1.6l 8v samurai swap guide? - Suzuki Forums: Suzuki Forum Site
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Old 08-20-2012, 10:38 AM   #1 (permalink)
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Default 1.6l 8v samurai swap guide?

Although I am a new member here, I have spent the past 4weeks building my '87 samurai daily driver weekend trail warrior(Saving an 87 samurai from the wrecker, budget daily driver plus build...). It is proving to require twice the work and money I naively expected. Now that it is running and inspected I realize it needs more power and since the 1300 already has a rod knock, I have decided to jump in and swap it out for a 1600 8v.
Problem is I cant find a complete how to guide, and yes I have looked... Alot. I have found an article that covers both the 8v and the 16v but it has left me with too many questions. Maybe i have just read too much and am confused.

My goal is to create for myself and future enthusiasts, a how to guide for the common 8v swap.

I remember reading that it mattered which year, tranny type and 4x4 or 2x4 the engine came from.

I would like to compile 2 lists of necessary donor parts and aftermarket parts for the swap. One list for leaving it carburetated and one for using the TBI.
Due to monetary constraints, I intend to use a 2TC toyota carb I found on ebay.

I have noticed that the members on this forum have been very helpful and I sure could use the advice and input of those who have gone down this road before.

Also, if there is already a guide out there please point me to it.
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Old 08-20-2012, 01:43 PM   #2 (permalink)
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So far what i have is...
The parts needed from the donor vehicle are:
8v Engine including alternator, waterpump, pulleys, valve cover, exhaust manifold.
Add throttlebody, aircleaner housing, entire electrical harness from ECM to headlights and ECM if you intend to go with fuel injection. The electrical harness and samurai speedometer should be sent out to trail tough for modifications for TBI.

Aftermarket parts needed are:
Engine mounts, adapter plate, electric fuel pump.

Can the samurai water hoses be used if they are in good condition?
Is there a seperate belt for the AC and PS on the 1.6l or will that need to be purchased also?
The 1.3 starter can be used with some grinding here and there for clearance.

The engine and tranny should be pulled together and installed together.

This is a good time to replace the clutch, pilot and throwout bearings (and rear main seal?).
Anything else?

How does it look so far? Ill rewrite it once its complete.
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Old 08-20-2012, 02:02 PM   #3 (permalink)
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Engine mounts are anchor brand 318cid dodge car mounts? Some modification required?

Engine should be pre 1996.

Also, need the coil and fan from the donor.
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Old 08-20-2012, 04:21 PM   #4 (permalink)
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Most of the Sammy hoses can be reuse if you use the Sammy inlet manifols and the steel pipe from the water pump. The block is a little taller so the pipes going up to the manifold will be too short. On my conversion I redrilled the bottom pulley and reused all the SJ accessories. I don't have AC but the same belt is used for the AC and PS although you will need a longer belt if you do have the AC. I used the SJ distributer and the 90 degree housing that goes with it, the SJ has a longer shaft than the 1.6 so the dizzy won't swap straight in. I used the SJ inlet and opened up the porting to suit the 1.6 head. The exhaust manifold was a good match so I left that stock.
You usually need to drill the top gearbox mounts although some kits do come with special bolts.
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Old 08-21-2012, 08:11 AM   #5 (permalink)
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Okay, so if we are not using the power steering and AC but want to keep the Track/kick alternator we will need to source a shorter belt.
And, we need to use the Samurais distributor and housing on the 1.6l. If you use the FI than you need to use the distributor from the donor.
Did I get that right?
I am still a little confused on the water hoses.
Does anyone have part numbers for belts and hoses?
How about clarification on the engine mounts?

Last edited by Sammy Jack; 08-21-2012 at 09:55 AM.
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Old 08-21-2012, 11:24 AM   #6 (permalink)
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Thats about right. Water hoses will also depend on whether you go FI or stick with the stock carb, if you go EFI then use all the 1.6 parts. One engine mount needs to be swapped or modded, I redrilled my mount but if I did it again I would buy one from one of the vendors.
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Old 08-23-2012, 08:03 PM   #7 (permalink)
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Default Not Complicated

Sami, I did the same swap last year and probably remember most of the concerns. Email me @ [email protected] with any questions and I will do my best. Geno
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Old 08-27-2012, 08:23 AM   #8 (permalink)
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Picked up the engine, harness and adapter saturday from Sean at aftermarket 4x4. Ordered timing belt, water pump, thermostat, gaskets, rear main seals, crank seal and cam seal today.

The trail tough adapter kit comes with a spacer to reuse the samurai engine mount on the driver side. No need to buy new mounts.
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Old 08-31-2012, 02:11 PM   #9 (permalink)
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Dont forget an oil pan gasket for the rear main seal, and Orings for the distributor and water pipe manifold where it meets the water pump.
Oh and also the gasket between the air horn and the throttle body if your going to go FI.

Plan on having your flywheel resurfaced. Napa does them around here as do machine shops.
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Old 09-09-2012, 11:43 AM   #10 (permalink)
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The stock samurai radiator hoses are good as is the heater hose from valve to manifold. I had to make a hose for the manifold to core from the samurai hose and a 90 joining them with a male male hose barb.

I used a male male hose barb to connect the new fuel line from the hard line on the frame to the hose coming from the throttle body.

If using the stock fuel filter you will have to dismount it and rotate it while the fuel pump is running to bleed the air and prime the pump.

An alternative to a body lift or special engine mounts is cutting the hood hinges and raising the back of the hood 1/2". I recommend adding some material to the hinge for safety sake.

Use the samurai plugs and harness for oil pressure, alternator power output, water temp gauge, starter motor.
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