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Monitoring of the duty cycle of the OEM injectors. • Ability to drive more than one injector. • The magnetic pickup will no longer be used for speed sensing. This will allow interfacing to any type of vehicle with an ignition coil. • Addition of Peak and Hold Circuitry to save power and offer better control of injector. Here the two wires (red and green) feed the controller with a frequency from the magnetic pickup in the distributor. This allows the controller to determine the engine speed. Installation Example: Suzuki Swift GTi This photo shows the injector controller mounted in a Suzuki Swift GTi. It is wrapped in foil to reflect heat from the engine bay. This injector setup ensures that fuel properly mixes with the air before it reaches the cylinders. The trigger for the injectors taken from the coil terminal to ensure the injector is fired on each induction stroke. The fuel for the fifth injector can be seen being taken off the fuel rail using a brass T-junction.

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Engine Options for the Samurai There are a number of possibilities for changing the engine in your Samurai, depending on where you live and what you want to accomplish. Suzuki Sidekick or Geo Tracker I (1989-1995) – The block from the 1.6 8-valve Sidekick or Tracker can be swapped in easily. This is by far the simplest upgrade, requiring modified engine mounts, transmission adapter plate, and provision (some sort of lift, or an adaptation from a G12 series engine) for the oil pan. Intake and Exhaust Manifold will fit, and finally the addition of an electronic fuel pump since the 1.6 head does not have lobes on it for the fuel pump. Petroworks can supply almost all necessary parts required for this task. Motors are a little harder to come by though. The next level to this swap would be the use of the Sidekick/Tracker Throttle Body intake system. This is a much more complex task and requires the complete under hood wiring harness, parts of the under dash harness, and computer from a donor car. Modification of the harness is required to install it into the Samurai. TR Also, the Speedometer cluster needs to be modified on the Samurai to add in a Vehicle Speed Sensor (VSS). This is needed by the computer to adjust timing during operation. Suzuki Swift – This is a G13 series engine with a counterbalanced crankshaft, twin overhead cams and fuel injection. One of the easier swaps to make, requiring only some minor wiring changes and a hole in the Samurai’s firewall for the horizontally mounted distributor (this engine was originally designed for a transverse mounting). Suzuki Sidekick or Geo Tracker II (1993-1995) – The motor from these cars are 1.6 16v, multiport fuel-injected. These motors are usually found in 4 door cars and will say “16 Valve” On the valve cover, Timing Belt cover or injector manifold. This is a much more complicated swap and requires a lot of wiring to interface with the Samurai harness.

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Fig. 5: 1. Remove oil felt. Using a screw driver, pry out oil felt. See Fig. 6. 2. Remove key. Using a hammer and punch, drive key from shaft. Disassembly of Compressor See Fig. 7. 3. Remove circlip. Using snap ring pliers, remove circlip. See Fig. 8. 4. Apply compressor oil to inner bore. See Fig. 9. Fig. 6: Removing Oil Felt Fig. 7: Removal of Key from Shaft Fig. 8: Circlip Removal Fig. 9: 5. Remove lip seal using special tool (A). The following explains this removal procedure: a. Fit special tool (A) into the clutch installation boss. See Fig. 10. Compressor Oil Application Special tool (A): 09990-48220 b. Turn special tool (A) until its protrusion engages with the groove provided on lip seal. See Fig. 11. c. Check that special tool (A) goes down slightly when the protrusion and groove are engaged. d. Turn special tool (A) by 30 -60 . e. Pull up on special tool (A) to remove lip seal. See Fig. 12. CAUTION: DO NOT re-use lip seal once it has been removed from the compressor.

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Suzuki; Samurai, Sidekick, Swift ENGINE MECHANICAL Before performing any on-vehicle adjustments to fuel or ignition system, ensure engine mechanical condition is okay. VALVE CLEARANCE NOTE: Swift DOHC uses hydraulic lifters. No adjustments are required. Samurai & Sidekick 1) Remove valve cover. Rotate engine until zero degree (TDC) timing mark of timing belt cover is in line with timing mark on crankshaft pulley. See Fig. 1. 2) Ensure cylinder No. 1 is at TDC on compression stroke. Remove distributor cap. On Samurai and Sidekick (TBI), ensure rotor is pointed upward at distributor hold-down bolt and to No. 1 terminal of distributor cap. On Sidekick (MPI), ensure rotor is at about 1 o’clock position and pointed to No. 1 terminal of distributor cap. If rotor is not as described, rotate crankshaft 360 degrees

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TESTING FUEL GAUGE Disconnect Yellow/Red wire connector at fuel tank sending unit. Connect a 12-volt, 3.4-watt bulb (light) to harness side of connector and ground. Turn ignition on. Ensure bulb lights and fuel gauge needle fluctuates several seconds later. If not as specified, replace fuel gauge. FUEL GAUGE SENDING UNIT Remove fuel gauge sending unit from vehicle. Connect an ohmmeter between sending unit connector terminals. See FUEL GAUGE SENDING UNIT RESISTANCE table. If resistance is not as specified, replace sending unit. See Fig. 1. FUEL GAUGE SENDING UNIT RESISTANCE TABLE