Nasty's Trooper Project

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Re: Nasty's Trooper Project

Postby nasty610 » Fri Aug 28, 2015 11:58 am

I understand everything can be done with enough money but I try to keep things as cheap and easy as possible. The main reason for that is there's quite a few guys on this forum that are on tight budgets. Keeping it cheap makes it easier for some of the other guys to follow in my foot steps. I also try to use OE parts as much as possible. The OEM's spend millions on R&D to make parts that survive so I'd be a fool to try cobbling something together that will fail at the worst time. So in the end if this is going to require custom fabrication to make it work correctly I'll probably scrap the project in favor of something that will bolt together.
1996 Isuzu Trooper Base model
Front t-bar crank, Rear lifted with 1st gen Grand Cherokee Coils, Cooper Discovery AT3 265/75R16
1991 Trooper Base Model
HD Sway-a-Way torsion bars, Sweet Camo Paint(adds 50 hp), Snowflakes w/ Firestone Destination LE2 265/75r16
Lift Coil Spring Options
Add-a-Leaf kits and Part Numbers
Longer Shocks for your Lifted Isuzu

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Re: Nasty's Trooper Project

Postby nasty610 » Sun Aug 30, 2015 3:22 pm

Just a quick update. I was going to finish buttoning up the engine until I realized the M8 bolts ARE NOT included in the head bolt kit I bought. When I looked in the manual it states to reuse the M8 and replace the m12. Wish I'd seen that earlier. I have 5 of the 6 bolts somewhere but the last one had to be drilled out when I removed the heads. So I'm either going to hit up Jerry for new ones or see if I can source a bolt locally that will work.
1996 Isuzu Trooper Base model
Front t-bar crank, Rear lifted with 1st gen Grand Cherokee Coils, Cooper Discovery AT3 265/75R16
1991 Trooper Base Model
HD Sway-a-Way torsion bars, Sweet Camo Paint(adds 50 hp), Snowflakes w/ Firestone Destination LE2 265/75r16
Lift Coil Spring Options
Add-a-Leaf kits and Part Numbers
Longer Shocks for your Lifted Isuzu

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Re: Nasty's Trooper Project

Postby nasty610 » Tue Feb 09, 2016 12:21 pm

So last week I went ahead and temp installed the heads. The reason I say temp install is because I didn't have the M8 bolts yet. It's a good thing I didn't torque anything down because I found the locating dowels when I was searching for another part. The dowels are small spring clips that insert into the block to line the head up correctly to the block. Not having them in isn't necessarily going to cause damage but they are there for a reason. It's pretty easy to see where they go because the the holes are enlarged for them to fit.

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1996 Isuzu Trooper Base model
Front t-bar crank, Rear lifted with 1st gen Grand Cherokee Coils, Cooper Discovery AT3 265/75R16
1991 Trooper Base Model
HD Sway-a-Way torsion bars, Sweet Camo Paint(adds 50 hp), Snowflakes w/ Firestone Destination LE2 265/75r16
Lift Coil Spring Options
Add-a-Leaf kits and Part Numbers
Longer Shocks for your Lifted Isuzu
nasty610
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Re: Nasty's Trooper Project

Postby nasty610 » Tue Feb 09, 2016 12:26 pm

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1996 Isuzu Trooper Base model
Front t-bar crank, Rear lifted with 1st gen Grand Cherokee Coils, Cooper Discovery AT3 265/75R16
1991 Trooper Base Model
HD Sway-a-Way torsion bars, Sweet Camo Paint(adds 50 hp), Snowflakes w/ Firestone Destination LE2 265/75r16
Lift Coil Spring Options
Add-a-Leaf kits and Part Numbers
Longer Shocks for your Lifted Isuzu
nasty610
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Re: Nasty's Trooper Project

Postby nasty610 » Tue Feb 09, 2016 12:42 pm

I got a quick picture of the intake port that looked the best. There's lots of room for improvement on these heads. Unfortunately I don't have the time or place to do it anymore. I forgot to get a picture of the exhaust side but they don't look any better. These are the 92-95 DOHC heads. If I had to make an educated guess the big performance gain these heads have over the SOHC is the bump in compression.
92-95 SOHC 9.3:1
92-95 DOHC 9.8:1
96-97 SOHC 9.0:1
Wish I'd taken some measurement before I bolted the heads on. Between the cylinder bore increase and heads being decked I should end up somewhere between 9.9:1 and 10:1.
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1996 Isuzu Trooper Base model
Front t-bar crank, Rear lifted with 1st gen Grand Cherokee Coils, Cooper Discovery AT3 265/75R16
1991 Trooper Base Model
HD Sway-a-Way torsion bars, Sweet Camo Paint(adds 50 hp), Snowflakes w/ Firestone Destination LE2 265/75r16
Lift Coil Spring Options
Add-a-Leaf kits and Part Numbers
Longer Shocks for your Lifted Isuzu
nasty610
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Re: Nasty's Trooper Project

Postby bradzuzu » Sat Feb 13, 2016 4:42 pm

You've been having a little bit of fun I see .. I wonder if you'll have any pining issues ?

Good to see you messing around with stuff :)
91 amigo sas toy front leaf- traded off :(
2000 amigo sas d44 wagonear 4 link
custom built buggy ffor the dirty stuff

My build up page
Four link pics
Intake R&R - port and polish

Sometimes trying is all you can do, but when you succeed , that's something to be proud of...
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Re: Nasty's Trooper Project

Postby nasty610 » Sat Feb 13, 2016 7:22 pm

I'm really not sure what I'll do if it does ping. The PCM will pull timing until the knock goes away but I'll loose quite of power that way. If I crank the fuel pressure the PCM will shorten the pulse width to keep the AF/R to stock levels.
1996 Isuzu Trooper Base model
Front t-bar crank, Rear lifted with 1st gen Grand Cherokee Coils, Cooper Discovery AT3 265/75R16
1991 Trooper Base Model
HD Sway-a-Way torsion bars, Sweet Camo Paint(adds 50 hp), Snowflakes w/ Firestone Destination LE2 265/75r16
Lift Coil Spring Options
Add-a-Leaf kits and Part Numbers
Longer Shocks for your Lifted Isuzu
nasty610
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Re: Nasty's Trooper Project

Postby bradzuzu » Sat Feb 13, 2016 9:49 pm

After all the messing around with mine I notice the areas that the system goes into open loop or just enrichens itself at higher rpms ... For instance lite throttle up past 3500 it will drop to 13.1 afr out of boost but that's ideal to be able to step down more ... Also you could always install atoning retarder , I think you can find something basic for less money than the fic6 I'm using ...
91 amigo sas toy front leaf- traded off :(
2000 amigo sas d44 wagonear 4 link
custom built buggy ffor the dirty stuff

My build up page
Four link pics
Intake R&R - port and polish

Sometimes trying is all you can do, but when you succeed , that's something to be proud of...
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Re: Nasty's Trooper Project

Postby 5009TWI » Fri Oct 28, 2016 10:43 pm

Hey Nasty, have you made any more progress with the rebuild? I remember you had issues with the distance after moving.

I got everything started with my project and then suddenly got a job offer in another city; have barely had any opportunities to make progress each time I go back to my folks' house where the Trooper had been during these months. Finally making time this weekend.
1992 Amigo S 2WD 4ZE1 5spd "Pequeña Blanca" Went on the hunt for a sensible, practical commuter car and instead I ended up buying this.

1997 Trooper S-Pep 5spd "Midori" Project car; engine rebuild currently on pause due to new job across the country.

1990 GMC Suburban R1500 SLE 350TBI "Regina" Daily driver from 2005 all the way until I bought the Trooper in 2015. Has resumed a well-deserved long nap until I can throw in an LQ4 & T56.
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Re: Nasty's Trooper Project

Postby nasty610 » Fri Oct 28, 2016 11:00 pm

I've made a little progress. At this point I need to pull the old engine and swap all the external parts over. One of these days I'll pull it in the shop and get it done.
1996 Isuzu Trooper Base model
Front t-bar crank, Rear lifted with 1st gen Grand Cherokee Coils, Cooper Discovery AT3 265/75R16
1991 Trooper Base Model
HD Sway-a-Way torsion bars, Sweet Camo Paint(adds 50 hp), Snowflakes w/ Firestone Destination LE2 265/75r16
Lift Coil Spring Options
Add-a-Leaf kits and Part Numbers
Longer Shocks for your Lifted Isuzu
nasty610
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Re: Nasty's Trooper Project

Postby 5009TWI » Sat Oct 29, 2016 2:04 am

Good to hear. My new job uses CAD software so I've been playing around with the idea of designing some timing covers with a slot for the cam sensor, then finding a 3D printing service to produce them.
1992 Amigo S 2WD 4ZE1 5spd "Pequeña Blanca" Went on the hunt for a sensible, practical commuter car and instead I ended up buying this.

1997 Trooper S-Pep 5spd "Midori" Project car; engine rebuild currently on pause due to new job across the country.

1990 GMC Suburban R1500 SLE 350TBI "Regina" Daily driver from 2005 all the way until I bought the Trooper in 2015. Has resumed a well-deserved long nap until I can throw in an LQ4 & T56.
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Re: Nasty's Trooper Project

Postby nasty610 » Fri Nov 25, 2016 8:03 pm

Wednesday I finally pulled the trooper into the shop for the engine swap. Not sure how you guys pull these engines in a driveway. I used a lift and this is probably the worst engine I've pulled in awhile. To be honest though I'm usually pulling BMW or VW/Audi engines. Anyways not a lot of pictures because I was by myself.

Spent a couple hours Wednesday pulling the manifold and driveshafts out. Really I screwed off for the most part and turned 45 minutes of work in a few hours.

Went back to the shop on Thursday and pulled the transmission and transfer case. I ended up pulling them as a unit without removing the exhaust. I have custom exhaust so I'm not sure if you do that with stock exhaust. Think this took me all of 3 hours. I kept forgetting to disconnect stuff like the shifter.

Friday I pulled the engine. Talk about a pain in the butt to do by yourself. There's so many little things tucked in ridiculous places and when the engine is coated in a mud/sand/oil mix you can't find anything. I ended up taking the tires off and setting it on the ground to make it easy to clear the radiator.

IMG_1110.JPG

IMG_1119.JPG

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1996 Isuzu Trooper Base model
Front t-bar crank, Rear lifted with 1st gen Grand Cherokee Coils, Cooper Discovery AT3 265/75R16
1991 Trooper Base Model
HD Sway-a-Way torsion bars, Sweet Camo Paint(adds 50 hp), Snowflakes w/ Firestone Destination LE2 265/75r16
Lift Coil Spring Options
Add-a-Leaf kits and Part Numbers
Longer Shocks for your Lifted Isuzu
nasty610
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Re: Nasty's Trooper Project

Postby nasty610 » Fri Nov 25, 2016 8:28 pm

Some shots of the engine coming out. Tomorrow a friend from work is going to make me a bracket for the cam sensor. Hopefully I can have this thing up and running tomorrow sometime.
IMG_1117.JPG

IMG_1120.JPG

IMG_1121.JPG

IMG_1123.JPG
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1996 Isuzu Trooper Base model
Front t-bar crank, Rear lifted with 1st gen Grand Cherokee Coils, Cooper Discovery AT3 265/75R16
1991 Trooper Base Model
HD Sway-a-Way torsion bars, Sweet Camo Paint(adds 50 hp), Snowflakes w/ Firestone Destination LE2 265/75r16
Lift Coil Spring Options
Add-a-Leaf kits and Part Numbers
Longer Shocks for your Lifted Isuzu
nasty610
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Posts: 1960
Joined: Thu Aug 08, 2013 10:07 pm
Location: Fayetteville, NC
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Re: Nasty's Trooper Project

Postby 5009TWI » Sat Nov 26, 2016 7:35 pm

Woohoo! Good luck! Extremely interested in seeing how y'all approach the sensor holder design.
1992 Amigo S 2WD 4ZE1 5spd "Pequeña Blanca" Went on the hunt for a sensible, practical commuter car and instead I ended up buying this.

1997 Trooper S-Pep 5spd "Midori" Project car; engine rebuild currently on pause due to new job across the country.

1990 GMC Suburban R1500 SLE 350TBI "Regina" Daily driver from 2005 all the way until I bought the Trooper in 2015. Has resumed a well-deserved long nap until I can throw in an LQ4 & T56.
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Re: Nasty's Trooper Project

Postby nasty610 » Sat Nov 26, 2016 8:51 pm

Doesn't seem like a lot happened today. Basically spent the entire day pulling parts from the old motor, cleaning them and then installing them. Lots of really dirty parts on the old engine.

My buddy in the photo is going to make the bracket. We talked and agreed a piece of bar stock bent to mount on the existing cover holes should be plenty strong.

Ended up going to Pepboys to find the 2 bolt exhaust flange. Damn things were $25 each because they are stainless. Really wish I could have found some cheaper ones but I want this engine in place tomorrow.

I was seriously considering not pulling the coolant supply pipe from the cylinder crossover pipe. In the end I figured I would since the rest of the o-rings were basically plastic and crumbling. Glad I did because the o-ring was completely flat and cracked when I touched it with a pick.

Not sure why the first pic is upside down. I didn't take it that way and it doesn't show up like that on my phone.

IMG_1130.JPG

IMG_1127.JPG

IMG_1126.JPG

IMG_1129.JPG

IMG_1128.JPG
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1996 Isuzu Trooper Base model
Front t-bar crank, Rear lifted with 1st gen Grand Cherokee Coils, Cooper Discovery AT3 265/75R16
1991 Trooper Base Model
HD Sway-a-Way torsion bars, Sweet Camo Paint(adds 50 hp), Snowflakes w/ Firestone Destination LE2 265/75r16
Lift Coil Spring Options
Add-a-Leaf kits and Part Numbers
Longer Shocks for your Lifted Isuzu
nasty610
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Re: Nasty's Trooper Project

Postby bradzuzu » Wed Nov 30, 2016 4:42 pm

I swear that pulling and cleaning parts part is the most agonizing time consuming job !!
I hope you get it all put back together and running with minimal issues ...
91 amigo sas toy front leaf- traded off :(
2000 amigo sas d44 wagonear 4 link
custom built buggy ffor the dirty stuff

My build up page
Four link pics
Intake R&R - port and polish

Sometimes trying is all you can do, but when you succeed , that's something to be proud of...
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Re: Nasty's Trooper Project

Postby nasty610 » Wed Nov 30, 2016 9:00 pm

Well I wanted it together this past weekend but ran into a couple snags though. Main one was my buddy wanted to work on his Harley while he helped me with the Trooper. Then he screwed up the bracket entirely. The other issue is the exhaust manifolds. The OBD1 manifolds dump almost straight down where as the OBD2 manifolds dump at more lik 45 degrees.
1996 Isuzu Trooper Base model
Front t-bar crank, Rear lifted with 1st gen Grand Cherokee Coils, Cooper Discovery AT3 265/75R16
1991 Trooper Base Model
HD Sway-a-Way torsion bars, Sweet Camo Paint(adds 50 hp), Snowflakes w/ Firestone Destination LE2 265/75r16
Lift Coil Spring Options
Add-a-Leaf kits and Part Numbers
Longer Shocks for your Lifted Isuzu
nasty610
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Re: Nasty's Trooper Project

Postby 5009TWI » Mon Dec 19, 2016 1:46 am

Regarding the manifolds, i remember Jerry and i spent a lot of time going back and forth in our PM conversation. It all centered around, "As i move downstream along the exhaust system, at what point do i no longer need to use new (i.e. DOHC) parts, and simply have to fab a connector or a bend to meet up with the remainder of the original exhaust system?" I take it that's where you're at now?

How are things looking, otherwise?
1992 Amigo S 2WD 4ZE1 5spd "Pequeña Blanca" Went on the hunt for a sensible, practical commuter car and instead I ended up buying this.

1997 Trooper S-Pep 5spd "Midori" Project car; engine rebuild currently on pause due to new job across the country.

1990 GMC Suburban R1500 SLE 350TBI "Regina" Daily driver from 2005 all the way until I bought the Trooper in 2015. Has resumed a well-deserved long nap until I can throw in an LQ4 & T56.
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Re: Nasty's Trooper Project

Postby nasty610 » Tue Dec 20, 2016 1:20 pm

I'm just about done. Need to buy some high pressure hose to connect the trans cooler since I ripped one. I have to either buy a larger step bit or use a grinder to finish enlarging the hole for my cam sensor. After that it's just fluids and the exhaust. Honestly the exhaust is one of the simplest parts. The DOHC manifolds dump almost straight down so you just need a 2" 2 bolt flange and a single bend to connect to your cats. Don't waste your time buying new parts or anything like that. Just get it all installed and to an exhaust shop. Should be fairly cheap to fab up what's needed.
1996 Isuzu Trooper Base model
Front t-bar crank, Rear lifted with 1st gen Grand Cherokee Coils, Cooper Discovery AT3 265/75R16
1991 Trooper Base Model
HD Sway-a-Way torsion bars, Sweet Camo Paint(adds 50 hp), Snowflakes w/ Firestone Destination LE2 265/75r16
Lift Coil Spring Options
Add-a-Leaf kits and Part Numbers
Longer Shocks for your Lifted Isuzu
nasty610
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Re: Nasty's Trooper Project

Postby 5009TWI » Wed Dec 21, 2016 5:32 pm

All good to hear. I never realized your Trooper was green. I think the gray trim on your's looks a lot better than the platinum-ish trim on mine.

If you have some time, feel free to post closeup photos of the sensor holder and also your method for securing the coils to the valve covers. They will be much appreciated!
1992 Amigo S 2WD 4ZE1 5spd "Pequeña Blanca" Went on the hunt for a sensible, practical commuter car and instead I ended up buying this.

1997 Trooper S-Pep 5spd "Midori" Project car; engine rebuild currently on pause due to new job across the country.

1990 GMC Suburban R1500 SLE 350TBI "Regina" Daily driver from 2005 all the way until I bought the Trooper in 2015. Has resumed a well-deserved long nap until I can throw in an LQ4 & T56.
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Re: Nasty's Trooper Project

Postby nasty610 » Thu Dec 22, 2016 7:26 am

I'll get some pictures when I go back to the shop.
1996 Isuzu Trooper Base model
Front t-bar crank, Rear lifted with 1st gen Grand Cherokee Coils, Cooper Discovery AT3 265/75R16
1991 Trooper Base Model
HD Sway-a-Way torsion bars, Sweet Camo Paint(adds 50 hp), Snowflakes w/ Firestone Destination LE2 265/75r16
Lift Coil Spring Options
Add-a-Leaf kits and Part Numbers
Longer Shocks for your Lifted Isuzu
nasty610
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Posts: 1960
Joined: Thu Aug 08, 2013 10:07 pm
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Re: Nasty's Trooper Project

Postby nasty610 » Sun Jan 01, 2017 10:31 am

Here's a picture of the bracket I made. It looks like crap and I plan to build a much nicer one once I make sure it works. Going to be a bit before I find out if it's right though. I was under the truck finishing some stuff up when I noticed coolant dropping from the oil drain plug. I check cylinder 4 and it's full of coolant. Not sure how but my head gaskets are leaking. One is OEM and the other is Fel-Pro. Hopefully it's just a bad gasket because if the heads are damaged this truck is going to the scrap yard. I'll know in a few weeks.

IMG_1176.JPG
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1996 Isuzu Trooper Base model
Front t-bar crank, Rear lifted with 1st gen Grand Cherokee Coils, Cooper Discovery AT3 265/75R16
1991 Trooper Base Model
HD Sway-a-Way torsion bars, Sweet Camo Paint(adds 50 hp), Snowflakes w/ Firestone Destination LE2 265/75r16
Lift Coil Spring Options
Add-a-Leaf kits and Part Numbers
Longer Shocks for your Lifted Isuzu
nasty610
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Posts: 1960
Joined: Thu Aug 08, 2013 10:07 pm
Location: Fayetteville, NC
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Re: Nasty's Trooper Project

Postby 5009TWI » Sun Jan 01, 2017 4:05 pm

Yeah I remember you describing getting the heads redone as a pretty big headache. Fingers crossed then; good luck!
1992 Amigo S 2WD 4ZE1 5spd "Pequeña Blanca" Went on the hunt for a sensible, practical commuter car and instead I ended up buying this.

1997 Trooper S-Pep 5spd "Midori" Project car; engine rebuild currently on pause due to new job across the country.

1990 GMC Suburban R1500 SLE 350TBI "Regina" Daily driver from 2005 all the way until I bought the Trooper in 2015. Has resumed a well-deserved long nap until I can throw in an LQ4 & T56.
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Re: Nasty's Trooper Project

Postby bradzuzu » Tue Jan 10, 2017 1:23 am

Oh what !! That's not cool , have you pulled the heads off yet ?
91 amigo sas toy front leaf- traded off :(
2000 amigo sas d44 wagonear 4 link
custom built buggy ffor the dirty stuff

My build up page
Four link pics
Intake R&R - port and polish

Sometimes trying is all you can do, but when you succeed , that's something to be proud of...
User avatar
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Re: Nasty's Trooper Project

Postby 5009TWI » Tue Jan 10, 2017 2:28 am

Brad: No, what I was referring to (if I'm remembering correctly) was during his teardown of the old motor he sent off the heads to be rebuilt and the shop either left one of the parts out or installed something incorrectly.

Nasty: Any luck with the coolant leak, or are you still waiting to find out? I can't imagine how frustrated you were after a year of work...
1992 Amigo S 2WD 4ZE1 5spd "Pequeña Blanca" Went on the hunt for a sensible, practical commuter car and instead I ended up buying this.

1997 Trooper S-Pep 5spd "Midori" Project car; engine rebuild currently on pause due to new job across the country.

1990 GMC Suburban R1500 SLE 350TBI "Regina" Daily driver from 2005 all the way until I bought the Trooper in 2015. Has resumed a well-deserved long nap until I can throw in an LQ4 & T56.
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