87 Suzuki Samurai

They just did the 6.5:1 gear change for T case on power block this last weekend.
[url]http://powernationtv.com/episode/XO2016-01/discount-datsun[/url]

Thanks Xaza! Sorry for the really late response. I was sure I had responded sooner but I don't see that post.

Just wanted to post an update because it's been a while since my last update.

I've got a couple projects going on right now so I've had trouble focusing on my Samurai.
I went to look at a rebuilt engine a couple of weeks ago. This was a really cool find and would have been perfect had it not been an Australian engine. It was the second engine put into a '91 Suzuki Sierra. The guy that owned it was in the military and stationed over there. I walked away because I thought it would have been a bigger project to swap all of my US emissions equipment off my engine on to his. But he had a cool Samurai, right hand drive model. Kind of regretting walking away from that engine but I would have had to get this engine swapped in a weekend and I thought swapping that stuff would take longer and then I'd have no idea if it would run well. I want it done in an afternoon if I'm just swapping 1.3 engines. I'd commit more time for the 1.6L.

Been having a hard time finding time to work on the tire carrier or maybe I'm just lazy.... I still need to figure out the trailer adapter for the tail lights or run individual lights for all the functions. I need to cut strips of flat stock to weld nuts to for mounting the bumper. Need to make the actual tire carrier portion. Basically I started this project with only the most basic plan. Haha.


Also been gearing up for what I hope will be an epic camping trip this summer. I purchased maps for the Colorado portion of the Shadow Of The Rockies Trail from [url]http://www.transamtrail.com/shadow-of-the-rockies-trail/[/url]

I may also purchase maps for the Trans America Trail too. In the process of getting stuff for a camp kitchen. Probably going to integrate fold down table into the tailgate for food prep/tools. Also realized my tent is too small for me, my girlfriend and my daughter so I'm looking for a good 3-person plus tent. Preferably a 4-season tent.

Going to pick up an older dual fuel coleman camp stove this weekend as well as I've been reading some stuff on expedition portal about them and I've been finding them really cheaply on craigslist.
I got a roll table from REI today as well. It only weighs 9lbs and it was on sale.

Also, been getting some Samurai parts too. I got new o-rings for the distributor as I think I may be losing oil from it as well.

Picked up a new oil-pressure sensor as I'm tired of the tubing to the gauge leaking too, I might tee it off and run the gauge and the sensor too but I think I'm just going swap in the sensor by itself.

Ordered the Panty liner from ZOR too. For some reason I was initially under the impression that his Snatch cradle eliminated all of the factory t-case mounts.

Have spare throttle and clutch cables coming in too. I've heard of these breaking and the worst possible times so I'd like to keep some spares on hand.

Going to change the fluid in the diffs soon too. Probably way over due.


I guess I'll end this post by saying that my initial plans to swap the engine have fizzled (might have one last ray of hope but we'll see) and that I'm going to put more attention into prolonging the life of this current engine.

The distributor do leak on these engines a lot of the time (age). replacing the O ring is the correct step. Do a good tune up and PCV valve (a fuel pressure test might be beneficial as well). The 1.3 isnt a bad engine (just a little underpowered). If your planning a geared T-case, it will wake your Sami up real nice. Sometimes all you can do is one small step at a time. You seem to be on the right path though...

I replaced the PCV valve a while ago. Not sure about the fuel pressure, I'd be interested in testing it.

Thanks Bloodbane.

Came across this today:
[URL]http://www.popularmechanics.com/cars/g2504/15-indestructible-vehicles-for-surviving-a-desert-drive/[/URL]

#9 - Suzuki Samurai!

I got a few things done to the Samurai. My handy dandy cell phone holder broke so I had to make another one. The ball mount was ok but the clip broke so I purchased another cellphone belt clip holster and modified it. This time I only used two holes because I think using all four made the holster too stiff and it caused the clip to break.


[IMG]http://www.detn8r.net/Samurai/2016/2016-03-21_00-51-2.JPG[/IMG]


I've been gearing up for an epic camping trip this summer so I've been upgrading my gear. Now that I feel like I can take my daughter camping with me and my
girlfriend I've decided to upgrade my camp kitchen. I picked up a couple of coleman stoves off of craigslist.


An old used and abused 413G and a nice 3 burner (but HUGE) 426b. The 413G doesn't work and needs a few seals replaced. I was hoping to pick up a duel fuel model but these are the only ones that panned out.


[IMG]http://www.detn8r.net/Samurai/2016/2016-03-21_00-51-1.JPG[/IMG]




I also picked up a couple of things on sale and my favorite store, R.E.I.!




Roll Camp Table


[IMG]http://www.detn8r.net/Samurai/2016/2016-03-21_00-51-4.JPG[/IMG]




My daughter helped me set up the new Alps Mountaineering Edge 4 tent.


[IMG]http://www.detn8r.net/Samurai/2016/2016-03-21_00-51-8.JPG[/IMG]








Saturday evening I managed to talk my nephew Jason into doing the work on changing the fluid in the diffs.


[IMG]http://www.detn8r.net/Samurai/2016/2016-03-21_00-51-3.JPG[/IMG]


At 103k, I'm not sure if this was ever done before.




This Sunday we got some good work done on the Samurai's rear bumper/tire carrier project.
The new dewalt chop saw finally got some use.


[IMG]http://www.detn8r.net/Samurai/2016/2016-03-21_00-51-5.JPG[/IMG]


We got the nut plates cut and welded the nuts to them and they worked out nicely.


[IMG]http://www.detn8r.net/Samurai/2016/2016-03-21_00-51-6.JPG[/IMG]


[IMG]http://www.detn8r.net/Samurai/2016/2016-03-21_00-51-7.JPG[/IMG]




I tried and failed at getting the harbor freight led tail lights to work. I was using a trailer adapter and the EP34 relay but could not get the lights to function properly. I poured over samurai wiring diagrams and had no luck. I have quite a background in electronics if I don't say so myself. I think I need a different trailer adapter or I need to get different lights or some more lights for individual functions (Tail/Brake/Signal).


That's it for now. I'm considering heading down to Moab this coming weekend to catch the last few days of the Easter Jeep Safari but we'll see....

Made a few changes to the Samurai this past week. Still no work on the rear bumper/tire carrier. Maybe this weekend.


I picked up a rampage top from Amazon only to discover that it was made incorrectly. They had sewn a zipper on upside down and it would not work. Joe (zukrider) sold me his old rampage top but it needed some work. The rear passenger tension strap had broken off. I used some climbing webbing and had my awesome girlfriend sew it on to replace the old strap. As soon as I went to install it, the drivers side strap tore off too.!!


I picked up some stainless steel webbing slides off mcmaster carr to attach some cam straps. I'm over complicating this setup I know but....


[img]http://www.detn8r.net/Samurai/2016-04-11_21-00-1.JPG[/img]


[img]http://www.detn8r.net/Samurai/2016-04-11_21-00-2.JPG[/img]


I think it gives the Samurai a nice look and I'm sure my daughter will appreciate the tinted windows. In fact the windows provide a lot more visibility than the stock top.


[img]http://www.detn8r.net/Samurai/2016-04-11_21-00-3.JPG[/img]




I also got the o-rings on the distributor replaced as well.


[img]http://www.detn8r.net/Samurai/2016-04-11_21-00-4.JPG[/img]




[img]http://www.detn8r.net/Samurai/2016-04-11_21-00-5.JPG[/img]




[img]http://www.detn8r.net/Samurai/2016-04-11_21-00-6.JPG[/img]


The o-ring on the housing had been coated in RTV or some other kind of sealant and the o-ring on the rotor seal was dry and cracking too.


I also adjusted the valves today and it seemed to make the engine quieter. I haven't noticed any other differences or improvements in performance either.

Well. This was a pretty productive Weekend!

I committed to tackling the rust underneath the battery that has been bugging me lately.

My biggest fear was that I would have serious rust on the firewall behind the front passenger fender. It turned out not being so bad on the firewall but I decided that the battery tray had to go.

I had some corrosion to deal with on the battery terminals. Not sure whats causing this but I have read that it could be overcharging or poor ground.

[IMG]http://www.detn8r.net/Samurai/2016-04-26_00-13-1.JPG[/IMG]

I had only been seeing this much of the rusting out hole for a few months now.

[IMG]http://www.detn8r.net/Samurai/2016-04-26_00-13-2.JPG[/IMG]

[IMG]http://www.detn8r.net/Samurai/2016-04-26_00-13-3.JPG[/IMG]

I had asked some people on Samurai group on Facebook if it was possible to remove the fender and I felt like I could get it done. Everyone suggested that I just remove the entire front clip. After working on this for two days I have come to the conclusion that it is not possible to remove the fender without some modifications. Next time I'll just remove the entire front clip.

[IMG]http://www.detn8r.net/Samurai/2016-04-26_00-13-4.JPG[/IMG]


[IMG]http://www.detn8r.net/Samurai/2016-04-26_00-13-5.JPG[/IMG]


I didn't plan on removing the stock battery tray, just cleaning up the rust and coating it with some POR-15 but the Battery tray was in worse condition that I thought.

[IMG]http://www.detn8r.net/Samurai/2016-04-26_00-13-6.JPG[/IMG]


I used an angle grinder with a cutoff wheel to remove the old bracket and I used a wire wheel on the grinder to clean away as much of the rust as I could.

I cut out around the rusted out hole so that I could patch it.

[IMG]http://www.detn8r.net/Samurai/2016-04-26_00-13-7.JPG[/IMG]

I used some steel plate to make a patch.

[IMG]http://www.detn8r.net/Samurai/2016-04-26_00-13-8.JPG[/IMG]

This is where my lack of skill as a welder really showed. Welding the thin steel of the samurai fender to the slightly thicker steel of the patch was challenging but I think I made a good effort.


[IMG]http://www.detn8r.net/Samurai/2016-04-26_00-13-9.JPG[/IMG]

I purchased the POR-15 super starter kit a couple of weeks ago and set out using it. I cleaned and degreased the area as best as I could.

I sprayed the area with the prep chemical and got to work fabricating a new battery tray.

I took my inspiration for the tray from Low Range Off Road's Dual Battery kit. It utilizes two mounts for the front clip for support.

[IMG]http://www.detn8r.net/Samurai/2016-04-26_00-13-10.JPG[/IMG]

I didn't get too many pictures of it but I'll post some soon. I still need to paint the bracket.

At this point I coated the area on the fender with the POR-15 and finished the battery tray with the help of my Nephew.

[IMG]http://www.detn8r.net/Samurai/2016-04-26_00-13-11.JPG[/IMG]

[IMG]http://www.detn8r.net/Samurai/2016-04-26_00-13-12.JPG[/IMG]

The POR-15 went on well enough. I hope it stands up. I'll top coat it with something else shortly.


The new battery tray only requires me to drill 1 extra hole in the fender and uses one 1/4-20 nut as a spacer.

I messed up when measuring the width of the battery and I ended up being a little too narrow for the battery tie down straps. I'll probably weld some more flat stock and a make a fancier clasp like in some of the higher end battery boxes.

[img]http://www.detn8r.net/Samurai/2016-04-26_00-13-13.JPG[/img]

[img]http://www.detn8r.net/Samurai/2016-04-26_00-13-14.JPG[/img]




That's it for now! I turned 30 today and my awesome girlfriend made me a Samurai Birthday Cake!

Nice work so far. At least you are getting all the things addressed that could cause issues down the road. So many people go right to making "mods" and never bother to to the routine stuff.

:wrench: nice work getting done on your sami.
so you really would like the 6.5 gears, they afford a 10% reduction in high range.
For your lights is it an issue with them not lighting up at all?? if you want to LED the turns wont flash with out use of a resistor as the flasher relay wont load up right.

any how keep plugging along.
check out lowrange off road they have great prices on a ton of sami parts.

Thanks Patrolman. I would love to do some more performance mods and throw bigger tires on this Samurai but those sort of mods are just out of my budget.

Dieseldoc, I'm really considering regearing the t-case though I think 6.5:1 would be a bit much for me right now on slightly larger than stock tires.

I've got the LED relay for the lights to work I just suspect that I have a poor connection or corroded wire. I may try some resistors as a last resort but for whatever reason I can't seem to find time to work on the bumper project.

I have the 6.5:1 T-Case gears and I run a 32" tire. They are deep gears, you might check out the 4:1 gears. It gives you a little better than stock, but not so much that you cant keep up with traffic.

As far as lifts go, I went with the rocky Road Outfitters bolt on 6" SPOA lift. Some folks have had problems with RRO in the past, but everything I did went easy. Not the most expensive kit out there, but it works for what I wanted. If I was to do it again I would do the YJ spring conversion (longer springs and gives you a way better ride) with the rears up front and revolver shackles. On my buggy I will go with 4 link front and 3 link rear (super flexy).
The little things you are doing now will pay off in the long run. Keep up the good work

Thanks for the input Bloodbane. Still on the fence about the tcase gears. I've really been leaning towards the 4.9:1 kit. I feel like I could get those installed in a weekend.

I've been hearing good things about the old man emu leaf spring lift for the samurai and I may go that route. Unfortunately I've heard enough bad things about rocky road outfitters that I'll just stay away from them. I've honestly never heard so many bad things about a company before.


I don't have enough in the budget for an extreme lift AND tires. If I went big I'm sure I'd have to get new rims too and I wouldn't have enough. I want some gearing and articulation. Maybe a locker in the rear.

With any lift spring be ready for a more severe ride until the springs are broken in. Being that the Samurai is such a short wheel base and leaf sprung all around. You can do the YJ conversion on the cheap is why I suggested it. you can get the springs from almost any pick-n-pull and companies like TrailTough, ZOR, LROR sell all the brackets you need to bolt them on. Gives you a lift and also a better ride (i just accept the ride for what it is).
When my dad was alive and would ride with me in my Samurai, he said he always felt violated after riding in it.....

LROR (lowrange off road) is your go to, other than ZOR ( zuks off road).
they have new yj springs at $200 an axle, this is the way to go as they act far better and are the 2" wide set up.
the 4:1 gear are not a bad set up but as you will grow I would step into the 6.5 as they will let you grow far past 32" tires.
the 10% reduction in high range is wonderfull on the freeway and hill climbs. youe would be able to get into a 32/33 with the YJ swap with little work.
wheels are easy to come by.


I have some sami parts for you if you want them.
I have two good T-case shifters.
A power steering conversion crank pulley, this is for the Trac/kick pump, you will love power steering on you little sami.
the 2 shifters were going to be done for a twin stick set up. its some fab work but can be done and works well.

Thanks DieselDoc. I think I am ok for now, I'll let you know.

Really considering my lift options right now. I might purchase some toyota axles so I'd want to get the YJ springs if I could. Just having trouble finding time for the research.

Anyway.

I have gotten a lot done!


I decided it was time to replace my door panels with something else. I had seen some ABS door panels sold but figured I could save some money by making them myself.


I chose to go with 1/8" black ABS sheets from the local plastic company.
[IMG]http://www.detn8r.net/Samurai/2016-06-25_00-23-27.JPG[/IMG]


I removed the factory door panels and removed the fabric from them to use them as a template for my new ones. I traced onto the shiny side with a gold sharpie. The textured side is the side I wanted facing out. I used a jig saw to cut off the curved part.
[IMG]http://www.detn8r.net/Samurai/2016-06-25_00-23-21.JPG[/IMG]


I removed the plastic inserts from the doors and replaced them with some rubber insulated rivet nuts.
[IMG]http://www.detn8r.net/Samurai/2016-06-25_00-23-17.JPG[/IMG]


[IMG]http://www.detn8r.net/Samurai/2016-06-25_00-23-18.JPG[/IMG]


I'm pretty satisfied with the end result. I used some 10-32 Stainless steel button head screws.
[IMG]http://www.detn8r.net/Samurai/2016-06-25_00-23-16.JPG[/IMG]


I picked up a new larger cooler from Amazon since our Yeti Roadie wont cut it on longer trips. I went with the Pelican Elite 45qt cooler.
It takes up a sizable area on the roof rack.
[IMG]http://www.detn8r.net/Samurai/2016-06-25_00-23-26.JPG[/IMG]


All the gear packs around it well enough. Or so I thought during the test load.
[IMG]http://www.detn8r.net/Samurai/2016-06-25_00-23-25.JPG[/IMG]


We took an overnight trip to Mount Herman a couple of weeks ago and I wanted to see how the roof rack and our camping kit worked out.
My girlfriends family has a long history of river camping on rafts and her mom gave us some old dry bags to pack our gear in in case it rained and the stuff on the roof rack got wet. I finally got a Hi-Lift as well and removed my spare tire since it wasn't holding air and mounted the hi-lift.
[IMG]http://www.detn8r.net/Samurai/2016-06-25_00-23-14.JPG[/IMG]


I still want to get some gear that packs better. I took advantage of the Memorial day sale going on at REI and got the Thermarest Quadra camp chairs for us. These pack up really nicely and the legs become the case. The next piece of gear I want to downsize are my old REI 3.5 Camp Beds. I had originally purchased them for winter camping 8 years ago and they have been used every since but they are big and bulky. I took the Coleman 426b on this trip because of the two camp stoves I had acquired it was the newest. It didn't perform as I expected and I'm not sure if it was just my unfamiliarity with this type of stove or if there was a problem with the Stove. I'm going to give the 413G stove a try next since I have replaced the plunger and tank cap on it already. The trip was pretty fun despite our late start. The inside of the Samurai didn't seem at all as cramped as it had last summer on the few trips we took it on and it was extremely nice to have all the stuff up on the roof rack and out of the way. The new tent had a buckle break and I had to use a zip tie to hold the rainfly down on that corner of the tent.


Fathers Day Weekend I was determined to make some progress on the new rear bumper and I committed to figuring out what was going on with the LED tail lights and the trailer adapter. Some fiddling around confirmed that I had a poor connection through the parasite connectors that someone had used to wire up a trailer plug.
[IMG]http://www.detn8r.net/Samurai/2016-06-25_00-23-9.JPG[/IMG]


The tail lights worked! I began removing the old bumper and permanently wiring in the trailer adapter. I removed all the hardware and brackets for the bumper and the license plate brackets.
[IMG]http://www.detn8r.net/Samurai/2016-06-25_00-23-7.JPG[/IMG]


I made some wire labels at work using our shrink tubing label printer so that I could accurately identify the wires in the future should I choose to rewire them again. I used some adhesive filled shrink tubing and soldered the wires to the trailer adapter to make sure that I had good solid connections that wouldn't corrode over time.
[IMG]http://www.detn8r.net/Samurai/2016-06-25_00-23-8.JPG[/IMG]

Since I had already made all the brackets for the new bumper I simply had to clean them up with a sanding disk on a grinder and tack everything in place. I used some clamps and got the new bumper tacked to the brackets so that I could take the whole thing to a more qualified welder.
[img]http://www.detn8r.net/Samurai/2016-06-25_00-23-6.JPG[/img]


I asked one of the professional welders at work to weld the brackets on for me and he did a great job!
[img]http://www.detn8r.net/Samurai/2016-06-25_00-23-4.JPG[/img]


[img]http://www.detn8r.net/Samurai/2016-06-25_00-23-3.JPG[/img]


When I installed the bumper the next day everything lined up perfectly! I did have the bend the top brackets up a little more as they warped just a tiny bit from the welding but everything looked great!
[img]http://www.detn8r.net/Samurai/2016-06-25_00-23-2.JPG[/img]


Now I just need to get the tire carrier portion done so that I can mount a spare tire, the hi-lift jack, jerry can, license plate.


That's it for now.

Good work - the door panel looks great!

Thanks Jim!

Wanted to do another quick update tonight.


When I owned my Jeep I was lucky enough to start wheeling close to town and with people who had OBA setups. A good mentor of mine had a nice relatively stock TJ with a YORK compressor and I was jealous of that thing. Eventually I purchased a Co2 tank from someone on the co4x4.org message board and I ran a 20lb Co2 tank for several years before destroying my jeeps drivetrain and eventually selling my jeep and all of my four wheeling stuff, Co2 tank included.


I've honestly only taken my Samurai out a handful of times and I would have loved to air down but I did not have a convenient way to air back up. After reading a few reviews I decided to bite the bullet and get the CKMA12 ARB On Board Air Compressor. I'm hoping to use it on July 4th weekend here in a day or so.


In all honesty, I'm a horrible planner and most of my trips end up with me leaving around noon and not setting up camp until it's already dark.


I had already thought about using the Samurai's jack mount under the hood as the base for something and when I got the idea to order the compressor I knew it would be the perfect location. I had to cut off the top loop that the jack used to hold itself in place. The compressor came with a mounting bracket and a baseplate which I used to mark and drill the mounting holes. 3 of the holes went through some material but the 4th hole really just needed to notch out the round hole in the middle of the jack mount. The baseplate would sandwich the jack mount with the mounting bracket.


[img]http://www.detn8r.net/Samurai/2016-06-30_00-45-4.JPG[/img]


The wiring harness left a bit to be desired. I've been doing electrical work for the past 12 years and I'll say that it was nice to have a well made harness come with this compressor. It was pretty well labeled and made but the layout under the hood of the Samurai .... it kind of sucks. So I wasn't happy with the location of the control relay I chose.


[img]http://www.detn8r.net/Samurai/2016-06-30_00-45-2.JPG[/img]


I actually unmounted it from here and ziptied this to some other bits of the harness.


There was an unpunched grommet in the firewall for the samurai that allowed me to run the switch wires to the left of the steering column to a hole that me and my nephew carved out with a dremel and utility knife. The compressor came with the fancy carling switches that ARB is known for. Unfortunately I didn't take a picture of that switch.




I had to run to Home Depot to pick up some plumbing for the compressor. It came with a cut off switch which will shut the compressor off when the pressure in the tank and lines reaches 100psi. The compressor has two ports for the Locker solenoids but only 1 port for a standard 1/4" NPT fitting. So I had to use a brass Tee with a nipple to connect the Shutoff Switch and quick connect fitting for an air hose.




[img]http://www.detn8r.net/Samurai/2016-06-30_00-45-3.JPG[/img]


[img]http://www.detn8r.net/Samurai/2016-06-30_00-45-1.JPG[/img]


I tested the compressor out a bit but I did not fill any tires. Though I'm pretty confident that this compressor will suit my needs just fine.

Made some progress on the tire carrier.

Got the swing welded to the spindle and the spindle welded to the bumper.
I had the spindle extended about 1/2" with a piece of steel the same diameter.

[IMG]http://www.detn8r.net/Samurai/2016-07-20_01-02-3.JPG[/IMG]


I came across Trail Gears Polyurethane tire mount and immediately decided to use it. I love simplicity in mounting. I picked up a 1' 1"-8 bolt from fastenal and some washers and lock washers.

[IMG]http://www.detn8r.net/Samurai/2016-07-20_01-13-4.JPG[/IMG]


Still need to add a diagonal support but I'm liking the tire carrier so far.

[IMG]http://www.detn8r.net/Samurai/2016-07-20_01-02-2.JPG[/IMG]


I had picked up the latch off of Amazon a long time ago. I was disappointed that I couldn't bolt it to the swing so I had to weld it.

[IMG]http://www.detn8r.net/Samurai/2016-07-20_01-13-2.JPG[/IMG]

The other side of the latch wend on easily enough.

[IMG]http://www.detn8r.net/Samurai/2016-07-20_01-13-1.JPG[/IMG]

[IMG]http://www.detn8r.net/Samurai/2016-07-20_01-02-1.JPG[/IMG]

So far I'm really liking the setup. Going to add supports for the hi-lift, water can and gas can.

I picked up some HDPE, the same stuff cutting boards are made out of. Going to use it to make the prep tables on both the tailgate and the swing.

[IMG]http://www.detn8r.net/Samurai/2016-07-20_01-13-3.JPG[/IMG]


That's it for now.

Still need to pack the bearings and get the prep tables welded on.

I've got the tire carrier finished! More or less.


I got a diagonal support welded. I had a slight issue with warpage while welding. I tacked another diagonal to the opposite side of the main tire support and strapped it down while it cooled.


[img]http://www.detn8r.net/Samurai/2016-07-27_00-00-11.JPG[/img]


Once that was done I welded a bolt to the swing and made a bracket to secure the top of the hi-lift.


[img]http://www.detn8r.net/Samurai/2016-07-27_00-00-1.JPG[/img]


Now that would complete any standard tire carrier well enough but I wanted to mount a jerry can or a water can so I made an additional support for one. I'll likely add another in the future but time was running our for me to go camping this past weekend. I was still doing some welding Saturday morning before heading out that afternoon.


[img]http://www.detn8r.net/Samurai/2016-07-27_00-00-10.JPG[/img]


I ran into some trouble. I had asked my nephew to grind away all the surface rust on all the metal and he accidentally stripped the threads on one of the bumpers mounting bolts and nut plate. The nut plate was salvageable I just need a tap. So I ran to Fastenal Friday morning to grab some new bolts and a 12M-1.75 Tap. I got home and fixed the nut plate and got everything mostly painted.


[img]http://www.detn8r.net/Samurai/2016-07-27_00-00-9.JPG[/img]


Everything was looking good except I needed a spot for my license plate. I used some scrap aluminum I had from making my mirror relocation brackets and the stock Samurai license plate bracket.


[img]http://www.detn8r.net/Samurai/2016-07-27_00-00-8.JPG[/img]


I got the prep tables mounted and everything packed up and was on my way to camp! We headed to mount Herman again for a 3 night trip.


The prep tables worked out great! I used some hinge material from home depot to mount the HDPE to the tailgate and the tire carrier.


[img]http://www.detn8r.net/Samurai/2016-07-27_00-00-4.JPG[/img]


[img]http://www.detn8r.net/Samurai/2016-07-27_00-00-2.JPG[/img]


My Coleman camp stove fit perfectly on the tailgate which is quite lucky for me since I didn't measure anything! I drilled some holes into the HDPE for some paracord hangers.


[img]http://www.detn8r.net/Samurai/2016-07-27_00-00-3.JPG[/img]


The water can mount I made worked great with our water can. I turned the can on it's side and it made for a great way to get water out of the can and into our water bottles and pots and pans for cooking and cleanup.


[img]http://www.detn8r.net/Samurai/2016-07-27_00-00-5.JPG[/img]


The whole setup worked out quite well. I need to refine our camp kitchen and kit a bit.


[img]http://www.detn8r.net/Samurai/2016-07-27_00-00-7.JPG[/img]




I made a snafu when I was showing off my tire carrier to my friend and I stood on it and I bent my spindle! I was able to bend it mostly back into place but I am disappointed with it's strength. I will be upgrading...


Despite that I did get some time to do a little bit of wheeling and playing around.




[img]http://www.detn8r.net/Samurai/2016-07-27_00-00-6.JPG[/img]


My daughter decided to climb in and pretend that she was the one driving after I got out to take some pictures.






Some things I'd like to improve



[LIST][*]Tailgate needs way to lock into the open position. I used a strap to secure it but that method seems clumsy. Same goes for the tire carrier.[*]The water can being able to mount on it's side was great for getting water out but we had to run around the tire carrier to get access to the spout. It would be nice if we could dispense water from inside the kitchen area.[*]Stronger spindle.[*]Want another spot for another can for longer trips.[/LIST]





I also discovered that my trailer light adapter didn't allow for my hazard lights to function properly. I think I might be making my own trailer light adapter soon.

Fred, LOVE seeing your build here. You're doing some really awesome and creative stuff!!

Thanks Peter.

Can't say any of my ideas are original. Been borrowing where I could.

Too tired to post another in depth write up so I'll just post these two pics. Picked up this 93/94 EFI 16 Valve Automatic Suzuki Sidekick yesterday! 141K miles.

[img]http://www.detn8r.net/Samurai/2016-08-04_01-39-1.JPG[/img]

[img]http://www.detn8r.net/Samurai/2016-08-04_01-39-2.JPG[/img]


Has a sputtering/bucking issue around 1500-2000k RPM. Adam seems to think it's a fuel mixture problem. Seller thought it was an electrical issue with the transmission. Not sure yet.

I've removed the Suzuki Security System from the Sidekick since the siren relay kept clicking. Someone had cut the wire to the siren long ago. I'm assuming that it kept going off.


I've yet to really dive into troubleshooting the issue but have come up with this list of items to hit.


Fuel Pressure Regulator
Fuel Pressure - Measured 35psi at idle - 40 under throttle
Vacuum Leaks
Plugged Catalytic Converter
Secondary Ignition cables.
Spark Plug Wires
EGR Valve
PCV Valve - Replaced since it was a cheap part
Faulty ECM - I plan on removing it to check for faulty components (capacitors?)





I planned on modifying the harness myself so I was going through Warbirds Harness Modification Instructions and he mentions that modifying the wiring harness from a 4 speed automatic donor is "significantly more complicated and not included in these instructions."


I've got access to the FSM for my sidekick through alldatadiy, so I can access the wiring diagrams for the transmission control module. Been trying to figure out what modifications are going to be necessary but I'm at a loss.

I have that same ARB compressor in my Jeep. It works good for me. I have 35" tires. Airing down to 15 pounds makes it take me about 20 minutes to air back up. I am not in any hurry, so it all works out.

Fred, I was going to recommend the kick fix website but it's no longer viable. I found this though:

[url]http://www.suzuki-forums.com/suzuki-sidekick-escudo-vitara-geo-x/49200-panic-time-where-kick-fix-site-6.html[/url]

About half way down is a "Download Zip file" link. Someone archived the site. It's clunky but check out the section under sensors, lots of good info on diagnosing the sensors.

The suzuki forums sidekick page was very helpful to me when I was chasing similar issues.

lol, nevermind I found it.

[url]http://www.fixkick.com/[/url]

Thanks Flashboiler. I have been reading through the fixkick.com website.

Half of my laziness with diagnosing the sidekick is that it hasn't acted up since I've gotten it. Haha!
I'ts been running fine.

I had discovered that someone had taken the valve cover off and never reinstalled it correctly. it was missing one bolt and only two of the remaining bolts were tightened.

Someone has clearly removed the RWAL module in the past since one of the plastic nuts was sitting on the drivers side floor.

The 60amp fuse was blown and the remaining tabs were bent in to complete the circuit. Whoever decided that bypassing a 60 AMP fuse was a good idea is brilliant!

Got off the phone with Petroworks and it looks like the oil pan and pickup modification service they offer is $125 which isn't bad. But I either have to pay $250 up front to get the pan shipped to me and then I get my $125 core refunded to me when I ship my pan and pick up back to them.

I really like your tire carrier and the way you made fold down tables for your cook stove. Nice!

Thanks JandDGreens!

I suppose I'll give a brief pictureless update. I've got the 1.6L engine in the samurai. I've yet to get all the radiator lines plumbed in and I plan on tackling the wiring this weekend. I've pulled the harness from the Sidekick and I've stripped it of all the electrical tape. I got the VSS from the sidekick installed into the Samurai's cluster. Suzuki made a spot in the Samurai for a VSS, almost like the Samurai was supposed to have fuel injection.

Ran into an issue with the Exhaust. Looks like I'll have to get one made or fab one myself.

Hi Fred,

I bought a 2" exhaust (lowrange?) and Doug Thorley header for my 1.6 swap. I had a shop weld it up, it's worked well... A little loud for the road but I like it snow bashing.

But, I've always struggled to pass NOx. I think it comes down to two things: The 2" exhaust came with a new cat, which I question the quality of (only because I barely pass Nox, usually the 2nd day testing) or the lack of back pressure from the bigger exhaust. The EGR system expects a stock level of backpressure and I've got less, so I must have less EGR flow.

Just some thoughts on what exhaust to go with.

I'd stick with stock exhaust adapted to the stock header.

Last weekend I was wheeling some hard trails in South Dakota and managed to smash my exhaust. It's smashed pretty good right by the t-case for a few feet and I can't say I notice any power loss.

I managed to get everything bolted together. I think I need to redo the hangers for the exhaust because it is TIGHT and it rubs the frame quite a bit.

Going to try and make a decent effort at posting an update here.


I started this project about a month ago. It's honestly probably the biggest project I've ever committed to tackling too!

I pulled the front clip from the Samurai as I knew it'd make things easier. I recommend that anyone attempting an engine swap in a Samurai do this as well. It's incredibly easy!
[img]http://www.detn8r.net/Samurai/2016-09-24_00-36-1.JPG[/img]

This made pulling the engine that much easier! Everything unbolts easy enough. I found it was easier to remove the heater core hose from the engine rather than the heater core. FYI.

[img]http://www.detn8r.net/Samurai/2016-09-24_00-36-2.JPG[/img]

I honestly used this 1/4" Socket Wrench and socket set for most of the removal. I also found myself using my 12mm and 14mm wrenches quite a lot as well.

[img]http://www.detn8r.net/Samurai/2016-09-24_00-36-3.JPG[/img]

My 3 Year old daughter helped me out as much as she could!

[img]http://www.detn8r.net/Samurai/2016-09-24_00-36-4.JPG[/img]

Pulling the engine out of the Samurai was the easy part!

Getting the engine out of the Sidekick was a major pain! I never got around to picking up Adam's engine hoist and I decided to use two ladders, a 2x4, a ratchet strap and some steel tubing. I didn't get the engine out of the sidekick this night it got too dark and there were some extra brackets bolting the engine to the transmission as well as the flywheel inspection plate.

[img]http://www.detn8r.net/Samurai/2016-09-24_00-36-5.JPG[/img]

The next day I got the engine out and began work on swapping the oil pan and pick-up out. The 1.6L's oil pans sump was a little too wide and would have come in contact with my front axle had I left it. To solve this I discovered I could use a 1.3L oil pan and modify a pick up. I purchased a new oil pan and modified pick up from Trail Tough so I could keep my 1.3L in usable/sellable condition.

[img]http://www.detn8r.net/Samurai/2016-09-24_00-36-6.JPG[/img]

[img]http://www.detn8r.net/Samurai/2016-09-24_00-36-7.JPG[/img]

[img]http://www.detn8r.net/Samurai/2016-09-24_00-36-8.JPG[/img]

I got the new oil pan installed as well as the transmission adapter plate and the 1.3L's motor mounts with the passenger side relocation bracket.

[img]http://www.detn8r.net/Samurai/2016-09-24_00-36-9.JPG[/img]

[img]http://www.detn8r.net/Samurai/2016-09-24_00-36-10.JPG[/img]

Ran into a slight issue with the exhaust. I was hoping to get away with using the Samurai's exhaust with the catalytic converter and everything but it did not want o fit.

[img]http://www.detn8r.net/Samurai/2016-09-24_00-36-11.JPG[/img]

I got the Sidekicks downpipe and catalytic converter installed and coupled to my muffler. It's rubbing on the frame everywhere and I think I can fix it if I move some of the exhaust hangers but I'll look into it more when I get the thing running.

I've been tackling the wiring these last two weeks. I've been using Warbirds Samurai Engine Swap Wiring Harness instructions as a guide. Unfortunately my donor sidekick is the 94' 4-Door 4-Speed Automatic Transmission version which his instructions reference as "...significantly more complicated and is not included in these instructions."

According to some people who have had Myron (of Zuks Off Road) modify their harness he gets rid of the Transmission Control Module altogether. One person from a facebook group, who works closely with petroworks, said that I need to keep the TCM to make everything work.

According to fixkick I can disconnect the TCM which puts it in Manual Test Mode (limp home mode). Which is what I suspect ZOR is doing by deleting the TCM. Right now I plan to keep the TCM connectors on the harness in case I need to try some stuff out.
[url]http://www.fixkick.com/tranny/slush/OD-flashes%20now%20what.html#manual_mode[/url]

Also, my Sidekick donor had Cruise Control. So I'm keeping the cruise control wiring as well in hopes of adding cruise control. The Cruise Control actuator is just a cable that pulls the gas pedal! Should be easy to swap into the Samurai!

Saturday I hope to get the fuel pump mounted and complete the wiring and hopefully add oil and get this thing running!!

Some Great sources I'm using! Huge thanks to HardLuk on ZukiKrawlers for his thread!


[url]http://www.azrockcrawler.com/_images/tech/2003/2-0216vmotor/2-0316vmotor.html[/url]

[url]http://www.billjohn.com/articles/engine/16valve/16valve.htm[/url]

[url]http://www.zukikrawlers.com/showthread.php?t=48353&referrerid=38154[/url]

Let me save you some grief, (assuming your using an external fuel pump) prime the pump. I had to prime my pump before it would work, I used a brake bleeder sucker tool like this.

[url]http://www.tooldiscounter.com/ItemDisplay.cfm?lookup=MITMV8020&source=froogle&kw=MITMV8020&gclid=CPuH5v-OqM8CFYF9fgod3loKew[/url]

Fred are you using an external fuel pump?
What psi will it be pushing?

Thanks Flashboiler!

I am using an Airtex E2000 pump. I believe it puts out 100psi. The regulator on the sidekick should bring it down to about 35psi