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Old 24th March 2009, 16:32   #1
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Question Project MG 416 W

Hellow Friends,

I am planning to unleash my dream project. - MG 416 W

The target is to install a Baleno's 1.6 liter engine in Gypsy King ,and retaining the 4x4 of course.

Experts, please advise me on the feasibility of the project, expected bottle necks and problems, hardware requirement, legal issues, approximate cost involved, etc etc.
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Old 24th March 2009, 18:36   #2
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These threads would be great places to start:

1. Swapping with a 1.6 engine (Gypsy engine swapping with Baleno 1.6L engine ?)

2. Gypsy options (Engine options for Gypsy.)
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Old 24th March 2009, 18:44   #3
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Saw an Army rally gypsy same days ago at the Sjoba rally,chandigarh, and it had just this sort of an arrangement. The driver was Capt.Amrinder Brar, and i think he is rated at No.06 in the Indian rally circuits. Also another famous rallyist, Sunny Sidhu is rumoured to have this arrangement in his factory sponsored Gypsy.
There are kits available abroad to mate the 1.6 to the factory gearbox, but since these rally vehicles were basically factory sponsored, it is highly likely that Maruti made their own in-house kits.
Infact, taking about Gypsy motor mods, there is a kit for available to mate the fiat/volks 1.9/1.9td motor to the gypsy gearbox. This is the same motor as was used in the previous generation fiat palios(India's last yr and ealier versions) and also the scoda octivia. If someone's come out with a kit to plant a coal burner where originally an 85Kgs(only) motor was to take command, means that the 1.9Td motor is amongst the lightest diesel motors available. I say this because the Toyota 2CT motor, that people in India generally build into a contraption weights 210kgs.
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Old 26th March 2009, 13:40   #4
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Smile Some Interesting Links

Hi,

I've been googling for the topic and i came across some interesting case-studies of the similar type of conversion done in UK.

The links are

Swapping 1300 cc engine to 1600 cc in my Samurai
this tells about a 1.6 liter ( 8valve ) carb. engine swap. I guess that its a G16a engine.

G16a into a samurai - Suzuki Forums: Suzuki Forum Site

The second link is more informative.

From the above links the challenges in the conversion will be

1. Mating the G.B to the the engine ( with or without using adapter plate? )
2. Which flywheel & clutch plate should i use ( 1.3 Gypsy King's or 1.6 Baleno's)
3. Mounting the engine. What all changes are required in the engine foundation
4. to close the hood due to Height of the engine ( should i go for body lift?)
5. The front axle hitting the Oil pan of the 1.6 engine. ( I am not interested in SOA or similar works)
6. Radiator installation ( as 1.6 is a transverse engine )
7. How to handle the extra weight of the engine?
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Old 26th March 2009, 14:47   #5
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There is one Black Gypsy which is in Mumbai. Check the Mumbai OTR posts. It faired quite well at the OTR. Monstrous sound as well.
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Old 26th March 2009, 15:21   #6
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Talking Specs. needed

Friends got a 2001 Baleno Lxi (side impact accident vehicle with almost intact engine bay)
can anyone enlighten on the engine specs.?
Google cant help me in this :-(

What all components can be transplanted to Gypsy?

I plan to take the following

Engine with flywheel &starter,
Alternator,
P.S pump,
AC ( atleast compressor)
Fuel filter and Pump.
Brake booster ( will it be an over kill?)
Windscreen washer unit
LPG Kit ( yeah the baleno had LPG kit on it )
Petrol tank ( to serve as a secondary tank)
Front Seats ( if its ergonomically safe)

Again awaiting your suggestions.
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Old 26th March 2009, 16:04   #7
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There's one in bangalore as well.
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Old 26th March 2009, 16:28   #8
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guys we have got 3-4 MG416 in my group, its a simple and reliable mod.

you will fall in love with the gypsy after this swap.

All you need is gypsy king, if you have gypsy 1.0 then you will have to get the 1.3 gearbox.

there is a pic of black 416 in one of my offroad season thread.. check it out
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Old 26th March 2009, 16:32   #9
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Are they carburetted or fuel injected, Pdev?
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Old 26th March 2009, 16:49   #10
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Quote:
Originally Posted by pdev29 View Post
guys we have got 3-4 MG416 in my group, its a simple and reliable mod.
Thanks PdeV, can i have some under the hood pictures or the contact info of the 416's owners? It will help me a lot.

I've outsourced the engine as well as king's G.B ( Ashwar87 outsourced them for me. )

My mechanic is suggesting to go with 1.3's Flywheel in the 1.6 engine so that it will fit inside the King's Gear box. But Iam a bit confused.
Which starter motor should be used? 1.3's or 1.6's ??
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Old 26th March 2009, 19:43   #11
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hi friends,
i just want to add few more doubts with what mexxentric has stated above, reg the clutch plates,is that good to go in for a after market "HIGH PERFORMANCE CLUTCH PLATES".
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Old 26th March 2009, 23:09   #12
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Can I ask how much the gypsy gearbox cost you?

@ pdev - can you please tell us about the baleno engine swap for gypsy in detail.
1. Does it sits on the stock mounts or new mounts have to fabricate?
2. Does the engine mates directly with gypsy gearbox or does one needs an adapter plate.
3. Does oil sump sits above the differential or its clear? Any other issue of front differential clearance during extreme articulation?
4. What about clutch, flywheel, starter motor?

cheers
vishwas
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Old 27th March 2009, 12:40   #13
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Got the G.B alone for 12k(excluding transportation from chennai)
I wanted the flywheel & 1.3 starter, but couldn't get it. :-(
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Old 27th March 2009, 16:09   #14
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Quote:
Originally Posted by MexXxentric View Post
Got the G.B alone for 12k(excluding transportation from chennai)
I wanted the flywheel & 1.3 starter, but couldn't get it. :-(
no worries i have one 1.3's starter motor.
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Old 28th March 2009, 14:00   #15
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Out of curiosity I wanna ask the experts, for an Baleno Engine Swap to non MPFI Gypsy does the wiring needs to be changed? what about the ECM?
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