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gp7186 Just got MTs
Joined: 09 Dec 2008 Odometer: 225 Location: Stoke-on-Trent
1991 Suzuki Samurai
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Posted: Thu Jul 02, 2009 4:30 pm Post subject:
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both the clutch master and slave cylinder came from the ldv pilot i had the gearbox from fortunately for me it wasnt leaking and was in pretty good condition a bargain for £10 for the lot from my local breakers. The clutch came from ebay a company had them on offer for around the £85 mark.
thanks gaz
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gp7186 Just got MTs
Joined: 09 Dec 2008 Odometer: 225 Location: Stoke-on-Trent
1991 Suzuki Samurai
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Posted: Thu Jul 02, 2009 4:32 pm Post subject:
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just looked on ebay under ldv clutch and they are still £85.97 with free p+p also there are some slave cylinders also listed
thanks gaz
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gp7186 Just got MTs
Joined: 09 Dec 2008 Odometer: 225 Location: Stoke-on-Trent
1991 Suzuki Samurai
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Posted: Mon Jul 06, 2009 9:06 pm Post subject:
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Suzuki SJ413 Samurai to Peugeot 1.9TD
Wiring conversion/connections list,
I will write what i used anything not listed was taped up and pushed to one side. here goes:
also mine is a 91 model samurai as i know wiring is different for older models
Section of loom fed from drivers side down the inner wing from fuse box i used the following
2x 4.00mm2 WHITE - YELLOW TRACER connect to the pug alternator terminal B+(Main Battery Charge Supply)
1x 1.5mm2 WHITE - RED TRACER connect to the pug alternator teminal D+ (Dash Battery Indicator)
1x 1.5mm2 BLACK - YELLOW TRACER connect to the pug starter solenoid
1x 1.5mm2 YELLOW - WHITE TRACER connect to the temperature sensor Suzuki in pug housing
To use the suzuki temperature sender take the peugeot green sensor cut off the plastic connector of the top and either turn down with a lathe and and you will see a perfectly sized there to tap either 1/8" bsp or 1/8" npt (both very similar in size e.t.c) or file down and tap in a vice. The screw the suzuki sender into the freshly tapped hole with a sealant of course and the screw the pug sender body complete with the suzuki sender back into the fuel filter housing where the original sender came from ,also with sealant
To use the peugeot glow plug relay the connections are as follows:
The terminals are numbered 1 to 5
No.1 - Chassis Earth
No.2 - NOT USED (was for the fuel pump timing advance relay i have not wired this up and it starts fine)
No.3 - +12v ignition (second position on ignition key switch)
No.4 - Starter Solenoid Back Feed (cuts out the relay when the starter is engaged)
No.5 - Dash light (because my samurai is a soft top i connected this to the heated rear window light on the dash panel - next to indicator flashing arrows)
Terminal B - Main feed from battery (brown cable, top right terminal with relay terminals facing you)
Terminal W - Feed out to the heater plug rail (white cable, bottom middle wit relay terminals facing you)
Also i connected a 25mm2 feed from the battery through the starter motor and then to the alternator B+ terminal as my main power cable
Also you will have to supply power to the Fuel Stop Solenoid via a fused supply and a relay
that should be everything you need for it to start
Gaz
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gp7186 Just got MTs
Joined: 09 Dec 2008 Odometer: 225 Location: Stoke-on-Trent
1991 Suzuki Samurai
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Posted: Sun Aug 23, 2009 8:41 pm Post subject:
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Fitted some add-a-leafs today to allow the standard springs to cope with the extra weight and SPOA.
gaz
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zukimoo Just got MTs
Joined: 17 Jan 2007 Odometer: 126 Location: Moncton, NB, Canada
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Posted: Mon Aug 31, 2009 11:11 pm Post subject:
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that is one nice looking rig with some nice work done to it....Do you think you could fit that motor without the SOA?
I've got a similar swap in mind but due to local laws and insurance issues I can't SOA. I've brought the zuke back to SUA and I'm having a blast with all the challenges on the trail. I really want the diesel engine but don't know if I can fit it SUA.
__________________________________ 1981 LJ 80...800cc of pure power
1985 SJ413 truck... |
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gp7186 Just got MTs
Joined: 09 Dec 2008 Odometer: 225 Location: Stoke-on-Trent
1991 Suzuki Samurai
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Posted: Thu Sep 03, 2009 4:16 pm Post subject:
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hi zukimoo
the engine i have used came from a peugeot 306 the sump has a bulge in the wrong place really and personally i think it would hit on the front axle. The engine was also fitted with another type of sump in the peugeot 406 and citroen xantia but i am not sure whether that will fit either. Can you not fit lift springs and gain the lift that way for clearance purposes
gaz
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muddymesser Mud Obsessed
Joined: 17 Jun 2008 Odometer: 7819 Location: preston
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Posted: Thu Sep 03, 2009 6:12 pm Post subject:
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can the sump be modifyed at all ?
__________________________________ http://suzukiclubuk.co.uk/forum1
Sign It Now
stickers and graphics made to order |
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gp7186 Just got MTs
Joined: 09 Dec 2008 Odometer: 225 Location: Stoke-on-Trent
1991 Suzuki Samurai
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Posted: Thu Sep 03, 2009 6:44 pm Post subject:
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Hi muddymesser just had another look and theres more room than i first thought. I suppose anything can be modified to fit heres some pics to show the clearance available but bear in mind i am SPOA and Add-a-Leafs aswell
thanks gaz
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john_sj413 Just got MTs
Joined: 23 Nov 2009 Odometer: 173 Location: eastbourne
1988 Suzuki SJ413
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Posted: Sun Dec 13, 2009 1:39 pm Post subject: 1.9
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looks like hard work fitting that engine, was going to do it to mine but it looks complicated
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nicks90 Mud Obsessed
Joined: 25 Feb 2003 Odometer: 2181
1995 Land Rover Defender
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Posted: Mon Dec 14, 2009 2:44 pm Post subject:
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Holy Z-bar, batman.
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gp7186 Just got MTs
Joined: 09 Dec 2008 Odometer: 225 Location: Stoke-on-Trent
1991 Suzuki Samurai
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Posted: Sun Jan 24, 2010 4:14 pm Post subject:
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The prop previously shown in this post was only temporary . I was only so i could move the truck around. I have now made a new prop which allows me to secure both flanges and misalignment errors will be taken up by the prop. I used a rotoflex coupling from a vauxhall SPAM which had an OD of 125mm and a 94mm PCD. Firstly i machined two identical 'Y' flanges and then parted off the original suzuki prop UJ on a lathe to maintain size and to keep the face square. I then welded it together and fitted it. The prop seems to give very little vibration but i may have it balanced in the near future. Heres a few pics
gaz
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forkrentfitter Articulating
Joined: 01 Jan 2007 Odometer: 523 Location: felixstowe
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Posted: Sun Jan 24, 2010 6:23 pm Post subject:
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coupling joint looks the same as discovery 300tdi,if you use one don,t buy a britpart one they are not too good.
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gp7186 Just got MTs
Joined: 09 Dec 2008 Odometer: 225 Location: Stoke-on-Trent
1991 Suzuki Samurai
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Posted: Sun Jan 24, 2010 6:25 pm Post subject:
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The discovery one was around 10mm bigger on the OD IIRC. That was going to be my next option over the SPAM coupling
gaz
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john_sj413 Just got MTs
Joined: 23 Nov 2009 Odometer: 173 Location: eastbourne
1988 Suzuki SJ413
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Posted: Wed Feb 03, 2010 11:00 pm Post subject: .
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looks good i didnt make up engine mounts on mine i used the engine cradle from the ldv and welded it to the chassis, fits perfectly
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gp7186 Just got MTs
Joined: 09 Dec 2008 Odometer: 225 Location: Stoke-on-Trent
1991 Suzuki Samurai
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Posted: Thu Feb 04, 2010 6:38 am Post subject:
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did you not use any flexible mounts ,because i thought the engine is bolted directly to the cradle, i.e no give which will mean massive vibrations and breakages. i dont think the cradle would fit using the turbo engine. post up some pics let us have a look
gaz
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sjtaitt Just got MTs
Joined: 15 Jun 2009 Odometer: 308 Location: Carndonagh, Co.Donegal
1988 Suzuki Samurai
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Posted: Sun Feb 21, 2010 10:02 pm Post subject:
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good job , did you order the engine mounts or did you get them costom built ??
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gp7186 Just got MTs
Joined: 09 Dec 2008 Odometer: 225 Location: Stoke-on-Trent
1991 Suzuki Samurai
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Posted: Mon Feb 22, 2010 6:21 pm Post subject:
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hi thanks for the reply, I made all mounts myself but the flexible section on the passenger side is a landrover v8 engine mount, the drivers side came with the engine (peugeot 306)i have just housed it in a steel mount.
thanks gaz
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john_sj413 Just got MTs
Joined: 23 Nov 2009 Odometer: 173 Location: eastbourne
1988 Suzuki SJ413
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Posted: Tue Feb 23, 2010 6:20 pm Post subject: .
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craddle is what the engine is bolte too in the van so it has rubber mounts,
im having trouble with the clutch, theres not enough movement in the hydrualic master culinder the clutch pedal feels like the acclerater whats yours like?
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gp7186 Just got MTs
Joined: 09 Dec 2008 Odometer: 225 Location: Stoke-on-Trent
1991 Suzuki Samurai
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Posted: Wed Feb 24, 2010 6:25 am Post subject:
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my clutch is short stroked and a little heavier than normal this because it aint possible to get the master cylinder bolted high enough up the pedal to give the same leverage and stroke as the ldv. i had to cut some metal out of the heater control valve bracket to get the master cylinder to bolt higher up
thanks gaz
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john_sj413 Just got MTs
Joined: 23 Nov 2009 Odometer: 173 Location: eastbourne
1988 Suzuki SJ413
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Posted: Wed Feb 24, 2010 9:05 pm Post subject: .
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i removed the heater control valve, mines really light tho i dont think its doing anything
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gp7186 Just got MTs
Joined: 09 Dec 2008 Odometer: 225 Location: Stoke-on-Trent
1991 Suzuki Samurai
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Posted: Thu Feb 25, 2010 5:38 pm Post subject:
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It sounds like the clutch system requires bleeding to me or you have a faulty master/slave cylinder
thanks gaz
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gp7186 Just got MTs
Joined: 09 Dec 2008 Odometer: 225 Location: Stoke-on-Trent
1991 Suzuki Samurai
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Posted: Sun Apr 25, 2010 6:58 pm Post subject:
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Following the diesel conversion spring wrap is now much greater due to the massive amounts of power so i thought i would show you what i have been up to over the weekend and to see what you think. I made it from a piece of 6mm plate for the diff/axle mount with 10mm plate mount tabs. I used 16mm rose joints for the link arms and they have left and right hand threads to make it all adjustable. The cross member is a piece of 60mmX40mm box section welded to the chassis again using 6mm plate on the ends
thanks gaz
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RobotMan Just got MTs
Joined: 06 Jun 2008 Odometer: 251 Location: Bishop Auckland
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Posted: Sun Apr 25, 2010 9:39 pm Post subject:
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I'm just on planning an anti wrap for my Series Landy. I'm pretty sure you need a swinging shackle at the chassis end to follow spring length change as it curves and flattens else it will bind and bend something.
__________________________________ Rob (Robotman) Taylor.
MonkeyMotorSport
Big Dog Engineering |
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gp7186 Just got MTs
Joined: 09 Dec 2008 Odometer: 225 Location: Stoke-on-Trent
1991 Suzuki Samurai
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Posted: Sun Apr 25, 2010 9:49 pm Post subject:
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good point i based it on the sky manufacturing one which is available from low range off road USA. I just changed their rubber bushed joints for 16mm rose joints. I will knock up a swinging shackle tomorrow at work to see what difference it makes
thanks gaz
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nivaman Articulating
Joined: 24 May 2006 Odometer: 929 Location: New Zealand
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Posted: Thu May 13, 2010 2:46 am Post subject:
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What a cracking build.
Are you an engineer?, just asking as i see everything done so neatly.
__________________________________ Lada a little car that takes you far. |
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gp7186 Just got MTs
Joined: 09 Dec 2008 Odometer: 225 Location: Stoke-on-Trent
1991 Suzuki Samurai
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Posted: Fri May 14, 2010 10:33 pm Post subject:
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thanks for the reply
yeah im an engineer by trade i have just come out of my time as an apprentice.
thanks gaz
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nivaman Articulating
Joined: 24 May 2006 Odometer: 929 Location: New Zealand
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Posted: Fri May 14, 2010 10:48 pm Post subject:
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They taught you well.
__________________________________ Lada a little car that takes you far. |
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robert Winch Assistant
Joined: 22 Jan 2010 Odometer: 68 Location: uk
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Posted: Mon May 24, 2010 8:59 pm Post subject:
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ive just fitted the pug engine with landrover axles
ive got to make new props do you think bolting the tbox straight to the g/box will work ok?
just an idea i had today while trying to figure out what to do with the short prop.
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gp7186 Just got MTs
Joined: 09 Dec 2008 Odometer: 225 Location: Stoke-on-Trent
1991 Suzuki Samurai
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Posted: Mon May 24, 2010 9:39 pm Post subject:
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That was one thing that i considered and may do in the future but you must make sure that the two boxes are bolted together via the flanges and via a cradle to hold them perfectly in line but it is definately possible and if you dont have the machining skills to make the prop doing it that way will save some expense and time
thanks gaz
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gp7186 Just got MTs
Joined: 09 Dec 2008 Odometer: 225 Location: Stoke-on-Trent
1991 Suzuki Samurai
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Posted: Mon Jul 05, 2010 2:11 pm Post subject:
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well finally i have got round to fabricating a swinging shackle for the top joint of the anti-wrap bar. I made it from 50mmX10mm flat pressed into shape and bored the top hole and fitted an oilite bush to allow it to pivot freely
thanks gaz
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