First of all let me say that there are two main purposes for this write-up. One is to inform Kevin Walker of how the progress is going on his big orange baby and the other is to inform and entertain readers interested in this type of engine swap. This is also the ONLY write-up I have done that also includes the customers actual opinion of the swap which comes at the end of this page. I do want to apologize to all of the anal retentive readers since this write-up will not be nine pages like the Sleeper Project, but more concise, because of the lack of time I have these days with two youngsters and running my aftermarket automotive business and my Suzuki specialty business. 

Here we go again. Another write-up about another 16 valve install. Hmmm, so what makes this one different? Well in this case it is the vehicle as well as it's owner. This install is on one well built Samurai that a lot of people know and have seen wheeling at Zuwharrie and even roll-over at the ZookiMelt last year. Most who see it just stare, maybe because of the blinding orange camouflage paintjob or because of all of the goodies installed on it. 

This Zuk should have "WIDE LOAD" written on the back of it! lol!

With Dana 44 custom axles, 37" Swamper Boggers, 5.89 differential gears and a GRS-1 T-case as well as a ton of other mods the Big Orange Camo Monster goes just about anywhere. For a list of all it's insane mods click on http://www.crazyoffroad.com/samurai.htm. Kevin has put alot of work into his Zuk and the next stage is just beginning!

The donor vehicle is a 1996 Tracker in almost perfect condition, but the Sammy needed the motor more than the Tracker! It has only 40K miles on the motor which runs perfectly and has with tons more power than Kevin's old 1.3 and it runs like a dream....the perfect engine to compliment a well-built Sammy. 



 The motor was meticulously removed from the white Tracker and prepped for installation into the Big Orange Camo Monster in the background. 


Here is a pic of the 1.3 Kevin had custom built with a Swift GTI short block, a Sumo II head (which was built before Asian Auto Parts actually started calling it a SumoII head), a Doug Thorley header, and a VW Solex carb with custom adapter to the Samurai manifold. 

The grill, and other vital parts were removed to prevent damaging them upon removal of the motor and tranny. Removal of the engine and trans goes a bit easier this way and installation of the 1.6 adapter kit is easier with the transmission out. First the wiring, cables, lines and hoses from the engine are removed as well as the power steering bracket is unbolted off of the side of the engine and set to the side. The antifreeze, engine and transmission oil are drained, the electric fan, and radiator are removed, the battery is disconnected, and the coil is unscrewed off of the firewall. 



The motor is hoisted out and if you look closely you can see the drivers side motor mount about to fall apart. This is an extremely common problem and as many times as this Zuk has been on it's side I am not surprised. It will be replaced with an early model 1.6 motor mount which are noticeably heavier duty and should not break the next time Kevin lays her over.... LOL!


 Lookin really empty in that engine compartment!

Centerforce clutch installed.

The 1996 1.6 16 valve engine ready to drop in. (Kevin, are you drooling yet?)

The new gas tank with a 1996 Tracker fuel pump installed in it.

The complete harness from the donor vehicle. Time to start slicing and dicing!

Motor installation.

 For those of you who know me, you know I usually don't let anyone wrench on my zuk except for me.  I had seen a couple of vehicles that Sean had done and they looked good, so I let him do the conversion.  



The temperature was around 50 degrees and the wind was blowing hard the morning I arrived at Sean's to pick up the Zuk.  He told me to hop in and crank it up without touching the gas.  I hit the starter button one time and the beast came to life.....and continued running without my foot on the gas.  If this had been the carb. motor that I was used to, it would have been 5 minutes before I could have removed my foot from the throttle or the engine would have died just sitting there. About 5 seconds later Sean says "Ok, let's take it for a test drive".  I said "OK".  About 5 more seconds went by and Sean asked me what I was waiting for?  I told him that I was waiting on it to warm up.  He looked at me with a bewildered look, rolled his eyes and said " I've got 2 words for you ..... FUEL INJECTED,  now lets go. So the vehicle was probably running for a total of 20 seconds or so before I put it in gear and let out on the clutch.  To my amazement, it moved without any hesitation.  The old motor would have died immediately.  As we pulled out of Sean's driveway, he pointed at a side street.  I turned on to the street and Sean told me to stop. I stopped in the middle of the road and Sean told me to take off like I was racing someone.  I looked at him like he was crazy. "Just do it!"  I took off.  The tach hit 5 grand, I shifted into second gear.  The tach was at 5 grand again so I shifted into 3rd.  As the tach climed effortlessly to 5 grand again, I let out of it.   I stopped the vehicle and looked in total disbelief at Sean.  My look was soon transformed into a ear to ear smile.  I asked Sean if he installed the 1.6 or a 350 Chevy.  He just laughed.  I could not believe that this little 4 cylinder could propel my 4,000 pound vehicle that fast.  Our next test was off-road.  

I came up to a 3 to 4 foot burm and Sean told me to put it in 4lo, 1st gear and let out on the clutch and don't give it any gas.  As I let out on the clutch, the vehicle idled right up the burm without me having to give it any gas.  

I turned around and idled up the back side which was even steeper. The motor never hesitated.  Sean then made me back down and just barely punch it.  

As the vehicle topped the crest, both front tires were in the air.  At this point, I could not have been any happier. 

See you guys at Zuwharrie in the fall!

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