Finally, remove the fan, shroud, and radiator. Remove the air box, disconnect and remove the battery, and label all the wiring and components so you know what it is later. Remove all of the wiring, cables, lines and hoses from the engine. The engine swap is easier if you remove the engine and transmission together. Even without modification to your 1600 engine you can expect to gain up to 25 horsepower over the stock 1.3L motor using a fully bolt on kit.ġ. The 1.6L 8-valve engine can also accept modifications such as the Thorley header, MSD ignition, and other great components to help soup up your new setup. The donor vehicles wiring harness will need to be modified for use in the Samurai as well as the Samurai speedometer which will need the speed sensor from the donor vehicle adapted to it. With 16-valve engines, you’ll need the engine wiring harness, everything attached to the harness, under dash wiring harness, ECM, instrument cluster and air cleaner assembly. You’ll need the fan, starter, alternator, coil, air cleaner, exhaust manifold and head pipe. You’ll need the complete engine with all the hoses and pulleys. If you want to use the 16-valve 1.6L, you want the Trail Tough kit!Ĭheck Out: Parts Needed From a Sidekick or Tracker: Trail Tough’s 1.6L conversion kit includes an engine adaptor kit, high pressure fuel pump, and modification of your donor harness completely color-coded labeled and ready install a well as modification of your speedometer. You will need the motor, wiring harness, everything attached to the wiring harness, instrument cluster and air cleaner assembly. On 1996 and up donor vehicles you will need to get the second 02 sensor portion of the wiring harness. When gathering parts for your conversion keep in mind that 1996 and up motors are OBDII and will not be smog legal for California. You’ll need to use the 1.6L starter and alternator. You can re-use your stock 1.3L manifolds, flywheel and clutch with the 8-valve 1.6L as well. The 1.6L swap adds very little weight keeping the Samurai a very light and nimble trail machine. The 1.6L has bigger intake and exhaust ports The 8-valve 1.6L head and 1.3L head are nearly identical. The 1.6L 16-valve will require the use of all the fuel injection components and require a complete rewiring The 8-valve 1.6L engine can use the 1.3L intake and a carburetor The 8-valve 1.6L has throttle body fuel injection while the 16-valve has multipoint fuel injection The 1.6L is a fuel injected engine and never came with a carburetor Looking for more power? A common engine swap is to swap out the Suzuki Samurai 1.3L engine for a 1.6L engine from a Suzuki Sidekick or GEO Tracker.
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