Well, I'm still here working on my conversion to my 1st gen 86 Trooper T/D. I'm currently moving the battery back under the rear seat so that I will have room for the SAAB intercooler I got off ebay last month. The old battery tray is out (I got one of those special drill bits that cut out
factory spot welds) and am I'm surprised at all the room I have there now. Gonna move the windshield wiper bottle to the other side, too. If I drop the front bumper a couple of inches or raise the body a little with a two inch kit, I'll be able to utilize one of the air inlets under the passenger side headlamp for the air I'll need for the intercooler. Did all this while I had the radiator out from doing the timing belt.

By the way, for all the c223 diesel trooper owners, the timing belt was tricky without the cam and pump lock much less not having the static gauge: first time I was a "tooth" off and got a lot nailing before I went back in and discovered my snafu. The injector WILL rotate a tooth when the tensioner is released to be replaced unless you have the inj pump lock. I searched all over the internet for an Isuzu diesel timing set and they are none to be found. I called a lot of dealerships only to find out that Isuzu is pretty much closing up shop all over the country. There is a cam locking pin that holds the injection pump in place while the belt is off, but I estimated where the belt was going to be when the roller (tensioner) was back in place and got it right on the mark (there are two arrows to help). Starts up and sounds good now. I still do have the problem of tightening the 39mm crankshaft end bolt to 50-60 ft-lb. The crank just turns when I try to tighten it now and the manual calls for pulling the starter and placing a flywheel lock in it's place. I don't think a eight year old could get their hands down in there to get to the starter bolts much less my big mitts. I think I'll use Locktight for now and torque when I pull the motor out to put into the 88LS unless someone else has a better idea.

I went over to Home Depot and picked up some small angle iron and mig welded up a battery box that will slip down into the square hole I will have to cut into the floor under the rear seat. Don't know if anybody is interested, but I
did take some pictures.

Jess
86 Trooper T/D
88 LS Trooper

I was able to tighten my crank bolt. I'm trying to remember how I did it. I believe I just put it in gear. I know I did not pull the starter.

I too rear mounted my battery. I also have a saab intercooler. You will want to get a blow off valve to replace that 15psi pop off valve. I got one on ebay from an eclipse. you need one that can hold 15psi (what the pop off factory valve provides). A blow off valve will keep boost from falling too far between shifts. When you pull the pop off valve, the good news is that underneath it, there is a threaded hole in intake. I intend to just plug this with a brass plug/nut when I determine size and thread pitch. This will allow you to reverse the intake inlet where turbo pressure currently flows into the intake. Right now, that small tight 90 degree rubber elbow won't leave room for 2 hoses. But as I said, with pop off valve out of way, you can reverse the turbo inlet adapter and have plenty of room for intercooler hoses/piping.

ps, make absoluteley sure you are at TDC, cause this engine will bend valves if the camshaft is out of sync. (complete rotate engine a couple of times to catch this) I pulled the valve cover and insured both valve lash clearances on no.1 cylinder were correct when cam and injection pump pulley arrows were precisely at each other and crank at TDC.