[Rodeo22]

So I've bought my 1.6 motor ( its currently in a later model Sierra but not a coily) to swap these motors it should be a direct swap ? There shouldn't be too much drama because of the coily situation ?

*side question*
I've got the motor, as previously mentioned its in the car but it's not hooked up / going.
The guy I bought it off said that all of the bits are there, just wondering if anyone could mention anything that isn't on this list?

1. Remove 1.3 motor
• Drain oil from motor and gearbox
• Disconnect battery, alternator and starter electrics
• Disconnect everything (air, fuel, wiring loom, exhaust, accelerator, clutch, leads, …) – LABEL ALL WIRES
• Disconnect motor and gearbox (12 bolts)
• Remove motor and gearbox
• Cut 1.3 exhaust manifold from exhaust pipe under car, must cut at the right position for 1.6 manifold to weld on

2. Join 1.6 motor to 1.3 gearbox
• Disconnect 1.3 motor from 1.3 gearbox
• Remove 1.3 fly wheel, clutch, sump and pickup, install onto 1.6
?? Is there anything else I need from the 1.3 e.g. starter ??
• Install adaptor plate to 1.6 motor
• Connect 1.3 gearbox to 1.6 motor
• Install motor and gearbox
• Install 1.6 exhaust manifold to motor and weld to existing 1.3 exhaust pipe

3. Install fuel system
*i know you've got to use a coily tank normally, so I shouldn't have to change anything seeing as this is a coily ??* (do I just skip this step)
• Connect hose from filter to high pressure electric fuel pump
?? What are the rules around where I can mount the pump. I will be getting in tough with the mod plate bloke before I do any of this, but any pointers would be appreciated ??
• Run a hose from the pump to the intake manifold
• Connect the wire from computer to the pump
?? Do I need a relay or fuse? If so, where / how ??
?? If I need new wire, what should I use ??
?? Can I re-use the existing 1.6 pump if I have one ??
?? Can I avoid using a surge tank to begin with (to save $$$) ??

4. Install air intake
• Mount the 1.6 air box, this will be a custom job
• !! Try different places to see if it can be fitted without needing a body lift !!
?? Can I just reuse the 1.3 air box, what are the pros / cons ??
• Connect air box to intake manifold

5. Wiring – WOO HOO!
*again I've got the modified loom from the "normal Sierra" is there much screwing around because of the coily??*
?? This will be the tricky part for me, can anyone give me some pointers ??
• Basically I'll be pulling the motor out of a front cut and plan to connect all of the sensors straight back up.
• The fuel line should be fine
?? I'll start to get a little stuck when need to start joining things between the old wiring loom and the new, any help ??

6. Instrument cluster / Speedo / etc.
?? How should I tackle this ??


7. DONE!!!
• Drive away and go nuts!

Thanks a heap guys really appreciate the wisdom.

[kenzook]

its late at night and i skipped through your post sorry, but i caught one thing, the pump, the point of a coily tank is so u can run a vitara "in tank" pump! then just replace the lines with high pressure stuff up to the front. and no need for surge tank with the in tank pump.

will re read the post tomorrow with more suggestions but it will all have been covered in the various threads already on here, look in the tech and faq.

[MrRocky]

The old "guy said it was all working and there" chestnut.
Unless you see it running yourself, your left with alot longer list of potential issues when time comes for start up troubleshooting if it doesnt start.