Getting ready for MOAB

I’ve gotten a lot of stuff done on the Samurai recently.
Early this year I solved my windshield washer fluid sprayer problem. I had accidentally smashed the hose when I removed the windshield frame last summer.

I relocated the on board air compressor the passenger side fender and ran a hose to a quick disconnect through the grill.

I finished the seat swap last week. I started making mounts a certain way first. I planned on using some flat stock running between the sliders but quickly realized that it was going to be a lot of work and I no longer have easy access to a welder and instead ended up using some angle iron.

The way the sidekick seats bolt into the sidekick higher on the middle of the vehicle on the tranny tunnel and lower towards the door side. So I needed to cut the door side mounts down to sit even with the tranny side mounts. I mostly followed the guide on izook ( without the welding.
I used two inch masking tape as a guide.

I had to remove the fabric and foam on the sidekick seats and detach the back rest from the frame as well.

On the tranny side I utilized the mounting holes left from the sidekick sliders and bolted the angle iron the mount. I had to mount the door side angle iron a little differently. I drilled sideways into the remaining metal of the door side mount. I made a template to transfer the original Samurai seat slider holes to the angle iron I mounted on the sidekick seat frame.

I got the passenger seat finished after some struggle with the mounting holes. One of the previous owners had added some pipe flanges as seat risers and drilled through the mounting nuts in the tub.

During this I solved another problem. The original passenger seat for the Samurai had a cable that ran down to the slider mechanism that would allow the seat to slide forward automatically when you pulled the reclining lever. This was a complete assembly and I discovered that I could use the assembly from the samurai seat on the new sidekick seat.

I began the drivers side the same as the passenger side but the sliders on the drivers seat are a little different. The bolts on the drivers seat were going to interfere with the sliders.

I solved this by countersinking them.

The sliding mechanism was still in the way so I added some spacers anyway.

One of the previous owners insisted on the seat lift for the drivers seat as well and mangled up the rear most brackets.

I purchased a head gasket set and power steering kit from petroworks as well. I think I’ll hold off on the head gasket until after the Easter Jeep Safari in Moab because I’m not sure I can afford the machining (if necessary) and I feel pretty confident that the engine will survive for quite some time.

I removed the old steering box easily enough and installed the sidekick power steering box with the wedge from Petroworks.

I wasn’t expecting much trouble with steering shaft but apparently there were two nylon pins that I had to break to get the steering shaft to shorten so that the rag joint would be in the proper location. At some point I’ll eliminate the rag joint as well.

The relocation bracket for the pump was a little confusing but I eventually got it installed. I had to try two belts before finding one that worked well.

You might notice that one of the mounts on the pump is broken nearest the pulley. I think it’ll be ok though. This must have happened in the sidekick somehow.

I ran into some issues with the reservoir as well. I was expecting the reservoir to mount somewhere near the radiator like in the sidekick but I ended up making a new bracket and replacing the hoses with longer ones and mounting it in front of the air box.

After that was all done I installed new shocks as well!

I did an oil change yesterday and I hope to get around to changing the fluid in the transmission, transfercase and differentials before the trip to Moab as well but I’m not sure if I will.

I also need to wire in the new Oxygen sensor.

I need to weld on or get some bolt on recovery points for the rear and install the reverse lights I bought before Christmas. Almost done working on the Samurai before Moab though.

My son was born January 29th and he has been a welcome distraction for me but I’m excited to take him camping in Moab next month.

More updates soon!

Samurai Plans

I wanted to revisit a list of planned mods I made early on and want to evaluate where I am now and where I’m going with the Samurai.

  • Fix The Engine Drinking Oil/Coolant Issue
  • Battery
  • My-Side Harley Carb Kit
  • Roof Rack – Packing Camping gear for two adults and a toddler now
  • Skid Plates – Diff Armor
  • Rear Tire Carrier
  • Rear Cage – Minimally since now I have a daughter to worry about eeping safe.
  • Full Cage – One can dream
  • The Transfercase Cradle from Zuks Off Road
  • Lockers
  • Lift – Goal to get on 33’s

That was a very randomly planned list of things.

So the things I accomplished were

  • Battery – Was forced into getting a new one as the old one predictably died.
  • Fix the engine drinking oil issue – Well I swapped out the engine but the new engine is leaking something… Not losing that much oil and I’m not losing coolant. But something IS showing up on the exterior of the engine.
  • Roof Rack – Been working out great!
  • Rear Tire Carrier – Want to change some things but I’ve got it done!
  • Transfercase Cradle from ZOR – I have it but I have not installed it…. Want to re-gear the tcase now.

Plans for summer 2017

Some things have changed. My son will be born February and we plan on taking him camping with us that Summer and I’ve decided to build a trailer to haul to camping gear as well. Expect a new thread at some point.
The roof rack worked out great for my family when it was just the three of us but I made a smaller roof rack with the understanding that I could use the space on the back seat next to my daughter’s car seat. Not going to work with an additional baby in the back. I’ll extend/remake the roof the roof rack for more cargo.

  • Head Gasket – If that is indeed the source of the leak on the new 1.6L
  • Add a receiver to the bumper. Can’t tow a trailer without a receiver hitch.
  • Roll Cage – Rear cage at minimum – but hopefully I’ll be able to just get the full cage all at once. Anyone know of a place I can get it welded? I’ve been liking this one from Low Range Off Road –
  • Transfercase Gears – Some Crawl would be nice.
  • Lift – maybe just SPOA to start but I’m not terribly concerned with lifting at the moment.

The big plan for The Summer is the Trailer.
With a trailer I can stow all the camping gear, food and water. I’d like to get a roof top tent to mount on the trailer as well. I’ve seen some cool things done with the harbor freight trailers as a base. The inside of the Samurai wouldn’t be as cramped if we could get the gear in the trailer.

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.