westcoaster

**edit July 7/2017**
In June of 2017 Photobucket suddenly and without warning changed it's terms of service and started charging $400 a year for users to link their photo's to internet forums (third party hosting) There was no way I would pay that.
Since the photo's contained in this thread are among the first images displayed in a google image search for diesel samurai swap, I felt it important enough to repair this thread.

http://bbs.zuwharrie.com/content was gracious enough to host the photos and allow me to link to them in this thread.
Zuwharrie is a forum focused on all models of Suzuki four wheel drive vehicles.

My build thread there: http://bbs.zuwharrie.com/content?topic=95861.0

Thank you Top for making an exception and allowing me to edit this thread.
Thank you Beekiller (zuwharrie) for now hosting the photo's


I have left the links to the photobucket images in place for nothing more than placeholders and maybe reference for google but have modified them to remove the [img ] tags and get rid of that annoying photobucket ransom demand
================================================== ======





Right, so the hotrod samurai's getting a new mill, ghetto style....


Picked up an '87 vw jetta cheap

http://i50.photobucket.com/albums/f3...z/jetta001.jpg
((picture of red VW Jetta deleted from Photobucket))

Went to town on the thing,

http://i50.photobucket.com/albums/f3...el001Large.jpg


Hmmmmm...... since when does the coolant from the rad leave a black ring around the bucket?

Meh, whatever..... moving on!

http://i50.photobucket.com/albums/f3...el003Large.jpg


1.6 VW turbo diesel, meet your new home!!

http://i50.photobucket.com/albums/f3...el007Large.jpg


Couple years ago I purchased a samurai with the 1.6 swapped in already. That proved to be somewhat of a failure as the compression ring on the first three cylinders was cracked in half and the cylinder walls were badly pitted from rust. Yet the thing still ran after a bit of coaxing to get it started.

I pulled the motor, returned it to a gas engine and sold it for what I had into it. essentially I got the adaptor kit and a bunch of parts to do the swap for "nothing" (It ended up costing me in other ways)

I was in the right place at the right time and got this car for $500. 383,000 km A little high, but whatever. It will get me running on this platform and allow me to work out any bugs on this "disposable" motor rather than a freshly rebuilt expensive one.
Judging by the number of bolts that were missing between the engine and the tranny, one or both had been swapped out in the past. There was enough crud coating everything to know it wasn't recent.

hamilton71801

Cool! You will need to stack it.

bullfrog5.9

tells us more bout it. was it hard to bolt up to the tranny of the little 4x4 where did u buy the adaptor plate or plates for it and any more pics

westcoaster

ACME ADAPTERS Suzuki Samurai Turbo Diesel

So get this....

I bought a used samurai with the kit already in it.

I had pretty much resigned myself to the fact I would be on my own with this swap.
There is a yahoo group for suzuki samurai diesel swaps. Tounge in cheek I asked what the chances were of getting tech support (acme adaptors run the yahoo group)
Not a problem, I get free tech support until the project is done AND the same product guarantee as the origional purchaser (acme part fails return it for a free replacement). Not only that, but they will provide tech support even if you didn't buy the adaptor kit from them (as in a competetors kit)

Jeff at Acme has snail mailed me another copy of the installation manual (free of charge) and has offered to send me a hose to overcome a problem I am having with the turbo oil return line.

I just have to give a shameless plug for Jeff and Acme adaptors. They are providing service that simply isn't heard of these day's

http://i50.photobucket.com/albums/f3...el010Large.jpg


http://i50.photobucket.com/albums/f3...el008Large.jpg


I still have to grind down the rear of the crank shaft on the diesel engine. Last weekend I managed to get the motor out of the jetta and stripped of any unnecessary parts. Now this weekend I get to start the adapting process.

I hope to have the samurai motor out and the diesel mounted before next week.

1-5-3-6-2-4

I've wanted to do that for a long time........not that I'll ever get around to it. but its still awesome.

westcoaster

Me too.... It's taken 5 years to get to this point believe it or not.....

My poor wife is tired of hearing me talk about it.

Raspy

I've been looking for a donor for mine. It's an excellent swap! And the 1.6 is probably the best choice.

Have fun with it and let us know how it works out

westcoaster

Alternator and passenger side motor mount in place.
Yes the drain hose from the turbo is interfering with the alternator. I need to change that around....

http://i50.photobucket.com/albums/f3...el011Large.jpg


http://i50.photobucket.com/albums/f3...el012Large.jpg


Covering up the rear main seal and the holes in the bolt holes in the crank (they go through to the crank case) in preperation for gringing down the crank shaft.

http://i50.photobucket.com/albums/f3...el013Large.jpg


Checking depth. Did I take enough off...

http://i50.photobucket.com/albums/f3...el014Large.jpg


Adaptor plate mounted.


http://i50.photobucket.com/albums/f3...el015Large.jpg


clutch and flywheel

http://i50.photobucket.com/albums/f3...el016Large.jpg


http://i50.photobucket.com/albums/f3...el017Large.jpg


A before pic of the drivers side filter housing.

http://i50.photobucket.com/albums/f3...el018Large.jpg



Prep for grinding the block to fit the angled filter housing.

http://i50.photobucket.com/albums/f3...el019Large.jpg


And installed. along with the drivers side motor mount.

http://i50.photobucket.com/albums/f3...el020Large.jpg

westcoaster

I'll separate the tranny from the engine to install in the samurai. Then the tough part of jerry rigging the plumbing begins. It's easy assembling everything. Now I have to make it work reliably....

It's a thing of beauty....

http://i50.photobucket.com/albums/f3...el021Large.jpg


http://i50.photobucket.com/albums/f3...el022Large.jpg


http://i50.photobucket.com/albums/f3...el023Large.jpg

1-5-3-6-2-4

.............well can't get away from it I guess. i just bought a '90 VW jetta diesel. get this 162,000kms. just over $1000.


I'll daily drive it to work until I find the absolute right Samurai and it'll keep the miles off my hotrod crewcab too I guess.

Raspy

1 5 3 6 2 4,

Excellent! What a deal!

Sammies seem to end up just wherever you find them. I see them in yards, and on the street with flat tires, parked out of the way here and there. Many of them won't pass smog and just get parked or sold dirt cheap.

You can get a nice transfer case gear set to lower the gears too. I got a 4.9:1 set and a Gorilla grip transfer case mount for mine. Since the case is divorced you can run a Toyota truck tranny if you want to. And in, I think 1987, Suzuki changed the OD ratio. A little research will set you up just right.

I sold my rag top and got a tin top with really low miles. Then I added limited slips front and rear, a set of 235s, a 2" lift with shocks, etc. Makes all the difference.

Next the diesel and I'll be set.

westcoaster

Nice!!!

I have the engine in now. No pics as I forgot the camera.

Have to get the plumbing set up and work out all the other little "issues"

Raspy

westcoaster,

Are you going to be able to make the tach work? And what will you do with all the carb wiring that is all over the place in there?

Also, did you get the Geo Storm starter?

Thanks for the pictures. Looks good.

1320

I was going to do a 1.6 16 valve swap in my sammy, but then I decided to put a ls1 in. I havnt done it yet, as the 1300 is still going. I use my sammy in the dunes (only, and all cut up) like a rhino, but better.

I measured it up for the ls1 though, and it looks pretty easy. I figured a glide probably, and a mostly stock ls1. I have lots of ls1 take outs that I ve replaced for street car guys going to storked iron blocks, so why not.

sammys are fun....looks good so far.

westcoaster

Right now the plan is to tie up the wiring and seal the connectors.

It's not set in stone that the diesel is staying in there. I may end up swapping back to the gas engine at some point.

The other alternative I have is to change out the wiring harness to the canadian version. The feedback carb, computer and all associated crap that came along with it didn't show up in Canada until 88.5 (my '87 samurai was imported from the states) That alone would eliminate a TON of copper, extra sensors and potential sources of electrical faults.

As for the tach....

Aparently all I need to do for that is weld a couple nuts and buy a ford tranny sensor to make the tach work....

A couple posts down will show what I'm talking about.... (complete with pictures and part numbers)
This "should" work for any gas/diesel conversion. (or anything you wish to measure the RPM on)
http://www.vwdiesel.net/phpBB/viewto...=3741&start=30