91 Trooper (Back from the Dead)

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91 Trooper (Back from the Dead)

Postby :Andrew » Tue Jun 21, 2016 3:04 am

Hello everyone, I though I'd take the time to properly introduce myself on this board and share some pics of my 91 Trooper that I bought last September. Soon after I got the truck the head gasket blew and the fuel pump died. I considered selling it, but after some encouragement from some members on this board, I decided to stick with it and have the head gasket replaced. I am glad I did! These trucks are really fun to drive and work on. Since then I've done a lot of other work on it and it's now a pretty reliable vehicle. My goal is to set this truck up for mild overlanding-like trips and for it to be a reliable truck to use while doing fieldwork for my job.

I hope to update this thread from time to time.

What I have done so far:
4 new tires (Mastercraft Courser LTR)
Replaced all vacuum hoses
Replaced air filter
Replaced coolant and heater hoses
Replaced distributor cap and spark plugs, plug wires, and ignition coil
New timing belt and accessory belts
New fuel pump (Bosch)
Replaced crankshaft seal and cam seal
New Fel Pro head gasket, Fel Pro intake gasket, Fel Pro exhaust manifold gasket, water pump, thermostat, valve cover gasket
New flex pipe on exhaust
New EGR pipe
Replaced EGR valve
Replaced Fuel Pressure Regulator
Replaced PCV Valve
Front and Rear Monroe Sensa-Trac shocks
Energy Suspension front sway bar bushings and end links
Recently fixed the rear interior dome light using a mechanical pencil spring and a copper BB (haha, had to mention it!)

What's next:
Replace lower ball joints and tie rod ends
Roof basket

Here's some recent pics...
Image
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Last edited by :Andrew on Mon Feb 27, 2017 2:48 pm, edited 2 times in total.
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Re: 91 Trooper (Back from the Dead)

Postby DSUZU » Tue Jun 21, 2016 3:58 pm

Good pictures, nice looking country. How many miles since the head gasket? Have you re-torqued the head bolts yet? Dennis
1991 LS Trooper 2.8 V6 5 speed conversion (Sold)
1989 LS Spacecab 2.6 5 speed 4x4 manual hubs, Rodeo torsion bars, extended shackles, 2" lift, K&N airfilter (drop in), dump bed conversion, burgundy interior change, warn brush bar.
Previously owned: 1987 Trooper II LS, 1989 Trooper (parts only), 1994 Trooper 3.2 Auto, 1997 Rodeo 2.6 5 speed, 1993 shortbed pickup 2.3 (project - sold) 1992 Rodeo 4x4 LS (parts car, devoured by Spacecab needs) plus some 70 plus other non Isuzu vehicles over the years.

http://forum.planetisuzoo.com/viewtopic.php?f=15&t=64060

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Re: 91 Trooper (Back from the Dead)

Postby :Andrew » Tue Jun 21, 2016 5:19 pm

Thanks. I've put about 400 miles on it since the head gasket replacement. I have not re-torqued the head bolts yet. I was planning to do it at 500.
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Re: 91 Trooper (Back from the Dead)

Postby DSUZU » Tue Jun 21, 2016 8:47 pm

1.000 is the recommended. To little and it may have not gone through enough heat and cool cycles. Too much 9like not at all) is inviting a future failure. Also check valve adjustment, but wait until 1,000 miles. Dennis
1991 LS Trooper 2.8 V6 5 speed conversion (Sold)
1989 LS Spacecab 2.6 5 speed 4x4 manual hubs, Rodeo torsion bars, extended shackles, 2" lift, K&N airfilter (drop in), dump bed conversion, burgundy interior change, warn brush bar.
Previously owned: 1987 Trooper II LS, 1989 Trooper (parts only), 1994 Trooper 3.2 Auto, 1997 Rodeo 2.6 5 speed, 1993 shortbed pickup 2.3 (project - sold) 1992 Rodeo 4x4 LS (parts car, devoured by Spacecab needs) plus some 70 plus other non Isuzu vehicles over the years.

http://forum.planetisuzoo.com/viewtopic.php?f=15&t=64060

The American dream is getting farther and farther away from the American.

If your wife has 5.00, and you have 20.00, your wife has...25.00

"Water is one of the greatest essentials of life. Without water, you can't make coffee."
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Re: 91 Trooper (Back from the Dead)

Postby RickP » Tue Jun 21, 2016 10:16 pm

Looking great. Glad to see you didn't give up.
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Re: 91 Trooper (Back from the Dead)

Postby chuffer » Tue Jun 21, 2016 11:47 pm

Good looking truck.
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Re: 91 Trooper (Back from the Dead)

Postby :Andrew » Tue Jun 21, 2016 11:52 pm

DSUZU wrote:1.000 is the recommended. To little and it may have not gone through enough heat and cool cycles. Too much 9like not at all) is inviting a future failure. Also check valve adjustment, but wait until 1,000 miles. Dennis

Thanks!
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Re: 91 Trooper (Back from the Dead)

Postby :Andrew » Tue Jun 21, 2016 11:58 pm

RickP wrote:Looking great. Glad to see you didn't give up.

Me too. Hopefully I can do some fun stuff now.
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Re: 91 Trooper (Back from the Dead)

Postby 6caver » Wed Jun 22, 2016 10:48 am

Great looking truck! What size tires are you running?
89 Isuzu Trooper S 4ZE1 5-Speed, Intermittent Wiper Switch Upgrade, Cruise Control Upgrade, Round Headlight Conversion, Added A/C, Aisin hubs

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Re: 91 Trooper (Back from the Dead)

Postby :Andrew » Wed Jun 22, 2016 10:58 am

6caver wrote:Great looking truck! What size tires are you running?

Thanks! 235/75/15
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Re: 91 Trooper (Back from the Dead)

Postby 6caver » Wed Jun 22, 2016 11:01 am

Thanks! They look good!
89 Isuzu Trooper S 4ZE1 5-Speed, Intermittent Wiper Switch Upgrade, Cruise Control Upgrade, Round Headlight Conversion, Added A/C, Aisin hubs

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Re: 91 Trooper (Back from the Dead)

Postby :Andrew » Fri Jul 22, 2016 11:53 am

I finally put new shocks on the back of the truck. The old ones were shot. These Monroe shocks ride pretty good for being so cheap. I think one day I might upgrade to a set of Bilsteins or Old Man Emus but these shocks are definitely fine for now and much better than what was on there.

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I also repainted the lower black trim. It turned out great, but I'll have to try and get a better "after" picture.
28413820255_4b4275729d_o - Copy.jpg



Unfortunately, I now have a larger problem to deal with. This past weekend while driving out to go camping, the truck developed a really bad oil leak. I was adding about half a quart every 100 miles. When I looked underneath the truck there was oil everywhere, all the way to the back of the rear bumper. I have yet to get under there and clean it up to check it out and see where it is coming for certain, but when I looked briefly the other day, I saw that it is almost definitely coming from the rear main seal. Unless it's a reaaally bad oil pan leak, but I think that is just wishful thinking.
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Re: 91 Trooper (Back from the Dead)

Postby :Andrew » Wed Jan 11, 2017 1:24 am

Last week I installed Energy Suspension bushings and end links on the front sway bar. I have always been hesitant to try these bushings on my vehicles for various reasons, but I am impressed. It made a significant difference in how the truck handles. It made the refrigerator on wheels handle much better!

I apologize for the poor quality photos. It was 15 degrees and I don't think my camera liked it.

Before:
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31692667420_8423c5ffe7_o.jpg


After:
31692659080_429ff2061c_o.jpg
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Re: 91 Trooper (Back from the Dead)

Postby itsmehb » Wed Jan 11, 2017 9:31 am

Unfortunately, I now have a larger problem to deal with. This past weekend while driving out to go camping, the truck developed a really bad oil leak. I was adding about half a quart every 100 miles. When I looked underneath the truck there was oil everywhere, all the way to the back of the rear bumper. I have yet to get under there and clean it up to check it out and see where it is coming for certain, but when I looked briefly the other day, I saw that it is almost definitely coming from the rear main seal. Unless it's a reaaally bad oil pan leak, but I think that is just wishful thinking.

Nice looking truck. Too bad about the oil leak. I never did the rear seal on mine so can't comment, but it's a mess to deal with, especially with our weather so cold. On your front suspension, it's probably best to do it all at once rather than piece by piece. Not too much more, and then you only have to deal with the alignment one time.
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Re: 91 Trooper (Back from the Dead)

Postby RickP » Wed Jan 11, 2017 12:52 pm

I desperately need new shocks, also. Did you ever figure out your oil leak?
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Re: 91 Trooper (Back from the Dead)

Postby :Andrew » Wed Jan 11, 2017 5:09 pm

itsmehb wrote:Nice looking truck. Too bad about the oil leak. I never did the rear seal on mine so can't comment, but it's a mess to deal with, especially with our weather so cold. On your front suspension, it's probably best to do it all at once rather than piece by piece. Not too much more, and then you only have to deal with the alignment one time.


Yes, I actually have several new suspension parts to put on but I'm not doing anything else until the snow melts.
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Re: 91 Trooper (Back from the Dead)

Postby :Andrew » Wed Jan 11, 2017 5:14 pm

RickP wrote:I desperately need new shocks, also. Did you ever figure out your oil leak?


I did figure it out. It's coming from the rear main seal but the good news is it is not near as bad as I thought it was. That repair will definitely have to wait until it gets warmer.
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