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JamesPT
11-20-2013, 11:07 AM
I thought I share my Build with you all!... Some variety for ya.

First off, its a 1998n European Suzuki (Santana) Vitara (Sidekick) Metal Top, 3door, 1.9 Turbo Diesel...

Santana is the Spanish Builder, that assembled the Turbo Diesel versions of the Vitara. They are a bit different than the US/Cdn sidekick in frame(yes, has one!), and accessories, and under the hood of course.

Its a Vitara, same as a sidekick/tracker, Suzuki used the original name in Europe, The NA OE partners like GM or Geo changed the name for US/Cdn to Sidekick, Tracker a and Sunrunner. Also, North America didn't get metal top 3dr versions.

The Engine, which is why some of you are here... Turbo Diesel!
Suzuki didn't product a TD until 2002 ish and therefore used engines that were already smog certified. 1995-98 they used a Citroen / Peugeot 1.9L inline4, IDI Turbo diesel made by PSA, called the XUD9(te, Sd, tey).

Great engine, and lots out there, used in the Pug 306's 205's and a bunch of European cars, with different injector pumps, injectors and turbos changing the power levels. Whats great tho, internally, not much changed, and most parts can be taken from a Sporty donor and applied.

Lightly modified (Stage 1 say), they product lots of Torque (200+) and some HP (125).
125 HP doesn't sound like a lots, but HP depends on RPM, and XUD's don't REV! But the Torque is almost alway on Tap. 2500rpm is near max torque and stays there till the limiter.

Driving one is like having two engines, Off boost, its slow and very easy to drive, really CALM! with enough torque to idle crawl... Get on the Boost and its a little monster.

Enough about that!... I'm a Diesel Convert, so I can go on and on!

The Actual Build Thread is already a couple pages long on another Forum, I'm gonna Transpose it to this Thread over the course of time, and at one point, my Portuguese and XJtalk will sync up.

Lets start with the Normal "BEFORE" photo!

Here she is Stock (with some MT's)
https://dl.dropboxusercontent.com/u/1279599/VitaraBuild/Vitara02.jpg

First thing to do with any Build, Suspension. Coming up!

NW99XJ
11-20-2013, 11:09 AM
I love a good Turbo Diesel build!
:popcorn:

JamesPT
11-20-2013, 11:21 AM
Not many Options for Suspension for a Suzuki Vitara (TracKick).

Theres Spacers and/or Spring, or Full Arms/Link kits, and I can count the producers of the Full systems on one hand.

Initially was heading for a Calmini 3" system, than found a Clone, that was a bit better, (I could get higher rated front springs needed for the TD's weight), and it was Cheaper than a US to Euro import. (4xFourArt).

https://dl.dropboxusercontent.com/u/1279599/IMG_1088.jpg

Heres the Kits, including Arms, Springs, Links, Triangle, Shocks. Even a Brake line for the rear(which didn't work... Santana did things different than Suzuki Japan.. Most times better than Japan, Tougher)
Before: Front & Rear
https://dl.dropboxusercontent.com/u/1279599/IMG_1102%20%28Mobile%29.JPGhttps://dl.dropboxusercontent.com/u/1279599/IMG_1103%20%28Mobile%29.JPG

After F&R:
https://dl.dropboxusercontent.com/u/1279599/IMG_1128%20%28Mobile%29.JPGhttps://dl.dropboxusercontent.com/u/1279599/IMG_1127%20%28Mobile%29.JPG
New Stance:
https://dl.dropboxusercontent.com/u/1279599/IMG_1126%20%28Mobile%29.JPG

Played around like that for some time, collecting other parts, but enjoying the new toy, and its added ability. I had plans for the TD, "More Power" of course.

JamesPT
11-20-2013, 11:27 AM
Around the same period, (Dec 2011) I had to swap out the Radio and so I also Dropped in a CB (got my license too).

https://dl.dropboxusercontent.com/u/1279599/IMG_1138%20%28Mobile%29.JPG

Vitara is a Double Din style, so I got a Cb, with forward facing speaker, and the end result seems nice.

Enjoyed the Vitara like that until the summer, all the time, making Big Plans for the Summer Pause (Don't do much Offroading in the summer around here, thats beach weather!)

JamesPT
11-20-2013, 11:36 AM
missing from Photos is my Stack Boost gauge.
http://dl.dropbox.com/u/1279599/IMG_1091.jpghttp://dl.dropbox.com/u/1279599/IMG_1096.jpg
http://dl.dropbox.com/u/1279599/Snorkel%20and%20Apollo.jpg

My 2011 Xmas Gifts to myself.
Snorkel(duh), K&N Apollo air filter, Intercooler, pipers etc ,Boost & EGT Gauge, Gauge pod, 8" MTX Powered Sub and other bit and bolts.


Also this happened:
https://dl.dropboxusercontent.com/u/1279599/2012-05-06%2019.57.36.jpg

For a Sidekick/Tracker/Vitara Owner, that actually Off-roads there truck, its like losing your virginity!
Until 96, Suzuki used Iron diff cases and 3rd members, After 96 they swapped to Alloy units to save weight, but they aren't as strong.
Took this as a Opportunity, and Swapped in some 5.125 gears (from 4.725) as I knew bigger tires are in the plans.
Also Swapped the Alloy front 3rd and Axle cases for Iron units from a 96.

JamesPT
11-20-2013, 11:48 AM
Photos are better than words (sometimes) SO.... Photo DUMP!

The fan need to move down 5cm to not hit the IC, I want to use the original, which is 27cm (11in) , but I may have to use something smaller, 8in or 2x 8in. *For the Winter, maybe I didn't need it, but summer I will.
s
http://dl.dropbox.com/u/1279599/IMG_1155.jpghttp://dl.dropbox.com/u/1279599/IMG_1156.jpghttp://dl.dropbox.com/u/1279599/IMG_1160.jpg
http://dl.dropbox.com/u/1279599/IMG_1170.jpghttp://dl.dropbox.com/u/1279599/IMG_1163.jpghttp://dl.dropbox.com/u/1279599/IMG_1174.jpg
http://dl.dropbox.com/u/1279599/IMG_1173.jpghttp://dl.dropbox.com/u/1279599/IMG_1176.jpghttp://dl.dropbox.com/u/1279599/IMG_1171.jpg


Also, in the works, is the Snorkel install, not started tho. just removed body panel.

http://dl.dropbox.com/u/1279599/IMG_1184.jpghttp://dl.dropbox.com/u/1279599/IMG_1188.jpghttp://dl.dropbox.com/u/1279599/IMG_1187.jpg
http://dl.dropbox.com/u/1279599/IMG_1186.jpghttp://dl.dropbox.com/u/1279599/IMG_1190.jpghttp://dl.dropbox.com/u/1279599/IMG_1191.jpg

And VoaLa
http://dl.dropbox.com/u/1279599/IMG_1189.jpg

JamesPT
11-20-2013, 11:57 AM
Top View, Snorkel mounted, Grill View.
http://dl.dropbox.com/u/1279599/IMG_1192%20%28Mobile%29.JPGhttp://dl.dropbox.com/u/1279599/IMG_1193%20%28Mobile%29.JPGhttp://dl.dropbox.com/u/1279599/IMG_1195%20%28Mobile%29.JPG

Missing the Fans (2x 8" pusher's)... lets fix that

http://dl.dropbox.com/u/1279599/IMG_1203.jpghttp://dl.dropbox.com/u/1279599/IMG_1204.jpg
http://dl.dropbox.com/u/1279599/IMG_1205.jpg

The 10" Fan didn't fit anymore, so I got 2x8" and wired them up (they are DEAD NOW... ebay fans suck!)

I also removed my front swap bar, with the 5.125 gears, she don't go so far anymore, and this helps the IFS get Sexy Flexie

JamesPT
11-20-2013, 11:58 AM
Noooooooo!

Anyone that know what this is, KNOW how much of a PitA it is
http://dl.dropbox.com/u/1279599/2012-04-18 18.48.15.jpg *UGH!

4.3LXJ
11-20-2013, 12:47 PM
What is that, oil cooler on the radiator?

JamesPT
11-20-2013, 04:10 PM
It's the nasty heater core!!!! The least favorite job

4.3LXJ
11-20-2013, 04:48 PM
What does your antifreeze look like?

Carves
11-20-2013, 05:14 PM
Good job on the little suzie.

They have a fairly good reputation down here, in the lighter duty 4x4 class.
I still miss my 1970's two stroke .. :D

Big tuff toyota owners will generally call em junk tho .. ;);) .. :D


X 2 with 4.3LXJ ... have a look at all your cooling system ... cleanliness and diesels go hand in hand .. ;);)

JamesPT
11-26-2013, 08:41 AM
New Rubber! (July 2012 ish)

BEFORE--
(Fedima MaxiGrip 195(/80)R15 c/ Suzuki Original janes ...15"x6" ET10)
https://dl.dropbox.com/u/1279599/1.jpghttps://dl.dropbox.com/u/1279599/2.jpg
https://dl.dropbox.com/u/1279599/3.jpghttps://dl.dropbox.com/u/1279599/4.jpg

The Tires and new Rims, O Pneus e Jantes
(Insa Turbo Special Track 235/70R16 c/ Jantes 16"x7" ET5
https://dl.dropbox.com/u/1279599/5.jpg

The Result!

https://dl.dropbox.com/u/1279599/7.jpghttps://dl.dropbox.com/u/1279599/8.jpg
https://dl.dropbox.com/u/1279599/9.jpghttps://dl.dropbox.com/u/1279599/10.jpg
https://dl.dropbox.com/u/1279599/11.jpghttps://dl.dropbox.com/u/1279599/12.jpg

JamesPT
11-26-2013, 08:43 AM
Updated the Tubes, and got a different non-curved entry into the manifold.
Also making room for the Bosch injector pump thats coming(came)

Installed a MBC to adjust pressure.

https://dl.dropbox.com/u/1279599/2012-12-18%2022.53.11.jpg
https://dl.dropbox.com/u/1279599/2012-12-18%2022.53.22.jpg
https://dl.dropbox.com/u/1279599/2012-12-18%2022.53.27.jpg

JamesPT
11-26-2013, 08:46 AM
The Bosch injector pumps installed, which has the boost compensating feature.
*
First Drive, Fantastic

Missing is the Pug Sport 306 175Bar injectors, Ebay!?

Other minor updates inside, including LED lights in the rear etc,...

https://dl.dropbox.com/u/1279599/Boschpump.jpg

JamesPT
11-26-2013, 08:47 AM
May 2013.Some updates!

The Drivers side transmission is now replaced, I broke it jumping out of a huge hole at the Encontro Suzuki!

I'm trying to convince myself to do the lfteixeira tranmission conversion now!
However, I just got the following parts to install, and I need to take my Vit to get the chairs reupholstered.

The Idea with the tubos, is to connect the Air filter to the turbo with less bends, but also move the location of the air filter a bit.

The Injectors are new Bosch units, @ 175bars! * Very hard to find new units for a reasonable price.

https://dl.dropboxusercontent.com/u/1279599/Screen1.pnghttps://dl.dropboxusercontent.com/u/1279599/Screen2.pnghttps://dl.dropboxusercontent.com/u/1279599/Screen3.pnghttps://dl.dropboxusercontent.com/u/1279599/Screen41.jpg

JamesPT
11-26-2013, 08:48 AM
May-ish 2013=======
Oh, forgot one update, Winch and steel bumper (PP!)
So, making this quick, here's the Photos and a link to the Winch.

https://dl.dropboxusercontent.com/u/1279599/UPS1.jpghttps://dl.dropboxusercontent.com/u/1279599/2013-04-13%2017.27.32.jpg
https://dl.dropboxusercontent.com/u/1279599/IMG_2636.jpghttps://dl.dropboxusercontent.com/u/1279599/IMG_2646.jpg
https://dl.dropboxusercontent.com/u/1279599/IMG_2647.jpghttps://dl.dropboxusercontent.com/u/1279599/IMG_2648.jpg
https://dl.dropboxusercontent.com/u/1279599/Finsihed.jpg

JamesPT
11-26-2013, 08:49 AM
Oct 2013
Bosch injectors installed, but the power seems to have gone Down?.. I think I need to Add more fuel, cause there is less or no smoke now too. *The Higher Pressure of the Bosch 175bar injectors is probably needing more force to open and therefore I need to increase the fueling screw a bit. *

But in other news, I have purchased a turbo and manifold to experiment on!
heres some examples.

https://dl.dropboxusercontent.com/u/1279599/Porting%20Experiment/1378498_10153395364505397_1433809924_n.jpghttps://dl.dropboxusercontent.com/u/1279599/Porting%20Experiment/IMG_3066.JPG
https://dl.dropboxusercontent.com/u/1279599/Porting%20Experiment/IMG_3060.JPG

Notice the inlet on the first photo, not at all cone shaped, just a blunt entry. As for as a Bigger Turbo, not interested in that.. That would make alot of peak power, but take ages to spool up. There isn't any room for a proper header 4-2-1 or anything like that, so I'm making the best with the stock parts (almost stock), notice no EGR on that manifold :-P

And Finally

https://dl.dropboxusercontent.com/u/1279599/Porting%20Experiment/IMG_3072.JPGhttps://dl.dropboxusercontent.com/u/1279599/Porting%20Experiment/IMG_3085.JPG
https://dl.dropboxusercontent.com/u/1279599/Porting%20Experiment/2013-10-23%2018.56.21.jpg

Still a lot of work to do here, Wish i had an easy way to get EastWood's stuff here!!!

JamesPT
11-26-2013, 08:51 AM
Just a taste...Go to 10:00

http://www.youtube.com/v/Ogu9ymp_93Q

JamesPT
01-13-2014, 08:40 AM
https://dl.dropboxusercontent.com/u/1279599/lda1.JPG
https://dl.dropboxusercontent.com/u/1279599/lda2.JPG

Minor Mods to the Fuel pin, this allows less fuel at low boost and more at full boost.
Worked out great. Took some time to get the tuning right, as everything is mechanical on this diesel, no ECU here!

(Oh, the Turbo/Manifold is still on the bench!, no time!)

Also installed some aftermarket (AVM) manual locking hubs, as the factory Auto's weren't handling the stress so good.

In other new, I have two new lower arms for the Front, to Pull the front tires 3cm (1.15inch) forward. Allowing larger tires, without body rub. Photos to come. Cya

jimmixj
01-13-2014, 09:14 AM
Nice buildup! Didn't much care for the Zukes but yours is very cool!

JamesPT
02-28-2014, 03:17 AM
Ola, Not much time for me to work on my Vitara myself, but I had some little stuff done!.

Installed that kit I mentioned before, the moves the front wheels 1.5" forward see photos.

Also had to put in new pinion bearings, so when it was opened up, I dropped in a LockRight locker... My opinion is mixed at this moment, but it does Work!

https://dl.dropboxusercontent.com/u/1279599/Finger%20test.jpg
https://dl.dropboxusercontent.com/u/1279599/Ruler%20Test.jpg
https://dl.dropboxusercontent.com/u/1279599/Ruler%20Test2.jpg

4.3LXJ
02-28-2014, 11:02 AM
The lockers always work well in low speed poor traction. But there are trade offs

JamesPT
03-28-2014, 10:04 AM
I'm really thinking about yanking out the LockRight, and going ARB. My paddle clutch + Lockright setup is a pita to drive, not smooth at all.
The paddle clutch engages like hitting a wall!, BANG! even when you try to be smooth!
Maybe I'll replace both, as I hate the clutch too!
Problem is, I need to drop in a SuzukiV6 clutch, meaning custom cutting my flywheel.

I think I'm destroying the U-joint very quickly in my rear shaft. :-(

4.3LXJ
03-28-2014, 10:58 AM
Not familiar with paddle clutch. Could you explain?

JamesPT
04-22-2014, 08:14 AM
Not familiar with paddle clutch. Could you explain?

Paddle Clutch

http://product-images.qedmotorsport.co.uk/vauxhall/c20xe/clutch/4-paddle-clutch.jpg

Basically, by limiting the Surface area of the clutch, the area that does contact, does so harder and with more pressure.
But also, hits really hard as it engages, almost like dropping the clutch each time you start, not a nice ride, fine for track cars, but not a 4x4.

JamesPT
04-22-2014, 08:26 AM
Turbo and manifold are back!

The Turbo!
https://dl.dropboxusercontent.com/u/1279599/TurboDyn1.jpghttps://dl.dropboxusercontent.com/u/1279599/TurboDyn2.jpghttps://dl.dropboxusercontent.com/u/1279599/TurboDyn3.jpg

Manifold!
https://dl.dropboxusercontent.com/u/1279599/TurboDyn4.jpghttps://dl.dropboxusercontent.com/u/1279599/TurboDyn5.jpghttps://dl.dropboxusercontent.com/u/1279599/TurboDyn6.jpg

Downpipe!
https://dl.dropboxusercontent.com/u/1279599/TurboDyn7.jpghttps://dl.dropboxusercontent.com/u/1279599/TurboDyn8.jpghttps://dl.dropboxusercontent.com/u/1279599/TurboDyn9.jpg


Waiting now for a huge project/build opportunity.

4.3LXJ
04-22-2014, 10:10 AM
That is pretty stuff.

JamesPT
04-23-2014, 11:50 AM
Rear Bumper and Sliders

https://dl.dropboxusercontent.com/u/1279599/My%20Slider%201.jpg
https://dl.dropboxusercontent.com/u/1279599/My%20Slider%202.jpg
https://dl.dropboxusercontent.com/u/1279599/My%20Slider%203.jpghttps://dl.dropboxusercontent.com/u/1279599/My%20Slider%204.jpghttps://dl.dropboxusercontent.com/u/1279599/My%20Slider%205.jpg

It time to take a break, I've collected a bunch of parts to install, The Turbo and a new rad etc etc... But I'm moving end of this month, and I'm losing my garage!

So SAD!,, I had (have till the 30th) a huge drive-in garage/basement that was 32'x38'!
I used 1/2 as my man space, with my toys there. New house is bigger, more rooms and better for my expanding family, but no garage! Theres space behind the house to do something, but thats gotta wait till I recoup some cash.

4.3LXJ
04-23-2014, 12:36 PM
Nice looking body protection there James. Sorry to hear about the shop space going away. Hopefully you will be able to get something going in the new place

XjJeepacorn
04-23-2014, 06:24 PM
I like your CDN sticker... oh and of course your work ;)

JamesPT
08-25-2014, 11:25 AM
Finally getting on with this!

Offroad season here starts up again in September,
July/August is all Beach time!, although I don't like the beach..cause I'm bleached enough lol... So I've been riding my 1966 Famel Zundapp X15 50cc bike!

Anyway,.... Heres the updates,
The parts are going on, I don't have time, so its being done at a local place that good with "Fab-ing", its not really a garage, its a rally car shop!

The red parts you've seen, but that blue one is my intake manifold, had it sent out to get the EGR sealed, and the EGR cooler (internal) cut out a bit.

I'll Post a video once its running, and let you hear the Turbo Sound, and maybe Roll some Coal!

https://dl.dropboxusercontent.com/u/1279599/VitaraBuild/Vitara33.jpghttps://dl.dropboxusercontent.com/u/1279599/VitaraBuild/Vitara34.jpg
https://dl.dropboxusercontent.com/u/1279599/VitaraBuild/Vitara35.jpghttps://dl.dropboxusercontent.com/u/1279599/VitaraBuild/Vitara36.jpg
https://dl.dropboxusercontent.com/u/1279599/VitaraBuild/Vitara37.jpghttps://dl.dropboxusercontent.com/u/1279599/VitaraBuild/Vitara38.jpg


:bacondance: :bacondance: :bacondance: :bacondance: :bacondance: :bacondance: :bacondance:
ALSO, just got the word, that I'm Working the 2014 Sema Show...Woohoo!
:bacondance: :bacondance: :bacondance: :bacondance: :bacondance: :bacondance:

bluedragon436
08-25-2014, 11:33 AM
IM looks good, and should def open up a bit more volume with having the EGR cooler trimmed out a bit... And nothing wrong with working the SEMA show, congrats on that!!

4.3LXJ
08-25-2014, 12:19 PM
Definitely pretty for sure.

XJ Wheeler
08-25-2014, 01:34 PM
Very nice! All those shiny parts makes me want to tear into my engine! Congrats on Sema!

Sent via messenger pigeon - i talk, he types.

JamesPT
06-02-2015, 07:41 AM
OLD PHOTO!, just shows the Intercooler
https://dl.dropboxusercontent.com/u/1279599/VitaraBuild/Vitara_50.jpg

JamesPT
06-02-2015, 07:44 AM
Old Photo, December-ish.
https://dl.dropboxusercontent.com/u/1279599/BackatHome.jpg

everything installed waiting to go out and play.

Picked up some Ebay Led's!
https://dl.dropboxusercontent.com/u/1279599/Led%20Lights.jpg
2x 16w fog lights, 16W ~ 1000 lum.
4x Mini 7 "Led Combo, 40W ~ 3200 lum, for the Roof rack (when I have one!)

https://dl.dropboxusercontent.com/u/1279599/Rear%20Disc%20Kit.jpg
Picked up a rear disc brake conversion from Zanfi.it, need to collect other parts now. Calipers.



https://dl.dropboxusercontent.com/u/1279599/VitaraBuild/Vitara45.jpg
LEDs mounted, about 20deg away from center, work great to light up the road sides.

JamesPT
06-02-2015, 07:47 AM
https://www.youtube.com/watch?v=z4EKXfZUymE

https://youtu.be/z4EKXfZUymE

JamesPT
06-02-2015, 07:51 AM
ARB's!!!!!!!!!!!!!!!!!!!!!!!!!!... RD204 & RD208(10bolt), Compressor, etc...

https://dl.dropboxusercontent.com/u/1279599/VitaraBuild/Vitara46.jpg

https://dl.dropboxusercontent.com/u/1279599/VitaraBuild/Vitara47.jpg


Gotz the 265/75R16's on my Techbook, 32" here I come... After... read below.
https://dl.dropboxusercontent.com/u/1279599/VitaraBuild/Vitara48.png



vocês já viu alguma da parte. Estive loucos do compras, com o cartao de crédito da empresa :twisted:

JamesPT
06-02-2015, 07:52 AM
brakes upgrade!

The front is getting a set of 5 door calipers and vented discs, new pads.
The rear is getting Fiat Stilo rear calipers with handbrake, vitara front discs, new pads, and of course the mounting kit from Zanfi.it

https://dl.dropboxusercontent.com/u/1279599/VitaraBuild/Vitara51.jpghttps://dl.dropboxusercontent.com/u/1279599/VitaraBuild/Vitara52.jpg
https://dl.dropboxusercontent.com/u/1279599/VitaraBuild/Vitara53.jpg
https://dl.dropboxusercontent.com/u/1279599/VitaraBuild/Vitara54.jpg

https://dl.dropboxusercontent.com/u/1279599/VitaraBuild/Vitara56.jpghttps://dl.dropboxusercontent.com/u/1279599/VitaraBuild/Vitara57.jpg

JamesPT
06-02-2015, 07:53 AM
https://www.youtube.com/watch?v=F69bdrHz62s

https://youtu.be/F69bdrHz62s

JamesPT
06-02-2015, 07:59 AM
In more recent news!

The brake conversion is still on my Floor!, I've been driving her, so no time to wrench!

BUT!.... On my last outing, I think i blow/burnt the head gasket, as when I returned home, the dash light for water/rad come on, took 2 ltrs to fill it up. Thats not normal at all.

I'm about 3 times stock boost, so I was expecting this, and now its June (ie: to hot to wheel), so Time to Pull the motor, and get it Bought...err BUILT.

Sending it to these guys http://veicomer.com/servicos/audi-1-9-tdi-pd/ they seem to know what their doing!

Let see if we can't get her to 250ft/lbs of Torque! Horsepower doesn't matter! (Horsepower is how fast you hit the Wall, Torque is how far you take the wall with you!)

4.3LXJ
06-02-2015, 11:31 AM
Three times the boost, that is a lot on a diesel. No wonder the head gasket failed. But it sounds like lots of fun :D

JamesPT
06-02-2015, 05:28 PM
Three times the boost, that is a lot on a diesel. No wonder the head gasket failed. But it sounds like lots of fun :D

Well, guess I shoulda stated, that It only run about 6-7psi to start, so my 18-20psi setup isn't all that crasy, but it is 3 * stock

I think the problem is older anyway, it had an Head/Block oil leak for the last 2 years. So could be a poorly seated head, warped head, stretched head bolts, etc.

4.3LXJ
06-02-2015, 05:31 PM
Could be. But 1.5 atmospheres is still some hefty compression numbers on a diesel