Quote: 1. If things break on the engine, how hard is it to replace? I've been reading up on baleno G16B conversions, and seems tricky/complicated
You won't need to do a conversion though - if the car is already running a baleno block and injection you just swap everything like-for-like. Baleno motors are common and cheap. If the engine is running coil packs it's most likely running complete Baleno injection, sensors and manifold, although it could have been done a number of ways. Still doesn't matter - just remove and replace from the old clock to the new.
Quote: 2. Are these engines realible? Read that cracking the block is a problem? Or is this only for vitara G16B?
Block cracking is a problem, especially for Vitaras. It's very common/unknown in Balenos. It appears likely this is due to coolant flow - in the Baleno it flows in one end of the head and out the other. That's not the case in the Vitara.
Otherwise, they suffer from worn valve stem seals. If these haven't been replaced, Id expect the motor to be little smoky on startup by 200K. Little else gives much problem. Crank pulley keyways can flog out.
Quote: 3. Car doesn't have air con hooked up (no belt, or controls).. but has compressor and everything else. Now I assume this is the set up from baleno.. how hard is it to get it to work in the vitara?
No idea. only the compressor will be from the Baleno. If everything else is intact then it should just be a matter of getting the right hose configuration made up and gassing the system, but, as always the devil is in the detail.
Quote: 4. Runs rough on idle.. read it could be an o2 sensor, possible vacuum line?
Not sure where you read that, the 02 sensor has nothing to do with idle quality. Could be any number of things - obviously plugs, leads, coils, but also fuel pressure, crank keyway failure.... Yes, it could just be a vacuum leak too.
Quote: 5. Any other prob to look out for? Common leaks or fixes? How long is a piece of string? This is a 25 year old car with an engine conversion and EFI wiring. There's many different ways this could be done. Maybe it's been done really well, maybe not. Does the check engine light work (as in, is it connected?) how was the fuel system done? how was the water piping done? how was it wired? Was an EFI instrument cluster with a VSS swapped in? how was the inlet piping and airbox done? Were the brakes upgraded to EFI spec?
The most important question is why THIS car? it would need to be REALLY cheap. Suzuki sold thousands of EFI vitaras with the G16B engine. Converting a carby car to EFI is a big and expensive job to do properly, yet the price of the converted car should/must be lower than genuine factory EFI car, which will be newer, and you won't ever have to wonder how/why/if something was done properly.
Steve.
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) im just cautious and dont want to buy a lemon. Liek you siad, no idea how the conversion was done, if properly/professionally or by a backyarder experimenting 