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Trail Tough Products * 133 Taft St Medford Oregon 97501*

1-877-SUZUKIS (877-789-8547)

Donor Parts List 2.0 / 2.3 Engine Conversion

***This conversion is  OBDII engine management and will not be smog legal in enhanced smog areas due to unavoidable check engine light or codes when installed in a Samurai. However, the actual emissions and running condition are no different than what would be in the Vitara or Tracker.

 

To perform a 2.0 or 2.3 liter Suzuki engine conversion into a Suzuki Samurai we offer the following do it yourself installation package - Item #TWO-200 which includes:

 

Custom flywheel, pilot bushing, custom full-circle motor mounts, engine adaptor plate and hardware, high pressure fuel pump, custom 3-core radiator, high HP pusher fan, and modification of your donor harness completely color-coded labeled and ready install a well as VSS modification of your speedometer. You will need to send us the complete under dash wiring harness from the donor vehicle from the ECM out to the headlights as well as the engine harness as well as your Samurai speedometer cluster for modification. The Samurai wiring harness stays in tact.
 
 
From the Donor Vehicle for both the 2.0 and the 2.3 you will also need:
 
Engine Complete -  (1999 to 2001 Vitara or Tracker 2.0 engine or Suzuki Aerio SX engine)
Alternator
Starter - there are 2 types - one wont work so you may need a 1.6 starter ( the one with mounting holes on the center line of the armature will work)
Power steering pump and high pressure hose to rack
Air cleaner assembly
Throttle Cable
Exhaust manifold with 3 bolt flange (tube type only) and first 02 sensor
Pre-cat for 3 bolt flange
ECM/PCM
Underdash and engine harnesses complete
2nd 02 sensor from cat
One of the metal fuel return lines from the frame rail to replace the one that is too small on the Samurai.
 
For the 2.3 engine conversion only, you will also need these additional parts from a 2.0 Vitara or Tracker:
 
Oil pan
Pick up tube
Tube type exhaust manifold
Pre cat for 3 bolt flange
Water outlet cap and pipe
Water bipass pipe
Throttle cable
High pressure P/S hose
And you will also need 1.6 Suzuki Sidekick or Geo Tracker Starter