ALH Samurai

1.9ZOOK

Veteran Member
Joined
Dec 13, 2015
Location
Downstream of a Volcano
TDI
ALH Samurai
Thanx Smurfie
I haven't gotten to the wiring yet but the plan is to get hold of a
complete interior ALH harness and only use what is needed of the Samurai
harness for lights, wipers,etc.
I'm also swapping in the ALH instrument cluster (which is going to consist of
some creative dash repair :) )and would like to be able to rig up some sort
of cruise control buttons by adding the brake and clutch switches.
Hopefully going this route I will be avoiding much splicing.
Sorry I can't help with your wiring maybe someone reading this can.
 

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)
On the ALH / BEW there are two brake wires to the ECU. When the brakes are off one must be 12V and the other ground. When the brakes are on, the condition is swapped.

The original Volkswagen brake switch does this or

R/BK goes to the brake light. Which is ground when the brake light is off and 12V when it is on. The other wire can go to a switch (MOSFET or relay) that gives that wire the correct signal when the brakes are applied.

Key is they much switch at the same time, so this is why I use a switch in all the harness that I do for customers.
 

1.9ZOOK

Veteran Member
Joined
Dec 13, 2015
Location
Downstream of a Volcano
TDI
ALH Samurai
Thank you Hasenwerk and Bubbagumpshrimp...
OK I heeded your warnings about the importance of accuracy with the
adapter so I ditched the first one which I knew was not right.Finally
met up with an acquaintance who has a nice Bridgeport with a DRO and
made a new adapter that I am real happy with.I decided to beef it up and
go full circle on it,this way there are two more bolts holding the bell housing
and three more on the engine side.I will feel much better now when I am
in low gear (78 to 1).


Started fitting the V6 Toyota starter,wont take much fabbing to mount it,
the bottom hole can be used just need one up top.

...and there will be plenty of room for the exhaust.

I realize that this will lock the oil pan in place but I figure if there is a need to remove the pan then the
whole engine will probably have to come out anyhow...:)
 
Last edited:

1.9ZOOK

Veteran Member
Joined
Dec 13, 2015
Location
Downstream of a Volcano
TDI
ALH Samurai
Adapter Plate is on.

Toyota V6 starter is mounted with 0.18 clearance for gears.
You can see the chunk of aluminum that was added and new mounting hole.

And a shot of the serpentine belt.
 
Last edited:

1.9ZOOK

Veteran Member
Joined
Dec 13, 2015
Location
Downstream of a Volcano
TDI
ALH Samurai
I'm posting a bunch of photos of what was done before the diesel was even considered.
Toyota mini truck axle modded to to accept a toyota E-locker and converted to cable
actuated.I used the e-brake lever to engage it.(with low gears who needs an ebrake)


The Samurai bench seats are hard to find in good shape and uncomfortable anyhow.
I traded a `96 tracker engine swap for the seats,15gal. fuel tank,brand new
BF Goodrich Tires,and other stuff.The rear seat out of the tracker was just too nice so I did all this work just to fit it.(gained 4" in width and still had to modify the bench seat)And it folds up like the original and two bolts remove it.





More of the 8" frame and front clip stretch.



Frenched in LED brake lights.

 
Last edited:

1.9ZOOK

Veteran Member
Joined
Dec 13, 2015
Location
Downstream of a Volcano
TDI
ALH Samurai
Vented Rotor upgrade.

Drilling out Samurai 5 lug rotors to fit 6 lug Toyota for the rears.

Reversed front shackles,high crossover steering with 1 ton Chevy tie rod ends.
The front and rear leaf springs are 47" rear Toyota truck with two leafs
removed from the rear set and one removed from the front.

The reverse lights are LED strip lighting.
Kinda blue but they will work.


 
Last edited:

1.9ZOOK

Veteran Member
Joined
Dec 13, 2015
Location
Downstream of a Volcano
TDI
ALH Samurai
Dash Work & Jetta stalks
Still have to clean up the bottom edge.

.

.

.

.

.
Start of wires

.
Fan Temp. Sender

.
Exhaust
 
Last edited:

1.9ZOOK

Veteran Member
Joined
Dec 13, 2015
Location
Downstream of a Volcano
TDI
ALH Samurai
TY greengeeker
Cleaning up the bottom edge may be a work in progress forever:rolleyes:
OMG,can this really fit in a Samurai?


Apparently so,with a lot of manipulation,lengthening,and kind words :D


Still have a ways to go but getting there.Should be getting the tuned ECU this week.:)
 

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)
You seriously didn't put ALL that wire into your vehicle? :confused:
 

ToddA1

Top Post Dawg
Joined
Aug 3, 2011
Location
NJ 08002
TDI
'96 B4V, '97 B4 (sold), '97 Jetta (scrapped)
X2 on the dash. I had to Google the stock dash... how'd you do it? Fiberglass?

-Todd
 

1.9ZOOK

Veteran Member
Joined
Dec 13, 2015
Location
Downstream of a Volcano
TDI
ALH Samurai
Thanx Todd
I annealed a piece of 14g. aluminum and shaped it over a wood
buck,then used Vulkem 116(polyurethane sealant) to glue the formed aluminum in place and to
adhere pieces of insulation type foam in all the gaps then bondo-ed.
The volkem116 is super tough I use it anywhere I want to keep water out.
The only down fall is it takes about a week to thoroughly dry.


 
Last edited:

vtpsd

Veteran Member
Joined
Aug 15, 2013
Location
Vermont
TDI
03 jsw TDI, audi 90 AHU swap
awesome! one of the most exciting part of a project like this
 

1.9ZOOK

Veteran Member
Joined
Dec 13, 2015
Location
Downstream of a Volcano
TDI
ALH Samurai
Yep! Thanx vtpsd
I wasn't planing on starting it so soon,the starter was out of adjustment,readjusted,
bumped the starter expecting a grinding noise and the engine started instead.
Maybe one full turn and it started,shut it of immediately because of no fluids.lol
 

1.9ZOOK

Veteran Member
Joined
Dec 13, 2015
Location
Downstream of a Volcano
TDI
ALH Samurai
@ToddA1-Yeah I wasn't expecting that,some gasser swaps can drain a battery trying to start them :)
I'm pretty stoked,took it on a 10 mile ride half road half dirt,wanted to flex it out a
bit on the dirt hills.I need to soften the suspension a little.
Anyhow it runs great and has a lot of "go" Malone 1.5 tune,125hp,220 torque.
Coming back down the long grade the temp dropped from 190 to just above the
three little bars on the Jetta temp gauge,I'm guessing 140ish.Outside temp about 60º,Is this normal?
I can't imagine what it will run at when it's 20º
 

ToddA1

Top Post Dawg
Joined
Aug 3, 2011
Location
NJ 08002
TDI
'96 B4V, '97 B4 (sold), '97 Jetta (scrapped)
Temp drop like that isn't normal. It should be able to maintain 190-195°. Good thermostat?

-Todd
 

1.9ZOOK

Veteran Member
Joined
Dec 13, 2015
Location
Downstream of a Volcano
TDI
ALH Samurai
Thanx Redg
I've always liked the Skoda Rally cars,to bad the nearest Skoda dealer to me is Nicaragua,about 3000miles south of the border :)
The engine and car had a horrible shake,discovered it was a blown engine mount.

So I used the cheap German(if there is such a thing) puck type mounts
and welded up this ****ty looking A frame thing and now the engine does
not shake violently when turned off.

Will get the right sized bolts some day.
 
Last edited:

1.9ZOOK

Veteran Member
Joined
Dec 13, 2015
Location
Downstream of a Volcano
TDI
ALH Samurai
The vibration comes right up through the seat,it's like getting a sonic ass massage lol :p
Would like to get rid of that but I think it is something I will have to try to ignore.
 

1.9ZOOK

Veteran Member
Joined
Dec 13, 2015
Location
Downstream of a Volcano
TDI
ALH Samurai
@ ToddA1
I changed out the thermostat and it comes up to temp fairly quick (95º out side temp) and never moves from the 190º mark,almost disturbing,I'm use to watching my Toyota gauge move up and down a little.
Did one of my fuel tank mods I do for radical rockcrawling angles...
it is my poor mans version of the swiveling snowmobile pickup or the walbro
teed puck pick ups.



Had horrible death wobble (bump steer) was due to to some crummy
suspension set up,change the whole front end and now steers like a
uhmm Volkswagon... :D
Also got the gas gauge working with the chevy sending unit,
Sending unit is 240 empty 33 full,VW is 255 empty 55 full so I
added a 5w 18 ohm resister so it is 258/51 close enough.
Also had to reverse the wire on the rheostat because it was reading backwards.
Took it on another shake down cruise,50 mile and I think I used less than 1.7 gal.
some of that driving was going up a steep grade for 11 miles @ 25 to 35 mph. and
some 4WD
Here is an entertainment only video.
https://youtu.be/zDrmwNzDqJU
And a photo of the volcano I live under,Mt. Shasta with Castle Crags.

I'm starting to have some confidence with the swap now,it is still hard for me to tell when I'm lugging it.
I'm use to a Toyota 22RE with about 116.5 hp and as much torque...lol
Thanx for looking Guys
Rice
 
Last edited:

ToddA1

Top Post Dawg
Joined
Aug 3, 2011
Location
NJ 08002
TDI
'96 B4V, '97 B4 (sold), '97 Jetta (scrapped)
I've read that there's a lot of delay built into the temperature gauges, so I wouldn't be concerned. The fact that it's now stable is pretty normal. I see 195° when fully warmed up, regardless of ambient temperature. When I saw funky readings, it was thermostat related.

As light as that thing is, I'd think anything below 1.5-2k rpm is lugging it.

-Todd
 

1.9ZOOK

Veteran Member
Joined
Dec 13, 2015
Location
Downstream of a Volcano
TDI
ALH Samurai
Been 3 months since an update and have made a list of things to fix
or modify. (hoping that may end some day...:D)
1st and easiest was modifying a badly seeping fuel tank.
I was having problems with the chevy sending unit so bought a used stocker.
The entire top was cut off because of the obscene amount of patches and
penetrations. (embarrassed to even show this:eek:)


Added two baffles...

Made a fitting to accept the stock gasket...

Welded the new top on and made a hold down ring to keep it in place.

Not too worried about pinholes because I will seal the tank with Bill Hirsch
tank seal.I've used the sealer before on other tanks,works good as long as
no heat is applied after sealing,otherwise pieces of the sealer will eventually clog everything.
(been there,done that)
Rice
 
Last edited:

ToddA1

Top Post Dawg
Joined
Aug 3, 2011
Location
NJ 08002
TDI
'96 B4V, '97 B4 (sold), '97 Jetta (scrapped)
Looks good. Think the baffle openings will pose an issue? Maybe trap doors would be better?

My Rabbit pickup tank had some pinholes. No aftermarket support for the pickups, but I just painted the outside with leftover POR 15, and it's been fine since.

-Todd
 
Top