The storm clouds gather on the horizon...
The bank account quakes in fear...
Project Thunderbolt has returned.
The Basics:
1989 Trooper, 5 spd, 4ze1 engine.
I had originally started this project way back when but after I determined that the engine was developing a rod knock, I found a different Trooper to drive around. The red one worked great but it didn't have air conditioning. That was a deal breaker for my daughters so I sold the red one to finance the build up of Thunderbolt. The original story is in the threads here:
https://www.planetisuzoo.com/viewtopic. ... 5&t=137907
Bad engine:
https://www.planetisuzoo.com/viewtopic. ... 5&t=138495
Replacement Trooper:
https://www.planetisuzoo.com/viewtopic. ... 5&t=138497
Cleaned up, fixed all the little things and then sold the red Trooper (it looked good!):
https://www.planetisuzoo.com/viewtopic. ... 5&t=143599
And now back to the blue!
Currently, I am installing sound deadener throughout. I did this in the red one as well and it made a nice difference. This time I think I am doing a better job. Instead of just covering everything I could, I did a little research. The best way I got it in my head was to think of sound waves like water in a river. A long stretch of flat sheet metal is like a smooth river channel, the sound just rolls through it. The deadener is like sand bars trying to interrupt that flow. So I did the inner and outer doors, the floor, the firewall and the rear wheel wells. I would have liked to do the roof but I am terrified of taking down the headliner, especially when it is in perfect condition.
Next up is installing the new crate motor. Since it is a new motor, I went ahead and got a new water pump (Thank you Jerry!) and radiator for it. I hate when engines overheat. I also got an upgraded alternator. Should be interesting to see how that works. I am planning on adding some camping electrical gear to this rig and I heard the stock alternator is a little weak.
By the way, if you are curious as to why this spot always rusts on the first gens, here is why. Just a catch spot for crud. Since I had the fenders off to replace the door hinges (no more driver drop when opening! Hooray) I figured I would POR-15 that spot on the fenders and rockers before they rusted out.
After that it is just the basics of new ball joints, new tires. I also am planning on putting in a new Exedy clutch whenever RockAuto gets around to sending it to me.
The debates:
1. Crate vs. rebuild-the endless debate. I had originally planned on rebuilding the motor in Thunderbolt. But after reading through several threads (especially Alan's), calling around for some machine shop pricing and being honest with myself, I decided to go for a brand new engine just for peace of mind. My number one goal is reliability. I just want to jump in and go. As anyone who has tried to source a 4ze1 crate motor, they aren't common. I found one at S&J Engines in Spokane. They had one core they rebuilt for me. Once I send my core back, they should have another in case anyone wants to go this same route. To my door it was about $2500. The fact that the engine runs smoothly in Thunderbolt now should make the swap go better since I am not repairing it as I go. According to *******, it should only take me about 30 minutes (yeah right! I wish J5 was my neighbor!)
2. 4 cyl vs. 6 cyl- I went around and around on this one. Thanks to Dick Hess for his advice. I am part of the bigger-is-better crowd with power, but I also like a fine running 4 cyl. If I want to go fast, I can fire up the big-block in the Chevelle parked next to it (hiding under all the boxes waiting for its turn).
3. Manual hubs vs. Auto-locking - I go back and forth on this one. I know the manual are better for long term durability, but for now I am going to leave the autos on. Most of my upcoming trips will be highway anyway. I did scrounge a set of manual Aisin's at the junkyard that I will put on someday.
4. Seats - I may do a writeup on this topic in another thread. I wander the junkyards just for fun to see what is there. Like every other 1st gen trooper owner, I want different seats. I wanted non-electric buckets with factory armrests. Not easy to find. I originally had seats from a 92 Suburban that I thought would be nice but they were too wide. I had a set of seats from a Nissan Quest but gave those to Dick for his project. Some Suzuki seats are ok. Some Kia's have armrests. The volvo seats are nice but no armrest. Lately, I think I found a winner. 2010 and up Dodge Grand Caravan front seats. I have my eye on a set at the yard. If I pick them up, I will do a writeup on them and adding the factory brackets.
5. Other parts to install- In my hoarding, I have managed to acquire a pretty decent pile of parts. I got a G80 out of a 94 trooper that I want to swap in. I have the rare rear sway bar that needs to go back in, some good KC off-road lights, rhino-line both bumpers black, the factory brush guard needs to go back on and I want to do the heavy duty tie-rod mod. Those parts will have to wait until it is running though.
Questions:
1. This is a classic "while-you-are-in-there" situation. I was already planning on a new clutch, new radiator with new hoses, new alternator, and new water pump. Is is common to replace the AC Compressor at this junction? What else am I missing?
2. Any wisdom to share? Members have been down this road many times and this is my first Trooper engine swap. Tips, advice or things to watch out for would be greatly appreciated. My initial plan was to remove the old engine with the itec still on (using J5's tip about removing the motor mounts) and then swapping everything over to the new block before dropping back in. Any concerns about that route?
I appreciate the fun I have had on this forum. Thanks in advance to everyone who took time to read my long post!
-Curtis (Boise Trooper)
The bank account quakes in fear...
Project Thunderbolt has returned.
The Basics:
1989 Trooper, 5 spd, 4ze1 engine.
I had originally started this project way back when but after I determined that the engine was developing a rod knock, I found a different Trooper to drive around. The red one worked great but it didn't have air conditioning. That was a deal breaker for my daughters so I sold the red one to finance the build up of Thunderbolt. The original story is in the threads here:
https://www.planetisuzoo.com/viewtopic. ... 5&t=137907
Bad engine:
https://www.planetisuzoo.com/viewtopic. ... 5&t=138495
Replacement Trooper:
https://www.planetisuzoo.com/viewtopic. ... 5&t=138497
Cleaned up, fixed all the little things and then sold the red Trooper (it looked good!):
https://www.planetisuzoo.com/viewtopic. ... 5&t=143599
And now back to the blue!
Currently, I am installing sound deadener throughout. I did this in the red one as well and it made a nice difference. This time I think I am doing a better job. Instead of just covering everything I could, I did a little research. The best way I got it in my head was to think of sound waves like water in a river. A long stretch of flat sheet metal is like a smooth river channel, the sound just rolls through it. The deadener is like sand bars trying to interrupt that flow. So I did the inner and outer doors, the floor, the firewall and the rear wheel wells. I would have liked to do the roof but I am terrified of taking down the headliner, especially when it is in perfect condition.
Next up is installing the new crate motor. Since it is a new motor, I went ahead and got a new water pump (Thank you Jerry!) and radiator for it. I hate when engines overheat. I also got an upgraded alternator. Should be interesting to see how that works. I am planning on adding some camping electrical gear to this rig and I heard the stock alternator is a little weak.
By the way, if you are curious as to why this spot always rusts on the first gens, here is why. Just a catch spot for crud. Since I had the fenders off to replace the door hinges (no more driver drop when opening! Hooray) I figured I would POR-15 that spot on the fenders and rockers before they rusted out.
After that it is just the basics of new ball joints, new tires. I also am planning on putting in a new Exedy clutch whenever RockAuto gets around to sending it to me.
The debates:
1. Crate vs. rebuild-the endless debate. I had originally planned on rebuilding the motor in Thunderbolt. But after reading through several threads (especially Alan's), calling around for some machine shop pricing and being honest with myself, I decided to go for a brand new engine just for peace of mind. My number one goal is reliability. I just want to jump in and go. As anyone who has tried to source a 4ze1 crate motor, they aren't common. I found one at S&J Engines in Spokane. They had one core they rebuilt for me. Once I send my core back, they should have another in case anyone wants to go this same route. To my door it was about $2500. The fact that the engine runs smoothly in Thunderbolt now should make the swap go better since I am not repairing it as I go. According to *******, it should only take me about 30 minutes (yeah right! I wish J5 was my neighbor!)
2. 4 cyl vs. 6 cyl- I went around and around on this one. Thanks to Dick Hess for his advice. I am part of the bigger-is-better crowd with power, but I also like a fine running 4 cyl. If I want to go fast, I can fire up the big-block in the Chevelle parked next to it (hiding under all the boxes waiting for its turn).
3. Manual hubs vs. Auto-locking - I go back and forth on this one. I know the manual are better for long term durability, but for now I am going to leave the autos on. Most of my upcoming trips will be highway anyway. I did scrounge a set of manual Aisin's at the junkyard that I will put on someday.
4. Seats - I may do a writeup on this topic in another thread. I wander the junkyards just for fun to see what is there. Like every other 1st gen trooper owner, I want different seats. I wanted non-electric buckets with factory armrests. Not easy to find. I originally had seats from a 92 Suburban that I thought would be nice but they were too wide. I had a set of seats from a Nissan Quest but gave those to Dick for his project. Some Suzuki seats are ok. Some Kia's have armrests. The volvo seats are nice but no armrest. Lately, I think I found a winner. 2010 and up Dodge Grand Caravan front seats. I have my eye on a set at the yard. If I pick them up, I will do a writeup on them and adding the factory brackets.
5. Other parts to install- In my hoarding, I have managed to acquire a pretty decent pile of parts. I got a G80 out of a 94 trooper that I want to swap in. I have the rare rear sway bar that needs to go back in, some good KC off-road lights, rhino-line both bumpers black, the factory brush guard needs to go back on and I want to do the heavy duty tie-rod mod. Those parts will have to wait until it is running though.
Questions:
1. This is a classic "while-you-are-in-there" situation. I was already planning on a new clutch, new radiator with new hoses, new alternator, and new water pump. Is is common to replace the AC Compressor at this junction? What else am I missing?
2. Any wisdom to share? Members have been down this road many times and this is my first Trooper engine swap. Tips, advice or things to watch out for would be greatly appreciated. My initial plan was to remove the old engine with the itec still on (using J5's tip about removing the motor mounts) and then swapping everything over to the new block before dropping back in. Any concerns about that route?
I appreciate the fun I have had on this forum. Thanks in advance to everyone who took time to read my long post!
-Curtis (Boise Trooper)