1988 Suzuki Samurai Buildup - Backyard Budget Buildup

This vehicle had been sitting for 10 years, so we decided to replace the fuel filter to prevent any large debris from entering the engine on its first attempt to start.

With the original fuel filter removed, the contents were emptied into a clear glass for inspection. The results were not good. The fuel filter contained a good amount of scale rust and was actually halfway full of water.

The tank was drained and a Perma-Cool fuel filter and water separator was installed inline with the stock filter. The Perma-Cool is designed to filter out water and particles as small as 2 microns, which should save our engine from any rust particles or water that might be in the tank. While the tank should actually be removed, inspected, and either thoroughly cleaned or replaced, the Perma-Cool filter would allow us to at least start the engine for the moment.

The cooling system was next up on the checklist before trying to start the engine. Any cooling system neglected for this length of time is sure to have some issues. Removing the thermostat revealed that the system was going to need some work.

Another trip to the local auto parts store and we had all of the necessary items to revitalize our Sami's cooling system.

To thoroughly flush the cooling system, a Prestone flush kit was installed. This innovative kit includes a T-fitting that is inserted inline on the heater core hose going into the firewall. A garden hose is attached and the water flows throughout the system for a few minutes until the water coming out appears completely clear.

A small, clear fuel filter was installed before the carburetor for extra filtration and to monitor for debris. It was finally time to turn the engine over. After a couple of tries, the engine started and to our astonishment, actually ran quite well. The timing needed some slight adjustment, but this was now a runner!

After just a couple of weeks searching all of the popular online-forum classifieds and auctions, we found just what we were looking for. For only a fraction of the retail cost, we found a complete Calmini 2-inch Shackle Reverse lift kit. As an added bonus, the kit also came with a Calmini towbar setup, which would come in handy if we ever wanted to tow the rig to the trail or limp it home.

Although our Calmini lift may not be new and shiny, it is a simple design, making it fairly indestructible, and it should work just as good as new. We began by removing the stock shackles on the front end of the Sami's leaf spring and replaced the factory rubber bushings with the steel inserts provided with the kit.