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92-95 16v Wire Manual

1. No Image Available Gray external red TPS Mass Air Flow Sensor MAF H Natural Black yellow TPS Gray orange TPS Revision 1 Page 8 of 36 Wiring Instructions for Samurai 16v Engine Swap WIRE BY WIRE DETAILS 16v ECM Harness Deconstruction FSM Wire Color Circuit Diagram Connection ECM C1 WHT Memory Power 8A 21 0 Extract socket 1 5212 Cut wire at first splice Separate bag wire BLK YEL P Crank Signal 8 21 7 Extract socket With A C extract terminal 5223 242 Without A C cut C205 lead off segment at first splice Cut wire 3 from CPP plug Separate and bag segment PPL C1 3 Extract socket YEL C1 7 Extract socket NENNEN C200 22 Cut wire 3 from first plug Separate and bag wire BRN ME Ignition Signal Tachometer 8A 21 7 C1 8 Extract socket NS 3 C201 8 Not Used C1 11 BLU BLK C1 12 A Ignition Power 8A 21 1 BLU BLK C1 13 MR 4 FPR 2 MAF 1 C204 17 A T Donor M T install Cut TCCR lead off segment at last splice before C204 Extract socket Separate amp bag wire Extract socket Gently pry the red terminal
2. jajawopaads ul HOSN3S 03345 9191 L W Joo poou HOIO3NNOO NIT VLVG MO3HO ALNA 13A TSA Idd HOSN3S 35nv5 3NION3 lt HOLIMS NOILISOd HOLN1O OL LHM NH8 e LHSI1 35nv5 diia Page 32 of 36 Revision 1 Instructions for Samurai 16v Engine Swa Wirin Sensors 8 3 ECM ENGINE WIRING HOSN3S HOSN3S N39AXO 11 SSVIN GSLV3H ZB 82S LW 1 6106S OL 28 88S LIN c we somnquisig jeuondo t SOL HOLIMS 2 3Hnss3Hd awe ONIH33IS lt H3MOd SHOLIO3fNI Lo 1904 HOSN3S pu NOILISOd or 31IIOHHI n HOSN3S 3ATVA NS 3A1VA TOHINOO INV1009 3ound E 3NION3 E 2 5 a HOSN3S 5015 Z naL uiv 34VINI ell 21 019 2 GIONSTIOS MN A 7025 0L zi 7025 22 12 025 81 7 7025 Bg _ 7 uo Ly I 2 pus ED AS wig hum SHO 1HM
3. Vaive Siona 84215 020420 _ C Reo Senn 25 LTGRRED 2 Signal 84275 OW Revision 1 Page 16 of 36 Wiring Instructions for Samurai 16v Engine Swap WIRE BY WIRE DETAILS 16v Engine Harness Deconstruction wre cor Diegram Comecon Notes Wire Color Circuit Diagram Connection MUN WHTIGRN Injector 8 Signal 84215 02092 _ WHT BLK f Fuel Injector 4 Signa 8 21 5 209 3 Leave wires terminals and connectors in place Suo we gt omes OMPSond 02095 eromen 022 AT nsa Leave terminal and wire in place Fluid Press Switch AT Ony 84212 02098 MT instal Extract socket Abandon wire 61002 Leave terminal adwen pece OOO Note C103 Terminals should remain undisturbed along with the Distributor EGRSV EVAPSP and both ECT pigtails C100 Note 3 For M T installations the C100 and PNP connectors amp wire leads should be removed For A T installations they should remain in place Part 5 16v ENGINE HARNESS INSTALLATION 5 1 After removing any extra wires band the harness with electrical tape every 3 or 4 inches back into its original configuration 5 2 Route the harness under the Intake manifold On the front of the motor connect the Injector Harness EVAP SV amp EGR PV valves the ECT and Temp Gauge sensors Then connect the distribu
4. Nu 1 WMau ls IVYNNVS HOLIOW H3TIOHINOO HOLIMS HOLVOIGNI Sd AV 1 HOLIMS H3dlM NOLLIOI OX 01 OL 01 01 32018 jeanuieg Page 34 of 36 Hevision 1 Wiring Instructions for Samurai 16v Engine Swap 8 5 MODIFED SAMURAI POWER DISTRIBUTION Option 1 BATTERY TO Alternator es Samurai FUSE BLOCK TO Starter TOP ROW Samurai LIGHTING SWITCH Front position light L gt Tail light L Side marker light L Front position light L cam Tail light R Side marker light R Illumination light VE License light Dash lighting Horn Interior light Clock Door warning buzzer amp ECM memory Stop lights tu Head light L WHT GRN CIGAR arr Head light ic Radio Cigarette lighter HAZARD 0 WHT Hazard warning lights Samurai MAIN SWITCH Note 1 Spare Fusible Link position available for Winch Controls Air Compressor or HID Lighting additional fusing required Note 2 Spare Fuse positions available for C B Radio Stereo Amplifier Aux Lighting and other accessories TURN BACK WIPER WASHER E Turn signal
5. HA HA AHM LHM IMD ima mea 17 I n 11 2 9 ay x 2 EA cO 6l 5 2 4 0 ooccceccecet 0 j 7 teres 4 4 4 4 4 4 4 4 44 4 44 444 Page 33 of 36 Revision 1 Instructions for Samurai 16v Engine Swa Wirin ission Transmi IC 3 Speed Automat 8 4 ECM ENGINE WIRING NE 1 qomos MIM HO 1n 19 SSd3ud 55 f ANOO 3nO0HOL Gina pesf JON 8 9 6022 OS ANALE AV 14d SdWVT 3901 ANOO dOls 1 5 ANOYOL 01 i en agy ima ait Ne Sd 43050 pee i HOLIMS 8 239S i 1 S628 OL Aa 401 NH9 TIV LV LOH LYVLS NI LOH 70 C Ltttttttt el 40193135 IWNNVIN LV 2 JA I 9 A A901 LJIHS NOILYNINNTII HOLIMS NOILSOd H91IMS WHLNAN AHY d l l atl N 4O peso peso uj Auo usum A 40 OL eee cee 9 9 9 9 ee NHO NH9 THA Y18 Q3H aJ 13A dGION31OS M198 YALYVLS eec tt to INYS HOLO3NNOO NOILYNINNATII TANVd OVAH
6. Relay signal A T Only SLS 4 Feed terminal through drivers side firewall grommet Route other end along firewall down fender well harness TCCR 2 Fig 20 37 3 and back up fender in front of the battery to TCCR plug Insert terminal as indicated GRN Stop Lamp B 8 4 SLS 1 Install Donor SLS Insert Samurai terminal as indicated Stop Lamp Signal SLS 3 Insert donor terminal as indicated SURA 1 Insertdonorterminalasindicated 00 donor terminal Insertdonorterminalasindicated 00 indicated Cut End EN to cut end of Samurai GRN WHT that used to feed Shift Diode YEL BLU Shift Lock Relay B A T Only 8 4 Cut End Tap splice wire into Wiper Washer feed at or near the fuse block 52 4 12 7 BLU BLK Shift Lock Relay B A T Only 8 4 SLR 2 Route wire as necessary to reach the Shift Lock relay plug 67777 Insert terminal as indicated Revision 1 Page 29 of 36 Wiring Instructions for Samurai 16v Engine Swap 7 18 Moving back to the engine compartment zip tie or band with tape the new combined firewall ECM harness together into each respective branch DO NOT WRAP IT fully until after you get the motor running just in case 7 19 Install the center firewall ground now designated G108 Reinstall the two remaining original firewall grounds see Fig 21 37 5 and secure the harness in place with the mounting tabs 7 20 After engine installation secure the ignition components to
7. 020420 Extract Separate and bag wire O WHTIGRN Fue Injector 3 Cono ears 9092 tract Separate and bag wire 0 0 Cut 12 from ring terminal Separate and bag wire SensorGroud ars R8 C204 19 _ Extract terminals Separate and bag wire segment AIT 2 2 FN 1 6294 extract terminals separate amp bag ATH Separate wire and bag pigtail 0 0253 Extract socket Separate and bag wire _ 620422 Separate and bag wire __ 620410 Extract Separate and bag wire __ 2093 Extract Separate and bag wire Revision 1 Page 11 of 36 Wiring Instructions for Samurai 16v Engine Swap WIRE BY WIRE DETAILS 16v ECM Harness Deconstruction Cut Diagram Connection Noes C204 remaining wires ORG BLK M AWD Switch A T only 8A 44 1 C204 1 M T install Extract pin and abandon wire 1 1 5275 A T install Extract cut wire at splice and bag TBLKIWHT WfGenerator Volt Regulator Input 84 30 1 C2042 Exactpn f OlPressueSwich oma 40 0 ORG WHT Not Used Extract pins and abandon wires WHTIRED narge indicator Light Power 84201 C2047 _ YELWHT Engine Temp Gauge Signal 8A 87 1 C200 7 Cut 3 from plug Separate and bag wire Grounds G200 G201 G202 8A 14 3 C204 11 Extract pin and abandon wire YE Backup Lamp M T 8
8. SUZUKI Samurai Engine Swap Wire Harness Instructions 1992 1995 Suzuki 1 6L 16 Valve By Joel Benoit a k a warbird CONTENTS INTRODUCTION Page 2 Part 1 GENERAL INSTALLATION NOTES Page 3 Part 2 TERMINALS amp CONNECTORS Page 4 Part 3 DONOR HARNESS REMOVAL Page 5 Part 4 DONOR HARNESS PREPARATION Page 7 Part 5 ENGINE HARNESS INSTALLATION Page 17 Part 6 SAMURAI PREPARATION Page 18 Part 7 ECM FIREWALL HARNESS INTEGRATION Page 21 Part 8 WIRING DIAGRAMS Page 31 Revisions Date Description 1 4 10 3 speed Automatic Transmission Wiring and Instructions 2 pending Air Conditioning Wiring and Instructions This information is intended to assist the Do It Yourself builder The builder assumes all risk for use All information is extracted from Factory Service Manuals However the relevancy of these instructions for any given application is not guaranteed No warranty is provided on parts amp materials if included Revision 1 Page 1 o
9. not req d for swap BLK YEL 9 Signal 8A 21 6 C204 3 install Extract socket PNP C1 2 install Leave terminal amp wire in place Separate Y and Bag segment oo AT install Leave terminal amp wire in place YEL BLK Oil Pressure Switch 8A 81 1 C204 4 M T install Extract socket Separate and discard BLK Ground A T Only 0204 11 M T install Extract socket A T install Leave socket amp wire segment in place C100 5 install Extract terminal PNP 2 4 M T install Extract socket Discard segment YEL Backup Lamp M T 8A 112 0 0204 12 M T install Extract socket and abandon wire ae A T install Leave socket amp wire in place PNP Backup Lamp A T 8A 112 0 PNP C2 3 A T install Leave socket amp wire in place BRN RED Backup Lamp M T 8A 112 0 C204 16 M T install Extract socket and abandon wire DJ A T install Leave socket amp wire in place PNP Backup Lamp A T 8A 112 0 PNP C2 1 install Leave socket amp wire in place LT GRN WHT EGR SV Control 8A 21 3 C204 5 YEL WHT Engine Temp Gauge Signal 8A 81 1 C204 9 EVAPSPSund SAZIS 02040 GRY Position Sensor 2 62048 GRYIRED Reference Voliage 6v 8428 2044 Leave wires terminals and connectors in place BLU WHT TPS Idle Switch Signal 8A 21 8 204 18 CGRVVEL Sensor Grona GeO TO Ar
10. 1 Page 4 of 36 Wiring Instructions for Samurai 16v Engine Swap Part 3 DONOR HARNESS REMOVAL preferably from engine donor vehicle 3 1 Disconnect Engine Wire Harness under driver s side dash Pry out the driver s side firewall grommet and cut it off the harness take care not to damage the wires Extract under dash portion of engine harness with connectors via engine bay side Remove engine with harness attached Then remove the wiring from the engine If engine teardown is not planned the Fuel Injector harness across the top of the intake manifold may be left installed No modification to it is required 3 2 It is not necessary to totally remove all the wiring from the engine bay However disconnecting components releasing tie downs clamps etc and removing the majority of the tape amp wire loom in advance will save time in the long run 3 3 Disconnect headlights turn signals marker lights grounds and all remaining components on both fender wells and the firewall Pull retaining clip off the front of the Igniter connector amp remove the plug Unplug the Coil Dismount the bracket from the firewall leave the components attached Unplug and remove the Noise Suppressor usually taped to the harness below the wiper motor Bag the ignition components together including the Igniter plug clip and set them aside for later 3 4 Remove donor vehicle instrument cluster and dashboard use caution with air bag system It is not
11. 3 Separate and bag 4 wire C207 pigtail BLU RED Shift Interlock 8A 138 0 C201 4 SLS e Stop Lamp Switch _____ 2 Separate and bag pigtail GRN Stop Lamp Power B 8A 110 4 SLS 1 Extract socket and abandon wire GRN WHT Stop Lamp Signal 8A 110 4 SLS 3 2 3 Extract socket Bag loose SLS connector EM Cut EBCM lead off at splice C203 5 Cut wire 3 from connector SLR 1 Extract socket Separate and bag Y segment Shift Diode YEL BLU Shift Lock Relay Power 84 138 0 50 1 Cut wire at first splice 5206 BLU BLK Shift Lock Relay Power B 8A 138 0 SLR 2 Extract socket Bag loose SLR plug 802 jBag wir diode pigtail Revision 1 Page 14 of 36 Wiring Instructions for Samurai 16v Engine Swap 4 8 ENGINE HARNESS DECONSTRUCTION 4 8 1 It is not actually necessary to disassemble the engine electrical harness The only reason for doing so Is to eliminate unused pigtails It gives you a much neater looking installation Leaving this harness as is will not affect engine operation in any way 4 8 2 The instructions on the following pages provide information on cleaning up the engine harness During this process the Oil Pressure signal and Generator control wires on the new harness are abandoned in favor of the Samurai wiring which is plug n play for the new motor The rest of the pigtails are A T related 4 8 3 Wire diagram references in the deconstruction tab
12. Insert terminal as indicated Feed cut end through firewall grommet inside to outside Splice on a 10 to 12 piece of 14ga RED wire S1D Route wire along firewall harness down branch leading towards transmission Fig 21 37 4 and along underside of transmission tunnel Secure wire to rear lighting harness every 4 to 6 Cut to fit and terminate as required for fuel pump installation 7 9 ECM INSTALLATION With some minor fabrication the donor ECM can be installed on the Samurai ECM bracket Fabricate a retainer for the ECM 1 x1 8 metal stock Modify relay bracket as necessary to hold the Main amp Fuel Pump relays Remove the LH angle bracket from the top of the ECM Carefully drill out the spot welds with a 1 4 bit just enough to free the bracket CAUTION DO NOT DRILL THROUGH THE CASE Use the nut plates on the top of the ECM to bolt the assembly together Insert two short bolts or screws not shown in the top of the welded nuts on the Samurai bracket Thread them all the way through and snug them down to take up any slack between the ECM and bracket Be careful not to over tighten them and dent the ECM case Reinstall the assembly in the Samurai OEM location Revision 1 Page 26 of 36 Wiring Instructions for Samurai 16v Engine Swap At this point You should have seven 7 connectors all with female terminals and three 3 wires 18ga WHT amp YEL amp a 10ga WHT or an 8ga WH
13. Option 2 8 6 Disconnect the Samurai ignition switch Pull the old WHT YEL wire terminal out of the harness connector and replace it with the new 8ga WHT GHN wire terminal Connect the 10ga WHT to the Auxiliary Fuse Panel input SAFTEY NOTE In Method 2 the old WHT YEL wire will be hot whenever the battery is connected Insulate the exposed terminal or insert it in an unused plug housing and tie it up out of the way Note this connection makes good un fused power source for future projects 7 12 Insert the BLK RED terminal in the Main Relay connector Route the wire the new auxiliary fuse panel Install the appropriate terminal and connect it to one of the outputs Mark this location FUEL INJ and insert a 15 amp fuse 7 13 Plug in the ECM Main amp Fuel Pump relays 7 14 Use the existing wire hangars to route the new 18ga WHT amp YEL wires from the ECM along the back side of the dash brace toward the divers side 7 14 1 Feed the WHT wire up to the clock connector Fig 20 40 20 and insert the spade terminal into cavity 3 opposite existing WHT wire Note if vehicle has a clock use a tap splice instead of the spade terminal 14 2 Route the YEL wire to a point bellow the steering column Let the bullet terminal hang there for the time being 7 15 Next install the Data Link Connector in an accessible spot under the passenger side dash and connect the pigtail to the ECM harness C206 Revision 1 Page 27 of
14. RED from Stop Lamp pial 1 C206 remaining cavities Not Used none Revision 1 Page 25 of 36 Wiring Instructions for Samurai 16v Engine Swap WIRE BY WIRE DETAILS 16v ECM Harness Integration Circuit Diagram Connection 8 _ C209 5 remaining cavities WocRe TO 84 TCR Misc remaining wires BLK WHT Igniter Coil Meter Power B 8 2 Cut End BRN WHT Coil Signal Feed C209 terminal through drivers side firewall grommet inside to outside Insert as indicated Insert C209 terminal Route wire along firewall down fender well harness Fig 20 37 3 back up fender to TCCR plug see Fig 8A 201 2 Insert terminal as indicated Feed wire end and relay terminals plus SLS 2 terminal for A T Install through the firewall grommet outside to inside Insert relay terminals as indicated Splice cut end to BLK WHT from Samurai 6 pin connector pigtail S2D Route wires along firewall harness Insert terminals as indicated 8 2 Insert as indicated creates a pigtail for the Coil Insert terminal as indicated Group wire with NS pigtail IG 1 Disconnect Igniter plug Insert terminal as indicated Reconnect plug Noise Suppressor Ground 8 2 Insert terminal as indicated Group wire with NS pigtail G108 Route wire along firewall harness Ground as indicated G109 Connect to ground tab on distributor after engine installation PNK BLK Fuel Pump Power 8 2
15. Request Signal 8 2 C1 17 Feed terminal through firewall grommet Insert as indicated Route wire along firewall down fender well harness Fig 20 DCC 2 37 3 and back up fender in front of the battery to DCC plug Insert terminal as indicated BLU WHT Idle Switch Signal 1 1 18 Feed terminal through firewall grommet Insert as indicated 2744 C204 18 Route wire along firewall Insert terminal as indicated BLU ORG Power Steering Press Signal 8 3 C1 19 Feed terminal through firewall grommet Insert as indicated 2 Bullet Route wire along the firewall toward the driver s side as far Connector jas it will go Leave 1 lead off main firewall harness 1 2 Not Used none C1 21 PNP Signal A T only 8 4 C1 22 Insert socket 0204 8 Feed terminal through passenger side firewall grommet inside to outside Route to connector Insert as indicated Cut End Hang over passenger side fender BLK RED ECM C2 BLK BLU ECM Ground 8 Feed terminal through firewall grommet Insert as indicated Route wire to Igniter Disconnect plug Insert terminal as IG 2 duse indicated Reconnect plug Gur End Route wire along firewall to a point about 2 inboard of the HAC bracket Let the extra wire hang down from there Revision 1 Page 23 of 36 Wiring Instructions for Samurai 16v Engine Swap WIRE BY WIRE DETAILS 16v ECM Harness Integration BK ECM Ground 8 2 Feed ECM HO2S and CMP terminals and wires through fine
16. YEL wire is attached by a ring terminal with the mount screw to the side with only one tab The remainder of the installation is the same 7 16 3 While you have the Combo Meter out check all the indicator and illumination bulbs Replace any burned out bulbs with good ones from the donor cluster As trivial as this sounds eliminating the possibility of faulty bulbs prior to troubleshooting and or tune up will save time amp aggravation 7 16 4 Reinstall the instrument cluster Feed the 5 wire bundle down and to the right of the steering column Connect the RED WHT BLU amp YEL bullet terminals C01 to their opposites 7 16 5 Construct an 8 segment of 18ga BLK wire with a Female bullet terminal to one end and a 14 ring terminal on the other Secure the ring terminal to the existing ground point on the dash frame below and to the left of the steering column Connect the BLK wire bullet terminals C02 Revision 1 Page 28 of 36 Wiring Instructions for Samurai 16v Engine Swap 7 17 A T INSTALLATION Only 7 17 1 Route WHT RED wire from TCC Relay now under diver s side dash to the Stop Lamp Switch above the brake pedal Insert socket at position 2 7 17 2 Route BLK RED from ECM amp PNP switch under dash to diver s side Cut the Samurai BLK RED wire 3 from the Clutch Position Switch connector and splice the two ends together S24 7 17 3 Route BLU RED Y segment leads from C209 to the SLR and C201 plugs
17. insert terminals as indicated Note C201 is only used for two wires BLU RED amp BLU GRN There isn t really a need for a disconnect at this point The plug can be eliminated by cutting off the terminals and splicing the wires together 7 17 4 Once the terminals for the Shift Diode and Shift Lock Relay have all been reinserted in their respective connectors plug in the components and secure them up under the dash WIRE BY WIRE DETAILS 16v Harness Integration for 3 A T Circuit Diagram Connection 8 00 C204 support bracket just to the right of the steering column C201 10 Route C201 end of pigtail toward center console and allow it to hang just to the left of the radio C201 BLU RED shift Interlock 8 4 C201 4 nsert pins route C207 pigtail to Manual Selector Lever or BLU GRN Wl Shift Interlock 8 4 C201 10 if not yet installed that general location C207 RED YEL Lighting switch 8 4 C207 1 Route wire back up under dash behind center console Locate the Illumination lamp plug for the HVAC panel Fig Cut End 21 40 18 Tap splice the donor wire into the RED YEL wire on the main harness side of the plug S2K RED GRN Illumination controller dimmer C207 2 Route wire back up under dash behind center console Locate the Illumination lamp plug for the HVAC panel Fig Cut End 21 40 18 Tap splice the donor wire into the RED GRN wire on the main harness side of the plug S2L Stop Lamp Switch WHT RED
18. otherwise discard ECM C2 BLK BLU Ground 8A 14 2 C24 Extract socket Extract socket G110 Cut 12 from ring terminal Separate and bag segment BLK ECM Ground 8A 14 2 Extract socket C209 7 Extract pin MAF 3 Extract socket may be grounded separately G110 Cut 12 from ring terminal BLK CMP Braided Drain ground 8A 21 7 Extract pin RED BLU Exhaust O2 Concentration _ E The CMP amp HO2S signals are normally carried by shielded wires A braided drain wire is spliced to the C2 2 ground Note segment very close to the ECM connector S218 Separate the shielded wires and ground segment from the harness but leave the splices intact Bag signal wires and attached ground segment together Separate andbag wie 7 771 Separate and bag wie Revision 1 Page 10 of 36 Wiring Instructions for Samurai 16v Engine Swap WIRE BY WIRE DETAILS 16v ECM Harness Deconstruction wire color Digram Comecion Notes Wire Color Circuit Diagram Connection Son eazre ces O OoOo Separate wire bag pigtail if ground wire terminal has already been extracted Cut wire 12 from ring terminal Separate wires bag pigtail 96 Extract pin Separate and bag wire O O O OR 000 Extract pin Separate and bag wire mone Valve Control cere
19. over the fender s 7 1 3 Route the 8ga WHT YEL wire up the fender harness along the firewall and through the passenger side grommet splice it to the WHT YEL pigtail from the Samurai harness S2X Note the WHT YEL lead from the new fusible link block is more than long enough you may want to cut a few feet off the end before splicing 7 2 The 16v distributor just clears the Samurai coil bracket The new Coil and Igniter must be located elsewhere on the firewall Identify a location for the bracket on the center firewall Consider relative wire length and available hood amp engine clearance Installing the bracket upside down will maintain proper directionality of the wires and connections Temporarily install the Coil amp Igniter at or near their final location To ensure proper clearance amp wire reach final installation should not be completed until the engine is in place 7 3 Depending on the amount of slack in the new harness and or the brand of O2 sensor the sensor pigtail might or might not reach the harness connector at the firewall The exhaust must be installed to know for sure An extension cord can usually be fabricated from leftover wires w terminals and connector housings eliminating the need for splicing 7 4 During assembly lay the IAT amp MAF sensor pigtails up on the cowl under the windshield out of the way These pigtails may or may not be long enough to reach their respective sensors The induction syste
20. required for the engine swap The least confusing way but unfortunately most time consuming to separate the wiring you need from the donor harness is deconstruct it wire by wire then reassemble the parts you need The term discard is used for items that are not required for the project However it is recommended that you box up the unused wires and parts and save them for parts 4 2 Cut wires ONLY when and WHERE instructed to do so 4 3 Some wire colors may vary particularly the grounds which may be any combination of BLK BLK GRN BLK BLU or BLK ORN or all BLK The shades of a color vary also i e PPL ranges from a light lavender to a dark royal purple Age and fading only add to the problem The lighter colors white yellow light green amp orange can appear gray The darker colors blue green amp red tend toward black Oil grease amp dirt can make color identification difficult if not virtually impossible sometimes Clean things up as best you can but don t get hung up on the colors If they can t be identified tag the wires with the color they are supposed to be amp move on As long as all the components are connected correctly the actual wire color is irrelevant 4 4 The O2 sensor signal wire is always shielded and supplied with a drain wire to ground It may be shielded individually or paired with a ground The outer shell can be gray brown or blue This color doesn t matter and is not referenced in the wire diagr
21. 206 leads forming a Y segment WHT DLC Power B 8 2 C206 9 S2G Attach a 1 4 male spade terminal to the other end of the new extension wire DLC Ground 8 2 C206 5 C206 pigtail ground to old ECM ground S2H BLK YEL Crank Signal 8 2 Insert ECM wire terminal as indicated 8 2 C205 8 With A C Insert terminal as indicated Cut Lead M T Install Splice to BLK YEL wire from 6 pin plug S2B M T Install Feed the spade terminal through firewall grommet inside to outside Route wire along passenger side fender well harness Fig 20 37 3 Turn inward about halfway along the fender Providing an 8 to 10 pigtail to connect to the Starter Solenoid A T Install Feed ECM terminal through the firewall 8 4 C204 3 grommet Pull about 12 of wire through the grommet and Insert terminal as indicated 4 BLK Duty Check Ground 8 2 DLC 4 Install Duty Check Connector on Fusible Link Bracket tab Route BLK wire along WHT GRN toward the center firewall Reroute the 5GS ground wire along WHT GRN wire from the opposite direction Spice BLK wires together where they meet S1B C1 3 Feed ECM terminal through the firewall grommet Pull about 12 of wire through the grommet and Insert terminal as indicated Route other end along firewall down fender well harness DCC 6 Fig 20 37 3 and back up fender in front of the battery to the DCC plug Insert terminal as indicated IG 3 Temporally Connect pigtail t
22. 36 Wiring Instructions for Samurai 16v Engine Swap 7 16 VSS INSTALATION The VSS mounts essentially the same way in the Samurai speedometer as it does in the donor However it must be provided with independent signal amp ground wires As with other aspects of this process there are several ways to do this One of them is detailed below 7 16 1 Cut two 2 pieces of 18ga wire 1 YEL 1 BLK Attach a 1 8 female spade terminal to one end of the YEL wire and a female bullet terminal C01 to the other Attach a 1 8 female ring terminal to the end of the BLK wire and a male bullet terminal C02 to the other end 7 16 2 Take the Samurai Speedometer out of the Combination Meter Before After a Cut longer leg off VSS bracket to form a tab Shape the tab so that the YEL female spade terminal fits on it b Install the VSS and connect the YEL signal wire Group the new YEL wire with the RED WHT amp BLU Mileage Switch wires Feed them through the back of the instrument cluster housing and reinstall the speedometer C Locate the VSS ground hole on the back of the cluster housing behind the speedometer Using a screw from the donor instrument cluster attach the BLK ground wire here Group it with the YEL RED WHT amp BLU wires to form a 5 wire multi end pigtail Note In order for plastic frame units to fit properly the small cage surrounding the reed switch must be carefully trimmed away Also the
23. 6 5 Locate amp disconnect the white 1 pin connector on the heavy WHT YEL wire and the white 6 pin connector with YEL BLK BLK YEL amp BLK WHT wires located between right side of glove box amp inside of fender see fig 21 40 8 Locate amp disconnect the 2 rectangular connectors 1 natural 1 blue under the dash on the driver s side above the fuse block see fig 21 40 2 This separates wire harness No 1 from wire harness No 2 Instrument Panel Wiring 21 20 19 Pme gt tooo ta j eranc es p 4 ee H WE corre 0 t 4 t la _ paul i AS 2A A NC ELO a xf Lea 1 16 2 ws fa 2 Earth 1 Wire harness No 1 8 To stop lamp switch 15 Door warning buzzer 2 To wire harness No 2 9 To heater blower motor 16 Check relay 3 To wire harness No 2 10 To radio 17 To wiper motor 4 To fuse box 11 To heater fan switch 18 To illumination lamp 5 Horn relay 12 To cigar light 19 To optional meter 6 To combination switch 13 To radio 20 To clock 7 To clutch switch 14 To ECM 21 To meter Fig 21 40 Note 1986 through 1988 Samurais with the round vent dash have an 8 pin connector instead of a 6 pin Fig 21 40 3 6 6 Remove the Combination Meter instrument cluster 6 7 Pry the firewall grommets out the engine bay side see Figure 21 3
24. 7 6 Be careful not to damage them Then gently pull the connectors on both ends of the firewall harness out of passenger compartment Let the wire bundles grommets and connectors hang over their respective fenders outside the vehicle 6 8 Unplug everything else on the firewall Remove the Ignition Coil Fig 21 37 16 Thermal Engine Room Switch fig 21 37 14 High Altitude Compensator Fig 21 37 15 and Noise Suppressor not shown Also disconnect the Brake Fluid Level Switch above the reservoir Fig 21 37 17 This allows the firewall harness more freedom of movement Revision 1 Page 18 of 36 Wiring Instructions for Samurai 16v Engine Swap 6 9 Disconnect the three firewall grounds see Fig 21 37 5 The 3 is behind the Coil near the center of the firewall 6 10 Loosen the firewall hanger loops by bending them down gently Pull the harness away from the firewall as much as possible This gives you room to work Note the wire harness branch that leads under the transmission tunnel Fig 21 37 4 It prevents the firewall harness from being completely removed from the vehicle With all the plugs disconnected and the clamps undone there should still be plenty of slack 6 11 Expose the wires by removing the tape amp plastic wire loom from the old harness Then unwind the internal tape that bundles the wires together Engine Room Wiring 6 5 15 14 13 12 1 Wire harness No 2 Battery T
25. A 112 0 M T install Extract pin and abandon wire PNP Backup Lamp A T 8A 112 0 A T install Extract pin Sap ap S208 A T install Cut at first splice and bag wire BRN RED Backup Lamp M T 8A 112 0 M T install Extract pin abandon wire bag C204 plug PNP Backup Lamp 8 112 0 A T install Extract Bag C204 plug C2032 2 203 2 A T install Extract pin Bag wire C206 remaining wires otter SSCS SSC RN 22427 0 WT RWAL Brake Spood Sensor 54440 C2067 bxracpiamdabadonwie 02 WHT Diagnostic Tool Power 8A 44 0 212 Cut at first splice and separate wire C209 2 remaining wires BLU RED Signal A T Only 8A 138 0 C209 6 install Extract and abandon wire SLR 3 A T install Extract terminals Separate and bag Y C2014 4 segment ee TCCR 4 install Extract socket Bag wire Revision 1 Page 12 of 36 Wiring Instructions for Samurai 16v Engine Swap WIRE BY WIRE DETAILS 16v ECM Harness Deconstruction Diagram Connection Misc remaining wires BRN WHT Coil Signal 8A 21 7 IGT 1 Extract socket Bag ORG wire pigtail pma socket Bag connector Ignition Ground 8A 21 7 Bag Y Segment and NS plug as a pigtail G109 09 oe Separate wire and bag relay pigtail BLK WHT Bu wHT Pfigniter Coil 8 Meter power 8A 17 7 2019 J Coil
26. AF 2 war ee side Set pigtail aside on cowl BLK BLU E independent ground MAF 3 Insert terminal as indicated Route wire along firewall Group with ECM grounds 222422 929448 Poste wire long Insert terminal as indicated ____ JNetUsed ttn 94 Route wire long Insert terminal as indicated LTGmWMK AC Valve Conr Feed terminal through grommet Insert as indicated 2242 0206 12 Route wire long Insert terminal as indicated WHTIGRN Fucl injector 8 Cono 0218 Feed terminal through firewall grommet Insert as indicated ee 5 NN C214 14 Insert Insert ECMterminalasindicated terminal Insert ECMterminalasindicated indicated peer Feed end through firewall grommet inside to outside Route wire along firewall Group with other ECM grounds FGRvEL SensorGround 0215 Feed terminal through firewall grommet Insert as indicated 1 C206 6 Insert other end into C206 pigtail as indicated Revision 1 Page 24 of 36 Wiring Instructions for Samurai 16v Engine Swap WIRE BY WIRE DETAILS 16v ECM Harness Integration Circuit Diagram Connection 00 RED GRN EGR Temperature Input 8 3 C2 17 Feed terminal through firewall grommet Insert as indicated C209 1 Route wire along firewall Insert terminal as indicated 2 1 Not Used none C2 19 RED BL
27. K Inlet Air Temperature Signal 8 3 C2 21 Feed terminal through firewall grommet Insert as indicated Route connector wire along firewall harness toward driver s IAT 1 side Set pigtail aside on cowl PNK HO2S Heater Control 8 3 C2 23 Feed terminal through firewall grommet Insert as indicated 1 25 3 wire along firewall Insert terminal as indicated LT GRN RED VA Fuel Injector 2 Control 8 3 C2 24 Feed terminal through firewall grommet Insert as indicated C204 22 Route wire along firewall Insert terminal as indicated LT GRN YEL EVAP SP Valve Control 8 3 C2 25 Feed terminal through firewall grommet Insert as indicated 1 2204 10 wire along firewall Insert terminal as indicated WHT BLK VA Fuel Injector 4 Control 8 3 C2 26 Feed terminal through firewall grommet Insert as indicated 1 C209 3 Route wire along firewall Insert terminal as indicated C204 remaining wires amp cavities ORG BLK 4WD Switch A T only 8 4 C204 1 Insert pin route wire to firewall 1 Cut End Splice to BLU BLK from Samurai 4WD Indicator S1H Not Used none YELIWHT Engine Temp Gauge Signal 8 4 Feed wire through firewall grommet Splice to YELAWHT from 6 pin Plug S24 9 Splice to BLK ground from Samurai 4WD indicator S1G YE Wrony 84 inser pin route wre to frewa 221277 Spice to VEL Stop Lamp paat SIE Splice to
28. L Wiper motor BLU Washer pump YEL cer Rear Defog LT gt Heater fan motor IG COIL METER Note Spare Fuse positions available for C B Radio Stereo Amplifier Aux Lighting and other accessories FUEL INJ AUXILIARY FUSE PANEL Revision 1 Igniter Gauges BLK Relay coils HO Sensor heater BLK RED Main Relay Page 36 of 36
29. SYMBOLS COMPONENTS Fuse 15 Amp oolenoid Temperature Sensor Heated O2 Sensor Reed Switch Relay Et Noise Suppressor 2 1 Ignition Coil Distributor Spark Plug Rotation Indicated WIRING 295 Donor OEM Splice _ e G16B Ground 110 Project Splice QS Project Ground G02 C204 Samurai Ground H Donor LL Connector amp TO Terminals Off Diagram Link H d SWITCH Samurai Plug W Project Terminal Samurai Firewall lt inside outside gt Project Connector inm Grommet G PSG Passenger Side Grommet DSG Driver Side Grommet Revision 1 Page 31 of 36 Instructions for Samurai 16v Engine Swa Wirin ission Manual Transm ECM ENGINE WIRING 8 2 2 Sma AAV dS rZ 1 i v geeg STS OL 7225 933 usep HOLO3NNOO NIT VLVG 9I SAWIL 11V LV LOH SAIL T1V lv LOH Nhu LYVLS NI LOH MOD 6515 49014 3513 SHIELD SHIELD YyOLNGlYLSIG 9 9 cz NHH 13A SN Id LHM NHH Hali GION310S wossaudns 3913915 3SION 5 LHM W1a wala OS8NWOD N 3 42 5 lt
30. T GRN hanging over the passenger side fender to the right of or inside the grommet A T installs will have an additional BLK RED wire ECM C1 22 pin yellow ECM C2 26 pin yellow Main Relay 4 pin color varies Fuel Pump Relay 4 pin color varies Harness Connector 6 pin w wires OR 8 pin w 8 wires white or natural Battery Harness Connector 1 pin white or natural C206 8 pin w 3 wires white or natural On the driver s side there should be two 2 connectors one white one blue and possibly 8ga WHT GRN wire A T installs will have an additional BLU RED Y segment plus a WHT RED wire Both with female spade terminals Near the center firewall there should be a group of either three 3 or four 4 ground wires hanging together 7 10 Feed the connectors amp wires on both sides into the passenger compartment Reinstall the grommets and mate the 8ga WHT YEL and 6 pin connectors their opposites by the glove box Fig 21 40 3 Connect the white amp blue connectors to their mates on the diver s side above the fuse block Then make the independent wire connections outlined below 7 11 Depending on which power distribution option is chosen Either the 8ga GRN WHT or the 10ga WHT wire from the new fusible link block becomes the primary power source for operating the engine Option 1 8 5 Install appropriate terminal on the 8ga GRN WHT wire and connect it to the Aux Fuse Panel input
31. Valve HO2S Heated Oxygen Sensor WOT Wide Open Throttle Switch Read the instructions all the way through before beginning Failure to do so may cause irreversible damage to the harness or engine components Revision 1 Page 2 of 36 Wiring Instructions for Samurai 16v Engine Swap Part 1 GENERAL INSTALLATION NOTES SAFTEY WARNING ALL WIRING SHOULD BE DONE WITH THE BATTERY REMOVED FROM THE VEHICLE 1 1 It is HIGHLY RECCOMMENED that you purchase the appropriate Field Service Manual for your engine model year either digital or print copy Though there are only two sections that are relevant to a transplanted engine the information is absolutely invaluable Much but not all of the required Information is also available in most aftermarket vehicle specific service manuals Haynes Chilton s etc The pertinent sections 6 amp 8 of the 1996 Tracker FSM may be downloaded for free from Acksfaq com donations are appreciated 1 2 1992 through 1998 Suzuki Geo GM vehicles with G16B 1 6 liter 16 valve engines can be identified by the 8 digit in the Vehicle Identification Number 0 for Suzuki badged vehicles 6 for Geo s U indicates an 8 valve 1 6L 1 3 The most common set up and arguably the simplest mates a donor Tracker or Sidekick engine with the Samurai 5 spd Manual Transmission Donor engines with Automatic Transmissions 3 or 4 A T are easily rewired to work with the Samurai 5
32. a Insert Relay terminals indicated FPR 2 204 17 Feed terminals through firewall grommet Route wires along MAF 1 firewall Insert terminal as indicated A T Install Re install Relay on Fusible Link bracket see Fig 8A 201 2 Feed terminal through firewall grommet 1 inside to outside Route wire along firewall down fender harness Fig 20 37 3 back up fender in front of battery to 8 8 relay Insert terminal as indicated Temp install plug 8 PPL YEL PACEL MIL Control Cut Lead Splice to BRN BLK wire coming from the driver s side S14 Feed ECM terminal through firewall grommet Insert as C1 14 indicated Route wire along firewall down fender well harness Fig 20 DLC 3 37 3 and back up fender in front of the battery to DCC 3 4 2 plug Insert terminal as indicated 3 LT GRN WHT EGR SV Control 8 C1 15 Feed terminal through firewall grommet Insert as indicated Route wire along firewall harness toward the driver s side C204 5 as it will go Insert the terminal as indicated Leave 4 lead off main firewall harness WHT YEL TCCR Control A T only 8 4 C1 16 Feed terminal through firewall grommet Insert as indicated Route wire along firewall down fender well harness Fig 20 TCCR 3 37 3 and back up fender in front of the battery to relay Remove plug Insert terminal as indicated Temporarily re install connector BLU YEL Diagnostic
33. absolutely necessary to remove the dash but its well worth the time and aggravation it saves Set the instrument cluster aside so the VSS can be extracted later 3 5 Remove the Data Link bracket amp connector s from under the diver s side dash Disconnect the pigtail at C206 Bag it and set it aside Note some vehicles will have two plugs on this bracket The second is a Data Link for the Rear Wheel Anti Lock Braking system Removing this pigtail is optional 3 6 Unplug the ECM amp Fuel Pump Relay under driver s side dash Remove the mount bracket with ECM and relays attached Separate the computer and relays from the bracket and set them all aside 3 7 A T Installations Only 3 1 The wire harness on the transmission itself should remain essentially undisturbed 3 7 2 If not already done disconnect the Manual Selector Lever harness at C207 Then remove the whole lever assembly Note This assembly includes the Shift lock Solenoid 3 3 There are also some key components and wiring under the donor dash that must also be removed for an A T swap These items are located above and behind the brake pedal Wire details are listed at the end of each relevant table Unplug and dismount the following items bag for later use a Stop Lamp Switch GRN BLK WHT GRN WHT WHT RED wires b Shift Diode YEL BLU amp BLU BLK wires c Shift Lock Relay wires are GRN WHT BLU BLK BLU RED BLU GRN 3 8 Disengage the ECM under dash ha
34. ail for later sale BLU WHT WA Vent Solenoid Valve Gv Oxygen Sensor C1 10 Cut drain wire at splice Pull sensor wire through grommet 1 774 BRN BLK signal 1 17 wire through grommet Separate wire and set aside for 1 GRN RED SY 5th Gear Switch 5GS C1 19 through grommet Separate segment Extract BLK 5th Gear Switch Ground ERE LL ground terminal reserve for future use Discard pigtail LT GRN Check Terminal C1 20 Pull wire through grommet Separate and discard pigtail ECM Ground C1 21 Pull wire through grommet Separate and discard segment BLK WHT Ignition Coil Meter Power Pull terminal and cut end through grommet Separate segment Pull terminals as necessary Cut all Generator extraneous leads off at splices leaving a 1 wire segment leading from the driver s side to the alternator plug Distributor Extract terminal Separate and discard Y segment amp Noise Suppressor Stop Lamp Power B SLS 1 A T install only Extract sockets remove Stop Lamp Switch GRN WHT Stop Lamp Signal 515 2 amp connector Cut off GRN WHT wire terminal from drivers side where it turns down the center firewall Revision 1 Page 20 of 36 Wiring Instructions for Samurai 16v Engine Swap Part 7 ECM FIREWALL HARNESS INTEGRATION 7 1 POWER DISTRIBUTION UPGRADE 7 1 1 Install the new fusible link block bracket on the Samurai right fender well in the same relative positi
35. amp Meter power B 8 11 7 C201 9 9 1 1 Extract connector terminals a 4 E 1 2 segment out of the harness 3 from fuse block A T Donor M T install Cut Stop Lamp switch lead off at first splice A T Donor A T Install Extract socket from Stop Lamp Switch connector 5131 Cut lead to C201 connector at 27 splice if present 5132 Cut lead to C204 connector at 3 splice where 25 Coil amp NS leads amp leads join the segment Bag remaining segment the segment Bag remaining segment Revision 1 Page 13 of 36 Wiring Instructions for Samurai 16v Engine Swap WIRE BY WIRE DET AILS 16v Harness Deconstruction for 3 A T rri P Extract sockets and abandon wires Reve Warring racao 24411 6075 TaiDomeB sarro _ PPURED ignition Switch Bulb Test 8A 41 0 0201 10 Separate wire bag pigtail __ GR RED Extract pins and abandon wires RED YEL Light Switch PARK 8A 114 0 falDomeB Ignition Switch Bulb Test 8A 41 0 Extract pins and abandon wires BLK WHT Igniter Coil Meter B 8A 11 7 C201 9 BLU GRN Shift Interlock 8A 138 0 201 10 Extract pin Bag connector with others C207 RED YEL Interior Lighting 8A 114 1 C207 1 Cut wire at first splice S291 RED GRN Interior Lighting 8A 114 1 C207 2 Cut wire at first splice S268 BLU GRN B Shift Interlock 8A 138 0 C207
36. ams The inner sensor wires also vary between WHT RED BLU or YEL BLU If paired with a colored wire the ground wire is usually GRA YEL If a ground wire is paired with WHT it is usually BLK 4 5 The Cam Position Sensor is located inside the Distributor The FSM shows the CMP signal carried on a shielded wire Like the O2 sensor there should be a braded drain wire to contend with However this is not always the case If the wire is not shielded no special handling is required 4 6 VARIABLE SPEED SWITCH EXTRACTION 4 6 1 Disassemble the donor Combo Meter instrument cluster and remove the speedometer The VSS assembly fits across the top of the speedometer frame The reed switch itself sits behind the rotating disk There are two types but they both fit in the same relative position a he metal frame assembly is secured in place by two screws on one side and a tang on the other Removing the screws allows the assembly to rotate up and out of the speedometer frame b The plastic frame type is secured by a screw on either side Removing the screws allows the assembly to lift straight up and out of the speedometer frame Revision 1 Page 7 of 36 Wiring Instructions for Samurai 16v Engine Swap 4 7 ECM FIREWALL HARNESS DECONSTRUCTION 4 7 1 Starting with the smaller ECM connector C1 extract the wire terminals and separate the wires one at a time unwrapping the harness as needed When you reach a connector record the termi
37. e A C relays for spare parts and put the bracket with the fuse link block 3 10 3 Dismount the Fuse Block under diver s side dash Cut the 8ga WHT YEL amp WHT GRN the 10ga WHT and 14ga BLK RED wires approximately 3 to 4 from their respective fuse terminals Follow the RED BLK wire to the Main Relay Unplug connector and extract the wire terminal Bag the wire 3 10 4 Disconnect the Ignition Switch pigtail Extract the terminal on the other leg of the WHT GRN wire from the connector 3 10 5 Pull the other three wire segments WHT YEL WHT GRN amp WHT through the firewall from the engine bay side Unwrap donor harness if not already done as needed and separate the wire segments from the firewall harness 3 10 6 After separating the C1 amp C2 pigtails remove the lead with the cut end from the WHT GRN segment at the splice 8276 Expose the splice cut off the extra wire and re insulate the splice Bag the Fusible Link C1 1 wire and C2 2 wire pigtails separately S118 1 REAR WASHER PUMP HARDTOP LSi 5 FUSIBLE LINK BOX 2 FRONT WASHER PUMP 6 DUTY CHECK DATA LINK CONNECTOR DLC 3 TORQUE CONVERTER CLUTCH TCC RELAY A C FUSE HOLDER AUTOMATIC TRANSMISSION Al 2 CONDENSER FAN RELAY CLUTCH RELAY Figure 8A 201 2 Revision 1 Page 6 of 36 Wiring Instructions for Samurai 16v Engine Swap Part 4 DONOR HARNESS PREPARATION 4 1 50 to 70 percent of the donor harness is not
38. f 36 Wiring Instructions for Samurai 16v Engine Swap INTRODUCTION Much has been written about swapping Suzuki s G16B 1 6 liter 16 valve engine into the Samurai It is mechanically very simple as engine swaps go but the wiring can be a daunting challenge for many To date it has been necessary for the DIY builder to perform extensive research gather all the information they can find try to make sense of it and take their best shot or pay someone that has already done it There is no one correct way to make this engine swap The variations are nearly endless Much of it involves personal preference What is presented here is a process that is known to be successful along with some of the more familiar options This article is not intended to be the definitive work on the subject matter but rather as a starting point for the compilation of collective knowledge have tried to present this as a basic technical manual It should be factual and unbiased If you disagree with any of the content or presentation will be more than willing to hear you out This is a living document It will be updated probably annually with relevant contributions and corrections from the Suzuki enthusiast community Please e mal all communication pertaining to this manual to Zuki oe hotmail com Abbreviations AIT Automatic Transmission IAC Idle Air Control valve 4AT 4 Speed Automatic Transmission pm Intake A
39. firewall grommet Be careful with the drain wire splices linsen ground wire terminals as indicated Route wire along the firewall harness toward the driver s as far as it will go Insert terminal as indicated Leave 6 lead off main firewall harness MAF 3 Route to MAF connector may have separate ground Cut Lead Route wire along firewall harness Group with C2 1 ground wire above WHT CMPSensorSignal 82 C23 msettermmalasindcated CMP Sensor Signal C23 3 Insert terminal as indicated T peses C209 5 Route wire along firewall Insert terminal as indicated Drain Wire 8 2 C209 4 Insert terminal as indicated YEL BLU C220 20 Insert terminal as indicated terminal Insert terminal as indicated indicated RED BLU Exhaust O2 Concentration 8 3 2 Route wire along firewall harness toward the driver s side as far as it will go Leave 2 lead off main firewall harness WHT C25 5 GRY RED JA Throttle Position Signal 8 3 Feed terminal through firewall grommet Insert as indicated 77771 C204 14 Route wire along firewall Insert terminal as indicated GRY Reference Voltage 5V 8 3 Feed terminal through firewall grommet Insert as indicated 1 C204 13 Route wire along firewall Insert terminal as indicated GRY BLK MAF Signal 8 3 Feed terminal through firewall grommet Insert as indicated Route connector wire along firewall toward the driver s M
40. he computer Either way wire splicing should be kept to an absolute minimum What splices there are should be staggered along the course of the harness to reduce the potential for shorts if they do come apart 1 7 In some cases it is easier to leave one or more wires attached to certain connectors These assemblies are referred to as pigtails The wire s may be attached to a component have terminals or be cut on one end But generally there will only be one plug 1 8 In these instructions multiple wires that are spliced together in various Y configurations are referred to as segments The wires may be cut or have terminals on the ends but usually won t have any plugs attached 1 9 Clear plastic zipper bags are probably the best way to organize this project Individual wires usually fit in snack size bags wire segments and pigtails in quart size bags The bagged wire for the entire project fits is a copy paper box The unused wire can be stored in an additional box roughly the same size 1 10 Don t cut any more wire than you have too Leave all pigtails and wire leads as long as physically possible Double back any excess wire on itself and incorporate it into the harness you may want or need it later 1 11 It is possible to swap both the 16v A C and P S systems into a Samurai together It requires special brackets and or repositioning the entire motor Most builders opt for just the P S Wiring instructions for Air Conditio
41. ir Temperature sensor 5GS Fifth Gear Switch IMS Idle Micro Switch CEL Check Engine Light Idle Up Solenoid CMP Cam Position Switch M T Manual Transmission Clutch Position Switch MAF Mass Air Flow Sensor DCC Duty Check Coupler MAP Manifold Absolute Pressure sensor DLC Data Link Connector MCS Mixture Control Solenoid ECM Engine Control Module MR Main Relay ECT Engine Coolant Temperature NS Ignition Noise Suppressor Filter EGR Exhaust Gas Recirculation Power Steering EGRS EGR Solenoid Park Neutral Position Switch A T only EGRSV EGR Solenoid Vacuum Valve O2S Oxygen Sensor EGRT EGR Temperature OLG Stop Lamp Switch ETS Engine Temperature Sensor for gauge SLR serra Shift Interlock Relay A T only EVAP Evaporative Emissions System TCCR Torque Converter Clutch Relay A T only EVAPSP EVAP Solenoid Purge Valve TERS cu Thermal Engine Room Switch Fuel Cut Solenoid Thermal Switch FPR Fuel Pump Relay TPS Throttle Position Sensor FPS Fluid Pressure Switch Vent Solenoid Factory Service Manual VSS Variable Speed Sensor HAC High Altitude Compensator VSV Vacuum Switching
42. lade screw driver and a little patience works just as well see Fig A Connector Face Leverage 0 Terminal Note It takes very little pressure to release the terminals but it does take a bit of finesse You have to pry the lock tab and pull the terminal out all in one motion Prying or pulling too hard will cause more resistance and may damage the terminal the connector or worst case pull the wire out of the terminal Figure A 2 3 Some plugs have a Terminal Positioning System TPS The TPS can be integrated into the connector housing like the ECM plugs which are hinged to the back of the housing or it can be a physically separate part Some are internal some are external Generally these are different color than the connector body The TPS if present must be removed to access the terminal lock tabs TPS Closed Installed TPS Open Removed Note Photo of external TPS connector not available at time of publication 2 4 For Suzuki vehicles The 100 series of connectors splices and grounds are located under the hood The 200 series is under the dash The 300 series is in the passenger compartment and the 400 series is in the rear of the vehicle Project splices are marked on the diagrams with red diamonds and are numbered similarly The 1 alpha series is located under the hood and the 2 alpha series is under the dash based on where they end up not where the splicing physically takes place Revision
43. les are from the 1995 Geo Tracker Service Manual GMT 95 JE They are provided to assist builders who have access to an FSM Prior model year manuals should have similarly numbered diagrams 4 8 4 To assist with identification images of the relevant connector faces are provided below ENGINE HARNESS CONNECTOR FACES Natural Note the 4A T has a plug that more closely resembles C204 EGR Solenoid Purge Valve EVAP Solenoid Valve EGR SP EVAP SV T En Distributor C100 A T only gums Gray orange TPS Natural Round 1x2 Plug No Image Available Natural Natural Revision 1 Page 15 of 36 Wiring Instructions for Samurai 16v Engine Swap WIRE BY WIRE DETAILS 16v Engine Harness Deconstruction FSM Wire Color Circuit Diagram Connection C200 ORG BLK Switch A T only 8A 44 1 C204 1 M T install Extract socket Separate and discard wire A T install Leave terminal amp wire in place BLK WHT Gen Voltage Regulator Signal 8 30 1 C204 2 sockets Separate wires and bag 2 wire pigtail with WHT RED JS Charge Indicator Light Signal C204 7 green plug attached Marketable item
44. lights is Back up lights YEL Wiper motor BLU Washer pump YEL cer Rear Defog LT TO Clutch or E 15 gt PNP Switch HEATER IG COIL METER FUEL INJ AUXILIARY FUSE PANEL Revision 1 7 Heater fan motor Igniter Gauges BLK Relay coils HO Sensor heater BLK RED Main Relay Page 35 of 36 Wiring Instructions for Samurai 16v Engine Swap 8 6 MODIFED SAMURAI POWER DISTRIBUTION Option 2 Samurai FUSE BLOCK TO Starter TOP ROW BATTERY TO Alternator Front position light L gt Tail light L Side marker light L Front position light L cam Tail light R Side marker light R Illumination light VE License light Dash lighting Horn Interior light Clock Door warning buzzer amp ECM memory Stop lights tu Head light L WHT WHT WHT RADIO CIGAR arr Head light eK Radio Cigarette lighter modified HAZARD WHT D 10 TURN WHT gu em BLU m f 1 BLK PLU WHT 7 BLU WIPER WASHER BLK YEL RED Samurai MAIN SWITCH TO Clutch or PNP Switch EUR HEATER WHT Hazard warning lights Turn signal lights is Back up lights YE
45. lock off the back of the connector housing Separate wire Extract socket Extract socket Separate and bag wire Extract socket Extract socket Separate and bag wire Extract socket Follow to remaining connector Extract and cut terminal off wire Separate and bag wire segment Extract socket Extract terminal Separate and bag wire Extract socket Extract socket Separate amp bag wire Extract terminals Separate amp bag wire segment A T Donor A T install Extract socket Separate amp bag entire wire segment DCC 3 Extract socket C200 2 Cut wire 3 from plug Separate bag Y segment Revision 1 Page 9 of 36 Wiring Instructions for Samurai 16v Engine Swap WIRE BY WIRE DETAILS 16v ECM Harness Deconstruction FSM Wire Color Circuit Diagram Connection LT GRN WHT GRN WHT EGRSVControl 84 21 3 SV Control 8A 21 3 C1 15 Extract socket WHT YEL TCC Relay Control A T only 8A 21 3 C1 16 socket TCCR 3 Extract socket Separate wire Bag for A T install otherwise BLU YEL Diagnostic Request Signal 8A 21 1 C1 17 Extract socket BERE Extract pin Separate segment Cut C206 lead off of segment at splice 8279 and discard Bag remaining wire O28 Separate and bag wire 7 22 JNoUsed etn C204 8 Extract pin IGS 6 Cut wire 3 from Ignition Switch pigtail Separate wire segment Bag for A T install
46. m must be installed to determine if extension is required 7 5 When pulling the new wires through the Samurai firewall grommets the side that faces the engine bay is considered the outside Unless noted otherwise most of the wires are fed from the outside to the inside 7 6 Again working at the Samurai passenger side fender build the new ECM and Relay pigtails according to the tables on the following pages There should be 10 to 12 of wire between the ECM connectors and the firewall grommet The relay pigtails need to be about 2 longer The splices for the WHT YEL BLK YEL YEL WHT and BLK WHT wires should all be made on the inside of the grommet so they wind up under the dash 7 7 During A T installations as the under dash wiring and components are reassembled their relationship to the new Samurai environment will become apparent The Shift Diode and Shift Lock Relays can be secured in place under the dash wherever they end up Taping them to a nearby wire bundle is perfectly acceptable 7 8 Using the Integration Tables on the following pages and the wiring schematics in Part 8 incorporate the new wiring into the Samurai harness Revision 1 Page 21 of 36 Wiring Instructions for Samurai 16v Engine Swap WIRE BY WIRE DETAILS 16v ECM Harness Integration Circuit Diagram Connection 8 00 0 ECM C1 WHT Memory Power 8 2 Insert terminals as indicated Splice a 4 piece of white 18ga wire to both the ECM amp C
47. nal position and extract the terminal If the wire branches off follow each branch to a connector and pull the terminal After separating each wire segment and or pigtail coil the wire loosely and place it in a small zipper bag Bag all wires by color ID and tag the connectors as they are released from the harness The loose plugs can all be bagged together Apply the same process to the Larger ECM Connector C2 and work your way through the Wire by Wire Deconstruction Tables on the following pages from there 4 7 2 Wire diagram references in the deconstruction tables are from the 1995 Geo Tracker Service Manual GMT 95 JE They are provided to assist builders who have access to an FSM Prior model year manuals should have similarly numbered diagrams wire colors may differ slightly 4 7 3 To assist with identification images of the relevant connector faces are provided below 16v ECM HARNESS CONNECTOR FACES Data Link Connector DLC A AATTEET EN o Hn mug gH B TTR mam ma Main MR amp Fuel Pump FPR Torque Converter Clutch amp Duty Check Data Link Connector Shift Lock SLR Relays DCC A T only 844 A ft Eel MALE PLUG PIN POSITIONS REVERSED Natural Natural Note the 4A T has a plug that more closely resembles C204 Igniter Rectangular 1x3 Connector
48. ning are not included at this time 1 12 The instructions will make considerably more sense if you take time to thoroughly review and understand the wiring diagrams see Part 8 Revision 1 Page 3 of 36 Wiring Instructions for Samurai 16v Engine Swap Part 2 TERMINALS amp CONNECTORS 2 1 It is essential to the success of the project that you master releasing amp reinserting connector terminals The wires with terminal attached can be routed places the connector bodies will not fit in particular the firewall grommets Cavities are numbered left to right amp top to bottom as viewed at the female connector face The locking tab identifies the top For wire to wire connections the male connector cavity numbers are a mirror image of their female counterpart The sex of a connector is determined by the pins and sockets not the shape of the housing 2 2 Most of the connectors you ll be working with are the Push to Seat type To remove release the locking tab from the front of the housing and the terminal comes out the back To install push the terminal into the cavity from the back until the locking tab seats there is often a faint but audible click Pay particular attention when disassembling the connectors to the orientation of the terminals in each plug If they are reinstalled upside down they can get stuck in the cavity and will not mate properly There are special tools designed for this purpose but a small jeweler s flat b
49. o Igniter do not install lock clip Route the other end along the firewall harness toward the C1 4 passenger side Feed ECM terminal through the firewall grommet and Insert as indicated PNK IE Fuel Pump Relay Control 8 2 C1 5 Insert terminal as indicated FPR 3 Insert terminal as indicated C1 6 Feed terminal through firewall grommet Insert as indicated Install DCC on Fuse Link bracket see Fig 8A 201 2 Route wire end along firewall down fender well harness Fig 20 37 3 and back up fender in front of the battery to the DCC Insert terminal as indicated Insert ECM wire terminal as indicated Splice on a 4 piece of white 18ga YEL wire S2C Attach a male bullet terminal to the other end C01 BRN Ignition Signal Tachometer 8 2 Cut End firewall grommet Insert as indicated BLU Main Relay Control 8 2 C1 10 Insert terminal as indicated MR 3 Insert terminal as indicated Starter Solenoid PPL Co No Duty Check Output O RG Co No Igniter Driver Output BLU RED Switch Signal 8 2 DCC 5 Co No YEL VSS Signal YEL BLK Idle Up Signal 8 2 e RT Revision 1 Page 22 of 36 Wiring Instructions for Samurai 16v Engine Swap WIRE BY WIRE DETAILS 16v ECM Harness Integration Circuit Diagram Connection _ _ Not Used C1 11 BCM BEN JEON d Insert ECM terminals as indicated BLU BLK Ignition Power 8 2 C1 13 8 2 MR 4
50. o starter alternator head light small light horn and etc To license light stop tail light 4WD switch Earth To wiring harness No 1 To head light small light etc To distributor To ignition coil To back up light switch To fifth switch gt gt Fig 21 37 6 12 Working at the passenger side fender TWSV Duty check coupler Thermal engine room switch HAC Ignition coil Brake fluid reservoir 6 12 1 Create a single wire pigtail by cutting WHT YEL wire 8 to 10 from the plug Bag pigtail and set aside 6 12 2 Create a 3 wire pigtail with the BLK WHT BLK YEL amp YELANHT wires and the 6 pin plug Cut wires 8 to 12 from the plug staggering the cuts approximately 2 apart Bag the pigtail 6 12 3 Extract all the terminals from the old ECM connector Deconstruct the rest of the harness per the following table Hevision 1 Page 19 of 36 Wiring Instructions for Samurai 16v Engine Swap WIRE BY WIRE DETAILS Samurai Harness Deconstruction WireColor Circut Connectin Notes 1 70 driver s side grommet GRYVEL Open Throne swen Gave f ide moo sma _ _ M M a PNGRLK p HohAludeCompensaor rensaeos 08 BRN WHT 3 Idle Up Solenoid Pull wire through grommet Separate segment Cut BLK WHT lead at first splice Bag pigt
51. on it was located in the donor Plug the 2 pigtails WHT YEL amp WHT GRN WHT into the bottom and install the fuse block a Ifthe original bracket is not available use the old air box bracket inside the right fender fwd of the battery to attach one side of the new fuse block Fabricate a simple bracket or use a long bolt amp spacer to secure the other side to the top of the fender well Leave about 1 5 of room underneath for the connectors 7 1 2 There are two methods for wiring in the new Fusible Link Block the one depicted in diagram 8 5 works for all Samurai model years The arrangement shown in 8 6 offers better load distribution but only works on 1988 5 amp up models In either case it is necessary to mount an aftermarket fuse panel under the dash The capacity is up to the builder but a minimum of one 1 additional fuse is required The new fuse panel should be located on the passenger side near the ECM amp Relays Option 1 8 5 Cut the terminal off the end of the 8ga WHT GRN wire opposite the connector Route the wire up the fender harness along the firewall and through the passenger side grommet Leave wire hanging outside over the fender Option 2 8 6 Route the 8ga WHT GRN wire w terminal up the fender harness along the firewall and through the driver s side grommet Route the 10ga WHT wire up the fender harness along the firewall and through the passenger side grommet Leave both wires hanging outside
52. rness Start at the ECM connectors and follow the wiring from there Remove clamps brackets ties tape etc as necessary disconnecting plugs as you go Note Many of the wires lead through the firewall to components in the engine bay DO NOT CUT ANY WIRES Extract connector terminals as necessary to free wire ends allowing them to be disentangled 3 9 Pry the remaining firewall grommet s out the engine bay side and cut them off of the harness Take care not to damage the wires Then extract the entire ECM harness from inside the vehicle carefully feeding the engine bay wires and connectors through the firewall openings Revision 1 Page 5 of 36 Wiring Instructions for Samurai 16v Engine Swap 3 10 POWER DISTRIBUTION UPGRADE PARTS Though not technically part of the engine swap this is definitely the ideal time to modernize the Samurai s primary power distribution system To do so remove the following parts from the donor vehicle 3 10 1 Dismount the Fusible Link Block Fig 8A 201 2 5 Remove the cover and disconnect the alternator amp battery leads Unplug the two connectors on the bottom C1 WHT wire amp C2 WHT YEL amp WHT GRN wires Reinstall the cover and set the fuse block aside 3 10 2 Disconnect the relays and remove the Duty Check connector from its mount tab Fig 8A 201 2 6 Remove the bracket from the fender and force the relays off the tabs Save TCC Relay for A T install Fig 8A 201 2 3 Save th
53. spd M T Specific notations for installing the donor engine with a 3 A T appear where necessary The 4 A T is significantly more complicated and is not included in these instructions 1 4 It is preferred but not required that the ECM and engine be of the same model year However as long as the computer has all the necessary inputs and outputs it makes no difference what motor it is physically controlling It should be noted that OBD1 vehicles 1995 amp earlier are much less complex than OBD2 vehicles 1996 amp after The earlier technology is far easier for the amateur auto electrician to manage OBD2 being more modern has nearly twice as many sensors amp controls Properly tuned OBD2 engines will provide slightly more power better fuel economy and cleaner emissions Replacement parts are also easier to find but of course are more expensive 1 5 Japanese Domestic Manufacture JDM 16v engines are available in the US but differ slightly in appearance and component locations A North American market computer amp wiring will operate a JDM engine but the adaptation requires a bit more forethought and planning 1 6 The factory uses machine crimped splices Hand crimping is not always as reliable but is much easier to do ooldering gives you a physically stronger connection but may change the resistance of the splice Both methods will produce acceptable results if done properly A bad splice might or might not throw off sensor input to t
54. the firewall connect the IAT and MAF sensors extend wiring if required and account for any loose wires check the in place wiring against the diagrams To prevent shorts cover the exposed ends of any wires that have been abandoned in place i e elect tape shrink wrap wire nut etc Note doubling a dead end wire back on itself before applying tape or heat shrink will reduce the likelihood of the insulation sliding off the end 7 21 Locate the ground point on the back corner of the intake manifold now designated G110 Cut ECM ground wires to fit Attach two 1 ring terminals two pairs of 2 if there are 4 one pair and one single if there are 7 22 Attach the ground wire connector from G108 to the tab on the back of the distributor Gi109 7 23 Tie up and secure the pigtail from the transmission for the 5 Switch It is not needed but must be left installed to keep the hole plugged Note the 5 Gear Backup Light amp 4WD Light switches are all interchangeable The unused 5 Switch makes a good spare for the other two 7 24 BEFORE INSTALLING THE BATTERY and after all components are fixed in their final locations Disconnect all the new plugs and grounds and run complete continuity checks on each wire in each circuit 7 24 1 Check for continuity within each circuit each wire end to end by color including grounds 7 24 2 Check for cross continuity between circuits each wire to each differently colored wire Any con
55. tinuity here indicates a fault 7 24 3 Connect amp Check grounds attach grounding terminals and check wires at relevant connectors for continuity to ground 7 24 4 Check each circuit for short to ground check each continuity to ground Make corrections ONE AT A TIME then re test Multiple changes during troubleshooting can make it nearly impossible to isolate a problem 7 25 During final reassembly apply a light coat of dielectric silicone grease to the terminals in each connector before plugging them back in This will help ensure good electrical continuity and inhibit corrosion 7 26 After all faults have been eliminated install the battery and run operational tests on each sensor per donor FSM 7 27 Once the engine is started perform tune up procedures timing amp idle adjustments per donor FSM specs 7 28 Check the Onboard Diagnostic System for proper operation Disconnect the battery to reset the computer Reconnect the battery and road test the vehicle 7 29 After the road test call up any Diagnostic Trouble Codes DTC that may be stored in the computer DTC 12 one flash of the CEL followed by two more repeated in cycles of three indicates all clear Record any other codes then follow donor FSM troubleshooting procedures to correct the problem Repeat the process until all DTC s have been cleared Revision 1 Page 30 of 36 Wiring Instructions for Samurai 16v Engine Swap Part 8 WIRING DIAGRAMS 8 1
56. tor 5 3 Once you are satisfied with the fit remove the harness and run complete continuity checks on each wire in each circuit Note There are no closed circuits in this harness Every wire is seated in an open connector on both ends Check each wire for continuity end to end by color including grounds Check for cross continuity between circuits each wire to each differently colored wire Any continuity here indicates a fault 5 4 Correct any faults then fit the harness with corrugated wire loom and wrap the entire thing in good quality electrical tape An additional wrapping of self fusing silicon tape will make it relatively waterproof but it s expensive 5 5 There will be a fairly long pigtail left to connect at the firewall Once everything is installed secure any loose harness sections to prevent chafing The bendable clamps from your old motor and or donor work well for this as they can be screwed or bolted wherever they are needed Revision 1 Page 17 of 36 Wiring Instructions for Samurai 16v Engine Swap Part 6 SAMURAI PREPARATION 6 1 Disconnect and leave behind all plugs necessary for engine removal 6 2 Remove engine 6 3 Remove glove box door door catch amp liner requires removal of the hood release cable 6 4 Disconnect the ECM see Fig 21 40 14 Remove the computer amp bracket together Separate them and save the bracket set the old computer aside you might be able to sell it later

92-95 16v Wire Manual

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