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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.

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Old June 16th, 2015, 19:18   #1
Pry_P
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Default Suzuki LJ-81, 1981 truck / TDI AHU

Here is my first build thread. I've owned this suzuki LJ81 pickup truck for 2 years now and i've been contemplated doing a frame-off restoration, along with a diesel swap. Well I started last week. I used this truck only off-road and for plowing snow, but I want to put it back on the road.



This little 4x4 is quite rare. The ancestor of the Samurai. It came from factory with a 42hp 4 cyl 4 stroke 800cc mated to a 4 speed trans. previous engines used in those trucks were 2 strokes. 2 and 3 cyl.


I got a AHU tdi for cheap, 505 000km. I am using an ACME adapter kit to adapt the tdi to a samurai 5 speed transmission and for engine supports.
I will have to work supports a bit, since this kit is designed for the samurai and not for the LJ. So far, a very nice kit. it makes things easier.


Truck will need a spring over axle lift for the oil pan to clear the centered front diff.

I found a 1.9td AAZ fuel pump at pick-a-part kind of scrapyard. 6.50$ +tx... I think it was a good deal.

Bolted that pump to the tdi. I heard different theories about using a straight TD pump on a tdi. Some say it wont work and needs the tdi internals, some say it works fine but not a powerhouse. I am not looking to go over stock tdi power either. I will try to bench start the engine later this week and see how it goes. I am waiting for a sidekick 1.6 starter.



The turbo is a T2 from the same 1.9TD AAZ
I must use an angled oil filter housing from a 1.8T Passat for the filter to clear the left engine mount.
Will need to adapt another steering box. The stock one is in the way of the bigger samurai transmission.



The biggest part of this project will be bodywork. Fabricating new floors, Fenders, ect.

Here is how it looked as of last week.





Engine/transmission bolted


Bed is removed, Body ready to be removed from frame.

Last edited by Pry_P; June 16th, 2015 at 19:22.
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Old June 16th, 2015, 19:23   #2
Pry_P
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Frame with old engine/transmission still




Cab ready for rust removal/body work


I will do my best to keep this thread alive for the lenght of the project.
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Old June 16th, 2015, 19:37   #3
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I hate you.

I'd give just about anything for an LJ81 pickup down here.
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'96 B4V: 356,000 miles Malone 2+, PP520's, 6 speed, 02J short shifter, E-Codes, G60 brakes, Evo plate, DMF, stainless exhaust, heated leathers, cold weather package
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Old June 16th, 2015, 20:51   #4
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Finally!!!! I've been wanting to see a diesel LJ swap forever! I've been trying to pick up two LJ20v's for a couple years now, but I just can't seem to strike a deal with the guy
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Old June 17th, 2015, 04:38   #5
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I would so love to have something like this!
Abacus, not an LJ, but there is a Samurai project on Craigslist:

http://nh.craigslist.org/cto/5037419276.html
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Old June 17th, 2015, 04:49   #6
Abacus
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Wow, that's cheap considering what that adapter costs. I'd have plenty of time to finish it since I'd be divorced if I even broached the subject.

My old Zuk is still going strong locally, although it's sporting different tires and paint job. I do miss it occasionally but have to schedule time for myself so I know I don't have the time for something like that anymore.

I wish we had the LJ series down here, or at last be able to find a decent SJ410. The Canadians and Europeans got all the cool stuff.
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'96 B4V: 356,000 miles Malone 2+, PP520's, 6 speed, 02J short shifter, E-Codes, G60 brakes, Evo plate, DMF, stainless exhaust, heated leathers, cold weather package
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Old June 17th, 2015, 17:35   #7
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That's what those trucks are called.

Awesome!
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Old June 17th, 2015, 18:44   #8
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After a lot of injector bleeding, i got the engine to start hanging under the hoist
Happy to see that the bare 1.9TD pump is able to at least run the tdi.
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Old June 17th, 2015, 19:34   #9
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Awesome
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85 Samurai- ALH tdi equipped

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Old June 17th, 2015, 20:39   #10
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Get a land rover 300 TDI pump from england and never look back. Give Ryanp/darkside a shout. They're less than $200 and have an 11mm head.

Freaking awesome truck BTW.
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Old June 18th, 2015, 04:09   #11
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Quote:
Originally Posted by Whitbread View Post
Get a land rover 300 TDI pump from england and never look back. Give Ryanp/darkside a shout. They're less than $200 and have an 11mm head.

Freaking awesome truck BTW.
Thanks ! I will try to keep it this way for now, but might give it a try later. I want to concentrate $$ on frame and body restauration.
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Old June 20th, 2015, 15:38   #12
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You should join here and throw up a thread as well. Lots of diesel zuki swaps here.
http://bbs.zuwharrie.com/content?board=48.0
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Old August 11th, 2015, 14:13   #13
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Here are some updates
Got the engine installed on the frame, along with other stuff over the past few weeks.
I tack weld everything for now. When the truck will drive on its own power and everything run and drive as it should, I will then strip everything down, finish welding, blast and paint before final re-assembly.

I used dodge 318 engine mounts. had to cut and angle the stock LJ lower mount bracket to corect some angle.
Did a spring over axle lift. In stock form, the oil pan was sitting on the diff. pumpkin.
To clear the piping from turbo to intake, The cab will need to be lifted 2"

I had to completely redo the steering system. The original steering box was in the way of the larger samurai transmission. I used a Toyota 2WD power steering box mounted forward and on the outside and converted to crossover steering, doing all custom steering rods from 1" bar.

I used the old suzuki engine mount and made a custom tranny support.

Had to lower and relocate the transfer case back. Mounted it on a plate welded between frame tubes. Was able to use the rear driveshaft as-is. I shorten the center driveshaft, and add lenght to the front one.

I use a ''performance'' aluminium radiator for honda civic. It is small enough to fit well. Did a custom support for it mounted to the frame.

I made a bumper from 2X5 HSS tube, reinforced the front part of the frame with 3/16" plate, and made new front shackle supports from square tubes.

here are some pictures:


Front end and radiator.


New steering links. not shown on pic, but the upper drag link is now bent to clear the oil pan.


Transmission tail support


Toyota steering box installed


Custom knuckle adapter for crossover steering


Picture before Transfercase and steering box new mounts finished.
I used a passat 1.8T oil filter housing. It is angled, and the filter now clear the frame and engine support.


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Last edited by Pry_P; August 11th, 2015 at 14:29.
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Old August 14th, 2015, 15:20   #14
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Looks great. Its going to be an awesome little zuk
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Old December 20th, 2015, 12:02   #15
1.9ZOOK
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Nice!
Love those trucks,will be watching.
Glad you went with the toyota steering box,flat pitman arms are available
if the angled one hits the spring.

Last edited by 1.9ZOOK; December 20th, 2015 at 12:05.
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