Mr Tin Man’s broken heart

Ok I figured it’s time for a long over do build thread


I have a 2001 Kaiser Silver VX that’s in need of a new heart. I’m kinda new to forums and I will do my best to document everything as I go along.


My Goal is a full diesel conversion while maintaining the Vx’s original form and function

The plan was to drop a 4bt that is sitting in my garage, but that prove futile due to the weight and size restrictions of the front end. I ended up choosing a mechanical 4jg2 with an Aisin-Warner 3-40le auto with my existing TOD transfer case. Plus I wanted to maintain the Isuzu name throughout the whole build. I am a novice and by no means a professional. I welcome your questions or ideas as I embark on this possible pointless journey.

1st Day home

[IMG]https://doc-0c-30-docs.googleusercontent.com/docs/securesc/ha0ro937gcuc7l7deffksulhg5h7mbp1/agsm23oqcqfb96fc8mmmkhceenool8to/1512957600000/15871805273479339623/*/1IXa6a9d100FytmZ0DPuduLglsKcVDH2o[/IMG]


[IMG]https://doc-10-30-docs.googleusercontent.com/docs/securesc/ha0ro937gcuc7l7deffksulhg5h7mbp1/j5ofi9spgnlnfqmcot2fv0tgalqjfjmf/1512957600000/15871805273479339623/*/1WB-CuNlajQcfbOoibExibqc_1tnPSUAo[/IMG]

I am not very familiar with Isuzu Diesel engines. Bat after a google search it looks like their might be an issue with cylinder #3 becoming fouled due to egr location. Any idea for a fix?

Thelgord

Egr delete is the best option for that problem.

Apologies everyone trying to figure out how to post photos.

http://www.vehicross.info/showthread...r-forum-images

No worries. Posting images has always proven problematic here. Above is a link on how to use DropBox.

I am very interested in seeing how this project turns out.

https://www.dropbox.com/s/n2ebz0vjbh...4231.JPG?raw=1

Quote:

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Originally Posted by Thelgord

http://www.vehicross.info/showthread...r-forum-images

No worries. Posting images has always proven problematic here. Above is a link on how to use DropBox.

I am very interested in seeing how this project turns out.

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Thanks, you are awesome. that was driving me nuts..

Definitely, one of the harder engines I've had to pull out. this was no easy project

https://www.dropbox.com/s/vn43c36i6k...4358.JPG?raw=1

Empty bay

https://www.dropbox.com/s/634lx5kros...4383.JPG?raw=1


The First Failed prospect


https://www.dropbox.com/s/q1jz9sk27l...4292.JPG?raw=1

Sorry still sorting out the picture orientation issues. The 4BT was from a generator with only 146hrs. Oh well, I'll save it for my next project.

Wow! That is a massive motor...

Or seems to be anyway...

Quote:

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Originally Posted by sm0ke3T1947

Sorry still sorting out the picture orientation issues. The 4BT was from a generator with only 146hrs. Oh well, I'll save it for my next project.

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Yeah...it's hard to appreciate w/o rotating. I'll assume this diesel was too tall?

I downloaded and rotated the empty engine bay pic...just for my edification. Notice you have a steering stabilizer shock -- which I believe is aftermarket. (I considered buying one myself due to a COLD shimey felt in a certain roadway every morning. Since I moved, I haven't noticed it anymore. Did you drive this little beast before/after that mod? If so, any feedback?

Boy...I tell you what; I wish I could plant a 383 SBC in mine! <grin>

Stabilizer was from the previous owner. That 383 is one mean engine. Definitely a great conversation piece

Oddly enough picture orientation on mobile view is correct. I’ll have to look into that.

Quote:

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Originally Posted by Thelgord

Wow! That is a massive motor...

Or seems to be anyway...

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Yeah Cummins 4BT are not really small engines. Almost 800lbs

Here is my purchased 4jg2 with Aw30-40le

https://www.dropbox.com/s/k52pvibyfv...4689.PNG?raw=1

Nice!

Motor mount dilemma

https://www.dropbox.com/s/avncheyv1k...20PM.jpg?raw=1


Go figure original 3.5 mount bolted right on. Next is a test fit

Next we will be doing a test fit.

Quote:

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Originally Posted by sm0ke3T1947

Motor mount dilemma

https://www.dropbox.com/s/avncheyv1k...20PM.jpg?raw=1


Go figure original 3.5 mount bolted right on. Next is a test fit

Next we will be doing a test fit.

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Correction! Inner rubber bot and chassi mount worked. Not the portion that bolts to the engine

Did compression test on new engine and everything looks good. Ran the engine and I must say, that I’m kinda of getting excited

Shout out to. Ipupgary at the planet. Without his write up this wouldn’t be possible


Ok, took some strength and serious finesse but motor is in. Looks like I’m a little close to comfort on the differential.
Transmission is sittin just about right ( willl require slight mod to brace it to the existing cross member & 4x4 shifter hole needed modification. 4jg2 oil pan was a bit tricky while setting in the engine but we got it. Luckily I’ve save everything from the old motor so I have been able to reuse a lot of miscellaneous item.

Things to tackle next are front cv shaft (I may change this to a U joint style)& rear shafts,shifter,radiator, transmission cooler lines, AC high and low pressure lines.

Damn this is getting exciting!

For those of you that are interested in on IpupGary's build thread on his trooper

http://www.isuzupup.com/viewtopic.ph...87600171f9f7ff

Quote:

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Originally Posted by sm0ke3T1947

Here is my purchased 4jg2 with Aw30-40le

https://www.dropbox.com/s/k52pvibyfv...4689.PNG?raw=1

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Found a short description of the engine in Wikipedia:
The 4JG2 is a 3.1 L (3,059 cc), 95.4 mm bore x 107 mm stroke version with indirect injection. It replaced the 4JB1-T in the Isuzu Bighorn (Trooper II) and Mu/Wizard (Rodeo) in most markets.[27] This engine was upgraded from mechanical injection to electronically controlled mechanical injection. Power levels ranged between 94 and 112 PS (70 and 84 kW) depending on specifications.

How will you integrate computer function? I wonder what the power levels are in HP/TQ terms? Why did you opt for a diesel platform? Low-end torque?

FYI: Still can't figure out why the orientation is sideways I've edited the pictures and uploaded them both on a desktop and a mobile device. Maybe someone here knows. pictures are added using the dropbox method (?raw=1).

Quote:

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Originally Posted by 89Vette

Quote:

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Originally Posted by sm0ke3T1947

Here is my purchased 4jg2 with Aw30-40le

https://www.dropbox.com/s/k52pvibyfv...4689.PNG?raw=1

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Found a short description of the engine in Wikipedia:
The 4JG2 is a 3.1 L (3,059 cc), 95.4 mm bore x 107 mm stroke version with indirect injection. It replaced the 4JB1-T in the Isuzu Bighorn (Trooper II) and Mu/Wizard (Rodeo) in most markets.[27] This engine was upgraded from mechanical injection to electronically controlled mechanical injection. Power levels ranged between 94 and 112 PS (70 and 84 kW) depending on specifications.

How will you integrate computer function? I wonder what the power levels are in HP/TQ terms? Why did you opt for a diesel platform? Low-end torque?

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Computer TBD (possible PCM piggyback for the tranny & TOD)/ Hp 125/ torque 255/ mainly for low end torque.

Keep in mind this particular engine is the mechanical version. Not a whole lot to it. As I have it understood most people who buy the electronic injection version usually swap it back to mechanical.


Reason: My dad always had them so inherently I learned while he taught. I Needed a challenge on something that’s been talked to death & That hadn’t been done on a VX. Plus my dad has Alzheimer’s and he doesn’t remember much, but when he hears a diesel grumbling he gets excited.

Quote:

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Originally Posted by sm0ke3T1947

Computer TBD (possible PCM piggyback for the tranny & TOD)/ Hp 125/ torque 255/ mainly for low end torque.

Keep in mind this particular engine is the mechanical version. Not a whole lot to it. As I have it understood most people who buy the electronic injection version usually swap it back to mechanical.

Reason: My dad always had them so inherently I learned while he taught. I Needed a challenge on something that’s been talked to death & That hadn’t been done on a VX. Plus my dad has Alzheimer’s and he doesn’t remember much, but when he hears a diesel grumbling he gets excited.

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I hope your dad hangs in there. Sounds like they are coming up with some better medications these days...if it's not already too late. Fingers crossed!

I'm curious what controls the injection on a manual setup? Seems I remember an episode of Wheeler Dealers that dealt with manual injection...maybe on a Mercedes? Or BMW? I'm pretty sure Edd had to rebuild/fix it though I can't quite remember how it worked. I'll probably remember in my sleep! LOL

Update:


1 motor Mounts finalized
2 Shortened rear shaft with custom transfer case flange complete
3 front shaft changed and lengthened from cv to U joint(2002 trooper).
4 Custom aluminum front differential flange made.
5 Oil filter will need to be relocated. too many things goin down on the right side, plus I have to make room for the 3 exhaust pipe
6 radiator hoses complete
7 transmission cooler lines complete
8 shifter Complete


Gonna try and test drive in limp mode possibly soon

I’m dreading the wiring. May outsource.




Test drive video coming soon

Picture is worth a thousand

https://www.dropbox.com/s/gjdy7zqha6...20PM.png?raw=1



https://www.dropbox.com/s/w59n5cmt39...20PM.jpg?raw=1


https://www.dropbox.com/s/mqwia8p1q8...20PM.jpg?raw=1

This. Is. Awesome!

It’s alive

https://youtu.be/4gJek1dsDRQ



Sorry!! I promise to post more details and pics soon.

In case I’m asked. Wire hanging on the front is a temp jumper cable.

Yes!

https://www.dropbox.com/s/pmaohn8coz...20PM.jpg?raw=1

Tight squeeze! This is the reason for the oil filter relocation

https://www.dropbox.com/s/7lmale0hgu...20PM.jpg?raw=1

Will have to fabricate custom fan shroud

https://www.dropbox.com/s/fa55v4lklk...20PM.jpg?raw=1


Knee deep into the wiring

https://www.dropbox.com/s/dr3w981f8r...20PM.jpg?raw=1

new transfer case location.

https://www.dropbox.com/s/3mz7xem332...20PM.jpg?raw=1

Now the wiring fun part begins. More to come next year.

For always providing a helping hand real BIG shoutout also to my neighbor Michael O & Steven G

thanks guys.

Amazing project! Great work!

This gives me a lot of hope for my own build.

Dude! Great work!! I can't wait to see the final product.

Hello to all, Sorry I’ve been out of the game for a long time. Just recently fired up the VX after a 2 year hiatus. I’m Happy to say that everything still works. I’ll post some updates here shortly.