Just for future reference in case anyone is considering putting a G16B into a Jimny that has a G13BB. This info came from someone who has just done the swap. It was completed in a couple of days by two people with no previous experience at this.
The engine came out quick enough and was on the deck for saturday lunchtime.
For the swapover of all the bits we deicided to start at the bottom and work upwards.
Sump and pickup pipe:
Off came the sumps as the Baleno one is at the front.
This is when we realised the Baleno has a crank sensor and using the jimny sump would not block the crank sensor hole in the bottom oil pump casting and leave the sump open to atmosphere. No Belzona to hand we welded a small plate on the inside edge of the sump to block it up. I have belzona'd it as well now, but still have an oil leak to attend to in that area that remains a mystery.
The oil pickup pipe is smaller where it enters the the oil pump so we had to cut and weld the end of the baleno one to the jimny pipe.
Had to drill and tap No. 4 main bearing cap to mount the Jimny pipe as well.
In Hindsight maybe the Jimny pump may have been an easier swap however I am a bit fussy about underrating the oil pump especially as the jimny was knocking.
Onwards and upwards...
Gearbox adapter plate.
Used the readily available SJ one just cut off the bottom parts below the bolts as it would have fouled the clutch cable bits n bobs. was gonna drill the block but after all the mucking about below we decided to for once take the easy option.. We were getting tired and grumpy!
Inlet manifold side engine mount...
On the Baleno the mount is 1" further back on the block so we manufactured a new one from 1/4" steel plate.
Water Pump rear pipe. (The one that runs the length of the Baleno block and round the side)
Again like the engine mount the Jimny pipe wouln't fit because the mount on the block was 1" back so we made a mount to fit it.
Flywheel.
Baleno one is too big to fit the Jimny box. Use the Jimny one. Straight bolt on.. At last something fitted!
Starter Motor.
Used a Skinny Bosch one. Fat Jimny one will not fit.
Front Pulley.
Used the Jimny one as the Baleno was different in diameters. Bolt on Swap.
Power Steering Mount:
Used the Jimny one: Bolt on Swap
Power Steering Idler / Air Con mount.
Because the block is taller the holes that bolt it to the head were 1" too low and fouling the exhaust manifold.
Solution: Cut the bracket in half an run with just the block mounting bolts (not recommended if you have air con - I don't!)
Exhaust side engine mounting.
Surprisingly, a bolt on swap.
Zorst Manifold.
Jimny one. Bolt on swap.
Exhaust pipe.
Requires a dent put in it by the bottom engine to gearbox mounting bolts to clear the wider block casting on the 1.6... Large Hammer!
Rear Water Jacket Blanking plate in the head (Where the T'Stat is on the baleno).
Used the Jimny one. Bolt on swap.
Inlet manifold:
Used the Jimny one as it has the T'stat in the right place. Bolt on swap.
NOTE! The engine will run with the Orange injectors from the Jimny but it runs like a bag of poo! Use the green ones from the Baleno inlet manifold and it's sweet.
This is interesting in that the Jimny and Vitara injectors have basically the same flow rate
Camshaft:
Had to use the Jimny one as the Baleno had a crank sensor. To check pull the cam sensor off the back and see if the cam has 6 - 8 lugs on it for the sensor to pick up on. If it's only got 2 then it's cam swap time.
Ignition sensor on rear of cam:
Used the Jimny one just for the sake of compatability. Bolt on swap.
I think that just about everything, and in all fairness it started 1st turn of the key even with the Jimny Orange injectors in.
1,000 miles later it's a nice drive as it goes everywhere in 5th. I don't know what's lost power wise by using the Jimny Cam, but it revs to 6,500 easily and pulls very well.
Fuel economy is about the same as when the G13B engine was fitted.
Jimny G13BB to G16B swap
Moderator: Committee
Re: Jimny G13BB to G16B swap
Great write up. There has been many 1.6 jimny's done, not sure how. AWD in melton done one about five years ago. D and G tuning have done a few too.
Rob
Rob