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 Post subject: Gti conversion into a Suzuki Sierra..
PostPosted: Wed May 09, 2018 8:27 pm 
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Joined: Wed May 09, 2018 11:48 am
Posts: 60
Location: brisbane
First thing you will need is rocks in your head and patients.. If you have both those things then you may find this helpful.

We started with a 92 leafy and a Mark 2 GTi engine..
The advantage of a gti is no adapter plate needed.. It bolts straight on..Existing Starter fits as does clutch but you need to swap the flywheel and clutch to gti ..

You will need...

Engine (you will need to swap the oil pickup and sump from your Zook to the gti) as well keep you Zook dip stick..

A FULL GTi LOOM.... The one we were sold had bits missing... Get as much Gti stuff of the donor,. exhaust, O2 sensor, all the plugs...not just the wires...

A set of extractors for the gti as the ports are further apart and round , not square , and a gasket of course. $23 Bursons..Make sure your manifold has the correct size hole for the gti O2 sensor..

make sure you get the O2 sensor with both male and female plugs off the donor gti as you will need that.. The plug should be added to the loom....our's wasn't because the supplier of the kit forgot the O2 sensor and plugs so we had a small white unidentified wire on our loom hanging at the back of the engine..It was a white wire at the very bottom of this pick... It almost got connected to the water temp sender because it was soo close to that sender and the wire had NO ID marked on it .. fortunately someone here said it was for the O2 sensor and the water temp sender used the existing wire...

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Some commodore engine mounts..Ebay..Holden Commodore VL 6cyl inc Turbo Engine Mount NEW PAIR RB30E. The bumps that locate need to be either ground off or drill small hole for the bumps to fit into. You will need to grind some of the mount off on the exhaust side or the extractors will hit..Easy..

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Wiring loom made for gti made for your version Zook.. Our Loom was made wrongly and had to be stripped open and redone...aaahhhh You would think that a $400 loom would be done properly......

We upgraded the alternator to an EL Falcon so you will need one of these belts..Ebay..Dayco 4PK840 Power Steering (without A/C) Belt fits Mazda 121 DW 1.5L Petrol B5 ...Make sure the alt comes with the plug and 100mm of wire to join onto. With this new more powerful Alternator you will also need to replace the cable from the Alt to the battery.. We used an earth strap with a 100amp fuse in line. You may need to change ?mod the bracket to fit this but not hard to do..The gti has 4PK pulley and so does the Ford so it's all good..

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We opted for an electric radiator fan because we already had one. It comes on when the ignition is on but we also have a switch on the dash so we can turn it off in water crossings etc and the light on the switch helps up to remember it is off.. You can get a water pump that fit the gti engine that a fan can go onto but you will need to hunt around for the fan spacer or make one..Good luck with that.

You should check the timing belt and belt tensioner pulley while it is easy to do. Replacing the belt is only $30 or so.. Ours looked good and money was an issue for my son so we left it after checking it..

A Coily fuel tank with an in tank pump or a Coily tank and an in tank pump from a Vitara which will fit the coily tank..
Because the fuel line will now be pressurized instead of being sucked from the fuel pump you will need to replace any section of non metal fuel line with new high pressure hose and same clamps. There is 2 small sections either side of the fuel filter near the back of the car on the driver side that we forgot and on out first test drive these blew apart.. The coily tank is a different size and the stuff on top of the tank will hit the car so I put 20mm spacer at the front and 10 at the back to give a bit more space between the two.. I just used 10mm thick nuts as spacers

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You will need either a 90degree offset dizzy or the option we chose is a 90degree cap that has the wires going out sideways from the cap.. If you choose this option the correct rotor for that cap is JR400 and available at Repco for $30. The cap is of an early model Mazda 323 TURBO 86-89 and the part number for the dizzy cap is JP706..Repco for $75 or ebay for $45....You will need to find a small screw to hold the rotor onto the dizzy shaft. They don't come with the screw....wt..You will also have to bash the %$#@ out of the firewall where the dizzy is otherwise your new engine is not going to fit.. The more you bash the better..If you can get in there 50mm you may even be able to get your dizzy cap off without removing your engine... These bits are off a Mazda early model 323 Turbo... 86-89... You can see the low profile dizzy cap, 90 degree coolant outlet and a couple of the plugs including the O2 sensor wire (white one) .. would have been handy if the loom maker had labeled that one......

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You need a GTi coil which will have a small power unit screwed to the bottom of the coil bracket which works as a heat sink..This power unit has something to do with the igniter and your new loom will have the 3 wires for this unit.. Make sure you supply the loom maker with the female plug for this unit so he can incorporate it in the loom. A gti loom should come with one of these when you first buy the gti loom...Ours didn't ...aaahhhh. You can use your old coil but you will need to get one of these Power Transistor units and mount it somewhere near there.

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Your loom will come with 3 wires that go to Noise Suppress unit...That is the small thing on the firewall that already has 3 wires going into a plug that goes nowhere.. It has NS on it and it just gets cut off there and put onto the new loom..

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You will also need to modify the air intake pipe or it will be too long to fit in the engine bay once an air filter is added. Fortunately the inner diameter of the intake is the same at the end as it is after you have carefully cut off the flexible boot type section. You will need to make or buy 2 tube joints so you can attach the 2 large vacuum hoses from the rocker...Once again I raided our pipes and joiners spares and put something together..

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You will need a bulb for the Check Engine light which already has a spot in you dash but has no bulb.. Your new loom will come with 2 CE wires and you need that to look for Flashing light codes .. :!: You could just put a bulb on those wire and leave it under the dash and sus it out if you had an issue..

The gti has the charcoal canister very close to the intake manifold and there is a sensor on the side toward the back of the intake manifold that suck the fumes from the canister so make sure you run the existing Zook hose over to that sensor. It will effect the tune if you don't ....

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The other issue you need to over come is getting the coolant from the back of the engine.. You need a 90 degree water exit. SCA etc will have that. Then you need to swap the short bit of pipe from the water pump on your old engine and transfer it to the new one.. Make sure you clean up the large "O" ring and use some propper sealant when you fit it. The piece of pipe from the Gti engine can be cut and braced using some home made wrap around brackets and there are holes that you can use to mount it.. I used bits of hose to make up the small lengths that join the metal bits together.

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You will also need to lengthen the accelerator cable to reach from the back of the gti engine to the front where the accelerator cable does it's thing.. I got an old accelerator cable and joined it to the cable by making a loop in each cable and then binding the loops with SS thread from another cable..I bound it for about 15mm on either side of the two interlocked loops then wrapped it in tape.. I had shrink wrap but forgot to feed it on before I bound the cables.. Works a treat and is not going to break any time soon. I used the tube bar thing that goes across the back of the engine to mount the cable adjuster bracket onto.

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Wiring the loom is easy if the loom is done properly as the wires/connectors should be roughly in the right place if you lay the loom on top of the engine it should all reach nicely.. There are 4 down the back of the engine which are a bit tricky to get to .. A green plug, a blue plug , and a white plug as well as a single terminal for the water temp sender which is a real pain to get on because you can't see it.. You may need a small mirror , a torch and 3 hands to get that sucker on. There is also an earth wire there that uses an earth wire that is on your old loom.

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Most of the old loom becomes redundant and can be wrapped in tape and hidden away when finished but there are a couple you will still use.. Eg the water temp mentioned above, oil pressure switch, earth for the dizzy, starter motor etc..

When you are finished it should all look like this.. All that remains is to modify a stock GTi filter to fit in and connect to the snorkel ..IN the mean time the pod does the job.
Note the addition of the tool box bolted into the engine bay...

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If I think of anything else I will update this ..In the mean time enjoy.. A stock G13b carby engine makes 63 HP... The gti engine makes 100HP so it is a nice little power gain.. We also have a G16 (98HP) in our coily which we fitted but that's a whole other story..

Unfortunately 2 days after we finished doing this conversion/install, the engine dropped a valve so now it is back out and in the process of stripping it down to see the damage and waiting on the supplier of the engine to find a replacement.. aaaahhhh....I hate cars sometimes...
One of the reasons I love Subarus soo much is as long as you do regular maintainance, they rarely have any issues and as long as you don't do silly stuff like winding up the boost to get extra power they handle spirited driving all day long..My Blue rex makes 180 kwatw on 16lb..My son insists that the gti engines are very strong as well but so far I am not impressed...
Parents be ware.. when your boys say..."Hey Dad Im gunna put a 1.6ltr Baleno efi engine in my Sierra" and then your other son says.."Hey Dad I'm gunna put a GTi engine in my Sierra"...What they both mean is "Dad, can you do 2 major conversions to our cars ?? "


Last edited by Toomanycars on Tue Jul 31, 2018 5:27 pm, edited 1 time in total.

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 Post subject: Re: Gti conversion into a Suzuki Sierra..
PostPosted: Fri May 11, 2018 5:48 pm 
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Joined: Mon Oct 12, 2015 11:30 am
Posts: 283
Location: Napier
Good little engines for sure. Sad that you might have been sold a dud one so soon! Looking forward to seeing it get out there and sand bashing.

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A Kiwi learning to fly in a Mk1.


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 Post subject: Re: Gti conversion into a Suzuki Sierra..
PostPosted: Wed Sep 26, 2018 3:22 pm 
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Joined: Thu Nov 10, 2016 10:01 am
Posts: 21
Location: sa
If I had this link 12 months ago this would have saved me soo much time and stress. #-o
I had the same issue, paid for a converted loom but when it arrived I had half the plugs missing off the loom and had no idea where they went to.
Two years of thrashing my motor and it finally dropped a valve and made a hell of a mess. Just dropped the engine off to be rebuilt today so hopefully will be up and running again shortly.


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