JIMNY TURBO

simon_doc · Posted: Tue May 20, 2008 10:40 am Post subject:

Thanks again CJ_Zuki. Yep am going to use the Jimny inlet manifold and exhaust header on the Baleno. Saves a lot of tedious mucking about. Have gaskets on order ready for saturday.
Should I use the baleno injectors fuel rail and fuel pressure regulator or stick with the jimny complete setup? Was thinking it may be an idea to swap them over as they are setup for the Baleno engine.

Simon

cj_zuki · Posted: Tue May 20, 2008 10:55 am Post subject:

Use the Jimny gear

rhinoman · Posted: Tue May 20, 2008 11:57 am Post subject:

CJ, do you know if the Jimny inlet mainfold has the same size ports as the Baleno engine or do the manifolds need opening up?

Simon, can you please get some pics of the differences in manifolds and the water pipe from the back of the pump.

cj_zuki · Posted: Tue May 20, 2008 2:09 pm Post subject:

simon_doc · Posted: Tue May 20, 2008 7:26 pm Post subject:

@ rhinoman:
A shot of the front of the manifold. You can clearly see the t-stat housing and top hose outlet. In the other pic is the heater hose (circled in red which connects to the water pump. Sadly the engine is still in the car so I cannot get anymore detail on the pump than that. Also it needs to stay in the car till the weekend as I need it to drive to work (sad but true.)

Simon

rhinoman · Posted: Sat Jun 14, 2008 11:54 pm Post subject:

Simon, did you get the 1.6 in?

simon_doc · Posted: Mon Jun 16, 2008 7:41 pm Post subject:

Sorry forgot about this thread,
Yes the 1.6 is in and running. Took us 2 days to do it as myself an the lad that was assisting me were total suzuki virgins!.

The engine came out quick enough and was on the deck for saturday lunchtime.
For the swapover of all the bits we deicided to start at the bottom and work upwards.

Sump and pickup pipe:
Off came the sumps as the Baleno one is at the front.
This is when we realised the Baleno has a crank sensor and using the jimny sump would not block the crank sensor hole in the bottom oil pump casting and leave the sump open to atmosphere. No Belzona to hand we welded a small plate on the inside edge of the sump to block it up. I have belzona'd it as well now, but still have an oil leak to attend to in that area that remains a mystery.
The oil pickup pipe is smaller where it enters the the oil pump so we had to cut and weld the end of the baleno one to the jimny pipe.
Had to drill and tap No. 4 main bearing cap to mount the Jimny pipe as well.

In Hindsight maybe the Jimny pump may have been an easier swap however I am a bit fussy about underrating the oil pump especially as the jimny was knocking.

Onwards and upwards...

Gearbox adapter plate.
Used the readily available SJ one just cut off the bottom parts below the bolts as it would have fouled the clutch cable bits n bobs. was gonna drill the block but after all the mucking about below we decided to for once take the easy option.. We were getting tired and grumpy!

Inlet manifold side engine mount...
On the Baleno the mount is 1" further back on the block so we manufactured a new one from 1/4" steel plate.

Water Pump rear pipe. (The one that runs the length of the Baleno block and round the side)
Again like the engine mount the Jimny pipe wouln't fit because the mount on the block was 1" back so we made a mount to fit it.

Flywheel.
Baleno one is too big to fit the Jimny box. Use the Jimny one. Straight bolt on.. At last something fitted!

Starter Motor.
Used a Skinny Bosch one. SPAM Jimny one will not fit.

Front Pulley.
Used the Jimny one as the Baleno was different in diameters. Bolt on Swap.

Power Steering Mount:
Used the Jimny one: Bolt on Swap

Power Steering Idler / Air Con mount.
Because the block is taller the holes that bolt it to the head were 1" too low and fouling the exhaust manifold.
Solution: Cut the bracket in half an run with just the block mounting bolts (not recommended if you have air con - I don't!)

Exhaust side engine mounting.
Surprisingly, a bolt on swap.

Zorst Manifold.
Jimny one. Bolt on swap.

Exhaust pipe.
Requires a dent put in it by the bottom engine to gearbox mounting bolts to clear the wider block casting on the 1.6... Large Hammer!

Rear Water Jacket Blanking plate in the head (Where the T'Stat is on the baleno).
Used the Jimny one. Bolt on swap.

Inlet manifold:
Used the Jimny one as it has the T'stat in the right place. Bolt on swap.
NOTE! The engine will run with the Orange injectors from the Jimny but it runs like a bag of poo! Use the green ones from the Baleno inlet manifold and it's sweet.

Camshaft:
Had to use the Jimny one as the Baleno had a crank sensor. To check pull the cam sensor off the back and see if the cam has 6 - 8 lugs on it for the sensor to pick up on. If it's only got 2 then it's cam swap time.

Ignition sensor on rear of cam:
Used the Jimny one just for the sake of compatability. Bolt on swap.

I think that just about everything, and in all fairness it started 1st turn of the key even with the Jimny Orange injectors in.

1,000 miles later it's a nice drive as it goes everywhere in 5th. I don't know what's lost power wise by using the Jimny Cam, but it revs to 6,500 easily and pulls very well.
Fuel economy is about the same as when the G13B engine was fitted.

HTH.

Simon

rhinoman · Posted: Mon Jun 16, 2008 9:13 pm Post subject:

Sounds like a good result then and not very different from a 1.6 swap into an SJ.

simon_doc · Posted: Tue Jun 17, 2008 7:20 pm Post subject:

Yes, actually very similar aside from the clutch cable and the injectors.
Wish I'd read up on how to do it in the SJ. I'm sure we could have saved about 4 hour work re-engineering things after realising we were going wrong.
Maybe an idea to find a Vittie 16V engine though as it'd save by being able to use the entire block, head and sump all in one with just the cam being swapped over for the ignition and the cam cover to mount the coils.

Worth a thought.

Simon