Suzuki conversions

Axis Power (TM) from KELTEC System, Inc.

Volkswagen Engine Adapter Kit for Suzuki Samurai

Background Information
Conversion Specifics
Kit Details
Pricing, Dealers and Support
Updates to Installation Guide
Looking for a VW engine?

Background

We started with a diesel.

We like diesels - read on and you will see why. We decided during our design phase, tho, to provide kits for all water cooled VW 4 cylinder engines all the way from the gutless 1.5L Rabbit diesel to the steroid stoked Supercharged Corrado. Buyer beware, not all engines are suitable for (practical) use in a Samurai.

The VW 1.6 TD seemed like a good power range for what we were looking for. The prototypes for the Axis Power kits were done on the 1.6 TD Jetta engine. Since then, we and our customers have installed other VW engines. Some require more work on your part, others are very straight forward. Here is our reasoning for the prototype:

Why a diesel for a Samurai?

Overall, the venerable Suzuki Samurai is a well designed, well built, "serious" 4x4. The engine has several drawbacks, though. The mighty diesel engine has long been a workhorse in the power industry used when the heavy work is done. You'll find it in everything including agricultural tractors and "semi" tractors. A conversion to a diesel engine will provide:

Better torque. The stock Suzuki engine produces approximately 55 ft. lbs. of torque, the VW turbo diesel produces over 90ft. lbs. This means almost twice the hill climbing capability compared to your current Samurai.

Better Fuel Economy. The stock Suzuki will get hiway mileage in the mid 20's MPG. A diesel powered Suzuki will get in the high 30's MPG. Even better improvements in fuel economy are found when 4 wheeling. This means more miles between fill-ups. This may not be too big of a concern in city type driving, but when you are out in the "bush" a long ways from a filling station, this can be real important. No more hauling fuel cans on 4 wheel outings.

Long Life. The stock Suzuki engine is not known as a "long life" engine. Although with proper care, they can last a reasonable amount of time. Diesels, in general, are designed to last for several hundred thousand miles. It is not unusual to hear of diesels with 400,000 miles or 500,000 miles before requiring rebuild.

Why a VW diesel?

The VW diesel has several advantages over other diesels.

Availability. VW diesels are one of the most popular diesels made for automotive purposes. The VW diesel (originally introduced as a 1.5L, normally aspirated version - we prefer the newer 1.6L Turbocharged version) was introduced in the late '70s and is, in larger displacement and updated form, still available. They are readily available in junk yards or from "donor" vehicles.
Cost. The availability of the VW diesel means that a significant quantity of "donor" engines is available at a reasonable cost. Prices range from $200 - 300 at a "you-pull-it" junk yard, $500 - 800 at a "full service" junk yard or $2,000 to $3,000 for new or refurbished engines. Rebuilding a diesel can be done cost effectively, as parts are readily available. In some instances a rebuilt diesel may be no more costly than a rebuilt Suzuki engine.
German Engineering. Achtung! Need we say more? By the way, Volvo (a company known for reliability) uses VW diesels in some of their automobiles.
Spares Availability. Since the VW is a reasonably popular diesel, spares are readily available, should you ever need them.
Support. There is a lot of information available on VWs and their engines. Many service manuals (including the "Idiot's Guide" - one of our favorite) are available, many repair shops and garages have experience with the VWs, and there are subscription news groups, bulletin boards and websites on the Internet.
It Fits! The VW diesel is approximately the right size, weight, power and RPM range. It is really a sweet installation!

Other modifications

Lift Kit. Due to the size and orientation of the VW diesel, You will need to provide a minimum of 3" lift on your vehicle. This is measured from the front axle to the frame. Various suppliers can provide these kits, or you can do your own. Typically this will be a "Spring-Over-Axle" lift or "High-Lift" springs.

What is Involved in the Conversion?

Donor Parts Required

Notes:

VW water cooled engines came in either a "North-South" installation (crankshaft in line with length of the vehicle, as in the Quantum or Audi Fox) or an "East-West" installation (typically called "transverse" mounted where the crankshaft is perpendicular to the length of the vehicle, as in the Jetta and Rabbit). Some donor parts MUST be from a "North-South" installation, others MUST be from an "East-West", but for many parts it doesn't matter.

Specific Donor parts:

Diesel Engine. Click here for a detailed list and associated risks of installing a variety of VW engines.

Flywheel flywheel is a special part in this conversion. The flywheel must be from a "North-South" installation donor. The VW flywheel must be modified. You can send it, along with your Suzuki ring gear, to KELTEC Systems for modification. We modify the VW flywheel and install your Suzuki ring gear on it, so it will fit into the transmission (bell housing). It must then be dynamically balanced. We can also provide the drawings to you if you prefer to do this modification yourself. Check our price list for this service. Unless you have your own machine shop and have extensive shipping (and / or duties), our price will be very competitive. The price of flywheel modification is not included in the kit.

You do NOT need:The donor engine does not need to have the Alternator, the A/C pump, any other belt driven accouterments, or a Starter motor. The kit allows you to use your Suzuki Alternator and A/C Pump.

KELTEC can supply SOME of the donor parts as well as extra parts required in your conversion. Check out the price list for some estimated costs on extra parts.

Click here for a detailed list of all parts including VW part numbers.

The Kit includes:

All kits include:

Engine to Transmission adapter kit

Pilot Bearing adapter kit

Starter Motor adapter kit

Motor Mount Assemblies (R&L)

Alternator Mount Assy.

A/C Mount Assy. Specify if you have AC, no AC or a power steering conversion.

Throttle cable adapter

Cross Member spacer kit

Oil Pan drain adapter

Installation Instructions

Technical Support

The Turbo Diesel kits (AP01-01) includes:

Diesel Wiring Harness (Specify if you have tach or not)
Fuel Filter Adapter
Turbo Intake Adapter Kit
Exhaust Header

The Normally Aspirated Diesel kits (AP02-01) includes:

Diesel Wiring Harness (Specify if you have a tach or not)
Fuel Filter Adapter
(no exhaust header, no turbo intake)

The Gas kits (AP03-01) includes:

Basic Wiring Harness

Note on Motor Mounts:
We currently offer only "low" engine mounts. These allow the VW engine to ride low in the vehicle so that no hood modifications are required, but a lift kit (2" minimum) is required. We were considering producing high motor mounts that allow the engine to sit higher in the vehicle, so no lift kit is required, but a hood modification will be required. An add on hood scoop is expected to suffice. We have not found enough interest in the high mounts at this time. Please contact us if you are interested in the high mounts.

Options:

Diesel conversions may need a Tach Converter to allow the alternator to feed your Suzuki Tach. As you already know a diesel has no sparkplugs, thus no feed to the tach. Many diesel rigs use a "center tap" on the alternator that creates a pulse. These pulses are then processed into usable tach signals. You can buy an after market tach or you can buy a Diesel Tach Converter from KELTEC. The Tach Converter is listed in our "Other Automotive Components" page.

Kit Alternatives:

We offer several kits, based on which engine you select. Also, for each kit, there are alternative parts, depending on the accessories your vehicle has. When you get ready to order, contact us for a detailed configuration of your kit. See the Price List for details. We still offer all parts on an A-la-carte basis for spares and for custom installations.

Pricing, Dealers and Support

Pricing Philosophy:

The Good News:
We aren't out to get rich on this kit. We run KELTEC as a small but serious business. We have no aspirations of becoming General Motors. We are more interested in providing a quality product and the best support in the industry. All kits and parts will be priced based on our cost with lower than average markup for inventory management and other aspects of this type of business.

The Bad News:
There are a limited number of Suzuki Samurais in the world. There are even fewer of their owners who will have an interest in (and be skilled enough to install) our kit. Low volume equates to higher prices than would be available if we had lots of volume.

So, buy lots of the kits and they will be less expensive!

We have deleted all pricing information. Too old, not relevent.

Dealers:
The Axis Power kit is sold exclusively through Authorized Dealers in the USA. We are currently seeking dealers for Europe, Australia and Africa. If you know of a company that would be a good dealer in those areas, please have them contact us.

Technical Support:
KELTEC Systems, Inc. will directly support the Axis Power kit. If you have any questions during or after installation, please contact us. Technical support is offered, free of charge - unless you are being rude or stupid. In that case we will either not give you support or charge you.