A HUGE Problem With The TDI In The Zuk... Ultimate Suzuki Samurai Buggy Build Episode 4.
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- Опубліковано 22 лип 2024
- I'm so glad we took the time to disassemble and inspect the VW TDI that came with this Samurai. There are often a few gremlins hiding in used drivetrains that are worth taking the time to fix while the motor is out.
Today, I'm going to pull this motor down to a short block and clean every nook and cranny. Then we will build everything back up with an upgraded cam shaft, upgraded head studs and even an upgraded turbo. This was very much worth the time and now we can move forward with the confidence that we have done what we can to ensure good power and reliability.
I hope you enjoy the process! I love engine work and even though this was time consuming I really enjoyed myself.
See you next Sunday!
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#offroad #suzukisamurai #rockcrawler - Авто та транспорт
fwiw - as someone who once worked in an automotive machine shop, if I take an engine down to this level of disassembly, you better believe I'm sending the block out for a deep tanking/cleaning as well as getting things checked out for balance. I can't, for the life of me, reassemble an engine without it being spotless. Just me I suppose.
That's the difference between professionals and not.
For sure.
Do it right so you don't have to take it apart again in the future. If you're in there, you might as well make sure everything's done right the first time.
I'm not a pro and I'm the same way. If it's out and the head(s) are off, it gets a rebuild unless it's a new engine to start with.
No it's not just you, has to be clean...
For a stocker head
Heads up in auburn wa
For performance
DG machine auburn
Dale Green is the smartest man know when it comes to machining.
Also if you are interested delta camshaft in tacoma will grind that old cam for the future High powered build if you are interested.
Love the channel man, thank you!
For hose lines might want to try "That Hose guy" in rainier Wa. I have used him and he is fast and affordable.
Thanks for the tip!
Heads up in auburn is the best around. Good turn around time and good quality. There super nice aswell. I work at a dealer in the area and have had dozens done by them. They also did my buddies 4g63 head, it makes 700whp.
Vibrant Performance for all your oil line (and all sorts of other hoses/tubes/ect.) needs! The dudes over at Speed Academy are always using their stuff.
Good call!
@@DirtLifestyle Williams oil filter service in Tacoma makes custom lines for cheap they made me extended lines for my sas Toyota just bring them the ends that you want or know what fittings you want and they will make them right there while you wait.
285K miles on that bad boy!!!! I can't remember what oil we put in it, but I believe it was the correct spec oil for us in the sweaty hot south....
Buds machine in Lakewood, great people and perfect machine work…
Thanks for the tip! I will hit them up on Monday
Came here to say the same, years of great work and reputation out of that shop
For the cylinder head work, try Heads Up, lnc. in Auburn. Joanne the owner will take care of you and if she doesn't do TDI heads she should know where to go.
Second this, I took my alh head to heads up, they do great work!
Yup Heads Up has done excellent work for me too.
@@caseystowe9110 I just came here to give the same recommendation. 😁
I was one of the subscribers/viewers to suggest letting us see the mistakes. Not necessarily YOUR mistakes, but mistakes others have made & potential mistakes avoided, as you have shown in this video/episode. Cheers Nate for giving me the option to NOT piss on the electric fence!
Love to see the TDI content. Id parts and Whitbread are amazing venders. Tons of braided stainless turbo supply lines on the market for TDIs.
Do you have a link by chance?
Love the TDI content. Great tips for saving time when it comes to an engine swap. A stich in time type of thing. I can wait for next week.
Love the mechanical episodes Nate. Keep it coming. I should have pulled the heads on my brand new 6.5L P400 when I got it and put head studs in but alas.. I was eager to just get a running truck. Oh well - live and learn.
Great to see you pull the engine down. One of my favourite things and so many people are afraid of it. Can't wait to see the suzuki on the trail.
Looking forward to seeing this progress 🎉‼️
Awesome inspiration, ive been staring at the 6.0L engine for my Jtruck for months while i tinker through this wire harness. Its grungy and very much looking like a fresh engine pull still. It is setting on the motor mounts BUT i've been contemplating pulling it back out to clean it up, freshen up gaskets and maybe even paint the thing. This video makes for all the more reasoning to do so!
Yep, was putting in a low mile running 5.3 in my FJ55. Looked at the cam and it had a spun bearing. Saw there were mismatched lifters. Decided to rebuild it after seeing how mean the PO was to the engine. Almost 2 years since build and its running great and I have no reason to believe it wont for some time.
I'm digging this build and the information you are providing. Thanks for the great content!
So excited for this build! Thanks for the constant inspiration Nate
If you want to keep it local to Washington there is a guy in Rainier WA called the hose guy. He does great work and can built most lines from oil to hydraulic lines.
You should definitely check out heads up in auburn they are good ppl. Joan the owner is the nicest lady and they have years of experience.
So excited to see tdi content again! I'm really looking forward to following this build!
I've had great success with braided oil lines as well as fuel lines custom made from Williams oil filter in Tacoma
Much thought trial error inspection of parts should be a successful build. Start up will be proof in the end. Enjoyed.
Picked up a 1986 F250 single cab long bed factory manual locking hubs 4 to floor odometer shows 69,000. mufflers tail pipes cut off. From the local salvage yard. Nevada DMV records show Elko county school district ownership 20 years sold at auction registered in Idaho 7 years. Came back to Elko county sold couple more times found abandon in truck stop Wells Nevada found a bill of sale dated February 2021 $300.00 in glovebox That 460 purrs like a cat when started no grey or black smoke coming out of the exhaust pipes. Dial of a head gaskets to show signs of oil leaked his Royal parents are the signs of the accuser maybe 4frontcu of the weekend and the rear seals maybe clutch works good. Going to need to pull the engine change all the seals maybe put the new freeze plugs in it. New gaskets but eventually if I live long enough this truck will become an off-road wrecker.
This has been a sweet build so far. Looking forward to the next episodes
I'm so excited to see this thing come together
I took my alh tdi head to Heads Up in auburn, they did a great job and I’m sure they could do the porting you need
Thank you for a quality video. To not only watch you work but also how descriptive you are with it. I’ll absolutely never have a situation where I’m working on a high horsepower TDI Volkswagen engine, but to watch it is badass!
I love that I found this channel from a video of yours that my 8th grade fab class teacher was using to teach us about fabrication.
Swagelok fittings would be ideal for that turbo oil supply... Anxious to see the engine in the chassis and the final front axle placement. Killer build
keep the content coming nate! enjoying this build alot.
I’ve always ran rotella in my Diesel engines and 350 chevys. But I run Royal Purple in my LS engines. Keeps them perfectly clean. Hell I recommend people use it if they plan on tearing their engine down in the near future. To either do a DOD/AFM delete or head swap etc etc. it just cleans so good but you’ve gotta keep a eye on the oil because it cleans so good you might need to change it sooner.
Great progress. Keep up the hard work.
Thanks!
My compliments on the choice of incidental music in your videos, it really adds to the enjoyment get from viewing👍
There's me worrying about changing the alternator in my zuk and you've just done all that in 18 minutes 😉 also realised I wasn't subscribed, am now
You can find BRM braided oil supply lines at KermaTDI or Darkside Developments (UK). Those are the only ones I know sell them. I had an '06 BRM Jetta for years. Your findings of cam and lifter wear are super common. I'd like to also add that Darkside Developments has PD150 injectors. They are a direct swap for the PD100's in the BRM and a substantial hp increase.
The knowledge you have of these parts on the market is absolutely mountainous
Dude that’s going to one badass little crawler…love it! 👊🏻👊🏻
I can't wait to hit the trail with it!
So envious of your skills!
I used speedway motors for premade stainless braid lines. I've been using Russell fittings when I make stainless lines. I had issues with fittings leaking when I used Chinese fittings from Amazon.
Thanks for the tip!
Another totally cool build. I'm looking for a build intensive 2023. Keep up the good work!
I second your recommendation of ID Parts. ID Parts is also a good source for Jeep 2.8L VMMotori parts.
Awesome to see you working with other creators. Ryan builds some awesome stuff as well. Waiting for his UA-cam to drop.
Always getting her done! Good job bro!
Thanks man!
im no TDI specialist but i have replaced a couple of camshafts on these things. Sometimes the fuel pump on the side off the head leaks some diesel in to the engine oil. And that takes out the camshaft. If its a bit suspect please fit a new one.
If the injector o rings leak they start having starting problems, especially if they sit for a few hours.
I put a stainless steel braided line on my bhw turbo input, got mine from kerma TDI, works good.
I'm late to the party and am not reading through these comments to see if someone suggested it but, for your hose solution you could always go to your local industrial hydraulic hose shop (there are mobile ones too, like Hosetek here in the southeast) and give them the fitting and pressure spec you need and they should take care of you.
Williams oil filter down on puyallup ave has all the custom hoses you need.
Perfect timing. I picked up a BEW for my XJ and have a Whitbread performance adapter kit sitting in a box ready to go. I'll definitely check out idparts when I start stripping the engine down
Any factory parts for German auto, go with FCPeuro, they offer a lifetime warranty on everything they sell (including oil) you just have to ship it back.
Welcome to the best and worst experience, but the thrill of driving when you are done is awesome! Not to mention the double takes you get from folks who know.
As always you delivered on the content, love your channel.
Thanks bro 👊 I appreciate it
Love finding local channels. I Enjoy the content. In the future I'll be swapping a alh tdi into something. If you need help locating odd parts or need help never be afraid to ask
This build is going to be rad!
Wish I could just spend a weekend picking your brain and hanging out in the shop with you. I can't wait until im doing builds something crazy like this one day. im very inspired!
Doin a good job bud keep it up
On the TDIs I had with 17, 20, 23 turbos I always used the original oil pressure tube, it was always plug and play.
The TDI makes 260hp only with a 1749 turbo hybridized to 1752 or 1756 if it has the original BE injectors of the PD130 ASZ or PD150 ARL engines
for offroad I used a BMW 2060 or 2260 turbo, in Portugal there are many cars and 4x4s with these turbos
I met the channel today and I'm already loving it, TDI is my favorite engine 👌
Awesome work bud.
Vibrant make an adapter from hard-line to AN fitting if that helps, otherwise I think they make stainless piping for oil lines in straights so you can bend them how you want.
Little bit of a jog from Tacoma but Belfair Hose & Hydraulic Inc. does real good custom lines and are reasonably priced.
Nate, I'm in NY, and we use a shop named Omni Services, which makes custom hoses for everything and also an Areoquip distributor. Take a look at their site, I'm sure they can build you anything you need and ship it to you. Good luck, and keep them videos coming. Jeff
Braided lines with AN fittings worked well to make custom fuel and power steering lines for my Ford F1 build. There are 100’s of fittings and adaptors to go from standard and metric threads to AN sizes, they could work for your oil lines.
This samurai is gonna be a little beast… I just did the 1.6L 16V swap on my channel and it has lots of power, but I can only imagine what this is gonna be like. Awesome video dude 🤘😎
Thanks brother!
Belfair hose & hydraulics could make you a nice high pressure stainless braided line for the turbo for what it's worth. Love the vids used to live down there wheeled all over Washington state.
Rick at Lewis & Goetz is who we used to go through for braided hose assemblies in Tacoma area.
You should bring on Dirt Road Therapy Jon for an episode!!! Two TDI wizards at work would be awesome
For braided stainless, try Pit Stop USA. I have had good luck with their selection of lines for a custom clutch line in a zf6 swap. Summit Racing also has a myriad of lines for all sorts of things.
This is awesome. I have a BRM I got for free. Well it’s the whole 06 Jetta l. Gonna swap it into something one day. Please do some in-depth wiring when you get there. Love the videos Nate!
Heck yea man. Great content. Love it.
Thanks brother 👊
Thank you so much.
No man, thank you for watching 🙌
Auburn auto machine is where I get all my engine work done.
Here's your feed line. Will be running it on mine soon. Should be right since we are both running stockish turbos.
M10x1 to male -4AN adpater
M12x1.5 to male -4AN adapter
90* -4AN elbow
45* -4AN elbow
30" long -4AN braided stainless hose with straight -4AN ends
Nate, If you head over to summit, they have a bunch of premade high pressure stainless lines for a reasonable price and you can usually find adpters to just about any thread from AN.
Will do! Thanks man
@@DirtLifestyle No prob. I used one for a power steering pump and it worked great.
Call a hydraulic line shop for your turbo line. Pirtek, fastenal, napa. Usually onenof those can make you whatever you need.
I’ve been binge watching your stuff, and I love it. As someone who loves to learn new things, I appreciate that you take the time to explain why you made the choice you did. I have a question, though. What are you listening to when you’re working on a project?
I can't help it but I'm just jealous....im so mad . Shop is awesome bud.
Really dig the effort you put into good film and edit work. I hope my videos come across a fraction of the quality of yours!!
Extremely smart decision to go with the tj transmission. You would've been swapping that trans in after the first drive that you put your foot down with the samurai trans. That vw diesel would've blown it apart not even trying.
A BV43b turbo from slightly later model Audis would be an even better upgrade for the motor, but you’d need to make sure the injectors are big enough so you aren’t running silly durations or getting high EGT’s.
Try looking to the European market for bits and pieces for the 1.9’s. We’re doing all sorts of crazy things with them.
The turbo feed lines will need to be braided ideally as you say. The solid lines are a garbage weak point.
S-tune, Matt Lewis racing and darkside developments all supply those, along with lots of other upgrade parts for the PD engines.
Shallow steel sumps are available to increase clearance and add resilience to the bottom of the engine.
Use VCDS lite (or buy the full version) to check the torsion angle now that you have had the head off/timing setup apart.
It’s vital for good power production, spool, efficiency and smooth running.
Fuchs Titan GT1 flex 3 5w40 is a great oil for the PD’s to avoid cam wear.
Nate, look online for a Parker Parflex catalog. Search the 91 series fittings to see if your connection options are there. Possibly use AN adapters. Then find your local Parker Store, ask for 929b Teflon hose. It’s a little heavier inner tube. I work for a Parker distributor, but I’m in Ohio or I would make you one for sure. Or if you need help I can help and even ship it to you.
Thanks! We do have a Parker distributor in Tacoma, I will check them out 👍
[insert meme of the TJ all covered in gunk watching all of its performance parts being used for the Samurai]😂
Lol for sure!
I want to build a turbo k20 or k24 for a buggy like your buddy built. TDIs are cool I just think gassers are better for crawlers.
you can always buy a AN flaring tool to make the hard line off of the turbo into a AN line adapter and just find out who's brand allows the for the heat you expect to see from the oil system. i'm using Fragola brand braided stainless sheathed teflon lines for a power steering system and they have been holding up fantastically. i'm wanting to say they are good to 3000 psi and 500 ish degree's so they may be your ticket for custom oil lines. they assemble with common hand tools and the hardest part is usually getting a clean square cut. so far as my memory goes there are several companies that sell a hard line crimp set up for making your hard lines adaptable to AN lines and you just need to buy the tube nuts to go with them and it should work nicely. i plan to redo all of my lines for my bronco with custom hard lines adapted to AN lines. if i do everything right i should be able to make it have just a few soft lines that work for all the major connections to clean things up and make field repairs really easy.
Oil lines from Williams oil in Tacoma. They will build any line you like.
A PD engine without a roached cam would be like coffee without water.
Another advantage to head studs is you fully thread them into the block, so there is more threads of engagement than a bolt that will usually not reach full depth.
I had the same issue using a CBEA from a Jetta, the exhaust points toward the front with the stock turbo. I had to get an Audi A5 TDI exhaust manifold and turbo, but the upside is it can handle an extra 30 HP
Kerma TDI sells a braided stainless turbo oil supply line.
Back in the day (1981) I got some high flow heads for my 69 Bug with a stroker motor from Small Car Performance. They are in Fife, looks like they do a lot of Subaru Conversions for Vanagons, they may still have an in-house machine shop or might be able to suggest a machine shop locally that can do what you want.
If the samurai is like a toy, Working on a classic mini is like playing with a miniature toy hahaha
williams oil and filter in tacoma might be the place to get braided lines or pirtek. pirtek does hydralic lines and repair especially in the field.
I don't know if Waterhouse is still around in Tacoma Wa. But they balanced my motor and were the go to guys years ago for anything like that Nate.
A lot of hydraulic shops will make custom stainless braided hoses and they're usually more affordable than pre-made ones.
Look into Driven Racing Oil Assembly Grease by Joe Gibs. He developed it because he was getting about 1 in 10 motors not making it through break in (flat tappet). Now he up to 1 in 75. I switched to it and it great stuff. A LOT BETTER then any other I have used.
As German vag guy I have to say if you need anything in a stronger version for those engines take a look at darkside developments from the uk. They build them for the drag strip but they have some crazy parts 👋
Oil lines for the turbo:
Go with AN lines, you can buy them premade in different lengths from several places, even Amazon. Search turbo feed AN line.
Yay!
Heads up in Auburn WA. Might give them a call. All they do is automotive heads
Old sbc are notorious for flat cams do to lack of oil changes and running 30 weight in states where you have a winter. Yes, new engines you HAVE TO run the recommended oil weight and type otherwise.... The newer Chrys;er hemis having issues with sludge and lifters spinning in there journals taking cams out. All from a lack of oil changes.
If you want to destroy an engine, don't change the oil.
Even the new cars that keep track of how you drive and how many miles you put on aren't really measuring the oil directly. There is no way to know unless you send the oil to a lab like Blackstone. Also there is an incentive from the car company to set that interval high so they can claim lower cost of ownership through fewer oil changes even though they know extended OCIs are deadly to engines. That's OK, they would rather sell you a new car anyway.
It would be so therapeutic to watch him work on the with the volume of the rock music just a tad softer. The music is too loud when you can't clearly hear the power drill he is using.
DANG MAN, if only you didn't live so far away, I have had a 1994 FORD 4 cyl 2.3 ltr Turbo SVO engine out of a mustang with just shy of 34,000 miles, and of course, "yes, it is the old story of a car that belonged to a old lady"..LOL.. all jokes aside, it really did, but she never drove it, because she counted on her husband to drive, and he past away. I got the engine for free, as my buddy wanted the clean body LX look, catch, I had to pull the engine. "Oh darn, wont get a fight out of me, and will be right over"... lol... That motor has been on an engine stand for about 25 to 28 years.. I had plans to blue print it so I could machine a quarter scale working unit.. But, that is never gonna happen as I have other stuff to do and just fell so low on the list of projects.. Would love to see one of these pimped out with some performance parts from ESSLINGER, WHICH I HAVE.. hint.... hint.. hint...But I am not shipping a crate to Washington state. too costly.. maybe summer time will be cheaper... I shipped an anvil to Cali from Indiana, and that cost me shy of $900, granted it was a huge & heavy mofo, but so is the 4 cyl..
Dg machine out of auburn does real good work
Good advice. You kinda make your own luck with the decisions you make.
PS: keep the music level below the talking level. I have to have to adjust the volume of the video several times while watching.
Check out vibrant performance for your steel braided lines!
Good call!
Yeah I use them all the time! They have great products!
Nate awesome video, 1,9 TDI engines are great, strong out of the box, and even better when using upgraded parts and being refreshed just as you are doing, I've seen so many people just go get a junkyard engine and dump it into whatever vehicle, not change any fluids ,fill with coolant, oh i mean water, coolant cost too much, get it wired and head out on the trails or the highway ,full send it, and boom, then they blame GM for making a shitty LS engine ,not themselves, LS swaps are done for the simple reason that they are plentiful, they are in every junk yard in North America , and you can get parts at any auto parts store for one, sure the LS can go for a few hundred thousand miles with good regular maintenance, 75% of them don't ever see that , with the TDI and your upgrades, you'll get the similar torque or more without the weight or size and your fuel will take you further on the trails, even back in the 80's when Volvo sold diesel cars the engines were VW/Audi diesels, inline 6's single over head cam design 3.0 litre N/A and 2.4 litre turbo intercooler ,not fast by todays standards, stoutly built, gobs of torque and great economy ,average 35mpg Canadian, 18 gallons, you could drive for 10 hours on a tank of fuel with A/C on and cruise set at 65 mph, so VW diesels are great, if you put your foot into it, these cars did roll coal, LOL, just not like a Cummins 👍
Williams oil filter in Tacoma makes custom lines… not cheap but they’re good.
I have gotten stainless steel braided hose at Timco in Fife.
You have summitracing in us.. like every damn plumbing line, fitting and hose can be found there.. i buy from there.. and live in sweden.. :D