[PORL]

Hi all, I recently just placed a baleno 1.6ltr engine into my Jimny.
I'm bored so I figured I will write a install guide with issues I came across included.
Sorry if it's a bit all over the place all the info is here though
Hope this is helpful, enjoy


I used the conversion kit that http://www.suzistore.com.au sells it is a great kit!

If you have a g16b vitara motor then lucky you. A lot of this won't apply (except the sump mod, read below) and some other stuff.

1st, take your bonnet off, disconnect all you electrics, the engine wiring harness very easy to remove,
*Remove the 1.6ltr cam sensor cover at the rear of the head, check the cam to see how many lugs it has, if it has lots your a lucky ducky, you can use the 1.6 cam, if not you need the Jimny cam read on.

CAM

I say do this in the car it's just easier.
Remove your timing belt cover ( you will have to remove various parts to do this )
Don't bother removing the crank bolt, just the five 8mm in the pulley
Remove timing belt.
Remove coil packs and rocker cover.
Remove cam sensor cap at the rear and all cam caps, and cam.
Take care of seals if you have no intention of replacing them.
If you do easiest way of cracking the cam bolt is to wrap old timing bet around timing wheel and clamp the timing belt in a vice and crack away, same to tighten it.
YOU WILL NEED TO BUY A NEW 1.6 TIMING BELT
AND A NEW TIMING COVER. THE 1.3 COVER WILL NOT FIT
*When installing the 1.6 cam be sure all rocker arms locate on the valves*


RADIATOR, WATER PUMP AND A/C

I removed the ac compressor from the 1.3 motor and cable tied it up out of the way as I didn't want to degas the system
Drain the radiator and remove top hose, just detach the bottom off the radiator at this point, no need to remove it.
Remove the radiator.
The A/C Compressor mount doesn't bolt up 100% to the 1.6 block but it still fits,
Once you remove the 1.3 motor it's easier to change over the bottom hose assembly.
The 1.3 water pump is NOT the same as the 1.6 (tensioner location is different) so don't bother trying to use it, just get a new pump for that engine if you need one.
Get rid of the 1.6 water pipe from the back of the pump and use the 1.3 one. (take care not to damage the O ring) you will need to make a little bracket to attach the 1.3 pipe to the 1.6 block, ( you will see what I mean it's easy anyway)
Remove the blanking plate from the back of the 1.3 head and bolt it onto the 1.6 when the time comes.
You will be using the Jimmy's thermostat on the inlet manifold

ECU, INJECTORS, INLET AND EXHAUST MANIFOLD

MAKE SURE YOU HAVE A SET OF GREEN 1.6LTR INJECTORS the 1.3 ones work but it will run poorly
Use Jimny Ecu it works fine.
Pretty straight forward just unbolt everything off the 1.3 and try your best to keep bolts with the parts they came from.
You will be using it all on the 1.6
*NOTE* fuel lines will not reach the rail when it is on the 1.6 motor as the block sits about 2cm ish higher than the 1.3, YOU WILL NEED NEW FUEL HOSES.
I kept everything off untill I had the 1.6 in the car, it's easier to install the motor without everything on it.

STARTER MOTOR

I used the reduction gear type, it has a smaller body,
I didn't see how the 1.3 starter motor could ever fit without serious grinding.
Saying that, I still had to grind away at the reduction gear type starter motor to make it fit.
You will see what I mean. Don't worry it just takes a little time to get it right.
You will use the bolts in the conversion kit to bolt it in.

ENGINE REMOVAL

Ok, so the engine bay is looking pretty bare now,
Disconnect clutch cable, keep it in the car you will use it.
Remove the bell housing bolts, wheel in your engine crane or whatever you have
( I used a car winch over a pulley attached to the roof )
Take up some slack, and remove engine mount bolts, wiggle and pull untill FREEDOM!
*BE CARFUL NOT TO PULL TO HARD TO PROTECT YOUR A/C CONDENSER

FLYWHEEL

Use the 1.3 flywheel
Don't be cheap and buy a nice heavy duty clutch.

MISC

Attach the adaptor plate to the gearbox,
Attach the engine mount adaptor under the water pump and fit the bottom radiator hose assembly.
Attach the engine mounts and flywheel and clutch.
*Do yourself a favor and dab a LITTLE BIT of grease around the tip of the input shaft spline, it always helps a bit as long as your clutch is aligned correctly*
Screw in conversion kit engine to bell housing bolts into the 1.6 block.
If the top right bolt doesn't screw into the locator hole skim the sidesof the bolt down with a grinder, don't kill the thread obviously.

OIL PUMP PICK UP PIPE
Trickiest part.
USE THE JIMNY SUMP, NOT A VITARA SUMP, THE DIFF WILL SMASH THE VITARA SUMP.
The pickup pipe where it goes into the oil pump is wider on the 1.6,
Cut the end of the 1.6 pipe about 1" down from where it bolts into the pump then do same thing with the 1.3 pipe
weld the 1.3 pickup to the 1.6 pump inlet pipe.
You need to drill and tap the No 4 main bearing cap for the mounting of the pickup pipe.
OR POSSIBLY JUST BUY THE VITARA BEARING CAP WITH A FACTORY HOLE? I'm not sure about this, worth checking it out though.
Seal the sump

INSTALL THE 1.6
Get the motor in. wiggle wiggle THUD *sigh of relief*
Bolt her up
Bolt everything onto the 1.6 motor
Exhaust should just line up and just miss the mounting bolt.
Connect clutch cable and adjust it in HEAPS to make up for the adaptor plate space difference.
Wire up the motor and fill all fluids.
VROOM it's allliivveee!

The increase in power is amazing, it's a new driving experience, offroading is awesome and fuel economy is about the same as the 1.3 you will loose a few Kms per tank.
I have 235/75 r15 and it drives with plenty of power.

Enjoy all.
PORL

[jonno_racing]

how did you go with engine mounts?

[PORL]

Engine mounts are same on passenger side. The conversion kit gives you a new bracket for the drivers side.

[gregc]

Do you know which g16b motors have lots of lugs and therefore won't need the jimny cam?

I.e. which year Balenos?

Thanks

[jonno_racing]

PORL any chance of a pic of drivers side bracket?

[PORL]

gregc wrote:

Do you know which g16b motors have lots of lugs and therefore won't need the jimny cam?

I.e. which year Balenos?

Thanks

I do not sorry mate

[PORL]

jonno_racing wrote:

PORL any chance of a pic of drivers side bracket?

I will try take one, but I doubt it will show you anything usefull it's pretty closed in.

It's different from the Ben t 1600 kit, that kit is for a Sierra

Here's a link to the kit I used. It shows the bracket clearly
http://www.suzistore.com.au/onlinestore ... etail.html

[jonno_racing]

PORL wrote:

jonno_racing wrote:

PORL any chance of a pic of drivers side bracket?

I will try take one, but I doubt it will show you anything usefull it's pretty closed in.

It's different from the Ben t 1600 kit, that kit is for a Sierra

Here's a link to the kit I used. It shows the bracket clearly
http://www.suzistore.com.au/onlinestore ... etail.html

ok i have a benT kit but no engine mount as i am going to make mine. thanks for the link!

[Birdman1985]

So I can confirm that the 01 baleno has only 2 lugs on the cam.

So I guess I'll be using g13 unit.


Can anyone tell me do I need to use the G13 injector manifold? It would make sense, as the balenos radiator outlet comes out of the rear and the jimny one is on the manufold???

[Birdman1985]

So I can confirm that the 01 baleno has only 2 lugs on the cam.

So I guess I'll be using g13 unit.


Can anyone tell me do I need to use the G13 injector manifold? It would make sense, as the balenos radiator outlet comes out of the rear and the jimny one is on the manifold???

[Rhinoman]

G13 manifold is the simplest way.

[jonno_racing]

sure is!
i will be updating my build thread later in the week, i am about 75% of the way though the conversion and there is some stuff that has stumped me/required a work around that isnt listed!

[Birdman1985]

Sweet as, can hardly wait.

[PORL]

Clearly written in the instruction. Use all g13bb shit on g16b motor

[-QIK-]

Taken off another forum:

Camshaft. If you have a Hardtop Jimny then it probably wont have a crank sensor. If it doesn't and the Baleno engine does then please pull the cam sensor off the back of the cam on the baleno engine. if you are lucky there'll be 11 pickup lugs on the end of the cam. if there's 2 then you need to use the jimny cam - I had to use the Jimny cam it just doesn't rev as hard (6000 + rpm) as the baleno.

Cheers,

Rob

[Rhinoman]

You just need to get the lug pattern to match, the hardtop/softop reference really refers to the difference between Japanese and Spanish models.

[-QIK-]

From the information I have read over the net it seems the later model ( 99-2000 ) Baleno engines are the ones to get when changing over. As they have coil packs like the Jimny G13bb.
Only real mod is the oil pick up in the sump, engine mount and the spacer for the gearbox. Seems an easy enough change over to me.

I'll be calling around in the morning to find myself an engine.

Cheers.

[Rhinoman]

My 2000 model Baleno had a crank sensor.

[PORL]

Changing the cam is easy, I can't speak to the power difference, but apparently the Jimny cam has more torque but revs lower

[cal213]

still completing my 1.6 conversion. been so very lazy, but i do have quiet a few pictures of the sump mods, engine mount, pickup pipe ect. :p

[Birdman1985]

cal213 wrote:

still completing my 1.6 conversion. been so very lazy, but i do have quiet a few pictures of the sump mods, engine mount, pickup pipe ect. :p

Yeah same here...been without a car for nearly 2 months now as i only get a few minutes here and there.

Ready to drop the 1.6 in now, just waiting for someone (anyone) to help me guide it as i tried and FAILED several times on my own.

For someone whos mechanical experience involved changing the oil, ive had an absolute ball during this experience and i am so glad i am trying it.

[cal213]

Mines all running, been good for a while. Bought baleno/vit injectors from ebay US and work fine. Made custom mounts for the ac and ps. Full 2inch exhaust with ebay 4-2-1 manifold and high flow cat. She has heaps of torque down low now.

[zammit]

hey guys,

sorry about the nOOb, question, i have a 1999 jimny and have sourced a G16b out of a vitara for it which im picking up Monday, (engine is coming with intake manifold and injectors)

can i confirm this is all i need fr the conversion, apart form a skinny starter and bell housing adpt, everything else of the g13bb with bolt on, (with mods etc)

and can i confirm that i dont need to use the 13bb cam, because its a vitara engine.

sorry if this has been asked before.

[Rhinoman]

The Vit will have a distributor so you'll have to use the Jimny cam and cam sensor if you can, if you can't you'll have to swap the heads.

[zammit]

Ah righto. So my best option would be to find a baleno engine?

[Birdman1985]

No, you use the vit, youll have the same issue with the baleno (model dependant). Just use your jimny cam and the cam sensor on the rear of the head.

[zammit]

so i wouldn't have to change the head over, just the cam and cam sensor? unless the vit head has 11 sensor flags? is this right?

[cal213]

I think it should be right if it has the 11 lugs. Could never find this info whrn i was doing my conversion so we just used my 1.3 head.

I need to measure up my ac and ps brackets i made! Along with getting the damn car back on the road

[tyharmon87]

what about the thermostat on the back of the baleno engine? can you cap this off and run the jimny intake with the thermostat inside and the outlet pipe on the water pump i am very curious about this because i have an 87 smaurai here in germany and have found a 1998 baleno 1.3 for 100 euro and would like to do the swap but dont like the thermostat in the firewall situation.

thanks

tyler

[Gwagensteve]

Yes. If you have an intake manifold with the thermostat on it you can blank the housing off on the back of the cylinder head

Steve.