We started a thread on this last week when we got hacked.
    I was wondering if there is any interest in keeping it going?
    I've started looking into doing the conversion
seriously after all the great info the members  
brought forward.

    My plan is to:
- Build adapter plate to mate 2.0 and kick 5 speed
- Custom flywheel to suit application using kick clutch
 assembly.
- Custom mounts etc.
- Custom injection (mega squirt or similar)
- Crank fire ignition (like I have on the airboat)

I want to:
- keep trans t/case etc all in stock position
- Not cut exsisting harness
- Keep install as easy as possible (I hate wiring)
- Get 135-150hp

Already have an engine I was saving for another project.

Any other thoughts or insight out there?

Zag

Only one thought, make a good write up of it, maybe with some drawings of the adapter, so that I can copy you  

talk to Eric(the moderator) about doing a write up and take tons of pics(even of the stupid little things).  we are searching for a 2.0 to drop into my mud truck that is way underpowered and high geared.

stu

From what has been said in the past the 2ltr will mate up to the 1.6 transmission but you need to machine the 1.6 flywheel to fit the 2.0 crankshaft. I don't know what you mean by crank fire ignition, is that some sort of magneto?

Thanks Rhinoman
    I've just eyeballed to this point but the 2.0l Sure doesn't look like a bolt up but I won't be sure till I get a trans to try it on.
    For the airboat I needed to eliminate the dist and the gear drive to make clearance for the prop drive. So I had to come up with a ignition system. The system I came up with was an adaptation of a GM system. I use a GM DIS coil pack and crank trigger with a custom mounting plate (mounts where the p/s bracket goes) to hold the crank trigger. The front harmonic balancer is machined with 7 trigger holes to activate the crank trigger. The trigger activates the module, the module triggers the spark plugs.
    Now double the whole system so you have 2 fully redundant ignition systems that fire the spark plugs.
    Easy to say but took a year of research and design to get it to work properly. I wanted the dual system to make sure I had a git home mode and if I work up the nerve to put it on the airplane. The whole engine is built with that attitude. (2) ignitions, (2) Carbs, (2) Fuel delivery systems...anything there is only one of has a 100% safety factor built in. The math has been killer.

Now if I can just find that last 500-1000rpm

Zag

Afew things i have picked with regards to the 2.0 into 1.6 conversion from talking to a couple of people.

The 1.6 and 2.0 have the same mounting points for block to transmission.

You will need to fab custom mounts as the 2.0/1.8 Kick had a chassis 60mm wider.

If you are using an auto you will need the torque converter and flex plate from the 2.0 and the 2.0 has an 8 bolt crank that will require machining and shimming to mate up.


Here's the link to an install in a Sammy

http://members.cox.net/aftermarket4x4/2liter.html

Contact Brent a call at Trail Tough as he does the kit for the Sammi and is pretty helpful.

http://www.trailtough.com/


The J20A engine has had slight variations in its output

94kW |removethispart|@ 6000rpm, 174NM |removethispart|@ 2900rpm

94kW |removethispart|@ 5900rpm, 174Nm |removethispart|@ 4300rpm

97kW |removethispart|@ 6000rpm, 166Nm |removethispart|@3000rpm

103kW |removethispart|@ 6000rpm, 193Nm |removethispart|@ 4000rpm (Japanese Market)


Bore x Stroke: 84mm x 90mm
Capacity: 1995cc
Comp. ratio: 9.3:1

Given these specs it's it's not so much a high revver as a torquer. Have a look here at a graph.

http://daniels.lumena.com/suzuki/Images/J20_1.jpg

Thanks for the input CJ

    I just had a 93 Tracker come in to be dissmantled in our shop so I will confirm things tommorow night with reguard to measurements. Sure would be nice if it bolts up. Also thanks for the links they have been really helpful.
   

Thanks Zag

Thanks for all the input everyone

    Well I can now confirm that the engine and trans will physically bolt together, we compared and mated them up last night.
    The next step is flywheels and clutches. The goal is to use the 1.6/16v flywheel (modified) and stock clutch.
I'll let you know how the measuring goes.

Problems expected in this phase...
1) Pilot bearing.
2) Flywheel spacing.
3) May need to step to aftermarket clutch due to power
   increase.

Zag

Another update
    Met with my machinist freind last night at the shop.
We measured up the 2.0L flywheel and the 1.6L flywheel. He doesn't think it's practical to modify the 1.6 safely to the 2.0L so he's going to machine a new flywheel for me (for a price) tomate the 2 together.
    It will use the 1.6 cltch/ pressure plate and ring gear but fit the 2.0. Also measured up the backs of the cranks and spent some time in the catolouges and found a pilot bearing that will work.

    It's going to take a few weeks before the flywheel is ready so I'm going to move on to other projects for a bit.

Next Phase
- What to do with injection?
- What to do with exhaust?
- Start figuring out how to adapt p/s.

It will be awhile before another update on this project.

Till then

Zag

Yes it can be done.. heres is a pick we machined the 1.6 flywheel. and have a new input bearing, although a bronze bushing would be cheaper. this is a 2.0 mated to a 1.6 bell and we mounted the toy be hind it instead of the 1.6 trans. Be more then willing to answer ?? if you have any just give me a call.
874-544-1823

Wow neat set up and that must have been a pile of machine work.
    My machinist was worried there wouldn't be enough meat to make the transition and felt it was just as easy to do the whole flywheel....but.
    What are you using for a clutch and I'd be curious to know why you went with the Toyota trans? Your set up looks alot tougher than stock. My idea is to keep it as close to stock as possible to make for the easiest possible conversion. But I sure appreciate the effort and expertice that has gone into your set up.

Zag

Wow neat set up and that must have been a pile of machine work.
    My machinist was worried there wouldn't be enough meat to make the transition and felt it was just as easy to do the whole flywheel....but.
    What are you using for a clutch and I'd be curious to know why you went with the Toyota trans? Your set up looks alot tougher than stock. My idea is to keep it as close to stock as possible to make for the easiest possible conversion. But I sure appreciate the effort and expertice that has gone into your set up.

Zag

link:  http://www.users.qwest.net/~salto/SOS.htm

stu

Wow neat set up and that must have been a pile of machine work.
    My machinist was worried there wouldn't be enough meat to make the transition and felt it was just as easy to do the whole flywheel....but.
    What are you using for a clutch and I'd be curious to know why you went with the Toyota trans? Your set up looks alot tougher than stock. My idea is to keep it as close to stock as possible to make for the easiest possible conversion. But I sure appreciate the effort and expertice that has gone into your set up.

Zag

For what you want to do the only machine work is to the 1.6 Flywheel. You can not use the 2.0 the diameter is to large and the bell wont fit over it. We are the U.S Distributor for the RingR and for Our application we used it with the Toy trans. All parts are readily avail.
As far as machine work to the flywheel yes there is plenty of meat to work with.  you have to open the surface area to fit the crank and and drop 8 hole sinto the flywheel. couple hrs total from the time you set up the jig for the FW on the mill. Also you use all stcok 1.6 clutch parts for your setup.

did i miss it, what is this 2.0 out of? :-/

pleas keep a parts list with #s, like the pilot bearing

Hi Guys
   Well over the weekend we accomplished a few things.
   Test fitted the engine with the custom made
   flywheel (was supposed to take 2 weeks but my
   buddy the machist ran out of work so punched it
   through), pilot bearing, a used clutch assembly that
   was lying around the shop with the transmission.

   Everything fits straight and true, clutch seems to work
   fine. So all those hard parts fit and seems to work
   together.

    By the way I am keeping a parts list with part numbers and applications. I am also keeping careful notes on how we did it in detail.
   Once it's up running and proves to work well I will find a way to post the details or make them available some how. In the mean time I intend to give updates as we make progress.
    The engine is from a 2000 Tracker and requires rebuilding. (cam chain thrown by lack of maint by previous owner). The intent is to get everything fitted and working before building the engine. That way everything is worked out before I take my wifes vehicle out of service.
    The next step is mounts and accessories, I've got a rolled kick at my business that already has the engine/trans pulled that I will use to contruct the engine mounts, p/s mounts etc and test fit. Till then....

Zag