1.6l 16V Motor Swap



1.6 16v Motor Swap

The next couple pages will detail some of the stuff I went thru and needed to swap a fuel injected, 1.6, 16 valve motor into my trail rig.  Some of the info on these pages was found on the internet via message boards and e-mails, some of it is my own experiences.  The information presented is  meant as a guide, your results may vary.

First you'll need to locate a donor motor.  The Suzuki Sidekicks and Geo Trackers are good candidates, either one has had 1.6l, 8v and 16v motors at some point.  The 1.6 8v is a very easy swap, you can even use your Samurai intake if you want to stay carbureted.  The 16v swap is more complicated and it is a different beast in layout compared to the 8v.  One of the reasons I chose the 16v route was it's power output.  While both the 8v and 16v put out comparable horsepower (80-96hp vs. 64 for the 1.3) the 16v puts out most of it's horsepower several thousand rpm sooner than the 8v.  This should be a big advantage for rockcrawling, more power at slower speeds.

I believe the 16v motors were available as early as 92.  Any 16v in a 95 or older Kick/Track is ideal, beyond 96 you'll have to deal with OBDII which means a lot of extra wires and sensors.  From what I have heard you can take a 96+ 1.6 and use an earlier distributor, ECU and wiring harness to avoid the OBDII.  My motor was from a 96 Geo Tracker with an automatic transmission, the hardest version to swap from what I have read.  To accomplish this swap you will need the motor, wiring harness, everything attached to the wiring harness, instrument cluster and air cleaner assembly.  You can make the Samurai starter work so the donor engine's starter is optional.  If you can, also grab the catalytic converter.  You can re-use the Samurai fuel tank, radiator, fan shroud and clutch.

96 Geo Tracker motor with automatic transmission

With the use of a Petroworks or Trail Tough 1.6 16v install kit you can connect your existing Samurai 5 speed to the 1.6 16v.  Some people have also swapped in the Kick/Track transmission and transfer case but that's a whole other write up.  The Petroworks install kit includes new motor mounts that lower the motor so it will clear the hood and moves it over slightly so the exhaust manifold will clear the drivers side frame rail.  You will either need to move the radiator over and down to use the stock fan or purchase an electric fan.  I didn't have good luck with using an electric fan on my 1.3 but I have heard the 1.6 16v runs a lot cooler.  

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Petroworks motor mounts and transmission adapter plate 

The fuel system requires a high pressure fuel pump that can put out at least 45psi of pressure.  I used an external fuel pump from an 89 Ford F-150.  It is a two wire hookup and accepts a 5/16 fuel line.  For the connections I used high pressure rubber fuel line between the motor and Samurai hard line, make sure you use fuel line clamps so they clamp evenly all around the hose without digging into the hose.  Also, double clamp all the connections.  Between the fuel pump and tank I put a Purolator fuel filter (PN F33144), this filter has a 1/4" npt connector on each end, a pair of 5/16 hose barb fittings easily adapts this to the high pressure fuel line.  The fuel return line off of the 16v motor is 1/4" and needs to be 1/4" to the tank to avoid building up too much pressure.  The Samurai return line was 3/16 but there is an easy fix, swap the hoses on the breather hard line (which is 1/4") with the fuel return hard line.  Do the same at the fuel tank.  

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Fuel pump and fuel filter 

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