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Discussion Starter · #43 ·
Email Jerry Lemond at [email protected]et. He carries a wide variety of Isuzu parts. I believe he was a national service manager for Isuzu NA, or something like that. You can trust him with your life.

Edit: Just wanted to clarify that Jerry for sure carries this part, and is who I ordered mine from.
 

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I haven't been able to update recently due to my BMW E30 taking up a lot of my time. I finally got tired of the constant ATF leaks, so I had it on jacks in the garage where I replaced a missing breather tube on the back of the transmission. Without it there it was spraying ATF all over the underside of my car, and at high revs, I was able to make a James Bond-esque smoke screen when the fluid would hit the red hot exhaust pipe right under the trans. Also, new steering rack, driveshaft, trans mounts. Just a bunch of stuff.

Back to the Trooper, I had some time to start cleaning out the engine bay. One of the first things I did when I got the Trooper was clean up the rust on the battery tray and spray paint it with some generic white automotive spray paint. I found this time that battery acid damage was more extensive then I first noticed. The worst part was right under the tray, which I didn't get a picture of.

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I found you could order a 12oz can of factory coded paint & clear coat for $40 through Walmart.com, which I did, and it was delivered within a week.

I suck at painting. I just don't have the patience for it. Most of the work is prepping the surface, and the actual painting is like 5% of the total job. Knowing this all going to be covered with the battery and the wiper fluid reservoir and other stuff, I wasn't too worried about it being perfect. Mainly I just wanted to protect against rust, and make the battery tray blend in a little better than with the generic white I used before. I cleaned up the rust areas to bare metal, and then hit it with some primer, I ended up spraying pretty much the whole left side of the compartment.

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Overall, it turned out pretty good. There are a bunch of runs here and there, and that one spot where I though I could clean up a run with a towel (you can't, fyi).

In the future, I would do more light coats, as opposed to two medium-heavy coats I did, but again, I lack patience. I still need to paint that black crossmember by the radiator, then I'll be ready to put the wiring harness and everything else back in place.
 

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shaggydoink said:
takemehome4LOroads said:
Overall, it turned out pretty good.
I agree, nicely done!

Jonathan
Thanks Jonathan!

giusedtobe said:
Where are you in the rebuild? I am behind you as I just got mine pulled. Just found this thread and will definitely follow.

Regards,
Alan
Hi Alan,

Thanks for your interest!

I've got the bottom end of my engine completed. I made a cardboard "head gasket" so I could secure the head on top with a few bolts, and assemble the top end.

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I painted the exhaust manifold with some high temp 2000F paint.

I still need to paint a little bit more in the engine compartment before I'm ready to start installing the engine.

Thanks to a member on the Planet, Kurt, I figured out I bought the wrong fuel pump. I thought the V6 and I4 pumps were the same, but he confirmed with Jerry they are not, so I'm going to install a Walbro unit.

I'll be updating more, as my other project car is taking up less time, and I hope to have my Trooper running by the end of the month. [fingers crossed]

-Bret
 

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That is looking very nice!
 

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Bret,

Rebuild looks very well along and fastidiously/meticulously done! See you're using the "Jerrycam" and wonder if you anticipate any problems getting your stead re-certified for California's stringent smog requirements? Any suggestions?

Best Regards,

GB
 

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Discussion Starter · #51 ·
gb89amigo said:
Bret,

Rebuild looks very well along and fastidiously/meticulously done! See you're using the "Jerrycam" and wonder if you anticipate any problems getting your stead re-certified for California's stringent smog requirements? Any suggestions?

Best Regards,

GB
Thanks! I posed this question to Jerry back when I ordered it and here was his response:

JLEMOND said:
IF EVERY THING ELSE EMMISSIONS WISE IS O N THE ENG AND WORKING IT SHOULD PASS , I HAVE SOLD THEM ALLOVER THE COUNTRY AND SOME IN CALIF , BUT NOT SURE IF THE CAL CUSTIMERS WERE IN A TESTING AREA,.
 

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Bret,

So, guess we'll just have to wait for your trial with the CALIF smog testing folks! Perhaps someone else in CA. can offer their smog testing experience with this cam on a recently rebuilt 4ZE4. I agree with Jerry that "IT SHOULD PASS", but emission testing in CA. can be trying. Hope you have the best of luck, emission wise. Please keep us apprised.

Best Regards,

GB
 

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My Walbro pump came in the other day, so I decided to tackle installing that, replacing the incorrect pump I had purchased earlier.

I didn't want to use the hanger from my current pump since the unit is basically brand new, so I got another hanger from the junkyard. If anyone is in the market for a barely used Bosch fuel pump for V6 and/or an OK condition fuel tank, let me know!

I ordered product number #8083-GCA314 from walbrofuelpumps.com. I've read some people have had issues fitting these to their hangers but this kit was pretty straightforward. I cleaned up the old frame, riveted on a new nitrile rubber flap, and installed the pump. The little rubber isolator piece between the pump and bottom of the hanger was a perfect fit. I soldered the new wiring as opposed to using the crimps because when I stripped the old wires, the copper was pretty patina-y and soldering would just take a few minutes more.

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Hey I like the shiny silver exhaust manifold paint! Did you use new bolts instead of the standard studs that go in the head?

Top work so far. My block & crank is at the machine shop. I am trying to decide whether to paint the block black like you did or do something nuts like the lime green I saw someone else did.

Alan
 

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Discussion Starter · #55 ·
Whoa guys. So I haven't posted any updates in about six months. Did anything interesting happen in the meantime? :shock:

After about a year and half of slowly plugging away at this project, and doing all of the "well I might as well do this too" things, I've finally got a running Trooper!

Putting the engine in was pretty straight forward. I dropped in the lower block first, then the completely assembled head as one unit. I made sure to put the dowel bolts in the right spots when joining the block to the bellhousing. Replaced just about every single piece of rubber that exists in the engine bay, including the quarter-mile of vacuum lines.

This Trooper build was and remains a great inspiration to me on how I want my truck to look and perform. That archived link thankfully has all the pictures that don't seem to exist on old car forums anymore.

giusedtobe said:
Hey I like the shiny silver exhaust manifold paint! Did you use new bolts instead of the standard studs that go in the head?

Top work so far. My block & crank is at the machine shop. I am trying to decide whether to paint the block black like you did or do something nuts like the lime green I saw someone else did.

Alan
I used to the standard studs. I originally got some copper plated nuts to put on there, but they were too long, or my studs were too short. Either way I got some stainless serrated nuts that had a thinner profile on there now.

Now for some pics:





I also never mentioned that I have a cargo cover! I didn't think much of it when I first got the truck, but have learned just how rare they are. (Mandatory RockAuto box also pictured)





After installing the engine and driving it around the block a few times, my Trooper got it's first oil leak! I was such a proud Dad. But seriously, I was super frustrated that some bead of RTV I laid a year ago was probably not sufficient somewhere around the oil pan. I decided not to mess around. I immediately ordered a fluorescent dye and UV flashlight on Amazon which REALLY works. The leak was emanating from front crankshaft seal retainer plate. I was able to remove the plate without removing the oil pan or engine (thank goodness). Jerry recommended putting a bead of RTV in the groove that the half circle seal sits in, which I had not done before. I got it all buttoned up and no more leaks...for now.

Also, I decided to check the torque on the head bolts after only maybe 10 or 20 miles of test drives, and was surprised that several bolts went a good 1/8 turn to reach the correct torque again. I've read some debate on when the head bolts should be retorqued, so there's another data point for you.

One big unknown with this truck was the transmission, since I bought it non-op and had it towed to my house. I'm happy to report that Aisin Warner auto trans shifts smooth as silk. Very impressive for such an old tranny. I had always imagined that my Trooper would be a manual, and failing that I could convert an auto to a manual, but I'm pretty happy with the current configuration and think I'll let that idea go.

It's idling nicely at 900 rpm. Just got insurance setup and now off to get it smogged and registered, and throw on some new tires.

Huge shoutout to Jerry, obviously. Also Dennis, Ed, and anyone who has ever posted here on the Planet. Such an invaluable resource for Isuzu owners.
 

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Very happy to hear of your success! That Aisain trans should give you good service. Beautiful Trooper!
 

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takemehome4LOroads said:
After about a year and half of slowly plugging away at this project, and doing all of the "well I might as well do this too" things, I've finally got a running Trooper!
Very cool to read this, enjoy!! :thumbup:

Jonathan
 

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Discussion Starter · #59 ·
I got this UV dye and paired it with this UV flashlight.

Oddly, I couldn't find a kit that has both of them together, on Amazon at least. Now that I've done the leak test I can use the UV flashlight to go scorpion hunting.

Oh, and make sure you take a second to shine the light on your car before you add the dye. Somethings will glow that you weren't expecting and you'll want to know that before hand. For example, my A/C compressor was lighting up so I thought my oil leak may have been starting from the valve cover and working it's way down. I realized later that the oil in the A/C system also has a UV dye in it. Wish I checked that ahead of time.
 
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