ZUKIWORLD Online | Suzuki 4x4 Editorial and Forum
ZUKIWORLD Discussion Forum => Build Diaries, How-To, DIY => Topic started by: Jluck on August 16, 2010, 09:33:02 PM
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well I figured I should put my build up sooner or later....
Ginnie pig; 1992 sidekick 4 door jx
here's the homely starting point;
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Ok man lets see those pics start rolling ...lol :P
I think I am going to swap a sidekick next ... I am at a slow crawl trying to get the cooling right the first time. NOT happy with the quantum radiator at all. The hose routing is a cluster F%#^ ...I am really thinking manifold right now. cold side and a hot side manifold ... we shall see
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here's the old "power"plant
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just like a cooking show....schazamm!!!! 30 minutes later its done. :P sorry about the lack of actual in process pics had no plan of doing a thread until recently, but I promise lots more pics of the rebuild. 8)
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well after 3 days of work its in an running. the clatter coming from under the hood is music to my ears but.........
after almost one tank of fuel I knew something was up but kept telling myself it was nothing major. ;) after deciding to be honest with myself I realised the engine I bought that was a "low mile German import 1.9 aaz turbo diesel" was actually a 1.9 aaz Canadian with a bad headgasket,bad injection pump gear,bad harmonic balancer,leaking injection pump, two leaking injectors and many incorrectly installed items I wheeled her back in the shop and got out the tools. :(
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i gave her a spritz of paint and got some goodies..... ;D
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got my exhaust back from ceramic coater and head back from aluminum head rebuilders of portland or. (supposed to be the best for vw diesel heads), more paint and pretty stuff.
went with the thickest ("three hole") O.E.M. metal headgasket to lower compression so i can raise boost pressures. >:D
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here's a couple pics of my gauge set up. ;D
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here is a photo of my kick as it sits now, lift spacers, trimming and 31's 8)
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here is some pics of what kind of stuff I had to deal with :-\
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this is how I found the injection pump gear,appears it was installed with a 8 pound sledge hammer (wow I wonder why it was leaking) >:( look close at the key groove.
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more goodies. ;D
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this is a easy to build injector pop tester I built so I can rebuild injectors. (feel free to copy it works great). :P
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updated motor pic (as it sits today)
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teaser for phase 2 or 3 where ever I'm at now. :P
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here is what I scored for my coolant plumbing. some prototype five layer one of a kind silicone one piece hoses that a local vw guy had built. WAY COOL. soooo much cleaner than the multi fitting and 13 hose clamp abortion that was before. 8)
~deeprecon1 this is what I did, if you look close at a earlier pic I trimmed the driver side MM and added metal to the bottom of mount to replace any integrity that may have been removed~
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Thanks for sharing! +1 TP
:)
-Eric
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got my water pump today. and what I learned....there are two types available one complete assy. with a cast iron impeller and just a bolt into housing type with a funky stamped sheet metal impeller. vw shop I deal with says the latter type have a "extremely" high failure rate. :o
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to be able to fit the oversized silicone hoses and to avoid the mess of elbows and hose clamps needed with the acme kit I did some mods.
1) cut front flat part of motor mount (above the bend to minimise loss of integrity)
2) added material to open bottom of mount to replace what I cut out (and left a drain slot at lowest point)
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Ya it looks like we need to hire a hose guy ! lol
I am fed up with the crazy hose clamp action really ...
J now you are making me feel self conscious about not making my motor look all pretty ! .... damn you
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I think its time to rethink that mount, why not make it underslung or something. there is gotta be a better way, its f-n ridiculous as-is
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I said F $#% it Im building hot and cold side manifold ... I hope it works ???
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well here's my progress for the day. 8)
here you can also see the finished plumbing
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Looks good. Any idea what the specs are on the new engine compared to the stock 1.6L?
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I will be sending my pump to Giles in Canada when I can find an extra 1k laying around, when I get that back I should have a 110-125 hp 175-250 tq motor (estimate)(but collaborated guess with Gilles) >:D
also have my turbo at bell turbo to work his magic. (don't know if that will gain much, just cant boost a IDI motor much) >:D
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well waiting on snail mail to deliver more under hood stuff figured I would see what else I can f#*k up on my 'kick... I cannot get the rear axles out they are a PITA! got a bigger slide hammer will try that when hands heal. :'( (and yes I took off all the nuts!)
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spools in, twin sticks are in time to tear down the front and regear 8)
more on the diesel soon....(waiting on parts)
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well progress is slow. I borrowed my father in laws tractor to use on the house I'm having built soooo.....you know what its like to borrow somethin from family, 3 hours of use and BANG!!!! goes the front hub....FYI john Deere parts are more expensive than Suzuki parts >:(
any way all I had time to do was mount the oil filter, I had it in a very bad place before. now it looks better I will just have to clean my engine bay at oil changes..
it fits really nice in otherwise unused realestate
what do you think ??? any better ideas??
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well, not alot of time to tinker with the 'kick but hers a couple current pics, got a few odds and ends done on 'er but nothing major.....BTW, I think I am going to rebuild the injection pump my self and save a ton of cash. and hopefully be off the road by hunting season.
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you should mount a drip pan under the filter so it doesnt mess all over your inner fender after every change.
matt
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got time to work on the 'kick so here's some current pics. (crappy ones)(I don't think my camera likes oil and being dropped daily)
no motor parts to finish that part so time to put on some other goodies that are collecting dust.
recent work..... trail tough bumper, smittybuilt winch (nice for the coin), regeared front and rear, rear spool, new front struts and brakes, 31" bfg's and procomp wheels.
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That thing is bangin man. I'd love to put a diesel in my Sammy but alas, I don't feel like it :P
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coming along very nice!!!
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this is something I have always wanted in a wheeling rig. its a in cab winch control from roadlessgear.com I was going to build my own but at the price of theres I could not resist. ;D
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here's a couple pics of the winch set up and how I modified the remote plug.
I first tried the solenoid box mounted to the winch motor but it left the box as the first point of contact. so the solenoid box is going on top of the drum.
smittybilt winches (and maybe others) have the plug on the top (or face) of the solenoid cover and with the trail tough bumper I could not get the remote inserted, I needed it on the front so I moved it.
BTW, the new cable and roller fairlead are not being used so if anybody is interested...pm me
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BTW......sorry about the horribly trashed interior pics, just looked at them, real embarrassing.(trying to do/modify or "fix" 10 things at once) :-[
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I just found it amusing that your new winch switch is mounted directly above your bottle opener. :D
With an in-cab or remote winch controller being used I will often just mount the control box under the hood. For the few times you need to use the hand remote you can just run it out from under the hood. But it does look cooler mounted on top like that.
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I dedicated a whole day to the sidekick today. the house can wait (I needed a break) ;D
well first thing I did was finished the winch mounting (I didn't like the nuts on the hawse bolts so I changed 'em out) and my synthetic winch rope showed up yesterday and I will spool it up at a later time.
then on to the injection pump. I decided to just reseal the leaking distributor head instead of a full rebuild which could have had disastrous results(the pump was a new rebuild anyway)(it was leaking due to a blown seal from overpressureing it with the stock 'kick fuel pump)
the reseal went good and it might just work when I'm done. :P
I went ahead and rebuilt the injectors my self too. (much easier than I always thought) these diesel are not some mysterious dark art that I always felt they were.
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got the inj. pump and rebuilt injectors installed, felt like a real milestone!! ;D got allot of other little things done too. like oil cooler and remote oil filter most the way done, new glow plugs and harness put in, injection lines on....I think that's all.
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All the projects are coming together. Looks good under the bonnet. :)
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I finally got some time to work on the 'kick last night (and this morning till 4:00am) and its almost up and running figured i would update the thread before it went stale. PICS SOON I PROMISE.
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I am looking forward to hearing the good news, this go around from what you have said from before. :)
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Way to hang in there Jluck, that's what makes a Suzuki enthusiast a special animal!
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well hers the update.......IT RUNS......IT RUNS GREAT........BUT.....THE BLOCK IS CRACKED!!!!!!!!!! :'( :'( :'( :'( :'( :'( :'( :'(
and I got the "craigslist" warranty to-boot.
dont know what else it can be its still over pressuring the radiator. if I had any hair this is where I would pull it out.
the "mad max manifold" is make shift until I get the turbo back.
this is probably deserved for using a non Suzuki power plant.
I think its time to cut my losses...ANY OFFERS?????
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Oh man brother, that is such a bitch! I feel your frustratioin, really. Are you sure your block is cracked? Is there any other way that could possibly be pressurizing the rad?
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Could be the head gasket. Did the head rebuilder check the head for cracks?
How about the thicker head gasket? or is it a stacked set of gaskets?
You could do a leak down test to figure out which cylinder it'd coming from
Also, on a Diesel, you don't worry about lowering the compression for running
higher turbo boost, the more the better, some tractor pulling diesels run compound
turbocharger systems boosting the engine by as much as 100 PSI :o this also
adds quite a bit of power as well, the advantage of too much air in a Diesel engine
is that the exhaust gas temps go down, and burning all of the fuel instead of
leaving black smoke clouds
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I dont think its a head gasket. its new oem metal one with apr head studs and a rebuilt head. I got my turbo back (another wasted 500 bucks) put it on and went for a longer drive. its still screwed. too bad cuz' it runs awesome!
anyways enjoy the pics. :(
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And the head stud torque is correct, does the spec change with the studs?
I was also wondering if the studs were too long and were bottoming on the
shoulders of the studs before clamping the head properly.
How about the intake manifold? is there any coolant running thru it?
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And the head stud torque is correct, does the spec change with the studs?
I was also wondering if the studs were too long and were bottoming on the
shoulders of the studs before clamping the head properly.
How about the intake manifold? is there any coolant running thru it?
the studs are correct for the engine and torque double checked (but I will check them again tomorrow) it is doing exactly the same thing as before thats why I tore it down. and I did not find a obvious "blow" on the old gasket which makes sense now. and the manifold is dry.
Could be the head gasket. Did the head rebuilder check the head for cracks?
You could do a leak down test to figure out which cylinder it'd coming from
Also, on a Diesel, you don't worry about lowering the compression for running
higher turbo boost, the more the better, some tractor pulling diesels run compound
turbocharger systems boosting the engine by as much as 100 PSI :o this also
adds quite a bit of power as well, the advantage of too much air in a Diesel engine
is that the exhaust gas temps go down, and burning all of the fuel instead of
leaving black smoke clouds
also on this. the AAZ motor is a indirect injection motor so it cannot take boost like a direct inj motor like you talk about here
How about the thicker head gasket? or is it a stacked set of gaskets?
its just one head gasket ::)
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After reading through here, Jluck, I can definately see why you are not happy with your T/D setup. I hope that you get it figured out soon, and for good.
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I was just looking into your problem, seems the heads are prone to cracking
but the block cracks are around the bolt holes in the block and it causes oil
to leak into the coolant.
The cracks that are common in the head are usually between the valves, and
that the heads are junk once overheated and warped, warpage limits are very
tight.
The head gaskets come in different thicknesses to compensate for the piston
popping out of the top of the block, and are supposed to be matched with
the same gasket, 1,2,3 holes or notches, I don't know if it's a different gasket
or just a different thickness on the notch gaskets.
The common cause of exhaust in the coolant is a warped head or gaskets not
sealing, and there is a special gasket adhesive that is supposed to be used and
is a must according to what I have read.
Hope this is your problem and not a junk motor, did you use the sealant on the
head gasket?
Wild
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I did it as instructed by my local vw diesel guru. (no sealant other than what comes on it) the head was checked and rebuilt too. I just dont know.....I will torque it down again (maybe tonight) once the sobbing stops. :'(
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thanks for the help wild, I think I have spent as much time on it as I'm going too. its time for plan b or c or d wherever I am now. maybe back to zuk power?? maybe cut my losses. just don't know.
I did go out and check torque and went up five pounds but no changes. still screwed. thanks again.
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FOR SALE.
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FOR SALE.
sad when a build thread ends with FOR SALE >:(
sorry your having so much trouble, but is now the time to turn back, or kick it's ass?
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Oh dude... I just read through this... I'm bummed for you, seriously...
Let's find a block.... Don't sell it yet.
-Eric
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Oh dude... I just read through this... I'm bummed for you, seriously...
Let's find a block.... Don't sell it yet.
-Eric
Seriously, im with Eric !
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thanks for the encouraging words guys but I think this kick has officially ran me out of curse words. I will take some time to think on it.
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thanks for the encouraging words guys but I think this kick has officially ran me out of curse words. I will take some time to think on it.
Good.... just take at least the Holiday break off and then consider what to do..
-Eric
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I have been enjoying your build, and it is looking great.
After a year (in time, not work) my V6 conversion was just where you are now. My transmission would not engage torque converter, computers not talking to each other. Finally I bought new wiring and new computers, rewired the computers and still same place (using old computers). FRUSTRATED Then found an indication that a power source was not functioning correctly, fixed it and most issues went away.
When you are starting the learning curve at the same time as building your conversion, setbacks at the end seem catastrophic. I was thinking all the time about what was wrong with my wiring for over a month. I hope you find the solution.
While my wife doesn't understand why we do this, she DOES understand your pain.
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thanks for the encouraging words guys but I think this kick has officially ran me out of curse words. I will take some time to think on it.
We could always help you make up a few new curse words if necessary >:D
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At least for now it's back to the drawing board.'I'm thinking about putting in a gas 1.8 turbo from a Audi tt roadster. If I can never achieve the mpg that I originally wanted in the start I might as well have something with hp. What do you guys think? ???
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If your going to go the turbo route, why not just do a 16V Motor? Easy to get, easy to turbo now that much of the developement has been done already, and more than enough power to make you happy. You'll still get decent gas milage, I average over 21 with 32x11:50 tires. *Your milage may vary. If you could just sell off your desiel stuff, you could do this turbo thing reletivily quickly, especially since you'll have plenty of help from people who have already suffered through all the frustration of the " learning curve." Hell, if I had to put together another turbo system now it would be sooooo much easier. I can tell you exactly what works and what doesn't.
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That's exactly why I don't want a16v it been done soooo much so many configurations, I want more of a challenge.
I've never been accused of being the sharpest knife in the drawer! :P
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Then you could get a dual OHC 1.8 or 2.0 VW engine and do a
turbo on that, those engines are potent in N/A form, add boost
and watch out, like 250 HP and torque out the ying-yang, but
seriously get out the hone, sharpen yourself and replace that
block, enjoy what you have done for now and work on another
project if you get board in a year or two
Wild
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The Audi 1.8t is virtually the same as the vw 1.8 with turbo already on it. The difference is I have a lead on a low mile Audi motor for a fair price.
And I know the diesel is not gunna keep me happy just gunna bite the bullet and convert it
Might change my mind 100 more times too. :)
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Ah, I get it. your just looking to do something different. Well, I say that's cool, love to see an Audi motor in that Zuk. I've often thought what a great motor my wife's 230 SC Mercedes is, tons of bottem end and revs right up there. Of course, just the thought of sorting out all the electrical would give me a stroke.
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I have a guy lined up who will wire it for 2-300 bucks,(he's ex-engineer for NASA)I defiantly don't want to do the wiring myself. That's stuff I just don't enjoy doing.(and not good at either)
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If I could afford tp pay people for work needed I'd get sooooo much more completed! ;D
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The main reason I put a turbo on the Sidekick was because I wanted to be
different, but the power wasn't bad either ;D
I started the Turbo project in 91' but with the Suzuki as a DD there was
never any time to start the project, the only way it got done was the engine
got tired and finally I ran it out of oil and ruined the #1 rod bearing, so rebuild
began and the turbo project began, but that was 10 years after I started the
initial thought of the turbo Sidekick
So if I had money to pay people to do stuff, I'd get more done too ;)
Wild
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I have a guy lined up who will wire it for 2-300 bucks,(he's ex-engineer for NASA)I defiantly don't want to do the wiring myself. That's stuff I just don't enjoy doing.(and not good at either)
That could be a good deal. Wiring & multiple computers had me stalled for many months. Love to have a set of seats out of a TT, they would look awesome in my Tracker.
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tomorrow I go and put deposit on my Audi motor!! muhahahahahahahah >:D marry Christmas to me! (cuz giving to yourself is still giving right??? ???)
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Giving a present to yourself just means that you get what you asked for. :D
Glad to see it no longer on the chopping block. I was pretty bummed out when I saw it on Portland craigslist.
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If it was not for you guys on this forum encouraging me I would have sold it! Thank you
Keep watching my new thread I might need the good words when I feel like pulling my hair out on the Audi transplant!