Isuzu Engine Swops for Dummies

[mike_ie]

http://photos3.pix.ie/E6/E4/E6E4CFDE1C2A4847914729671E6993F1-0000358552-0003139343-00500L-F8F5A6DEC0F94569BD41837B62213055.png

...because if I can do it, anyone can :D

I know that the Isuzu conversion threads may have been done to death for some, but a few people have asked me to post my own progress, so I figure why not. If nothing else it'll give a few people somethign to laugh at along the way.


The reasons for changing to the Isuzu engine differs form person to person, but for me it was pretty simple:

My 300tdi was getting about 12km to the rebuild, which wasn't quite living up to what Land Rover promised when they started churning them out of Solihull.

I'd recently gotten the chance to drive a few Isuzu County's - namely rijidij's and SteveG's and I found that the Isuzu engine was filling all the gaps that I found with the 300tdi - it had torque and then some to spare, and the powerband was just so completely different from teh 300tdi, no more struggling up hills, no more flat spots in 5th gear, so on and so forth.

If I was going to have to source a replacement engine anyways, it may as well be the engine that I want.

Vern bribed me with the promise of a shed, and beer.

I was stuck in Alice Springs, and, lets face it, *everything* seems like a good idea when you're stuck in Alice Springs.



http://photos4.pix.ie/D7/96/D7962A99A3DF420ABE5E23E391DCA0C0-0000358552-0003136687-00500L-9F8FE8D4BFAF4D0DABD86A6A5A620F72.jpg

The donor vehicle is an '83 Range Rover which has the 4BD1 engine, turboed, which I'd picked up from Matt (rovercare), who had in turn picked it up for a guy in Victoria. Apparently the engine and drivetrain was previously sitting in a Defender, and the engine had a complete rebuild about 90,000km ago, so hopefully it'll more or less drop into my defender without too many hassles.

http://photos4.pix.ie/48/B9/48B98BA55FF54525844886AC94734614-0000358552-0003136684-00500L-74B3F8AABB184218B9E40B385F0251E1.jpg

The Range Rover is pretty much as you would imagine an 83 Range Rover to look like 30 years later, but the running gear I'm pretty happy with, engine sounds sweet, turns over first go, goes like the clappers even though I'm continuously being told that it has a lot more oomph in it.

http://photos2.pix.ie/B1/F2/B1F226736CA242A0A0384D34B8E47F34-0000358552-0003136685-00500L-685AA78EC106412A90BEFFA9A5DAE29E.jpg

The turbo itself is definitely an aftermarket addition :D Custom made manifold, not sure what the turbo is off yet so a little concerned that it might be a tight fit under the Defender bonnet. Will know more later.

[rijidij]

G'day Mike,
Good to see you've got your project under way.


........and the engine had a complete rebuild about 90,000km ago

For an Isuzu, that's virtually brand new, not even run in yet, although Matt probably wound the fuel screw out about 12 turns and set the turbo at 30psi :eek: :D .......lucky these engines are as close to indestructible as you can get, so it wouldn't make any difference anyway :D

I'll be following your progress.

Cheers, Murray

[justinc]

You'd be kidding right Murray??? The fuel screw is in the ashtray, and the wastegate line plugged up...:wasntme::twisted:


JC

[rovercare]

I never even picked it up, so it's untampered:)

[mike_ie]

G'day Mike,
Good to see you've got your project under way.

This *is* your fault, you realise that? Your fault for letting me behind the wheel of that bloody County of yours.... :D

Thanks for the feedback though - there'll probably as many questions as answers as I'm working through it so hopefully the AULRO community will be able to help me out yet again. It'll be slow going till the DEfender gets here of course - trying to get all of the small niggly jobs out of the way first...

[mike_ie]

N.B. Apologies in advance for quoting all the facts and figures about the Isuzu engine that most people here probably know in their sleep. I'm posting this thread simultaneously in an Irish LR forum, where the engine is not so common, and it saves on the questions later....

Haven't posted in a few days - combination of working long days and nights, and a fridge full of beer. So time to catch up.

Right, time to get the engine out. Front grille and rad off the rangie, engine mounts and tranny mounts loosened up.....

http://photos2.pix.ie/29/FD/29FD2F8238BE4BC6B4BDD8C30DDF1C51-0000358552-0003136683-00500L-B84D4635D6A14101A58CDE8435B95120.jpg

Slowly but surely easing her out. To keep things simple I'm taking out the entire drivetrain back to the transfer case in one go.

http://photos3.pix.ie/69/19/691974A96F0C437EA308E865F433704E-0000358552-0003136682-00500L-4F0DAD3ACE5D44638EAFA58CB9476547.jpg

First proper look at the engine. Looks good so far - clean, and no gaping holes anywhere we wouldn't want them. At 338kg for the engine alone plus another 50kg for the TC and about the same again for the gearbox, it's a bit of a pig of a thing to get out gracefully.

http://photos4.pix.ie/01/38/01384EBF61A44842AFEA4E1242DBA4AA-0000358552-0003136681-00500L-C8DDF24E001E4CB18CB28053FDD6BB96.jpg

FREEDOOOMMMMM!!!!!!

http://photos3.pix.ie/D0/AE/D0AE248A64A04B11AE4D1549DAC23875-0000358552-0003136680-00500L-B8040F5856AC498CAD60B8A62B33B9B0.jpg

Now let's take a closer look at that turbo setup.... Let me say that it does work, and works well, but if there's any work to be done on the engine, I'd prefer to do it now while it's (a) out of the engine, and (b) while I'm waiting for the Defender to get here.

http://photos4.pix.ie/E5/C5/E5C57EA37F7846A0B67EFC5C7DD74A26-0000358552-0003136679-00500L-90AF533B8C0A45BD9606FFD939CD844F.jpg

http://photos4.pix.ie/EC/E5/ECE5041342DC4A308620E52CB4CC0FE7-0000358552-0003136678-00500L-E622E317F98E4989AE2FE105F278B405.jpg

Loving the custom mounting brackets.... :D

http://photos4.pix.ie/40/52/40524D5836BE483C9F5932E2AE3DE566-0000358552-0003136676-00500L-11081ED78C20438AAF8756C8526F482A.jpg

Looks like someone has had a go at making an exhaust brake at one time :eek: :eek: :cool:

https://www.aulro.com/afvb/

https://www.aulro.com/afvb/

[rick130]

Pull that manifold off, give it a clean up internally with a die grinder if it hasn't been done already and just get it HPC coated inside and out.

I like it :D

[rover-56]

Guy who made that manifold is an artist - it should be cleaned up and hung up as a mobile. :D

Spent a fair bit of my working life bending tube - I can appreciate the work that went into it:cool:

Terry

[isuzurover]

Pull that manifold off, give it a clean up internally with a die grinder if it hasn't been done already and just get it HPC coated inside and out.

I like it :D

x2 - I would be happy to run that manifold. As long as the pipe is thick enough it looks like it will continue to do the job.

[Vern]

Ben, i'm sure if you want it that badly, mike will sell it to you. His engine now sports an isuzu turbo manifold and vnt turbo:cool:

[mike_ie]

Yep - will have a bunch of stuff up for sale in the next few days to help fund this build as soon as I get off my ass and list them, including that turbo & manifold... so if you want it that badly.... :D

[Dougal]

Subscribing.

[mike_ie]

Subscribing.

Appreciate it. Though don't expect an epic conversion :D It's more like how much work we can cram into a week or two in Vern's shed... :D

[mike_ie]

HAve plenty of time before the defender gets here, so time to do as much prep work as possible. Drivetrain was broken down to give everything the once over. Not worried about the engine as it felt and sounded great in the Range Rover, however the gear changes felt a bit sloppy, so definitely worth taking a look.

Sump had to come off the engine anyway, to be cut down later, so why not take a look inside.

http://photos2.pix.ie/C0/2E/C02EC27B78F64A198A2C635C8838A00B-0000358552-0003145712-00500L-0FF85EA57C3147678F066EA098FB314A.jpg

Just what I like to see - nice, clean oily bits. No signs of wear anywhere at all.

http://photos5.pix.ie/11/F8/11F844B53B9C4B5DB0CABEB51596F2D3-0000358552-0003145711-00500L-4F11362399D74F27BD28B6982DDF06D2.jpg

Same under the rocker cover.

http://photos2.pix.ie/DB/32/DB32FBE410DE459CBA5083CFE0DDE6E8-0000358552-0003145710-00500L-50B5D097AB8844EBAA9D81FC32891985.jpg

Cracked open the transfer case inspection panel to take a look...

http://photos5.pix.ie/75/D4/75D41CB9BDAB48048E958EADF090FCE3-0000358552-0003145709-00500L-5FD9142D86464365A815CD10F2885DFE.jpg

The transfer case looks to be in excellent condition, 1.222 gearing, no play in the input gear mainshaft, no wear on the input gear mainshaft splines, bearings are good. Checked any play in the system against Vern's recently rebuilt TC and all seemed pretty comparable. So all in all, pretty happy.

http://photos2.pix.ie/09/1E/091EBC39A4B64F6C9E1BA87BC85D2FAC-0000358552-0003145708-00500L-ABE8999B3A3744EFB4A39188E5BA6BA1.jpg

While I had the input gear out, and seeing as it had no wear, I figured it would be no harm to crossdrill it to increase lubrication to the spline. I've seen plenty of threads out the on the interwebs about how hard it is to do this, that the drill bits won't get through the case hardening, etc. A well set up pillar drill with the input gear well secured and squared, and a tungsten carbide drillbit, and although it takes a bit of time to get through the case hardening, it's a pretty straightforward job.

Before:

http://photos5.pix.ie/D2/02/D2020D907E1B4C898CAC136DD9C96269-0000358552-0003145707-00500L-AF0DFD13A15148AB9830E1512C0BC86D.jpg

After:

http://photos2.pix.ie/80/A1/80A1E094060B4217B4B7A6A45C0037DF-0000358552-0003145706-00500L-BB20588DA23D4A6EAE3249E162E9D4AC.jpg

The gearbox, I was happy to find, was an LT85, which was used on the V8 versions of the 90 and 110. Better still it was a solid case LT85, as opposed to the later split case variety, which is much weaker, and AFAIK, more prone to bearing failure. While it won't match the 4-speed LT95 in terms of robustness, it's probably the best 5-speed for the job other than using an Isuzu gearbox and adapter kit.

http://photos5.pix.ie/C5/5A/C55A87CF0649483E95225FE5127DD19C-0000358552-0003145705-00500L-CB55ACB8A72342B1986D53A1A93A4C60.jpg

Because of the position at which the gearbox sits under the cab of the Range Rover, someone had obviously cut the gear selector shaft, bent it, and welded it up. An easy five minute fix with the welder. However, when the cover plate was lifted off... looks like they took a sledge hammer to the gear shaft in order to bend it. The nylon collar that secures the ball joint of the shaft was in a hundred different pieces - cheap fix, but certainly explains the even-more-sloppy-than-usual landrover gear changes...

http://photos5.pix.ie/D5/45/D545109F1E2744E49B76BBC99261A8FB-0000358552-0003145704-00500L-85FE9395BFD245A685F4F4CAA664A234.jpg

http://photos5.pix.ie/A4/52/A45244A2A3994AE5A2486337948E6D62-0000358552-0003145703-00500L-8A03E8FA8C0B4F4D8A2D184B1B20EA0F.jpg

More bad news inside...

AS soon as the extension housing came off, the most obvious issue was a bodged repair to the 5th gear selector fork - one of the bodged welds had broken and was obviously about to fail completely....

http://photos5.pix.ie/3E/19/3E1957C0F1A949F1989BA01BD512D15A-0000358552-0003145702-00500L-F10385E145A84DDC9E95621DED572FDB.jpg

And this was floating round inside the case.

http://photos5.pix.ie/BE/D7/BED7B01D8E9349F9AD34D1FC3A02D092-0000358552-0003145701-00500L-BC41A2717C3A48E499D88E70F6BB461D.jpg

A quick look at the RAVE manual told me that one of the slipper pads for the 5th gear synchro had been broken up and spat out, so all in all, not good news.

http://photos5.pix.ie/9F/64/9F64F3F921764ED89BEC20BC99E2208B-0000358552-0003145700-00500L-088195FF9C294AD9805E8C99131F83D1.jpg

Other issues included a missing bias spring from the gear selector assembly, and a loose input shaft bearing. Obviously this gearbox had been cracked open before, and a few items didn't make the cut when it came to putting them back in :(

Had a chat to JC down in Tassie about what my options were, and as luck would have it, he'd pulled an LT85 with a busted input shaft out of a customer's Defender sometime before christmas, and it was still sitting on the shelf somewhere, awaiting a trip to the scrapheap. Same solid case gearbox, low mileage, and it's on a pallet up to Victoria as we speak. Between both gearboxes, we should have one decent one sitting on the bench by the end of the week.

[Jitterbug]

Nice build Mike, I tried to buy that RR, phoned up and had a chat to the bloke, in the couple of days it took me to decide that I would buy it, it had already been sold then changed hands another 3 times!
My plan was to do like you and use it as a donor car for the motor into my 6x6. I will be back on the hunt for 4bd1 soon so will be following this with interest! Subscribed.

[mike_ie]

Nice build Mike, I tried to buy that RR, phoned up and had a chat to the bloke, in the couple of days it took me to decide that I would buy it, it had already been sold then changed hands another 3 times!
My plan was to do like you and use it as a donor car for the motor into my 6x6. I will be back on the hunt for 4bd1 soon so will be following this with interest! Subscribed.

Yeah, that sounds about right :D Don't think the original owner knew who was actually buying it by the time things had sorted themselves out :D

[rijidij]

This *is* your fault, you realise that? Your fault for letting me behind the wheel of that bloody County of yours.... :

Sorry :D........I think you were converted in the first few hundred metres of the drive :D
Once you're back on the road we'll have to do another trip to give your 'new' car a good run.

What brand/model is the turbo you took off ?? I might be interested in the turbo and manifold if nobody has their name on them already.

Cheers, Murray

[steveG]

Guess I'd better follow whats happening since my name's been mentioned ;)

Steve

[isuzutoo-eh]

What brand/model is the turbo you took off ?? I might be interested in the turbo and manifold if nobody has their name on them already.

Cheers, Murray

I am interested as well, Murray has call before me of course...

[flagg]

I am interested as well, Murray has call before me of course...

hehehe good to see :thumbsup:

[mike_ie]

At the moment I'm at a bit of an impasse - waiting for the Defender to get here, and waiting for JC's gearbox to make it up from Tassie, so time to give the engine a once over, and to order in everything I need. for now though, using Vern's Isuzu parts to get everything mocked up until my own come in.


Ordering the Isuzu bits and pieces has been interesting - for the most part I've been ordering straight from Patterson Cheney Trucks in Dandenong as their prices seem to be the best, even in comparison to some of the truck wreckers yards, though I've learned that as soon as I mention "Isuzu" and "Land Rover" either their eyes glaze over, or I get the same :blink: face that I assume is usually reserved for people who admit to killing small animals or homeless people in their spare time. But anyhow, they are ordering in a shiny new exhaust manifold for me, as it's more suited, size and position wise, to the turbo I plan to run.

A word to those who don't already know - the turbo manifold comes in two flavours:

1984-1987 non-watercooled manifold (P/N 8-94119292-6)
1988 onward water cooled turbo manifold (P/N 8-94366247-0)

The earlier manifold has the flange slung horizontally underneath, while the later manifold has the flange set at about 30 degrees off vertical. for the purposes of this engine swap we'll be using the later manifold, as it gives a bit more leeway as to what turbo can be used in the limited space underneath the defender bonnet.

Images shamelessly stolen from the internet

http://photos3.pix.ie/87/F9/87F94E45D8484E7C9E2DBC9DE2318E2E-0000358552-0003151537-00500L-D43026754BE848908253862DFA1B3DFF.jpg

http://photos5.pix.ie/46/BD/46BD53B0B62A4337BFF8DA6FCA19E5D7-0000358552-0003151536-00500L-699A20DC84A045B1A01E9C28D3931BF2.jpg

The turbo of choice is a GT2260v variable geometry turbo, from a 3.0l Iveco Daily van, namely because others have run it with the 4BD1 without issue, it will give a good combination of early boost but not be strangled on the highway, but more importantly, Vern had one that was sitting idle on the shelf that was in need of a rebuild, and he's more than happy to experiment on my engine before bolting one onto his own :D

However, the turbo has a T2 flange, and the manifold a T3, so in order to mate the two, a T2/T3 flange adapter has to be made up. A few people have made these up already - you can see the steps below.

http://photos2.pix.ie/0B/F0/0BF0C9FC49B843DD991816DF5B8933C4-0000358552-0003151535-00500L-EEF4427FB71F4118978C1F865518CA1B.jpg

Manifold with T3 flange:

http://photos4.pix.ie/C1/D1/C1D158B0875443CDA7E2F6F3C66A099E-0000358552-0003151534-00500L-643814C2441744AD86E4A931D4FF480A.jpg

First part of the adapter bolted up:

http://photos3.pix.ie/63/95/63958AEC7A8146F4BDADFF8905C1164E-0000358552-0003151533-00500L-347636E6328B40EF9FC6EE4B96B0A60D.jpg

Second part of the adapter bolted up:

http://photos5.pix.ie/4E/66/4E66CA078FD74661B0D2E9A4382E1ECC-0000358552-0003151532-00500L-32604E7994F04DF2A3A3D9A63CF1C4A5.jpg

Manifold studs bolted up to take the turbine housing. Only modifications you need to make is to drill out the threads in the turbine housing to take the studs.

http://photos4.pix.ie/25/A6/25A69BB07CED46E197E8648FC430F9E2-0000358552-0003151531-00500L-00C2DE9EB5CA46A88D30D517EDC15319.jpg

Turbine housing bolted up. For now it's just a dry fit - will be using high temperature copper gasket cement on all mating surfaces later.

http://photos2.pix.ie/DA/0E/DA0EFCF5B071456EB43AF84DC740C6DC-0000358552-0003151530-00500L-2B51A00D147D454983D78D5391D5E6A3.jpg


For anyone curious as to how a variable geometry turbo actually works (I know I was), well here you go. The principle is simple - the optimum A/R ratio of the turbo at low engine speeds is very different from that at high engine speeds. If the A/R ratio is too large, the turbo will fail to create boost at low speeds; if the A/R ratio is too small, the turbo will choke the engine at high speeds. VGT turbos get around this by shifting the angle of a ring of vanes inside the exhaust housing depending on engine requirements. which change the angle of exhaust gas into the turbine. Essentially it's a variable A/R ratio housing.

http://photos5.pix.ie/AA/22/AA22A704D33F496E9A5C8F169A6A57E1-0000358552-0003151529-00500L-555613884798444E84D5BC4A0717F9CA.jpg

Vanes open:

http://photos2.pix.ie/A1/A1/A1A1DB7432E64007A7305BC7E206AC98-0000358552-0003151528-00500L-88A451EBFCD940A3B62AE9B4B888AA9C.jpg

Vanes closed:

http://photos4.pix.ie/1D/4A/1D4A6E8414D9481E8DF6E36571ADAFEB-0000358552-0003151527-00500L-DAD6D670049D462F8CEE2E28CBC3B621.jpg

Changing the position of the outer ring adjusts the pitch of all vanes in the turbo.

http://photos3.pix.ie/6F/3C/6F3CA32E466E4C319D85BE6B93367553-0000358552-0003151526-00400L-A65A342E35D64DBDBBA3C3499F57C3E0.gif

The plan is to control the VNT actuator through a Dawes valve, as shown.

http://photos4.pix.ie/2F/A2/2FA2D404DB624AEDB27CC13DAD15DA47-0000358552-0003151525-00500L-A5308388BDDD410899C1FDFEEBC3DB26.jpg

This turbo wasn't in the best of shape, so it was a good excuse to overhaul it. SteveG can at least take solace in the fact that I learned from his experience that the compressor spindle is reverse threaded, and thankfully nothing went snap as I disassembled it. The damage is pretty obvious - old parts on top show a worn bearing, a chewed up turbine wheel, a chewed up washer seal (pieces of which probably chewed up the turbine), and a number of bent and seized vanes. This thing obviously ran low on oil at some stage judging by the scorching and discolouration of the turbine shaft.

http://photos5.pix.ie/09/A2/09A248F796574C548F49F68633E90C6B-0000358552-0003151524-00500L-6DD6C338E02A4FFEA9BE3F10556B7420.jpg

I ended up rebuilding the turbo while bolted to the engine, because the standard layout didn't really suit the plumbing I wanted to run, and the actuator ring needs to be set up to line up with the VNT lever (you can see the notch for the arm in the 7 o'clock position). There's a small locating dowel in the turbine housing that will need to be redrilled once everything is lined up.

http://photos2.pix.ie/D4/31/D43144A87B4E4AC1B13AA5C6554E06A8-0000358552-0003151523-00500L-2B15B4B4C0D84F2A91081AB090742E04.jpg

http://photos3.pix.ie/F0/7E/F07E05CED3DF4C41924BAAEE01E9AB44-0000358552-0003151522-00500L-9DA3797A24744C81B99BADC4D8E82728.jpg

Compressor housing going back together....

http://photos4.pix.ie/37/24/37241051D99D4584A36813BD64F754DF-0000358552-0003151521-00500L-9B3E7BB1BBAA43C9B6E859235D51549F.jpg

http://photos5.pix.ie/34/62/34621393893C40669FBDCD8DE5C6A1BD-0000358552-0003151520-00500L-738628D4C6B04987A29E08C3BCEEFB55.jpg


Vern scratching head and coming to terms with "righty - loosy, lefty - tighty"..... :D

http://photos2.pix.ie/D9/D8/D9D8BE22E6F1442CA65F7BA98BC5E290-0000358552-0003151519-00500L-FCE617B040F24EA09BE672B6F3938A0B.jpg

Side view of the turbo and spacers. As you can see, it brings the turbo out from the engine by about an inch, but only raises the overall height marginally.

http://photos4.pix.ie/C9/2B/C92BB7BD1D294670A30E3012DB3EE402-0000358552-0003151518-00500L-342E4A2F496E45F686BBAF7834F639EB.jpg

As you can see, the orientation of the turbo is much more suited to what we want to do in terms of running intercooler hoses, etc. The turbo cartridge also happens to line up perfectly with Garrett's recommendations of having the water ports at an angle of approximately 20° from the horizontal

http://photos5.pix.ie/24/92/24923454000043E6A96AC5FCC6E62447-0000358552-0003151517-00500L-59694D66227D41BB96B450F862C33835.jpg

http://photos4.pix.ie/D2/22/D222D5258643401DA1F0D976567C8F49-0000358552-0003151539-00500L-A09AB0C20AA645D2A61606FED2191377.jpg

Exhaust outlet tack welded in place for now. Once the sump is cut and shut, the exhaust will run down behind the alternator and in between the chassis rail and the engine, same as a 300tdi. For safety's sake, will run a heatshield between the alternator and exhaust later.

http://photos2.pix.ie/89/F7/89F7AB72CD944ECAAF1034F2826AFED5-0000358552-0003151515-00500L-76D09FD265084D0F93C2F05763114203.jpg

http://photos2.pix.ie/AA/7A/AA7A6CF1A8434ED89F3415FD9ADFD26E-0000358552-0003151514-00500L-2D5BB0ED16164E08B585C51F2DC9BFF1.jpg

[steveG]

Good work Mike:D
Where did you source the bits for the turbo?

Steve

[mike_ie]

Good work Mike:D
Where did you source the bits for the turbo?

Steve

The turbine wheel and spindle were from another GT2260 that was knackered, but still had serviceable parts. Also took the actuator ring from that too, as mine had visible signs of wear from when I assume the vanes seized up. Bearing, oil ring, etc came from a turbo rebuild kit from fleabay.

[Bush65]

Good write-up, but just because I'm a pedantic old basket, with turbine housings A/R doesn't mean aspect ratio.

'A' is the nozzle area
'/' is the symbol for arithmetic division
'R' is the radius from the axis of the turbine shaft to the centroid of the nozzle area 'A'

You should be happy with the GT2260V.

For reference, while you have the engine out, check the numbers cast into the right side of the block - 2 of the digits will be the year of manufacture.

[mike_ie]

1986, assuming I'm looking at the correct digits.

A/R - yes you are correct, brain is fried at this stage from long days :D Will correct.

[Dougal]

Good to see my turbo adapters getting some mileage.

The manifold you've got pictured at the top (high mount T25) is I believe an industrial only item. The original Isuzu truck item looks similar but is split port for an IHI turbo and T25 turbos need modified to fit.

Just in case others reading this thread get some ideas.

[tony66_au]

Sooooooooo..........

It begins!

[tony66_au]

BTW for those who haven't been following all of Mikes journey over the many different threads from research to purchase I just quoted from Mikes first post as a proud Deefer owner from this thread here .

http://www.aulro.com/afvb/members-rides/71210-ive-just-become-proud-owner.html


Heh - thanks - at least now I can actually post as a Landy owner - t'is a nice feeling. Once I get it down here I'll be spending a few months retrofitting it for a round the world trip - I'll try to post an account of it here. Funds will be tight so it will be a DIY job all the way, unless I can get some local sponsorship, so I'm pretty sure I'll be posting here fro a tonne of advice over the up and coming months :)

Ahhh if only you knew !

Got to say though you have real Landy owner stickability mate.
Kudos!

[mike_ie]

BTW for those who haven't been following all of Mikes journey over the many different threads from research to purchase I just quoted from Mikes first post as a proud Deefer owner from this thread here .

http://www.aulro.com/afvb/members-rides/71210-ive-just-become-proud-owner.html



Ahhh if only you knew !

Got to say though you have real Landy owner stickability mate.
Kudos!

Heh - I try to give my share of advice where I can :D And, love 'em or hate 'em, I"ve driven them on six of the worlds seven continents, so I won't be changing anytime soon. For better and for worse, and all that.....

[Judo]

Just noticed your "location" Mike. hehe :cool:

[tony66_au]

Heh - I try to give my share of advice where I can :D And, love 'em or hate 'em, I"ve driven them on six of the worlds seven continents, so I won't be changing anytime soon. For better and for worse, and all that.....

So you are not even a little tempted to swap to the Range Rover and put the old girl back together again and sell off the engineless Deefer??

I am of course biased.........

[mike_ie]

So you are not even a little tempted to swap to the Range Rover and put the old girl back together again and sell off the engineless Deefer??

I am of course biased.........

Nope, but if you're tempted to buy a rego'ed, Isuzu certified Range Rover that just needs an engine, give me a call... :D

[rijidij]

Nope, but if you're tempted to buy a rego'ed, Isuzu certified Range Rover that just needs an engine, give me a call... :D

G'day Mike,
Between me and a couple of mates, we've got Isuzu engines of various types laying around in the workshop, so don't break up the Rangie before looking at the options of repowering it. It would be a shame to see it go when it's certified and everything. I'm tempted to make you an offer for it.

Cheers, Murray

[tony66_au]

Go for it Murray!

If I bring one home without an engine im for the chopping block or the sneaky lastrator ring.

[rijidij]

Go for it Murray!

If I bring one home without an engine im for the chopping block or the sneaky lastrator ring.

I'd probably be for the chopping block too, but I think I can outrun her :D
It's hard to sneak a Rangie into the shed without it being noticed :D

Cheers, Murray

[tony66_au]

You can always claim its a template vehicle for the New RRC products....................
I noticed an absence in your gallery.

My wife pointedly asked me years ago where the V8 Volvo came from and being pretty quick on my feet I told her it was an engineering mule from the workshop....

Being just as quick on HER feet and slightly sneakier she then claimed it has her daily and told me she would give me a full report on its flaws and issues lol

Never got that report.

[mike_ie]

G'day Mike,
Between me and a couple of mates, we've got Isuzu engines of various types laying around in the workshop, so don't break up the Rangie before looking at the options of repowering it. It would be a shame to see it go when it's certified and everything. I'm tempted to make you an offer for it.

Cheers, Murray

Was thinking of taking the rattle gun to it tomorrow, so just as well :D She's pretty much as I got her, minus the front grille and radiator which is sitting on the floor of the shed.

She's rego'ed to the end of March, and certified with an Isuzu motor, so feel free to make an offer :)

[Bush65]

[i]...

Looks like someone has had a go at making an exhaust brake at one time :eek: :eek: :cool:

http://photos4.pix.ie/AF/43/AF430BBFD87240FAA3F2A7F29FDB3EBE-0000358552-0003136675-00500L-7A32D66D8742456EA2D777781BD57BD2.jpg

http://photos4.pix.ie/5C/63/5C6338B2A04E4DC983B191FAE3ED5F2F-0000358552-0003136674-00500L-EDAE6872F7024C72AFB44C7003EBD754.jpg
Exhaust brakes like that are stock fitments in Isuzu trucks. They reportedly work well as a brake and are also used in cold conditions to warm the engine up quicker. In Isuzu's the butterfly is opened/closed by a pneumatic or vacuum valve and a control circuit with switches on the brake and clutch pedals plus dash.

[mike_ie]

Exhaust brakes like that are stock fitments in Isuzu trucks. They reportedly work well as a brake and are also used in cold conditions to warm the engine up quicker. In Isuzu's the butterfly is opened/closed by a pneumatic or vacuum valve and a control circuit with switches on the brake and clutch pedals plus dash.

This one definitely wasn't stock, and was more of the "opened/closed by a piece of bailing wire located somewhere down in the driver's footwell" variety.... :D

[Mocky]

The main problem with exhaust brakes is the excessive wear to the exhaust valve guides.

Mocky

[EchiDna]

Stopping a 2 ton vehicle vs 8 ton truck will make that less of a problem though Mocky ;-)

[mike_ie]

Stopping a 2 ton vehicle vs 8 ton truck will make that less of a problem though Mocky ;-)

It's the kind of thing I'd happily have a bash at rigging up, if for no other reason than to see how effective it would be. Though I've heard that they have minimal impact on something as light as a 4WD....

[tony66_au]

Id have a shot at a Jacobs Engine brake!

[steveG]

Soooooo.........

Is the Isuzu in yet or what??? :wasntme:

Steve

[rovercare]

Id have a shot at a Jacobs Engine brake!

How?

[mike_ie]

Soooooo.........

Is the Isuzu in yet or what??? :wasntme:

Steve

Still trying to get the bloody 300tdi out!! It's a bit on the warm side for all this physical activity :D

[steveG]

Still trying to get the bloody 300tdi out!! It's a bit on the warm side for all this physical activity :D

See you've gone soft since Alice Springs. We're even giving you a 10deg reprieve down here ;)

Steve

[mike_ie]

See you've gone soft since Alice Springs. We're even giving you a 10deg reprieve down here ;)

Steve


It's Damien's fault really - his shed doesn't even have aircon, or a hoist??? How's a guy supposed to work in these conditions????!! :p

[loanrangie]

It's Damien's fault really - his shed doesn't even have aircon, or a hoist??? How's a guy supposed to work in these conditions????!! :p


Thats where the amber liquid cooling comes into the equation ;).

[tony66_au]

How?

Honestly? Dunno.

Take some headwork in guessing, maybe I should check the Jacobs site again and see if they have something for small engines yet

[tony66_au]

It's Damien's fault really - his shed doesn't even have aircon, or a hoist??? How's a guy supposed to work in these conditions????!! :p


Yeahhhh Nup.....

Actually id be more concerned about finding a Copperhead or Brownsnake hiding in something cool on a day like today, Came face to face with a Brown working in the barn last year under a car and theres snake poo in my big shed now so the buggers are there.

No worries about Tigersnakes as they are nocturnal hunters and the party animal of the snake world but that said id keep an eye out at night for them and they also climb stuff. :eek:

[tony66_au]

Im not helping am I?

[slug_burner]

Yeahhhh Nup.....

Actually id be more concerned about finding a Copperhead or Brownsnake hiding in something cool on a day like today, Came face to face with a Brown working in the barn last year under a car and theres snake poo in my big shed now so the buggers are there.

No worries about Tigersnakes as they are nocturnal hunters and the party animal of the snake world but that said id keep an eye out at night for them and they also climb stuff. :eek:

Not much activity in your shed then? Given most snakes will give people a wide berth, it must get fairly quiet in that storage facility of yours;)

My wife wants to know if snake poo is the poo you do when you see a snake unexpectedly?

[Vern]

It's Damien's fault really - his shed doesn't even have aircon, or a hoist??? How's a guy supposed to work in these conditions????!! :p

Your going about it all wrong mike, you should be sitting back and getting the Mexican to do all the work, they're used to the heat, right?;)

There are some fans above your sleeping quarters if that helps. A/c is in the office, but ya not wheeling that bloody engine in there, sally will kill you.

As for the hoist, got no room, all your crap is in the way. I'll wait until you leave:D

Now back to work:p

[mike_ie]

*whistles*....

*wheels engine back out of aircon'd office......*

[Blknight.aus]

we just put one of the aircraft air con units into the shed when it gets too hot.

50lb of r134a in it and it makes a 250ish hp diesel powered genset sing for its supper on full make cold, we know we've over done it when the boss comes out into the workshop then goes back into the office aircon to warm up.

[Vern]

^^^^^^show off:D

[tony66_au]

Not much activity in your shed then? Given most snakes will give people a wide berth, it must get fairly quiet in that storage facility of yours;)

My wife wants to know if snake poo is the poo you do when you see a snake unexpectedly?

Certain times of year they get fairly aggressive (Browns) and Coppers are just individuals.

They feed well down that part of my place as theres a good supply of bush rats and will then head for shade on hot days to sleep off their meal, I also have a leaky tap down the other end of the barn so theres the water source.
Snake poo looks like a jelly bean, colour varies based on diet and age of Poo.

They dont always bugger off but the day I had the close encounter I was on a creeper under a car fixing some damaged wiring on an old Merc with a solder gun and the noisiest thing I had was a butane torch for the heatshrink which wouldnt work with a snake anyway so I hauled butt and got vertical and stomped my feet which stopped and turned it around.

So all work now goes on in the garage near the house and apart from a cranky egg bound bluey and the odd skink I get very little wildlife up there.

If you ever get the chance have a chat with a snake catcher about some of the jobs they get and where they remove snakes from. :eek:

[Vern]

Have seriously considered putting a big dumpy in my shed, sheds insulated so should work well.:)

[Vern]

We've only had tigers up here. Although sal said she nearly ran over a red belly on the mower. I don't like tigers:(

[wrinklearthur]

I have a tiger snake feasting on my chook eggs. It needs relocating with a twelve bore. :twisted:
.

[tony66_au]

This time of year if Jen want to go work the sheep she usually gets me to go fang about the front paddock (Where the Rangie sat for ages) which will 1 in 3 times send a snake off to the boundary so the Dog, Jen or Sheep dont get bitten.

Red belly blacks, Tigers, Browns and coppers are all locally found too especially if a neighbor cuts hay or similar (I dont know where you are but im guessing out of town like me).

[Vern]

Near the old camp on the strez. Darli estate

[Blknight.aus]

^^^^^^show off:D

I only do it so that I can enjoy a hot coffee out of the machine. :wasntme:

[tony66_au]

Izzit Swapped yet?

[Vern]

nup, goes in today, should be going early in the week as need to get some things made up like hydraulic lines etc...

[strangy]

Foot tapping..... raised eyebrow,

C'mon Mike I thought you would have been tap dancing by now:)

[tony66_au]

nup, goes in today, should be going early in the week as need to get some things made up like hydraulic lines etc...

Bewdy!


Foot tapping..... raised eyebrow,

C'mon Mike I thought you would have been tap dancing by now:)

Riverdancing? Lord of the Dancing?

[superquag]

... And a diesel powered Classic has always been my ideal car... Especially a (reliable, strong, long-lived..) JAP diesel....

Life is not fair !:eek:

95 Classic Vogue SE, 3.9 Buick reject V8...

[tony66_au]

So make Mike an offer on the carcass and drop an Isuzu oil burner in it!

BTW those Reject Buick V8's do rather well when properly tweaked and really aint so bad.

[Vern]

Foot tapping..... raised eyebrow,

C'mon Mike I thought you would have been tap dancing by now:)

Nah, he's dragging his feet, I think I'll have to open the beer fridge:)

[mike_ie]

Well despite Damien's best efforts to describe me as the laziest sod on earth, the reason for the lack of updates have been long days and 4am finishes, and no energy to post the results afterwards. But I will keep the updates coming, albeit a bit delayed.

Waiting for the defender to arrive, I decided to stip down and clean most of the engine bolt ons and spinny bits, and give them a once over before they went into their new home. That included, in no particular order, injectors and glow plugs, starter motor, alternator, water pump etc. The great thing about these engines is that so many normally throwaway itens such as the water pump can actually be broken down to component parts and refurbished, definitely a step up from the 300tdi.

Water pump was in pretty good condition, all things considered.

http://photos3.pix.ie/A9/EE/A9EE1CA5DF264DFAB1AD924FC58CCB85-0000358552-0003157609-00500L-BEB415B261FF4D2F98A352D6B50FC03D.jpg

http://photos2.pix.ie/74/8A/748A08EE15744293A424F21A77AD4016-0000358552-0003157608-00500L-EF49061590804295994ECB216C1E4AD6.jpg

Injectors and glow plugs given a cleanup and bolted back on. While most people don't bother hooking up the glow plugs here, they are necessary for cold starts in Europe, and seeing as the relay and wiring from the 300tdi is just sitting there, it's an easy job to get them running.


http://photos3.pix.ie/07/8A/078AE1CB20E94195A4615EAA847B1567-0000358552-0003157607-00500L-B49C44E3687540B3A8E13685F80A0D04.jpg

http://photos4.pix.ie/10/CC/10CC9B6B9C424A68A189BC9FE910D80A-0000358552-0003157606-00500L-7CFD934F31C0424484B794AF6FE8D908.jpg

Time to cut down the winged sump to allow for easier routing of the exhaust. I did price a wingless truck sump from Isuzu, but at over $400 I couldn't justify the expense for what is basically a mild steel can.

http://photos5.pix.ie/D3/9A/D39AE95DFE924C3D8B88C7735E885ABE-0000358552-0003157605-00500L-29A83023BCFA4DD4820BD96C3848F2FC.jpg

https://www.aulro.com/afvb/

I followed pretty much the same template that SteveG did when he cut down his sump. Or at least I thought I did. Sump all marked up and ready to go.

http://photos5.pix.ie/BE/2E/BE2E4AFA4E0048E790BA4AD8E7D62EF0-0000358552-0003157603-00500L-29308C97E8F64E50A88355DA14C1A544.jpg

Wing cut off and ready to be shortened up.

http://photos4.pix.ie/03/60/03608CB520424864AD22B85E4F378035-0000358552-0003157602-00500L-AA49E8D834D748ACBA03E255B1E30CA6.jpg

....and this is why you shouldn't use angle grinders after four or five beers. Apparently for all my measuring, I still managed to come up short, and the cutout section fo the wing didn't line up. Cue some more butchery with the grinder, and tacked up an inch wide strip from the offcut to fill the gap. Spot welded for now, but once it's all TIG'd up, it'll be perfect.

http://photos3.pix.ie/42/BE/42BEA9289F1D44FAA76DFF6B8B20F37F-0000358552-0003157601-00500L-98C7CB67B6844712B090FA3B25EB48AE.jpg

http://photos2.pix.ie/D5/92/D5920741680B4092B44D9F51FA0EFA62-0000358552-0003157600-00500L-F02C40BB7FCD4EA6B5FEC8022AE278ED.jpg

http://photos4.pix.ie/FC/63/FC6350015DAF4C629DD2DEF2306E416E-0000358552-0003157599-00500L-3DB404D818A14DF597C0A9D9093EE869.jpg

Seeing as I'm running a new turbo setup, it would be a shame not to intercool it, and seeing as one came up for a good price (I don't want it, get it out of my shed and it's yours), I jumped at it. At 300 x 610 x 85mm, there should be no issues with restriction.

http://photos5.pix.ie/88/29/8829DE8B6A59498192EB5D3F5424DF91-0000358552-0003157598-00500L-CCD6B6CFBF274F08B040FA63B75EEDEA.jpg

However, the only issue is the location of the inlet and outlet are in the wrong locations. So either abandon the idea, or....

http://photos3.pix.ie/D8/42/D8429F71F3674553A52EFE39E6D78B6D-0000358552-0003157597-00500L-C90B228337DD4D6E854797724840CADE.jpg

A quick bit of work with the right sized hole saws...

http://photos2.pix.ie/EE/1A/EE1A0E7E533D446986A2ACECC2F55B3A-0000358552-0003157596-00500L-E2369A1036B54F10A2148BE9F18760ED.jpg

http://photos4.pix.ie/55/9A/559AFF47B96D4DDC9E8C7DAF9866632A-0000358552-0003157595-00500L-8B298938E3704DC49587B705F56D50A7.jpg

Two circular cutouts from some 5mm aluminium plate (which I forgot to photograph) to fill the voids, and she's ready for welding up at the weekend.

http://photos3.pix.ie/B1/11/B11176BD74F84A5B97B33D426E8DAC10-0000358552-0003157594-00500L-0D851F78297047C7B719E0B114F3BA8C.jpg

http://photos5.pix.ie/F7/67/F767C81CEF3B4C8EA8225471F3D96F6E-0000358552-0003157593-00500L-B0A264E60F9C4412891A8F8A4FE69328.jpg

The new bits have started to arrive, first in the door was the radiator. I'd shopped around for an Isuzu County radiator, but anything I found was in such bad shape that it needed a prohibitively expensive recore, so I went with a County V8 radiator from Gary at Classic Land Rover in NSW, and I'll swap out the radiator inlets and outlets later.


http://photos2.pix.ie/C3/D2/C3D2159DF25344838739E6E6B66182BA-0000358552-0003157592-00500L-B6024A5E90CC42C29E7FF6CE203999C3.jpg

Air cleaner has also been ordered. Gave Donaldson a call, only to find out that they won't sell directly to the customer, and that to buy the Donaldosn filter housing with filters directly from Land Rover wouldn't leave me much change from $500, which is a whole lot of money for a tin can. So I went with the Fleetguard option as many before me have done, same primary and secondary filter setup as the Donaldson, but $318 for filter housing, filters and brackets.

The choice came down to the AH19066...


http://photos2.pix.ie/E3/41/E34102C81C004709A944AF555F683F22-0000358552-0003157591-00500L-3A8509AE22EA49899E75F0798DC49C28.jpg

...or the AH19268...

http://photos2.pix.ie/88/5E/885E61C806D44AC18969F4095D1E558A-0000358552-0003157590-00500L-6C406AE4029F4078AEB688183A635974.jpg

Same physical size, roughly the same flow rate (≈300CFM). After seeing the filter setup in SteveG's County, I went with the AH19066 - the inlet will be blanked off and the 3" dust ejection valve can be retasked as the air inlet, and in my opinion, for what it's worth, the top hat arrangement of the filter cover makes it easier to (a) change the filters, and (b) orientate the inlet to whatever position most suitable to the snorkel setup in the Defender.

[mike_ie]

Woohoo! She's finally here!! After a long and convoluted route from Alice Springs to Melbourne via Darwin, where along the way the transport company managed to lose my keys and immobiliser fob, and the tandem trailer nearly did cartwheels on the final leg of the journey to Vern's shed, she's finally here.

http://photos4.pix.ie/CA/F4/CAF47A1E66D042CFB469737561D95B79-0000358552-0003158304-00500L-CEBBA0FF30D645F6927BFD40EDC9485D.jpg

While I was in the city picking up the defender, I also picked up the LT85 gearbox that JC sent up from Tassie. The gearbox itself apparently won't select a gear, but should have salvageable parts that will get mine running again. I realise that this gearbox could well have come out of a forum member's vehicle at some stage, so hopefully take solace in the fact that parts of it get to live to fight another day.

http://photos3.pix.ie/C1/5F/C15FFE14D959471CB5F0C25B10DB9FB8-0000358552-0003158303-00500L-B2623F000CFA447884000F45569105A2.jpg

Twins!

http://photos4.pix.ie/B5/AE/B5AE435D062548EA91303692E8327A3B-0000358552-0003158302-00500L-7CB79F4EC4814EC9B07ED5A38BF24632.jpg

Now that I have the two gearboxes side by side, it looks like a few "modifications were made along the way, the most obvious being the shortening of the bias spring turrets, assumedly to fit it into the Range Rover transmission tunnel.

http://photos4.pix.ie/28/2D/282D3D6D02C14CB5A0DEF4BD2672671A-0000358552-0003158301-00500L-ED7281A50281470483E2FF105E7F9EB4.jpg

Extension housing off, and 5th gear exposed. Apparently I'm not the kind of person who can just follow the RAVE manual instructions of "Do not displace selector fork slipper pads when removing fork" without thinking "why not???", and tapping said gear with a hammer, and after hearing springs and ball bearings pinging off the roof of the shed, spent half an hour on my hands and knees trying to relocate them... :/

http://photos3.pix.ie/8A/E6/8AE64366B4DB493C89BC7E739810DC42-0000358552-0003158300-00500L-4F26D677404C489A95392EB6B19233DD.jpg

All of the components of the 5th gear synchro back in one place. Just as well, considering that 5th gear is one of the many things that need replacing in my LT85.

http://photos2.pix.ie/CC/E5/CCE54321308E429FA2377C9F083C6A2A-0000358552-0003158299-00500L-0882C3977666431984E2809743934C8E.jpg

Gearbox top cover off the donor gearbox. Now to see what exactly has gone wrong.

http://photos4.pix.ie/81/43/81438B449A0F45018359649577072427-0000358552-0003158298-00500L-DC6EDF9A756C4270B94A13B5A2DCDA68.jpg

Selector rails and forks taken out, to get a better look at the main gear assembly. Thought at first that the problem might have been a broken main shaft, but everything is looking good. 1st/2nd and 3rd/4th synchros both select their respective gears, though 1st/2nd synchro was jammed pretty tight.

http://photos3.pix.ie/64/E9/64E9A8503081490FA7DDA78D78400EAB-0000358552-0003158297-00500L-AA865A97D97C46A2A8D1B9A913BBAD7F.jpg

As it turns out, the selector forks were the problem 1st/2nd selector fork in particular had both tongues worn almost clean off. In addition, compared to the selector forks from my LT85, they seemed a lot more lightweight, not sure why, but it certainly contributed to their failure.

http://photos2.pix.ie/EA/DD/EADDFB67950D4E1DA4B2929FE056E917-0000358552-0003158296-00500L-0BA9867DC808445EA2232DFD5A8871CF.jpg

http://photos4.pix.ie/86/69/86696F6B7A704E1EAD13380538A27ED2-0000358552-0003158295-00500L-9545E4D4C10B440687763913A3F744C8.jpg

Gearbox going back together, this time with functioning selector forks.

http://photos2.pix.ie/D4/B9/D4B942E5199A4EC28A584D5DD7A8E814-0000358552-0003158294-00500L-567EC0F7936545F592A0C41AD865B816.jpg

http://photos4.pix.ie/B6/18/B618A9EE47A34AB990E72EA9DD43FD73-0000358552-0003158293-00500L-82537BFE83C847E4A0028B8F39877D82.jpg

All done, and ready to go in. Gear changes seem decidedly more gated than when the transmission was in the Rangie, no doubt due in large part to the now functioning bias springs. Gear changes all seem solid, though the gearbox does feel a bit more "agricultural" than the R380 in the Defender. We'll see how she flls later full of syntrans oil before I'll make any conclusions.

http://photos2.pix.ie/C5/54/C55419E483714AEC91C35870A55574A3-0000358552-0003158292-00500L-ACEA497C26AD4B238D5830A32F37D648.jpg

Finally, she's in the shed. The 300tdi, who will forever be known as "the bastard", ready to be taken out. Engine is pretty much toast, some of the spinny bits shall be making their way to a new home, and unless someone out there wants a 300tdi for a rebuild project or something, she'll make a good anchor, and not much else.


http://photos2.pix.ie/68/09/6809F7CA98694220A5C5885185D2FD9B-0000358552-0003158291-00500L-8C32B10BF735453E9B486CCEB81159B7.jpg

http://photos5.pix.ie/BA/C4/BAC483088FA94ECA943DD45A5CAC1448-0000358552-0003158290-00500L-062A73E13B1C49C288BC7F6DBF70A101.jpg

http://photos5.pix.ie/01/C5/01C51735AA9B42C7B81569967F7C2D96-0000358552-0003158289-00500L-DC980426F30341448E256316F3B06A44.jpg

http://photos5.pix.ie/FD/E8/FDE8D4EE02184FD49C489BC4A4856DBB-0000358552-0003158288-00500L-275CF0EBB3A840E2A2CE673515AE5D09.jpg

Time to reassemble the Isuzu drivetrain for the Defender transplant. 300tdi and Isuzu bellhousings side by side - there's a noticeable difference in size. Clutch cylinder is also over on the passenger side, so more plumbing. It's also slightly longer, which presumably would mean a new main gearbox shaft for an r380 conversion.

http://photos5.pix.ie/DB/B9/DBB98ED10ED54A7BB57952308EE732F7-0000358552-0003158287-00500L-3B8524CD88EA4B2384F9B28590338C7F.jpg

The hits start coming early it seems. Clutch fork pivot sheared upon tightening up. Wasn't applying much force at the time, so I'm suspecting that it was fatigued from before.

http://photos5.pix.ie/4F/E3/4FE35CFEA06F483A9725EB9D9BE1EA66-0000358552-0003158286-00500L-5F43679515004F2AA8D440231A15BCF7.jpg

http://photos5.pix.ie/80/A7/80A7431330F74F83843EC0FE5DE9F05F-0000358552-0003158285-00500L-A8CF4EA2BBEB420684D72EA207E3CFEB.jpg

http://photos5.pix.ie/42/18/421897ED81BA44C09A8114CCD917B0E2-0000358552-0003158284-00500L-4F7EC080BD2A4C58943FF9970D4998C6.jpg

Either way, time to machine up a replacement. Drilled and tapped the remains of the pivot, and threaded up a new bolt section.

http://photos5.pix.ie/BB/08/BB08E727FF9A497691A6F0434277574E-0000358552-0003158283-00500L-929AFFFE06634B56AEA1415906CBFB02.jpg

http://photos5.pix.ie/64/3E/643E58D0C13949CDB2517BD3B2D521AA-0000358552-0003158282-00500L-3E88106A1B324118AC7D940819700929.jpg

Just like a bought one!

http://photos2.pix.ie/74/23/7423330465934CBA974175E32115EDA7-0000358552-0003158281-00500L-F7636B007CEB43ED92B50D89613FAC1F.jpg

http://photos5.pix.ie/2C/0E/2C0E62E48EAB4CA991816A993FB977AC-0000358552-0003158280-00500L-78EB2962154D472D82B0EA64F4E23B8B.jpg

Damien using his favourite workshop tool to cut off the 300tdi mounts and clean up the chassis.

http://photos2.pix.ie/1A/36/1A36AAAA69C341108E4C1DFA790DDB38-0000358552-0003158279-00500L-9C57B28A09BC4ECA9570E02BCD8117B9.jpg

LT85 bolted up... LT230 to follow.

http://photos5.pix.ie/77/3C/773C32B738B248D992366961B29614CF-0000358552-0003158278-00500L-0E9B60A20BA6479B808DC4A46E4FC5A2.jpg

I've decided to go with the 1.222 RRC transfer case. Ideally I'd be matching the engine up with a 1.003 TC, but considering that I'll be running laden most of the time, I could probably do with a lower first gear anyways. Crunched the numbers on both TC's, and running 265/75 tyres, the results are as follows.

LT85 gearbox with 1:1.003 TC

http://photos5.pix.ie/1A/ED/1AED71D659734BAA8BACE6E8555EDF45-0000358552-0003158277-00450L-FD250BCDC9B144F58B87BE7476329CE9.jpg

http://photos5.pix.ie/8A/9D/8A9DBBE3B70E42D08FC240E8DB85AC66-0000358552-0003158276-00500L-809FB000AD6A40B48E834A2ECDA6F833.jpg


LT85 gearbox with 1:1.222 TC

http://photos3.pix.ie/8D/AA/8DAABDC1AF634D26AF7901F146332496-0000358552-0003158275-00451L-0368B1E5B44B4720AFF14341FAEC1264.jpg

http://photos3.pix.ie/A5/FD/A5FD2BD4256244A2ACE239B47C218F40-0000358552-0003158274-00500L-BBBDB7786C2C4477B957B4F519AC375F.jpg

1st gear is noticeably lower with the 1.222 TC, and 100kph highway speeds will put me at 2216 RPM, which is only 150 RPM removed from 4th gear with the 1.003 TC. Will try it for now, and if I decide that few less revs at highway speeds would be more beneficial, especially with the turbo, I can swap it out later.

[wrinklearthur]

Just after reading about the works in progress, I had to smack my right hand, it started groping about for a shifter.
.

[justinc]

Hi Mike, great work there!

Yes it is a good thing to see that trans being 'recycled'. Strangely before it jammed up and lost drive it was shifting pretty well, even with those forks:o.

It was certainly going to be a non event down here, the vehicle it came out of is now extensively modified/ changed, so good to see it get a new life:) (and free up some space on the floor, too...)

I guess it is a good thing I don't like to throw too much out....:D


JC :)

[mike_ie]

Hi Mike, great work there!

Yes it is a good thing to see that trans being 'recycled'. Strangely before it jammed up and lost drive it was shifting pretty well, even with those forks:o.

It was certainly going to be a non event down here, the vehicle it came out of is now extensively modified/ changed, so good to see it get a new life:) (and free up some space on the floor, too...)

I guess it is a good thing I don't like to throw too much out....:D


JC :)

Yep, it's a good thing for me at least :D Well as you can see, the selector fork on the right which came out of your gearbox, was almost worn through!! 3rd/4th selector fork was on its way out too. The used ones that I've put in are a bit polished, but they'll get me to where I want to go. Have two new forks and a bearing kit ordered at home, as I'll be pulling the drivetrain out anyways to galv the chassis once I get back.

[mike_ie]

Actually, do you have any idea if there are different "grades" of selector forks? The one from your gearbox were decidedly lighter and less beefy all round, particularly 3rd/4th?? I should have gotten some better photos at the time, but they were thinner in cross section, with big cutouts, to, I assume, save on the amount of metal used in manufacture? It certainly played a part in their failure, that's for sure.....

[mike_ie]

Well, D-day has arrived, and the Defender is going to be receiving its new engine. Front of the shed cleared, beer in the fridge, and Steve and Hugh (SteveG and HPLP), as well as Damien, volunteered their time to give me a hand. Steve thankfully, brought along the TIG welder, more to prevent me from melting fist sized holes in important bits of metal, than anything else.

Steve gets set up to TIG weld the intercooler and sump....

http://photos4.pix.ie/B7/76/B776801425A541B9BA8158B39F0E5E21-0000358552-0003159036-00500L-80DC00C4780D43A6836DA318F40CEAEA.jpg

http://photos3.pix.ie/10/09/1009452F8B27480A852784294D8EE710-0000358552-0003159035-00500L-526BFCCB4BA84E45BD30A41A887EACEA.jpg

...while myself and Damien get the engine and drivetrain set up to be dropped in.

http://photos4.pix.ie/87/55/875571318EB54808A32528DFD2510533-0000358552-0003159034-00500L-851538363BD44B69A10FEA26EC2B6A63.jpg

With four sets of hands, getting the engine in was a lot more straightforward than getting out the tdi was.

http://photos3.pix.ie/24/C2/24C279D563CF4EED908C65209CF68F62-0000358552-0003159033-00500L-37648C5180A14E71804F2E39731D563F.jpg

http://photos4.pix.ie/E2/CD/E2CD65D78A1D4693915F0BEAC94781B8-0000358552-0003159032-00500L-22D7FB1C953949458A5D11522F191DEF.jpg

With any Defender engine swap, the gearbox/Tcase mounts are used as a point of reference, as they are common across the board, the bolt holes being slotted to allow about 25mm of play for the entire drivetrain fore and aft. However, try as we might, we couldn't get the engine to move forward far enough, and after much head scratching as to why, we took a look inside the Defender...

http://photos3.pix.ie/8A/A0/8AA056E047554993B75F38B2DDF4E443-0000358552-0003159031-00500L-67F54D3E1E23459FAFE8D4F5DC01109F.jpg

For some reason I had gotten it into my head that the R380 and LT85 transmission tunnels were compatible, which clearly they are not. A little research tells me that the R380 tranny tunnel (not a phrase you want to google btw :eek: ) sits about 38mm nearer to the seatbox than the V8/ LT85 one. A quick measure shows that the R380 and Lt85 heights are more or less the same, so in theory it should be possible to relocate the transmission hole in the tunnel and all should be good. I initially thought that I could cut and shut it, but it turns out that the R380 tranny tunnel is made from fibreglass for God-knows-what reason, so for now I've just pulled it out, and will figure out how to fix it later.

Almost in.....

http://photos4.pix.ie/1E/B6/1EB6AA2B85A249188F90433FC327BA73-0000358552-0003159030-00500L-14D32DBDFE834617BA0DA1472CFC0EE2.jpg

I'd taken measurements from a couple of Isuzu Countys, including Steve's who had driven his down, so here are a few landmarks for locating the Isuzu engine in the engine bay. I used the crankcase pulley as a point of reference. Pulley centre is 278mm from the LHS chassis rail, and if you throw a straight edge across the top of the chassis rails, the bottom of the crankshaft pulley sits 58mm below it. Set it up at about 53mm and weld the mounts at that, as the engine will settle about 5mm or so into the rubbers.

http://photos3.pix.ie/AE/21/AE215D4FAB02439396C651574F4435E7-0000358552-0003159029-00500L-AA8D33E9DB3645C896F9BDBEEB2BF2E0.jpg

Longitudinally, if you eyeball the engine from above, the timing case cover sits about 14mm forward of the 4 bolt steering box bleed screw.

http://photos4.pix.ie/D1/39/D139880EE219473D9ABB193FA58C6BEC-0000358552-0003159028-00500L-FB7069CF143943728529375C3D6D18D6.jpg

The tolerances for these measurements are reasonably tight, as the engine and attachments sit pretty snugly in the engine bay. In particular, keep an eye on the starter motor lug, and make sure that it's far enough away from the LHS chassis rail. Mine is about 25mm away, which is fine.

http://photos3.pix.ie/69/DA/69DAD88C75DF4737B0739AB11DF4A70C-0000358552-0003159027-00500L-10FF20C4FE3A46FC92C9AE4F4131ABC4.jpg

Once the engine is in its final position, it's time to get welding. I decided to reuse the Range Rover engine mounts, for simplicitys sake.

Mounts as they were on the Rangie....

http://photos4.pix.ie/E7/3F/E73FA311F96B4DE2A4BD53F6A51B5BE2-0000358552-0003159026-00500L-312A11D90E3246E9B5AD4B1CDE73BC9D.jpg

http://photos3.pix.ie/42/77/427726709A53425BA3D311280E9B26E5-0000358552-0003159025-00500L-E3C876C6B6CA44F8B7F5A0052C86BC7F.jpg

... and now on the Defender, waiting for the welder...

http://photos4.pix.ie/CE/BE/CEBE4CD80ED24A54B467F1F8D1512D93-0000358552-0003159024-00500L-13A3089E34B94FCB9D6916B1A6273245.jpg

http://photos3.pix.ie/FC/DC/FCDC12525D604433877B90071E8B3D7A-0000358552-0003159023-00500L-0E40C47ACC8F4522B5553A38F1ED6DF0.jpg

She's in!!! :D :D :D

As straightforward as the post makes it seem, it's still a days work just getting everything set up okay and fettling everything into position, then checking and double checking everything before the final welds are made. Engine sits well in the bay, is level (thermostat housing is a good place to eyeball this from the front, and of course, thanks to Damien, Steve and Hugh for their help all day.

Now the hard work begins.... :D

[isuzurover]

...I initially thought that I could cut and shut it, but it turns out that the R380 tranny tunnel is made from fibreglass for God-knows-what reason, so for now I've just pulled it out, and will figure out how to fix it later.
...

So is the LT85 tunnel.

[rick130]

...I initially thought that I could cut and shut it, but it turns out that the R380 tranny tunnel is made from fibreglass for God-knows-what reason, so for now I've just pulled it out, and will figure out how to fix it later.
...



So is the LT85 tunnel.

Plastic surgery's not so new after all :angel:

[123rover50]

Great thread. You guys sure can work:D

[mike_ie]

Great thread. You guys sure can work:D


Damien drags his heels a bit, but the rest of us aren't so bad.... :p :wasntme:

[Bush65]

....
I initially thought that I could cut and shut it, but it turns out that the R380 tranny tunnel is made from fibreglass for God-knows-what reason, so for now I've just pulled it out, and will figure out how to fix it later.
....
The 86 120 I bought came sans engine and gearbox (owner had transplanted them into a rangie). Because of the modifications to the fibre glass trans tunnel (and the KLR stickers on the windscreen and tray), I presumed the original LT85 gearbox had been swapped for an R380 at some stage.

The surround for the gear levers had been cut out of the fibre glass tunnel and a couple of pieces of aluminium sheet pop riveted to the tunnel and the surround pop riveted back in the new position.

[Vern]

Damien drags his heels a bit, but the rest of us aren't so bad.... :p :wasntme:

Hey, I just go to work to keep you in this lavish lifestyle you like to keep:p

[mike_ie]

The 86 120 I bought came sans engine and gearbox (owner had transplanted them into a rangie). Because of the modifications to the fibre glass trans tunnel (and the KLR stickers on the windscreen and tray), I presumed the original LT85 gearbox had been swapped for an R380 at some stage.

The surround for the gear levers had been cut out of the fibre glass tunnel and a couple of pieces of aluminium sheet pop riveted to the tunnel and the surround pop riveted back in the new position.

Yep, was discussing this with Steve and we pretty much came to the same conclusion - cut out the opening, with a lip to work with, move it forward the inch and a half or so it needs on a piece of aluminium, and rivet in place. Much less work for me than the other way round like your setup, as my tunnel is already plenty big to take the LT85...

[mike_ie]

I don't suppose anyone can grab me a photo or two of an LT85 transmission tunnel, particularly an overhead shot, and a measurement from bulkhead to the shifter opening, plus the dimensions of the opening itself??

[isuzurover]

I don't suppose anyone can grab me a photo or two of an LT85 transmission tunnel, particularly an overhead shot, and a measurement from bulkhead to the shifter opening, plus the dimensions of the opening itself??

Sorry camera betteries need charging, however:

Opening is 16.5 cm W x 25 cm L - note these are ODs measured with the boot still on.

Firewall to front edge of opening = 6 cm. Note that was with carpet and fuse box in place. I tried to account for the carpet...

[mike_ie]

Next step is to get the big, bulky items into the engine bay, so that everything else can be worked in around them. First in is the new radiator and intercooler. Since I couldn't source an Isuzu radiator for decent money, I picked up a new County V8 radiator instead. Almost identical to the Isuzu radiator, just the inlet and outlet need to be swopped around and brazed back in, it's a straight fit into the Defender.

http://photos2.pix.ie/9F/32/9F32B38B125C48559EF7EBB223E00DAF-0000358552-0003160690-00500L-6A0B37DF92CF464E9D7E182A760B8C46.jpg

The intercooler is another matter though. At 602x300x85mm, it's not exactly small, and even though I have an extended front shroud, the intercooler still needs to sit inside the crossmember to that the intercooler inlet and outlet can pass through the wings.

Now seems like a good time to show the results of Steve's handiwork with the TIG...

http://photos5.pix.ie/16/3E/163E0C34E57F4C8CA7F173687F7E5A22-0000358552-0003160689-00500L-70DE8E1F0A604D618445F7E6696A95E6.jpg

http://photos4.pix.ie/D7/03/D703E91BA1334139B1B9337A8584AAD9-0000358552-0003160688-00500L-7E76CE8C02C94AFB981DE322D779FC45.jpg

...and here is where my intercooler needs to go - obviously not enough room.

http://photos3.pix.ie/0B/26/0B267B2B86CE44ED959B4FB05038CC05-0000358552-0003160687-00500L-68D182EDB1EF45018C8ED4597EF69834.jpg

Obvious solution is to move the radiator back further into the engine bay, but my Isuzu came with a viscous fan, the front face of which sits out 92mm from the front of the fan pulley, and already close enough to the radiator without running the risk of sending jagged bits of plastic through it.

http://photos2.pix.ie/62/F6/62F6BCB06EB6473883FCBCB7A678BCA9-0000358552-0003160686-00500L-BBED60CEA2E94D44A8F30BFBD790DCC1.jpg

Standard Isuzu fan sits 32mm closer to the engine, so in the end, I swapped mine out for a standard bolt-on fan. I'm sorry to lose the viscous fan, but I need the room, so....

http://photos4.pix.ie/3C/1B/3C1BE18F2D054C3EAE34DC6570E3C74A-0000358552-0003160685-00500L-F99B2C4BCC87495EA1E232CBDD537D30.jpg

A quick check with the measuring tape tells me that moving the radiator back 35mm will give me enough room to sit the intercoller back enough that the inlet and outlet will run through the wings. This still gives me 55mm between the fan and the radiator, which seems reasonable.

http://photos5.pix.ie/C2/D8/C2D8C0065FF3440CA8F2EC1C3C623B09-0000358552-0003160684-00500L-4AA27BAEE248447683CFDD9F2BD573A7.jpg

Radiator mounts set back 35mm...

http://photos3.pix.ie/16/41/1641393393AF439E8EC4A2168432DDD7-0000358552-0003160683-00500L-1F90D0B4B15D49B5A4A3DB79E348E46A.jpg

http://photos2.pix.ie/E6/DF/E6DFAD71E908487B8CF56E2B3A8CEEAB-0000358552-0003160682-00500L-AE0249194CC54AEBB53717E8C441465F.jpg

County radiator seems to be 10mm shorter than the 300tdi rad/intercooler combo, so top radiator brackets need to be extended 35mm and cut down by 10mm accordingly.

http://photos5.pix.ie/16/59/165916BFC15F4185B604D6440896CFBC-0000358552-0003160681-00500L-48BE741D16A04939B877CCCF9AF406EC.jpg

Radiator and slam panel dropped in to test fit everything...

http://photos4.pix.ie/70/EE/70EEB5CE1B4E410582ECE46B9720AA10-0000358552-0003160680-00500L-5DBA13A9B3294701A109E84D6B3EB3D8.jpg

http://photos3.pix.ie/E3/2C/E32CDB6E4BF54F5DBA89C8920527186B-0000358552-0003160679-00500L-03AFBD4225E14D1CBF8774C978F605A4.jpg

In order to run the intercooler lines, they need to run through the Defender wings. However, there isn't a whole lot of room to work with. Within the wing itself there are two baffles - one below the headlight, and one about 76mm lower, presumably to add rigidity and keep dirt out.

My intercooler has 2.5" inlets, which seems pretty standard. With silicon hose around it, that gives us a 76mm requirement. Nearest bigger holesaw I had was 85mm, which is perfect as it gives some breathing space for the intercooler lines. I don't usually like chucking out measurements because everyones needs are different, but the following measurements might come in handy for someone doing the same, as there really seems like there's no other place to run them.

http://photos4.pix.ie/1D/C9/1DC9F5BDD758464BB0FEDB089FDB7E82-0000358552-0003160678-00476L-18D4330390C94F10BCE58409A2EF8BCD.jpg

I didn't want to go through the upper headlight baffle, but going through the lower baffle didn't seem to be a problem. First, drill and rivet the lower baffle to keep the holesaw from mangling it, then centre the holesaw 5mm below the keyhole cutout
http://photos2.pix.ie/5C/E6/5CE602FE714E4894A571CB85F9B3139C-0000358552-0003160677-00500L-FC583E99D5B740C19F537C07BDD9829C.jpg

http://photos5.pix.ie/4A/C6/4AC643A95F22496B89AF0F3996B261D6-0000358552-0003160676-00500L-2039E0AA8ACF4A3BB41B5641D558E8EB.jpg

Come up from underneath with the same holesaw, file the edges, and job done. As you can see, there's bugger all room. I'll run some trim around the edge of the cutout later to stop the edges from cutting the intercooler line.

http://photos2.pix.ie/68/5B/685BA50C87AB4E558008AC5D3F57AECD-0000358552-0003160675-00500L-26CB006378084D488174D098690F9824.jpg

Test fitting radiator 35mm further back...

http://photos3.pix.ie/32/C5/32C5F8FD0CF8423F88A8670382416509-0000358552-0003160674-00500L-270A90E20578485F88F615A0DFF0E2CB.jpg

http://photos4.pix.ie/AE/C1/AEC125FAF126481CA324CE9064934123-0000358552-0003160673-00500L-C95030215DC74FCBAF538CF0EB9DEC88.jpg

...now mounting up the intercooler....

http://photos2.pix.ie/FF/69/FF69F8234F484B0B9D074296699A8FE7-0000358552-0003160672-00500L-24A389E3308546F98D2986FC19397CD2.jpg

http://photos3.pix.ie/76/55/765509AE270D431B9E76C9CEEE02E4F6-0000358552-0003160671-00500L-7503EEE9A9474A6FADAB016E19CD47E6.jpg

http://photos4.pix.ie/AA/D5/AAD5CC6782F74CB9B54CFFB7B55E089C-0000358552-0003160670-00500L-D5676AFF3FBA450CB8564BD70C734E23.jpg

Plenty of room around the intercooler lines so hopefully no chafing...

http://photos2.pix.ie/9C/7C/9C7C9A02563F4B5FBC5CAF2C68582554-0000358552-0003160669-00500L-508AABC4601D4CE08F6355B225D5B110.jpg

I want to keep the factory aircon at some stage, so the aircon condenser will sit behind the extended shroud in front of the intercooler. I was planning on using the condenser that I had taken out, but after a chat with JC on the phone, who told me in no uncertain terms that the Defender condenser was a :censored::censored::censored:, I'll hold out for something better further down the line.

http://photos3.pix.ie/29/9D/299D1252525A433FBAEA6B3EEA210178-0000358552-0003160668-00500L-732F2487D22C4A5997524C7DD224FB58.jpg

Sump welded up and painted...

http://photos4.pix.ie/18/C5/18C548BC3A0F451592E3509E66586E15-0000358552-0003160667-00500L-79F6DE721F214C1588091A60223311AF.jpg

http://photos2.pix.ie/29/6C/296C72F230234E03B06F9F1D8F5DAA5A-0000358552-0003160666-00500L-4C249101DEA749A8BF138FF36E034624.jpg

The AH19066 air cleaner. Just a bit bigger than the stock 300tdi one... :D To modify it, the inlet will be removed and covered, and the dust outlet will be modified and used as the inlet.

http://photos3.pix.ie/14/51/1451699D3D4046F283DCD464F2CEE5AB-0000358552-0003160665-00500L-D88791512B9642CAB3D47B436CEC43EE.jpg

The housing and twin filter elements...

http://photos2.pix.ie/E2/B9/E2B939136FF34B7FA8AE86A0E2AD6006-0000358552-0003160664-00500L-8AC49496831D431481550B0507EE65BE.jpg

Never fun taking a grinder to a spanking new piece of kit.... :/

https://www.aulro.com/afvb/


more to come later....

[slug_burner]

The sump looks like a bought one!

I think that the D1 condenser is a lot better than the thing they put into the defender. Mine is a locally installed condenser, that together with the terrible placement of the evaporator in the passengers foot well make the whole thing very average.

[strangy]

Nice Mike, very nice .....

[Landover]

Nice Mike, very nice .....

Yes I agree. I think they took it to the right place, I don't think this could have been achieved on your front nature strip in Alice.

[goingbush]

You guys !!!

Mike, love watching the rebirth of your Defender , your going to have to record the first fire up & stick it on youtube for us

[wrinklearthur]

You guys !!!

Mike, love watching the rebirth of your Defender , your going to have to record the first fire up & stick it on youtube for us

X2.
.

[strangy]

Yes I agree. I think they took it to the right place, I don't think this could have been achieved on your front nature strip in Alice.

Absolutely right there,I wouldn't wish a nature strip engine swap on anyone I liked;)
Damien seems to have a better stocked beer fridge too, oh and I can't TIG weld either!

[tony66_au]

Looks like its all underway at Casa Del Vern and I am amazed at the level of friendship extended by the community as a whole.

This could have been a very expensive nightmare without the amazing generosity of the AULRO community and especially those involved in helping out which turns out to be a huge number of people from many states and territories extending facilities, advice, beer, accommodation, vehicles and who knows what else.

Sort of like a big green oily hand of Land Rovery friendship!

[Yorkie]

^^^^ what he said. great build thread for some of us not so mechanically talented. :)

so once it is all together where next on the itinery, back to alice to check out the bits you missed?. ;)

[Judo]

^^ As per last few posts! I really enjoyed watching this thread! :)

[disco_ute]

Hi mike

I have a complete condenser from a 300 tdi that's yours if you want it.

Pm me if you are interested.
Mick

[mike_ie]

Hi mike

I have a complete condenser from a 300 tdi that's yours if you want it.

Pm me if you are interested.
Mick

Appreciate the offer Mick - I have the one that came out of her myself - but was advised by a few very knowledgable people not to put it back in, and to try and source one from a D1 instead. Defender one is too light, fins not very effective, not much good at the whole cooling side of things, and after looking at it close up, I'd tend to agree.

[mike_ie]

Absolutely right there,I wouldn't wish a nature strip engine swap on anyone I liked;)
Damien seems to have a better stocked beer fridge too, oh and I can't TIG weld either!

Don't knock the nature strip - it seemed very appealing at the time compared to the red Rooster car park :D The help you gave me was well appreciated.


The sump looks like a bought one!

Have to thank Steve and his TIG welding skills for that one, rather than me. I'm not the worst with a MIG welder, but nowhere near good enough not to melt big holes in something that thin.


I think that the D1 condenser is a lot better than the thing they put into the defender. Mine is a locally installed condenser, that together with the terrible placement of the evaporator in the passengers foot well make the whole thing very average.

Pretty much exactly what JC said on the phone to me, and recommended that I find a D1 condenser and put it in its place.


^^^^ what he said. great build thread for some of us not so mechanically talented.

I wouldn't go that far - I'm more from the "I'm not very smart, but I can lift heavy things" camp, where everything can be achieved if you can find a bigger hammer. But we're getting there.

Have to get some braided lines made up today, so off to get shafted by either Enzed or Pirtek right now....

[rick130]

[snip]

Pretty much exactly what JC said on the phone to me, and recommended that I find a D1 condenser and put it in its place.

[snip]


I agree, part of my day job is repair/service/designing refrig and a-c systems and the Tdi condenser is pretty ordinary.
The fin spacing is too fine, it blocks a fair bit of air to the radiator and I/C in the little bit of testing I've done. (as in drive up a hill with the condenser and observe temp climb/max temp. Remove condenser and repeat. Re-install condenser and repeat.)

[loanrangie]

I could be wrong but Mick's (disco ute) condenser is from his D1 before it became a disco er i mean rangie er ute.

[disco_ute]

Appreciate the offer Mick - I have the one that came out of her myself - but was advised by a few very knowledgable people not to put it back in, and to try and source one from a D1 instead. Defender one is too light, fins not very effective, not much good at the whole cooling side of things, and after looking at it close up, I'd tend to agree.

Sorry I should have mentioned its from a discovery 1
Mick

[Vern]

So for those who want to know, mikes project is more advanced than the story tells, he's doing a good job. I've been unable to do much due to work commitments and dramas (work)( mike understands) so he's basically on his own, I'm just providing the roof and tools.
On the up side, my dog is giving him the ****s:) ball ball ball ball ball ball ball ball ball:D

[BigJon]

On the up side, my dog is giving him the ****s:) ball ball ball ball ball ball ball ball ball:D

I have one of them, aren't they great? :cool:

[Vern]

Between the dog and the kids, mikes progress is slowing down:)

[mike_ie]

So for those who want to know, mikes project is more advanced than the story tells, he's doing a good job.

That....that almost sounded like a compliment...?! How much d'you have to drink this evening???? :p

[Vern]

Enough mike, just enough:D how's the shopping going?

[mike_ie]

Enough mike, just enough:D how's the shopping going?

Meh - got messed around by Enzed who called me at 4:45 yesterday to tell me that no, they didn't have the bits needed to make up my lines after all, after promising me the world earlier in the day. Luckily JC put me in touch with a guy who got me the fittings this morning.

Picked up a D1 condenser from Mick this afternoon too, so the defender one is going in the bin:)

[Vern]

So enough bits to fire it up?

[mike_ie]

So enough bits to fire it up?

In theory.... yes :)

[Vern]

Cool

[HPLP]

well then Mike,


Does it run???

H

[Blknight.aus]

Save the defender one, get a second compressor for the AC and use the defender one in front of the disco one (and its fans if you fit them) as the oil seperator and air cooler for onboard air.

It'll also save the dead bugs guts from eating away the proper AC condensor and give it a little armour for a front end tap.

[Vern]

well then Mike,


Does it run???

H

Nah, he's reinventing the wheel:D

Doing some rewiring at the moment, and making brackets. Trying t get everything made properly before firing it up.

[Sparksdisco]

Nah, he's reinventing the wheel:D

Doing some rewiring at the moment, and making brackets. Trying t get everything made properly before firing it up.

Sounds like he either needs to up the beer intake so he slaps it together
or stop the beer intake so he hurries up:D:D:D:D

[mike_ie]

Bloody hell, talk about working under pressure?! :D You realise that if you read all the other Isuzu swap threads here, they go along the lines of "it was a cold winters day when I pulled the County into the shed to strip her down...." <cut to years later> "...well we've since had two children, and the recession has come and gone, but finally the County is running again..." :D I think I'm doing alright, though admittedly I'd like to have made more progress the past few days than I have.

Engine is in, SteveG's old 2½" exhaust has been transplanted and welded up, unfortunately the electrical upgrades of a couple of years ago sat right where the air cleaner now wants to reside, and I had no other choice than to rip it all out. Windscreen washer bottle was sitting right where the turbo wanted to be, so that's now gone, have to find me a TD5 one that sits under the passenger side wing (anyone got one for sale???). Because I'm running WVO as well as diesel, I'm finding it hard to shoehorn both filters and heat exchanger into the engine bay. Waiting on Damien's pipe bender to make an appearance tomorrow so I can bend up the intercooler and heater pipes and the engine bay will look a bit more complete. Have a couple of fittings (power steering and turbo) to braze up too.

And of course, there's the dogs (ball ball ball ball ball ball ball ball ball ball ball ball ball throw the ball ball ball ball ball ball ball ball maybe if I lie on top of the tools he'll throw the ball ball ball ball ball ball ball ball ball) and the kids (What does this do? Are you welding? Are you done yet? How do I make explosives?) :D

Beer intake is almost nil these days - that'll change after she cranks over though :D

[mike_ie]

Nah, he's reinventing the wheel:D

Should I take a few photos of the 4BD1 Range Rover gathering dust in the other end of the shed? :angel: :wasntme:

[mike_ie]

Well the work is progressing slowly but surely out here in Damien's shed... :p

http://photos5.pix.ie/AF/23/AF2390E55B884CDFA507B99C53D3EA29-0000358552-0003167092-00500L-7EDD38825E44444AA927D8520CBBB7A6.jpg

continuing from last time, the air cleaner housing needed to be converted from its factory state to something more suitable to under the defender bonnet.

http://photos5.pix.ie/B6/E2/B6E282D2949D48CD91C950EB703F7BCF-0000358552-0003167091-00500L-3FF956C92FFD4B59AB9F4FE4FD215746.jpg

Old inlet was cut out and a patch welded in its place....

http://photos3.pix.ie/F5/D7/F5D7077CE82346F3BAB0D2F91AB62958-0000358552-0003160663-00500L-798940FC902644A2AA08A788C24A40E1.jpg

dust ejection aperture was drilled out to its full 3" diameter...

http://photos5.pix.ie/54/D4/54D4040762E544F4A2AC5077951D7037-0000358552-0003167090-00500L-F441E0C14F844F39A9F3BCF382410C8C.jpg

My one concession to vanity so far - I filled and sanded the imperfections left by the welded in patch, and resprayed the filter housing. If a job's worth doing, it's worth doing well and all that....

http://photos5.pix.ie/7E/DB/7EDB67343DE64CD09DA4FD86F2607978-0000358552-0003167089-00500L-9D92657CB2BF41479F82B73877289558.jpg

Only thing left to do is to unclup the plastic swirl vanes from one end of the main filter element and clip them on teh other end, and job done.

http://photos5.pix.ie/75/60/75602AC7D0C44A308D8C36511A5DC90F-0000358552-0003167088-00500L-E0A70C16D3FB423CA95F5BF933A14CCF.jpg

Was it worth adapting the Fleetguard housing over just buying the Donaldson/Land Rover one off the shelf? Up to you, but in my opinion yes. $200 of a difference for a glorified tin can is nothing to be sniffed at, and money aside, Donaldson not allowing the public to buy directly from them, and instead letting Land Rover inflate the price to over double... that doesn't sit right with me. But to each their own.

My plan was to mount the filter housing behind the engine, just over the bellhousing, as most others have done. There isn't a whole lot of room to play arouns with - too close to the engine, and it's a pain in the ass trying to change the filters, too far away, and you'll have the housing bouncing off the bulkhead 2000 times a minute, and a nice bukhead shaped dent in the housing.

I had two criteria for the filter housing - I wanted the outlet lined up in the same plane as the inlet for the turbo so that I could connect them with a simple 90° reducer, and I wanted the straps for the housing to sit more or less centred on the housing itself. Considering the vibrations that the 4BD1 puts out, the housing brackets tend to break over time, so keeping it somewhat balanced might help things a bit.

The bracket itself uses the two top bolts for the bellhousing adaptor, plus two more tapped holes about 64mm above for support. One thing I will suggest is that you make up the bracketry for this before you fit the engine, as the holes are offset from each other, and a pain in the arse to measure once the engine is in place. I was lucky enough to have a second engine sitting in the corner of the shed to measure off, others may not be so lucky.

The rest of the bracket will depend on what setup you plan to run, but the following measurements will be common to all. Additionally, the bellhousing adaptor is 26mm thick, to the top bolts will beed to be spaced out the same distance from the block.

http://photos5.pix.ie/FC/FA/FCFA4A6D1D894832BE76D19FA414D46A-0000358552-0003167087-00500L-F979B407FF264BEFA176D7D56CFE823E.jpg

The finished bracket - it looks a bit like the starship Enterprise, but it makes sense when its bolted up.

http://photos5.pix.ie/DA/BC/DABCDD9BD65A4E40BBED078D9A422406-0000358552-0003167086-00500L-8142C888BE4449758EDCFBF5F1D5DD30.jpg

http://photos5.pix.ie/F8/13/F81300BC31BF48829B36E989B6A612A9-0000358552-0003167085-00500L-BB0ECCB5D74442F18ADF1072A1F797E1.jpg

offset towards the drivers side to align the filter housing with the turbo inlet.

http://photos5.pix.ie/2C/97/2C972FAA330343659D721663A628C459-0000358552-0003167084-00500L-7926987B5B7A4DA5942E92C467423E20.jpg

http://photos5.pix.ie/93/A2/93A2BE1A28BE4C97B578F6332872F748-0000358552-0003167083-00500L-63506EE6DBD8428D982829FE85D0D595.jpg

Sittign in its new home in teh engine bay. Housing is sitting centred, and is at the correct height and offset to line up with the turbo. Unfortunately for me, this also happens to be exactly where I located relays and aux fuses for a wiring upgrade a couple of years back, so spent the afternoon gutting the wiring to be refitted elsewhere later :(

http://photos5.pix.ie/B7/D4/B7D4B83E56D346FCBEAE3856D81A4D50-0000358552-0003167082-00500L-22DDF76B4DC5494183203581B467A378.jpg

SteveG had recently upgraded his exhaust to a 3" system, so I happily grabbed the (not so) old 2½" exhaust to replace my tattered 2" setup.

http://photos5.pix.ie/7C/85/7C8502B7007C46CC839B1FD8C48BCA15-0000358552-0003167081-00500L-62EFD391A843463F9A0F735A447F0A35.jpg

Seeing as it was already sectioned, I simply welded on some flanges and hangers, and bolted her up. Keep at lest one flange for directly under the starter motor though - any further down the line and the turbo downpipe won't have room to come out. Ask me how I know this... :wasntme:

http://photos5.pix.ie/F5/68/F568910A982847659EA6D928560D872B-0000358552-0003167080-00500L-54425A7485C54B7DBAFC61483609EFA1.jpg

http://photos5.pix.ie/48/AA/48AA17F77906411A8D5133190ED370E8-0000358552-0003167079-00500L-FB18B2BE3E404C74863F6E2A4480EABA.jpg

Slight dogleg to get round the bellhousing. Might have to weld a heatshield to the pipe here at some stage, to stop if from frying the clutch cylinder.

http://photos5.pix.ie/C1/71/C1719FCDB6114E6F943A7AA2788A04AB-0000358552-0003167078-00500L-32D82F3A39C04AD49EDD8940796FA549.jpg

http://photos5.pix.ie/D3/22/D322298A60754785AB3EC7EBDB2C2AA0-0000358552-0003167077-00500L-333951BC1A2640C4AB57B0E6B13C93FC.jpg

Clutch slave cylinder now sits on the opposite side of the bellhousing, so had to plumb across to suit... should have done this before the engine went in.

http://photos5.pix.ie/22/18/2218C7809C0E4526A7623AA784CCC9C7-0000358552-0003167076-00500L-AC632778F98F48129EC7385E13E1B019.jpg

My new least favourite job - bending up brake and clutch line. Unfortunately didn't have a pipe bender, so every round object was put to use as a former, but at least I did have a flaring kit to do the ends.

http://photos5.pix.ie/CB/7F/CB7F8642DA9F4DF994672D64B8F88BC2-0000358552-0003167075-00500L-A25BCAE121334ADBB8D8E3099D8ED707.jpg

As mentioned earlier, the R380 transmission tunnel didn't fit the LT85 gearbox, so rather than try to source one, I modified the R380 one to fit. A few measurements told me that the layout of the gear and diff lock levers was about the same - gear lever centred, diff lock offset 20mm right of centre, so the only thing I needed to do was relocate the opening 50mm towards the bulkhead and everything should line up, and I should be able to use the same gaiter for the levers.

As it was...

http://photos5.pix.ie/F1/C2/F1C239BE904C480B90CEF3C077363BE3-0000358552-0003167074-00500L-4F163F1CAC7A4C5C93A9B944E9CCABF4.jpg

Tunnel marked up and cut...

http://photos5.pix.ie/47/35/473571FC0E504E5092721D0416E497A3-0000358552-0003167073-00500L-A7F2BE887C01477C9ABC775C2C99D763.jpg

http://photos2.pix.ie/71/B6/71B64C4E2DAE42D8885C8C8C0BC9EC85-0000358552-0003167072-00500L-E5DAF0A7EFBE4FCA85CF0B7FE45B3BFA.jpg

Lever aperture shifted forward 50mm and temporarily held in place...

http://photos5.pix.ie/9E/47/9E47B44B16444CBFBB07AA1DB90E08F4-0000358552-0003167071-00500L-6FC95DF7FFC046BAA293F0F596467889.jpg

first layers of fibreglass underneath to give support.

http://photos2.pix.ie/4E/5A/4E5A55C797F34437B9620C6DAB292D9F-0000358552-0003167070-00500L-71539F4941424F03973170709E45B164.jpg

Subsequent layers of fibreglass, plus a final layer of fibreglass mesh to tidy it all up...

http://photos5.pix.ie/A9/03/A903A4329B9D4ACA91D63439635D329B-0000358552-0003167069-00500L-29F9ADF00B4247C3808FE751B506DD1E.jpg

http://photos5.pix.ie/9C/73/9C732C8D08B44A178423A31515933AD5-0000358552-0003167068-00500L-3595BFE868084C38BA3AA2422D48067A.jpg

http://photos5.pix.ie/8B/34/8B3475EABA834A7DB5AB8AB644E4AF82-0000358552-0003167067-00500L-89DD3978F64B4E7C8B9F7CE3AD135CE3.jpg

Not the most exciting update so far, but hopefully someone will glean something from it. Next time, bending up and plumbing all the intercooler plumbing...

[Bearman]

Nice work Mike, I can see you are a bit of a perfectionist:D

[mike_ie]

Nice work Mike, I can see you are a bit of a perfectionist:D


Not really. More of a lifelong member of the I'm-too-poor-to-halfass-it-and-do-it-again-later club... :)

[goingbush]

Mike, I reckon if the government got wind of this they would make you an Honorary Australian Citizen, you take Australian ethos of "patch it up with a bit of No8" to a new level, something that, it appears, has sadly been lost down here over the last few generations.

That Donaldson is a work of art, What about the SS Enterprise bracket , you didnt do that with a hole saw and a bastard file, (did you ??) I dont see a CNC bench in the background shots in Verns shed but the work you are turning out is top shelf

Just curious, do you have a trades background,

If your any measure of your countrymen I think they should also change Irelands moniker to the Clever Country instead of the Clover Country.

[mike_ie]

Mike, I reckon if the government got wind of this they would make you an Honorary Australian Citizen, you take Australian ethos of "patch it up with a bit of No8" to a new level, something that, it appears, has sadly been lost down here over the last few generations.

That Donaldson is a work of art, What about the SS Enterprise bracket , you didnt do that with a hole saw and a bastard file, (did you ??) I dont see a CNC bench in the background shots in Verns shed but the work you are turning out is top shelf

Just curious, do you have a trades background,

If your any measure of your countrymen I think they should also change Irelands moniker to the Clever Country instead of the Clover Country.

Tradie's background, not particularly, have my sparkie's ticket from years back, and a couple of engineering degrees. And if there's a job out there I've probably turned my hand to it somewhere along the line. But more of an ability to pick up any tool and figure out how to use it, or at least have a go. Everything's an opportunity to learn, and all that. Still nothing compared to what I've seen some people churn out here though!

No CNC machine, so everything's done by hand or with a 1mm cutting disc, though might be time to put a word in Damien's ear about picking one up :p

[steveG]

Good work Mike - its coming up really well and agree with others about your workmanship :BigThumb:

Looking at your welding on that exhaust flange, I've no idea why you got me to pick up the MIG torch while I was there...:angel:


If you haven't already done it, tack the clamp nuts for the filter housing onto the mounting brackets so they don't try to drop off every time you undo the clamps.

Steve

[rick130]

Not really. More of a lifelong member of the I'm-too-poor-to-halfass-it-and-do-it-again-later club... :)


As neighbour said to her husband when looking at ride on mowers;

"We're too poor to be cheap"

I've used that a few times since I heard it, I reckon it's a great ethos :D

[mike_ie]

Good work Mike - its coming up really well and agree with others about your workmanship :BigThumb:

Looking at your welding on that exhaust flange, I've no idea why you got me to pick up the MIG torch while I was there...:angel:

Cos if the engine falls out next time I'm in Alice Springs, I can hardly shout at myself, now can I? :p


If you haven't already done it, tack the clamp nuts for the filter housing onto the mounting brackets so they don't try to drop off every time you undo the clamps.

Will do.

[steveG]

Cos if the engine falls out next time I'm in Alice Springs, I can hardly shout at myself, now can I? :p


Hmmm. Hadn't thought of that.
Lucky all my work has a concrete guarantee - it expires once you leave the concrete! (and I did check that Vern has an long non-concreted driveway :p )

Steve

[strangy]

Hmmm. Hadn't thought of that.
Lucky all my work has a concrete guarantee - it expires once you leave the concrete! (and I did check that Vern has an long non-concreted driveway :p )

Steve

Which is perfect as my nature strip is dirt too so no warranty comebacks from Alice;)

[HPLP]

Keep it up mike! Its good reading, sitting on the beach in airlie! H

[Vern]

Hue (sp), you bastard:D

[mike_ie]

Well the days left on my visa are counting down, and the pressure is definitely on to get finished. Frustratingly, time has been spent, or wasted, depending on how you look at it, just figuring out how to get everything placed under the bonnet, and working. But it's coming together, hopefully before I get deported.

Oil sump ready to go back on the engine. The Isuzu sump comes with two gaskets - an inner rubber gasket between sump and engine block, and an outer rubber gasket between sump and retaining bands.

https://www.aulro.com/afvb/

Looks like my measurements when mounting the air cleaner housing panned out - everything lines up nice and neatly.

http://photos5.pix.ie/49/7E/497EE20EB77C43AEB23FFED7F99C13EA-0000358552-0003176938-00500L-051FC7EE3E6A4CF9A15AD31E9A9D8A53.jpg

http://photos5.pix.ie/F4/F6/F4F6FCD42F044EE09250696C2476C5C3-0000358552-0003176937-00500L-ACFAFB8B71C34488AEADDD3AF2A47344.jpg

The plan is to run 2½" stainless steel intercooler lines, and seeing as I had to make up new heater lines, I decided to do those in stainless too. At $5/metre for ¾" stainless tubing, it was as cheap as any other option, and it looks good.

Courtesy of Damien's pipe bender, shaping up the ¾" tubing wasn't a problem, however a test run with the 2½" proved to be too much for it. With the heater lines bent the way they are, it should only take a few straight sections of rubber hose to link engine to heater box and back.

http://photos4.pix.ie/BC/3A/BC3A84DF6855400BA5B67D4AA2DE72C6-0000358552-0003176936-00500L-2184C276FB554D8F9E9BC284F7F05C04.jpg

http://photos5.pix.ie/00/02/0002AC3B0AB341CF8B2454C452C384C6-0000358552-0003176935-00500L-0CE565B80E594907A93D58453960B6F4.jpg

http://photos4.pix.ie/24/F0/24F048B56F47443F9EF254481C02C9F8-0000358552-0003176934-00500L-55909CCDB2624F62B30A628238673EC7.jpg

Turbo coolant lines will tee in later...

http://photos4.pix.ie/E7/57/E757376D09E642B0BF784178576E337A-0000358552-0003176933-00500L-5849DE7B901046888459572468B33385.jpg

And this is how the experts do it apparently. Most of the intercooler bends would be done with silicon elbows, but I needed to put a ben in the intercooler -> intake manifold section, as the tight space didn't really allow for silicone elbows. Brought my stainless tubing to an exhaust place, and this is the best he could do.... :/ Even more shocking, the guy told me he'd happily put this into an exhaust system.....

http://photos4.pix.ie/5F/7E/5F7E741373F5438B869D04A7080FB574-0000358552-0003176932-00500L-6C4D95F4E767453B81C4ADD2083A12DD.jpg

I was getting worried at this stage because I was getting caught for time before the weekend, but luckily an exhaust place nearby had this sitting on the shelf and were happy to offload it for a few dollars. In the end, much better than anything I could get bent up.

http://photos4.pix.ie/6B/45/6B4566E78D86423F847045E9C8FAD126-0000358552-0003176931-00500L-1302129C113A482FA920976E57EC97CD.jpg

A few queries, and I found out that welding stainless tubing to the mild steel manifold flange wouldn't be a problem, so the original manifold piping got cannibalised for the flange, the stainless 180 degree section got cut to the required angle, and everything lined up....

http://photos2.pix.ie/3E/97/3E9710CBCDF54B78B7983BE92CF16C9A-0000358552-0003176930-00500L-D7E8FF6DFDAB4F399C9E9F80AEDA4CF3.jpg

HAve to admit I was nervous welding this up. First time welding stainless, had all of three stainless arc rods, so bugger all to practice with, and not enough stainless or flange to do it over again if I screwed up. Fortunately a few welds with some scrap stainless got me a feel for the arc welder, and overall it didn't turn out so bad.

http://photos2.pix.ie/FF/93/FF93382A34B6428080B07242B9C58DC0-0000358552-0003176929-00500L-B48C72212F9C498E8B7B3EAF8F82075B.jpg

http://photos4.pix.ie/77/57/775744AB21B74C19AF9B15DE0641787D-0000358552-0003176928-00500L-9659C8160DD84B65B502050ECB8DDCCF.jpg

Slowly, it's taking shape. There's actually quite a lot more curve to the intercooler pipe than the photo suggests. I also used a humped silicon connector to dampen the vibrations from the engine down to the intercooler.

http://photos4.pix.ie/1B/A0/1BA04B6031844C39951F13BE43B4CECD-0000358552-0003176927-00500L-34F534679A7B4951B6BBBE2096C078B9.jpg

http://photos2.pix.ie/61/43/61430C76126E4251A9D4AFF1CD071733-0000358552-0003176926-00500L-D1211E1BBCEB415887042832AF501FC9.jpg

Seeing as the engine is out of a truck, it doesn't have the standard electric cutoff solenoid that the 300tdi had. Instead, a manual valve cuts off fuel to the injector pump, driven mechanically, either by a push to start/pull to stop cable, or an EDIC motor. For $45 I picked up an EDIC motor out of Mazda T3500 truck from a local truck wreckers - as much as I like the simplicity of the pull stop cable, I have to get this Defender into Ireland, and I'm fairly certain that it's a requirement in order to pass roadworthy. The mechanism is simple - a relay driven motor releases or retracts a cable with the application of power, which in turn opens or closes the injector pump cutoff.

http://photos5.pix.ie/45/AE/45AE910543094E93AB063BD1FFFD3ACF-0000358552-0003176940-00500L-73C331148C494495A7218D886E42E825.jpg

The only change I made was to lengthen the cable to suit where I wanted to mount the EDIC, swapping out the original with a modified accelerator cable from a Hyundai, or Subaru, or somethingorother.

http://photos2.pix.ie/12/13/1213690C0B34402D97543C36D6EED12C-0000358552-0003176925-00500L-2067754985ED46A08281F1BFCBFA6990.jpg

Original cable endings are made of some kind of amalgam, or pewter, or something with a low melting point, as I quickly found out when I heated one to remove it from the original cable... :/

http://photos3.pix.ie/E2/C0/E2C0C71D081540BE85D5BBFCE7C078AE-0000358552-0003176924-00500L-37EE4F3DBD924F05A7CEB7FAC70B9F88.jpg

EDIC mounted up under the wing, behind the drivers side light. Out of the way, up high enough to remain dry in almost any situation.

http://photos2.pix.ie/1C/47/1C47481AF3A844958FFFF9E8625F1B88-0000358552-0003176923-00500L-5AB2066B71C4496A91E2408529871705.jpg

http://photos3.pix.ie/62/C6/62C62DADBEE0434C9CC57B00834C5771-0000358552-0003176922-00500L-D21F1650E4CD45E0827849EEA9E9F55A.jpg

http://photos3.pix.ie/EB/10/EB10F96DECA145529B20FBABC97A4152-0000358552-0003176921-00500L-74529C9D50974DD79589ACD7E12FD521.jpg

By far the biggest pain in the ass is organising everything within the confines of the engine bay. A lot of stuff has t be moved around, brackets have to be made up for everything. In my setup, I need to mount a provent, two fuel filters (diesel and SVO) a heat exchanger (SVO), power steering bottle has to be moved, and because of the position of the turbo, I lose the 300tdi windscreen washer bottle - will have to replace it at a later stage with a TD5 one, which tucks in under the passenger side wing.

HAve I mentioned how much I hate making up brackets...

Provent....

http://photos2.pix.ie/8A/BE/8ABEB026E6B742A3A733EA912B5F9762-0000358552-0003176920-00500L-A34185E530B74FAEA92307F5F8D672BE.jpg

30 plate heat exchanger...

http://photos3.pix.ie/04/8A/048AC2597D5B45A1B064F4932E59381B-0000358552-0003176919-00500L-86FCF62AFD8F47D5B757538187AB5A6C.jpg

power steering bottle...

http://photos2.pix.ie/CB/0F/CB0FC894CBD54EA29B7BFF3FCDADFD78-0000358552-0003176918-00500L-66F6951642F244B2868A10B28E8F391B.jpg

fuel filter...

http://photos2.pix.ie/A3/05/A305FA0C9AFE4C308F5F14F9832BF850-0000358552-0003176917-00500L-5A93439FF6E044A48B1AC8F884F21ABB.jpg

Genius that I am, I ran the intercooler line straight through the only position available to mount the power steering bottle. In my defence though, there weren't really many alternatives to where I could run it, So I guess I'll be bending the hydraulic lines around it for now.

http://photos2.pix.ie/0F/66/0F666CF3EB0D440BBF190019249C37F1-0000358552-0003176916-00500L-32185FB7C3324FB7A858C1D8003AAAE5.jpg

AS it turns out, the power steering pump comes in two flavours - outlet on the front (hard to find)

http://photos5.pix.ie/E0/1C/E01CAFDF549349DD91BE7DDAED10ADC2-0000358552-0003176915-00500L-C57EF04B661045E98FDB8A01D89757CD.jpg

...and outlet on the side, which is far more common (courtesy of Vern's Range Rover).

http://photos2.pix.ie/60/59/6059BCE4EC544C11901252FB209D5280-0000358552-0003176914-00500L-605A2EF2D8414C8EB55BF36C1BCAF6EA.jpg

Where this impacts Land Rover engine swops is with the steering box - the side mounted outlet comes within a hairs breadth of the steering box hard lines, and usually requires quite a bit of fettling to get everything to fit. Luckily my donor vehicle had the former power steering pump, so plumbing was far easier.

http://photos5.pix.ie/05/1C/051C9AA60C1246429328D5FB628E7B68-0000358552-0003176913-00500L-759D84197AC84E9980C6F8CD31AEE19D.jpg

http://photos2.pix.ie/5B/D1/5BD1FF51C47449F2878A4F95F2564C30-0000358552-0003176912-00500L-602480CDD028433B8A2BD22528B62A51.jpg

The engine bay is beginning to come together.

fuel filters mounted...

http://photos2.pix.ie/6D/AE/6DAE8D5370B3443AA6A2420F597B3F50-0000358552-0003176911-00500L-B0C3DF4E7A32495E8670182BAA0416CC.jpg

Provent and heat exchanger mounted....

http://photos5.pix.ie/C8/1D/C81D83DD6CFE4DA1BCF9AE2499DB078F-0000358552-0003176910-00500L-24D2E43F94BB41838A77BB07E2B72785.jpg

It's beginning to look like an engine bay again!

http://photos2.pix.ie/D4/11/D411E4D574524AF29C1F022E72008AD3-0000358552-0003176909-00500L-EC2BAAD1EA884844A4A0AF99155FAAEA.jpg

Next installation: Does Mike finish on time or does he get deported.... :(

[Bush65]

... The Isuzu sump comes with two gaskets - an inner rubber gasket between sump and engine block, and an outer rubber gasket between sump and retaining bands.

http://photos5.pix.ie/77/20/7720FD3EB88440B1BDE6DF296546AF86-0000358552-0003176939-00500L-9D62DAA59065437096C33ED1E61F7819.jpg
...
Late 88 on 4BD1's run smoother and quieter, so the acoustic dampening sump gasket wasn't necessary and Isuzu changed to a "normal" gasket.

Good work, and good write-up Mike.

[Dougal]

Are those stainless heater lines flexible enough to span between a shaking engine and not-shaking-as-much body?

[mike_ie]

Are those stainless heater lines flexible enough to span between a shaking engine and not-shaking-as-much body?

The ends of the stainless are longer than they will be in their final state - needed to leave length on them for bending.

There's going to be 8 to 9 inches of rubber across a bend from the engine to the heater box, so there'll be no issues with vibration (I hope) :)

[Judo]

Still loving this write up and all the detail you're providing Mike. Can't wait to hear you've got it all working! :thumbsup:

[strangy]

Looking good Mike:cool:

[steveG]

Good work Mike.
I can help with storage space if you happen to get deported before you finish. Might have to store some of those bits on my County for a while - inconvenient, but I'll put myself out to help ;)

Steve

[mike_ie]

Good work Mike.
I can help with storage space if you happen to get deported before you finish. Might have to store some of those bits on my County for a while - inconvenient, but I'll put myself out to help ;)

Steve

Your generosity is staggering :D

[eddy]

Mike,I would be looking at changing the black coolant bottle,they are notorious for splitting at the seam.Add a low coolant alarm and you will have some protection to preserve all your excellent work.

[mike_ie]

Mike,I would be looking at changing the black coolant bottle,they are notorious for splitting at the seam.Add a low coolant alarm and you will have some protection to preserve all your excellent work.

Good points, definitely. If I posted every nuance of this project, and little thing I planned to do, I'd never get any actual work done, and would definitely get deported then. There's a thousand little jobs like that that never got mentioned earlier, but I already have a low coolant alarm from the 300tdi that will be wired up, and the coolant bottle has been on the cards for a while now - myself and Vern were chatting about it inly a few days ago. I just need to get my hands on one, and I need to get a TD5 washer bottle from somewhere too. Appreciate the feedback though :)

[Judo]

While the generosity is flowing, I should point out I'm happy to be an off-road test driver if you need someone to see if it can handle the Aussie bush. My fees are reasonable. :ohyes:

[mike_ie]

While the generosity is flowing, I should point out I'm happy to be an off-road test driver if you need someone to see if it can handle the Aussie bush. My fees are reasonable. :ohyes:

Sounds good. Perhaps I should just leave the defender at yours entirely then, just use it on my visits to Australia then. Could get you to exercise her on a weekend basis, for a nominal fee of course :p

[mike_ie]

Late 88 on 4BD1's run smoother and quieter, so the acoustic dampening sump gasket wasn't necessary and Isuzu changed to a "normal" gasket.

Good work, and good write-up Mike.

That's interesting, because when the 4BD1 was running in the Rangie, it was one of the quieter ones that I have heard - Vern can back me up on this one. I was concerned about engine noise prior to purchase, but it seems like I've gotten lucky in my engine choice???

[Bearman]

The turbo does seem to quieten them down a bit.

[Dougal]

The turbo does seem to quieten them down a bit.

Turbos are the best thing ever for diesels.
Muffles intake noise.
Muffles exhaust noise.
Preheats the air to quietn the combustion noise.
Provides a nice whistle.
More power, more torque.
More efficient.

What's not to like?:cool:

[rick130]

Turbos are the best thing ever for diesels.
Muffles intake noise.
Muffles exhaust noise.
Preheats the air to quietn the combustion noise.
Provides a nice whistle.
More power, more torque.
More efficient.

What's not to like?:cool:

Throttle response sucks compared to an NA engine but I can live with that :D

[justinc]

Throttle response sucks compared to an NA engine but I can live with that :D

mmm, rick you haven't driven a 4BD1T yet then?:cool: My NA engine 'now with kompressor' throttle response is the same as before but now with 40% more torque added:twisted:

JC

[Dougal]

Throttle response sucks compared to an NA engine but I can live with that :D

I've recently (last week) gone back down in turbo size. I'm again running a T25 with a smaller compressor wheel than a 300tdi. Boost response is excellent.
To get the same torque in a NA engine you'd need about 8 litres. Isuzu do make those too.:D

[Disco Muppet]

Wow, An impressive read, and quite a staggeringly generous response from the people of AULRO. Good to see!
Hope you get it up and running soon, I can definitely see an Isuzu county project in my future.
That's if I don't have to spend all my money replacing the windows within a 5km radius of my house after my mothers shriek of "You bought WHAT?!"
:lol2:
Nice work, best of luck with it! :cool:
Cheers
Muppet

[rick130]

mmm, rick you haven't driven a 4BD1T yet then?:cool: My NA engine 'now with kompressor' throttle response is the same as before but now with 40% more torque added:twisted:

JC


I've recently (last week) gone back down in turbo size. I'm again running a T25 with a smaller compressor wheel than a 300tdi. Boost response is excellent.
To get the same torque in a NA engine you'd need about 8 litres. Isuzu do make those too.:D

OK, I'm just comparing a TD42 to a TD42T which at one time I was jumping out of one, into the other, then a 300Tdi :( (then something with a 6/354T Perkins :D)

[steveG]

Need a status update Mike - it's gotta be running by now.. :)

Did you need to cut off the roots that were growing down into Verns shed floor, or has it got enough grunt to tear them out??

Steve

[Vern]

Well no, but I think the dog is eyeing it off as a new kennel its been sitting that long:)

[steveG]

Bugger - be nice if it did a few K's on Aussie roads rather than straight to the boat :(

Whats still left to do?

Steve

[Vern]

Get it going:p

[mike_ie]

As it happens, spent the last couple of hours getting the Disco going... Old age is finally catching up with it... :)

Tomorrow, connecting up the coolant hoses, filling it with fluids, and connecting a set of jump leads to the starter motor to see what happens.

[Vern]

Old age, its a rebuilt motor.:(

[steveG]

As it happens, spent the last couple of hours getting the Disco going... Old age is finally catching up with it... :)

Tomorrow, connecting up the coolant hoses, filling it with fluids, and connecting a set of jump leads to the starter motor to see what happens.

Don't tell me its taken this long and the starter still isn't wired up properly :angel:

Steve

[mike_ie]

Old age, its a rebuilt motor.:(

Motor's fine, what was in the fuel tank wasn't. I got a bad batch of fuel somewhere, or possibly what came out of my tank when I drained it. Either way, 300tdi's don't run on brown sludge apparently :D

[mike_ie]

Don't tell me its taken this long and the starter still isn't wired up properly :angel:

Steve

You'll have to talk to the sparky about that one... :p

[Vern]

Ha, oil perhaps:angel: Texas tea, clogged the filter?

[Vern]

Sparkies got enough on his plate. Plus at the moment I couldn't even get under the car with my back and all:(

[steveG]

Motor's fine, what was in the fuel tank wasn't. I got a bad batch of fuel somewhere, or possibly what came out of my tank when I drained it. Either way, 300tdi's don't run on brown sludge apparently :D

I've watched plenty of CSI.

What I think we have here is the beginnings of a 300tdi serial killer.

First occurred in Alice Springs a few months back, and now a seemingly healthy 300tdi succumbs to the mysterious brown sludge.
Surely it can't just be coincidence *key dramatic music*....

Steve

[mike_ie]

Ha, oil perhaps:angel: Texas tea, clogged the filter?

Thought occurred to me, don't worry. Wasn't running on oil though by the time I got to yours, just the expensive stuff :D I drained my diesel tank into yours, but there's a good chance that the rusty bits went with it. Filter was fine - crap didn't get past the tank end of the fuel line.

[mike_ie]

Sparkies got enough on his plate. Plus at the moment I couldn't even get under the car with my back and all:(

"bad back" - the fallback of every tradie :p

Seriously though, hope you're doing better - you looked in quite a bit of pain yesterday.

[Vern]

Spent the morning at the physio, then in bed most of the day, physio again Thursday. Thank god I have workers:)

[Vern]

I've watched plenty of CSI.

What I think we have here is the beginnings of a 300tdi serial killer.

First occurred in Alice Springs a few months back, and now a seemingly healthy 300tdi succumbs to the mysterious brown sludge.
Surely it can't just be coincidence *key dramatic music*....

Steve

Stop it Steve, your scaring me and my wallet;)

[flagg]

Driving it round yet? :D

[mike_ie]

Driving it round yet? :D


Update later today ;)

[loanrangie]

Ok its later :p.

[sheerluck]

Ok its later :p.

It's been later since earlier!

[Dougal]

Do you guys really expect to peel Mike from driving his new toy just to update the horde of lurkers living vicariously through his build?

The other scenario. He still can't get it started.:wasntme:

[disco_ute]

Do you guys really expect to peel Mike from driving his new toy just to update the horde of lurkers living vicariously through his build?

The other scenario. He still can't get it started.:wasntme:

YeS.

[rick130]

Do you guys really expect to peel Mike from driving his new toy just to update the horde of lurkers living vicariously through his build?

The other scenario. He still can't get it started.:wasntme:


:lol2: Cruel, but made me laugh :D

[Blknight.aus]

bet he called it a piece of crap again....

my offer still stands.

oh and today (probably his visa too by now) doesnt have much later left in it.


Bet I can get a headgasket, timing belt, plumbing rejig and pump tweak done faster than he can bleed up the suzi?

[mike_ie]

Thanks for the... um... support??

Having problems getting fuel to the actual injectors for some reason. Lift pump and primer are definitely working, fuel is getting as far as the bleed screw in the injector pump - in fact fuel is getting all the way through the injector pump because I can hear the return line dribbling into the jerry can that I'm using as a fuel tank for now. So, fuel in IP, but fuel not getting to injectors.

Battery is dead from cranking, so waiting for it to charge before I can try anything again.

On a separate note, is there anything special about the mechanical lift pump that it can't be replaced with an electric facet pump? Not necessarily for now, but something I may need to consider for my SVO setup later...

[rovercare]

Crack fuel line to filter, pump lift pump, crack line after filter, pump, crack line that enters pump, pump, crack injectors, hold full throttle, crank until fuel spills, do up one at a time, it should go

I have a brand new prime pump here if you need it

[rovercare]

On a separate note, is there anything special about the mechanical lift pump that it can't be replaced with an electric facet pump? Not necessarily for now, but something I may need to consider for my SVO setup later...

Its mechanical, that's whats so special about a 4BD1:)

EDIT: if you have fuel at the pump, you may just need to crack the injector lines, hold throttle, crank and do up as they spill fuel

[mike_ie]

Yep, definitely have fuel at the pump - when I hand prime it I can hear it going through the pump and back through the return line. Haven't changed anything since it was in the Rangie, so not overly worried, just thought she'd fire up easier than this. Waiting for batteries to charge before I try bleeding her again.

[rovercare]

Yep, definitely have fuel at the pump - when I hand prime it I can hear it going through the pump and back through the return line. Haven't changed anything since it was in the Rangie, so not overly worried, just thought she'd fire up easier than this. Waiting for batteries to charge before I try bleeding her again.

Jumper leads? another battery?

You need to expel air from line to injectors once run dry, sometimes it will start and self bleed, just hold the throttle flat for max fuelling, but with a hand its easier to bleed them

[mike_ie]

Jumper leads? another battery?

You need to expel air from line to injectors once run dry, sometimes it will start and self bleed, just hold the throttle flat for max fuelling, but with a hand its easier to bleed them

Have gone through both available batteries trying to get her running - they're on charge now. But while they still had enough power to crank, I had fuel at the IP, and plenty of it. But all the cranking in the world isn't getting fuel up the lines to the injectors....

[JDNSW]

Have gone through both available batteries trying to get her running - they're on charge now. But while they still had enough power to crank, I had fuel at the IP, and plenty of it. But all the cranking in the world isn't getting fuel up the lines to the injectors....

I know it is obvious, but the fuel shutoff is not off is it?
John

[steveG]

Hopefully someone that has done it more recently will confirm, but from memory when you prime them the primer pump goes hard unless you have something cracked. Sounds like that's not the case for you.

Any chance you've got the cutoff lever in the cutoff position? Its spring loaded to run (position closest to the engine block).

Steve

[rovercare]

I know it is obvious, but the fuel shutoff is not off is it?
John


Hopefully someone that has done it more recently will confirm, but from memory when you prime them the primer pump goes hard unless you have something cracked. Sounds like that's not the case for you.

Any chance you've got the cutoff lever in the cutoff position? Its spring loaded to run (position closest to the engine block).

Steve

These guys are thinking well! make sure the lever is in the "free" position, just disconnect the cable

[mike_ie]

I know it is obvious, but the fuel shutoff is not off is it?
John

EDIC motor isn't connected, and fuel shutoff is sprung to the "run" position, so all should be good...

[rovercare]

Had you cracked the injector lines at the injectors?

[mike_ie]

Had you cracked the injector lines at the injectors?

Yep - not getting any fuel topside.

[rovercare]

Yep - not getting any fuel topside.


If you crack an inlet line at the fuel filter and hand pump, do you get lots of fuel coming out?

Kiki pumps are generally a doddle to prime

[mike_ie]

As I said, I'm gettign fuel to the injector pump. Have cracked the inlet to the IP, get plenty of fuel when I prime the pump, so no problems there. Am getting fuel THROUGH the pump, because I can hear it returning to the tank.

Last try a few minutes ago, I started getting a small amount of fuel to injector#1, but batteries don't have enough go to continue cranking for the moment.

[rovercare]

As I said, I'm gettign fuel to the injector pump. Have cracked the inlet to the IP, get plenty of fuel when I prime the pump, so no problems there. Am getting fuel THROUGH the pump, because I can hear it returning to the tank.

Last try a few minutes ago, I started getting a small amount of fuel to injector#1, but batteries don't have enough go to continue cranking for the moment.

Throttle flat whilst cranking?

Should come up with a good battery and crank then

Although 2 flat batteries is alot of cranking!

Nothing silly like fuel line in jerry sucking from the bottom restricting flow either?

[steveG]

If you're struggling for battery to crank with, how about pulling the glow plugs to reduce the compression and allow it to spin a bit more freely at least until you get fuel up to the injectors.

Steve

[mike_ie]

She starts :)


:banana::banana::banana::banana::banana::banana:

[steveG]

About bloody time!

Geez u know how to drag out the inevitable ;)

Steve

[drifter]

YAY

[mike_ie]

About bloody time!

Geez u know how to drag out the inevitable ;)

Steve


That right??? :D


Major milestone today - the County completed its first real Isuzu powered test drive today. Only about 10mins as I didn't want to get too far from home ;)

I didn't realise until tonight, but its exactly 9 months since I started pulling the 200tdi out for the conversion. A lot longer than I expected, but then I ended up doing a lot more work than planned.

:p

[rovercare]

She starts :)


:banana::banana::banana::banana::banana::banana:

Sooo, what was the drama, that you flattened two batteries?

[Blknight.aus]

About bloody time!

Geez u know how to drag out the inevitable ;)

Steve


That right??? :D



:p

I think he was pointing out that youve dragged out the starting process...

There are people on this forum who have mangaged to get them to start out of the vehicle without a fuel system attached, thats how much these engines love to go...

what did you do to offend yours?

[wrinklearthur]

Ah! you can't fool me.

You fellows had it going, way before and you were fishing for bites on the computer while enjoying a beer.

Any way, what's next?
.

[mike_ie]

There are people on this forum who have mangaged to get them to start out of the vehicle without a fuel system attached, thats how much these engines love to go...

what did you do to offend yours?

You tell me? As I said in earlier posts, could not for the life of me get the injector pump to send fuel up to the injectors, no matter what I did. To the point where I was beginning to think that there was a blockage somewhere.

[Davehoos]

not unusual for IP not to allow fuel past the check valve if its been parked for some time.cant think of the correct name for the check valve on top of the plunger [segment-element??]--the ingector line attaches to the pump.

I have a 3 cyl chinese diesel with bosch pumps that will missfire all day but slightly move it as it goes into the pump[remove the clamp bolt] and away it goes.

inline-bosch-zexel pumps with the mechanical lift pump often have drama with the lift valves and prime pump-the old rodeo with a strainer on top of the engine mount......but iv had no luck adding an electric pump.i have now a good supply of pre pump strainers and have not copared life span yet but i like the steel wool strainer or john deer use.

in the inline pump on the outlet is a pressure releif valve--a few times i thown these across the floor and felt better when looking for the bits.you thunk tat if fuel is returning to the tank then it should go.

I ran into a issue with a potential carree move at work explaining to a learned gent that the loss of power and runout of fuel issue he had was very basic stuff that any moron could expect to occure-that he had over expectation of the system and after he finished making a mess he should clean up----i didnt get the promotion.

[rick130]

[snip]
I ran into a issue with a potential carree move at work explaining to a learned gent that the loss of power and runout of fuel issue he had was very basic stuff that any moron could expect to occure-that he had over expectation of the system and after he finished making a mess he should clean up----i didnt get the promotion.

Hahahaha, I like it.
How to win friends and influence people :D

I think this is why I work for myself, although I nearly tell customers this sort of stuff instead :angel:

[flagg]

Congratulations Mike!! I had the same prob with mine after a fuel lurgy. I had to pump the hand primer for a full 45min before it ran. My arm nearly fell off, and if it had i would have beaten myself to death with it out of frustration.

[Vern]

For some reason the fuel shut off is sprung in reverse:(. And a leaky injector. Fixing it now.. see how it goes:)

[mike_ie]

Any chance you've got the cutoff lever in the cutoff position? Its spring loaded to run (position closest to the engine block).

For some reason, as I only found out today, I seem to have an injector pump that is spring loaded to stop, not run :confused::confused::confused:

Have compared it to a couple of other injector pumps, including Damien's, and the spring on mine is a mirror image of all of the others. It's not just a case of simply flipping it upside down either, or something that's been chopped and changed, it's been manufactured like this. It's obviously not a big fix, just bizarre. Any ideas if some of the 4BD1 driven vehicles were set up in this way???

[Blknight.aus]

the original engine may be from an industrial application where the equipement is required to shutdown in the event of an emergancy or loss of control power.

[steveG]

Its too quiet on this thread - either Mike is catching up on sleep now its all done or is out doing laps of Gippsland with the Isuzu smile ;)

Whats it like to drive with the VNT and huge intercooler? Have you found a place to store the fuel screw yet :D

Steve

[Judo]

Have you found a place to store the fuel screw yet :D

Steve

:twisted:

Does "losing the screw" kill fuel economy much?

[Vern]

Its too quiet on this thread - either Mike is catching up on sleep now its all done or is out doing laps of Gippsland with the Isuzu smile ;)

Whats it like to drive with the VNT and huge intercooler? Have you found a place to store the fuel screw yet :D

Steveunless he's pushing it, he isn't doin laps anywhere:D

Although I require my shed back this weekend to prepare for a family holiday, so he better get a move on:p

It is running, just sorting the Turbo out, this would have to be one of the smoothest 4bd1's I heard.

[mike_ie]

Its too quiet on this thread - either Mike is catching up on sleep now its all done or is out doing laps of Gippsland with the Isuzu smile ;)

Whats it like to drive with the VNT and huge intercooler? Have you found a place to store the fuel screw yet :D

Steve

Mike is trying to stop oil coming out through the turbo at a rate of knots - have had to rebuild it twice so far. Finally looks to be sorted, I think - road there's a film of oil seeping past the turbine that I'm hoping is just residue from earlier. Engine does sound smooth though, if I do say so myself. Long overdue an update I know, but have been busy...

[justinc]

mike, how have you done the return line from the turbo oil feed? it needs to be on its own back to the sump not tee'd in to the alternator return.

jc

[steveG]

Mike is trying to stop oil coming out through the turbo at a rate of knots - have had to rebuild it twice so far. Finally looks to be sorted, I think - road there's a film of oil seeping past the turbine that I'm hoping is just residue from earlier. Engine does sound smooth though, if I do say so myself. Long overdue an update I know, but have been busy...

Bugger :(
Any idea what was causing the leak? There's not much to go wrong with the seals I wouldn't think unless one got damaged during assembly.
Its not a case of the drain being too small and causing the oil to back up inside the turbo like JC has reported in the past is it? Or too much oil supply (IIRC its a 1.6mm restriction that the journal bearing turbos need)?

Anyway, if that's the only thing left to sort out before its back on the road you're almost there!!

Steve

[Vern]

Jc, it runs back to that cover plate thingy below the side plate
(Oil pump drive cover perhaps)??, enlarged the fitting and seems to be OK, but has the pro vent drain it'd into it as well.

[Vern]

Bugger :(
Any idea what was causing the leak? There's not much to go wrong with the seals I wouldn't think unless one got damaged during assembly.
Its not a case of the drain being too small and causing the oil to back up inside the turbo like JC has reported in the past is it? Or too much oil supply (IIRC its a 1.6mm restriction that the journal bearing turbos need)?

Anyway, if that's the only thing left to sort out before its back on the road you're almost there!!

Steve

Turbo has new seals in it so shouldn't have a problem there. I just think the oil couldn't get away quick enough, and/or to much oil pressure.?. Interesting about the restricter though, better look into this one.

[steveG]

Turbo has new seals in it so shouldn't have a problem there. I just think the oil couldn't get away quick enough, and/or to much oil pressure.?. Interesting about the restricter though, better look into this one.

I can't find the source of that restrictor size, and Garrett are saying in this info that a restrictor isn't necessary unless oil pressure is excessive: http://www.turbobygarrett.com/turbobygarrett/sites/default/files/PDF/Garrett_Turbo_System_Optimization.pdf
There's some other good reading in there.

What size is the drain fitting back into the oil pump cover?

Steve

[justinc]

Jc, it runs back to that cover plate thingy below the side plate
(Oil pump drive cover perhaps)??, enlarged the fitting and seems to be OK, but has the pro vent drain it'd into it as well.

mmm, i'd remove the provent return and try it.

jc

[Vern]

I can't find the source of that restrictor size, and Garrett are saying in this info that a restrictor isn't necessary unless oil pressure is excessive: http://www.turbobygarrett.com/turbobygarrett/sites/default/files/PDF/Garrett_Turbo_System_Optimization.pdf
There's some other good reading in there.

What size is the drain fitting back into the oil pump cover?

Steve

At a guess, half inch

[steveG]

At a guess, half inch

Mine is only 3/8 BSP, and has no problems so if its at least that big it should be fine.
I'm assuming its a nice straight run from turbo straight down into the fitting on the oil pump cover? No hose loops or nasty angled fittings etc?

Any chance the small breather from the rocker cover is plumbed into the inlet manifold (pressurising the sump) as was the problem in this thread: http://www.aulro.com/afvb/isuzu-landy-enthusiasts-section/155311-oil-turbo-question-2.html

Steve

[mike_ie]

Mine is only 3/8 BSP, and has no problems so if its at least that big it should be fine.
I'm assuming its a nice straight run from turbo straight down into the fitting on the oil pump cover? No hose loops or nasty angled fittings etc?

Any chance the small breather from the rocker cover is plumbed into the inlet manifold (pressurising the sump) as was the problem in this thread: http://www.aulro.com/afvb/isuzu-landy-enthusiasts-section/155311-oil-turbo-question-2.html

Steve

From what I gathered, the turbo should be able to handle the 4BD1 oil pressure without being restricted, so should be okay there. I think the issue was with the oil return, bored it out and it's looking okay - certainly not getting the pints of oil shooting through the turbo that I got earlier. Getting a very, very slight film on the exhaust side of things but it looks to be residue that is being forced out - barely enough to put a smudge on a white cloth. I'll keep an eye on it, and but my bet would be that once the residue blows through, it'll be good.

[mike_ie]

mike, how have you done the return line from the turbo oil feed? it needs to be on its own back to the sump not tee'd in to the alternator return.

jc

sorry - on tablet pc so didn't see this earlier. Tapped into the cover plate as per your thread from a while back, 1/2" line from turbo with provent drain tee'd into it. Seems to be good now, as per above post.

[Dougal]

A turbo spitting oil is never the seals. It's either too much oil supply pressure or too high crankcase pressure. If you are that close that a rebuild kit made the difference, I would suspect you could be pushed back into problems quite easily.
Stock the 4BD1T has a turbo oil supply line maybe 70cm long which through internal friction drops the turbo oil supply pressure and flow to managable limits.
What is your breather setup?

[mike_ie]

A turbo spitting oil is never the seals. It's either too much oil supply pressure or too high crankcase pressure. If you are that close that a rebuild kit made the difference, I would suspect you could be pushed back into problems quite easily.
Stock the 4BD1T has a turbo oil supply line maybe 70cm long which through internal friction drops the turbo oil supply pressure and flow to managable limits.
What is your breather setup?

Dougal, it wasn't the turbo rebuild that made the difference, the issue seems to have been with the oil return - one of the fittings had a small bore and was restricting the return, causing a buildup of pressure. Bigger bore fitting, and and seems to have come good, but will keep an eye on it but I'm optimistic for now.

[Dougal]

Dougal, it wasn't the turbo rebuild that made the difference, the issue seems to have been with the oil return - one of the fittings had a small bore and was restricting the return, causing a buildup of pressure. Bigger bore fitting, and and seems to have come good, but will keep an eye on it but I'm optimistic for now.

Good to hear you found a real cause. How's progress?

[mike_ie]

Good to hear you found a real cause. How's progress?

Fine, now. Turbo certainly did give me an "oh ****" sinking feeling for a while though. Putting back in the fuel tank and hooking the battery up by means other than jump leads, connect up a few small but important bits like the steering column, and will hopefully take her for a run around the block

[mike_ie]

Took her for her first test run about ten minutes ago, nothing major, just up and down the road. You've no idea how good it feels to be behind the wheel of my own vehicle again.

Engine itself pulls like a train, there's quite a bit of vibration in the drive train that need to check out, and now the wiring under the bonnet needs to be tidied up. But for the first time I can actually say that the end is near.... :)

[goingbush]

Well done Mike,

whats the deal with the visa, can you continue on your Aussie travels ??


...... there's quite a bit of vibration in the drive train that need to check out, ......

vibration the same as when your driving a tractor ????
isn't that SOP for an isuzu :wasntme:

[tony66_au]

Took her for her first test run about ten minutes ago, nothing major, just up and down the road. You've no idea how good it feels to be behind the wheel of my own vehicle again.

Engine itself pulls like a train, there's quite a bit of vibration in the drive train that need to check out, and now the wiring under the bonnet needs to be tidied up. But for the first time I can actually say that the end is near.... :)


ITS ALIVE!
Congrats Mike, I thought it hadnt gone critical as I hadnt seen a huge plume of diesel smoke North east of me.

That said I havent had a Chugga chugga TOOT TOOT from any Deefers trundling past my place so I assume its still not 100%.

And if Vern hasn't pointed out my place yet its easy spotted because it looks like a 70's Mercedes dealership...........

[Landover]

ITS ALIVE!
Congrats Mike, I thought it hadnt gone critical as I hadnt seen a huge plume of diesel smoke North east of me.

That said I havent had a Chugga chugga TOOT TOOT from any Deefers trundling past my place so I assume its still not 100%.

And if Vern hasn't pointed out my place yet its easy spotted because it looks like a 70's Mercedes dealership...........


He's hit the road Tony. Last report was seen heading north from Eden. There is some info on the VNT Turbo tread. He has got it running but not at full power as it blows the intercooler hoses off. Needed to hit the road so had to make do.

Mike if your out there, a bit of an update would be nice. Hope it's all smiles.

[tony66_au]

Thanks David!

I was wondering if he got deported it had gone so quiet.

[tony66_au]

Disappeared into thin (Or fat) air has Mike?

No forum visits since May and zero updates...

Shame the story hasnt continued...

Cant have been eaten by a Croc, Bunyip attacks are a southern thing.... Too far east for the Milat Bro's.

Hmmm