Suzuki Samurai 16V Engine Swap

I’m back to daily driving my Samurai! Been working out some kinks here and there.

I made a bracket for the igniter.

In addition that I cleaned up the wiring under the hood pretty well. I wrapped everything with electrical tape and split loom tubing. I also took the opportunity to remove all of the automatic transmission wiring from the engine harness.

With all that done I noticed I fresh oil on the exterior of the engine.

The oil was the oil pump so I figured the gasket on it was going bad. I was advised to do the water pump and timing belt at the same time.
I put in an order from Petroworks for all the stuff I’d need, including a new timing cover.

In order to get the oil pump off I needed to remove the lower timing pulley/cog and the oil pan. There’s a nut in the center that holds it on but in order to get it off I need to hold the cog in place. I stupidly tried to pry against one of the pulley screws with a screwdriver while trying to break the bolt free and ended up cracking the cog.

I got on the ColoradoZuks Facebook group and asked for one and someone happened to have one about 30 minutes from my house on an engine block they were willing to give me for free!
Huge thanks to for the measurements for making the tool needed to remove this bolt properly. You can see it in the bottom portion of the picture.

With the new cog I installed oil pump and water pump.

And after all that I still have an oil leak.

I believe it may be from the front of the head gasket but the oil leak is slow and I’m not noticing and smoking or oil in the coolant.

In other news I purchased an OBD1 to USB cable and I plan on using the rhinoman software to read data from the ECM but have yet to get it to work.



Leave a Reply

Your email address will not be published. Required fields are marked *