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Common Suzuki MightyBoy engine conversions

Workshop - DIY Guides

If you're considering an upgrade to the wheezy standard engine in your MightyBoy then this article will give you the basic info you need to tackle the job.

 

Please note that under proposed DOTARs legislation, all of the engine conversions listed on this page require certification by a qualified engineer to be legal for road use. Before you start an engine conversion you will need to consult with your local transport department, and possibly an engineering signatory.

 

The difficulty scale in this article is based on the assumption that the person doing the job is a decent backyard mechanic with access to suitable tools. Costs are based on the assumption of using second hand parts (including engine/gearbox), and being able to fabricate small parts at little/no cost. Costs do include engineer's certificate and custom subframe work.

If you plan on paying someone to do the work, reduce the difficulty to zero and double the costs.Wink

Difficulty scale:

1 - Simple. Conversion can be performed in a day or two with little or no custom fabrication required.
2 - Moderately easy. Engine/gearbox physically fits in engine bay but will require some fabrication of items such as drive shafts/engine mounts.
3 - Difficult. Engine/gearbox physically fits in engine bay but requires fabrication of engine mounts and drive shafts, along with upgraded fuel lines and wiring of electrics.
4 - Very difficult. Engine/gearbox will not fit in standard engine bay without modifications. Also requires custom fabrication, upgraded fuel lines and wiring.
5 - Extremely difficult. As per #4, but engine bay requires extensive modifications and upgrades to most major components of the vehicle.


Firstly we should start with the specs of the factory F5A engine:

Engine model: F5A
Specifications:
543cc, 3 cylinder SOHC, carburettor. (Naturally aspirated)
Power:
19kw (35nm torque)
Gearbox: 4 speed manual

Now we move onto the conversions:

 


Naturally aspirated (non–turbo)

Engine model: F8B

Specifications: 796cc, 3 cylinder SOHC, carburettor.
Power: 29kw (59nm torque)
Donor vehicle: Suzuki Hatch ('83-'85), Suzuki Alto ('86-'88 )
Gearbox: 4 speed manual
Installation difficulty: 1
Estimated cost: $500-1000 ($2500+ if using a rebuilt motor/gearbox and new hoses, engine mounts etc)

Details:

This is by far the most common and simple upgrade for a MightyBoy - a direct bolt in solution that increases power by 50%. Assuming you have all the parts you need, the entire job will take less than a day.
You can do the install with just the bare motor, manifolds, carburettor and distributor, but you are far better off with the gearbox and radiator as well. Best bet is to find a wrecked Hatch or Alto and use it for parts.
Don't be put off by the 4 speed gearbox either, it has the same final drive as the import F6A 5 speed gearbox, so cruising at highway speeds is much easier on the motor.
Rebuilt motors, rebuild kits and spare parts are still readily available locally for this motor, as it is still used widely in India.

 

Engine model: F8C

Specifications: 796cc, 3 cylinder SOHC, mulitpoint EFI
Power: 38kw (69nm torque)
Donor vehicle: Daewoo Matiz ('99-'04)
Gearbox: 5 speed manual (cable select)
Installation difficulty: 3
Estimated cost: $2000-2500 (Purchase of a Matiz with a wrecked body and good running gear)

Details:

The Daewoo Matiz uses an updated version of the Suzuki F8B. It maintains the same dimensions, with the addition of EFI and a 5 speed gearbox. Installation is basically the same as for an import F6A turbocharged motor, with custom engine mounts and upgrades required for fuel, and transplanting of the wiring loom. Changes to the exhaust are also required.
Parts for this engine are readily available, however costs are unknown at the time of writing.

 

Engine model: G10A

Specifications: 996cc, 3 cylinder SOHC, carburettor
Power: 38kw (80nm torque)
Donor vehicle: Suzuki Swift GA ('83-95)
Gearbox: 5 speed manual
Installation difficulty: 2
Estimated cost: $1500-2000

Details:
Like the F8B, G10A conversions are also quite common. The added bonus of this motor is that it has a 5 speed gearbox. To install you will need the engine cradle (subframe) from an automatic MightyBoy, as it has more suitable locations for bolting up the gearbox. The G10A also has an electronic ignition, and some models have an electric fuel pump, so bear that in mind when thinking about wiring. The exhaust system will need to be reconfigured too.

Later models (89 onwards) have hydraulic lifters, whereas earlier models have standard tappets. Hydraulic motors are distinguished by a thinner, aluminium rocker cover, whereas the older models have a rocker cover made of black tin.)
Spare parts for this motor are readily available locally and not overly expensive.

 

Engine model: G13BA

Specifications: 1298cc, 4 cylinder SOHC, carburettor.
Power: 50kw (101nm torque)
Donor vehicle: Suzuki Swift ('85-'98 ), Holden Barina ('85-'92)
Gearbox: 5 speed manual
Installation difficulty: 4
Estimated cost: $3000-3500

Details:
This conversion is quite rare, but possible. The biggest hurdle with installation is that the engine and gearbox are 50-70mm too wide for the engine bay. This means that substantial work is required to cut, reshape and reinforce the chassis rails. Unless you are handy with metal fabrication I would give this one a miss. If you do want to tackle the job, be sure to consult an engineering signatory before you start!

Parts for this motor are readily available locally at reasonable prices.

 

Engine model: G13B

Specifications: 1298cc, 4 cylinder DOHC, multipoint EFI.
Power: 74kw (113nm torque)
Donor vehicle: Suzuki Swift GTi ('86-'98 )
Gearbox: 5 speed manual
Installation difficulty: 5
Estimated cost: $3500-4000 (Double this figure if you plan on using a rebuilt motor/gearbox.)

Details:
Much the same as for the G13BA, only with the added requirement for new fuel lines, fuel pump and massively upgraded brakes to cope with the additional power.

Parts for this motor are readily available at reasonable prices.

 

 


 

Turbocharged

 

Engine model: F6A (and K6A)

Specifications: 657cc, 3 cylinder SOHC/DOHC, multipoint EFI.
Power: 47kw (ECU limited) (91nm torque)
Donor vehicle: Japanese import Suzuki Alto, Cervo, Works.
Gearbox: 5 speed manual.
Installation difficulty: 3
Estimated cost: $3500-4500

Details:
The most common of all turbocharged engine conversions, the F6A is easily obtained through Japanese spare parts importers. Depending on your method of installation (and engineer's requirements) you will need to either graft the engine cradle from the donor car into the MightyBoy subframe, or make custom engine mounts. In any case, the easiest way to get almost everything you need for the conversion is to purchase a front cut.

Additional items that will need to be installed are new, larger fuel lines, an EFI fuel pump (and surge tank), and upgrades to the front brakes.
The exhaust system will need to be reconfigured too.

Many parts for these engines are not easily obtained locally, and can be quite expensive to import.

 

Engine model: F5A

Specifications: 543cc, 3 cylinder SOHC/DOHC, multipoint EFI
Power: 47kw (ECU limited) (71nm torque)
Donor vehicle: Japanese import Suzuki Alto, Works
Gearbox: 5 speed manual
Installation difficulty: 3
Estimated cost: $3500-4500

Details:
Same as for F6A

 

Engine model: F6B

Specifications: 658cc, 4 cylinder DOHC, multipoint EFI
Power: 47kw (ECU limited) (98nm torque)
Donor vehicle: Japanese import Suzuki Cervo Mode
Gearbox: 5 speed manual
Installation difficulty: 3
Estimated cost: $3500-4500

Details:
Same as for F6A, with the added disadvantage of being rarer. Parts for these engines are rare and expensive to obtain.

 

Engine model: CB61

Specifications: 993cc, 3 cylinder SOHC, carburettor
Power: 50kw (106nm torque)
Donor vehicle: Daihatsu Charade G11 ('86-'87)
Gearbox: 5 speed manual
Installation difficulty: 2-3
Estimated cost: $2500-3500

Details:

Much the same as for the G10A conversion, the CB61 requires custom engine mounts and upgrades to the fuel system and exhaust. It also has the added difficulty of requiring custom driveshafts and upgrades to the brakes.
Parts for this motor are becoming rare, especially the turbo and carburettor components.

 

Engine model: CB70/71/80/90

Specifications: 993cc, 3 cylinder DOHC, multipoint EFI
Power: 74kw (126nm torque)
Donor vehicle: Japanese import Daihatsu Charade GTTi G101/G102
Gearbox: 5 speed manual
Installation difficulty: 4
Estimated cost: $4000-5000

Details:
If you fancy a challenge then this is the conversion for you. This engine is the tightest squeeze you can get in a standard engine bay, and requires the fabrication of engine mounts on the chassis rails, subframe mods along with all the other fuel system and brake upgrades, exhaust reconfiguration, wiring and custom driveshafts.

The engines themselves are becoming increasingly difficult to find, and spare parts are even more difficult and expensive to obtain.

 


 

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