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[Overlord475]

Hey guys,

Myron has asked that I start a build thread to discuss my G16 OBDII build.
It's been a slow going process as I don't have a lot of free time to get out in the garage, but I'll update as things do progress.

In the mean time here is a bit about my build:

I recently picked up a round vent 88 Samurai JX for my wife as a project. Being that this is her rig, it is meant to be a DD and very rarely off road. With that I mind I opted to go with a rebuilt OBDII 16v from ZOR instead of a diesel. Need to be able to reach highway speeds.....

As a point of reference... Myron at ZOR is amazingly helpful as I am sure many of you know.
Being new to the Zuk world he has been a great help in teaching me and getting the build going.

I actually purchased a full "big idea" kit from him:

        Rebuilt OBDII 16v G16
        Modded Harness + VSS + ECU
        Aluminum Radiator
        Rebuilt Trans and Tcase
        AC & Power Steering Kit
        Brake Rebuild Kit
        OME 2.5" SPUA Lift Kit
        And more....

He has done great by us and I would recommend his services to anyone...
He has really gone the extra mile for us.... or 10.

Here is a pic of the Rig when we picked it up (we don't live in TX):

   

Here it is in it's current state:

    Full Build Album : https://www.flickr.com/gp/64009513@N04/5k99f3

   

   


And here is our inspiration... Plus a black CarTops hardtop and minus the guy with the .50 cal:

   

[dadstoybox]

Welcome to the cool kids hang out !

[The PHLOOP]

Welcome to the ZORum. We do have a section for builds. I'll post it later as I'm on the way out of the house right now.

Look farther down the main page for the Build it, Run it, Break it, Repeat! section, thats what your looking for.

[Still Zukin]

Welcome to the Zorum

[Overlord475]

Alright guys, here goes post number 1:

Here are a few more pictures of how the Zuk looked when we picked it up:









Front Axle:


Rear Axle:

[Overlord475]

Here is a complete list of the items ordered and received from ZOR:

1. Reman. G16 16v Engine
          Dressed OBDII Engine
          Alternator
          Silicon Hose Kit
          Painted
2. OBDII Engine Harness & ECU
          Harness w/ VSS, etc.
          ECU
          EFI Components
3. Radiator Kit
          Aluminum Radiator
          Honda Cap
          Required Coolant Hoses
4. Petro Works Trans Adaptor Plate
5. ZOR MotorBoat Eng. Mounts
6. AC Kit
          AC Compressor
          AC Required Brackets
          AC Hose fittings (compressor side)
7. PS Kit
          PS Box/Pump
          PS Box Mounting Plate
          PS Hoses
          PS Reservoir w/ bracket & hardware
8. Fuel Pump
          e-2000 pump
          Fuel Pump platform
          Fuel Pump soft lines
9. Stuby Starter
10. Gates Clutch
11. Remanufactured Transfer Case
12. Remanufactured Transmission
13. 2.5" Lift Kit
          Old Emu Springs
          2" Shacles
          Pro-Comp Shocks (Front & Rear)
          Bushing Kit (Poly)
14. Front Swat Bar Spacers
15. Drive Shaft Spacers (2)
16. Brake Kit
          Front / Rear Rotors & Drums
          Front / Rear Pads
          Rear Slave Cylinders
          Rear Pad Spring/Hardware kit

[Overlord475]

Here is the G16 during M.Y.'s rebuild:























And a video of M.Y. starting it up after the build:

https://www.flickr.com/photos/64009513@N04/20927448788/in/album-72157653051703150/



^^^^ Figured I post a flattering pic of M.Y. while I was at it....

[Overlord475]

Now, the beginning of the actual build.

I first started by putting the springs, bushings, and shackles together:

Make sure not to over tighten your shackle bolts.
The arms should be parallel to one another without that "pinched in" look. Otherwise you'll develop "stiction":







Don't forget to grease your bushings, sleeves, and bolts before installing into the springs.
I like to use copper anti-seize as the cooper is a good metallic lubricant that will not breakdown or evaporate overtime.
Also, blue lock tight the nuts:





Next was removal of the old 1.3" tractor engine....






My really good buddy from work regularly comes over to help.
There is normally much laughter and beer involved.

[Overlord475]

Next was removal of the front axel for rebuild.




Cleaning the grim and grease off of the front axel:




Next we installed the fresh bearings into the carriers.
Note : The applied grease shown is for ease of pressing in the bearing races only.




Note : The below pictures shows the bearing set in the race but it has not yet been packed with grease.
          The bearing itself should be packed with grease before installing the hub back on the axle.

Here is a how to on packing bearings : https://www.youtube.com/watch?v=akh0WhkudrM





Removed the front brush guard and sold it.
Looked like someone had made the bracket at home out of scrape angle:

[Overlord475]

The wife then started de-greasing the engine bay:












Then installed the PS bracket and box:

[Overlord475]

Next, I started working on the e2000 fuel pump bracket.
It is placed near the gas tank on the rear passenger side of the car:





Here is the Fuel filter and old hoses removed:




Next was installation of the VSS into the cluster.

M.Y. has a really great video discussing how to prep-your OBDII harness as well as how to install a VSS into your cluster.
The discussion on VSS installation starts at ~33mins in the below video:

LINK : http://youtu.be/3pzbIIT5CVc

Here is my install pics:









These connects connect to the body harness (green) and ground (black).

[Overlord475]

Next was engine installation.

[The PHLOOP]

Your going to pack your hub bearings with grease not just glop some grease on the race and drop the bearing in right?

[mkyhmltn]

Your going to pack your hub bearings with grease not just glop some grease on the race and drop the bearing in right?

I was going to ask the same thing.

[Overlord475]

Your going to pack your hub bearings with grease not just glop some grease on the race and drop the bearing in right?

Of course. The picture only shows the bearing race installation.
When I fully re-assemble the front axle all will be greased.