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'86 K5 Isuzu 4BD1-T swap

shanker

shanker

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I've been meaning to start a thread here about my Isuzu Turbo-Diesel engine swap for a while. It's good to get input from the veterans.

I purchased the engine and accessories from a friend of a friend in Daytona Beach Fl. He was running the Isuzu motor in his C-30 Dually for a few years, but switched back to a BBC before the Gas prices went up. I bought the complete engine with a SUPER rare factory SAE #3 bellhousing mated to a chevy SM465 trans, and a complete set of chevy motor mounts that he had fabricated. I had just built up my 700R4 and wanted the overdrive, so I saved those manual trans parts & bought a diesel torque converter.

I'm running the Isuzudieselswapper aluminum adapter ring to mount the auto trans. They were very helpful, answering all my questions before I bought a kit.

I had to cut out the crossmember due to oil-pan clearance, and I'll be running a tubular Big block style X-member from ORD.

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The blue hose by the alternator is an oil drain. The Isuzu Nippondenso alternators came with a vacuum pump on the back of the alternator, so I can run my power brakes etc. It has oil-fed bearings like the turbo, so it'll last forever.

I had a set of custom power steering hoses made to mate the chevy steering box fittings to the AN fittings on the power steering pump. The Isuzu diesels have a hydraulic pump built right in to the front of the block.It has a huge capacity reservoir tank and a lot of flow. I could run a hydraulic winch, or even a dump bed with that thing!

I tried cranking the engine with one Optima 1050cca redtop.. not even close to adequate. I'm running dual batteries to crank this thing. That's the factory setup anyway.
 
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The motor's an oldie, manufacture date is 1980. It's actually a 4BD1 non-turbo. The engine block and head is identical to the newer 4BD1-T. The P.O. was a diesel tuner and bolted up a T25 turbo using some sort of kit. The N/A motors had slightly higher compression I think, and the T25 turbo is larger than a factory one so it should make good power. The injector pump has already been tuned for this setup. I want to add an intercooler but I'll wait & see how it runs out of the box.

I'm running a newer style alternator & a/c compressor bracket from an NPR truck.
 
Help

I recently bought a shut-off solenoid from a used parts place that I deal with regularly. It's designed for a later 80's model NPR truck. Do I have a different injector pump than the later models?

The solenoid has provisions for a shut-off cable and another cable that pulls the "enrichment" for initial startup. I can only find one lever on my injector pump, and i don't know which function it has!

What do you guys think?

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the 14ft box trucks with these motors get mid-20's for mileage.

My K5 is actually more aerodynamic than the huge box & weighs a lot less. I'm running 3.08 axle gears and 35's so the gearing should be right in the sweet spot on the highway (1,700 RPM).

Probably 25-30 mpg. some claim more. The guy that sells the B/H adapters get 28 average in his fullsize pickup.
 
Here are the gauges I set up over the winter. I just finished plumbing and wiring everything up. I am now intimately familiar with the GM wiring diagrams!

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It's a 3.9 liter 4-Cylinder. Rated at 105 HP and around 300 ft-lb stock. Mine has a much bigger turbo and a tewaked injector pump though :)

I'll probably be adding an intercooler once the truck has been running well for a few months.

These engines are in the 18ft Isuzu and chevy Box trucks (12k GVW).
 
UPDATE: The truck runs! I finished the rear disc brake swap and I'll be installing the radiator & plumbing etc.
 
Sweet! Glad to hear it's running now. I subscribed to this thread just to see how it comes out.
 
Here's a new pisture as of today. Radiator & shroud are in. I'm sorting out the 700R4 TV cable and the heater hoses.

My buddy works for penske and he gave me a pair of air-suspension seats from an international truck. I'm installing '90 suburban captain's chairs on these bases for a super-comfy setup! the air valves are fed by blue plastic air line Identical to the ones used for my ARB air locker compressor. :D Pics coming soon.

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I chose the Isuzu over the 4bt because I found one first. I got a great deal on this setup and it was already in a chevy, so I had an easier time swapping it. The built-in power steering pump makes swapping easier and also the vacuum pump on the alt was a nice way to get power brakes. No need to hydroboost swap unless you want it.

The Isuzu motors are notable quieter and make a little more power than the cummins in stock form. Plus this one has been hot-rodded a little :D

I have a Pyrometer probe installed, but I was too broke to buy a matching auto-meter gauge when I did the dash. I'll be adding it before the truck is on the road (stupid I know, but I wanted to see the dash in so bad!)

Another plus is that I can buy parts for the motor at a chevy dealership because the isuzu box trucks were all re-badged as chevys too.
 
so how much would you say you have invested if you want to share?:D
i think its a great idea for a swap. just for those exact points you named.
 
I have about 3,000 invested in the swap so far. The engines are very expensive compared to gassers.
 
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