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Underbody braces, turbos and more!

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PostPosted: Sat Feb 24, 2007 2:53 pm 
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Location: St.Thomas
J18A Powered 1994 Suzuki Swift Sedan
Built by Kevin Armstrong & 'Dave' Crawford.
July 2006
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My exsisting swift shell wasn't straight so i decided to buy another car to base the project on. I stumbled upon a working 1.6Glx sedan swift, it was manual and that would save us alot of trouble in the future. The car was stripped and the engine sold on to provide extra funds for the project.
The engine n harness were acquired but no 1.8 ecu could be sourced on the island to use the coil packs etc from the original system, so Dave came up with the idea of using the 1.6/1.3 baleno ecu(which many suzuki 'men' and supposedly top electricians said wouldn't work) and splice the harness into the exsisting 1.6 harness.
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So after removing all the original 1.8 electronics from off the engine(only keeping the sensors). WE fitted the flywheel which was a lightened and balanced item i got from Dave, the clucth and pressure plate setup was a mixture of 1.8 and 1.6SOHC parts(which by the way are the same).With that done we moved on to other thngs.
Instead of lifting the engine into the engine bay then bolting up the box we decided to remove the box n fit everything up first, Good thing we did. By the looks of the things the box would have fitted the 1.8 with no problems but it wasn't to be. the box wasnt going down meeting the block flush, so time to take measurements it was later discovered that the 1.8 Baleno and 1.6Swift box both had the same lenght input shaft but the lenght of the splines were different with the 1.8 ones being shorter. So out came the grinder to grind down the splines equal to the 1.8 ones. Tried refitting the box again and it was perfect, and here i was thinking smooth sailing form here on now car should be done by weekend, yeah rite!!
Upon lowering the engine n box into the engine bay it was clear that the engine wouldn't fit the way we had planned without major mods. With the gearbox taking it's original posistion(using a 1.6 swift in an original 1.6glx sedan) the engine would hit the chassis rail. So the chassis had to be persuaded to go back 1 1/2 ", So we had to use a BFH(Big Fucking Hammer) a Hilti(Pablo's idea) and a torch to get the inside of the chassis back the required amount. Finally the engine would drop into the engine bay with the box bolted up.
NB.The engine can fit in the engine bay without mods, but because we didnt want to alter the gearbox position and cut and weld axles with did the above. Also instead of beating the chassis you can cut out the chassis and box it.
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With the engine 'fitting' in the engine bay in the correct position 2 of the 3 swift mounts bolted right up, the 3rd had to fabricated. An old engine mount bracket from a 85-87 fwd lancer was used, that was extensively modified to work as the 3rd swift mount. Now a bracket had to be fabricated and weld to the chassis to bolt the mount unto.The bracket was made up of 3x11/2" hollow section and 1/4'' steel plate.Now with the engine finally mounted it was time to do the electrics but first we had to fit the distributor for the 95 efi system to work. What we did was remove the CAS and got a alloy bushing made to reduce the size and bolt the distributor into the solt, Very Simple.
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The original idea was to use the car exsisting harness and splie it with the 1.6 baleno engine harness, but with the shell having power windows etc it was proving difficult due to the fact the schematics where lent out n never returned. So i was stuck at that point for about 2weeks with no 'suzuki man' on the island having the schematics or either not willinig to lend us. I had to resort to the internet to try and find some info. Luckily the guys on http://www.Clubaleno.co.uk pointed me in the right direction and i got the complete manual for every Baleno.
Now with the shcematics in hand we started doing the wiring but 3 wires were still at large and we didn't know where they were suppose to go....by now i was getting cruel as fuck. So the decision was made to strip the Complete harness from the car and use a Complete car Harness from a sedan Baleno(by doing that some weight was saved with the baleno harness cause it uses smaller wires compared to the swift). After a day of installing the harness and fitting back the interior together the car was ready to start. With the first swing of the key it rumbled to life.
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Spec:
1840cc engine
Intake Cam timing advanced
1600 swift 3.7:1 gearbox
B16 honda 4-1 extractors (awaiting Aerio 2300 extractor)
2 1/4 exhaust
Nothing else done to the engine

130hp @5200 rpm
113lb/ft@2800rpm
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Rite now Ecu is the 'limiting' factor original system limits at 7200rpm mines is 6500rpm.

Thanks To Dave, Pablo and Jerome even though he aint do much..... :wink:



Bigger things yet to come......One thing i can stand about it, is that is FWD with so much low down torque....... :twisted:

ps.document contains some grammatically errors but...i think you will understand.

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PostPosted: Sun Feb 25, 2007 1:34 pm 
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Location: Winnipeg
Thanks for sharing the details of your swap. I was considering a J18 swap into my Mark1...then turbo it of course...
Does the J18 have the same bolt pattern as the G16 for trans? Is the Flywheel/crankshaft bolt pattern the same too?


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PostPosted: Mon Feb 26, 2007 12:50 pm 
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yea they share the same bolt pattern i'm using the G16 box at present. No the flywheel's aren't the same. the J18 uses an Eight bolt setup compared to the Six bolt of the GSeries.

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PostPosted: Sun Mar 04, 2007 9:39 pm 
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Location: Ontario
this is pretty cool got any video's of it in action?


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PostPosted: Thu Mar 08, 2007 12:58 pm 
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¸oh my f()*YU) god a j-series engine in a swift!!!sickest ride i've ever seen :twisted: :twisted:

everyone said me it was unpossible, but right now I know it is, i have one thing to do....

j20?hum...

maybe j23 :twisted:

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PostPosted: Tue Mar 13, 2007 7:54 pm 
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Should get some vids in a couple months when i change the gearbox to a 4:1(either 1.0 or gti box)...the plan is to rebuild it into a Full race circuit car. So then i can take a shot at developing a JSeries engine.

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 Post subject: my type of swap mate !!!
PostPosted: Tue Mar 27, 2007 3:22 pm 
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Location: ILAMABAD
i have dont the exact same swap but luckily have the orig 1.8 JDM engine n ECU n its kicking butt at the momet
love the power to wait figres
n yea .... have u figured out how can u get the Speedometer to work mate ..becoz thats causing problems
plus the axels keep coming off from time to time


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PostPosted: Tue Apr 17, 2007 3:38 pm 
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Did the J series bolt up to the gearbox made for the G series?


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PostPosted: Wed Apr 18, 2007 2:56 pm 
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The JSeries Has the same Gearbox Bolt pattern as the G16 engine.

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PostPosted: Sun Apr 22, 2007 4:25 pm 
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Nice, then maybe I'll look into getting one.

How much does a J series weigh?


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PostPosted: Mon Apr 30, 2007 10:27 pm 
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ok so now i can see my gti with a j23 with 500 to the wheels :twisted: lol

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PostPosted: Mon May 14, 2007 11:37 am 
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But on the subject of gearboxes, does anyone have any idea whether the H series V6 has the same pattern as well?


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PostPosted: Sun May 20, 2007 12:37 pm 
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H series, meaning vitara 2.7etc. no the bolt pattern is different. We too have a 2.7V6 in a Baleno almost complete.

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PostPosted: Thu May 31, 2007 5:01 pm 
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G16B_Sedan wrote:
We too have a 2.7V6 in a Baleno almost complete.


Any sneak preview on this? :shock:

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1991-GTi: JE 75mm 11:1 pistons,Ported head, Single UD pulley (OCC),Sandros chip,Aluminium flywheel,3tech 222/365 cams, Cultus headers,Cultus IM,50mm tb,Crane cams adjustable cam gears,Apex suspension, 4.39fd GB.
1989-GTi: 3Tech 210/340 Cams,Cultus IM, B&G springs, TD04L turbo, Apexi SAFC, Suzukird UD pulley, Circuitse7en dual boost controller, AEM wideband, AEM water / meth injection kit, HKS bov.
2001-Altezza AS200: Stock.-sold
2003-EVO7 GT-A
Aruba "one happy island".


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PostPosted: Thu May 31, 2007 5:22 pm 
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:shock:

I want vids.

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PostPosted: Fri Jun 01, 2007 3:55 pm 
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Location: exeter, devon
:shock: what they said

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PostPosted: Fri Jun 08, 2007 10:58 am 
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:drools: you guys are SOOO cool..I have been considering an2.3 in a gti shell..and swapping a H series in as a rwd rearenge setup (use th H20a block, then fit th H27a internals and a turbo charger...hehe horsepower in a "2litre turbo" street legal 900kg or less car)
Keep up th good work guys :D


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PostPosted: Fri Jun 08, 2007 4:46 pm 
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will see wat i can do about some pics.

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PostPosted: Mon Sep 10, 2007 11:38 pm 
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G16B_Sedan wrote:
will see wat i can do about some pics.


Any update on this?

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1991-GTi: JE 75mm 11:1 pistons,Ported head, Single UD pulley (OCC),Sandros chip,Aluminium flywheel,3tech 222/365 cams, Cultus headers,Cultus IM,50mm tb,Crane cams adjustable cam gears,Apex suspension, 4.39fd GB.
1989-GTi: 3Tech 210/340 Cams,Cultus IM, B&G springs, TD04L turbo, Apexi SAFC, Suzukird UD pulley, Circuitse7en dual boost controller, AEM wideband, AEM water / meth injection kit, HKS bov.
2001-Altezza AS200: Stock.-sold
2003-EVO7 GT-A
Aruba "one happy island".


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PostPosted: Fri Sep 14, 2007 6:41 pm 
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not as yet. havent got the chance i'm currently rebuilding mines to a higher spec.

about 12-12.5:1 Cr, 1907cc, rally spec cams(re-grinds), gti 4.1:1(eventually suzukird 4.9:1 diff kit).

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PostPosted: Tue Oct 02, 2007 11:05 pm 
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Location: Melbourne
Anyone know if the J sereis engines have hollow sections on the crankpins?

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PostPosted: Thu Oct 25, 2007 10:00 am 
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Well unfortunately or fortunately for me i have scrapped the swift shell and now the 1900 is going in my mk1 escort racer...

Stay tuned much better things to come, now i'll get to see the real potential of this engine :lol:

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PostPosted: Mon Oct 29, 2007 12:53 am 
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G16B_Sedan wrote:
Well unfortunately or fortunately for me i have scrapped the swift shell and now the 1900 is going in my mk1 escort racer...

Stay tuned much better things to come, now i'll get to see the real potential of this engine :lol:


Will be looking forward to it!!! which box r u running for rwd?

also do you know if the crankpins are hollow when you remove the sump?

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PostPosted: Sun Nov 18, 2007 9:36 pm 
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RWD box is from the Suzuki Samurai 1300.
its a basic bolt on fit, jus need to drill the 2 bottom holes in the block to finish bolt up the box.

flywheel will also be from the Samurai(but any G13b should work). It would need fresh holes drilling to accomidate the Jseries 8 bolt crank pattern.

Dont think the Crank Pins are hollow though will check 2mor.

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PostPosted: Sun Nov 18, 2007 9:39 pm 
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will try to get those pics of the Baleno for u guys tomor also.

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