I did the 1.6 8V conversion on my 88.5 Samurai.  I’m putting the original intake manifold from the 1.6 (donor 89 Sidekick) into my Samurai.  Meaning-I’m going to install the fuel injection.  Question is; will the Samurai original fuel return line be large enough or will I have to go with a larger diameter line because of the high pressure pump needed?

the fuel line should be ok.  you could probably go a little larger.  quick question though, why spend the time to convert to fuel injection on the 8v, why not 16v?

The 16V is just a different head, along
with the other stuff like EFI and manifolds.

The biggest headache is getting the 1.6 block
adapted and into the Sammy, now the 16V head
will be a snap if and when you want to do the swap.

And yes, if you have a return line, it should be
big enough to take the flow back to the tank.

Wild

quick question though, why spend the time to convert to fuel injection on the 8v, why not 16v?

I could not find a 16V and I got a great deal on the 8v.  I'm happy with the 8V, much better than the 1.3

eff...i was just curious, not knocking you at all.  Its time for me to put a 1.6 in my sam and was jus curious why you went with the 8v route.  Thanks

We ran a new fuel line using the origional from the Tracker.  Though I have heard of people using line purhased at a Kenworth (Large Truck Dealer).  Pulled the origional fuel line loose at the tank and it became the return line 1/4".  Then attached the new fuel line where the old line connected to the tank.

We did drop the fuel tank down to make the connections.  Used the origional clamps along the frame to hold the new line.  works well with plenty of fuel intake and sufficient return line.  Took about 2 hrs to install.

Captain Jack