Samurai – How To Swap The 1.6L Into The Samurai Pg. 4 – iZook – Suzuki 4×4 Tech Information, Accessories, Travel & Adventure

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When we added the air cleaner to the engine compartment, we noticed right away that the power steering reservoir would have to find another home. We fabbed up a small bracket to keep the air cleaner just above the stock jack mount on the drivers side inner fender well. There was just enough room to mount the breather without it getting crushed by the hood. The wiring harness and accelerator cable came next. If you are a stickler for neat installations then here is where you can really shine. We found that the new wiring harness could be held along the firewall with zip ties so it would blend in with the stock unit. You just have to pay close attention to leave plenty of ‘play’ in the cabling so that when the engine moves it will not get torn out. The picture on the right shows the routing of the accelerator cable and the new location of the PS fluid reservoir. It is on a bracket we fabbed to bolt right on the engine block. There wasn’t anywhere else to put it. (After testing and then thrashing we found that the vibration of the engine had no ill effects on the system. Here you can see where the new harness is attached along the firewall and then run into the rubber grommet behind the battery. This takes it down to the area where we mounted the new computer. Plugging and splicing in all the wires for the computers didn’t take very long. When everything was plugged in, we noted how much play we had in the wires and installed the components where they would be least likely to get kicked or damaged. As a matter of fact, you can only see them if you lay your head on the seat. The picture in the lower right shows how hidden they are.

This fuel injected engine went into a, 87 Samurai, so an electric fuel pump came in the installation kit. The trick to this installation is all in the mounting… if you don’t use the insulation provided, or you tighten it up too much it will be veeeery noisy. We also added a bit of old hose and zip ties to protect the fuel line from scuffing where it came close to the emergency brake cable. Overall, this was a fairly simple installation. All the hard stuff (wiring mostly) is done for you in the kit. You just have to add the muscle and a little attention to detail when setting everything into place. There are a few other kits out there, but most don’t include the wiring harness setup like this one. One last thing, You have to send your gauge cluster back to trail tough so they can make a small electronic change* so that your speedometer will talk to the new ECM (computer).