1.6 16V Install
I have been putting this off
for a while but I am ready for fuel injection and a little more power.
Follow along on my 16v adventure, and don't try this at home unless you have
some time to kill.
Step 1, the block is
installed. I used a Petroworks install kit. The motor mounts move
the motor down and towards the passenger frame rail to allow clearance on the
drivers side for the exhaust manifold and eliminates the need for a body lift
(the 16v block is tall!). This solves a few problems but makes another,
with the motor moved over I can't get the Tracker fan in the Samurai fan
shroud. I will either have to move the radiator over an inch or run an
electric fan. Before I went any further I wanted to get the wiring
harness in the vehicle.
I have about 28 hours into the
wiring harness at this point. That includes 6 hours spent stripping the
dash and pulling the stock Samurai harness out. Here's what I have done to
the Tracker harness so far:
1. Cut all the electrical
tape and wire conduit from the harness.
2. Using a schematic from
the a repair manual, I eliminated all non-essential wiring. This includes
all the lights, horn, airbag, radio, A/C and heater related wiring.
3. What's left was
re-taped and I did a test fit as shown in the pictures above. I'll try and
take some more detail pictures as I go. I was going to do a write up on
the wiring but I haven't found a good schematic so right now I am winging it.
The fuel injected motors use a
reed switch in the speedometer to send pulses to the ECU. I know people
who didn't bother to put this in the Samurai speedometer and the only downside
seems to be worse fuel economy. You can send off your Samurai speedometer
to get the switch installed for $50 + shipping form various Suzuki vendors, or
you can try the install yourself. I am not sure if this works yet but
here's what I did. The first picture is the Tracker speedometer removed
from the housing, the reed switch (or VSS) is shown in the picture to the right
(I forgot to get a picture of it before I took it apart). The important
thing to look at is the two holes I have indicated.
Carefully disassemble your
Samurai speedometer and lo and behold it has the same two holes in it!
Take a small drill bit (smaller that the two bolts that held the VSS in the
Tracker speedo) and drill the holes thru. Next run the screws in to make
some threads. The second picture shows the VSS installed in the Samurai
speedo. You'll need to connect two wires to the switch, the yellow wire goes to the tracker ECU, black to ground. I
routed these out of the speedo via the holes for the check engine reset switch
Tracker ECU mounted above my
I made a plate to mount the
Tracker fuse box, power distribution blocks, etc. The main power
distribution block from the Tracker is mounted on the passenger side. I
cut the firewall behind the distribution block so I could plug everything in
from the engine compartment side. The only circuit being used is the
main fuse. I'll hook my lights and other accessories up to some of the
other circuits (the ABS is 60 amps and the A/C circuit is 50 amps)
The radiator needed to be moved
over about a half inch due to the motor mounts shifting the motor over for
exhaust manifold clearance. I cut the passenger side radiator mount from
the frame and turned it into a flat plate. I then drilled two 11/16 holes
in the frame and welded the mount to the frame so the nuts are sticking thru
the holes I drilled. I made a spacer for the other side. I also
ended up having to slot the radiator brackets so I could drop the radiator down,
again due to the motor mounts being lower than stock to allow the engine to fit
under the hood without a body lift. To avoid this you could use an electric
fan, Flex-a-lite makes one that fits the Samurai radiator perfectly, P/N
110R and you can even get them in different colors. The downside is the
fan runs nearly $300.
My new dash taking shape.
The Samurai instrument cluster will be mounted in the middle of the dash.
I also retained the stock lower brace since it ties the sheet metal into my cage
Here's a shot of the motor
mount and transmission adapter plate that come in the Petroworks 16v install