Ari Karhu, 1987 Suzuki SJ410

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AriK
MegaSquirt Newbie
Posts: 4
Joined: Wed Jun 14, 2006 12:34 pm
Location: Espoo, Finland

Ari Karhu, 1987 Suzuki SJ410

Post by AriK »

Name: Ari Karhu

Vehicle: 1987 Suzuki SJ410

Engine: 1298cc (G13BA), I4, Ported head and Bosch TBI injection system.

Injection: Bosch Mono-motronic (TBI), 1 injector (0 280 150 664) 530 g/min@3bar (100% Duty), Used pressure ~1.2bar, Suzuki manifold with DIY adapter plate.

Description: All problems solved so far, works like a charm! Tuning issues with idle and emissions, but hope the hires code solves this.

Website: -

Swapped engine to the SJ from a -97 Samurai. The zukis own Mikuni TBI was too funny, so swapped it to a Bosch Mono-motronic system (from VW Golf). Also the surgetank and pump was from VW. Electric carburator pump is feeding the surge tank.

Only needed to make a adapter plate to fit the bosch to the zuki manifold. Original pedal cable fitted nicely with small mods. The airfilter is a Pipercross PX300 with modded baseplate.

The head was ported and also weird "idle turbulation" airchannels were plugged with brass pipes. The intake was also ported and aligned with the head.

The coil is also from the Bosch system and features a non-smart dwell amplifier. The amplifier caused problems, so I disassebled it and intalled a VB921 driver in it.

the injector is from a Renault Clio 1.4 and also the TPS (7-pin) is from the same car. The 4-pin TPS from VW had two different scale potentiometers so couldn't use it with MS. The 7-pin has at least one full scale option.

Trying to make the idle DC motor to work with a PIC controller and H-bridge driver. Still having trouble, so at the mean time using a Bosch ISV (0 280 140 505).

Couldn't set the idle to pass the emissions test, so now I'm running the hires (hr8f) code. Let's see if it helps. Wired a 6.8ohm 50W resistor to the injector, because the hires code lacks the PWM ability. Seems to work ok...

Some images:

Adapterplate: http://www.ultimatevw.com/tmp/suzuki/g1 ... tronic.jpg
Engine fitted: http://www.ultimatevw.com/tmp/suzuki/sj410-g13ba.jpg
Intakeport with brasspipe: http://www.ultimatevw.com/tmp/suzuki/tu ... ct1297.jpg
Intake with little grinding: http://www.ultimatevw.com/tmp/suzuki/tu ... ct1292.jpg
Engine ready: http://www.ultimatevw.com/tmp/suzuki/suzuki2.jpg
The car: http://www.ultimatevw.com/tmp/suzuki/suzuki1.jpg
Igntionmodule: http://www.ultimatevw.com/tmp/suzuki/vb921-module.jpg
AriK
MegaSquirt Newbie
Posts: 4
Joined: Wed Jun 14, 2006 12:34 pm
Location: Espoo, Finland

Post by AriK »

I built a new box to the suzuki using v3 PCB and swapping a MS2 CPU.

Works pretty well! No problems so far...
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