[abheekg]

I could source the following preliminary information from my friends regarding the power steering in a 1998-2005 suzuki vitara.

Does the blow up of the Ps pump in the second pic look like the recent pump that you have acquired ?
I believe that the additional wires may be present in a newer model vitara power steering pump. Let me see if I can get my hands on the service manual of the newer vitaras

I am sorry if this adds to the confusion but I am going into such depths so that we go to the bottom of this and do it once and do it perfectly.

Here are some info scanned from the service manual of a 1998-2005 model vitara.

[MexXxentric]

Originally Posted by abheekg

Why, what happened to the baleno pump ? why did u decide to use this new pump over the baleno pump ?

My mech. wanted the pump also. even you words were an inspiration to get a pump along with its mounting

Originally Posted by abheekg

Ok. One confusion clears and the other begins :
From what I have studied, newer vitaras came with rack and pinion steering mechanisms while the older vitaras had such steering boxes.

It may mean that you may have ended up with the box of the old vitara and the pump of the new !!

seeing the service manual pages, I am afraid you are right.
the set has reached my home and my friend will courier it to my mech.
So within a week, i will post the final outcome.
Iam lucky as these guys have "return if it doesn't fit" offer

Originally Posted by abheekg

Let me confirm this from my friends in maruti and I will update on the thread.

Please do. The scrap man told that the pumps in old/new vits are the same.(might be in looks)

Originally Posted by abheekg

As the discharge rate of the P/S pump increases in proportion to the
pump revolution speed, a flow control valve is added to control it so
that the optimum amount of fluid for steering operation is supplied
according to the engine speed (driving condition).

This pump may be a part of the newer electro-hydraulic power steering systems that are found on many vehicles these days.
I will try to look up the manual of the vitara and update on the thread.

That sounds interesting. Do enlighten on the function of this pressure switch. anyway the Baleno's pump doesn't have any wiring

Originally Posted by abheekg

Could you enquire about the bulk price of a pump-box assembly too ?

350 dhs for single set including hoses, reservoir etc. now you can guess the bulk price

[MexXxentric]

A little googling saved me from worry
Also sorted out the confusion " the unit belongs to Suzuki sidekick/Tracker

I found this advt. at ebay. Note the pump. Its similar to the one i've purchased na?

Also find the picture of P.S box mounting frame(fitting without drilling the vehicle.)

[Amar82]

Any update on MG416 project , how far is it from finish line???

[MexXxentric]

I am expecting mechanical completion by mid Sept.

[MexXxentric]

The new engine and GB assembly was lowered into the engine bay.
The firewall required a little tinkering to accommodate water outlet

The oil sump is interfering with the front differential.
The oil pressure sensor wiring in the sump is restricting us from modifying the sump.
This is the current challenge.

Any suggestions from fellow BHP-ians are most welcome.

I don't have any pictures right now with me. Will give a detailed report within 2 weeks.

[Amar82]

I think you are experiencing problems after every step, i was about to buy a baleno engine myself for the transplant but looking at your thread i have dropped the idea. Anyways best of luck and do keep us posted.

Cheers
Amar

[MexXxentric]

Oil sump issue is solved.
We used oil pan from 1.6 EPI Suzuki block and integrated the sensor mounting to the same. Oil pickup was lengthened a little.
Water jacket issue is also solved by relocating the thermostat and sensor.
Now new engine mounts are getting fabricated.
GB and transfercase are maintained in OE position.

Amar,
these problems were anticipated ones. The project is all about learning.

Works to be done-
Installing PS
New radiator(custom copper core)
Revamping AC to suit R134 gas

next expected bottleneck- MPFI wiring.

[krishnathanthri]

Hi MexXxentric,

Updates please!!

When the mechanical work will get over?

Krishna

[MexXxentric]

Originally Posted by krishnathanthri

Hi MexXxentric,

Updates please!!

When the mechanical work will get over?

Krishna

Krishnaa.

here you go...
see the pictures of the 1.6 block in the engine bay.
Mounting is fabricated and will be installed tomorrow.

[MexXxentric]

Detailed updates

Water outlet
Both water outlet and inlet were facing the firewall side.
The thermostat & ECT sensor assembly attached to the water outlet was protruding beyond the engine firewall which demanded denting of firewall.

We shifted the thermostat assembly to the front of the engine by fabricating a stainlesssteel tube piping. This tube will be insulated(hot insulation) to limit the the sensor temperature reading error due to the elongated pipe.
Similarly the water inlet pipe was given a 180 degree bend to get the water inlet facing the front of the engine.
Now both the water outlets are facing the front of the engine.

[MexXxentric]

Crank Case or Oil pan
As mentioned before, the original baleno's Oil pan interfered with the the front differential as its oil storage area was near the timing chain by design.
Oil pan also housed the CKP Sensor.

I managed to get the Oil pan from 1.6 EPI Block,which got the oil storage part near the flywheel. The bolt pattern in the new oil pan exactly matched that of baleno's except for the sensor mounting.So that part alone was cut and brazed to the new oil pan.
Oil pickup tube(strainer) had to be lengthened and fitted to the frame.
1000cc Gypsy's oil pickup was modified to fit into the oil pump.
We were lucky to find a tapped hole in the second crank shaft bearing holder, to which the new oil pick up tube was fitted.

Advantage- Adequate clearance between axle and oil pan with out compromising on Oil holding capacity.
Even if the brazed part fails, it not going to spill out oil completely as the main oil storage area is intact.

Future plans- to get the OE oil pick up tube from 1.6 EPI block.

Pict1 - difference in Oil pans. the one with red liner belongs to 1.6 epi

Pict2-CKP sensor mounting hole in the block

Pict3- Semi finished new Oil pan in position. Note the Gap between axle and pan ( 4-5 inches)

[pramodkumar]

Shreejith,

Wont a SPOA setup increase the distance beetween the oil pan and the axel? I feel 4-5 inches would be a bit less as during offroading the axel might hit the sump resulting in damage to the sump and which means getting stranded in the middle of nowhere, correct me if i am wrong.

BTW: i need some help from you, i will PM you the details later.

Pramod

[MexXxentric]

Originally Posted by pramodkumar

Shreejith,

Wont a SPOA setup increase the distance beetween the oil pan and the axel? I feel 4-5 inches would be a bit less as during offroading the axel might hit the sump resulting in damage to the sump and which means getting stranded in the middle of nowhere, correct me if i am wrong.

BTW: i need some help from you, i will PM you the details later.

Pramod

SPOA will help for sure.
I kept that as a last option
We managed to achieve OE clearance with out any spring modification or SPOA or shackle lift.
Target is to maintain OE clearance even when the vehicle is loaded.
this will be achieved by rearching the springs or by adding an extra leaf.

Axle wont hit the sump as there is bump stopper to take care of that.

[Bailee_Jatt_Boy]

@MexXxentric what is going on dude? No updates for a while!

I had lost this thread but while I was reading Xtreme Powers pimped Gypsy thread this thread came back to my mind.

What is the latest status? Is the Gypsy back on the road as a bigger meaner machine?