KAP Suzuki Jimny - rebuilt for the road

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try rotating the pick 90 degrees it works for me every time

Jack

Well not for me!

Top work

Progress is a bit slow again, but conversion plate is in place



But unfortunately the rear crankshaft oil is little damp, so a new one is coming on Tuesday



and I'm replacing the tired water pump although James P had kindly put on a new timing belt - Top Bloke!



Hoping to get it in by the weekend.

Phil

Arse, arse, arse, another delay.... The Jimny and Vitara water pumps look identical, since my Jimny one was brand new, I thought it would be a quick swap, which I did....I went to put the timing belt back on and it wouldn't tighten up, on closer inspection the cam bolt fixing is about 10mm closer to right on the vit one, meaning the timing belt wont tighten up and my brand new Jimny pump is useless. So off to Newcastle tomorrow first thing for a 2 hr return journey to get the correct pump. How can it be economical for suzuki to build two pumps with only a slight difference?!?

HACKED OFF NOW

Phil

In the last couple of days I sourced a water pump and fitted that and also changed the rear crankshaft seal (which was weaping slightly), refitted the flywheel and clutch, and threw the whole lot in to the engine bay! Easier said then done, the engine refused to line up, which meant it took me a few hours to get everything aligned and in, I was despairing by the end. For anyone else doing this by yourself, I would recommend removing the inlet and exhaust manifolds and taking off the engine mounts before even putting it near to the engine bay! So now begins the long job of connecting everything back up again and hoping it all works.

I wont even be able to drive it when its changed as the front wheel bearing has collapsed - so I'll need to fix that as well

Phil

IT LIVES

I had it running for a few minutes, and seems to be smooth running so far. I have stopped now with the engine conversion and moved my attention to rebuilding the front axle so I can take it for a test drive. I swapped the drivers side bearings, helped massively by having a 20T press. So next its passenger side, which should be fairly quick now I know what I'm doing. Then bolts the wheels on and get it out on the road to get properly up to temperature and look for leaks / issues.

Engine ready to install



Ongoing work...








Phil

Jeez, this software in doing my napper in....

1st pics was the engine ready to fit, 3rd pic was a new Rocklobster box.

Phil

Try photo bucket

First proper test drive today, and it pulls like a train, what a difference, 5th gear is now usable. It was just a few miles to check nothing was leaking and let it get properly warm, but initial impressions are good, although I do think my 1.3 was very tired. Just a few small jobs to finish off now.

Both front wheel bearings are also changed, quite an easy job but owning a press makes a big difference.

Phil