I drive a 1987 Suzuki Samurai with a 1.3L engine. It’s a fun little truck to drive and it gets good gas mileage.
It was originally equipped with a very temperamental computer controlled carburetor. Sometimes it would idle at 800 RPM, other times 1100 RPM. Another issue was that it ran poorly in cold weather. After failing emissions, I decided it was time to convert to fuel injection.
1991 and newer Samurai were originally equipped with fuel injection. Unfortunately, not many were made and finding used parts is difficult. Fuel injected 1.6L engines in Geo Trackers and Suzuki Sidekicks are much more common. They can be found in nearly any U-pull salvage yard. It is popular to swap one of these engines into a Samurai. I wanted fuel injection, but wanted to keep the 1.3L engine. I decided to use the fuel injection from a 1.6L engine on my 1.3L.
A high pressure fuel pump is needed for a fuel injected engine. A frame rail mounted pump is very noisy, so I used a new “in tank” unit.
I purchased a new tank for a 1991 model Samurai. This tank is designed for an “in tank” pump. I coated the new tank with Herculiner.
I fabricated a fuel filter mount and installed it on the frame rail near the tank. I ran new steel supply and return lines. The rubber sections were plumbed with fuel injection rated hose and clamps.
An intake manifold from a 1991 Samurai was found on eBay. It is my understanding that a manifold from an 8 valve 1.6L engine would also fit on a 1.3L. I pulled the throttle body injection assembly, engine control computer, distributor and ignition system from a 1991 Geo Tracker at a U-pull salvage yard. I also pulled all of the sensors and clipped the electrical connectors from the wiring harness.
I pulled the wiring harness out of my Samurai and split it open. All of the wiring for the old computer and carburetor was removed. I installed the new engine control computer under the dash in place of the old computer. Using the electrical connectors from the 1.6L, I built a new wiring harness from scratch. I also installed a speed sensor in the speedometer of my Samurai to work with the 1.6L computer. The 1.6L distributor was a bolt in replacement for the 1.3L distributor. The new ignition system is controlled by the new computer and was incorporated into the new wiring harness.
This picture shows the intake manifold and throttle body injector. To fine tune the air/fuel mixture, I put an injector for a 1.3L engine in the 1.6L throttle body.
With fuel injection, the truck runs great and gets better mileage. It also passes emissions testing.