92' Sammy Engine Swap for a 1.6L Questions - Suzuki Forums: Suzuki Forum Site
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Old 07-05-2012, 03:34 PM   #1 (permalink)
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Default 92' Sammy Engine Swap for a 1.6L Questions

I just posted my first post about purchasing a 92' Sammy and I'm looking at swapping the 1.3L for a 1.6L 16-valve motor.

I tried searching the forum, but I couldn't find answers to my specific questions. Perhaps someone can link me to a buildout thread for this swap?

Here are the questions I'm trying to hunt down answers for:

1. Do I need a full adaptor kit and ECU for a 92'?
2. Is $950 a good price for a 1.6L that has been overhauled?
3. What's the ballpark labor costs for the engine swap (I'm not comfortable doing this myself)?
4. Is there anything else I'm missing to make this a successful swap?

Thanks so much in advance.
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Old 07-06-2012, 09:05 AM   #2 (permalink)
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You will need to use the computer from the 16v. There is also another wiring harness involved.

You are lucky. You are at least in the same state where that conversion was made into an art form... You are about 270 miles away from Trail Tough in Medford. They can do that swap in their sleep.
You say you are not comfortable doing it on your own, well, there is your answer.
Give them a call and they can give you all the prices/time table information you need.
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Old 07-06-2012, 09:15 AM   #3 (permalink)
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Thanks BillJohn! I literally just found Trail Tough's site late last night and was surprised when I saw an Oregon address. By the way here's a good link for any future members looking for a good guide for a 1.6L swap.
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Old 07-06-2012, 09:17 AM   #4 (permalink)
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Hey, BillJohn - any idea how tough it is to remove the wiring harness from a sidekick/tracker?
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Old 07-06-2012, 09:26 AM   #5 (permalink)
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Just like a Sammy, mark and disconnect. They all take time and patience.
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Old 07-09-2012, 02:07 PM   #6 (permalink)
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Hey BillJohn,

Aside from the motor, intake and exhaust manifold, ECM and wiring harness do I need anything else from the donor vehicle? i.e. Radiator, Alternator, etc.
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Old 07-09-2012, 02:12 PM   #7 (permalink)
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If you have the option to pull the whole engine (with accessories like Alt and PS) then do it! The belts are not the same and it will take longer to make your sami alt work with the 1.6 setup. You also want the starter from the 1.6. Same reason.
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Old 07-09-2012, 02:15 PM   #8 (permalink)
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Thanks! I'm good without the radiator though?

So here's the search list I have so far, please tell me if I'm missing anything:

- 1.6L 16v Motor
- Exhaust Manifold
- Intake Manifold
- ECM
- Wiring Harness
- Alternator
- Power Steering
- Starter
- Anything else???
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Old 07-09-2012, 02:36 PM   #9 (permalink)
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I did it straight from a kit, no additional hunting needed. The kit came with the following:

A complete 1.6/16v engine with starter, computer and wiring harness, air cleaner, an engine adaptor kit and a power steering kit to bolt the 1.6 PS into the Sami frame.
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Old 07-09-2012, 02:37 PM   #10 (permalink)
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Rad was fine.
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