Outer Limits 4x4 Board

Gday fellas,

I apologise if some of this information is on another thread, I have searched thoroughly and found bits and pieces of information. I do not have a whole lot of technical knowledge regarding engines, but am trying to gather as much information as possible to make the change over easier for my mechanic.

I purchased a 1.6EFI engine (I think it might be a g16?) and 5 speed manual gearbox from a 94 or 95 vitara and am going to put it in my 89 Suzuki sierra SWB (1.3, 5speed man). There are a couple of things I'd like to know, to make the job as easy as possible for my mechanic (he doesn't have a whole lot of time and is unwell at the moment).

Basically, the issue is that although the new gearbox is wider than the old gearbox from the sierra and thus doesn't fit in the tunnel under the car. Also, as the new engine is larger than the sierra's, the gearbox sits further back than the old gearbox and thus the gearleaver and transfer case will sit in different spots than the gearbox from the sierra. (the transfer case might even sit back near the handbrake which is another isse).
If anyone has done this conversion what did you do regarding the gearbox (ie. cut out the sides of the tunnel to make it fit - I think this has to be done unless i get a lift kit (dont want to do) however once cut out and widened, I will have to modify the seat brackets on the drivers and passenger side).
Also regarding the engine, are new mounts necessary, or are they to be relocated? Also, will the radiator fit in ok with the newer engine, or do we need to modify that somehow?
Also, once the modifications are done to make the engine and gearbox fit, what did you find was the best way to actually get them into the car? My mechanic said he wont be able to attach the gearbox to the engine and then place the total unit in the car as the front end of the sierra is attached to the car and can't be removed. Thus did you blokes first put the gearbox in then the engine or vice versa?
Are there any other issues which we need to address before we get the engine in the car (eg. sump?)?

Basically I am trying to get information to make the change as easy for my mechanic as possible, and if there are any things he should do to the engine/gearbox before he puts it in the car, can you please let me know?

Thanks,
Derm

dermott_b wrote: Gday fellas,

I apologise if some of this information is on another thread, I have searched thoroughly and found bits and pieces of information. I do not have a whole lot of technical knowledge regarding engines, but am trying to gather as much information as possible to make the change over easier for my mechanic.

I purchased a 1.6EFI engine (I think it might be a g16?) and 5 speed manual gearbox from a 94 or 95 vitara and am going to put it in my 89 Suzuki sierra SWB (1.3, 5speed man). There are a couple of things I'd like to know, to make the job as easy as possible for my mechanic (he doesn't have a whole lot of time and is unwell at the moment).

Basically, the issue is that although the new gearbox is wider than the old gearbox from the sierra and thus doesn't fit in the tunnel under the car. Also, as the new engine is larger than the sierra's, the gearbox sits further back than the old gearbox and thus the gearleaver and transfer case will sit in different spots than the gearbox from the sierra. (the transfer case might even sit back near the handbrake which is another isse).
If anyone has done this conversion what did you do regarding the gearbox (ie. cut out the sides of the tunnel to make it fit - I think this has to be done unless i get a lift kit (dont want to do) however once cut out and widened, I will have to modify the seat brackets on the drivers and passenger side).

I have never done this conversion nor do I know alot about it, but I'm pretty sure (from reading around on here) that its alot easier to buy an adapter and mate the 1.6 to your 1.3 sierra's gearbox.

dermott_b wrote: Also regarding the engine, are new mounts necessary, or are they to be relocated? Also, will the radiator fit in ok with the newer engine, or do we need to modify that somehow?
Also, once the modifications are done to make the engine and gearbox fit, what did you find was the best way to actually get them into the car? My mechanic said he wont be able to attach the gearbox to the engine and then place the total unit in the car as the front end of the sierra is attached to the car and can't be removed. Thus did you blokes first put the gearbox in then the engine or vice versa?
Are there any other issues which we need to address before we get the engine in the car (eg. sump?)?

The whole front clip of a sierra CAN be completely unbolted, right back to the firewall. This includes the bonnet, front quarter panels & guards, front grill etc... This way you can bolt the gearbox to the engine and then swing it under the car from the front...
Not sure about engine mounts or radiator sorry...

I also believe with the higher intake on the vit engine, to clear the bonnet of the sierra you need to fit a 2inch body lift. Although you dont need to do so with a Baleno motor IIRC.

When removing the front clip, some of the screws will be a I'm gayer than aids! to get out. Basically use the old hammer and cold chisel option to get them undone and replace them with something easier to undo.

Have a look in want33s build up thread for more info on this

And definitely go the sierra box and tcase with BenT adapter. Sooooooo much easier to set up, not to mention better range of aftermarket gearing available

As already said, just use the sierra gear box, much easier. If it is the Vitara engine you will need the 2" body lift as suggested. The Baleno motor doesn't require this as its intake is at the same height as the engine.

search + read....

I have a buildup on here detailing this also.

sump - use the 1.3 one cutshunt the oil pickup
wiring - have fun
uses Bent's adapter plate, takes care of gbox(use the 1.3 one) and engine mounts.

u need at least a 1-2" BL to clear the intake manifold.

Nic

Nicbeer,

you got a ink to that build up?

Wouldn't mind having a read also. Seems we are building similar rigs.

Click on the orange writing in his sig line.

Cheers mate

theres a couple of high res pics on here somewhere of my sump mods also.

and yeh linky below

any more q's chops, send em through.

thanks fellas for all the info.

The problem with using the gearbox out of my sierra is that mine is on the go, and is probably going to need replacing at some stage. As said before I don't know alot about car mechanics, but is the sierra gearbox heavy duty enough to handle the extra power from the 1.6EFI, or does the adaptor plate help that in any way? I should be able to get a hold of another sierra gearbox from a wrecker hopefully.

Also, is there any way I can fit the engine in without a body lift? I don't really want to lift it, but if necessary I'll have to.

Cheers

bonnet bulge or custom engine mounts to lower the engine down into the bay. beware its gets lower to the front pumpkin also.

gearbox - they are fine if u drive it without ramming the gears in etc. like any box.

adapter plate just makes the two work without welding tabs etc on.

U did i presume got the airbox,coil, wiring and ecu etc for the new motor as well?

Yeah mate, I have everything I need. My brother is an auto electrician so he is going to do the wiring for me.

I'll do a search regarding custom mounts and see what I can come up with...

thanks

Wouldn't recomend dropping the engine lower. Make some mounts up if you have to & lift the bonnet. By dropping the engine down as NicBeer said it puts the sump closer to the diff. Doesn't allow alot of room for problems you may come across.

A bodylift isn't a bad thing. Yes it raises your COG but you can run bigger tyres more easily & it will fit the engine. They aren't that hard to do. Try searching a few guys have done good write ups.

heres my body lift write up.

http://www.outerlimits4x4.com/phpBB2/vi ... hp?t=93393

cheers

i was thinking of doing the same thing to my SWB with reguards to the vit gear box & transfer to avoid using my 1.3 box. i did some measurements to try DUEL transfers to cheaply get reduction, and the further i looked into it the worse off i got. ie not enough room shaft wise to run duel transfer, as u said about where the sticks pop out, using vit box & transfer ONLY, u will have to make up drive shafts front and rear, there is not many gear reduction ratios available for transfer IF u stick with that option, and most of all it was alot of work just to avoid spending a couple hundred on an adaptor plate that will bolt up with no hassles.

just my experiences

(Could be burned here so flame suit is on)
It can be done without a body lift!
I'm not sure about the suspension lift in order to clear the sump as i run Lux diffs. It will fit in the tunnel with a small amount of massage. But you need to fit a custom "jack shaft" (box-transfer). Aslo once in place you will need to bend the shifter as the vit one comes up alot more vertical so you hit the dash when driving.
The engine is using standard mounts but i have torn a few of them and also on full flex i have put a small ding on the bonnent. This was done when the near side engine mount broke. If i get a chance i will get some photos and email them to dermott.

WHITS wrote:(Could be burned here so flame suit is on)
It can be done without a body lift!
I'm not sure about the suspension lift in order to clear the sump as i run Lux diffs. It will fit in the tunnel with a small amount of massage. But you need to fit a custom "jack shaft" (box-transfer). Aslo once in place you will need to bend the shifter as the vit one comes up alot more vertical so you hit the dash when driving.
The engine is using standard mounts but i have torn a few of them and also on full flex i have put a small ding on the bonnent. This was done when the near side engine mount broke. If i get a chance i will get some photos and email them to dermott.

so what ru saying??? u are using a vit motor and box and transfer?? what had to have a custom jack shaft??? from where to where

so what ru saying??? u are using a vit motor and box and transfer?? what had to have a custom jack shaft??? from where to where


I have an X-90 (Vit) motor and 5spd box mounted on the original engine mounts. This is mated to the standard Sierra transfer in its orignal position. The jack shaft runs from the vit box to the transfer.

whits i was asking about this setup a while ago with no clearcut answers, did you have to make up some sort of funky bearing support on the back of your gearbox to support the out put shaft or did you slide a modded jackshaft straight onto the output, are they the same size spline?
jason

mr green wrote:whits i was asking about this setup a while ago with no clearcut answers, did you have to make up some sort of funky bearing support on the back of your gearbox to support the out put shaft or did you slide a modded jackshaft straight onto the output, are they the same size spline?
jason

The vit manual box output has a bearing and seal and is the same spline as Sierra, you just need to make a mount for the rear of the box and cut down the jack shaft. With the tunnel I drilled the spot welds from the firewall back to the section of floor where it rises for the seat mounts and using a small jack spread the tunnel a little and welded it back up. Then plate the origional shift hole and cut a new hole. The heavier flywheel and larger diameter clutch makes it much nicer when crawling.

thanks for the info hyzook, was your a 1lt or is the tunnel a proble for all sierras. would a body lift do the trick or is it a width issue?
thanks again for the info

mr green wrote:thanks for the info hyzook, was your a 1lt or is the tunnel a proble for all sierras. would a body lift do the trick or is it a width issue?
thanks again for the info

Mine was a 1.3 and has body lift so its a width issue, it needs to be wide enough to allow you room to slide the box back if you need to remove it with the body on.