Outer Limits 4x4 Board

zooker wrote:

mr green wrote:funny you should mention that, since i have had my maruti, i have fitted electric fuel pump, boosted brakes, fuel injection and am organising power steer now.

Similar here, done the efi and power steer and Im now looking at boosting the brakes.

Any chance you could explain what was needed to add boosted brakes into your maruti, and do you have any pics?

cheers

too easy. removed the pedal box, marked out holes for the boosted pedal box( from memory the top 2 holes lined up but the bottom two were out a bit) bored the main master cylinder hole out to the boosted diameter ( started out with a die grinder but that section of steel is pretty thick so i drilled about 100 holes in a circle and tidied it up with the die grinder) fitted the boosted pedal box, fitted booster and master cylinder, bleed brakes.
i should point out though, i had no real break performance problems, i just like the cushy feel of the booster and i had all the parts there and thought i might as well do it when i had the motor out.
not much point in pics now as the booster hides all the tricky stuff. i must start taking pics as i go
Jason

Ok cool, I might look at doing it when I do the vit brake upgrade.

One more question Mr Green, did you have to remove the dash to remove the pedal box? It looks like a PITA and I'd rather avoid it

Cheers

i was too lazy to take the steering column out so i pulled the clutch pedal out so i could feed it over the column. bit fiddly getting the pedal back in but quicker than taking the column out

Quoted from another thread I was hi-jacking

504_matt wrote:Hi jaffa, firstly is your car really a maruti, not all LWB suzuki's are maruti's, did you get it with a 1 litre engine in it or a 1300, secondly did you actually fit the engine yourself or have someone do it.

I agree with joeblow, all maruti's come with 1 litre engines and therefore have 1 litre mounts on the chassis which differ from 1300 and 1600's. All that I have seen with 1300's or 1600's have had the mounts on the chassis altered to suit.

Hi, yes it is a Maruti. Im positive that the chassis is Maruti too because the chassis number is at the rear of the chassis near the spring hanger amd not under the front guard like a sierra, came with 1ltr Maruti engine and 4 speed. Yes I did fit the engine myself. I may be completely wrong and maybe it is alot easier to fit a 1.6 into a 1ltr sierra/maruti than I was led to believe.

All I had to fit the 1.6 in was use a plate on the drivers side to effectively bring the chassis mounting point forwards

pics of the mounts please

I take some tonight, I'll try and get some measurments from firewall and front of chassis too

Here are the pics and some measurements.

Measurements (not exact to the mm but very close)

Passenger side:
Firewall seam ]<---205mm--->[Engine Mount]<---495mm--->]Front of chassis

Drivers side:
Firewall seam ]<---190mm--->[Engine Mount]<---490mm--->]Front of chassis

Info on plates

Passenger Side Plate

Maruti Udyog Ltd India
MG410WT
VIN MA5EGC21T00XXXXXX
Engine F10A
Built May 1990





Driver Side Plate

approval No 3040
Catergory NA
Maruti Udyog Ltd
Suzuki Sierra MG410
GVM 1370
Seats 2
VIN: MAG5EGC2100XXXXXX
7/90 (assume its the compliant month/year)
(Usual ADR crap)




Passenger Side Mount





Drivers side from outside (easily visible thanks to one of you body lift kits Joe) I know that the plate method I have used is dodgy and I will probably change it one day


From Top





Vin No @ rear of chassis (numbers between the 2 plate, rego sticker and the chassis are the same)





Gear Box Mount (also straight bolt in)





Original Engine (numbers match with plates and rego sticker)




The engine I have put in I got out of a swb sierra, that car was originally a 1ltr (SJ40 I think) and it did have the engine mounts on the chassis modified

Please can someone tell me, is my car weird or is everyone wrong and it is really easy to put a 1.6 into a 1ltr sierra/maruti?

yeh that is the same engine mount as my maruti which is almost the same as the original 1lt except we have 2 10mm bolt holes instead of 3 8mm. these are nothing like the 1.3 lt mounts. you have gotten away with it buy using the 1lt lowered w strap. When i fitted the g16b to mine i used the flat 10mm plate on both sides and some average looking bits of rhs in place of the w strap to lower engine enough to fit (just) without a body lift

Another pic I found with no engine in at all, you can clearly see the mounts and chassis havn't been modified





This is a SJ410 1ltr SWB Sierra chassis dimensions drawing........





and this is a long wheel base chassis dimension drawing, it must be a 1ltr because the engine mounts arew in the same place




You can see in my pic from inside the wheel arch looking at the drivers side engine mount that it is in a different location to the shock tower in either of the drawings (this assumes that the drawing a labeled correctly)

mr green wrote:you have gotten away with it buy using the 1lt lowered w strap.

Im not following you here, the motor that is in it now is a 1.6 and its not lowered at all.

mr green wrote:When i fitted the g16b to mine i used the flat 10mm plate on both sides and some average looking bits of rhs in place of the w strap to lower engine enough to fit (just) without a body lift

I have a 2 inch body lift and strap/plate on one side only

Im not sure I understand what you mean, sorry.

Jaffa wrote:Here are the pics and some measurements.

Measurements (not exact to the mm but very close)

Passenger side:
Firewall seam ]<---205mm--->[Engine Mount]<---495mm--->]Front of chassis

Drivers side:
Firewall seam ]<---190mm--->[Engine Mount]<---490mm--->]Front of chassis

Info on plates

Passenger Side Plate

Maruti Udyog Ltd India
MG410WT
VIN MA5EGC21T00XXXXXX
Engine F10A
Built May 1990





Driver Side Plate

approval No 3040
Catergory NA
Maruti Udyog Ltd
Suzuki Sierra MG410
GVM 1370
Seats 2
VIN: MAG5EGC2100XXXXXX
7/90 (assume its the compliant month/year)
(Usual ADR crap)




Passenger Side Mount





Drivers side from outside (easily visible thanks to one of you body lift kits Joe) I know that the plate method I have used is dodgy and I will probably change it one day


From Top





Vin No @ rear of chassis (numbers between the 2 plate, rego sticker and the chassis are the same)





Gear Box Mount (also straight bolt in)





Original Engine (numbers match with plates and rego sticker)




The engine I have put in I got out of a swb sierra, that car was originally a 1ltr (SJ40 I think) and it did have the engine mounts on the chassis modified

Please can someone tell me, is my car weird or is everyone wrong and it is really easy to put a 1.6 into a 1ltr sierra/maruti?

SOLVED!......yes you DO have 1.0 litre engine mounts, and the chassis drawings are of 1.3 origin. notice how your passenger side engine mount sits on top of the rail...the 1.3 version sits almost flush with the top edge of the rail. the angle of your mount to the rubber is not correct also. your engine will be sitting much higher than it has to. on the chassis drawings you will also notice that the g/box cross member is of a 1.3 design. the 1.o litre maruti sits on top of the chassis and is straight, though marutis will line up with a 1.3 five speed. so there you go...you DO have 1.0 litre mounts......you had my brain worried there...

Hi Jaffa, thanks for the pics, your engine mounts are 1 litre and you have made the 1600 fit by adding the plates, you will find that the engine is not really in the correct position but it shouldn't worry you if you are doing general 4x4ing, if you were punishing the vehicle you may have problems with breaking engine and gearbox mounts. A mate here in QLD had one done exactly like yours and recently had 1300 mounts welded in to get it right because he had some vibrations betwen 80 and 100km.

Passenger side 1300 mount


Driver side 1300 mount

Thanks guys, I finally know that my car isn't weird or dodgy, and now that you mention it Joe the mount on the passenger side does look like its not on the right plane. If I start having issue with breaking engine mounts or anything I will look at changing the mountings, I think the 6.5:1 gears (on 30" tyres) must be helping by the motor not having to work as hard because of the lower torque required with the gearing. I also dont have any vibration issues at any speed.

So basicly what I have learnt from this is that it isn't hard to fit a 1.6 into a 1ltr like everyone says, if you are happy to have the motor sit higher than normal and don't mind it not being 100% right (or legal)

Jaffa wrote:

mr green wrote:you have gotten away with it buy using the 1lt lowered w strap.

Im not following you here, the motor that is in it now is a 1.6 and its not lowered at all.

mr green wrote:When i fitted the g16b to mine i used the flat 10mm plate on both sides and some average looking bits of rhs in place of the w strap to lower engine enough to fit (just) without a body lift

I have a 2 inch body lift and strap/plate on one side only

Im not sure I understand what you mean, sorry.

sorry for the poor interpretation and this late reply (damn puter froze last night) the w strap ( well thats what i call it anyway. bolts between your chassis mount and the rubber mount) on your one litre has the centre bolt hole for the rubber mount well below the two holes for the chassis mount bolts where the 1.3 has the three holes inline. i'm sure thats cleared it up below is the my maruti setup with the g16b and no bodylift. very close clearances as the accelerator cable just touches the bonnet. another note is the 5 sp gearbox in the factory mount, has the gearstick housing at the very rear of the tunnel hole. didn't look in to it too much i just trimmed a bit off the bracket that holds the boot on.

Ok has anyone out there had a WT maruti front diff apart? I need to know whether they have a 4-pin or a 2-pin carrier. I am putting a locker in mine and need to know if I have to get a 4-pin carrier out of a NT diff.

I have heard that the early WT sierras which had NT flanges on the diffs came with a 4-pin front diff. My WT maruti also has NT diff flanges. So I am hoping that it has the 4-pin centre, I just need conformation from someone who has had one out.

Cheers

could be either, pull it out and check before you buy. With maruti's you
never know what parts have been used.

Here's a stupid Murati Q:

Last time I washed mine I pushed the windscreen washer spray nozzle in!
Were do I get to it to fix it? under the dash somewhere?

taz_rx wrote:Here's a stupid Murati Q:

Last time I washed mine I pushed the windscreen washer spray nozzle in!
Were do I get to it to fix it? under the dash somewhere?

Fold the windscreen forward and you'll be able to get to it easily

I have solved another quirky maruti mystery.

WT Maruti's have:
- WT diffs/axles
- 4.09 ratios
- NT driveshaft flanges
- 4-pin front diff (so you can install a locker straight in )

i was under the impression they had 4.11 ratio's. The marutis are a mixed bag, they are not all the same. There are variants in both w/t and n/t

I just picked up a Maruti for a good price. It has a stuffed rear diff though so i need to figure out what diff to put in and if its going to be the same ratio.

Mine is a 95 model with 75000 clicks on it.

I have lockers to suit a NT still in boxes. I also have TG 6.5 transfer gears. Will they fit the Maruti?

I'd say yes to the gears and a positive maybe for the locker.
Sent a PM to U.

Yes to the gears and lockers will fit if its a WT maruti. NT have 1L diffs.

Good luck finding a rear diff though, I just recently busted mine and couldnt find a replacement. They are a 4.11 ratio. I ended up just putting a NT rear diff in and getting 3.9 ratio put in my front diff. (however that does mean I now have 1 set of 4.1 gears which I took out of my front diff. PM me if you'r interested )

i have 2x 4.11 maruti w/t diffs $350 ea complete selling as a pair but im in perth

Thanks for the offers guys. Its just the pinion bearing thats gone so ill probably just rebuild the diff unless you want to sell them alot cheaper. Freight would be a killer from Perth.

Just found out that the diff flange may be a Maruti hybred. Large bolt patton, small spline size. Well this is the case with my NT.

Just wondering if anyone knows if there is any difference in Sierra steering boxes. Looks as though mine in my Maruti has worn out and I need to replace or get rebuilt. And NO, I don't want to convert to power steer, I like the exercise I get from it when wheeling.

I believe they're all the same.

Steve.

Zute wrote:Just found out that the diff flange may be a Maruti hybred. Large bolt patton, small spline size. Well this is the case with my NT.

Zute wrote:Just wondering if anyone knows if there is any difference in Sierra steering boxes. Looks as though mine in my Maruti has worn out and I need to replace or get rebuilt. And NO, I don't want to convert to power steer, I like the exercise I get from it when wheeling.

yes diff flanges are Maruti only, the splines are not interchangeable with 1.3 and the bolt pattern are nt. (wt maruti). And the steering box is interchangeable with other zooks ( i swapped mine over last week )
jason

Ok thanks Guys,
So can I split a NT uni and mate it with the Maruti uni ?
Ones a inside circlip and the other is outside. I think.