www.tdiclub.com

Economy - Longevity - Performance
The #1 Source of TDI Information on the Web!
Forums TDIFAQ Articles Links Meets
Orders TDI Club Cards TDIFest 2013 Gone, but not forgotten VAG-Com List Unit Conversions TDIClub Chat Thank You



Go Back   TDIClub Forums > VW TDI Discussion Areas > TDI Conversions

TDI Conversions Discussions on converting non TDIs into TDIS. More general items can be answered better in other sections. This is ideal for issues that don't have an overlap and are very special to swaping engines.

Reply
 
Thread Tools
Old January 19th, 2012, 21:16   #1
number3114
Member
 
Join Date: Jan 2012
Location: Reno, NV
Fuel Economy: 32
Default '86 Suzuki Samurai TDI Swap

1986 Suzuki Samurai hard-top;
1.9L TDI 1Z diesel motor from a 1993 VW Passat: 90 HP and 149 ft lbs torque. So far, gets about 32 mpg in this vehicle;
Toyota 5-speed Transmission and T-Case with 4.7:1 low-range & 1:1 high-range;
Dana44 rear differential with 3.73 gears (tall gears were selected to keep highway RPM low: 2500-rpm @ 75-mph);
Reinforced Samurai front axle with heavy-duty 26-spline shafts;
Rear disk brakes using Samurai rotors, Audi 5000 calipers, and Acura Integra parking brake cables;
Toyota MR2 intercooler;
Volkswagen Quantum radiator;
Honda Prelude air-filter-box;
Jeep Wrangler fenders;
Suzuki SJ410 grill;
Dodge D50 motor-mounts;
Chevy S10-Pickup oil pan;
15-gallon petroworks fuel tank;
5-gallon stainless-steel jerry-can is integrated into the fuel system (automatically drains into main tank);
Air-lockers with on-board compressor;
Roll cage is welded into the body to provide solid mounts for tailgate & roof rack;
Compartments for storage & stowaway-winch are built into the floor;
Body, Frame & Wheelbase were lengthened four inches;
Three inches were removed from the cab-height (for increased stability & aerodynamics);
Leaf-spring mounts were raised one inch (to keep springs even with contour of frame and to lower vehicle);
FOA coil-over shocks can be adjusted to provide additional lift (and softer ride);
32-inch tires;
Many more parts from the local Pick-n-Pull.

Here are some pictures of the (relatively) finished vehicle. Before & After comparisons are in the next post, followed by some random pictures I took during construction. I'll try to get some more pictures and commentary up shortly.
http://forums.tdiclub.com/showthread.php?t=341609


Suzuki Samurai diesel front

Suzuki Samurai diesel rear

Suzuki Samurai diesel inside

Suzuki Samurai diesel undercarriage

Suzuki Samurai diesel TDI motor front

Suzuki Samurai diesel TDI motor side

Suzuki Samurai diesel construction 1

Suzuki Samurai diesel construction 2

Suzuki Samurai diesel TDI motor 1

Suzuki Samurai diesel TDI motor 2

Last edited by number3114; March 10th, 2013 at 19:44.
number3114 is offline   Reply With Quote
Old January 19th, 2012, 21:26   #2
number3114
Member
 
Join Date: Jan 2012
Location: Reno, NV
Fuel Economy: 32
Default Before & After



















number3114 is offline   Reply With Quote
Old January 19th, 2012, 22:14   #3
Zedbra
Veteran Member
 
Zedbra's Avatar
 
Join Date: Feb 2006
Location: Squamish, BC
Default

great job! you did a lot of work to make all that come together. those old samurais are fun little trail rigs, do you think a little more lift / tires are in the future?
__________________
2005 Jetta TDI GLS: VNT17VB, 3 Bar, Malone Stage 4, BiXenon retros, OEM Fogs, ST Coilovers, OZs


Zedbra is offline   Reply With Quote
Old January 19th, 2012, 23:40   #4
number3114
Member
 
Join Date: Jan 2012
Location: Reno, NV
Fuel Economy: 32
Default

Thanks, yeah it required much more work than I ever imagined. I would have probably not started it had I only known.

As far as the lift... I actually went to great lengths to avoid lifting it. The cab's been lowered 3" and the spring-mounts were modified to achieve an additional 1" drop (though my coil-overs do raise the vehicle back up an inch or so). It seems like everyone's able to make a decent off-road vehicle by lifting these things... It takes a little more effort to achieve those results by lowering it. As an added bonus, this thing is actually quite stable out on the highways too. I was more interested in an all-purpose vehicle for road-trips and exploring, and less interested in something that can only be used to crawl over boulders.

Having said that... I'm thinking about adjusting my coil-overs to increase the lift by maybe a half-inch... My theory is that if the entire weight of the vehicle is supported by the coil-overs (allowing the leaves to be completely slack in the vehicle's resting state), then I will have a good inch of travel on only the spongy coils. This should make for a comfortable ride on washboard and rocky roads. But as I start to bottom out, the beefed-up leaves should increasingly resist the force, allowing me to reduce the total travel necessary and allowing me to keep the vehicle low and stable. I admit that articulation will not be a strong-point for this vehicle, but that's what lockers are for :-).

Edit: I just took the vehicle on its first off-road trip and the suspension worked exactly as I had hoped... The ride was comfortable and I never felt the vehicle bottom-out. I also really started appreciating my 4.7:1 low-range, which I was unsure about previously.

Last edited by number3114; January 25th, 2012 at 20:53.
number3114 is offline   Reply With Quote
Old January 20th, 2012, 00:29   #5
number3114
Member
 
Join Date: Jan 2012
Location: Reno, NV
Fuel Economy: 32
Default



















number3114 is offline   Reply With Quote
Old January 20th, 2012, 01:26   #6
number3114
Member
 
Join Date: Jan 2012
Location: Reno, NV
Fuel Economy: 32
Default



















number3114 is offline   Reply With Quote
Old January 20th, 2012, 05:56   #7
Abacus
Veteran Member
 
Abacus's Avatar
 
Join Date: Nov 2007
Location: Nobleboro, Maine
Fuel Economy: And the miles just keep ticking away
Default

That's really sweet. I love my Zuk, but am still running the stock engine.

Why no swaybar disconnects? They'd help tremendously with your flex.
__________________
'97 B4: 441,000 miles Malone stage 3, PP520's, Stage 2 cam, SBC3, ARP studs, Westach EGT/Boost, Koni Reds/Yellows, 2 1/4" exhaust, 2.5" Cat, no mufflers or EGR, Evo plate, leathers
'96 B4V: 333,000 miles Malone stage 3 , PP520's, Scangauge, Bilstein TC's
'96 B4 (wife's): 210,000 miles Wettenauer Chips, Sprint 205's, Bilstein TC's
HEX-USB-CAN Vag-Com, A3/A4/B4 timing belt tools & manuals, IP socket, alt & specialty tools.
Abacus is offline   Reply With Quote
Old January 20th, 2012, 06:53   #8
markd89
Veteran Member
 
Join Date: Oct 2009
Location: Los Angeles
Default

The engine-bay looks factory -- like it's all meant to be there.

Really nice work :-)
__________________
1978 VW Bus 1Z TDI Build thread: http://forums.tdiclub.com/showthread.php?t=308793
markd89 is offline   Reply With Quote
Old January 20th, 2012, 07:34   #9
BarnyardsTDI
Veteran Member
 
Join Date: Oct 2010
Location: Austin, Texas
Fuel Economy: Depends on my right foot
Default

Amazing build!!! Great Pics.
__________________
BarnyardsTDI is offline   Reply With Quote
Old January 20th, 2012, 08:05   #10
rsxsr
Veteran Member
 
rsxsr's Avatar
 
Join Date: Jul 2007
Location: Loxahatchee, Florida
Fuel Economy: 29.25 mpg over 7200 mile trip.
Default

Very professional. Must have taken you all weekend to do.
__________________
1982 Diesel Vanagon Camper with an ALH TDI conversion.
rsxsr is offline   Reply With Quote
Old January 20th, 2012, 10:57   #11
number3114
Member
 
Join Date: Jan 2012
Location: Reno, NV
Fuel Economy: 32
Default About the sway ber...

There actually is a quick-release mechanism (sort of) on that bar, though it's hard to see in the photo. I have bolts connecting the bar to the leaf-spring plate (not welded-on studs w/nuts). On the right mount (left in photo), you can see the reflection off the bolt-head. "Quick-release" involves taking out those bolts and taking the nuts off the top mounts. I had pins and pin-locks on that same bar in a previous Samurai and kept breaking and loosing the small pins and pin-locks.
number3114 is offline   Reply With Quote
Old January 20th, 2012, 12:31   #12
dieselzuk
Newbie
 
dieselzuk's Avatar
 
Join Date: Dec 2011
Location: Eugene, Or
TDI(s): none,yet
Default

Excellent build. Thanks for all of the pictures too. What transmission did you use, the W56, or did you get a hold of a R151f?

I'm looking to do the same thing, but with an 98 AHU engine. I'm starting phase one very soon by buying a 1998 VW Jetta TDI. After that I'm going to slowly build up all of the parts that I need. Thanks again.
dieselzuk is offline   Reply With Quote
Old January 20th, 2012, 15:08   #13
rspring
Veteran Member
 
rspring's Avatar
 
Join Date: Sep 2009
Location: Florida
Default Nice!

Great build. Love to do a TDI swap into my Zuk. Have a 16v right now...
__________________
2004 .:R32 with too much to list - TDI swap underway. 2009 Jetta CR140 RC STG1+, 3rd Gen 4Runner - CR swap coming
rspring is offline   Reply With Quote
Old January 21st, 2012, 13:01   #14
CFM
Veteran Member
 
Join Date: Dec 2006
Location: Wells, Maine
Fuel Economy: All-time best of 73.2 mpg so far...
Default

Great job! If I hadn't seen the "before" pictures, I would have thought it came from the factory that way.
CFM is offline   Reply With Quote
Old January 21st, 2012, 14:55   #15
glitdi
Veteran Member
 
glitdi's Avatar
Default

That my friend is probably the best expedition zuk I have seen to date. I love the integration of the roll bar into the body. Starting a project in the next year or so like this how much money have you got tied up into it? (If offense is taken feel free not to answer)
Really like the job you did congrats on a great expedition/zombie apocalypse/ daily driver/zukyotawagon
__________________

OCD Member #4

Last edited by glitdi; January 21st, 2012 at 14:58.
glitdi is offline   Reply With Quote
Reply


Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump

Similar Threads
Thread Thread Starter Forum Replies Last Post
05 TDI into Suzuki Sierra/Samurai/sj413 Bluesuzy TDI Conversions 11 April 3rd, 2011 07:55
1988 suzuki samurai 1.6TD "debbie" swap CaTdi2002 TDI Conversions 1 July 30th, 2010 19:48
TDI-M to Toyota in Suzuki Samurai (sort of) deepmud TDI Conversions 5 March 30th, 2007 11:43
1985 1.6L tdi being swapped to a Suzuki Samurai Larrysoffroad TDI Conversions 18 March 11th, 2007 23:11
1987 Suzuki Samurai with TDI-M deepmud Other TDI/Diesel Picture Gallery 4 September 9th, 2006 10:15


All times are GMT -7. The time now is 18:25.


Powered by vBulletin® Version 3.8.5
Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.
Copyright - TDIClub Online LTD - 2014
Contact Us | Privacy Statement | Forum Rules | Disclaimer
TDIClub Online Ltd (TDIClub.com) is not affiliated with the VWoA or VWAG and is supported by contributions from viewers like you.
1996 - 2013, All Rights Reserved
Page generated in 0.15379 seconds with 10 queries
[Output: 130.29 Kb. compressed to 109.01 Kb. by saving 21.28 Kb. (16.33%)]