Well, I have posted teasers parts of this project up in the General Talk Forum back in October. I announced my intentions to do this project about 2 years ago when I bought the car. (Yea, I know, I'm slow. But, I get them done eventually) So, I thought I'd post up the official build here.
And since it is an Isuzu and I did convert it from gas to diesel I thought you WVO guys would appreciate this! <img src="/forums/images/graemlins/lol.gif" alt="" />

And YES, this will be a WVO vehicle when it's all done.
My buddy Jerry was very instrumental in this build. More than you'll ever know. I talk to him daily too!
Here's what I started with.

It's an "89" I Mark 1600cc (gas) DOHC sedan. Talk about a clean 89. (Thanks Jennifer, I'll let you drive your baby again when I drive it to Georgia in the Spring. <img src="/forums/images/graemlins/smile.gif" alt="" />)


Here's the original power plant. 1.6L DOHC Fuel Injected 140 HP.


Here is the "Replacement"


It's an Isuzu 4ZC1-T 1500cc Turbo Diesel. About 90 HP, if I'm lucky! It came with a 3 speed auto, but I want more of everything! So Jerry and I did some digging in his "collection" and found a flywheel for it.


We couldn't find the correct size clutch plate for it. The stock Isuzu clutch plates were either too big, or too little. But the spline count and size was correct. So I cut a big one down.(A little redneck, but it worked, and it static balanced just fine. <img src="/forums/images/graemlins/lol.gif" alt="" />)


The 5 speed that was in the I Mark actually bolted up to the TD engine. Even the starter fit our mix and match flywheel.


On an odd note the cold idle is water temp sensing. Which meant it needed a "T" off the heater lines to get the cold idle to work. Here's the firewall side showing the "T's"


Here's the cold idle in the lower right corner. (I have one hose with both ends of the hose attached in a loop to keep the dirt dobbers from building in them)


I had to build my own glow plug relay circuit, and I built the one Jerry has drawn up for all you other guys that have needed to make one. I made mine out of a pair of Ford starter relays. Sorry no picture! But if you want to see it I'll post one up of it later.

The alternator has issues as in the voltage regulator is toast. But I'll rebuilt it and mix and match parts to make one that will stop the over charging.


Oddly enough the C223 2.2L TD exhaust flange is the same size as the 4ZC1-T 1.5 td. Since I couldn't use the DOHC gas exhaust flange it needed a new way to get rid of the nasty fumes.


And that meant I had to build my own 90deg to get to the flex tube.
[img]http://i31.photobucket.com/albums/c369/Curtis-J/89%20I%20Mark/DSC00423.jpg[/img]

I tried not to destroy everything in case I ever need to swap the gas motor back in.
And of course the catalytic converter had to go.
[img]http://i31.photobucket.com/albums/c369/Curtis-J/89%20I%20Mark/DSC00418.jpg[/img]
I made a replacement that bolted in its place.

The in tank fuel pump put out too much pressure for the injector pump. And there was already a lift pump in the injector pump. So it had to go. I made a new pick up tube and installed a GM type fuel screen. (ThatÆs the thing that looks like a white sock)I'll be adding a small electric pump outside the tank to use once it's converted to WVO.
[img]http://i31.photobucket.com/albums/c369/Curtis-J/89%20I%20Mark/DSC00426.jpg[/img]

And since I'm dealing with a Turbo Motor I decided to add an oil cooler. It was plumbed for one, but it didn't come with the engine. So, I got one from a 1000 cc Yamaha crotch rocket motorcycle. A little modding to make the lines connect and it will be mounted in front of the radiator. A perfect size in every way.
[img]http://i31.photobucket.com/albums/c369/Curtis-J/89%20I%20Mark/DSC00424.jpg[/img]

Finally, the day came to set the engine in the empty engine bay. I had to make some plumbing to feed the turbo and then get that pressure to the intake. But that was the fun part.
[img]http://i31.photobucket.com/albums/c369/Curtis-J/89%20I%20Mark/DSC00386.jpg[/img]

And let's not forget, I need to know how the little engine is doing, so I got some more gauges for it.
[img]http://i31.photobucket.com/albums/c369/Curtis-J/89%20I%20Mark/DSC00415.jpg[/img]

Here are a few more teasers of the engine bay once it was ready to fire up.
[img]http://i31.photobucket.com/albums/c369/Curtis-J/89%20I%20Mark/DSC00431.jpg[/img]
[img]http://i31.photobucket.com/albums/c369/Curtis-J/89%20I%20Mark/DSC00430.jpg[/img]

And "Ta Da" here's the video of the engine running.
[img]http://i31.photobucket.com/albums/c369/Curtis-J/89%20I%20Mark/th_MOV00428.jpg[/img]

It lives! My remote start is still hooked up for the video.
Just a few loose ends and then time to register it for the street.

Can I get an AMEN?

So to sum it up, it was not the hardest engine swap I've done. But it had its moments. I collected parts for more than two years. Once it got pulled into the shop it took three weeks of my spare time in evenings and weekends to do the conversion. If you look close you'll see the tires have dried mud on them. I had to do a few donuts in the back pasture with the 140 horse DOHC motor before it got pulled. What FUN! <img src="/forums/images/graemlins/lol.gif" alt="" />

Left to do: I still need to rebuild the voltage regulator and get the front end aligned. (I took most of it off to remove the engine and tranny, and to keep from hitting my head on the brake rotors while working under the lift.)

The gauges need a pillar housing mount to get them mounted.
I'll be adding driving lights, rewiring the factory fog lights, and adding a cruise control for the long drives to Atlanta. And a killer stereo is on order with blue tooth and MP3 input. My GPS will be mounted on the dash too!

I'll be looking for a set of 3:55 gears for the differential out of a 1.5 TD gas 85 to 88 I Mark. It has 4:10Æs now and if I can get the 3:55's I think I can see close to 50 mpg's out of it.
It needs new tires and I am not real crazy about the wheels. I'm told they are very rare and valuable! But, they gotta go too.

And the manifold on the air conditioner is for a low mount and now that it's mounted high on the motor it's gotta change. I removed the compressor for the pictures but the mounts and pulleys are all made.(Jerry and I will do the mods to the ac system this spring, and get the AC working, when I drive the car to Atlanta to visit him.)
I will definitely be getting the windows tinted. It gets hot here in Texas.

Curtis

In case the video link doesn't work for some of you....
http://s31.photobucket.com/albums/c3...t=MOV00428.flv

And if you have to ask why? Then you don't know me!


Because I can, that's why. <img src="/forums/images/graemlins/notooth.gif" alt="" />

Man-O-Man this is awesome! You did a sidewinder gasser to transverse diesel engine swap. And in your spare time no less.And you found the time to take pictures too! Well done.

Now that's a sweet little ride that started up right away <img src="/forums/images/graemlins/kewl.gif" alt="" />
I'm wondering what kind of mileage you'll be getting out of it.
Do you plan on running bio-diesel?
VERY nice job.

Van <img src="/forums/images/graemlins/patriot.gif" alt="" /> <img src="/forums/images/graemlins/cheers.gif" alt="" />

Thanks for the props guys.

Once I locate and install the 3:55 gears in the diff, Jerry and I think 50 mpg is a definite possibility.

Now all I have to do is find an old, not too wore out, 85 to 88 I Mark with a 1.5L Turbo gas engine that I can remove the gear set and carrier out of and it will be set.

Looks like I need to go get some pictures of the little fuel tank I built for the bio diesel conversion process.
It's a 3 gallon tank I will mount in the left rear corner of the trunk and it will plumb into the transfer valve mounted next to the fuel lines coming out of the main fuel tank. The little tank will be for the dino fuel and the wvo will go in the stock tank. Did I mention I picked up a NEW factory I Mark tank that I will be adding the water heater lines to? This way I can warm up the bio fuel before I switch from the small tank to the WVO fuel. It will also have a temp gauge sensor in it. I don't like welding on gas tanks that have had gasoline in them. So that's why I have a new one.
I'll get a picture of those after lunch to show you what's next on the mod list for this car.

Later.

Curtis

Congrats, that's a very clean conversion.

Where did you source that motor, is it intercooled and what boost does it run?

Thanks!
I got the engine from Jerry. The only 1.5L TD Engine he had.
It looks like it but it's not intercooled. That rectangle
thing is the air cleaner.

Boost? Dunno yet for sure. Should be around 9 to 11 lbs. IIRC. I'll let you know once I get the alternator working where I can register it in Texas and run it down the highway. This project is not really about boost or horse power. If I wanted a Rice Racer, I would have left it with the 140 HP DOHC it had in it. Man that thing would fly!
I am putting in the gauges to monitor the engine performance for some economy figures.
Sorry to disappoint you Speed Junkies! <img src="/forums/images/graemlins/smile.gif" alt="" />



Ok, the other day I promised to get you some pictures of the other small tank that will go in the trunk for the regular diesel fuel and the new stock tank for the WVO that I'll be adding the heater lines to for the bio diesel. Now not to confuse you, but the stock tank that is in it now will be replaced with this new one. Unless I can figure out how to mount one of the 26 gallon Trooper tanks I have for a main tank. How cool would that be to have 2 1/4 times the fuel capacity?

Here the group shot.


I made the little tank out of an air tank I bought at Harbor Freight for about $20. on sale. I used it because of the thickness of the steel they used to make this thing. It's much thicker than the stock tank. I brazed a new filler neck onto it. It will still need a cradle to mount it to the floor. But that's a no brainer. The fuel transfer valve is that little funny thing with 6 ports, and red wire wrapped around it..


This is a close up of the new I Mark Tank. See how clean? <img src="/forums/images/graemlins/smile.gif" alt="" /> Only 11 gallons, darn it! There looks to be some room for a bigger tank under the car if I put a skid plate under it for flying debris off the front tires.


Curtis

hey curtis... looks great. i wanted to mention(you probabley allready know) that a company called arctic fox makes a coolant heated, stainless steel fuel pickup tube called a hotfox, in different lengths and is designed to retrofit, in a hole similar to a sending unit.
aside from that, im interested in the glow plug relay....
again, your project looks awesome!!! (www.enviofuel.com has great products/ideas for wvo) good job!

I didn't know about Artic Fox Co., but that's exackly what I'm building for mine. I'm using some steel fuel line and bending it with one of those small fuel line shapers. Then brazing the tubes through a round piece of heavy gauge sheet metal with barbed fittings on the ends of the tubes. I have a water valve that is vacuum operated that will turn the water flow on and off. The old engine had a boat load of electro vaccuum switches on it, so hooking it up will be a no brainer. There is even an aftermarket thermostat that I can get to control the temperature of the water. I'm just going to use a hole saw to make the access hole in the tank and will add a reinforvcement plate through the fuel pump hole to the underside of the tank top. Two spot welds to keep the reinforcement plate in place will be simple enough to do if I drill two extra holes in the bolt circle. A few sheet metal screws and a gasket like what the fuel pump uses and it done.
I even have enough steel tubing to run from the firewall, at the heater core, to the fuel tank.
With a temperature gauge bung brazed to the tank, it will be a first class set up.
My kinda play time.
Too Easy!

Uh, wait a minute, is that more information than you wanted? <img src="/forums/images/graemlins/lol.gif" alt="" /> <img src="/forums/images/graemlins/lol.gif" alt="" /> <img src="/forums/images/graemlins/lol.gif" alt="" />

Well I'm headed out to put Melissa Miata back together so I can get back to finishing up the I Mark. She broke her radiator last weekend So I ordered her a new one, rather than try and fix that one.


Curtis

hey, i love the full detail descriptions... it sounds like you are all set up.
ive seen some sketchy setups (copper!!!!argg!!), and am happy with enviofuel's system. in oregon, with the winters, we're using the heated pickup, a heated filter, another in-line heater(another coolant powerd one from arcticfox called a linehauler), and a veg-therm on a thermostat as needed!
keep it up, i for one love it!

Well, I have some bad news. It seems that the turbo bearings are toast. Gonna have to pull the thing tomorrow and change them and the put in new seals as a precaution. Think I'll just take it over to my buddy's turbo shop and let him do it for me. Looks like I'll be busy rebuilding the voltage regulator on the alternator while he does the turbo thing.
Today I got all the plumbing done, except for mounting the small tank in the trunk. That I'll try and do tomorrow as well. But, at least the transfer switch and fuel pump are in and working. Oh and I wired in some new circuits to run some other pieces without the ECM. I turned off the power to it to simplify things. And, cause I think I found another I Mark wiring harness I can use on the gas motor to build me a really nice sand buggy. I'll need that ECM for the buggy. <img src="/forums/images/graemlins/smile.gif" alt="" /> Just what I need. Another project.

Curtis