Hey Members,
I am seeking advice on the possibility of putting a 1992 1.6L Vitara engine into a 1988 SJ410.
Seller is selling the SJ410 with a blown 1.0L engine and a running 1992 1.6L Vitara engine with 220,000km for $1500.
How difficult would this conversion be to complete as a project, e.g.
What gearbox should go in / Transfer case?
Tail shaft and gear issues?
Electric Fuel Pump
Wiring / ECU Issues?
Mounts for Engine and Gearbox?
Its my first project and seems good for an entry level as they seem easy enough to work with, plus I have the support of a few Zook fanatics? But is it a money pit?
Any pointers would be great!
Regards,
Reece
1988 SJ410 conversion 1992 1.6L Vitara Engine
1988 SJ410 conversion 1992 1.6L Vitara Engine
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Re: 1988 SJ410 conversion 1992 1.6L Vitara Engine
You will need a sj413 gearbox .
BenT Adaptor plate to bolt engine to gearbox
Custom gearbox cross member
Possibly custom transfer case mount
Custom engine mounts
Custom exhaust
Trans tunnel modifications to fit the 413 gearbox
Custom eletrical loom and electric HP fuel pump
Maybe a body lift to clear engine ,
Can use stock transfer , but liking at the tyre size you probably want after market gears in the transfer .
410 cvs , not the strongest , R&p gear changes hard to find .
Prob a bunch more small stuff as well
410 is different running gear to 413 and samurai
BenT Adaptor plate to bolt engine to gearbox
Custom gearbox cross member
Possibly custom transfer case mount
Custom engine mounts
Custom exhaust
Trans tunnel modifications to fit the 413 gearbox
Custom eletrical loom and electric HP fuel pump
Maybe a body lift to clear engine ,
Can use stock transfer , but liking at the tyre size you probably want after market gears in the transfer .
410 cvs , not the strongest , R&p gear changes hard to find .
Prob a bunch more small stuff as well
410 is different running gear to 413 and samurai
LR110 ..... LJ50 project 
Chris.
Chris.
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teamorange
- Driver/Navigator
- Posts: 49
- Joined: Wed Oct 19, 2011 11:34 am
- Location: Northland
Re: 1988 SJ410 conversion 1992 1.6L Vitara Engine
my 2 cents worth
SJ410 with 1 litre engine heaps of fun standard, unlikely to break stuff, and will put a huge smile on your face whenever you drive it off road. (i cant answer on-road as i have never owned a road legal one)
Start collecting parts such as the Escudo's motor and power steering, then go build something else from scratch after you know what you want from a truck/buggy. I was inspired by pirate4x4.com suzuki section heaps of build threads there.
Cheers
SJ410 with 1 litre engine heaps of fun standard, unlikely to break stuff, and will put a huge smile on your face whenever you drive it off road. (i cant answer on-road as i have never owned a road legal one)
Start collecting parts such as the Escudo's motor and power steering, then go build something else from scratch after you know what you want from a truck/buggy. I was inspired by pirate4x4.com suzuki section heaps of build threads there.
Cheers
Re: 1988 SJ410 conversion 1992 1.6L Vitara Engine
Reece,
Probably the biggest problems with any engine conversion are re-wiring, making new engine mounts (and removing the original mounts in the process), and making sure it will fit. You also have to consider how to mate the gearbox shaft to the transfer case, and before considering this you should make sure the new engine plus gearbox is not a lot longer than the engine plus gearbox it is replacing (otherwise the engine and gearbox will not fit in the same space without moving the engine further forward, which then means the radiator may be too close to the engine!)
Sounds like a big hassle, but if you have a good welder and grinder, plus some other tools like a metal-cutting bandsaw, then you can create almost anything if you really want to. Re-wiring can be a bit daunting but if you already have the loom to go with the engine then you can sort it out (but it may take time).
My son and I have an SJ410 that originally had a Datsun Sunny A15 motor, and we have recently thrown that out and have installed a Toyota 4AGE 1500 engine. This necessitated a lot of extra work that took over a year to complete (mainly because I hardly worked on it except in short bursts) but it's now up and running. We have retained the SJ410 transfer case, axles and diffs, and we run 31 inch tyres on it. Having said that, we are still to get out and give it a good thrashing to see how these original components take the extra power.
To give you some idea of the work involved have a look at the Susan thread in this section. Note that our vehicle is NOT road legal so we can get away with a lot as far as changing things is concerned. Good luck, Pete.
Probably the biggest problems with any engine conversion are re-wiring, making new engine mounts (and removing the original mounts in the process), and making sure it will fit. You also have to consider how to mate the gearbox shaft to the transfer case, and before considering this you should make sure the new engine plus gearbox is not a lot longer than the engine plus gearbox it is replacing (otherwise the engine and gearbox will not fit in the same space without moving the engine further forward, which then means the radiator may be too close to the engine!)
Sounds like a big hassle, but if you have a good welder and grinder, plus some other tools like a metal-cutting bandsaw, then you can create almost anything if you really want to. Re-wiring can be a bit daunting but if you already have the loom to go with the engine then you can sort it out (but it may take time).
My son and I have an SJ410 that originally had a Datsun Sunny A15 motor, and we have recently thrown that out and have installed a Toyota 4AGE 1500 engine. This necessitated a lot of extra work that took over a year to complete (mainly because I hardly worked on it except in short bursts) but it's now up and running. We have retained the SJ410 transfer case, axles and diffs, and we run 31 inch tyres on it. Having said that, we are still to get out and give it a good thrashing to see how these original components take the extra power.
To give you some idea of the work involved have a look at the Susan thread in this section. Note that our vehicle is NOT road legal so we can get away with a lot as far as changing things is concerned. Good luck, Pete.