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Suzuki Every van progress

Discussion in 'Microvans' started by t_g_farrell, Sep 14, 2021.

  1. t_g_farrell

    t_g_farrell Member

    I don't see a specific area on the forum for build threads or similar for our rides, so I thought I would start this thread to document what I am doing to get my, new to me, van ready for the road. Feel free to move this to a more appropriate section. I thought it would get lost in the Carry section.

    My intent is to document the state of the van as I received it and my ongoing plans to get it ready to be a daily driver for local errands and things. I'll try to post pics of before and after and/or links to resources or products I used along the way.

    I intend to keep it stock, no intention to strip emissions or hotrod it, just get all the 25 year old cruft fixed up and running up to snuff.
  2. t_g_farrell

    t_g_farrell Member

    So I washed and waxed the van in the past week. Needs a good go over it with a buffer to bring the paint back to a better shine. I've found a lot of small treasures in the van while going through it. Heres some of what I've found:


    Starting from the lower right we have a remote mount radar detector, a lrge coil of wire that was under the dash used to surface a DC power plug in the upper dash insert, a magnetic sign, a magnetic clip, a magnet, some randoms bits and at the center is a gizmo that plugs into the lighter. I also found a device mounted under the battery that is a large capacitor for boosting the battery voltage under load (some bs fast and furious stuff here):


    Still to remove this. I'm going to get a Type 51 EverStart battery and at that point I'll remove this thing.
    Last edited: Sep 20, 2021
  3. t_g_farrell

    t_g_farrell Member

    I swapped all the exterior lights to use LEDs, heres the ones I bought off amazon that I've used in the past for other projects:

    https://www.amazon.com/dp/B00JRE38EA?psc=1&ref=ppx_yo2_dt_b_product_details (1157 red for brake lights)

    I still had a bunch of 1156 leds from the same folks that I used as well. Heres some pics of the results:

    Front DRL bulb on passenger side is LED:

    Rear backup and brake lights using leds on left side:



    Front signals both with LEDs (hard to capture on the blink)

    Amazing how much brighter these are. I also swapped in LEDs for both of the dome lights.
  4. t_g_farrell

    t_g_farrell Member

  5. t_g_farrell

    t_g_farrell Member

    Oh yeah I also got a hose to fix the preheat hose from the exhaust manifold to the air filter box. I order this and at 1 inch ID its a little small but with some cutting and aluminum duct tape I made it work. Pics to come. Its the closest I could find that would work. I even looked in McMaster Carr , Grainger, Jegs, and Summit with no luck for ~1 in ID hose like this.

  6. fmartin_gila

    fmartin_gila Active Member

    Got to be some really oddball stuff if you can't find it at either Graingers or McMaster-Carr.

  7. t_g_farrell

    t_g_farrell Member

    Yeah well, that and this type of hose is rarely used in car these days with no carburetors and EFI with direct injection etc. Its one of those paper/aluminum collapsible or bendable hoses that goes from the exhaust shield to the air intake on the carb. Very common in cars with carbs. Even the one I found was slightly too small of an ID diameter but I was able to use it.
  8. t_g_farrell

    t_g_farrell Member

    20210922_194942.jpg These are the new handles, lighter gray but look what better than the old ones
  9. t_g_farrell

    t_g_farrell Member

    So I was looking at the struts and shocks and noticed I have brand new springs under there. I wonder if they are replacements or enhancements. Meaning, the van rides kind of harsh and wondering if the springs are heavier than stock. Looks like they were swapped in without changing the struts or shocks at all. Its obvious the van was used to haul stuff around by the scratches on the painted areas inside by the rear door openings.
  10. t_g_farrell

    t_g_farrell Member

    So the springs are blue and have the word DOWNSUS on them. I think they are HD springs, probably in the 200-300 lb range. I found mention of OEM replacement springs and it looks like the stock spring rates are 162 front and 158 rear. I may source these and replace whats there. I want a smoother ride. Not sure how wall the shocks work since the heavier springs may be limiting their affect on things.
  11. t_g_farrell

    t_g_farrell Member

  12. t_g_farrell

    t_g_farrell Member

    Got a new battery to replace the old one that was in there with the big capacitor installed on it. The new battery is from wallymart, its an EvertStart 51 which just fits the van battery tray and hole.
    New battery being charged with SAE to JIS post converters:

    Old battery out and tray cleaned. Check out all the ground attachments on the neg side. Is this normal? Theres ground wires going to the tranny, engine, chassis in a couple of spots. All over!


    The new battery installed and hooked up. 500+ CCA and man it makes a huge difference on starts.


    Covered the posts in some Vaseline to help keep the corrosion down.
  13. t_g_farrell

    t_g_farrell Member

    I then worked on replacing all the vacuum lines in the engine bay. Went with blue ones so I could keep track of what I was changing. I also pulled the aribox out, cleaned it and verified the heater hose vent system worked. I also pulled the intake snorkel off and coated it inside and out with Goop cleaner and cleaned it all up. Heres all the old hoses I yanked out:


    This is with all the new hoses. I bought 20 feet of hose and ran short on the EGR, which I used some black new silicone I had laying about. Theres still some more hoses up under the chassis so I'll get another 10 feet of blue to finish that out later.


    The white cover is off the choke/ throttle assembly as I also adjusted the idle and wanted to verify the fast idle works for the AC. Interesting thing to note, on this van the fast idle kicks in not just for turning on the AC but if any electrical load is placed on the engine. I checked this by turning on just the HVAC fans and watched it adjust as I incresed or decreased the fan speed and by turning on the headlights. It all seems to be idling good and dealing with load fine now. Before it was a bit tempermental until hot. I have yet to check the idle speed by hooking a guage up to the ignition, I'll do that when I do a tuneup.

    Next things to do are fuel lines and filters and coolant lines and flushing.
  14. t_g_farrell

    t_g_farrell Member

    So I noticed that there are what look like 2 fuel filters on this van. Did some research on the parts diagrams and there is only one filter up by the tank before the pump and the other "filter" I see up in the engine compartment is called a fuel reserve. So I assume these are required to keep the flow regulated to the carb. In my picture above of the new vacuum lines, you can see t he fuel reserve in the lower right hand corner by the AC hoses.
  15. t_g_farrell

    t_g_farrell Member

    Gettin my title this week! Should be legal with a plate soon.
  16. t_g_farrell

    t_g_farrell Member

    Title is here. Plates next.
  17. t_g_farrell

    t_g_farrell Member

    Got tuneup parts, timing belt and water pump parts on the way.
  18. t_g_farrell

    t_g_farrell Member

    Parts are in. Will commence with installation this weekend. I bought the parts through my dealer but they all ended up coming from G&R Imports in Mo. Small markup by my dealer but nothing crazy. So good on them.
  19. t_g_farrell

    t_g_farrell Member

    My wheels had Nissan center caps but when I removed the driver rear wheel to get ready to work on the timing belt it said Suzuki. Looks like its a Wagon R wheel from a later model, 4x13 size with 4x100 PCD.

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