Hello everyone. I didn't see a section for the x90 so I guess the Sidekick section will have to do. I'm buying an x90 with the intention of doing a V6 swap and I had a couple questions I wanted to ask. I'm looking at swapping in the Suzuki H series engines like the H24A and H27A used in the Vitara. I plan on only rear wheel drive and want to keep the manual trans. The Vitara came with a 5-speed and I asked one of the local junkyards if they had one. They do and said the "dummy transfercase" is included. So here comes the questions.
What is a dummy case? Just an empty t-case?
Is there a 5-speed that will bolt up to the H series engine with just a typical tailshaft housing?
If I do decide to do 4wd, is the Vitara t-case suitable for the x90? Is the front driveshaft on the same side of the car as the x90 t-case?
Does anyone have a thread with a Vitara engine swap?

I'm not new to custom fabrication so assume I don't have any limitations in that area. Mounts and brackets are cakewalk as well as electrical wiring and rewiring.

Thanks.

Make sure you get the entire donor vehicle.  Otherwise you will probably be missing something that is needed to do the swap.  You will probably want to put a body lift on as well to make sure you have enough clearance on the hood, or you could modify the hood with a scoop of some sort.

Doner cars are hard to come by. I've never had good luck finding any. I do have some connections at the local yards that get me some killer deals though. I'm probably going to have to piece build it.

On that engine swap. There is NOT a dummy t-case behind a manual 2wd in the GV or XL7 engine combos. It's just a plain ol' manual or auto tranny with a single output... Make sure to verify what you're getting...

Good luck!  -Eric

On that engine swap. There is NOT a dummy t-case behind a manual 2wd in the GV or XL7 engine combos. It's just a plain ol' manual or auto tranny with a single output... Make sure to verify what you're getting...

Good luck!  -Eric

Thanks. This is the Vitata your talking about right? So the 2wd just has a typical tailshaft housing? Does the 2wd use a longer rear driveshaft then the 4wd? Is the Vitata AWD or 4WD?

How strong are the stock Sidekick/x90 diffs? How about the Vitara 5-speed transmission? How much power can I realistically shove through them and maintain some reliability?

Quote from: ebewley on November 25, 2010, 07:51:03 AM

On that engine swap. There is NOT a dummy t-case behind a manual 2wd in the GV or XL7 engine combos. It's just a plain ol' manual or auto tranny with a single output... Make sure to verify what you're getting...

Good luck!  -Eric

Thanks. This is the Vitata your talking about right? So the 2wd just has a typical tailshaft housing? Does the 2wd use a longer rear driveshaft then the 4wd? Is the Vitata AWD or 4WD?

Eric is referring to the fact that having the entire engine wiring harness and ECU from the donor vehicle will make the swap a LOT easier!  Also, the XL7 and GV are just larger variations of the same basic vehicle

I am not intimately knowledgable with the newer Vit/Trackers (although I do own an '02 Tracker 4-door with the 2.5), I believe that the existing diff and drivetrain can take the extra HP of the 2.5 Suzuki v-6.

Things start fo go just a bit flaky when you stuff a GM 4.3 v-6 into a Suzuki...

I hope that this helps!

I was thinking I'd retain the x90 diffs. They are the same as the Sidekick correct? If the Vitara diffs are stronger and would work I can probably get my hands on those too.

I was thinnking about it and it would be really easy, and cheaper, to swap in a Mazda BP. They are good for 250+ on stock internals and 12-15psi. I'd be able to use the stock x90 wiring harness for the most part. I still have my heart set on the v6 swap. I'm suprised I can't find anyone whos done the 20 25 or 27 swap to a Sidekick. o.O

you might contact Sean at aftermarket4x4 (http://members.cox.net/aftermarket4x4/2liter.html)

He is the Suzuki engine swap Guru on the East Coast (& probably everywhere else...)

I am still doing an 05 2.7 V6 swap into my 93 tracker. Been waiting for two weeks to get the BCM, and waited that long for the TCM.  With the newer electronic packages, piecing a swap together is FRUSTRATING.  You can't just swap engines and transmissions any more.  Installing them in a vehicle is not the problem, computers have to match, to transmissions, to engines, to computers.  If you stick with the pre 05 models, only one computer, but still have to match engine and transmission. 
YOU REALLY NEED TO GET EVERYTHING!!!  Motor, Transmission, Computer, WIRING (motor, transmission, dash, computer, and everything in between).  Best way is with a donor vehicle, because what you forgot, or didn't think of, is still there on the donor.
Or, piece it together, and probably wish you had just bought a donor.

Oh Yes.  It does sound sweet, and has lots of speed with just 3rd & 4th, because I am still missing the Body Control Module. 
ALSO, Get a hard copy FSM for both vehicles.

I'm not limited to using the Vitara ECU. I have the know how and electronics background to run the Vitara engine off any V6 ecu I want. The only major issues doing so are the wiring connectors to fit the Vitara's sensor connectors and having the correct crank/cam trigger pulses. The rest is easy. The tune may be off a bit due to the different VE charistics between engines but it's not as bad as you think. The feedback loops, fuel trims, and choice of injectors can usually compensate for the differences. I wouldn't expect a GM 4.3L ECU to be anywhere close but as long as it's a newer engine with similar design it's not so hard.

Then you won't have any problem.
  It is the feedback on the CAN system that Suzuki is using on 05 and above that has me stumped.  With no BCM, the ECM has a communication failure, so the TCM sees the comm. failure and goes to Fail Safe Mode.  No torque converter lock-up, only 3rd & 4th gears, no downshift, etc. 
With the ability to make any motor & tranny work with whatever computers at hand, you should not have any issues.

Wiring connectors ARE a vexing issue.  I have cut two connectors in half, and sanded them thinner, to get one connector that I could not find.  I have also soldered the ends of wires, inserted them into a female connectors and RTV'd them in place.  Which is why I was emphasizing just getting a donor vehicle, it would have been easier (and my wife would not think I was NUTS). 

Squeezing it in and connecting drive train is not hard to do - making it function correctly takes more time.
I look forward to your build.

Oh yeh I hate Canbus. If one thing is missing -bam- the cel is on and u fail emissions. I'll find an obd2 ecu without canbus.

Is there a center diff on the x90/Sidekick or Vitara? My intention is awd for street use. Suspension will will be lowered and likely 17" wheels with 45 or 50 series tires.

Is there a center diff on the x90/Sidekick or Vitara? My intention is awd for street use. Suspension will will be lowered and likely 17" wheels with 45 or 50 series tires.

If the donor vehicle did not say "All Wheel Drive" (& I can't think of any Suzuki SUV model that offers AWD - certainly anything older than a XL7...), then there is no center differential or viscus coupler.  That said, driving any part-time 4WD vehicle on dry pavement is a very bad thing to do.