G16 motor in a 1999 Carry van.

Suzuki van tech question and answers.
8
Posts: 185
Joined: Fri Feb 22, 2008 8:14 pm
Location: Melbourne

Kruizin wrote:I haven't come across the 2nd gear issue before, but the synchros of third have flogged out in both of my Carrys, (but I do give them an absolute caning!) The box in the van was repaired by the local mechanic in Warragul (some years ago, can't remember the company) for under $500 and I just haven't got around to it with the ute, but I don't consider the gearboxes to be weak. I don't personally think that 1698cc is THAT much bigger than stock that you should need a beefier gearbox unless you're doing tractor-pulls. Replacing or repairing the stock box occasionally might still be cheaper than installing a non-stock box. There are a lot of factors, but I'd try it with a stock box first... :thumbup1:
Thank you for the gearbox tips, I did hear the sierra box had its
issues and this is actually a beef up version of that with thicker
gears but same synchros. This is the second time Ive come across
a carry with box issues and there was another from a guy up north
with the 3rd gear issue also at 140,000klms.

Looking at your Beast I think you where doing the tractor pulls!!
what a great setup and reminded me the other day of someone else
driving up the road in essendon area (if I remember) of a similar
ute with bullbar but in alloy and just bigger road wheels,
Your ute has totally convinced me they are the ultimate suzuki ever
brought into australia.

Did you have any issues with the engine mount on one of the sides?
Kruizin
Posts: 10
Joined: Mon Feb 14, 2011 8:36 pm

Thanks 8. No issues with the engine mounts in either vehicle, but I have managed to flog the centre out of a couple of the front diff mounting rubbers in the ute, which just serves to remind me that these vehicles weren't designed to do the things I do to it. :wink:
8
Posts: 185
Joined: Fri Feb 22, 2008 8:14 pm
Location: Melbourne

Sounds like the abuse it gets is better than
the other halve copping it :)

On your thread in Redline I couldnt figure out how
you did the bolt re-threading to suit the smaller
box, where they using time serts?
Kruizin
Posts: 10
Joined: Mon Feb 14, 2011 8:36 pm

My memory of that is kind've sketchy as it was at least four years ago, but the Baleno engine required two holes to be drilled through the flange on the Carry box. I made some aluminium blocks up which fit into the fillet where the flange meets the side of the bellhousing which allowed me to use longer bolts and place the heads further from the flange where there was no fillet, effectively sandwiching the gearbox between the engine block and the fabricated aluminium blocks. Does that make sense?
8
Posts: 185
Joined: Fri Feb 22, 2008 8:14 pm
Location: Melbourne

Makes sense and nifty way of going about it.

You used the g13bb flywheel and clutch?
if so it should spin up a bit faster
Kruizin
Posts: 10
Joined: Mon Feb 14, 2011 8:36 pm

Yep, the Baleno motor didn't come with a flywheel so I used what I had... Port sizes were the same, so the exhaust and intake went straight on. Biggest issue was adapting the electronic crank sensor. :)
8
Posts: 185
Joined: Fri Feb 22, 2008 8:14 pm
Location: Melbourne

You probably have a couple of KWs more than the original Baleno motor.
The smaller clutch should act as a good relief for the gearbox
compared to the bigger clutch in an AWD setup with a lead foot :)

I know the cast exhaust is restrictive but usually helps with
torque down low but would there be and advantage with a 4-2-1?

Im thinking making one in SS for about $120 in parts alone
(I have an SS flange, SS butt welds from Geordi, tacking them
in position and then finished by someone with a tig or mig)

and then heat reduction tape to help midrange further and
reduce the engine bay heat that usually overheats the coilpacks
over very hot Melbourne summer days in traffic.
Kruizin
Posts: 10
Joined: Mon Feb 14, 2011 8:36 pm

You are correct on all counts, but I put the larger motor in purely to gain bottom-end torque as I was carting around two adults and about 200kgs of dogs on the weekends, and I got tired of having to change down on some of the local hills. It went VERY well after the upgrade and I didn't feel that further modifications were necessary for my purposes. :)
8
Posts: 185
Joined: Fri Feb 22, 2008 8:14 pm
Location: Melbourne

Kruizin wrote:You are correct on all counts, but I put the larger motor in purely to gain bottom-end torque as I was carting around two adults and about 200kgs of dogs on the weekends, and I got tired of having to change down on some of the local hills. It went VERY well after the upgrade and I didn't feel that further modifications were necessary for my purposes. :)
200kg of dogs!!! hate to ask your their food bill!!!
unless of course you do what we use to when we did
feed them roadkill :) was a bit of work stripping
out the guts/skinning in the shed but loved my poochs.
oldvanman
Posts: 67
Joined: Thu Sep 24, 2009 10:49 am
Location: Dubbo NSW

G'day

I am getting ready to have a crack at the conversion.

Yesterday I have bought a 99 Baleno for $300:
http://www.gumtree.com.au/s-ad/birmingh ... 1002909156

A good read is at:
http://redlinegti.com/forum/viewtopic.p ... g16B+carry

I have also found these:
http://www.bigjimny.com/index.php/forum ... jimny-g16b#
They mention a few interesting things including using the Baleno injectors.

http://www.reallymeansounds.com/forum/t ... ry.115175/
He claimed he didn't have to modify the sump.


One of the problems is the small exhaust manifold.
I saw this:
Image
at:
http://www.suzuki-forums.com/suzuki-car ... ifold.html

And one to fit an APV:
Image at:
http://www.modifikasi.com/showthread.ph ... SUZUKI-APV

I thought about using the exhaust manifold off an APV van but looking at the bolt patterns I don't think it is going to work. Maybe someone knows knows?
I am chasing up a price on a set of custom extractors.
Is anybody interested in a group buy?
Once a 2%er, always a 2%er. (old vanners know what I mean)
8
Posts: 185
Joined: Fri Feb 22, 2008 8:14 pm
Location: Melbourne

thanks for the pics OMV, I really like the last one by far it has the nicest bends and lengths before the collector. Ill be in for the last one if available, it sure is annoying that we cant buy stuff off ebay from indonesia as the APV is made there.
I bought an APV sump and oil pick up for the conversion myself and just started the conversion today using also a 99 baleno motor.
Need to find a bigger radiator made in alloy rather than the stock copper one I have as I think there is some incompatibility with the all alloy engine and copper cored radiators as the coolant doesnt seem to last long enough before internal corrosion destroys the water pumps and heater core. Im not sure but seem to have a heater core blockage and radiator was replaced 2 years just after it was new due to corrosion.

I did see one carry with a big bore 77mm g16b the second time the other day and it was not holding back on the fast lane of the freeway. The old dude driving has a lead foot :)

the one on this link doesnt seem to have the main ladder brace most g16b engines have and would cause clearance issues on the carry sump like it did for previous conversions.
I believe that brace helps with the mains moving around somewhat with that long stroke.
Kruizin
Posts: 10
Joined: Mon Feb 14, 2011 8:36 pm

It's nice to see a few people attempting this conversion since I did mine. I'll be watching to see if any of you come up with better solutions to the problems encountered as I still haven't ruled out the possibility of doing the same conversion to my AWD Carry Truck. :twisted:
oldvanman
Posts: 67
Joined: Thu Sep 24, 2009 10:49 am
Location: Dubbo NSW

G'day

It is going to happen.
I picked up a 1999 Baleno 2 door with 160k for $300 on Gumtree.

The idea of using the APV sump and pickup should save some work and my neighbour has offered to make a set of extractors and free flowing exhaust.

Regards
Chris
Once a 2%er, always a 2%er. (old vanners know what I mean)
8
Posts: 185
Joined: Fri Feb 22, 2008 8:14 pm
Location: Melbourne

Abs want 290aud for a clutch kit so far thats the best price in Australia
but going to highway clutch tomorrow to see If I can get a better price
on their kit or rebuild the OEM one I have with organic non asbestos ceramic
lining and machine lightly the pressure plate.
8
Posts: 185
Joined: Fri Feb 22, 2008 8:14 pm
Location: Melbourne

Highway clutch service $140 aud with recoed pressure plate

also got timing belt for 36.20 made by Bosch yet Repco wanted 99aud for :lol:
supercrap auto is good sometimes :)

Looking at making my own headers atm but cant find the flange I made up about 3 years ago.
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