Hi all, I recently just placed a baleno 1.6ltr engine into my Jimny.
I'm bored so I figured I will write a install guide with issues I came across included.
Sorry if it's a bit all over the place all the info is here though
Hope this is helpful, enjoy
I used the conversion kit that http://www.suzistore.com.au sells it is a great kit!
If you have a g16b vitara motor then lucky you. A lot of this won't apply (except the sump mod, read below) and some other stuff.
1st, take your bonnet off, disconnect all you electrics, the engine wiring harness very easy to remove,
*Remove the 1.6ltr cam sensor cover at the rear of the head, check the cam to see how many lugs it has, if it has lots your a lucky ducky, you can use the 1.6 cam, if not you need the Jimny cam read on.
CAM
I say do this in the car it's just easier.
Remove your timing belt cover ( you will have to remove various parts to do this )
Don't bother removing the crank bolt, just the five 8mm in the pulley
Remove timing belt.
Remove coil packs and rocker cover.
Remove cam sensor cap at the rear and all cam caps, and cam.
Take care of seals if you have no intention of replacing them.
If you do easiest way of cracking the cam bolt is to wrap old timing bet around timing wheel and clamp the timing belt in a vice and crack away, same to tighten it.
YOU WILL NEED TO BUY A NEW 1.6 TIMING BELT
AND A NEW TIMING COVER. THE 1.3 COVER WILL NOT FIT
*When installing the 1.6 cam be sure all rocker arms locate on the valves*
RADIATOR, WATER PUMP AND A/C
I removed the ac compressor from the 1.3 motor and cable tied it up out of the way as I didn't want to degas the system
Drain the radiator and remove top hose, just detach the bottom off the radiator at this point, no need to remove it.
Remove the radiator.
The A/C Compressor mount doesn't bolt up 100% to the 1.6 block but it still fits,
Once you remove the 1.3 motor it's easier to change over the bottom hose assembly.
The 1.3 water pump is NOT the same as the 1.6 (tensioner location is different) so don't bother trying to use it, just get a new pump for that engine if you need one.
Get rid of the 1.6 water pipe from the back of the pump and use the 1.3 one. (take care not to damage the O ring) you will need to make a little bracket to attach the 1.3 pipe to the 1.6 block, ( you will see what I mean it's easy anyway)
Remove the blanking plate from the back of the 1.3 head and bolt it onto the 1.6 when the time comes.
You will be using the Jimmy's thermostat on the inlet manifold
ECU, INJECTORS, INLET AND EXHAUST MANIFOLD
MAKE SURE YOU HAVE A SET OF GREEN 1.6LTR INJECTORS the 1.3 ones work but it will run poorly
Use Jimny Ecu it works fine.
Pretty straight forward just unbolt everything off the 1.3 and try your best to keep bolts with the parts they came from.
You will be using it all on the 1.6
*NOTE* fuel lines will not reach the rail when it is on the 1.6 motor as the block sits about 2cm ish higher than the 1.3, YOU WILL NEED NEW FUEL HOSES.
I kept everything off untill I had the 1.6 in the car, it's easier to install the motor without everything on it.
STARTER MOTOR
I used the reduction gear type, it has a smaller body,
I didn't see how the 1.3 starter motor could ever fit without serious grinding.
Saying that, I still had to grind away at the reduction gear type starter motor to make it fit.
You will see what I mean. Don't worry it just takes a little time to get it right.
You will use the bolts in the conversion kit to bolt it in.
ENGINE REMOVAL
Ok, so the engine bay is looking pretty bare now,
Disconnect clutch cable, keep it in the car you will use it.
Remove the bell housing bolts, wheel in your engine crane or whatever you have
( I used a car winch over a pulley attached to the roof )
Take up some slack, and remove engine mount bolts, wiggle and pull untill FREEDOM!
*BE CARFUL NOT TO PULL TO HARD TO PROTECT YOUR A/C CONDENSER
FLYWHEEL
Use the 1.3 flywheel
Don't be cheap and buy a nice heavy duty clutch.
MISC
Attach the adaptor plate to the gearbox,
Attach the engine mount adaptor under the water pump and fit the bottom radiator hose assembly.
Attach the engine mounts and flywheel and clutch.
*Do yourself a favor and dab a LITTLE BIT of grease around the tip of the input shaft spline, it always helps a bit as long as your clutch is aligned correctly*
Screw in conversion kit engine to bell housing bolts into the 1.6 block.
If the top right bolt doesn't screw into the locator hole skim the sidesof the bolt down with a grinder, don't kill the thread obviously.
OIL PUMP PICK UP PIPE
Trickiest part.
USE THE JIMNY SUMP, NOT A VITARA SUMP, THE DIFF WILL SMASH THE VITARA SUMP.
The pickup pipe where it goes into the oil pump is wider on the 1.6,
Cut the end of the 1.6 pipe about 1" down from where it bolts into the pump then do same thing with the 1.3 pipe
weld the 1.3 pickup to the 1.6 pump inlet pipe.
You need to drill and tap the No 4 main bearing cap for the mounting of the pickup pipe.
OR POSSIBLY JUST BUY THE VITARA BEARING CAP WITH A FACTORY HOLE? I'm not sure about this, worth checking it out though.
Seal the sump
INSTALL THE 1.6
Get the motor in. wiggle wiggle THUD *sigh of relief*
Bolt her up
Bolt everything onto the 1.6 motor
Exhaust should just line up and just miss the mounting bolt.
Connect clutch cable and adjust it in HEAPS to make up for the adaptor plate space difference.
Wire up the motor and fill all fluids.
VROOM it's allliivveee!
The increase in power is amazing, it's a new driving experience, offroading is awesome and fuel economy is about the same as the 1.3 you will loose a few Kms per tank.
I have 235/75 r15 and it drives with plenty of power.
Enjoy all.
PORL
