ZUKIWORLD Online | Suzuki 4x4 Editorial and Forum
ZUKIWORLD Discussion Forum => Build Diaries, How-To, DIY => Topic started by: deeprecon1 on July 26, 2010, 11:11:13 AM
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truck bed liner
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Diamond plate
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That'll be sweet when done. Can't wait to see it.
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I just did a 1.9 turbo diesel swap in a sidekick, if you have any questions shoot me a pm. 8)
~Jared
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Good luck! I'll want to see it when it's finished. Hope to see you on the local trails
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I'm going to follow your diesel conversion with big interest though I'm also going to put a VW turbo diesel in my SJ413 :)
As you can see in the topic of my SJ413 build that is a low budget project. Yesterday a bought a VW turbo diesel, 150000 km and in acceptable condition, for 500 Swedish kronor (that is about $70). I'm going to use a homemade conversion kit (adapter plate and modified flywheel). If you want I can post pictures of it in my topic here in Build Diaries. I have only engine mounts and some other small parts left to make.
$2940 for engine and conversion kit is a little over my budget. ::) I hope to make it for under $300 including service and changing the timing belt ;)
Kind regards from
Hannes in Sweden
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Those VW deisels are much more plentiful in Europe and everywhere else other than the US, making them much more attractive. In the US they are prized and quite expensive for a good one.
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I can see a business idea here ;) Maybee I should buy a few hundred VW diesels in Scandinavia for almost nothing and export them to US. :laugh: (Sorry deeprecon1 for the of topic)
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Sign me up.
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I can see a business idea here ;) Maybee I should buy a few hundred VW diesels in Scandinavia for almost nothing and export them to US. :laugh: (Sorry deeprecon1 for the of topic)
Just the engines and related hardware and you really COULD have a business!
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well got home today for the unboxing of the diesel... told myself I was only going to clean it up and prep ..lmao.
I got the new flywheel and adapter installed ... look really good. I removed the all the grime and and crud as best I could.
This thing is getting 3 inch exhaust straight out to a high flow ? brand muffler ... I got lots of fab work ahead but should be a kick in the pants ...
pics coming
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1.6td transformation
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turbo outlet
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oil filter offset plate SEXY!
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TAKE A LOOK AT THE ROOM I HAVE TO GET THE OIL COOLER LINE IN .... :o DAMN
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;D ok so I destroyed the VW factory alt. bracket. Remove the water pump POS .. I have read many places that it blows ...
So I ordered another high dollar part ... man this thing is a money pit for sure.
no more stinkin water pump sucking on the engine .. and routing should be a breeze.
* but a part must be made to do this right !
Oh and I got the one in two out model ... HD 55GPM ! this vw is going to run cool !
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so here is what i did with 2 hours .... tonight
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;) Looks Good!
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Is that an external electric water pump?
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Sure is ... going to have lots of water flow ...
Im pulling the stock motor out of my Zuk tonight and the install begins Sat ... hellya ! lots of pics coming...
Also I will post ton of pics on the water pump and how I route them. Remote water pump ...I know over kill but what the heck
... Stupid clutch kit has not arrived yet ..... oh well ...
I just ordered the GM alt kit from Jeff |removethispart|@ acme ....
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Ok engine is out ... ready for a new owner .. email for video of it running.
Debbie is now topless and and gutless ... I will post pics in the morning ... I found a RUST spot damn it ! ...ok I fixed it !
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Ok so now I can go spend Sat looking for parts and bits....
Should be running and on the road in a week .... I am really concerned about making sure the engine runs cool.
So my list grows ...
Drain the GAS
install stage 3 clutch " when it shows up !" I hate mail order .... i want it now
degrease engine bay and paint
mount radiator
order front bumper and LED lights
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lookin good, keep the pics coming! Ive almost got my turbo diesel sidekick back together and will start a thread soon. really curious to see how the water pump works out! 8)
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ok test fit is done ! check out my sweet overflow tank ... I found a complete 86 Jetta 1.6td if someone wants me to pull it and ship
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ok so I need my welder and some sheet metal fab ...
water pump and alt test fit complete ... I am not sold on my location 100% I did run a new oil line from the oil pump/cooler to tOK my radiator is done ... I found a Passat donor today at pick and pull... much better option than the Quantum IMO.
Just a little bigger and has straight hose outlets... so I had time to fab the Radiator support. this is rough til I can get her welded up ..
he turbo much cleaner ... IMO what do ya think ?
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and some more pics
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starting shape up nice ....
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Ok I am going for it ... I will remote the Battery somewhere? Copper manifold it is I have the hot side almost done...
I need to put the tees in and route houses ...
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It's looking good! :)
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the cooling system has me intrigued to say the least. would you build another turbo oil supply line for me? that is nice and clean looking. 8)
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Im friggin tired .... lol but the pics must go up ...
alt bracket in ...
new oil return line...
hot side water manifold done ....
new alt in ... needs the belt ... easy step
checkout the solution i had for the water pump ...
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and more
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Ok so I can machine garage fab and run hose ... But I am going to need some help on the electrical side for sure.
I dont pretend to know a thing about doing electrical work..... I know red cable plus ... black cable neg ....
So I am going to need some serious help this week. I did purchase the ACME wire kit for the glow plug with relay and fuse ....
So if you are a electronic wiz I would love your help and insight. I can run wire and make it look pretty just dont know a thing about it ....
Electricity equals = F^&% Magic ... lmao
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very impressive on the water pump, now you could run the manual pump for a back up plan huh? you should show Jeff what you did I think you have figured it out!!! ;D
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Ok so i only got a few hours in tonight ... the cooling system is done .... the electric pump works great.
I am going to revise the hot side manifold ... hose barbs ....
Take a look this thing should run cool for the most part .....
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the diesel lives and breaths .... I have lots of loose end to clean up but she is up and running
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congrats!! I HOPE to hear mine going clickity clack soon...
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Nice work on the project. You'll have to let us know how she handles.
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well got the cooling all dialed in so far.
still have a little air in the system and a few little bugs I need to work out .... i really want to find a accurate temp gauge ... for the ZUK
the video is just the first test run more pics of my set up tomorrow
CIMG0441 (http://www.youtube.com/watch?v=W-ZiL_YWJWc#ws)
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I forgot to mention today was the first test drive .... ;D I cant wait to get her on the road for a real test, my new calmini lift is stiff and bouncy still needs to be broke in right
intake tomorrow and exhaust this weekend
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Exhaust? I think it sounds GREAT now! Love that whistle.
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Ran her today for a hour straight ... never above 135F ... this is with no thermostat. I have a second electric fan going on when snail mail gets it to me.
VW emblems to be mounted as soon as they show up from snail mail ....
Lesson learned, dont drive down a bumpy road at any speed without securing the hood ...lol ! yes I have a new dent in hood small but a reminder to pay attention to what im doing.
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Nice work! Love that whistle too, turbo's are sure fun. Your lucky the hood didn't take out your windsheild and frame too! ;D
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Ok I MOUNTED THE NEW STEERING STABILIZER LAST NIGHT. " PRO COMP" BOLTS DIRECTLY TO THE AXEL AND STEERING ARM.PLACED THE $4 BLUE BOOT TO MATCH THE THE CALMINI DUST BOOTS.
I NEED TO POST SOME PICS FOR YOU ALL...
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ok so I have been tinkering here and there ... tear down rebuild over and over again ... lol
electrical almost done and happy ... some pics of progress
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Niiice. Bet she kicks butt on the trails when you're done with all that torque.
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Clean electrical work. :)
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it all looks great man, i may have missed it but whats the conversion cost up to this point/projected?
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its kind of shocking when you tally it up....I had to stop counting at 5+k just under the hood :o, I wonder how many wife's know about this forum? ???
it would be kind of hard to argue that vacation we could not afford this year.., or "you really don't need that heart transplant do you"...... :laugh:
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Same here. My little tracker has cost me a lot. But, I paid more than normal market value for the base vehicle...but I couldn't pass it up, when I test-drove it, it was oh so clean for being a 20 year old truck! I could probably sell it now for $1k-$2k less than invested...but NAH i'll keep it forever.
And good thing I don't have a wife otherwise she'd find this pretty fast...i spend over half my internet time on this site. If only I'd apply as much research into my college papers that I apply into my Tracker, then I'd actually learn something in those classes!
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well the wife went on a long vacation ... wont be back ... my 3 kids are almost grown only one left in the house.
So now its just two boys and lots of toys !
lmao we all live here like trolls :P
I want so bad to sell the sami "not going to happen" and buy a kick to convert to diesel .... well next year maybe, my 17 yr old son will pull his head out of his rectum and I can give him the sami ....
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wow, I was thinkin about doin that conversion but with what im making now.... eff that :P
be sure and post dyno results when you get it all done!
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So... You on the road now deeprecon1?
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Ok I need to take a ton of pics...
She is drivable but not ready for trails just yet....
I have been busy with work and life ...lol
I just got my rims in today .... will have tires installed this week.
Part Number: PCW52-5885R2.5
* Rock Crawler Series 52 Gloss Black Powder Wheel
* 15x8, 5 on 5.5 Bolt Pattern
* Backspace = 2.5 in.
* Max Load = 1600 lbs
* Finish = Gloss Black Powder Coat
* Center Caps sold separately.
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starting to come together :D
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Pic 1 two fan switches and glow pug momentary swtich
pic 2 all my wiring coming into cab. I have to put it in a fiberglass box "small "
pic 3 do these tires make me look fat ?
Pic 4 new shoes
exhaust next I swear ... she is on the road
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How much exhaust work needs to be done?
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Drone I have to have the whole thing done ..from the turbo all the way to the rear bumper .. and add a high flow muffler
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That looks great! How much lift and what size tire?
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Do you have the flange to come off of the turbo?
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Drone yes I do ...
you thinking flex steel exhaust ?
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That looks great! How much lift and what size tire?
3" calmini lift
Tires kelly safari tsr 31 x 10.5 x 15
750 out the door for 5 ! mount balance and stems
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Drone yes I do ...
you thinking flex steel exhaust ?
I'm sure you know deeprecon1 but I will say it anyways. definitely use a braided type flex coupler somewhere on the exhaust (closer to the engine than the tail) for vibration and harmonic reasons
mine has a 6" 'er and I think its too short, I'm going to a 10-12" 'er
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For sure J ... Im not sure I wont let a shop fab it .... I can pick up the flex coupler at auto zone 12" cheap enough
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OH I almost forgot ... tomorrow I visit the local rock crawler fab guy ... bumpers roll cage ...hell ya !
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