Outer Limits 4x4 Board

yep, tis ay. good work pj.

Just a few more updates on my build


The 1.6 with the wildcat extractors, here the engine mount is modified as they only just fit.


Bulletproof armour for my gearbox, otherwise known as the 6mm adapter plate ive started to make. So far everything is lining up perfectly.


The locating dowel i lathed up at work out of half an old ubolt. Basically the thicker part is 15mm or the thickness of the original engine dowel, and the other 12.95mm which is the original size of the gearbox dowel. Then i drilled and tapped the inside to 10x1.25mm thread, so now im going to insert a 10mm 'recoil' into the engine bolt holes to reduce the diameter, then fit a long threaded rod through my dowel pin. So then i screw the rod and dowel pin into engine block till it bottoms out, then fit the gearbox over the smaller part of the dowel pin, then use a nut to hold gearbox on. For the opposite lower dowel pin, im going to use the original and precicely drill a 15mm hole in the 6mm plate to locate it.


The lot sitting on a bench in a corner at work. Makes it so much easier to work on. When i removed the gearbox at lunchtime to measure things up, i came back to it at the end of the day and the smart ass bastards at work bolted it back onto the engine, they even bolted the starter motor back onto the gearbox. They said they were even considering carrying it out the back and refitting it back into the sierra hehe


Other side of the gearbox plate.


Few other interesting views.

pj, what year is the motor?

just interesting in seeing the different intake sections. mine says mpi i think on it and seen a couple diff ones.

Its a 99 model

my motor is a 2000 model but that motor is the exact same as mine, even down to the bursons oil filter

hi i just got the baleno motor put in my car just wanting to know what has to be done to get the tacho working any help would be great
thanks greg

The tacho works off the alternator, so just connect the alternator up properly and it should work fine.


I was just thinkin too, has anyone machined up an adapter and spaced out theyre flywheel 6mm to compensate for the adapter plate? From doing a bit of measuring the input shaft should still sit a little into the spigot bearing so thats ok, and the friction plate should still have enough contact on the input shaft splines so thats ok, but im worried about the throwout bearing moving too far off the gearbox nosecone and getting jammed or something. Maybe instead of spacing out the flywheel i could make a 6mm spacer and fuse it to the wear surface of the throwout bearing to space that out, but im not sure if it needs to be hardened to survive wearing against the pressure plate fingers.


EDIT: *erk* cant beleive i said tacho runs off alternator, its wrong ppl

PJ.zook wrote:The tacho works off the alternator, so just connect the alternator up properly and it should work fine.

ooo, how did you work that one out pj?. im guessing because we run the same head config, that i could run mine like this.... will have to do it when i swap the BB into the LWB.

Finally hooked up my baleno tacho today grafted into suzys instument cluster! So now i have the baleno 200Km/h speedo,And the baleno tacho!
T'was abit fiddly but it was sort of a bolt in thing!

*1 long screw for a tachowire screwed it all in.
*Cut abit off the sierra original plastic (around the backing light bulbs)

*Wired in some connection hoops to the tacho terminals, Work out which one is Power,earth and tacho signal from the ecu. Then wired it into the original accesorys power/earth
*Used part of the baleno black surround cos the tacho is smaller, so u get light coming through.
*Use baleno arrows
*Also found out, mine was showing it was revving at 3k, so i popped the arrow off again and put it on kinda crooked below the stopper, so it grabs the spindle, then move it past the stopper, push on and check again. Hard to explain.
*Also used the vitara vss in speedo for the computer, lines up with the baleno odometer kinda ok. But the kms were more in my odo. ah well

Spike_Sierra wrote:

PJ.zook wrote:The tacho works off the alternator, so just connect the alternator up properly and it should work fine.

ooo, how did you work that one out pj?. im guessing because we run the same head config, that i could run mine like this.... will have to do it when i swap the BB into the LWB.

I'd like you know how you figured that too, I think it runs off the crank/cam angle sensor and the signal is provided by the ECU.

The Alternator just has ig+ and L terminals like any other.

Steve.

you can't make a flywheel spacer other wise your starter will not engage properly. i have just finished making 2 adapter plats, yes they work but i wish i was not so miserable and just bought them off bent. looks like you have the right tools to do it but damn it has to be accurate

Good work Bluesuzy, any pics?


Mr Green im very confident i got it spot on, plate turned out well so im happy.
I finished modding the sierra sump with the crank angle sensor holes welded in, also finished modding the pickup today too.

i have pics but my net is sooooo slow its unbelieveable. Taking ur time pj! my engine was in the car with mounts and plate and sump modded within the week Nah just stirring the wait is worth it but.

lol well it doesnt help being a perfectionist, plus i can only spend an hour or so after work every few days. Ive been meaning to work on it every night this week, but every time i have breakdowns i have to attend afterwork, except for tonight.

More pics


Modded sump, unfortunately i didnt have access to a tig as planned so i mig'd it and ground it back a little.
Before i welded the section on, i dry fitted teh sump and made sure that none of the crank would hit the baffle, it was at least 15mm away so that will be fine. I heard that some ppls cranks are hitting the baffle so i checked.


Crank angle sensor section cut from baleno sump and grafted onto zook sump. Is this how everyone else did it?


Modded pickup. I cut the large diameter mount from the baleno pickup and welded it in place of the sierra one, then cut the old tag off, refashioned it and welded it on over the bearing cap with the threaded hole. There was no hole where the old bracket was.


Transferred the larger EA alternator onto new engine from my old 1.3, fit great, have to get a multirib pulley though.

with the alternator.

is that the 1.3/1.6 or modded bracket

Its the 1.3 brackets that i previously modified to fit alternator. Plus the 1.6 brackets wouldnt have fitted, as the 1.6 alternator has a single wide lug that sits between the two lugs on the bracket, whereas the 1.3 alternator had 2 lugs held by 2 lugs on bracket, which was same as most larger alternators, such as the Fords.

Yup your sump looks b e a utiful! Did mine the same, but with a stick welder, and yes it was a pain in tha bum. The support bracket also i found out the same, and i made the little baby support bracket same as u. And also, i just kept my alternator. I thought it would be stronger than the sierra one anyway as its meant to run a power windowed/steering airbagged baleno

Finally got to upload some pics! Still everything is running fine! No problems at all with the motor. Gotta love efi and the late model technology!

PJ.zook wrote:
Modded pickup. I cut the large diameter mount from the baleno pickup and welded it in place of the sierra one, then cut the old tag off, refashioned it and welded it on over the bearing cap with the threaded hole. There was no hole where the old bracket was.

Q. is there any main reason that the Vit block(as i have) has two bars running over the bearing caps? like below

for strength under hi load conditions. don't remove them. later models didn,t have these but they also had a different cap design.

In regards to the sump, didn't jimny g13bb also have a crank angle sensor? (or is my memory daft)

the tone wheel is on the crank gear but there is no sensor there. it runs off the pickup on the back of the cam.

my g13bb has a CAS - crank angle sensor.

few questions,

1) could you just use the jimny sump on the baleno motor if you suck at welding?
2) the 'hi load conditons' bars running along the g16, were they on the carbies? or early 16vs?
3) Could the bars be used on a 1.3l? (g13a, ba, b, bb)
(like building a turbo block or something)

Just a small update, i have been sorting out the wiring from what i need and dont need, snipping out all the wires i can use. Im keeping the airconditioning too, going to use the baleno evaporator and TIG up a custom airbox. This means a suprising amount more wiring and relays, so im also keeping the relay and fuse box and mounting infront of my second battery.

The loom went from this giant mess...


...to this neat little bunch





Also for everyone looking for a wiring diagram and plenty more info on the motor and electrics, you only need to download archive part 9 from the following link. The PDF contained therein had every little bit of info i needed.

http://www.skidmark.co.uk/suzuki/sy.htm



On another note, does anyone happen to have the aircon 'computer' that they dont need from theyre conversion, it should be on the side of the airbox, i need it and forgot to keep it from when i stripped the baleno.

Oh yes and another question, when people made custom thermostat housings, did you use steel or did you have to use aluminium like the original? I think this is a stupid question but just a little worried about expansion rates etc...

My original water piping as you see in the pics is mostly cut up now. I didnt have a thermostat. It caused endless problems

However i have one now, Its full custom but...

Steel machined on a lathe, all recessed for the thermo and sensor tapped, welded piping etc. I will get a recent pic 4 ya

Santos wrote:few questions,

1) could you just use the jimny sump on the baleno motor if you suck at welding?
2) the 'hi load conditons' bars running along the g16, were they on the carbies? or early 16vs?
3) Could the bars be used on a 1.3l? (g13a, ba, b, bb)
(like building a turbo block or something)

PJ i take it that u have trimmed the loom a bit? as i think mines a bit longer than that.
where u guys mounting the ecus?

Santos
1 no idea, i'd say if sump fits the G13 then it should fit the g16 fine cept for the sensors if there. mine is a std 1.3 sump as no CAS
2 G16A mpfi thats what mine is
3 maybe