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Rebuilding Greg's Sierra

Tech Talk for Suzuki owners.

Moderators: lay80n, sierrajim

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Rebuilding Greg's Sierra

Post by greg »

Hi All,

Since there don't seem to be too many projects going on in the Suzuki Forum at the moment i thought i would keep you all up to date with what is going on with my little car.

Basically the scenerio is that two things have occured:
1. My little 1.3 engine is starting to die, its producing a lot of smoke and is chewing through oil.
2. My driving style and what i want to achieve when driving has changed. I'm no longer thinking about how to get up a track the easy way, now i want to have a crack at driving the hard way and acknowledge that there is a chance that i won't make it.

So, what these issues have required is a little rebuild of the car.

First up was the motor, it had to have Fuel injection because i am always flooding the carby with the car on big leans, so the obvious choice for the driving i like doing was the vitara 1.6 EFI engine, but as anyone that has tried to find one of these engines will tell you, they tend to be as rare as hens teeth and plenty costly.

Another suggestion that was generated out of the suzuki club was the little engine out of a Suzuki Cappuccino (a car that i had never heard of)... This is as much a novelty choice as anything else as it is only 660cc's and 3 cylindars with a groovy turbo sneeze idea :D . This has become the motor of choice and i have recently shipped a front cut from a Japanese Import Cap in the past few days.

The second issue was how to set up the car so that it could cope with my poor attempts at driving the un-drivable. The obvious choice for this was to reduce the number of panels on the car, and increase the strength of the passenger area. This lead to the soucing of a soft top body, and will lead to the installation of a 6 point roll cage.

So basically the whole process will include the following tasks:
1. engine swap (1.3 sierra to 660cc cap)
2. body swap (hard top to soft top)
3. gearing upgrade (5.12 diff gears)
4. roll cage and bull bar (new cage, get rid of arb bar to reduce weight)

So, that's the briefing on the project. I'll try to keep you all up-to-date on how it is travelling with the inclusion of a few pics etc.

I look foward to your comments / feedback.

Cheers,
Greg
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Post by robbie »

make sure you keep us posted on what went wrong during the build, what plans needed to be changed during the build..

and pics to describe all the stories :D

good luck dude :wink:
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Post by greg »

Problems so far:

1. importers did not include the jack shaft (yoke) from the back of the cap gear box. However, as it turns out, a 1L sierra yoke fits perfectly so it looks like all is good there.

2. finding someone that has an EFI Vitara Fuel tank - i have just sourced one from NSW.

3. finding someone with some 5.12 diff gears - ended up buying some through Overkill (Sam) in NSW.

lots more issues going along but we'll see how it all goes.
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Post by nicbeer »

You selling the body and bar?

cheers
[url=http://www.outerlimits4x4.com/viewtopic.php?p=930942#930942&highlight=]Zook[/url]
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Post by greg »

you would appear to be in perth so i don't know how worthwhile shipping a whole body would be, but yes, the hard top body and the ARB bar are going to be available.

note: the arb bar mounting plates have been modified but i'd imagine that i could get them re-set back to fitting a stock application.
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Post by OVERKILL ENG »

sounds good so far keep us informed on the buildup.
We need more extreme ZOOKS out there.Glad to be of help.
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Post by christover1 »

gee, my Frog is getting left behind, :cry: I suppose I need to use my age and cunning, :evil: to keep up in da bush, christover. :onfire:
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Post by N*A*M »

:x :cry: :roll: :oops: :twisted: :shock: :lol: 8) :finger:
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Post by bigsteve »

:( :( :( :( :(
I have soft-top envy
:( :( :( :( :(
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Post by christover1 »

bigsteve wrote::( :( :( :( :(
I have soft-top envy
:( :( :( :( :(


angle grinder therapy can help :silly:
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Post by bigsteve »

Dont tempt me, I'm very unstable, I'll do it, I'm not afraid.
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Post by moose »

bigsteve wrote:Dont tempt me, I'm very unstable, I'll do it, I'm not afraid.


I have an old 89 hard top body about to be chopped & dumped !!!!!
do ya wanna come practice a soft top conversion ????? :finger: :finger:
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Post by greg »

Well i checked out the coffee machine on Saturday. Looks very small but it actually just as tall as the sierra motor is - just shorter from front to back.

The front cut does not have a radiator or the original intercooler - i assume these were damaged in the write off accident - the car has taken a hit in the front drivers side corner.

Progress Update:
1. My fuel tank is being shipped today from sydney to melbourne :D

Modifications Required List Update:
1. We are going to get a custom intercooler made for it.
2. Requires a thermo fan as the cap motor does not drive a fan. However, the wiring loom from the cap should allow us to drive the thermo.

more info as it develops.
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Post by Damo »

What tranny does the capp motor have?

Sounds like a cool setup, will be really interesting to see how the little blown 3 pot goes.
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Post by greg »

the cap has a 5 speed manual which looks very similar in size to the sierra 1L box... i believe that the gears are a bit taller though - that's why i had to find the diff gears.

currently the gear box has an extension of about 40cm to where the shifter stick sits to change gears... this would mean that the gear shifter would end up where my elbow is when driving the car (i.e. in the handbrake area), so we are hoping to be able to remove this extension and fit a regular 1L sierra shifter stick to it :D

Note: In Japan i believe this motor (F6A or K6A) comes stock in their Sierra (Jimny) and comes with an Auto too... Which we suspect may be able to bolt straight into place instead of the manual which would be pretty nice too :D
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Post by N*A*M »

nice 8)

i'll have a latte thanks
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Post by greg »

today's update.

The body swap and diff gear change over is looking good for the 28th at Total 4wd (i'll add the charge to your tab shall i NAM :D )

So it looks like the body swap will happen before the engine swap.
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Post by N*A*M »

when did you book the 28th in? :?

i had that day booked :x
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Post by greg »

i guess early last week - tuesday it would have been... same day that the arrangements for the cap front cut had to be made...
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Post by N*A*M »

well that's all right then :? i think

it's all good :)
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Post by bigsteve »

moose wrote:
bigsteve wrote:Dont tempt me, I'm very unstable, I'll do it, I'm not afraid.


I have an old 89 hard top body about to be chopped & dumped !!!!!
do ya wanna come practice a soft top conversion ????? :finger: :finger:


Ohh it could be beautiful, I have a box of 8inch cutting disks
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Post by Guy »

Steve if ya really want to do this .. I would be hapy to supply a few beers for afterwards :twisted: .. I would even provide car and trailer to get the body to whereever .. and dump it if we really screw up .. :x

I wanna chop my hardtop into a trayback ... But would like to get in abit of practice on a non working model before I take to mine with a grinder ... again ...
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Post by bigsteve »

Apparently Moose has such a body for the hacking.

I have a bit of a plan brewing, will you be at the meeting tomorrow??
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Post by Guy »

Yeppers should be at the meeting at least for a while.. work permitting .. (Curse people resigning and servers litterally catching on fire in far flung states like QLD).

Guy
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Post by N*A*M »

dude buy my body!

it's already cut up for ute cab conversion.

seriously non rusty body in top nick!

see the early pages of my members post!
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Post by bigsteve »

N*A*M wrote:dude buy my body!

it's already cut up for ute cab conversion.

seriously non rusty body in top nick!

see the early pages of my members post!


Tempting but I'm told that unfinisheditis is highly contagious, my zook is still a DD.
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Post by N*A*M »

i think i will keep the body and finish off the welding, glass and paint
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Post by greg »

Today's Update. The diff gears have arrived (thanks Sam), and the fuel tank is in melbourne too. :D
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Post by OVERKILL ENG »

We want some pics :x :x :x :x :lol:
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Post by greg »

Today's Update.

1 x EFI Fuel Tank is now resting quite comfortably beside my desk after its long journey down to melbourne :D
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