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Old 09-13-2013, 10:55 PM
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Old40Dog Old40Dog is offline
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Join Date: Mar 2009
Location: Evergreen, Calirado
Posts: 1,643
Default Old40dogs Diesel Conversion Project

Theres always a lot of discussion about how to justify the expense of a diesel swap. Well, my plan has been to build a truck that I can drive until they wont let me drive anymore. I tend to keep my vehicles until I cant justify repairing them anymore. Mileage improvement,

Those who have known me for a while know that I bought my 1992 FJ80 with a current 308K on the clock and its 3FnE with a diesel swap in mind. Actually its 3FE with around 150K on it is from Treys FJ62 into which he did a nice V8 swap. I initially thought Id swap in a 1HDT then a 1HZ and add a turbo, but I kept running into the same issue. $7-$10K for a donor motor that Id still need sink another couple of grand into the rebuild. The result would be a sweet set-up, but just a little too pricey for my budget and taste.

At Cruise Moab, I spoke with a fellow from Portland who had swapped an Isuzu 3.9L Turbo Diesel into his FJ60 and was very pleased with the results. It was a clean conversion and was much quieter than another 60 on the run that day running a 4BT Cummins. It was suggested that I check out
Longbows (Don in Tucson) diesel conversion thread on Ih8mud. Don was so happy with the results with the Isuzu swap into his 60 that he did one in his 40 and is planning still another swap into his wifes 80.

The Isuzu 4BD2T is a 4 cylinder indirect injection intercooled turbo diesel with a Bore x Stroke 102 mm x 118 mm Displacement: 3,856 cc (235.3 cu in). Horsepower is 100kw (135 SAE Gross HP) at 3,000rpm, torque is 345Nm (255 Ft-lbs SAE) at 2000rpm. The 1FZ-FE produces 212 horsepower (158 kW) at 4600 RPM and 275 pound-feet (373 Nm) at 3000 RPM. Ill use an adapter to a A442F Toyota automatic transmission with a modified torque converter.

Im expecting this swap too take some time as I expect to be able to work on the project only in spurts as time and funds will drive the schedule. The donor vehicle is at my office in Denver (near I-25 & CO) and Ill remove the engine and necessary other items there and do the work on the 80 in Evergreen. If youre curious enough to want to hang out to observe or to lend a hand, all are welcome. Ill post up here as things progress. The next several weeks are already committed to some work travel and of course the Outlaw Run. I expect to get started on removing the engine from the Isuzu in late October/early November.

Pics of the Isuzu NPR (GMC badge) Donor and the FJ80 Recipient.
Attached Images
Dave K,TLCA#20150,KFDOG,'69 FJ40-"Toyolet",'92 FJ80 {Isuzu diesel conversion underway} ,2011 Replica M416 w/RTT,'98 Taco Xtracab 4X4, Project='72 FJ40, '05 Passat TDI-DD.
"It is the first responsibility of every citizen to question authority." "A republic, if you can keep it". Benjamin Franklin 1706-1790
"The problem with socialism is that eventually you run out of other people's money [to spend]." Margaret Thatcher 1925-2013

Last edited by Old40Dog; 11-15-2013 at 11:27 PM. Reason: Add pics
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