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Discussion Starter · #1 ·
This is a continuation of my intro post seen here http://www.planetisuzoo.com/viewtopic.php?f=24&t=85395

I picked up an 88 Trooper with a 4cyl. auto that had been sitting for a couple of years.

I picked the Trooper up today. It was fun loading it up by myself. I couldn't find my darn come along, so I used a chain hoist to get it on the dolly.
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I gave it a much needed bath.



I'll be installing the new engine at the shop at my work and getting in the shop was fun by myself, also. I used a winch we have on a cradle.


I'm picking up a wrecked one in the morning that the engine was just rebuilt a few thousand miles ago.
 

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Discussion Starter · #2 ·
I picked up the wrecked Trooper this morning. I had to use my wheels and tires to get it to the shop. It's in pretty bad shape, but the guy supposedly did a bunch of work to the engine, transmission and axles before it was wrecked. I hope to get a little work down this weekend. However, I have to leave next week to work in MN for possibly 2-4 weeks, so progress will be slow.
 

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Discussion Starter · #5 ·
DSUZU said:
You're off to a good (or bad - addiction) start. Good looking LS you picked up Dennis
I hope it doesn't turn into a Trooper addiction. :) The problem I have, while others look for the best example of a vehicle with the lowest miles, I seem to search out derelicts. I've revived a few over the years. My favorite was an IH Metro that was sitting for 10 years and I bought for $700. Owner thought it needed a new engine, but I had the carb rebuilt and put new points in it and it started right up. I wish I would have kept it. It's the one vehicle I regret selling
Before


After


wmorrisiii said:
The new one looks great, the parts one not so much. Looks like it got whacked good. Once you get done with the parts Troop you should be able to part out whats left. A few extra bucks always helps on these projects. At least it looks like you have good access to the engine :D
I'm going to have to do some surgery to get the engine out of the wrecked one. The sheet metal is mangled up next to it on the right side.

I steam cleaned the engine on the wrecked one and pulled it into the shop. Luckily, two of our trucks our out of state on jobs for a month or so, so I have some extra room.

 

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Discussion Starter · #7 ·
DSUZU said:
Love that old walk-through. Don't hardly see any of those down this way. Hope you got a killer price for it. Dennis
I sold it a few years ago and got $4,200 for it and thought I did good. However, nowadays they go for about that much in non running and rusty condition.

I got the engine, transmission and transfer case out of the wrecked rig. (I need a new phone. The camera sucks)
 

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Discussion Starter · #9 ·
Not much more to report. I was out of town for work for 3 weeks and took a few days off. It's been a while since I've pulled and replaced an engine and I'm trying to get the motivation to work on it. I'm reading some of the other builds to try to get me going, but the shop isn't heated and it's about 45 degrees out there and not much of a desire to go out there. I have removed the transmission from the "new" engine and trying to get the starter off the old one so I can remove the transmission out of the good Trooper, but the lower bolt won't budge. Letting some PB Blaster soak.
 

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Discussion Starter · #11 ·
wmorrisiii said:
Laughing, letting PB Blaster or Break Free soak is one of my favorite forms of procrastination. Especially when it's cold.
:lol: Well, it did do the trick. I got the starter off the old engine, so I can start removing the auto trans out of the Trooper. I did get the "new" engine on the stand and remove some of the brackets that were broke from the accident. I found out my daily driver Festiva has a cracked block, so that will get my full attention until it's up and running.


 

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Discussion Starter · #13 ·
Well, the guy I'm going to buy the used engine from for my Festiva is out of town for a few days, so I decided to work on the Trooper some more. I finally got the trans and engine out. I have to admit, I thought since the Trooper is a bigger vehicle it would be easier to work on, but it has been the exact opposite. Practically every bolt was a fight to remove and I have broken 2 socket u joints. I could remove the engine, trans and transfer case as one unit from my old Eagle in about 2 hours or less. Well, Monday I have to go back to MN for work for a few days and drive a truck back, so it will be another week or so before I can do anymore work to it. I'm taking the weekend off from mechanical crap and pondering on whether I should just scrap all my junk cars and buy a decent running one. :?



 

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Discussion Starter · #17 ·
Not much progress. Last week I steam cleaned the "new" engine and pulled the cam out. I'm currently working in the atlanta area, so I made a visit to Jerry Lemond's a picked up a box a parts including one of his cams. He's a terrific guy. I hope get back working on it in a few days when I get back home.
 

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Discussion Starter · #19 ·
I'm slowly making some progress. I installed Jerry's cam, new timing belt and tensioner, water pump, intake manifold gasket, and misc. hoses. I also, "cleaned" and installed new o-rings on the fuel injectors. The old ones were quite hard and brittle and glad I checked them. I wanted to make sure the fuel injectors weren't clogged from old ethanol fuel, so I made a little rig with 3/8" ID tubing and a brass plug that I drilled a small hole in the plug and inserted the straw from a can of brake cleaner. I powered them briefly on and off with 12v and saw a nice pattern and no leaks.


 

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Discussion Starter · #20 ·
I've got a little bit done in the last few days. I plugged the fittings for the air pump. I cut the tubing short so the flared end will still be in the fitting and tapped the top of the fitting for an 1/8" NPT plug. The ID of the fitting is a hair bigger than what you would normally want for a NPT thread, but it worked out perfect. I tapped them without about 7/8 of the tap and that allowed the plug to thread almost all the way into the fitting so there wasn't alot of the plug sticking up. I would have rather used a socket head plug, but I already had these.




I've got the engine and transmission sitting in the Trooper. That was fun. I've still got a lot wires, hoses, etc. to hook up and figure out where some of them go. I know I have a horrible memory but refuse to do a better job of cataloging stuff when I take it apart. Does anyone know where this L bracket goes? I can't remember where I took it off from. It had a bellhousing bolt in one of the holes, but not sure that bolt came out with it and I couldn't figure out a place for it.


 

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Discussion Starter · #27 ·
gruff54 said:
Sorry, all mine are manuals. The one 2.6 auto I have doesn't have the tranny in it. It's in the back of the truck. Where are these lines located? The lines may still be in place.

Mike
They are on the right side of the transmission and go by the right side of the engine and then connect to the radiator. I would need to see it installed in the vehicle. There is a bracket near the front of the engine and I don't know what it was originally attached to.
 

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Discussion Starter · #31 ·
I spent most of the weekend working on my Husky WR300 on Saturday and replacing a fuel pump on my Festiva on Sunday since I was towed home Saturday night. I was messing with the Trooper this morning and noticed when I turned the key, there weren't any lights coming on the dash. Checked power to the fuses and no power to ignition coil or meter fuse when key was on. I noticed there was an LED for an alarm and thought it might be the culprit so I tried to track it down. While wiggling the panel under the steering column to try to figure out how to take it off, I forgot I had the key turned on and a bunch of lights came on. There is a loose wire under there somewhere I have to track down. I turned the key to start and it started for a split second. Now it just cranks but still no start. I noticed the fuel pump keeps running when the key is on. Is it supposed to? Most vehicles I've worked on, it just comes on for a few seconds until the engine starts.
 

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Discussion Starter · #32 ·
I removed all the alarm BS. There was a loose wire where they spliced in for engine kill. The fuel pump still runs constant with key on, engine off. I swapped relays and it still does it. I pulled the connectors from the ECU and it kept running. It wouldn't start with the pump running constantly so I decided to try to crank it with the fuel pump relay out to clear it out and it started up. I put the relay back in and it kept running. It's not in any condition to drive yet though. I'll have to figure out why it stays on with the engine off.
 

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Discussion Starter · #33 ·
I'm putting this link here for future reference so everything is in one spot. I was able to get the fuel pump working correctly. viewtopic.php?f=1&t=86672&p=765258#p765258

I guess the plus side to all of these issues is that troubleshooting has given me an idea how everything works, so that when there is an issue in the future, I have a better understanding of it.
 

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Discussion Starter · #34 ·
The link in the above post has some info of what I've been doing the last few days. It's alive!!!!!!!!!!!!! I drove it out of the shop today and just on our very short road. I don't have it registered yet. It idles nice and seems to run really well and I wasn't expecting the 4 cylinder to feel this peppy. I did a nice smoke show with a little water on the tires. The Trooper's catalytic converter was either original or the original style and I could hear stuff rattling in it. Also, the muffler was peeled wide open from a backfire I suppose. The donor Trooper had a modern high flow cat and a tube muffler. I installed those and it sounds fantastic. I can't wait to get this thing on the road. The only issue right now is that the fuel gauge isn't working. Thanks for everyone's help so far and I don't think I would have gotten this far without Jerry's help.
 
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