The radiator is from a ~1985 Mercedes 300td. It fits just between the frame rails. It does require either an inline filler, or a remote reservoir (recovery tank) like the Mercedes came with. So far cruising will sit just above the thermostat temperature, idle will reach 200 after about 20 minutes of sitting still.
Category Archives: 1988 Suzuki Samurai – 4G63 swapped
The samurai is out and about
The samurai runs
Samurai gauges are in.
Getting ready to install the new setup
Oil pan mods
So the initial problem is with steering interference.
So to remedy this, I’ll chop it up and turn that drain out the other side.
This is cut and flipped. I tried massaging the metal to shape, but it’s a ways off.
So I threw some pie cuts in it.
Then leak tested it with hot oil.
Tada! Now paint.
The new intake manifold
I started with some 1.75″ mandrel bends. They are the same diameter as my throttle bodies, and smaller than my intake ports, so I figured it was a decent balance.
I’m using my mock up head as a welding fixture.
And they wind up like this.
I still need to put the coil mount on it and paint it.
Fresh black engine enamel.
Heat shields /splash guards for my air filters.
My brake booster vacuum plumbing.
The GSXR 1000 air box is a little too tall.
I have to pull my timing cover to get to my water pump, because I can’t run my alternator on the driver side as I planned. Unless I make the samurai right hand drive. I will not.
Making an adapter for the samurai stock alternator might work, but the samurai has a lot more electronics in it than it did stock, so the higher output Mitsubishi, or gm1 wire is a better choice.
Intake manifold comparison
This is the Evolution manifold. It clears well, but needs to be clearanced and filled to clear the injectors and fully seal against the head.
Like that. Also the egr is on the wrong end and you have to tap and plug the egr hole in the head.
Here is the 2g dsm intake. The throttle body will interfere with the brake master cylinder. I could make a simple 45° bend/spacer for it.
Here are the itbs from a gsxr 1000 I believe. These look promising. I can repurpose the injector holes as vacuum ports since my injectors are in the head. I just need to find air filters.
The boots need trimmed on the outers so they will line up though.
Here is the sheet metal intake I built when this motor was going to be a 30+psi drag monster. It doesn’t fit the bill here, but I wanted to see how it fits.
Here you can see the sheet metal intake that was on it. It has ~11″ runners. I didn’t like the lack of response it had. That was tested with the turbine housing, and 2.5″ short exhaust vs, 2.5″ straight off the header with an inserted muffler.
Here is a measurement of the area I have to work in.