[lowzone]

LOL....28.00 shipping!!! i just went to order one so i could have a new one on my 95 Pickup in NC...... 83.86 for ONE....if i ordered 6, it was only slightly higher.

 

[lowzone]

must be coming in from Japan for that much. if they still have them, i might pick up a few. Couple years when they are no longer available...BUAHAHAHHAHAHAHAA

 

[MrDunge]

So worked for a couple hours last night. Notched out the manifold mounting plate and the bolts slipped in no problem.

Had to flip the injectors w the plug facing down. Why. Bc the thermostat housing wouldn't fit w them the other way.

Still deciding how I want to route the way to long oil feed line. But may just go around the back of the head.

Lots Still to do. But one step closer.

 

[Shift-1]

So worked for a couple hours last night. Notched out the manifold mounting plate and the bolts slipped in no problem.

Had to flip the injectors w the plug facing down. Why. Bc the thermostat housing wouldn't fit w them the other way.

Still deciding how I want to route the way to long oil feed line. But may just go around the back of the head.

Lots Still to do. But one step closer.

Is the oil line regular Steel Braided line? Any reason why it cannot be shortened with a new AN fitting?

 

[MrDunge]

Is the oil line regular Steel Braided line? Any reason why it cannot be shortened with a new AN fitting?

Yea it's braided with crimped fittings on the end. Honestly I've been looking at it and it may be best that way so I can make sure it doesn't get to close to the exhaust manifold

 

[MrDunge]

Important update

So more progress on the build however I ran into a problem. Where I put the oil return bung in the oil pan isn't going to work. I put it next to the oil dipstick.

The reason it won't work is because when you fill it full of oil it will actually fill into the bung high enough to almost run out. I didn't realize that the oil went that far up in the lower pan. This will block the oil going back into the engine and back oil into the turbo which will create pressure on the return side and blow the seals.

Luckily I have another upper oil pan to work with and after looking at it Ill have to go into the driver side a least half way forward and nearer to where the block meets the pan to make sure that there is free oil flow back into the engine.

Just a bump in the road. Unfortunately the oil pan I have is coated in grease that used to be oil inside and out so a deep clean and paint will be needed.

 

[Dragon22re]

Important update

So more progress on the build however I ran into a problem. Where I put the oil return bung in the oil pan isn't going to work. I put it next to the oil dipstick.

The reason it won't work is because when you fill it full of oil it will actually fill into the bung high enough to almost run out. I didn't realize that the oil went that far up in the lower pan. This will block the oil going back into the engine and back oil into the turbo which will create pressure on the return side and blow the seals.

Luckily I have another upper oil pan to work with and after looking at it Ill have to go into the driver side a least half way forward and nearer to where the block meets the pan to make sure that there is free oil flow back into the engine.

Just a bump in the road. Unfortunately the oil pan I have is coated in grease that used to be oil inside and out so a deep clean and paint will be needed.

Not sure if I am just seeing things, but it looks like that lower crankshaft pulley is backwards. The fixed shoulder should be facing away from the oil seal retainer. I do not want you to have the same problem I did.

 

[MrDunge]

Not sure if I am just seeing things, but it looks like that lower crankshaft pulley is backwards. The fixed shoulder should be facing away from the oil seal retainer. I do not want you to have the same problem I did.

Good catch and you are correct. I need to flip it. Lesson for the day. Don't work on your stuff dog tired.

 

[Shift-1]

Yea it's braided with crimped fittings on the end. Honestly I've been looking at it and it may be best that way so I can make sure it doesn't get to close to the exhaust manifold

could it be run around the front of the motor and cable mounted to various bolts along the way?

 

[GenOner]

I noticed in a pic you're running EGR, is this not an issue at higher RPM turbo boost?

 

[MrDunge]

I noticed in a pic you're running EGR, is this not an issue at higher RPM turbo boost?

So I have run w/o a EGR since I had the Trooper, like 10 years. After speaking w Billy and Jerry about it, they both recommended I use the EGR again. Billy had pinging under load when he had his removed and after he reinstalled it went away. After that conversation i decided to run EGR and monitor the a/f after install and see what the numbers look like. I can always take the tube off and plug the holes after the fact much easier than reinstall everything once back in the truck. I still have more research to do on if a check valve may be needed for the concern you mentioned.

 

[MrDunge]

Latest update.
I redid the oil pan drain return for the turbo I am much happier with the location and the fact the oil will drain freely into the pan. a couple of pics show what I did

I also got the egr tube attached which was a PIA I used copper pipe to splice in, and multiple high strength hose clamps to hopefully keep it from leaking. At this point if it does a little idk if I will really care lol

I also mocked up the exhaust @TonkaToy is going to come next weekend and weld it up, since I plan on dropping the engine in the trooper then.

Installed some hood louvers in the hood to help w heat trapping,stainless steel, I think they ended up nice.

Next post will be the intercooler install since I can only post so many pics per post

 

[MrDunge]

Ok so the intercooler. This was interesting since I decided to use a bigger cooler. It barely fit and there was "some cutting" involved. Its tight but it fits and I get to keep A/C. I had to cut out the center of the grill but it will fit back on the front. I have some black mesh coming to fill in the hole and so i can put my Isuzu badge back on.

Got a power steering cooler as well. I have a Lokka locker in the front and when I wheel hard in 4Lo with alot of wheel turning my power steering fluid will get so hot that it will almost boil in the resv. Hopefully this will mitigate that.

Mocked in the gauge pods and ran everything, I need to hook the wiring but at least it through the firewall and ran the correct lengths.

I am hoping to get it running within the next couple of weekends, wish me luck and if any questions feel free to ask

 

[lorenzo816]

man i wish i had a pic of that block after I olympic deadlifted that sob in the back of the mega. Sucker has come a long way.
sidenote, yes I got some floor for you. Melissa may have a timing cover. If not, i can check the 2.3 we have.
and bad Brad Blake is busy staying off the sosh meeds. He hasn't been on fb much either. Me and another guy have a msgr chat still goin that goes back a few years, sooo yea he's alive and well.

and I'm just gonna say you're not gonna finish it before the spring ride just so you will get your butt in double time and get it done. Unlike my schizo multi project havin a55.
that reminds me I might need to post up my project progress

 

[Enemigo]

Looks like the FMIC is up high enough that you could still fit a winch on there.

EDIT: Looks like you've already got one up front.

 

[MrDunge]

man i wish i had a pic of that block after I olympic deadlifted that sob in the back of the mega. Sucker has come a long way.
sidenote, yes I got some floor for you. Melissa may have a timing cover. If not, i can check the 2.3 we have.
and bad Brad Blake is busy staying off the sosh meeds. He hasn't been on fb much either. Me and another guy have a msgr chat still goin that goes back a few years, sooo yea he's alive and well.

and I'm just gonna say you're not gonna finish it before the spring ride just so you will get your butt in double time and get it done. Unlike my schizo multi project havin a55.
that reminds me I might need to post up my project progress

Tony sent me a lower cover. Pretzel is sending me that piece of metal. You on the other hand are the one who won't be finished for uwharrie and you'll have to witness my awesome from the passenger seat of Paul's rig lmao

 

[GenOner]

Latest update.
I redid the oil pan drain return for the turbo I am much happier with the location and the fact the oil will drain freely into the pan. a couple of pics show what I did

I also got the egr tube attached which was a PIA I used copper pipe to splice in, and multiple high strength hose clamps to hopefully keep it from leaking. At this point if it does a little idk if I will really care lol

I also mocked up the exhaust @TonkaToy is going to come next weekend and weld it up, since I plan on dropping the engine in the trooper then.

Installed some hood louvers in the hood to help w heat trapping,stainless steel, I think they ended up nice.

Next post will be the intercooler install since I can only post so many pics per post

Nice work on the louvers

 

[MrDunge]

Update, good, bad, and ugly

With the help of Tonka Toy I got the engine in and bolted up, there are some clearance issues with the downpipe coming off the back of the turbo, I lost the parking brake so Im gonna have to relocate it, the pipe goes right through the center of where the cable runs and the pivot bar also hits the exhaust. I am not comfortable with how close some of the heater hoses are to the exhaust and the brake booster hose. I ordered some heat shielding wrap for the hoses to mitigate that.

The plumbing for the intercooler went in good and I just have a couple of specific length pipe to get it right which i am waiting on. Its tight as hell though lol

Somehow in the install the radiator developed a leak in the seam which i didnt realize til after it was installed and had some pressure on it, so thats gotta come out and get replaced...........

The Injectors are WAY to much......I did the math wrong and instead of 550cc I actually need around 400 (btw stock are around 330). It started and ran but you can smell raw fuel coming out the exhaust. This is after i turned the adjustable FPR pressure way down. If I turn it over 25 psi the engine floods out and cuts off.

After some intensive reading on here and over the net I may go back to the original stock injectors since i have another intake and rail but idk yet. Time isnt on my side. Either way the injectors are going to have to be swapped.

I am happy with the way the front grill turned out, the mesh I think looks real good.

 

[mudoilngears]

From what I can see in the pictures that looks like a brass radiator, I would repair vs replace. They are quite easy to solder.

 

[MrDunge]

I have repaired that radiator like 3 times already. It's like 10 years old. I'm gonna replace it. It was holding on like my hopes and dreams. Lol