Fuel tank changes

Ealier in the week, i observed the variouse compenents of the fuek tank.
After disassembly, we we tried to find the best way bring the tank into good condition.
A quote from a shop to coat the overly rusted tank, and replacing the steel vent line seemed the best way to go.
But after further research, don found an auto recycler from the southern states that could provide the same gas model fuel tank of the isuzu trooper, and in good condition with almost no rust, for lower cost.

When the tank arrived yesterday, i removed all the ripped off lines and clamps, prepairing it for new ones.

i needed to find a way to remove the pump its self and find a new method to retrofit it into a pickup, as the diesel engine does not require a pump.

When i removed the pump from its bracket, the steel lines it was attached too floated about 5 inches from the base, so we got a rubber fuel line, in place of the pump, and cut it to float about an inch from the base of the tank so left over debris and heavy gunk would not be sucked from the botton. After a clamping and simple tiestrap fitment, the retrofitment is complete.

The tank is being reassembled and will be connected in a later stage of the diesel conversion.

Oct 5th edit:

Continued on preperation for fuel tank. I got under the car and removed the 2 fuel lines. The vent line was left in place just in case it would be needed, but if it wont be neccisary, it will be removed aswell.

Engine and Transmission Removal

Its time to remove the Engine!

So we started out with placing chains with bolts around the engine in the most convenient spots for it to be lifted out.

after connecting the chain to the engine crane, we started to lift an inch or 2 and checked if

there are any connections left. We disconnected some small ground wires and the positive battery terminal wire.

after lifting some more, the engine was lifting the trooper itself. the transmission was lifting

the car because the angle was too shallow,so Don got under the vehicle with the hydraulic jack lift to adjust the transmission height appropriately as the engine was being lifted from the front.

the largest problem we got into was the oil pan being stuck against the drive-shaft. with some tweaking, lifting and lowering, nudging and the help of a crowbar, we had enough clearance. Don lowered the transmission in the back and I kept lifting the crane while peter pulled the

crane back, so the engine could be pulled up and out.

it's so rewarding to see the front of the car without the engine, all the various components seperated, we have a broader view now on that we can see the space were working with for installing the diesel engine.

Under the hood - almost ready to remove engine/tranny!

Today we lowered the trooper from the hoist, back on the floor.

We removed various components to prepare for the removal of the engine.

-We removed bolts from the motor mounts

-The frame cross member was removed, and we used the floor jack to support the tranny.

-Both the the air conditioning lines and power steering lines were disconnected

-Disconnected all the vacuum lines and electrical connections

* We made sure all the lines and electrical connections were labeled with tape/marker as well as saved to identify for when we reassemble and be retrofitted with new connections for the diesel engine *

Under chassis parts

First we lift the trooper(BIG HORN) on electric lift.

Amd we Remove the

- Front & rear drive shaft

- fuel tank & disconnect fuel line

- Disconnect transmission connectors & linkages

- Remove transfer case shifter

- Remove the complete Exhaust system (the bolt of the Exhaust are very tight So we used OXY/ACET torch)

-Disconnect the starter motor wire & alternator wire

Plasma cutting the frame to allow engine removal

Today we decided that the best method to remove the engine and transmission out the front of the isuzu as a whole.

-In order to lift and remove the engine and transmission, the cross member support for the radiator must be removed to have enough clearance.

-After further inspection and discussion, Peter's idea was the greatest, which is to remove the cross member support was with the plasma cutter, at the most convenient spot for both enough clearance for the engine/transmission and ability to replace the cross member

-It would be easier to cut the cross member and replace with either re-welding or bolding steel plates, rather than separating and transmission, which would involve removing the engine from the top and transmission from the bottom of the vehicle

Remove radiator etc

Today we continued to remove the front end parts of the trooper:

-A/C condenser

-Fan & shroud

- radiator system

-Hood

* unfortunately we broke one hood mount bolt & windshield washer connector.  we'll have to fix that later!

Front grill parts

In the first day we removed the:

-front grill

-front headlights

-skid plate (a metal plate cover under the engine for portect the engine)

-Front bumper

- drained the engine & cooling oil

Introduction to our gas to diesel conversion project

Welcome to Rockway Tech's blog for our first ever diesel conversion project!  The vehicle of choice is a 1994 Isuzu Trooper 4X4 with a 3.2L V6 gas engine with auto. transmission.  The plan is to remove the gas engine and install a 3.1L diesel (4JG2) engine and auto. transmission in its place.  A group of 3 students and their teacher will perform the transplant in the fall semester of 2011.  The projected finish date is December 2011.


To begin the conversion, we needed to educate ourselves on what we were undertaking.  We researched the vehicle and engine information of both the gas and diesel engines.  We acquired an online manual for the original gas engine model of the 1994 Isuzu Trooper.  We also found an excellent PDF file manual online 4JG2 diesel engine Trooper.  The first few days were spent educating ourselves to understand the conversion process and the changes we would need to make to get the 4JG2 to fit in our Trooper.

The picture of the Trooper was taken after some work was already done.