Offroad-Express

Well this is my coil sprung Suzuki Samurai 1997.
I brought it back in June this year off Samx4x4 in Warkworth for $5500.


Photo's from Samx4x4

Its basically stock apart from the usual club truck mods.
The mods were:
2" Body Lift, 30" Hankook MT's, Superwinch hubs, Fuel Tank Guard, Bull Bar, Extractors and 2" exhaust, Roll bar, CB Radio, Spotties, snorkel, Roof racks, Tough Dog Steering Stabilizer.
Haven't really done anything to up until now so I though I might start a little build of it.
So the plans are:
1.6L 16V Injected Escudo motor
Repaint at some
OME Suspension lift
ARB rear air locker
Front and rear bars
New MT's as the current ones are getting low.
Will be a slow build as apprentice wages limit spending

Brought this on TM a few weeks back,

Scored it for $800 and it was drivable. The guy had rolled it as he used it for 4wding and he brought another one so he swapped all the bits over.
The motor is all i'm after and its seams to be a great runner. Already had new extractors, new head, new water pump and a new clutch.
So last weekend I started stripping all the bits I need out of it.
Pulled the motor out last weekend:


Adaptor kit thanks to Ben

Fuel Tanks, Samurai tank on the left and Escudo on the right

Being a coily Samurai the Escudo electric fuel pump fitted straight into the Samurai tank which saved a bit of mucking around.

The 1.3 just about ready to come out

Lookin good - Your gonna love the power increase

That should go hard. Once that new engin is in.

Cheers guys,

Got a bit more done today.
Old 1.3 motor is out.


Since I don't have a large suspension lift, in order for the sump to clear the diff I had to use the 1.3 sump and modify the 1.6 oil pick up using the 1.3 strainer.
New oil pick up, had to cut it and weld the 1.3 strainer next to the mounting tab.


Also had to remove the baffle plate in the sump.
Baffle plate cut out,


The sump had a little surface rust so I cleaned it up.
Ready for paint


All painted

you've got a pretty good collection of toys for an apprentice mate

Sadam_Husain wrote:you've got a pretty good collection of toys for an apprentice mate

Haha well most of the gear is my old man's.

nice looking really good, will need to have a drag race again when u got your new motor in, mine is getting a wee bit more power soon

Yeah sounds like a plan You planning on a turbo?

No fair, how am I going to keep up? Supercharged 4AGZE FTW

zukmeista wrote:No fair, how am I going to keep up? Supercharged 4AGZE FTW

Harry, You could always ask for a head start. Thor Looking good fuel injection no flat spots a whole heap more fun

yup turbo the old girl, took me 2 days to strip one side of the motor and find a turbo that would work not too big not too small. wanted a turbo inbetween a ct12 and ct20. ah and harry a ct12 turbo would go nicely on ur zuke:)

Harry needs something to push those monster truck tyres he's got!

new2zukes wrote:yup turbo the old girl, took me 2 days to strip one side of the motor and find a turbo that would work not too big not too small. wanted a turbo inbetween a ct12 and ct20. ah and harry a ct12 turbo would go nicely on ur zuke:)

I have a ceramacoated Schedule 40 manifold for a 413 and a turbo that ran on a b1600 at 5lbs

Stop it your giving me crazy ideas!

thats the idea

Bit more progress.
I had cut the old baffle out of the sump so it would clear the new oil pickup. After talking to a few people I decided to make a new baffle to be safe.
Cardbord template


Made the baffle out of 0.9mm sheet metal


We welded the baffle in and I repainted it again.

Fitted the 1.3 clutch and flywheel. The clutch out of the 1.3 looked fairly new so im going to use it for now.

The two studs that go into the rear of the motor the M12 threads hadn't been cut deep enough so I took them into work and ran a die nut down them and got them to fit.
Also the bottom pulley bolts were loose and one had been broken off. Managed to get it out and replaced with some cap screws.

Fitted the adaptor plate to the gear box


1.6 just about ready to go in

Also when I pulled the old 1.3 out I discovered it had a broken engine mount that I hadn't picked up on Thanks to suzookyman he gave me one.

Got the 1.6 in the engine bay




Still have lots to do. Have to sort out new air intake, fuel hoses and wiring.

Lookin

You running your original radiator or the Escudo one?

Depending if you have a body lift or not you may have to cut the bonnet to close it.

Running the Samurai one for now going to fit a temp gauge to keep an eye on it. If it runs to hot I will put the Escudo one in.
I already had a 40mm body lift and the bonnet closes without touching. Do you run Bens adaptor kit in your zook?

suzukisport wrote:Running the Samurai one for now going to fit a temp gauge to keep an eye on it. If it runs to hot I will put the Escudo one in.
I already had a 40mm body lift and the bonnet closes without touching. Do you run Bens adaptor kit in your zook?

I still run my standard SJ413 radiator with no issues. Will eventually ditch the viscous fan and run a electric one - Was thinking of rear mounting the radiator as i have the room but not just yet.

Yes i have Bens kit in mine - All his stuffs nicely made

Looking good Thor

Cheers

PuddleJumper wrote:I still run my standard SJ413 radiator with no issues. Will eventually ditch the viscous fan and run a electric one - Was thinking of rear mounting the radiator as i have the room but not just yet.

Yes i have Bens kit in mine - All his stuffs nicely made

Yeah I put the old 1.3 viscous fan back on for now as I know it works well, will probably put an electric on it at some stage.
I very happy with Bens kit, will be getting a rear disc conversion kit off him sometime soon.
When I looked at your truck a couple of months back on a 4wd run, it didn't look like you had a body lift. You have only cut a little out of the bonnet?

I think you may be a bit dissapointed with the holding power of the 1.3 clutch
Had a brand new one in mine when i did my engine conversion, and first trip out with the tyres let down it only lasted half a day before it gave up.
Ended up with one that prettymuch cost the same off waikato brake and clutch, that used a mitsi cover which gave it quite a bit more surface area, that coupled with a sprung center button clutch = no slip and a clutch you could still ride justa little
Cheers

Hmm I will give it ago. Its not a very difficult job removing the gear box, makes it even easier with a hoist. But if it does slip it will be coming straight out.
What clutch cable did you use? I have been told the Suzuki ones break easy.

I just use a standard suzuki one and used to have a few issues with them. If I had kept it any longer, I was going to change to a hydraulic set up.
It was allmost like when the engine bay got hot it would let the cable lining flex a bit and you wouldnt get full clutch travel. I know it shouldnt have worked like that but it did. Think I got a custom one made that was twice as thick and covered in a heatshield sleeve, that fixed it but that hydraulic setup was always in the back of my mind.

Sounds interesting, will keep it in mind. Cheers Tim

I suppose it comes down to how you drive it....
I've got a stock clutch on my 100hp gti with rocklobster gears spinning 31's and it's holding up sweet.

loads of guys in Aus running g16s with stock clutches as well.

The gerneraly agreed word in the zuk community is that a heavier clutch will break the stock cable at an in opportune moment deep in the bush.

Thor, the one in Rossco's 413 is 1 I had made up in 2001 prior to do the winch comp and it is still there, it has about 1200lb clamp pressure, it has alwyas used the standard 413 clutch cable

Dr_PC wrote:Thor, the one in Rossco's 413 is 1 I had made up in 2001 prior to do the winch comp and it is still there, it has about 1200lb clamp pressure, it has alwyas used the standard 413 clutch cable

Enough said!.......and he gives it a bit of welly