97 Coily Samurai

[new2zukes]

looking really great should be in the mud in no time.

[suzukisport]

Cheers for the info guys, the only way I will know its going to last will be get out and drive it once up and running.

Did a little more today. Hooked up my power steering, I am running the Escudo pump and the rest of it is just the old coily powersteering box ect...
Also tomorrow have to go to an exhaust shop and get a boss as where the O2 sensor goes into the extractors is in the wrong place for me as it hits the firewall, so I need to relocate it.
Oh and thanks to suzookyman, he is sorting out my accelerator cable through a mate
A mate of mine who is a auto sparkey is coming up for a look tomorrow to see what needs to be done to wire it all.

[suzukisport]

looking really great should be in the mud in no time.

Thanks Martin, can't wait to get it back up and running again and take it out 4wding.

[suzukisport]

Not much of an update, been really busy at work.

Heres where the old O2 sensor goes and it his the firewall, the circle is where I relocated it to and closed off the old hole.


Got all my powersteering hooked up again. Using the 1.6 pump and all the rest is the old 1.3 stuff.


New bits


Heres the 1.6 accelerator cable end that goes to th pedal.


Heres the 1.3 end


I put the zook on the hoist on Sunday night to start on the exhaust, turned my front wheel and heard grinding noises from the diff. Drained the oil and found that is has full with water One of the previous owners had used garden hose for the diff breathers and over time it has obviously gone brittle and had a split down by the diff in the hose. I'm hoping its just bearings, will probably start to pull apart tomorrow night.

[new2zukes]

I put the zook on the hoist on Sunday night to start on the exhaust, turned my front wheel and heard grinding noises from the diff. Drained the oil and found that is has full with water One of the previous owners had used garden hose for the diff breathers and over time it has obviously gone brittle and had a split down by the diff in the hose. I'm hoping its just bearings, will probably start to pull apart tomorrow night.

dont you just love it when you go to do something and you find 10 more things that needs fixing. i have this problem at the moment do a turbo upgrade and find that the headgasket is blown the rear axle seals gone both d shaft uj's buggered and ive stopped looking now.

looks like your cracking on nicely with the mod i have heard nothing but good things about the power increase from a 1.3 to 1.6

[suzukisport]

Cheers Martin.

Pulled my front diff out, the other day.



Have to try and source some new bearings for it this week. Will also do wheel bearings all round, swivel hub kit, king pin bearings and will do rear diff bearings while im at it. I looking at buying this as its the cheapest I can find although I dont want junk ones anyone know what they are like?
http://www.autopartsspecialists.com.au/ ... r-Kit.html

The grease has had water in it as well.


Cleaned both sides.


Next job will be the exhaust, heres a old exhaust we had when we had the 2.0L V6 in the Vitara.

Have three Coby's I will probably try them out.
Got my accelerator cable back thanks suzookyman, I will fit it when its off the hoist.

Thor

[suzukisport]

Ok so I have been a bit slack lately but I am nearly there. My auto sparkey started last week, doing a great job and very quick, wiring is about 90% complete.
Spaghetti



Heres where I ended up mounting the computer, cable tied it in, but trust me its firmly mounted.


A new fuse box he has been doing.


Think I am going to avoid drilling a hole in the firewall, the loom can going through the rubber grommet for air con models.


More new bits,



Another job I am getting my sparkey to do is a head light kit, as Suzuki drivers know, the factory head lights are about as good as two candles. So he is putting some relays and and other stuff which should make them 10x better.



New front bearing pressed in.



I have got all the front end back together now, I had to make up a tool so I could doing my wheel bearings to the correct torque, suzookyman leant me his tool to doing the but being a coily they have a different set up and wasn't going to work.
Also just brought this,
http://www.trademe.co.nz/Browse/Listing ... =446818796

And rear wheel bearing kit from where I brought the front kit from,


All that's left to do is wiring and a few little fiddly jobs and the rear bearings, all going well should be up and running next weekend .

[mudslut]

Good work Thor,its lookin good ,go the coily

[suzukisport]

Thanks Dan, its coming along slowly. Always like the Coilys, just a bit different.

[mudslut]

They are different some people love them ,some hate them, i love them, i miss mine (damn ex mrs should of left her a few months sooner )oh well

[suzookyman]

They are different some people love them ,some hate them, i love them, i miss mine (damn ex mrs should of left her a few months sooner )oh well

Just passed your old truck the other day, it,s up here nowadays still looks mean as.
Al

[suzookyman]

You should of taken those stupid stone deflector thingies off when
you had a chance, maybe next time.
Al

[Dr_PC]

Good going Thor, Doesn't matter that it is slow, theres a recession on, so everything is slow I'm told. Thre main thing is that you are making progress, and that it is being done right the first time.

[suzukisport]

You should of taken those stupid stone deflector thingies off when
you had a chance, maybe next time.
Al

Thought about it but thought it was best to leave them on.

Good going Thor, Doesn't matter that it is slow, there's a recession on, so everything is slow I'm told. Thre main thing is that you are making progress, and that it is being done right the first time.

Thanks Dan. Yeah I like to try and do things once but make sure it right the first time, saves allot of hassles.

[suzukisport]

More progress today. Did my exhaust and fitted it all.






Im going to try it with just two Cobys, still have one more small Coby if its to noisy.

Heres all the left over loom that I didn't need.


Heres where the extra look going through the firewall


I nearly done, auto sparkey should be complete Tuesday and hopefully doing my rear bearings and seals for a club trip next weekend.

On the Escudo it has a charcoal canister to catch fuel vapours, my Samurai doesn't have the lines to the fuel tank for it and and inlet in the tank. Is it ok to block this off? Any ideas?

[PuddleJumper]

On the Escudo it has a charcoal canister to catch fuel vapours, my Samurai doesn't have the lines to the fuel tank for it and and inlet in the tank. Is it ok to block this off? Any ideas?

On mine i reused the canister off the Escudo - I also stole the hard line of the Escudo "reshaped" it and ran it down the inside right hand chassis rail to the tank.

[zukmeista]

So what made you decide to leave the shields on?

[suzukisport]

So what made you decide to leave the shields on?

No harm in leaving them on.

Tried to start it tonight but didn't want to, auto sparkey is going to bring his computer around tomorrow to try and diagnose it.

[suzookyman]

So what made you decide to leave the shields on?

No harm in leaving them on.

Tried to start it tonight but didn't want to, auto sparkey is going to bring his computer around tomorrow to try and diagnose it.

Bet ya it's the red wire, you know the one the left

[zukmeista]

So what made you decide to leave the shields on?

No harm in leaving them on.

Tried to start it tonight but didn't want to, auto sparkey is going to bring his computer around tomorrow to try and diagnose it.

Sucks that it didn't start, but it was running before it went in, so it will run again

[suzukisport]

Yeah I drove the Escudo into the shed then pulled the engine out. It just has to be something simple. Fingers crossed we will get it to start tomorrow. Hopefully my bearing turn up before the weekend so I can do the rear end and go out on the club trip.

[zukmeista]

I can't remember whether you already had the axles out or not but they can be hard to get out so I made a plate that bolts onto the axle studs with a hole in the middle for a slide hammer to bolt through. If you need it send me a txt.

[suzukisport]

Thanks, I will have a go and see some time this week.

[suzukisport]

Ok so things didn't go to plan with taking it out. We couldn't get the engine to run for a couple of weeks. It turned out to be the feedback signal from the coil, if the ECU doesn't see this signal then it cuts the injectors. The signal is taken from the noise suppressor and is the same signal that runs the rev counter. So it took awhile to find what the problem was.
But it runs now! Haven't taken it out of the shed yet as I am still doing a few other things yet.

Fitted and wired up the temp gauge



The gauge isn't blurry it just the camera, my sparkey wired the gauge so when you turn the headlights on it dims the lights on the gauge so its not to bright.

Pulled my rear end apart to do the bearings and seals

The left hand side had an oil leak to that meant cleaning the brakes which I would constantly be doing with drums so I got this,



Disk brake conversion kit thanks to Ben, who I also got my engine adaptor off, he makes very nice kits

So tomorrow after work I have to source the following parts,
Mitsubishi Galant 89-92 rear calipers with brake hoses, plus handbrake cables, handbrake lever balance bar and adjuster nut.

Also spent last weekend parting out all of the sellable bits off the escudo, tipped it on its side which made it easy to work on.

Took the rest to the scrappys during the week 420kg in total.

[wayfastwhitee]

Awesome project you've got going. What do you reckon the total cost of doing the 1.6 swap would be? If you don't mind me asking

[suzukisport]

Awesome project you've got going. What do you reckon the total cost of doing the 1.6 swap would be? If you don't mind me asking

Cheers for that!
Hard to say what the total cost would be, I brought the complete Escudo for $800, which I have mostly made back by selling parts off, the engine adaptor $200, plus me and wiring don't mix so a mate of mine did it. Lots of the little bits add up as well fuel hoses ect, but it should be worth it!

[suzukisport]

Well its been long awaited, but its just about there. Took it for its first drive tonight, one word AWESOME! Way more power than the little 1300. Only drove it up and down our road 4 or 5 time trying the new brakes. Will upload photos later

[suzukisport]

Haven't been getting many photos sorry, been more focused on getting it going.
Heres the new intake pipe that I made up, two and a half inch stainless




When I had the auto sparky wiring the Zook I got him to do a head light upgrade kit, makes a huge difference. For anyone that has driven Samurais at night I would recommend doing this!
Heres the relays



Didn't manage to get any of doing the disc conversion, but its all done and seams to be working well, its a very good handbrake.
Couple of little things to do finish tidying wiring and a new power steering pump as the one in there has noisy bearings.

Will try an get a running video soon.

[new2zukes]

should have it all going ready for the club champs this weekend

[suzukisport]

Been postponed due to all the recent rain