D2 going under the knife for TDI instal....
- Thread starter Roving Beetle
- Start date
mikelambert1987 said:
Excellent! I have been lurking here and posting a little, but no big updates so i have avoided the flames that nip at my heels here in this thread! :smilelol:
I have I very very large gapping hole under the hood/floor where a motor and tranny used to be and a mess of wires carefully hung up and over the windshield at the moment. Everything came out well, nothing cut or hacked like I have seen people do all too many times.:ack:
I started fabricating the mounting for the crank sensor as well as the TPS, looks like they will swap over without too much hassle.
Big decisions such as what color to paint the clean and etched 4BD1T are in my head... heh heh - maybe pink? :rofl: Or not. I am a big fan of lighter colors so you can see if something is drooling/pukeing etc. Maybe a light grey or offwhite/tan would look nice? I am going to be fabricating a nice cast/machined cover for top of the engine with a LR design in it, that will probably be polished with the LR relief design painted. Anyway...
Today I'll finish some more little stuff, and the first of the week I hope to get the rest of the heavy duty parts for the 700R4 so i can slide that back together. (It's in a million pieces now) It was a GM factory rebuilt out of a Chebby 6.2 diesel with only about 3k miles on it when the motor took a dump - so it's a nice one to beef up as it's all "updated" and just needs better clutches, HD sun gear, HD drum and some tweaking here and there. Fun stuff......
I'll post up some pics soon. Keep forgetting to bring the cam home - I may have a shot or two of the motor right after I pulled it on the computer here...... I'll check in a minute.
Here's a couple pics.... they don't show much - sort of a "yup, that's a diesel, so what Doug" 
I find it exciting though! LOL.
Anyway, more to come soon of the *cough* pink *cough* motor.
(I joke about the pink as i have a friend who painted his motor red and the paint went REALLY pink the first time it got hot - he was sooooooo pissed. :applause:
And, one of the Disco right after I first brought her inside for the job.... still full of all her fluids even.
Maybe some day I will figure out the DWeb style of pic posting.... till then links it is. Sorry!
I find it exciting though! LOL. Anyway, more to come soon of the *cough* pink *cough* motor.
(I joke about the pink as i have a friend who painted his motor red and the paint went REALLY pink the first time it got hot - he was sooooooo pissed. :applause:
And, one of the Disco right after I first brought her inside for the job.... still full of all her fluids even.
Maybe some day I will figure out the DWeb style of pic posting.... till then links it is. Sorry!
Diesel weighs in at about 340 pounds heavier. I have a set of HD 3 inch lift RTE coils up front and MD 2 inch lift in back. It will sit just about level when she's all in there.
Another update:
Tomorrow the motor slides into the engine bay for mock-up of the engine and tranny mounts. Not sure I'll get to actually building the mounts as a "friend" borrowed the plasma cutter so the actual mounts may have to wait a day or two.
Oh well, he helps me out a lot too, it's all OK-Dokey.
Anyway, looks like the crank sensor will go in fine. I had to machine off the ring on the Rover flywheel center and mount it to the Isuzu FW behind the adapter for the GM flexplate/converter combo.
TPS will be reused along with the original throttle body (with the plate removed) so as to save the stock Rover cable hook-ups for the throttle as well as the cruise. Sounds odd, but it will hook into the Isuzu fuel linkage and intake with not much fuss and look like it belongs there in the end.
Rover AC comp/clutch will be re-used as well. Only little problem there is a mount for it (minor) and I need to machine several multirib serp. belt pulleys over to fit on the Isuzu to convert it from V-Belts. Or at least convert part of it (may as well do it all)
Transmission selector switch is a bit of a pain as the 700R4 shift shaft is too big (fat) to fit through it. Not a big deal but I need to TIG an indexed stud onto the end of it and machine it all pretty again so the selector will slide over it and line up right on the new mount on the side of the trans. That way i can retain the shift indicator on the dash as well as everything it relates to. Lucky for me they seem to have the same range of motion within a few mm. So far so good........
It's a huge undertaking and trying to balance full time running the boatyard, building one full new boat for a customer, keeping my normal car shop customers happy and keeping the wifey happy - I have been busy. But i LOVE it!
Doug.
Tomorrow the motor slides into the engine bay for mock-up of the engine and tranny mounts. Not sure I'll get to actually building the mounts as a "friend" borrowed the plasma cutter so the actual mounts may have to wait a day or two.
Oh well, he helps me out a lot too, it's all OK-Dokey.
Anyway, looks like the crank sensor will go in fine. I had to machine off the ring on the Rover flywheel center and mount it to the Isuzu FW behind the adapter for the GM flexplate/converter combo.
TPS will be reused along with the original throttle body (with the plate removed) so as to save the stock Rover cable hook-ups for the throttle as well as the cruise. Sounds odd, but it will hook into the Isuzu fuel linkage and intake with not much fuss and look like it belongs there in the end.
Rover AC comp/clutch will be re-used as well. Only little problem there is a mount for it (minor) and I need to machine several multirib serp. belt pulleys over to fit on the Isuzu to convert it from V-Belts. Or at least convert part of it (may as well do it all)
Transmission selector switch is a bit of a pain as the 700R4 shift shaft is too big (fat) to fit through it. Not a big deal but I need to TIG an indexed stud onto the end of it and machine it all pretty again so the selector will slide over it and line up right on the new mount on the side of the trans. That way i can retain the shift indicator on the dash as well as everything it relates to. Lucky for me they seem to have the same range of motion within a few mm. So far so good........
It's a huge undertaking and trying to balance full time running the boatyard, building one full new boat for a customer, keeping my normal car shop customers happy and keeping the wifey happy - I have been busy. But i LOVE it!
Doug.
Doug, I'm watching this with great enthusiasm. I don't really care which t-case you use, I'm just interested in how you are going to incorporate all of the electronics so the computers will all remain happy.
If it's not too time consuming, would you please document all of the electrical modifications that you have to do?
Thanks for breaking new ground - I'm fed up with being the guinea pig.
If it's not too time consuming, would you please document all of the electrical modifications that you have to do?
Thanks for breaking new ground - I'm fed up with being the guinea pig.
Roving Beetle: I check this post daily to check your progress. You must have the patience of Jobe to start this project. Best of luck to you. That should be sweet once you get it all wrapped up.
Thanks all.... just another quick update with a pic of the 4BD1T in the truck - just to mock up the mounts and see if everything will fit.
Starter is a little closer than I'd like to the frame, I knew this but now that it's in, I may try and find a smaller starter like a "Mean Green" type - if it's available. If not I may have to fabricate something up.
Anyway, here's a shot of it in the engine bay right about where it will end up. There is no extra room I will tell you that!
http://img.photobucket.com/albums/v198/desertboatco/4bd1trover1.jpg
Doug.
Starter is a little closer than I'd like to the frame, I knew this but now that it's in, I may try and find a smaller starter like a "Mean Green" type - if it's available. If not I may have to fabricate something up.
Anyway, here's a shot of it in the engine bay right about where it will end up. There is no extra room I will tell you that!
http://img.photobucket.com/albums/v198/desertboatco/4bd1trover1.jpg
Doug.
M
MsAwesomness
Guest
Wow Doug,
I've always been a fan of those men that are willing to try something different! You would be the wind beneath my wings anytime...
Women love men in rovers and you're one of them!
I think you live close to me, we should roam together sometime
you are one Deep Man
All the best
ms.awesomness
I've always been a fan of those men that are willing to try something different! You would be the wind beneath my wings anytime...
Women love men in rovers and you're one of them!
I think you live close to me, we should roam together sometime
you are one Deep Man
All the best
ms.awesomness
Best of luck with the project. I'm considering taking something like this on when the 4.6 goes. Would be SOO much easier if they had just sent diesel rovers over here from the get go.
Surf said:
Yes, yes it is - glowing red turbo housings are one thing - smoldering hood paint (or worse
) is another!! I have certainly thought of that and being in the boat building business I have plenty of heat shielding materials on hand. It will be wrapped then have a stainless steel heat shield over the exhaust/turbo housing as well as quality material on the hood itself. I see no issues with this at all. I have run very large turbos at close distances on past cars (Audi) and with the right heat shielding have had no issues. And these were gas cars running much higher temps through the turbo housings and downpipes.That said, I have considered putting a subtle "tasteful" (if i can find a way to do so?) hood scoop on it to direct air through an upper, but still forward mounted intercooler. (instead of mounting the intercooler in front of the radiator/AC. The air could then be channeled back to above the turbo and manifold. Maybe even a louvered hood like the import tuner boy racer's do.
Just thinking out loud.... anyway....Painted her all up today, light grey/silver and black - looks like it should, and nice and clean!
I think I've got the starter all set, not a big issue there and I have plenty of room again. I will be putting a small inset in the pass side of the oil pan for diff clearance... may build a whole new pan out of some seriously heavy metal as this one is a little dinged already and I'd love to not EVER have to worry about the pan. We'll see....
SO so sooooo much fun!!!!
What are you doing about all the electronics associated with the rover computer etc. not getting signals from the proper sensors?
mikelambert1987 said:
"Simple" :smilelol: answer is that the important sensors are still going to be there. The Rover engine is actually is very very uncomplicated set-up all things considered. There is more to it, but that's the short version of it. I'll post up a lot more as i go. Pics and a write-up will certainly follow.
Doug.
Roving Beetle said:That said, I have considered putting a subtle "tasteful" (if i can find a way to do so?) hood scoop on it to direct air through an upper, but still forward mounted intercooler. (instead of mounting the intercooler in front of the radiator/AC. The air could then be channeled back to above the turbo and manifold. Maybe even a louvered hood like the import tuner boy racer's do.
Maybe you should have a look at this thread...
http://discoweb.org/forums/showthread.php?t=11256&highlight=hood+scoop
jymmiejamz said:Maybe you should have a look at this thread...
http://discoweb.org/forums/showthread.php?t=11256&highlight=hood+scoop
Wow, I ....... ah ....... can't believe i just read over 6 pages of that before my head hurt and i had to stop! :banghead:
Some good info I suppose, but nothing I had not really thought of I guess. My idea was to put a scoop at the forward leading edge of the hood where air flow would push the air in and about the middle of the hood (right where the turbo/downpipe is) it should be a "low pressure" area to help pull the air out at speeds and/or simply let the hot air rise up and out at low/stopped speeds. I doubt it would have any more "pull" out from the middle of the hood at speeds than the "pull" from under the truck so in fact it may do nothing except let a lot of heat out at slow/stopped speeds which in this case is exactly what I'd really need.
Would it do a lot? Maybe not in terms of ENGINE COOLING, but as far as manifold and turbo housing cooling that are only cooled by the air around and in them (Only the turbo cartridge are cooled by coolant/oil) it would probably help quite a lot.
I'll mock up a cardboard and duct tape scoop, just for laughs and post it up - that will get some good old intraweb flames going! :rofl:
Mike,
Since you asked it's going excellent. The motor is back in again for what i hope to be final motor mount figuring and details. The trans is hooked up as well via the adapter (www.isuzudieselswapper.com) for trial fit and mount relocation, cable hook up trials etc etc.
I'm going to try and throw a couple pics in here - one is overall of the motor sitting in there with all the weight on the truck, she holds it very very well with the HD RTE 3 inch springs i might add. The other shot is how how close the bellhousing and adapter are to the firewall. I may have to "clearance" the firewall just a tad for wiggle room. :ack: Either that or make up a 1/2-3/4 inch body lift to add a little room. I may do just that actually.
I *DO* have to "clock" the starter which involves cutting the ears off the mounting plate and welding them back on, it's an aluminum housing that holds the gear drive for the offset starter and mounts it to the cast iron bellhousing. I have one marine supplier i deal with regularly trying to find me an industrial or marine starter that hugs the block better - no luck yet. It's either this or modify the frame rail really.
http://img.photobucket.com/albums/v198/desertboatco/P1010982.jpg
http://img.photobucket.com/albums/v198/desertboatco/P1010979.jpg
I am LOVING it! It's a blast and trip and keeps my head spinning. I am just SOOOOOOOOOOOOOOOOOOOOOOOOOOO happy after messing with it a while everything inside the truck works 100% now including the alarm and such. very very pleased so far.
Spent about an hour at the local mom and pop parts store looking for decent motor mounts for it. I am trying to find a dual density hydraulic mount to help quiet it but also hold the 750-800 pound beast up. I think i found some for a large Mercedes diesel, we'll see how they look when they come in tomorrow.
Doug.
Since you asked
it's going excellent. The motor is back in again for what i hope to be final motor mount figuring and details. The trans is hooked up as well via the adapter (www.isuzudieselswapper.com) for trial fit and mount relocation, cable hook up trials etc etc.I'm going to try and throw a couple pics in here - one is overall of the motor sitting in there with all the weight on the truck, she holds it very very well with the HD RTE 3 inch springs i might add. The other shot is how how close the bellhousing and adapter are to the firewall. I may have to "clearance" the firewall just a tad for wiggle room. :ack: Either that or make up a 1/2-3/4 inch body lift to add a little room. I may do just that actually.
I *DO* have to "clock" the starter which involves cutting the ears off the mounting plate and welding them back on, it's an aluminum housing that holds the gear drive for the offset starter and mounts it to the cast iron bellhousing. I have one marine supplier i deal with regularly trying to find me an industrial or marine starter that hugs the block better - no luck yet. It's either this or modify the frame rail really.
http://img.photobucket.com/albums/v198/desertboatco/P1010982.jpg
http://img.photobucket.com/albums/v198/desertboatco/P1010979.jpg
I am LOVING it! It's a blast and trip and keeps my head spinning. I am just SOOOOOOOOOOOOOOOOOOOOOOOOOOO happy after messing with it a while everything inside the truck works 100% now including the alarm and such. very very pleased so far.
Spent about an hour at the local mom and pop parts store looking for decent motor mounts for it. I am trying to find a dual density hydraulic mount to help quiet it but also hold the 750-800 pound beast up. I think i found some for a large Mercedes diesel, we'll see how they look when they come in tomorrow.
Doug.