isuzu 4BD1T swap?! (1 Viewer)

[Dougal]

Yep, my turbo be the first one IHI-RHB6. Your right about it being pretty hard to find parts for. Dougal, are you running the free floating T25 on your 85' 4bd1 currently? If so, what type of mods did you have to do to use it?

I'm running a wastegated T25 at the moment. It's originally off a Nissan CA18DET petrol motor. Has 0.49 A/R exhaust housing for very quick spool.
I have some boost at 1200rpm, 10psi by about 1400rpm and 19psi before 2000rpm.

It goes very well.

 

[andrew.fletcher]

Can someone confirm vehicle weight on a '93 16' Isuzu box truck. I could only find one listing on line which gave it a weight of around 12-16,000 lbs. I'm looking at one that will need to be trailered so I've got to find a truck/trailer combo that can handle it.

 

[Dougal]

Can someone confirm vehicle weight on a '93 16' Isuzu box truck. I could only find one listing on line which gave it a weight of around 12-16,000 lbs. I'm looking at one that will need to be trailered so I've got to find a truck/trailer combo that can handle it.

Cab chassis is about 2500kg for the NPR59. The bodies aren't factory and can vary a lot.

 

[astr]

Can someone confirm vehicle weight on a '93 16' Isuzu box truck. I could only find one listing on line which gave it a weight of around 12-16,000 lbs. I'm looking at one that will need to be trailered so I've got to find a truck/trailer combo that can handle it.

I have a 94 NPR 16' diesel box truck with automatic transmission and no lift gate. There is no weight on the title but an empty weight of 8,050 is placarded on the side of the truck. As Dougal pointed out, the weight can vary a lot depending on who made the box and what options there are. However, this shoulld give you a good ball park number. The 12-16,000 lbs is most likely the maximum gross weight.

 

[andrew.fletcher]

Astr and Dougal-
Thanks for the correct weights. I've decided to part it in place and drop the scrap off at a local scrapyard.

Well it's taken me 6 months+ to find one but I finally got my Isuzu diesel. It's a 4BD2T that was torn down for a rebuild then never quite put back together. After sitting out in the elements for 3 years it had to be torn down again, gaskets replaced and should be ready to go in my FJ55 in a couple of weeks. Now I just need a tranny behind it.

This brings up question 1. Can I use this transmission with an adaptor to either the transfer case that's in the 55 or the TC that I have from an '85 FJ60? It's an automatic which is what I'm looking for.

Since I bought the whole truck I'm trying to figure out what all I should take off of it either to use on mine or try and sell. The truck itself is a lost cause. Even though there's no damage and it's only got 67k on it, it sat unregistered for 3+ years so the back fees on it make it un-appealing in one piece.

Parts I think I need that aren't on the engine:
Intercooler
Fuel shut off/enrichment motor/cables
Tranny- see above
Fuel/water separator
Radiator?

If anyone else had one they parted out, what's worth taking off to try and sell?
Cab-no damage
16' box
Power steering box
Brake calipers
What else???? It's about a 6 hour drive to where it's at, so I'm driving down, getting what I need then having the rest towed down the street for the scrap metal.

Drew

 

[astr]

.... Parts I think I need that aren't on the engine:
Intercooler
Fuel shut off/enrichment motor/cables
Tranny- see above
Fuel/water separator
Radiator?...
Drew

If it came with an exhaust brake (vacuum-activated butterfly valve downstream from the turbo) get that as well as the associated solenoids. Get the vacuum reservoir and get the engine shutdown/enrichment motor assembly. It should be mounted on the right side frame rail and connects to the injection pump with one or two cables. It probably is enclosed in a white plastic bag. Also consider getting all the electrical harness with the connectors intact. It is a lot of work to pull it but you'll be glad you have it when you begin the install into your 55. If the truck came with an automatic transmission and your are considering using it, be sure to get the transmission computer and the associated wiring harness.

My philosophy has been to pull anything that might possibly be useful. If you don't use it, you can always throw it away later. If you need it and have to buy it latter, it will probably cost a bunch.

Seems that the biggest hangup that everyone has encountered with this swap is the lack of suitable engine to transmission abapters or Isuzu transmission to Toy t-case adapters. RHINO has successfully installed a 4BD1 in his 55 using the Isuzuswapper adapter. I don't remember which tranny he used but it is posted somwhere here on MUD.

Good luck and keep us posted as to your progress.

 

[Dougal]

In addition to ASTR's comments, get the gear lever and clutch master/slave cylinders.

I'd also take the entire air intake system (cleaner, hose connections etc. They may be too big for what you need, but it's worth checking.

 

[andrew.fletcher]

My original plan was to go with the Isuzuswapper adapter which according to the website can use 200R4, 700R4, 4L60 and 4L60E automatic transmissions. Since I now have the transmission, I'm wondering if it will hold up. The challenge will be to either find an adapter or have one made for the transfer case. I don't plan to wheel it real hard so it may work for me.
You're right Astr, I think I'm gonna pull as much stuff off of it as I can or at least as much as will fit in the garage. I'm quickly running out of space as I keep getting more parts and haven't actually put anything on the truck yet! The biggest challenge for me is figuring out what's what. I never saw the engine in the truck and some parts were in storage, in the cab and in the back. What I really need is some diagrams.

I checked out Rhino's when I was in Phoenix last month, what a great ride! He's running the Isuzu adapter with an R150.

 

[RHINO]

andrew, a handfull of us here can prolly identify everything, pop a few pics or something and we can get ya all sorted.

 

[andrew.fletcher]

I took a few photos but not nearly enough of the underneath. Any help much appreciated. Looks like I've got a little bit of time before I head back down there again.

 

[astr]

I took a few photos but not nearly enough of the underneath. Any help much appreciated. Looks like I've got a little bit of time before I head back down there again.

Yes, that is the Fuel cutoff/enrichment thang. The motor mounts might still be attached to the motor.

 

[88tlc]

isuzu to 4l60 to toyota transfer case

got the isuzu diesel, 4BD1T mounted up to a rebuilt 4L60 using the isuzu diesel swappers, then an AA adapter to the toyota transfer case. It all went to together really fast, it is amazing what you can do if you throw some money at it!

got the flywheel drilled by a machinist, so that I could attach the IDS spacer.

4L60 trans is a heavy duty K case transmission, with a custom converter for big torque low stall. the output shaft was replaced with the 2WD shaft, provided by the AA kit, so that it worked with the adapter and split case TC.

install flex plate, and adapter ring, and the 4L60 mounts up cleanly.

 

[88tlc]

Diesel Train for the FJ62

another few pictures of the Diesel Train!

4bd1T -IDS - 4L60 - AA - TLC splitcase transfer case.

some details I would love some input on.

 

[88tlc]

dieseltrain in the FJ62

we slid the whole thing into the FJ62, and it really fits pretty good.

the rear crossmember looks like it can bolt into the same location saving some removal and remounting, and reusing the existing driveshafts.

the motor mounts will be fabbed up from scratch, using a ford mount shown.

plenty of room in the front of the engine.

good clearance on the starter, turbo is a little close to the brake assy but I think will be okay

the pan to pumpkin clearance is perhaps 3 or 4 inches. I have OME lift that I will install to help some of the clearance, but as it sits now without the engine weight on the frame it seems pretty good.

 

[88tlc]

Fuel cutoff/enrichment

Yes, that is the Fuel cutoff/enrichment thang. The motor mounts might still be attached to the motor.

is this assembly also required on the 4bd1T? In another post somewhere you guys mentioned the cable that is on the inside of the injection pump, between IP and the engine, this was the enrichment cable?

how is this controlled or actuated?

 

[astr]

is this assembly also required on the 4bd1T? In another post somewhere you guys mentioned the cable that is on the inside of the injection pump, between IP and the engine, this was the enrichment cable?

how is this controlled or actuated?

Congratulation! Looks like you've made great progress

Some engines had only a cable that shuts the engine down (my 4BD2 for example). Others had two cables coming from what the manual calls "Engine shutdown unit". The engine shutdown unit is the thing andrew.fletcher has labled "fuel cutoff/enrichment" a few posts prior. The second cable, according to Dougal, is used for enrichment during starting. Here is a link with pictures: http://www.4btswaps.com/forum/showthread.php?t=1710

I've looked through my FSM's and can't find any reference to the enrichment cable but all contain reference to the shutdown cable. I noticed that the engine shutdown unit depends on some additional contacts within the ignition switch to function. I don't know if an FJ62 ignition switch would have the extra contact (labled P1, P2, and A in the diagram below). It may be easier to replace both cables with simple pull cable like the old style choke cables.

I hope this helps.

 

[Dougal]

is this assembly also required on the 4bd1T? In another post somewhere you guys mentioned the cable that is on the inside of the injection pump, between IP and the engine, this was the enrichment cable?

how is this controlled or actuated?

The enrichment cable on my 4BD1T is also controlled from that solenoid pack. The cable from that extends to the top of the fuel pump, there is another short cable which connects that to the cam on the side of the pump near the block.

With key to on, this cable pulls and releases, locking the fuel pump into a part throttle position, that's released as soon as the governer starts working (I'm guessing idle speed).

I haven't seen it in manuals either, I pulled my pump governer apart to see how it worked.

 

[andrew.fletcher]

88tlc - Thanks for the photos and specifics on your conversion. I think I'm gonna end up with the exact same set-up that you have for my 55.

astr- Thanks for the diagram, that will definately help with what wiring to take off of the Isuzu when I strip it.

Definately feeling like progress finally!!

 

[RAYJON]

Great thead... and thanks for those contributing to the information...

I am definately interested in the aw450 to the toyota transfer case.. I have 2 80's and this would be a great swap, someone take them apart and see if the output shafts are the same please......If so I will be buying a motor and trans very fast... as this would be the best of both worlds and meet the emissions standards here, Then I can keep my 80's even with 4+ $ gas/diesel here in the Kalifornia....

 

[euclid]

got the isuzu diesel, 4BD1T mounted up to a rebuilt 4L60 using the isuzu diesel swappers, then an AA adapter to the toyota transfer case. It all went to together really fast, it is amazing what you can do if you throw some money at it!

Very cool. about $1400 in kit cost?

4L60 trans is a heavy duty K case transmission, with a custom converter for big torque low stall. the output shaft was replaced with the 2WD shaft, provided by the AA kit, so that it worked with the adapter and split case TC.

Did you decide on the 4l60, then go find one, or did you use it because you had it? Wondering why you didn't use a 4L

we slid the whole thing into the FJ62, and it really fits pretty good.

the rear crossmember looks like it can bolt into the same location saving some removal and remounting, and reusing the existing driveshafts.

the motor mounts will be fabbed up from scratch, using a ford mount shown.

plenty of room in the front of the engine.

good clearance on the starter, turbo is a little close to the brake assy but I think will be okay

the pan to pumpkin clearance is perhaps 3 or 4 inches. I have OME lift that I will install to help some of the clearance, but as it sits now without the engine weight on the frame it seems pretty good.

Same crossmemember, same driveshafts! Wow that is exciting.

Room in front for an intercooler?

Is the 62 on stock springs right now?

Great job, thanks for pioneering for us 62 guys.