Outer Limits 4x4 Board

I'm looking for info that is probably already written down somewhere. I've searched Outerlimits and heaps of other forums and websites, put together a list and want to find out what I have missed.

I want to put a 1.6 EFI motor into my sierra. Essentially I'm after the easiest installation but want to keep in mind that I'll be doing 4Bing, so any recommendations about the type of motor to look out for would be great. I'm not a mechanic, but know a couple that will help me out. Unfortunately they don’t have much experience with zooks, so I want to run this by people who have done it and know what they are talking about. After that my mates can help me, but I also want to learn about all of this stuff. Also, if you could post or email pics you'd be saving my dodgy imagination.

Below is a list of parts I'll need to do the job. The first part is definite requirements, the second bit lists things I might come across. Does anyone know what this stuff should cost and the best place to get it?
1. Vitara front cut (or whatever model I end up choosing)
2. Adapter kit
3. High pressure electric fuel pump
4. Belts, hoses, oil
===========
. Clutch
. Machined 1.3 flywheel


Below is a list of steps that I have put together that are required to do the install. I have attempted to put them in some sort of order, so please let me know if I've got the order wrong or missed something.

1. Remove 1.3 motor
• Drain oil from motor and gearbox
• Disconnect battery, alternator and starter electrics
• Disconnect everything (air, fuel, wiring loom, exhaust, accelerator, clutch, leads, …) – LABEL ALL WIRES
• Disconnect motor and gearbox (12 bolts)
• Remove motor and gearbox
• Cut 1.3 exhaust manifold from exhaust pipe under car, must cut at the right position for 1.6 manifold to weld on

2. Join 1.6 motor to 1.3 gearbox
• Disconnect 1.3 motor from 1.3 gearbox
• Remove 1.3 fly wheel, clutch, sump and pickup, install onto 1.6
?? Is there anything else I need from the 1.3 e.g. starter ??
• Install adaptor plate to 1.6 motor
• Connect 1.3 gearbox to 1.6 motor
• Install motor and gearbox
• Install 1.6 exhaust manifold to motor and weld to existing 1.3 exhaust pipe

3. Install fuel system
• Connect hose from filter to high pressure electric fuel pump
?? What are the rules around where I can mount the pump. I will be getting in tough with the mod plate bloke before I do any of this, but any pointers would be appreciated ??
• Run a hose from the pump to the intake manifold
• Connect the wire from computer to the pump
?? Do I need a relay or fuse? If so, where / how ??
?? If I need new wire, what should I use ??
?? Can I re-use the existing 1.6 pump if I have one ??
?? Can I avoid using a surge tank to begin with (to save $$$) ??

4. Install air intake
• Mount the 1.6 air box, this will be a custom job
• !! Try different places to see if it can be fitted without needing a body lift !!
?? Can I just reuse the 1.3 air box, what are the pros / cons ??
• Connect air box to intake manifold

5. Wiring – WOO HOO!
?? This will be the tricky part for me, can anyone give me some pointers ??
• Basically I'll be pulling the motor out of a front cut and plan to connect all of the sensors straight back up.
• The fuel line should be fine
?? I'll start to get a little stuck when need to start joining things between the old wiring loom and the new, any help ??

6. Instrument cluster / Speedo / etc.
?? How should I tackle this ??

7. DONE!!!
• Drive away and go nuts!

If you've got this far, cheers and thanks for reading. I hope you can help.

So bloody fantastic to read a post that has been researched... WELL DONE

I haven't done this conversion but as far as I know the oil pump pickup tubes are different diameters.
You need to join the 1.3 pickup tube and screen to the 1.6 bit that fits into the block.
Front cuts don't come with fuel pump so you'll need to get one somewhere.
You may get lucky and get a coily tank from wreckers.
If you read OOZuks build up in members he has a pic of a Walbro fuel pump that fits straight into a Vitara tank.
Use that pump and a Coily fuel tank.

I'm not sure about the Vitara VSS but I have read on here that with a bit of work a swift speedo with inbuilt VSS can be fitted to Sierra cluster.


If you can... drop the whole exhaust, don't cut it until you have the 1.6 in the car. Will be easier to work out the best place to cut the pipe.
Jas

VSS info at bottom of this page

http://www.azrockcrawler.com/_images/te ... otor2.html

vtara 1.6 speed sensor will bolt straight into your cluster if its a widetrack. think i've done similar on nt 1.3's too.

joeblow wrote:vtara 1.6 speed sensor will bolt straight into your cluster if its a widetrack. think i've done similar on nt 1.3's too.

Or a narrow track...

Steve.

Gwagensteve wrote:

joeblow wrote:vtara 1.6 speed sensor will bolt straight into your cluster if its a widetrack. think i've done similar on nt 1.3's too.

Or a narrow track...

Steve.

that's what James said...

yep about right.

have a read of my buildup, ive done the same conversion. (click on orange text in sig)

VSS is easy
i run two fuel pumps(2 filters also) a carby style feeder pump and VL pump style, i had starvation issues with the VL only.

Yes the 1.6 and 1.3 pickups are different diameter. u need to cut and shunt it. watch out for the girdles on the bottom of the head if u get a 1.6 with them.

also u will prob have to cut some/all of the baffels out of the sump to clear the pickup.

i got my frontcut from Justjap in Syd and freighted to perth.

1. remember the gearboxs switches if removing the box. i did the motor and box at same time.

2. u will need 1.6 starter if getting frontcut or grind side of 1.3 starter.
get some extractors $220 wildcat ones clear the engine mount by a bees d$%k also has the O2 sensor hole in there.

3. upgrade the return for the fuel, i ran a new line same as the original inlet line.
Mines low press filter > low press pump > high filter > high pump.
i mounted my pump on the chassis rail out of the way near the orig filter spot.
u will need to run new wires to hook up to the ecu for the pump, reuse the relay on the ecu for the fuel pump.

4. yep i did this
can do this without a BL but intake will hit the bonnet.
depends on config but the air flow sensor is right at the filter end of the box, also i think the vit one is more waterproof.

5.
have fun
u will need to strip out the unnecessary stuff (wipers, lights, etc)

then basically yes u can hookup the same plugs etc
mount the ecu also in this step out of the way of water, mines in the glovebox,
theres about 5-7 wires that need joining up to old harness

6.
use orig sierra one and fit VSS into. run new wires up to cluster for the vss and also the check engine light.

7.
ooh yer now u have power

I'm almost at this stage of my buildup, from what i understand.. using the vit gearbox is a better way to go? you remove the tranfer and your jackshft goes straight in? that way you negate the need to modify your 1.3 starter, you dn't need the adapter plate and you have a larger clutch surface..?

Yep, that's my understanding too, and it's how I'd be putting a 1.6 in a car if it was a manual.

Plus, vitara gearboxes aren't that hard to find, whereas good 1.3 sierra boxes are getting rarer.

Steve.

plus vit manuals are bullet proof.....and the aw4 more bullet prooferer...

I've been in touch with people who have spent heaps on new exhausts (extractors, etc.). Would a stock Vitara exhaust be sufficient? Will it clear the chasis and engine mounts?

Also, a lot of posts I've read have said costs blew out quite a bit. I know enough people to help me do the job myself, but don't want to get half way though and find that I need to pull a grand from somewhere.
* What things will i definetly need (parts and maybe costs if you know),
* What little surprises could I find along the way (e.g. shagged clutch) and
* What would be a reasonable amount of $$$ to keep in my back pocket for things along the way (nuts, bolts, oil, beer, whatever).

Also, some people have mentioned that an alternative option is to use a vitara engine / g-box and the sierra transfer. This sounds easier as I'd only need one engine mount and gearbox mount (and wouldn't need the adapter kit).
* Is it this simple?
* Does the Vit have a divorced transfer as well?

the vit manual will require a new crossmember, hole for the shifter, output adaptor for the jackshaft, and a bit of tunnel massaging. but once in you will find it a much better gearbox and last forever. the only weak link is the cluth but its still better than a 1.3 clutch. the vit has a mated t/case which can be removed or modified for dual cases with the sierra one as shown.

I dont want to take the car off the road for very long as its my daily driver, so the christmas break looks to be the time if I decide to go ahead.
It would be good to do everything I can with the 1.6 before I even think about taking the 1.3 out of my zook.

It would be good to find a spare sump now that I know I have to do some fab / modification to get the 1.3 sump onto the 1.6 block. I happen to have a 1ltr motor in bits lying around at home.

?? Does anyone know if it would be possible to use the 1 ltr sump / pickup in a similar fashion to the 1.3? This way I could get all of the fab work done for the 1.6 before I take the 1.3 out.

Also, I'm a bit confused with the starter motor. Some people have been telling me to use the 1.3 and others say the 1.6 is the way to go. I thought the starter was matched to the flywheel. So if I use the 1.6 starter, I wont need to change over the fly wheel right?

?? Will this have an impact on using the sierra gearbox?
?? Also, how will this affect the clutch I use?

1 litre sump no. sometimes you have to bite the bullet and have both motors out so you can adapt stuff. ausie spec 1.6 and 1.3 starters are pretty much the same. when you use a sierra g/box you may have to grind the block and or the starter to have it sit flush. if you have the import reduction start 1.6 narrow body starter than that will bolt on no probs (the ones i much prefer to use). 1.3 gearbox= 1.3 flywheel. 1.6 gearbox= 1.6 flywheel. it will take some time to do a conversion like this neatly and properly, don't rush it.