Hello everyone, new here an my first post. I just bought a 1986 Trooper with the 2.2L turbo diesel 4x4, with 109,000 miles on it for $350 bucks. Only thing wrong with it is it needs the clutch replaced. the guy i bought it off of started to replace it but decided he was gonna restore the whole thing. So he started tearing hoses off, pulling wires and unbolting things. Well he lost interest, pushed it into the back corner of his driveway and there its sat for 3 years. info on these things seem to be hard to find when you dont know where to look. this seems to be the best place so far. I was wondering, does anyone have any pics/diagrams/anything that would help me get all the hoses and wires hooked up? the passenger side seems to be where all the mess is at. Also anything to look for or pay particular attention to or things that often break? Once it gets in my shop its gonna get all the fluids changed, lubed, brakes checked out everything before i even fire it up. I want everything to be right from the start so i dont waste time an money chasing down lil problems. I hope someone has any kind of information that can help me because i hate guessing where wires go.

Joe,
I probably can't help with the trooper, I have a 1981 Pup with the c223 diesel n/a, one thing ever one told me was to make sure to change the timing belt after one has set up a long time. this is a good place for info, also there is a Isuzupup.com forum that has a lot of info to. I found a wiring diagram over there for my truck, not sure if the trooper is wired the same. The glow plug wiring should be the same. Should be a fuel filter on the fenderwell on Pass side. also there should be two relays that control glow plugs. If someone with a trooper does not help I will take pic of my pup for you if that will help.
good luck
freddie

Im not sure, but i think the P'up and trooper are like the Chevy s-10 and blazer. same frame and everything, different body. I think at this point, anything i get will be of more help than just guessing.

In many ways, it would be simpler if that were the case, but the Trooper/P'up shares little more than some powertrain options with the S-10/Blazer line. Different frames, bodies, etc. The later Hombre was a rebadged S-10, but that's about it.

I've since passed on my shop manual, but what I recall is that the Trooper and P'up were screwed together pretty much the same across years from the firewall forward, at least. Wiring information for the truck should translate, although I won't swear that component location will be the absolute same between the two.

Hang tight, and I'm sure some of our resident diesel burners will be able to chime on the subject.

James

joeschmoe -- sent you a PM.

WELL JOE I GOT ONE OF THESE LITTLE TICKERS TOO(SINCE FEBRUARY 08)
I HAVE DONE A LOT OF THINGS TO MINE BUT BE SURE TO CHANGE THE TRANNY OIL / THOSE THINGS ARE HARD TO FIND IN WORKING ORDER AND COSTLEY TO FIX
IL WILL SEND PIC'S OF WHATEVER YOU WANT JUST LET ME KNOW WHAT YOU NEED
ALSO THERE IS A ROUND PLUG ON THE ALTERNATOR THAT I NEED A DIGRAM FOR TO GET MY TACH IN WORKING ORDER OR AT LEAST BE SURE I HAVE HOT WIRED CORRECT. ANYWAY THE TACH IS THE ONLY THING THAT I HAVE NOT FIXED.
PS IF THE BLOWER MOTOR QUITS WORKING LOOK UNDER THE RESERVE TANK FOR THE RADTIOR (DRIVERS SIDE / BACK OF HEAD LIGHT) THERE IS A INLINE 20 AMP FUSE A IT WILL FIX IT. THAT ALONE TOOK 5 WEEKS TO FIND & FIX

I need pictures of what color wires hook up where, and all the (vaccum?)lines around the injector pump area. Also, on the thermostat housing, theres 2 sensors. Labeled 1, and 2. number 1 is easy to find at the parts store, but i cant seem to find number 2, it has 2 wires with one connection terminal horizontal, and the other vertical. Whats up with this? Man i really wish i had some sort of manual for this thing. I think im gonna end up keepin this thing. original plan was to take the motor out, scrap the rest, and plant the motor in the s 10, but the more i work on this thing, the more i like it.
And by the way, this forum community is nothing short of great! I'm a member on a couple other forums and this one is definetly the most helpful and friendly one so far. It makes owning a unique vehicle as these, that much more enjoyable. Oh ya almost forgot, my email is joeshmoe_44883@yahoo.com for anyone that has any info they want to pass along, thanks!

Well some updates, found one of the coolant sensors, the one wire one i guess is for the gauge and is $86.09 at NAPA, ya, holy crap. The 2 wired one I couldnt find anywhere, so im thinking its gonna have to be ordered from a GM dealer. My diesel mechanic friend said its probably for the glow plugs, when it senses the coolant temp is up to norm, it tells the plugs they dont need to come on since the engine is already warm. Ordered the timing belt, a heater hose, the lower radiator hose and i think a few more things. I also wired up a boost gauge and an egt gauge so i have an idea whats going on when i add the intercooler, some more fuel, and possibly water/meth injection. I also tried to pull the tranny last night with no success. all the bolts out, exhaust is out of the way, cables and wires disconnected, got it out maybe 3/4 of an inch and it just wiggles, but doesnt want to just break free. Is there any tricks to getting it out that i dont know? the shift levers and driveshafts are removed in case anyone asks.
I also kind of started on the inside, new carpet is going in. I threw a battery in and turned the key and the only thing that works is lights. The wiring on these things doesnt look fun, made worse by the previous owners hack job. this is turning into more of a project than i thought, but i like a challenge.

IF YOU ARE REFERING TO THE SINGLE WIRE SENSOR ON TOP OF THE THERMOSTAT HOUSING THAT IS FOR THE GLOW PLUG SYSTEM SO THAT IT TELLS, THE G/P CONTROLLER TO NOT LET THE G/P,S PREHEAT ON A WARM ENG , THE TWO WIRE SEN, IS FOR THE FAST IDLE CONTROL HAS NOTHING TO DO WITH THE TEMP OR THE GLOW PLUGS, THE ENG TEMP SENSOR IS MOUNTED ON THE AIDE OF THE HOUSING THTA THE THERMO IS MOUNTED AND HAS A PUSH ON CONNECTOR , IF YOU HAVE A.C IT IS BEHIND THE A.C BRACKET , BUT YOU CAN SEE IT AND GT THE WIRE BACK ON,AS IT HAS PROB FALLEN OFF, YOUR TRANS IS PROB, JUST RUSTED TO THE INPUT PILOT BEARING, IF YOU CNA MOVE IT BACK 3/4 IN JUST KEEP WORKING AT IT A LITTLE AT A TIME AND TI WILL FINALLY COME CLEAR, YOU DO NEED TO REMOVE THE FRT DRIVE ASSY FROM THE TRANSFER CASE , OR THE TRANS WILL NOT CLEAR THE FLOOR VERY EASY, BE CERTAIN AND REMOVE THE BRACKET THAT IS BOLTED TO THE FRAME UNDER THE TRANS THAT THE TRANS MOUNT SITS ON, ONCE THE TRANS CLEARS THE FRT PILOT BRNG, YOU HAVE TO TILT THE TRANS DOWN IN FRONT AND ROTATE IT TOWARDS THE DRIVER SIDE A LITTLE AT A TIME AS YOU KEEP THE TAIL END UP AND ROTATE IT A LITTLE MORE AND THEN DOWN IN FRT , THEY ARE A HANDFULL BECAUSE THEY ARE VERY HEAVY UNITS AND THE CENTER CROSSMEMBER IS NON REMOVEABLE.. JERRY

Thanks for that info! Im gonna try to get it removed tonight and install the new clutch. Also gonna throw some fresh clean oil and fuel in her, and try to start it tonight. The original plan was to get it all back together and then start it, but once again my diesel mechanic friend said from experience to start it first to make sure nothing is wrong with the engine. If there is i can easily take the engine out and get it fixed since the trans is aready out. I'm crossin my fingers hoping everything is ok yet. Its been a few years since it last ran.

Well we didnt try to start last night, but we did get the transmision out, yay. well then i noticed a bearing in the crankshaft was almost completely gone, there was oil leaking from the rear main,and when turning the transmission input shaft by hand, the only time i can get the transfer case to spin when in 4WD, was in 4th gear. So i'm not a tranny expert, but i think this means its shot. Drained the oil and only small particles of metal fell out, no chunks. And there was a sensor on the side of the transmission that was pretty beat up, anyone know what sensor it is?

Talked to my transmission guy this morning,said the transmission is probably toast. So i've gone lookin for a used tranny. Anyone know if the diesel and gas trannies are the same? at www.car-parts.com, they list the gas trannies but say they cant find any diesel ones. Hmmm. If they are the same I'll just buy the gas one.

Well, pulled the motor today, turbo compressor seal is leaking oil. I'm thinkin i'm gonna cut my losses and scrap the vehicle, should get about $200 for it and i'll have a diesel motor out of it too that i can put into an s-10 like i had originally planned. Its looking like its going to cost to much to get this thing running as is. Its a sad day for the ol trooper, only has 109,000 miles, but sitting around for years has just takin its toll.

The gas and diesel trannies are different.

Gee that's sad that you're going to scrap the entire truck over a tranny.
There are always solutions. If you were closer I'd come get it. I could use another parts truck for my TD Troopers, but the wife would not be happy.
There is a front bell housing that is out there that will allow a gas Transmission to mate to the C223 TD engine. I know, because I have one for one of my project trucks. But, they are very rare. And the diesel trannyÆs, although few and far between, can be tracked down. I may even have a spare after I get my TD Troopers built. But, I'm hanging onto it for the time being as a spare. Just in case.

Maybe I should prepare you, that to have a Professional Shop do a rebuild kit for that Turbo will cost you in the $450 dollar range. And it will take a Professional to get it right. If you need pistons then you'd better prepare yourself to take out a loan. These engines are expensive to rebuild, unless you have spare parts, because they are so rare in the U.S.

Anyway, enough doom and gloom.

Don't send it to the crusher without letting us know first. Especially me. You have a lot of parts that some of us need for our Trooper projects. And if you don't have room to store it for a while and time to be patient, then by all means let me know. These kind of trucks require a lot of patience to gather all the pieces and rebuilt them to get them running. (Ever see Tanks on TV? Same thing almost. I may just have to make a road trip to rescue you from your nightmare and gather some pieces for the other guys on the forum for their TD Trooper Projects.

Does that make sense?
Curtis

If it gets that far Curtis, we'll have to figure out how to snag dinner together or something as you go by.

James

Slow down man ! If I remember right the gears and shafts are the same in the gas tranny. Gas troopers can be found on craigslist CHEAP with a blown head gasket. The difficulty here is that the bellhousing is the front half of the transmission case too.
Use a gas tranny for a guts donor.
The s10 or s15 diesels had a borg warner trans, this is the one with the separate "bellhousing".Rare

Have you done a compression check yet ? A leaky turbo seal is hardly a reason to throw it out either.There Was a turbo+manifold on fleebay for $99 last week.
Or you could go non turbo.
http://cgi.ebay.com/ebaymotors/ws/e...=&item=320263269830&rd=1

Do a proper compression test on that thing, if it cranks and doesn't knock,then check the oil pressure with a manual gage... should be above 50psi @cold idle.

Here are the isuzu transmissions and their applications
MANUAL TRANSMISSION
ISUZU Amigo/Pick-ups/Rodeo/Trooper 1981-1996
http://www.autozone.com/shopping/repairGuide.htm?pageId=0900c1528006282b
nice cutaways...

At the moment I'm waiting on my stimulus check so i can put a transmission in my other car. I think i'm going to keep the trooper, Its in such nice shape that i really dont want to scrap it. i think im just going to drive my other car and save to get the tranny rebuilt, but im afraid of what the parts cost will be. Anyone have a guess to how much it will cost to rebuild the transmission? If its going to be too much I may just keep the motor and sell the whole trooper to someone.
Right now the head is off and at the machine shop getting checked out, I'm planning on porting it a little bit, but not too much, as i heard that supposedly the heads are known to crack. Hopefully some new stainless valves an maybe ceramic coating the exhaust valves and pistons with a dry lube coating on the piston sides. Sizing up a variable vane turbo now and will hopefully build a custom exhaust manifold to move the turbo forward and face forward, eliminating those stupid 90* bends in the intake an exhaust. The engine should breathe better and easier and should see the turbo spool pretty early in rpms thanks to the variable vane.
The new carpet came the other day and should really complement the interior since the carpet is the only thing that looks bad in this thing. The headliner still looks new and the seats dont even look worn. So once the motor is done, interior cleaned and put back together, the only thing left will be the transmission.
Out of curiousity, how many of the diesel trooopers were built? The way it sounds and how hard it is to get parts, not many i guess.

I bought one last year, and just bought another a month ago, not as rare as you think, one on ebay now, and always on craigslist somewhere in the US. PLENTY of usefull and helpfull people on this site and isuzupup.com and planetisuzu.com
plus tons of parts in AU and NZ and shipping not to bad at that, once dialed, they are a true trooper. def. replace the timing belt though, i went through that one about 6 months ago, did a little damage but not half as bad as i was thinking, i too was looking to give up and give away until i got alot of help on these sites. my first one runs on bio/veg and looking to convert this new one soon too. congrats and a great find.

Ya i've already posted this is probably one of the best forums i've been on, might not be the most active, but that means theres less people talking trash to other members. You said troopers aren't bad once there dialed in and that brings up a good question, what kind of motor tuning has everyone done? I have an EGT and boost gauge plumbed up so that will help my tuning process, but it'd be nice to hear what the most common tricks are. Has anyone installed an intercooler on their trooper? I'd love to put a front mount but there doesnt look to be much room for one. Any ideas out there?

Well its come down to it, i'm gonna sell it. I just dont have the time and money for it. The engine and transmission is out. The engine will have a new clutch/pressure plate and new cutch pilot bearing,new rear main seal, new timing belt, new head gasket, new intake and exhaust manifold gaskets, and a new fast idle sensor. Its already plumbed for boost and EGT gauges. Once it gets back together i'm going to start it to confirm that is starts and runs. I'm also going to change the oil and oil filter before starting it.

The transmission needs repaired, am not sure whats wrong with it, drained the oil and no large pieces, just metallic shavings. shifts fine with no binding, transfer case works fine too.

The trooper itself is in really good condition, no rust holes at all as it was in florida most of its life. Have brand new carpet for it. Seats are intact and are not torn, headliner looks new too. previous owner took out the radio and left it a mess, but it will clean up nicely and the new carpet will really make a difference. Its also a 4 door. any questions feel free to ask, I live in Tiffin, Ohio 44883. Prices? Not real sure but probably around $800 for everything all together. Or probably $300 for the motor, and probably $600 for the whole trooper body without motor an trans. tranmission will probably be around $70. I dont want to part it out, so please dont ask. Oh ya if it matters, all tires are in great shape, still hold air and i would say about %80 tread left. Spare tire is still brand new.

If anybody needs the motor, I'll be up in Ohio from the 11-17 August and could transport it back to Spartanburg, SC or Atlanta, GA.... from there? Or, if I could flat tow the whole thing?

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

I just wanted to give everyone a heads up, if I dont sell it within 2 weeks i'm going to be forced to take it to the local junkyard and scrap it. I really dont want to do that but I have no choice.

Welcome to the forums Joe, sorry I missed the beginning of these posts. Did I miss it if you said where this Trooper is located? Even with fuel prices the way they are I am almost positive everyone on this Isuzu Diesel forum is on the edge of our seats wondering what the demise of one of these rare vehicles is going to be. We have all seen these Troopers sell for five times what they should, and this saddens most of us because we are more interested in just keeping ours in good shape not resale value. I paid $800 for a basket case similar to yours, I still hope to rebuild it, it probably needs more parts than it is worth, but still, the notion of a parts car is fairly enticing,
Please do let us know what you are going to do, with her

$500 for the whole thing, I really dont want to scrap it, and at that price its less than i have in it. I decided not to buy all new gaskets and put it all back together because of parts. The trooper is at my house in Tiffin, Ohio.

You might want to post this on.... http://forum.planetisuzoo.com/viewforum.php?f=2&sid=2b39ee9ae7c5e77a4c148b6d782999c8

and.... http://www.isuzupup.com/index.php

I know there are some people who might be interested on those sites..... especially for the motor... hate to see an Isuzu engine or truck go to scrape.

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

maby craigslist too?

HI,
IS THE MTR COMPLETE?? AND IS IT A C223TURBO DSL? IF SO, I AM A BUYER. I HAVE A 86 ISUZU TURBO PUP SPACE CAB WITH A THRUST-WASHER ISSUE IN THE CRANK.

PLEASE ADVISE.

ANDY

I MAY NEED YOUR HELP, IF THE SELLER HASN'T SOLD THE MTR YET. I HAVE A FRIEND IN CHESNEE SC THAT HAS A YARD THAT I BUY EQUPT FROM AND THE MTR CAN COME FROM THERE TO ME ON A LOAD.

THX

ANDY

e-mail sent to seller at 10 am this date

thanks
mike

Glad to see that maybe we can save this engine. <img src="/forums/images/graemlins/notooth.gif" alt="" />

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

Yes I sure hope so, It kills me I cant save this myself, but we all know sometimes we have to make sacrifices. Hopefully someone takes it and gives it the life it deserves.

well somehow the Trooper survived extinction and I still have it. Got a new job, paid everything off, now the trooper is in my sights again to get running. I'm gonna check on quotes to get the tranny rebuilt and i need to rebuild the turbo. The biggest problem is the cylinder head, its cracked on 3 out of 4 cylinders. I've been searching for a week on the internet and cant find any, zero, nada. Does anyone know of any place to get parts? The absolute hardest part to find is the fast idle switch part #8-94234-651-0. i found a website that has everything you need www.myisuzuparts.com but i've submitted several part requests but no answer. I really want to get this running, i could really use it for work surveying farm fields. If i absolutely cannot get parts, i have a cummins 4 cylinder turbo diesel that i could maybe swap in. rated 120hp and 300 ft/lbs of torque. but that would require ALOT of work..... sigh.

sent a Private message to you

hey everyone, it has been a looooooong time since ive posted on here. well good news, my trooper is getting redone. Got a new cylinder head about 3 years ago from jerry, and the fast idle switch. just got the head back from the machine shop, had everything swapped over. had to regrind the valves, shim it, and decked it .005". checked the main and rod bearings, mint condition. im hoping this engine has the stronger rods, considering it looks like a rod went through the block, and someone (probably isuzu) patched it, and the oil pan. fuel pump was siezed, so that and the injectors are going in for a rebuild. once those get back the engine should go together and be done. then i gotta get the trooper itself in and start work on that. new wiring harness, carpet, brakes etc. ill post pics when everything gets started.

i also acquired an isuzu 4bd2t complete with starter, alternator, a/c compressor, trans, and intercooler. I'd like to sell it since i dont have a use for it. although i think im going to save the intercooler for the trooper.

Well, did you get it going yet?

I've got everything I need to get mine going too and I've been so busy I havn't been able to get it back together either.

So I know what you're going through!

no i dont have it together yet, in fact its apart more now than it was before. I've found out alot about it tho. for one it has gen 3 rods! sometime in its life it did throw a rod out the block and pan. i bout a variable vane turbo that involves programming a microcontroller to use. with this new turbo i can have boost almost immediatly, and will hold it all the way through the rpm band without choking the engine on the high end.
i sent the block out to the machine shop, the deck was o-ring to handle any amount of boost i can throw at it, good for 70psi. the cylinders were honed and measured, i really need oversized pistons, but cant find any. I had the crank balanced and good thing, the front was off 27 grams. should definitely be a smooth runner now. got all new bearing installed, cam is getting sent out to get re-ground to handle more boost/fuel. the diesel kiki injection pump is the same as the bosch ve pump, so im swapping out the pump head for a 10mm head, and running a 11mm cam plate to push the plunger as hard as it'll go. should give me 160hp worth of fuel if i wanted. My goal is 120hp, and we'll go from there. Also going to build my own intake and exhaust manifolds. the intake will house a cummins 5.9L intake air heater. this will help start an warm the engine up with the milled 19:1 compression pistons.
The trooper itself is getting the body pulled off, frame gets bead blasted and re-painted. the body has only a couple rust spots on the bottom, so those are getting fixed, new carpet, and then maybe repainted. Lots an lots of work to do. Ive been hanging around the www.isuzu-pup.com forum, ive posted pics up in the thread, a trooper revived. take a look and let me know what you think!