Suzuki TDI Swapped Samurai Truck Conversion

[The_Lobbster]

Figured I don't have a build thread on here, so I decided I should bring everything I got over. I started with a 1986 samurai, engine is a 1998 AHU 1.9 TDI with a mechanical injection pump. Geo tracker transmission, transfercase with 4.24 gears and twin sticks. Toyota driveshafts, samurai axles with chromoly shafts, lockers, and 5.13 gears. Jeep YJ springs, missing links in the front. Frame is stretched 18", cab chopped and half enclosed. Here's some pictures to get started.

 

[The_Lobbster]

Heres the sami, before chopping, and after.

 

[The_Lobbster]

Chopped and stretched the frame today. 18” longer now. Still need to plate the frame, it’s currently just tacked into place.

 

[The_Lobbster]

 

[The_Lobbster]

 

[The_Lobbster]

 

[The_Lobbster]

My favorite part, the flatbed build!!

 

[The_Lobbster]

 

[The_Lobbster]

 

[The_Lobbster]

 

[The_Lobbster]

And this is how it sits currently. I need to install a new head gasket yet, but I'm still getting there.

 

[LJTim]

Coolest thing I've seen all day! Nice job!

 

[zukijames]

Let’s party !

 

[Bart]

Sweet build. Very cool.

 

[The_Lobbster]

Replaced the head gasket this past weekend. While I had the head off, I took my time to clean the injector seats and holes as best I could, they were caked in carbon and nastiness. Used a pipe brush and an entire can of carb cleaner. Was trying to ensure my newly built, balanced and flow tested injectors had zero issues sealing up. I love having ARP head studs, makes it much easier than having to replace the head bolts every time I have it apart. Old glow plugs were toast too, so ordered up a set to replace old ones, which I never used. I plan on carefully threading the plugs on these, so I can use a nut and a ring terminal connector.

 

[The_Lobbster]

Trying to get this thing back together so we can go wheeling when a friend that moved to Ohio comes back next month to pick up his samurai and take it home. So I swapped back to non-power steering to get it moving again, since I kept having so many issues with it. Threw the timing belt back on, installed and seated my new injectors, and fired it up. It seems to run a lot better, I think my old set of injectors were shot.

 

[Coco]

I have always wanted to put a TDI engine into something like that. Either a Samurai, or a Yota.

 

[The_Lobbster]

I have always wanted to put a TDI engine into something like that. Either a Samurai, or a Yota.

I've done two samurai TDI swaps. If I ever do another though, it will be into a Yota, or possibly a 2 door wrangler. The Toyota swaps have been very common lately, and the people doing them seem to be very impressed and happy with them.

 

[The_Lobbster]

Current status. Gotta redo down pipe and exhaust, cooling system, again, and figure out some other little things.

 

[The_Lobbster]

And how it used to be before I chopped it all up. This was pre lockers, still spring under, 31's. Part of me wishes I had never gone as extreme as I did. I miss being able to daily drive it down the highway safely (somewhat)