88 sami with a bhw and a w56

[sbluke55]

So I'm in the parts gathering and disassembling phase. Just bought parts to do the cam, timing belt and bs delete. Also bought the adpator from diesel conversion specialists. I liked them because they use the oem flywheel. Getting ready to pull both motors coming up. My question is can I use the oem accessory drive. Since the passat is not transverse I think it will just drop in and I can reuse the stock hoses and stuff. What do you guys think. I'm also using fast forward to do the harness.

 

[sbluke55]

So.... any ideas?

 

[PickleRick]

Im using the w56 matched to my bhw in a 1st gen ifs 4 runner.

I plan to use all my stock vw accessories, this especially includes the air conditioner. The only way i won't use the VW accessories is if they won't fit in the frame or hit the ifs/steering components.

Even then I'll try to make brackets to move them.

In the past I had a hose hydraulic shop take the diesel engine stock accessory hoses and attach them to the install vehicles hoses. Basically welding/braising the hoses from one vehicle to the other so both ends match. Lengthen and or shorten/ make bends or what not where needed.

 

[ManicMechanic]

You should be able to reuse the accessory but you might need to move the steering box to outside the frame. I switch to a steering box from a 90s body 4runner because the accessory's on my ALH would hit the samurai steering box or the sidekick power steering box.

 

[sbluke55]

Awesome. Thanks for the heads up. I'll give some updates as I go. Working on the passat here soon

 

[Chuck78]

Have you gotten into any major work with the swap into your Samurai? I'm curious how it'll work out. How much lift do you have on the suspension? YJ springs and spring perches over axle?
If you're in the Suzuki Diesel group or TDI swapped trucks group, I might have commented on your posts before.

 

[1.9ZOOK]

I'm using an IFS Toyota PS box, only thing is you might need a flatter pitman arm.
I'm spring over with Yota axles.

 

[Chuck78]

I'm using an IFS Toyota PS box, only thing is you might need a flatter pitman arm.
I'm spring over with Yota axles.

1.9ZOOK, what engine are you running in your Samurai?

How much lift, & how's your clearance between the high steer tie rod and the front of the oil pan?

That's the area that gives the most trouble on a full high steer Samurai swap. The ALH, BHW, & all newer PD & CR engines have the oil pump at the front of the engine at very front of the oil pan and nearly at the bottom.... The AHU, 1Z, 1.6TD, AAZ 1.9TD etc have the oil pump in the rear, and are the best / easiest for a Samurai swap.

 

[Chuck78]

I determined so far that a Doomsday Diesel clocked (early version) adapter positioning my ALH or an ALH-BHW mTDI hybrid at 15 degrees (Toyota V6 bellhousing adapter) or 20 degrees (Toyota 22R cylinder bellhousing) gives the best diff and accessory clearance, & allows you to shove the engine back to the firewall and clearance the firewall on the passenger side without having the heater blower motor in the way or having to rebuild the heater box from scratch in a better configuration.
The vacuum pump needs a bit of clearance to remove it. The biggest limiting factor on the ALH head for firewall clearance when relocation the engine rearward is the VW coolant flanges.you can only shove the 20 degree clocked engine back as far as the upper radiator hose nipple allows before it touches the blower motor bumpout area of the Samurai firewall

I might machine a custom billet 2pc coolant flange to gain an extra 7/8" of clearance to push the engine further back to get that extra clearance needed for the high steer tie rod to oil pan front.
You could probably gain even more than that if you designed it appropriately. It's only the very end of the radiator hose nipple that touches the blower motor area of the firewall.
And towards the passenger side of that, there is pretty much nothing in the way behind the firewall for clearancing for the vacuum pump and the rest of the coolant flange.

 

[Chuck78]

Also, clocking the engine 20° reduces the overall installation height 2 inches, as well as getting the oil pan further away from the differential, and getting the alternator etc further away from the samurai steering box and frame rail.

On a clocked application, if you got an all steel VW forklift pan that fits the ALH / BHW / etc, and a BRM oil pump or just the smaller higher volume/pressure BRM oil pump 23T sprocket and chain installed on the ALH pump (30T stock pump sprocket) on an ALH or BHW, with an ALH pickup tube, and clocked at 20° with the Doomsday adapter or a TD Conversions or Whitbread adapter, you could cut the bottom corner off of the oil pan and have more like 3-3/8" shorter installation height.

 

[1.9ZOOK]

1.9ZOOK, what engine are you running in your Samurai?

How much lift, & how's your clearance between the high steer tie rod and the front of the oil pan?

That's the area that gives the most trouble on a full high steer Samurai swap. The ALH, BHW, & all newer PD & CR engines have the oil pump at the front of the engine at very front of the oil pan and nearly at the bottom.... The AHU, 1Z, 1.6TD, AAZ 1.9TD etc have the oil pump in the rear, and are the best / easiest for a Samurai swap.

It's an ALH, but I stretched the frame and front clip 8" ,so the axle and oil pan have plenty of room.
6" inch lift

 

[coalminer16]

How do you get around the electronics with ecu ect? Friend has a sami with an AAZ and looking at the ALH but that is the hangup is the electrical part. Not doing an mtdi and not putting the dash in. I am doing it for him. I know mechanics but struggle on what is kept or removed for the electric.

 

[PickleRick]

Do you have the part number for the fork truck oil pan?

 

[jmodge]

https://www.partsplaceinc.com/vw-linde-forklift-1-9l-28-8-engines.html. Look here

 

[Chuck78]

Do you have the part number for the fork truck oil pan?

Unfortunately I do not, and it is not showing up in there on Parts Place. It has to be the ALH style block, 1999.5 and newer, or 1998 and newer excluding the AHU and other international variants of the AHU.

But... S&P Automotive stock it, & will even sell you a version modified with armor on it.

Metal Man Parts also sells it.

I looked extensively for any reference to the OEM part number online and I could not find it, and those were the only two sources that I could find of that pan without having the part number. Not a bad thing however, to support the small time shops that support us.

 

[Chuck78]

How do you get around the electronics with ecu ect? Friend has a sami with an AAZ and looking at the ALH but that is the hangup is the electrical part. Not doing an mtdi and not putting the dash in. I am doing it for him. I know mechanics but struggle on what is kept or removed for the electric.

If you send your computer out to a tuner, they can do an immobilizer delete, EGR delete, automatic transmission delete, anything you would need, as well as give you a stage 1, 2, 3, etc tune. It's going to cost more than a used mTDI pump however, vs keeping your donor's used eTDI pump plus paying $300-500 for tunes and probably the same amount additional if you hire out the wiring harness modification portion.

If you are looking for reasonable power and mpg, mTDI is just as good, and has proven to be far more reliable for those that have had both such as myself and many others.

If you're looking for enough power to potentially bend your ALH connecting rods, it's best to leave the tuning to a professional, and there is probably not a professional performance tuner of mechanical pumps readily available near you, so it is best to hire that out in the form of ECU tuning.
Without a skilled tuner, especially on an mTDI, you might have more smoke than his desirable under acceleration, when pushing for well over double the stock power output. Stock is 90 horsepower. These things are easily capable of double that with injector nozzle and turbo upgrades, mechanical pump or stock VW TDI mechanical pump with the electronic throttle and dynamic timing control. They are the same base pump, mTDI & eTDI, the Bosch VE rotary injection pump. Its the Pumpe Deuse 2004+ engines that are all computer controlled, no chance of running all mechanical. More power, more reliability issues to address with upgrades however.

 

[Chuck78]

The wiring through the 2007 models really is not that bad though. I still prefer mechanical but my daily driver is electronic TDI due to the OEM platform which I could not bear to part out! $400 ALH donor Jetta wagon that turned out to be one of the best daily drivers I've ever had, after a lot of door/window/lock nuissance repairs needed due to poor engineering on modern VW's. At least the engine drivetrain suspension and brakes is incredible!

 

[PickleRick]

Thank you. Is that the lowest profile oil pan that fits the ALH/BHW motors?

 

[Chuck78]

Thank you. Is that the lowest profile oil pan that fits the ALH/BHW motors?

Yes, the hybrid pans with the steel bottom and cast aluminum sides are likely about the same height as the steel pans, but the all steel pans can be cut and clearanced more if you are running the engine with an adapter that clocks it over towards the passenger fender to get the oil pan away from the front differential.
Also if you want a BRM oil pump sprocket and chain, you gain another 5/8" of additional clearancing ability for the oil pan, if not 7/8". That is normally done as a high performance modification for more oil flow and higher oil pressure, to spend the pump faster, but it is also a smaller and can gain you just a little more clearance.

 

[PickleRick]

What oil pickup would you run with the fork truck pan?

 

[Chuck78]

What oil pickup would you run with the fork truck pan?

The ALH pickup I believe, although some of the newest hybrid pans have a different steel bottom, the newest VW OEM versions, and one guy was saying that on his BHW with the hybrid pan swapped on, he thought he needed the 1.8T 2.0 pickup that has a gooseneck in it to lift if up off the bottom of the pan slightly, or else he would've had to trim the bottom of the pickup tube slughtly below the screen