ALH Samurai

1.9ZOOK

Veteran Member
Joined
Dec 13, 2015
Location
Downstream of a Volcano
TDI
ALH Samurai
Edit; The photo album has been lost,I will post a link to a new album if
anyone is interested...:(Hopefully most of the photos have been restored.
.
https://postimg.cc/gallery/fsridktc/
.
Hello everyone
I'm really enjoying all the conversions here and have learned much.
This will be my first diesel swap,first I'll start with a little background
on the Samurai. A year and a half ago I swapped in a 1996 GM 3.4 SFI
(transverse)engine mated to a Toyota W56 tranny.The engine was pretty tired
and I wanted something with better fuel mileage.I looked at the Toyota diesels because they would have been a bolt in,but
was non-plussed with the mpg of the 1KZ and the 2KD engine is NOT available in the states.So for good mileage
and availability the 1.9 looked really good.
Here is the Samurai...
I have done numerous mods to it


The main mod was stretching the frame and front clip/hood 8".
This was done not only so the V6 would have plenty of room but to get the engine behind the axle (closer to a mid engine )

Should have plenty of room for the ALH (the ALH is actually 4" longer than the V6)


All for now
Still collecting parts
Rice
 
Last edited:

1.9ZOOK

Veteran Member
Joined
Dec 13, 2015
Location
Downstream of a Volcano
TDI
ALH Samurai
Thanx 89vr6,
yea I had the pleasure of meeting and driving Jeff's (Acme)
1.6 Samurai and was impressed.That was in`06,I bought the adapter kit but never did the swap.(sold it)
 

1.9ZOOK

Veteran Member
Joined
Dec 13, 2015
Location
Downstream of a Volcano
TDI
ALH Samurai
Some more photos of the 3.4
Since it was a transverse engine I can use most of the cooling
and exhaust(2.5") parts.

I had no room for the exhaust on the passenger side so I did this,and
would like to run the diesel's exhaust around the front also,if turbo and
engine mount allow.
 
Last edited:

89vr6

Veteran Member
Joined
Sep 11, 2012
Location
Clarksville,TN
TDI
2000 base
You're putting the ALH in now then yes those should be plenty I'm running the stock Toyota isolators
 

Frankenyota

Member
Joined
Mar 24, 2015
Location
Tampa
TDI
ahu/88 4runner
Those are the same mounts I'm running in my 4runner/ahu swap. I got mine from Napa when they had their sale. They have a little bit of vibration at idle, but don't bother me at all. Nice samurai. I had a tintop and still regret selling it.
 

1.9ZOOK

Veteran Member
Joined
Dec 13, 2015
Location
Downstream of a Volcano
TDI
ALH Samurai
Thanx Guys,they have been bought.
Frankenyota I too had a tintop at one point,that's what inspired me
to get the best of both.A convertible hardtop.I cut the top of a wrecked one and modded it,4 bolts and it's on or off.


...and I did get something done towards the conversion on a snowy day.
the adapter cut out.
https://s19.postimg.cc/w1kveq19v/P1670256.jpg
 
Last edited:

89vr6

Veteran Member
Joined
Sep 11, 2012
Location
Clarksville,TN
TDI
2000 base
Looking good man, make sure you align everything nice n pretty or you'll end up with clutch failure
 

1.9ZOOK

Veteran Member
Joined
Dec 13, 2015
Location
Downstream of a Volcano
TDI
ALH Samurai
Thanx 89vr6
Yea it took awhile to lay it out.
On the lathe I made a plug with a center mark for both the ALH and an old 22ret engine
I have and stuck them in the end of the crank,then made centers on bolts that threaded into the blocks.
I used a pair of dividers to find all the centers on the plate by cross measuring from the crank plug to
the bolt centers and then between all of the bolts.
This photo is just a reinactment:) (already removed some of the bolts)

I used a 1" drill bit to countersink with so they came out a little rougher than
I liked,but it works.

Are any of you Toyota swap guys running the cover?
 
Last edited:

1.9ZOOK

Veteran Member
Joined
Dec 13, 2015
Location
Downstream of a Volcano
TDI
ALH Samurai
Finally had some time to work on the swap...
I could not source a 21mm od bushing anywhere so bought a 12x18x19mm
graphite impregnated bushing,then made a bushing for the bushing.
https://s19.postimg.cc/w1kvev6gj/P1670262.jpg
Also made a tensioner to eliminate the AC (thanx for whoever thought of this)
so simple.Just need to get the right belt length.
https://s19.postimg.cc/kcgvqxxib/P1670315.jpg
https://s19.postimg.cc/hidqdh0gz/P1670336.jpg
Got the engine in the bay,some things I thought would be a problem ,weren't.
https://s19.postimg.cc/ub1ud8c0z/P1670330.jpg
...like the coolant glow plug thing and the brake booster pump.
Have to get creative to join the heater line.
https://s19.postimg.cc/iagecmudf/P1670322.jpg
Here's one problem,I'm going to notch the frame rail and french in a piece of pipe to get the clearance it needs.about 3/4".
https://s19.postimg.cc/yo0dvov2b/P1670319.jpg
https://s19.postimg.cc/khkn0upgj/P1670355.jpg
Oil pan clearance,no problem.
https://s19.postimg.cc/lmep62bvn/P1670328.jpg

Power steering pump and line clears the steering shaft by 1 1/2".
 
Last edited:

1.9ZOOK

Veteran Member
Joined
Dec 13, 2015
Location
Downstream of a Volcano
TDI
ALH Samurai
Plenty of room up front...

...and back. I was originally going to rout the exhaust around the front of the engine but there is enough room over the tranny
without being too close to anything.

There will be enough room for the 210 york compressor.This photo makes it look bigger than the engine:D
 
Last edited:

1.9ZOOK

Veteran Member
Joined
Dec 13, 2015
Location
Downstream of a Volcano
TDI
ALH Samurai
Didn't realize I had the belt on wrong in that photo,should be like this.

I made two 14.5mm stand offs to get past the uneven alt housing.
and have to use two m8x1.25x100mm bolts to replace the stock ones.
 
Last edited:

1.9ZOOK

Veteran Member
Joined
Dec 13, 2015
Location
Downstream of a Volcano
TDI
ALH Samurai
Last edited:

Hasenwerk

Vendor , w/Business number
Joined
Nov 28, 2003
Location
Quesnel, BC
TDI
1982 Cabriolet (BEW|VNT17|Stage4), 1989 VW TriStar Syncro soon-to-be CR TDI (CBEA), 2001 Ford Ranger Edge 4x4 (ALH|VNT17|R520|Stage4)
Love the mount design - I did similar with the Vanagon and it works very well. There is one long term issue with this design and that is the adapter plate. If your adapter plate is aluminium you will eventually pull the studs out of it as there is nothing supporting the center mass of the engine transmission combo. For the Vanagon, I ended up making a set of brackets that bolt to the engine and to the transmission that use a bolt with some blue locking compount to ensure that the pulling force is not on the adapter plate but over the steel hard parts I installed - only the twisting force is transmitted into the adapter plate.
 

1.9ZOOK

Veteran Member
Joined
Dec 13, 2015
Location
Downstream of a Volcano
TDI
ALH Samurai
Thanks Hasenwerk-
Yeah that's a good idea,I figured there should also be more support somewhere mid span.
This is how it sits now,that's a huge space between mount points.
 
Last edited:

1.9ZOOK

Veteran Member
Joined
Dec 13, 2015
Location
Downstream of a Volcano
TDI
ALH Samurai
Thanx Andy,I was fortunate that the engine that was in it before was
pushed forward enough to not have to move the drive train for the 1.9 to totally fit.

This radiator that was in the rig is big enough to cool a small block Chevy
and after reading several comments about how cool the TDI's run I knew
it had to go.

I had a smaller radiator from a previous project that I think would be perfect.
It is 4.5" narrower and is meant to cool a 4.3L. so should be good.

So out with the big and in with the smaller...

...and that allowed room for the intercooler (which I had no idea where it was going to fit beforehand)
Intercooler isn't mounted yet.


Front view


just noticed the PS cooler is crooked,must fix.
 
Last edited:

1.9ZOOK

Veteran Member
Joined
Dec 13, 2015
Location
Downstream of a Volcano
TDI
ALH Samurai
This weekend was Bracket weekend...
First was the Mystical Orb coolant bracket



Backside hold down.

Next was the intercooler bracket from hell...
the bottom mount is an internally threaded aluminum stud welded to the radiator.
I don't know if the intercooler being so close to the radiator is a great idea
but there is really no where else for it to go,and it is still better than none,
I would think.


Then the double grip fuel filter bracket...
There is innertube strips glued to the two straps.

And lastly,the Toyoda PS reservoir bracket...

An overall shot of the engine bay.

I think the only thing left to fabricate is the exhaust.
 
Last edited:

hikeit

New member
Joined
Feb 21, 2016
Location
Boston
TDI
1.6TD & AAZ (Samurai)
Just finished dropping an AAZ into my SJ410/Samurai, can't wait to get it on the trails. I only have half an inch between the PS pulley and the steering gear, so might need to tweak something there... need to check how fast the 22R toyota was spinning the pump to know if a smaller pulley / shorter belt would work without overdriving the pump.

great to see your progress with the ALH so far!
 

1.9ZOOK

Veteran Member
Joined
Dec 13, 2015
Location
Downstream of a Volcano
TDI
ALH Samurai
@Brewer & nmz787
Thanks for the encouraging words Guys.

@Hikeit
I stretched the frame 8" and am using a Toyota steering box and it is still
close.
I'm not familiar with the aaz brackets,but could the bracket be modified to move the pump away from the box?
 

hikeit

New member
Joined
Feb 21, 2016
Location
Boston
TDI
1.6TD & AAZ (Samurai)
I'm not familiar with the aaz brackets,but could the bracket be modified to move the pump away from the box?
I'm using the engine brackets from acme, which bolt up to the stock frame location, on that side I needed to already push the bracket an inch further from the frame. I'll look at going another inch, there's plenty of room in the trans tunnel, and the motor's already sitting low, the oil pan i'm using was modified by the previous owner to avoid hitting the tie rod.

EDIT: realizing you meant the PS pump bracket... there's very little room between the pump and the timing cover, but i hate the bracket that's in there now, it has no adjustment and i have to disconnect the pump from the engine to change the belt... maybe time to make a new one that lifts the pump up a few inches to get out of the way completely

I'm also running a toyota box, and need to figure out what the previous owner did to the firewall, the steering wheel is too high up... I wonder if I could put in a tilt wheel from a tracker.
 
Last edited:

smurfie

Member
Joined
Feb 1, 2014
Location
Missourri
TDI
2.5, 1.9 and 2.0
Great build. I have a problem in my build with the ECM and the Brake switch connections. How have you handled this? Especially the two brake wires from the ECM. How did you connect them to the Sammi harness.
 
Top