I have decided to jump in and swap out my 1300 for a 1600 8v. Problem is I cant find a complete how to guide, and yes I have looked... Alot. I have found an article that covers both the 8v and the 16v but it has left me with too many questions. Maybe i have just read too much and am confused.

My goal is to create  a how to guide for the common 8v swap.

I remember reading that it mattered which year, tranny type and 4x4 or 2x4 the engine came from.

I would like to compile 2 lists of necessary donor parts and aftermarket parts for the swap. One list for leaving it carburetated and one for using the TBI. I intend to use a 2TC toyota carb I found on ebay.

I sure could use the advice and input of those who have gone down this road before.

Also, if there is already a guide out there please point me to it.

I have my 1.6 8v installed but haven't started it up yet.

Main things were the:
harness (had someone on the forum do it for me, will find his contact)
Engine to tranny adapter (use the full ring version, tad stronger, trail tough)
Electric fuel pump  (Ford F150 pump from Amazon)
Motor mounts (trail tough came with brackets to adapt)  I used Dodge 318 truck mounts  http://bbs.zuwharrie.com/content?topic=120823.0
And the speedo fix for speed sensor input for the injected ECU   http://bbs.zuwharrie.com/content?topic=115835.0



This link has the basics:
http://www.zukioffroad.com/Tech_Library/engine_swaps.shtml

There are other details like the intake that will get you in trouble.  Some use a body lift to clear the hood, I used a honda intake which is shorter and keeps the intake on teh cold side of the block.

A complete guide would be great to get all the info in one location.  There are just so many variables and ways to do it.

 

Im looking to create the cheap and easy way guide, maybe eventually it will become a compilation of how to guides for different variations of engine swaps. That would be awesome!

So far what i have is...
The parts needed from the donor vehicle are:
8v Engine including alternator, waterpump, pulleys, valve cover, exhaust manifold.
     Add throttlebody, aircleaner housing, entire electrical harness from ECM to headlights and ECM if you intend to go with fuel injection. The electrical harness and samurai speedometer should be sent out to trail tough for modifications for TBI.

Aftermarket parts needed are:
Engine mounts, adapter plate, electric fuel pump.

Can the samurai water hoses be used if they are in good condition?
Is there a seperate belt for the AC and PS on the 1.6l or will that need to be purchased also?
The 1.3 starter can be used with some grinding here and there for clearance.

The engine and tranny should be pulled together and installed together.

This is a good time to replace the clutch, pilot and throwout bearings (and rear main seal?).
Anything else?

How does it look so far? Ill rewrite it once its complete.

Here's a little more.

So, if we are not using the power steering and AC but want to keep the Track/kick alternator we will need to source a shorter belt.

And, we need to use the Samurais distributor and housing on the 1.6l unless we use the fuel injection in which case we use the donor distributor.

Did I get that right?

I am still a little confused on the water hoses.
Does anyone have part numbers for belts and hoses?
How about clarification on the engine mounts the link gives two different oppinions and no definite part number.

Picked up the engine, harness and adapter saturday from Sean at aftermarket 4x4. Ordered timing belt, water pump, thermostat, gaskets, rear main seals, crank seal and cam seal today.

The trail tough adapter kit comes with a spacer to reuse the samurai engine mount on the driver side. No need to buy new mounts!

Yeah, about that mount thing... I wouldn't get too excited about that just yet.  Once you start trying to stab it in there you will see that you still might need to try the 318 monts.  they are cheap and plentiful at your local parts store.  I looked around for the exact formula of adapters and mounts to get this to work perfect the first time in without issue.  The only thing I discovered is that everyone has their own opinion and most everyone has a little variation that helped them to get thiers to fit.  Plan on some time, blood, and a few choice words to get the motor in the first time.

Damn, I really dont want to drive to autozone again, its at least an hour round trip. Im hoping the stock mounts work.

Check over the engine thouroughly so you can get all the parts you need lined up before you start work. I didnt and had to have a timing belt cover shipped next day saturday delivery. I also found a busted distributor cap bolt to slow me down.
You will need an oil pan gasket to change the rear main seal.

Dont forget the orings for the distributor and the water pipe manifold. I did, dont know if the one for the water pipe is that important but while its apart may as well.

Also if going FI get the gasket between the air horn and throttle body, and a 5/16 metal hose coupling for the fuel feed line.

The fan belt to use for just the alterantor and fan is 4pk0800 aka 315K4.

This is how much needed to be ground off the 1.3L starter.




This is what the engine mounts will look like with the trail tough kit. Easy but the hood wont close.





With the valve cover off the cam seal can be pressed out from behind.
The front crank seal will come out easy by drilling two small holes in the gasket, threading two small screws into those holes and pulling.
The rear main seal is easy but you will need to drop the oil pan (good time to check the oil pickup screen) and replace the gasket.

Setting the timing is easy, and I wish I had taken a picture, its just a matter of aligning dots and marks.