Hello everyone, doing a diesel swap to the all mighty samurai. Well its my boss's rig, That means hes funding the whole thing and ill be doing all the work so i want to get a little heads up on this.

All the lifting is done on the samurai so i dont have to worry about oil pan clearance and all that fun stuff to factor in.

 What is the best VW engine to get for these? Any years? i know its going to be the 1.9 turbo .  But is there any year i should aim at getting?

Does anyone know some of the more difficult things to do on it? Any major modifacations im going to have to make?

Any ammout of information will help me out a lot.

When i do start doing the work i will be sure to being my digital camera and get as many shots as possible...then post them on here for you all to see.


Thanks a lot


Millski

I take it there arent too many people on here with a diesel samurai.
Well i guess when i start the work ill just post loads of stuff.

I'm pretty sure that in a previous post someone posted a link to a diesel Zuks forum.

I was going to do the swap in my Tracker but costs were just to much

NON TDI, is alot easier to swap in...

I also read that the VW Jetta (94-97) from Canada are preferred.....

the 1.9's are great but can have crank pulley problems which if left unchecked can wreck the crank. the 1.6TD's are much easier to find and with an intercooler and pump mods can equal the 1.9 in power. I too abandoned the diesel swap as it was going to cost roughly 3-4 grand to get roughly the same power as my current 1.6 and better gas mileage. I am now going down the road of a GV v6 swap which will double my power and get me roughly the same gas mileage as I have now

diesel swap as it was going to cost roughly 3-4 grand

How do ya figure? Even if you went the expensive route and bought the Acme kit, you should only be half of that with everything. The kit is $800, and if you can't find an engine for < $800 your not looking hard enough 

ya sorry thats CDN!! at least 2 grand US though. motor 800 to 1000 kit 800 misc 3-400 easy. I have done lots of engine swaps before and the small stuff ads up quick. Also for a kick the gearing is wrong unless you run 33" tires so you need to regear to 4.62's or something.

This is the suzuki diesel section on Zuwharrie.com

Should answer alot of your questions.

http://bbs.zuwharrie.com/content/board,48.0.html

thanks for all the infor, i know were getting the acme kit and hes going to get a canadian 1.9, he already found in for i think 900 so it should be to much.
His sammy is currently sittin on 33 mudd terrains, with the crawler  6.1 gears in the T-case.
so he has no gearing problems.  I just hope he gets the full wireing harness to the car, and some good diagrams, or else im going to be have a long day.

Millski

wiring on a diesel is very simple and I think the Acme kit covers it all. only thing you will need is a glowplug relay box.

as for gearing you may want to check RPM's because diesels do not like revving as much as a sammy 1.3

well that will be nice, the wiring thing that is.

I already brought up the topic of being a rather high RPM for a diesel to sit at.
my boss didnt think so, i thinks thats mostly becuase hes a 65 year old guy that is very very stuck in his own ways.  90% of the time it will come back to bite him in the ass, which means loads more work for me.  what ever thou

thanks again

Millski