1.6 16 Valve

Hello Guys,
I recently bought a 88 suzuki samurai, the guy before me had started a engine swap from a 95 esteem 1.6 liter 16 valve. The replacement engine is already set in and bolted up. Has the petroworks adaptor in it. I have the computer and engine harness from the esteem and alot of other misc. parts.
Concerns I am starting with are:

1) wiring harness hook up from old 88 harness to 95 harness What does and does not need to be connected to make engine run correctly and what are my options?

2) fuel pump what are my options? I do have the esteem pump and sender.

3) starter there is a bracket at the motor to intake and is in the way on the both starters I have. I would have thought the orginal starter would fit but neither do without the removal of this bracket.

This is mt first samurai, I turn a wrench for a living so the task doesn't scare me away from it but any thoughts or help I would be grateful. I bought this rig just to hunt and trap out of so no hard 4 wheeling will be done in it. Just going down two tacks and crossing washes. Was loooking for something that would give me decent gas mileage.

Thanks for the help.
Brent
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Old 07-04-2011, 07:05 AM   #2 (permalink)
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Pretty much all of the EFI related wiring will need to be hooked up to get it to run properly. Have you got the FSM for the Esteem? there is a schematic for the EFI wiring in the EFI section, that will show you which wires that you will need from the loom.
You may be able to fit the Esteem pump into the Sammy tank, I've never tried it. The easiest solution is to source a tank and pump from an EFI Sammy.
Have you got the cooling system plumbed in yet? how have you solved the problem of the coolant outlet at the rear of the engine?
I would fab a new bracket to replace the one on the intake, I would be wary about running without it.
I think that the 16V swap is the best one for the Sammy and the Esteem EFI and ECU is far superior to the setup fitted to the Track/Kick models so its well worth getting it finished.
The Esteem was also badged as a Baleno, check out the conversion thread here:

auszookers Community Forums Talking About Stuff Good Tech CairnsZook's Baleno G16B conversion
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Old 07-05-2011, 11:25 AM   #3 (permalink)
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rhinoman
I looking at a similar convert, a 2000 estm. I'm assuming it has a 2.0 16v(I'm going to look at it today). I also have an 88 sammy, tintop. It would seem keeping the estm trans would be better than adapting. Is the estm trans as strong as the tracker/sidekick trans?
game on citizendan
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Old 07-05-2011, 11:51 AM   #4 (permalink)
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The Esteem is front wheel drive so the trans won't work, if it is the 1.6 engine then an adapter plate/kit for a Track/Kick motor will work, those are available from a number of vendors. The 1.8 engine is a lot trickier because that is a J series engine, the 1.6 and 1.3 are G series engines. The 1.8 is very similar to the 2.0, there is an article on fitting one of those engines on the aftermarket4x4 website.
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Old 07-05-2011, 12:18 PM   #5 (permalink)
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I have been enlightened! I've visited wikip and its suk eng site, however, the estm has never impressed me so I didn't know its specs other than eng sizes. If it is a 2.0 then it should still be a reasonable purchase since it includes all of the "other" parts that I would not get with a bare eng. I go to "check it out!"
Thanks and game on citizendan
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Old 07-07-2011, 04:24 PM   #6 (permalink)
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Another correction! Its a 1.8 and a total oiler. However, as I stated before the additional parts (inj; ecu; wiring; etc.) will make the difference with the eng posing as a core for a rebuild. My memory may be bad but I'm good at it! "Must be something in the air."
game on citizendan
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Old 07-08-2011, 02:33 AM   #7 (permalink)
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The 1.8 is going to be a lot more work, a build thread would be good.
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Old 07-08-2011, 10:58 PM   #8 (permalink)
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A 2.0 or better a 2.3 is my first choice, however, a 1.8 will suffice for now. Yes, I know they're more work. But "there is no substitute for cubic inches" or centimeters. Plus, the real upside is my 1988 gross polluter is upgraded with a more powerful, more efficient, newer engine. Lastly, no one has ever accused me of doing anything easy. I'm sure I'll be asking plenty of questions in the future!
game on citizendan
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Old 07-09-2011, 11:58 AM   #9 (permalink)
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Well on the plus side once you have the 1.8 fitted the upgrade to a 2.0 or 2.3 will be much easier
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