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What starter for a VW diesel conversion?

 
 
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kkk2
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Joined: 09 Oct 2006
Odometer: 58




PostPosted: Tue Jan 26, 2016 9:45 am    Post subject: What starter for a VW diesel conversion? Reply with quote

I am doing a 1.9 vw tdi conversion using the suzuki flywheel, and starter motor, will the suzuki starter be man enough to spin the 1.9 diesel as it was designed for a 1.3 petrol? are there any other starters that can be used with this setup please? thanks
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mike328
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Joined: 10 Dec 2014
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PostPosted: Tue Jan 26, 2016 7:47 pm    Post subject: Reply with quote

we fitted a diesel to my mates sj and he ended up buying a high torque one like this;

http://www.autoelectricsupplies.co.uk/category/138

if I remember right the smaller size of it did us a bit of a favour when squeezing the exhaust down pipe past it and all....

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kkk2
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PostPosted: Tue Jan 26, 2016 8:48 pm    Post subject: Reply with quote

Thanks for that reply, I have contacted wosp and they have discontinued the suzuki starter, so back to square one,
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mike328
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PostPosted: Tue Jan 26, 2016 10:54 pm    Post subject: Reply with quote

there are more companies around doing similar stuff! give RatSport a try for a Denso unit....
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suzukivit1
Just got MTs


Joined: 15 Dec 2010
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PostPosted: Wed Jan 27, 2016 9:58 am    Post subject: . Reply with quote

i made one up from the diesel back end and the vitara front had to machine up a spacer.
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Munkee
Off-Road Guru


Joined: 30 Mar 2008
Odometer: 1505
Location: Hampshire


1999 Suzuki Vitara

PostPosted: Wed Jan 27, 2016 11:40 am    Post subject: Reply with quote

I had to get a starter from Acme in the US.

The standard starter was not man enough Sad

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Steve

In America, some fundamental Christians believe that the world is only 5000 years old, In England, some of us drink in pubs older than that.
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kkk2
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Joined: 09 Oct 2006
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PostPosted: Wed Jan 27, 2016 12:58 pm    Post subject: Reply with quote

Munkee wrote:
I had to get a starter from Acme in the US.

The standard starter was not man enough Sad


Thanks for that Did you use a suzuki flywheel for your conversion?

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mike328
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PostPosted: Wed Jan 27, 2016 7:26 pm    Post subject: Reply with quote

we used SJ flywheel, think it came (already modified?) in the adaptor plate kit.

Got it machined to fit bigger vitara clutch after a few runs out as the SJ one didn't cope!

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Munkee
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Joined: 30 Mar 2008
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1999 Suzuki Vitara

PostPosted: Wed Jan 27, 2016 11:58 pm    Post subject: Reply with quote

kkk2 wrote:
Munkee wrote:
I had to get a starter from Acme in the US.

The standard starter was not man enough Sad


Thanks for that Did you use a suzuki flywheel for your conversion?


Yep. A modded one from Acme. I used the flywheel, adaptor, and a few other acme bits.

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Steve

In America, some fundamental Christians believe that the world is only 5000 years old, In England, some of us drink in pubs older than that.
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kkk2
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PostPosted: Thu Jan 28, 2016 2:29 pm    Post subject: Reply with quote

Thanks for the reply, I see on the Acme site they have the starters for $185.00, I hopefully have sourced one nearer home, will keep you posted, should have it next week all going well.
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mike328
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PostPosted: Fri Jan 29, 2016 8:52 am    Post subject: Reply with quote

Sounds good, how far along are you with this?

the other problem that came up now ive started thinking about it was clearance for oil filter against the engine mount. We took out the water/oil cooler to make the space but it turned out wasn't a great idea, these engines seem to need one... My mate ended up buying a sandwich plate oil takeoff and fitting an air/oil one instead...

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suzukivit1
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PostPosted: Fri Jan 29, 2016 12:48 pm    Post subject: Reply with quote

i modded the std vit flywheel removed the lip round the rear of the flywheel opened the center up and fitted an adaptor plate that houses the sprigot bearing, i have a spare one somewhere if you want pics.
16v clutches are the biggest you can run and they fit on the 8v flywheels to,dont be tempted to buy a paddle clutch with an unsprung center it must be sprung or it will eat the clutch plate and the gearbox output splines.
you also need to cut a little off the end of the vw crank at the flywheel end where it tapers down there is pice on here somewhere or steve may still have them.
colin
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kkk2
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Joined: 09 Oct 2006
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PostPosted: Fri Jan 29, 2016 9:27 pm    Post subject: Reply with quote

mike328 wrote:
Sounds good, how far along are you with this?

the other problem that came up now ive started thinking about it was clearance for oil filter against the engine mount. We took out the water/oil cooler to make the space but it turned out wasn't a great idea, these engines seem to need one... My mate ended up buying a sandwich plate oil takeoff and fitting an air/oil one instead...


Not too far tbh, I have the Vw engine fitted to a suzuki gearbox on the bench, didnt want to go any further until I had resolved the starter issue, thanks for the heads up on the oil cooler. Looking forward to moving this along now, currently running a 1.6 but could do with a bit more torque.

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mike328
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PostPosted: Sat Jan 30, 2016 7:57 am    Post subject: Reply with quote

looks Cool keep us posted.
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Munkee
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1999 Suzuki Vitara

PostPosted: Sun Jan 31, 2016 10:27 pm    Post subject: Reply with quote

pics of the crank mod;

[img][/img]
[img][/img]
[img][/img]

Do remove the facotry oil 'cooler', replace it with a sandwich plate and a proper oil cooler - big one. for the oil filter, either use a remote kit, or get an angled filter mount from a vw caddy.

What engine are you fitting?

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Steve

In America, some fundamental Christians believe that the world is only 5000 years old, In England, some of us drink in pubs older than that.
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mike328
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PostPosted: Mon Feb 01, 2016 12:28 am    Post subject: Reply with quote

I don't remember having to mod the vw crank...guess the flywheel that came in the kit must have been machined to fit the crank instead??

hope you found an AAZ engine, the mechanical injection makes it a doddle to get running and more reliable for our needs Very Happy

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kkk2
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PostPosted: Mon Feb 01, 2016 7:55 am    Post subject: Reply with quote

mike328 wrote:

hope you found an AAZ engine, the mechanical injection makes it a doddle to get running and more reliable for our needs Very Happy


I only understand mechanical engines, so none of that fancy leccie stuff for me Smile Smile Smile

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suzukivit1
Just got MTs


Joined: 15 Dec 2010
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PostPosted: Mon Feb 01, 2016 10:06 am    Post subject: . Reply with quote

I run the AFN with full ECU control, i had no problems with the oil filter housing on the vitara with the AFN it must sit in a bit...the AAZ also fits in a jimny with an AFN oil cooler and filter housing fitted.
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Munkee
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1999 Suzuki Vitara

PostPosted: Mon Feb 01, 2016 11:14 pm    Post subject: Reply with quote

kkk2 wrote:
mike328 wrote:

hope you found an AAZ engine, the mechanical injection makes it a doddle to get running and more reliable for our needs Very Happy


I only understand mechanical engines, so none of that fancy leccie stuff for me Smile Smile Smile


TDIs all had ecus... whats the engine code?

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Steve

In America, some fundamental Christians believe that the world is only 5000 years old, In England, some of us drink in pubs older than that.
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kkk2
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PostPosted: Tue Feb 02, 2016 9:06 am    Post subject: Reply with quote

Nearly sure its an 1Y Audi engine (1990) with a turbo bolted on to it. mechanical pump (Bosch), a bit of a mongrel tbh. I bought it modified, and it was running in a suzuki sammy but kept failing on the starter issue.
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suzukivit1
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PostPosted: Tue Feb 02, 2016 12:50 pm    Post subject: . Reply with quote

think 1Y and 1Z are the start of the ecu control but you can have them on mechanical pump.
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kkk2
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PostPosted: Tue Feb 02, 2016 1:49 pm    Post subject: Reply with quote

Has anyone heard of a landrover 200/300 tdi diesel pump being fitted to these engines?



the power of google:
https://www.youtube.com/watch?v=Y889dPRF400

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suzukivit1
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PostPosted: Tue Feb 02, 2016 4:19 pm    Post subject: , Reply with quote

yes never looked in to it tho.
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Munkee
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1999 Suzuki Vitara

PostPosted: Tue Feb 02, 2016 6:46 pm    Post subject: Reply with quote

yep. they're a higher pressure pump designed for direct injection engines (the early VW engines were indirect injection (IDI) due to the precombustion chambers.

The landy pump is run on later direct injection VW engines to remove the ECU.

1Y was the early 90s IDI NA 1.9. Does yours have a bosh pump with LDA (boost compensator) on top?

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Steve

In America, some fundamental Christians believe that the world is only 5000 years old, In England, some of us drink in pubs older than that.
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mike328
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PostPosted: Tue Feb 02, 2016 7:05 pm    Post subject: Reply with quote

Munkee wrote:
TDIs all had ecus...


Yep but TDs didn't Wink

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aniesigh
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1991 Suzuki Samurai

PostPosted: Tue Feb 02, 2016 7:20 pm    Post subject: Reply with quote

I also used a starter motor from acme on my old tdi SJ, tried the SJ one and it wouldn't even turn it over. Didn't really look much into any cheaper hybrid solutions etc as just wanted to know it was going to work (was all that was stopping me drive it!)
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1990 Suzuki Samurai 1.9TDI (sold)
http://forum.difflock.com/viewtopic.php?t=53747

new truck build thread:
http://forum.difflock.com/viewtopic.php?p=595221#595221
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