1.9 AAZ Suzuki Vitara build - IDI Engine - VWDiesel.net The IDI, TDI, and mTDI source.

• 1.9 AAZ Suzuki Vitara build by vako on 19 Oct, 2010 09:48
• hi guys, i live in gorgia (europe) and a'm about to start suzuki vitara/tracker diesel convertion. my stock 8 valve engine had problems from the day the car was bought. as it appeared there was a crack in cylinder block, so repairing is impossible. 4 months ago i bought 1.9 TD egnine for 500$ . the seller gave me a money back guarantee, if there will be any other problems when the engine is started after the swap (but that guarantee had expired because i haven't yet started the engine)
  
   i opened a topic here about my crankshaft spocket. an at the end  i came to the decision that it will use only alternator  and one v belt. no powersteerning for now .
  
   last weekend i fitted engine to vitara angine compartment. only  audi style oil filter adapret and little oil pan modifications are needed. i have also done templates for engine mounts and this weekend i'll make them from 6mm steel plates.
  
   now i'll post some photos of the project 
  
  
  my suzi 
  
  
  AAZ the day bought it
  
  
  after buying diesel engine i was lazy so i continued using my car with it's petrol engine which was not in very good shape 
  
  
  
  
   
  
  after a little accident 1 month ago (only radiator, hood and one frame tube were damaged)
   i startet with my diesel swap.
  at first i disassambled my engine.as i expected there was a rod knock 
  and i started getting the parts ready for fitting diesel engine...
  
  
  
  
• #1 by vako on 19 Oct, 2010 09:59
• at first i had my flywheel redrilled to fit vw crank.
  
  
  but the next day i found out that one hole was rdilled from the wrong side  as i wasnt able to find nex suzuki flywheel i had no oyher way than doing this...
  
  
  
  
  i hope it will work fine :X
  
  here is the adapter plate i had no money to buy this plate from "acme adapters" so i had to do it myself 
  
  
  
  
  
  
  
  next step fitting the gearbox to the plate
  
  
  
  
  
  
  
  
  
  and fitted to the engine bay 
  
  
  
  
  
  
• #2 by vako on 19 Oct, 2010 11:04
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  play between the teeth of the oil pump is 0.2 mm. acording to the service manual it is the max allowed wear. so i thin it will work for 20k kilometers or so
• #3 by vanbcguy on 19 Oct, 2010 11:11
• Looks like a fun project!!
  
  I'd be tempted to replace the oil pump personally... My truck had some scoring like that and decided it wouldn't prime again after an oil change.  Worked perfectly fine until some air got in it - resulted in me being stuck in Regina for several days. 
• #4 by vako on 19 Oct, 2010 11:34
• Quote from: vanbcguy on 19 Oct, 2010 11:11

  Looks like a fun project!!
  
  I'd be tempted to replace the oil pump personally... My truck had some scoring like that and decided it wouldn't prime again after an oil change.  Worked perfectly fine until some air got in it - resulted in me being stuck in Regina for several days. 
  

  
  now, before i have started it for the first time, i try to spend as little money as possible, and to start the car as fast as possible. if everything works well i think i'll make some modifications next summer.  because vitara is the only car i have and it also is my daily driver.         
  
      going by bus to the university every day is a real hell for me... 
• #5 by vako on 20 Oct, 2010 12:19
• one more question, yesterday when i was checking vacuum pump i noticed that there is some play between the teeth of the intermediate shaft and vacuum pump.      the play isn't serious so i think i shouldnt be worried.
  
  this weekend i'll take my oil pump to the person who sold me my engine and maybe he will exchange it, if he has another pump from aaz if he doesn't, than i'll have to use what i have
• #6 by gldgti on 20 Oct, 2010 23:47
• Does look like a fun project.
  
  I am really not keen on your flywheel though.... I would be worried about cracking between the bolt holes. Flywheels do a lot of damage if they come loose.
• #7 by vako on 21 Oct, 2010 00:15
• Quote from: gldgti on 20 Oct, 2010 23:47

  Does look like a fun project.
  
  I am really not keen on your flywheel though.... I would be worried about cracking between the bolt holes. Flywheels do a lot of damage if they come loose.
  

  
   to be honest that did happen to me when i had freshly assembled suzuki engine. i have forgotten to tighten flywheel bolts properly so they came loose after ~20-30 minutes after starting the car  the sound was so loud that i thought it was a broken crank  but when i removed the engine (in suzuki removing the engine is far more easy for me than removing the gearbox )  a found out that fywheel bolts were barely holding themselves in the bolt holes  but there was no damage at all.
  
   in this case i think that even if that piece, marked with blue, completely breaks away, the bolt will hold it in place. and other 5 bolts will keep flywheel on its place for the other hand....    lets see how it works  if something goes wrong i know how wobbly flywheel sounds
• #8 by RabbitJockey on 21 Oct, 2010 04:25
• i need to build one of these for a winter rig...
• #9 by vako on 02 Nov, 2010 13:11
• http://www.youtube.com/watch?v=MLpNgajBi4E
  
  oil pressure and leak testing today... i think pressure is perfect
• #10 by macka on 02 Nov, 2010 18:38
• vako,
  
     just fill the holes with 6011 welding rod. Make sure you heat the flywheel first after you prep the surfaces to be welded. I've done that fix on a mitsu flywheel.