non suzuki swap

[zooky]

Its been awhile since an update. I havent done much due to the holidays so this will be quick. I've been doing the wiring, its not complicated but has been taking more time than I would have thought. I am running all the wiring in the toyota harness and removing all the unused wires and connectors. It's almost done, I have everything ran and just have to terminate a few more things, it will be a clean install. Most wires are as hidden as I could get them. While I was at it I ran new heavy gage wires for the headlights, the stock wiring was pretty rough, this should give me brighter lights.
I installed a cluster with a tach and some LED's I relabled. I had to do some rewiring of the clusters connectors. Again, not a big deal but something to be aware of:


I added boost and EGT gages. Here is a pic, the lighting was horrible, so it didnt come out so good:

[redidbull]

Hey Randy just came across this. Great article but don't you ever rest.  Jim

[zooky]

Hey Randy just came across this. Great article but don't you ever rest.  Jim

I cant stop! My wife wishes I would do something more productive though

[redidbull]

.........My wife wishes I would do something more productive though

Don't they all....JIm

[CTBrent]

Are you driving it yet??? How's it go... ?

I think my TD is going in the 410k infront of the dual cased yota trans... with 5.29 yota's spooled up... I have all the parts just no space to wrench. That and I have this 46 Dodge I've been messing with...

[supazuk]

talk is cheap brent lol

[redidbull]

Are you driving it yet??? How's it go... ?

I think my TD is going in the 410k infront of the dual cased yota trans... with 5.29 yota's spooled up... I have all the parts just no space to wrench. That and I have this 46 Dodge I've been messing with...

WOW the infamous CTB shows up!!! Glad to have you on board. Jim

[zooky]

Are you driving it yet??? How's it go... ?

I think my TD is going in the 410k infront of the dual cased yota trans... with 5.29 yota's spooled up... I have all the parts just no space to wrench. That and I have this 46 Dodge I've been messing with...

no, not driving it yet. I haven't been getting "quality" time in the garage. I am still doing the wiring, cant believe how long its taking me and this is what I do (did, before cushy job) for a living. Its not that its hard, I am deleting the unused wires and running the new wires into the toyota harness and fuse box. Made some good headway yesterday, would like to have the electrical wrapped up in the next few days.
 You need to get building there buddy, lose the girlfriend, she is slowing you down
 Sounds like it will be a sweet rig once its done. I have a good 22R left over from this project that I would like to put in the sami if I'm up to it. I should sell the sami and build something more street friendly...

EDIT: oh yea, if any of you New England guys are looking for a diesel, there is a N/A in a Jetta at Car World in Candia, rare find around here. They get like $150 if you pull it. It was complete, well, except a glow plug relay

[quietmission]

Still great progress.  I wish that i was as skilled as you are.  Right now, i have pulled the 1.6 td from the vw and it just sitting in the garage.  I need to have someone check it for me in case i need a rebuild.  Any takers from MA, NH with good rebuild skills?  Will pay!
I want to start collecting parts to start my project in spring.  Any case,  good luck with the project and hopefully i can see it in person one day.

Hammy

[zooky]

thanks, its nothing complicated, just time consuming. With family and other commitments I am lucky to get a few hours here and there. If I get 4-5 hours in one shot thats a good day. You should go through the engine yourself, its a good educational experience. Did you do any checks when it was still installed?
 I just got my Dakota Digital tach converter, that should be the last of the wiring. Thank god. Yesterday I started retaping the wire bundles and ran all the wires for the glow plug relay circuit. I hope to get the wiring complete by tomorrow, including relocating the battery to the back. I also have to reroute the wiring harness that goes to the transmission and starter, the factory routing really jumps out at you. Sorry there havent been any pictures lately, I am sure that nobody cared to see the 'birds nest' of wires around the fuse box. Another roll of black tape and a few zip-ties and that disaster will be gone. I hope to start plumbing the intercooler and cooling (fuel too) soon, that should be more interesting.
  Tech: When doing any wiring it is important to label everything, its easy to lose track of whats what. Lets face it, wiring is the least exciting part of any project. Its tedious and has no 'bling factor'. Im an aircraft mechanic and my specialty is avionics, I've been wiring aircraft for years and its not fun. Electrical problems can be a nightmare so take your time with it. I am (trying) keeping track of all the changes I am doing to the electrical system on a photocopy of the toyota wiring diagram. I've been trying to keep up with it but have to go back and update it. If I have any electrical problems it will be easier to fix, without it it will be a nightmare to (possible) future owners.
With that being said, I didnt label much. And I know better
 

[zooky]

Well, wiring was going good, its about 95% done. I forgot to run the starter wire in the bundle and dont feel like adding it right now.
 I was hoping to be able to rotate the turbo output housing so I could easily route the intercooler plumbing, well that aint gonna happen. I rotated it to where I wanted it but when I tightened the turbo to the manifold the turbo output housing would hit the intake. There are ways around that but I'll live with the stock position. I am mocking up the plumbing. Any reason this wont work? I am worried about the one hose running behind (over actually) the cooling fan, dont want to heat up my cooled air.

[deepmud]

wow - looks so factory

I don't think the hose will pick up much heat - especially since about the only time heat is an issue you are moving a lot a air thru the tubing and going down the road fast It might warm up in stop and go traffic, but who cares?

Nice job. No one but me will be able to work on my "thing" lol It's pretty hacked

[quietmission]

Hey Zooky,

What kind of radiator and intercooler setup are you using?  It looks very nice but looks small and fit well there.  I wondering if you made your own setup as well as special brackets.  Thanks...

[zooky]

the radiator, intercooler, electric fan (including temp switch and relay assembly) and mounting brackets are from a Volvo 740(?). Everything fit in there perfect. I was (am) concerned about its ability, but the components are from a heavier car with a turbo 6 cylinder so I am hoping it will cool this engine adequately. If not I will have to find something that will. Its bigger than it looks in the truck, its not as wide as the VW radiator but its taller. I
 I havent messed with the exhaust yet, cant avoid it much longer. I am going to have to go down then accross under the transmission due to transmission shift linkages in the way. I hope to look at it this weekend. I think its the only big job I have left. I have a bunch of loose ends to tie up.

No one but me will be able to work on my "thing" lol It's pretty hacked

thats how my sami is

[quietmission]

How about the brackets to hold them down?  Anyways, the fan looks big enough to help cool it down.  On a side note, this setup would be ideal for samurai diesel setup if one can get it to fit in there.   Just a thought...