91 Storm Trooper rebuild project

Post pictures of your Isuzu here. Document Mods, showcase unique features and generally show off your truck

Moderator: Staff

91 Storm Trooper rebuild project

Postby Docloucks » Sat May 01, 2021 10:14 am

Ok so here I go. Had an ‘88 a ‘94 and a ‘98 over the years. About to dive into my new ‘91 that I picked up in Nor Cal for $2k with a bad rod knock and no power but still moving. Clean body, nice 2” lift and great rubber.
Specs: ‘91 Trooper with 4 cyl 4ze1 and manual transmission. Plan is to start pulling the motor this weekend and get it up to Reno to Shawn Anthony for a complete rebuild. Lots of “Might as Wells” to happen. Will pull the tranny and have a local shop go through it. Definitely a new clutch and then put it all back together.
I have reasonable diy mechanical skills and great internet. Lol. I have pulled and a replaced an engine in an old CJ5 back in college 30-years ago. I’m less flexible but more patient now...
Following an old Chilton removal instruction and extra tips gathered from the forum and YouTube.
Fingers crossed! Will post updates and pics as I go for those interested. Tips and advice welcomed!
You do not have the required permissions to view the files attached to this post.
Docloucks
Drives on Pavement
 
Posts: 9
Joined: Thu Apr 15, 2021 12:34 am
Has thanked: 4 times
Have thanks: 1 time

Sponsor
 

Re: 91 Storm Trooper rebuild project

Postby Docloucks » Sun May 02, 2021 5:22 pm

Weekend 1 up; radiator, shroud and fan out, all the electrical and vacuum labeled and disconnected, exhaust tailpipe pick up removed, PS disconnected, Next weekend I'll borrow a cherry picker and go for the pull. Leaving the Itec on. Will wrestle the tranny bolts and cross my fingers. Working slow and methodically with only a few hours each day per weekend. Final removal will determine if I have the balls to attempt re-install. Like the built not bought approach... fingers still crossed
Docloucks
Drives on Pavement
 
Posts: 9
Joined: Thu Apr 15, 2021 12:34 am
Has thanked: 4 times
Have thanks: 1 time

Re: 91 Storm Trooper rebuild project

Postby BoiseTrooper » Mon May 03, 2021 1:40 am

Nice rig! Welcome!

I recently put a 4ze1 crate motor in my '89.

If you are going for a full rebuild anyway, I think it is easier to pull the head and itec combo as a complete unit. That way you don't have to try to get to the intake bolts underneath the plenum on the itec. You can just take the whole head off and the itec comes with it. It makes pulling the block easy after the head/itec is off. I have pics of pulling the old motor on my Project Thunderbolt thread.

You can do it!

If you have access to a lift, I found I was able to stand under the transmission and reach up on either side like I was giving it a hug and was able to reach those bolts pretty well. Otherwise, the trick of removing the motor mounts and dropping the engine and transmission tilts down a couple inches gives you more space. (it rests on the crossmember) J5 has a vid on youtube on it.

Kind regards,

-BoiseTrooper

For this post the author BoiseTrooper was thanked by:
Docloucks
BoiseTrooper
Loyal P'up
 
Posts: 138
Joined: Tue Apr 16, 2019 2:50 pm
Has thanked: 47 times
Have thanks: 2 times

Re: 91 Storm Trooper rebuild project

Postby giusedtobe » Mon May 03, 2021 7:46 am

Nice! From your college timeframe I think we are ~ the same age. Not trying to take $ away from Shawn but you can rebuild it yourself if you have a reasonable machine shop in the area. I am not as flexible as I once was either but managed all the work alone. I had done a fair amount of peripheral auto work; brakes, water pumps etc. but had never dug into the guts of a motor. With the help of people here I rebuilt mine. I have a thread called 2.6 rebuild if you are interested.

Alan

For this post the author giusedtobe was thanked by:
BoiseTrooper
giusedtobe
Trail Master
 
Posts: 554
Joined: Wed Jan 22, 2020 5:34 pm
Location: Knoxville TN
Has thanked: 29 times
Have thanks: 28 times

Re: 91 Storm Trooper rebuild project

Postby Docloucks » Mon May 03, 2021 11:03 am

Baby steps... I'm going to leave the internal rebuild to the pros this time and see if I can try and not screw up the rest, lol. Lots of knowledge out there to help me through it hopefully. Now I get to do my day job all week and prep for next weekend

giusedtobe wrote:Nice! From your college timeframe I think we are ~ the same age. Not trying to take $ away from Shawn but you can rebuild it yourself if you have a reasonable machine shop in the area. I am not as flexible as I once was either but managed all the work alone. I had done a fair amount of peripheral auto work; brakes, water pumps etc. but had never dug into the guts of a motor. With the help of people here I rebuilt mine. I have a thread called 2.6 rebuild if you are interested.

Alan

For this post the author Docloucks was thanked by:
BoiseTrooper
Docloucks
Drives on Pavement
 
Posts: 9
Joined: Thu Apr 15, 2021 12:34 am
Has thanked: 4 times
Have thanks: 1 time

Re: 91 Storm Trooper rebuild project

Postby mudoilngears » Mon May 03, 2021 12:33 pm

Docloucks wrote:Baby steps... I'm going to leave the internal rebuild to the pros this time and see if I can try and not screw up the rest, lol. Lots of knowledge out there to help me through it hopefully. Now I get to do my day job all week and prep for next weekend


I'd make sure the pros are pros before sending it to the pros. If you take my meaning...
Image
1998 Rodeo LS 4x4 4JB1-TC Diesel Swap, Moog CC247 coils, more mods to come!

SOLD- :( 1990 Isuzu Amigo 4X4 4ZE1 engine. Front Aussie Locker, HD Sway Away T-bars,Smittybilt XRC8 winch.
Build in progress...
User avatar
mudoilngears
Almost Joe Isuzu
 
Posts: 2246
Joined: Sun Jun 17, 2012 9:49 pm
Location: Costa Rica
Has thanked: 19 times
Have thanks: 187 times

Re: 91 Storm Trooper rebuild project

Postby giusedtobe » Mon May 03, 2021 4:06 pm

mudoilngears wrote:
Docloucks wrote:Baby steps... I'm going to leave the internal rebuild to the pros this time and see if I can try and not screw up the rest, lol. Lots of knowledge out there to help me through it hopefully. Now I get to do my day job all week and prep for next weekend


I'd make sure the pros are pros before sending it to the pros. If you take my meaning...


Agree. You do it yourself then you know its done right.
giusedtobe
Trail Master
 
Posts: 554
Joined: Wed Jan 22, 2020 5:34 pm
Location: Knoxville TN
Has thanked: 29 times
Have thanks: 28 times

Re: 91 Storm Trooper rebuild project

Postby paulevans76 » Tue May 04, 2021 4:42 pm

That looks like the one that had a build thread on here some years ago. https://www.planetisuzoo.com/viewtopic.php?f=1&t=74710 The owner dumped ton of time and money into it and then sold out of isuzu after getting frustrated with it and his other projects. If that is the same rig, it looks like it was partially parted out. I don't think the photos still work but it was same very nice white with round eye grill, but the owner had black interior done. The wheels and tires look the same too.
Scratch n Dent special 1991 Trooper S
3.4 V6 - Holley TBI, CompCams 252H, 1.6:1 roller rockers, +1mm DOHC pistons, MSD ignition, custom tune, "Ed Mc Special" 2.5" exhaust
MUA5 w/ 3.07's & fixed yoke
SAS - Waggy F D44 - 5.38's, RCV's, OX locker; Rodeo R 44 - Detroit, truss
Front Y-link radius arms, coils; Rear SOA, OME leaves, anti-wrap bar
35x12.50/17 General Grabber X3's on 17x9 Interco Birddogs
Trail armor and Warn XD9000
The White Whale - a temporary daily driver 1991 Trooper - 2.8 V6, MUA5 - stocker resto (sold)
1994 Samurai - 1.3 FI - OME suspension, 31's, 6.5:1 tcase, 5k milemarker SxS winch, more to come!
User avatar
paulevans76
Almost Joe Isuzu
 
Posts: 2070
Joined: Tue Mar 21, 2006 10:04 am
Location: Lake Wylie, SC
Has thanked: 224 times
Have thanks: 185 times

Re: 91 Storm Trooper rebuild project

Postby Docloucks » Tue May 04, 2021 5:07 pm

Nope. Similar but not the same one. Carfax mileage and owner history doesn’t add up. Plus it’s got stock brown interior. The guy I got it from did switch out the grill and lights to the round but have tons of paperwork and receipts. Great recall though. I’m impressed
Docloucks
Drives on Pavement
 
Posts: 9
Joined: Thu Apr 15, 2021 12:34 am
Has thanked: 4 times
Have thanks: 1 time

Re: 91 Storm Trooper rebuild project

Postby mudoilngears » Tue May 04, 2021 7:14 pm

Bart's Trooper was the first thing I though of when I saw this.
Image
1998 Rodeo LS 4x4 4JB1-TC Diesel Swap, Moog CC247 coils, more mods to come!

SOLD- :( 1990 Isuzu Amigo 4X4 4ZE1 engine. Front Aussie Locker, HD Sway Away T-bars,Smittybilt XRC8 winch.
Build in progress...
User avatar
mudoilngears
Almost Joe Isuzu
 
Posts: 2246
Joined: Sun Jun 17, 2012 9:49 pm
Location: Costa Rica
Has thanked: 19 times
Have thanks: 187 times

Re: 91 Storm Trooper rebuild project

Postby Docloucks » Tue May 04, 2021 7:40 pm

well hopefully Bart's was badass and will lend some cosmic force to mine being that it is Star Wars day...
Docloucks
Drives on Pavement
 
Posts: 9
Joined: Thu Apr 15, 2021 12:34 am
Has thanked: 4 times
Have thanks: 1 time

Re: 91 Storm Trooper rebuild project

Postby Docloucks » Sun May 09, 2021 10:12 am

Labeling, bagging and tagging.... boy there are a lot of hoses, electrical connections and vacuum pieces. Praying my tape labels, videos and pics help me figure out how to put it all back together! I get the strange feeling I will need resources to figure the puzzle back out, lol.
You do not have the required permissions to view the files attached to this post.
Docloucks
Drives on Pavement
 
Posts: 9
Joined: Thu Apr 15, 2021 12:34 am
Has thanked: 4 times
Have thanks: 1 time

Re: 91 Storm Trooper rebuild project

Postby giusedtobe » Sun May 09, 2021 6:10 pm

Take lots of pictures and label like you are doing and you will find it surprisingly easy. If you lose a label and forget you can find it here in photos or just ask and someone will know.
giusedtobe
Trail Master
 
Posts: 554
Joined: Wed Jan 22, 2020 5:34 pm
Location: Knoxville TN
Has thanked: 29 times
Have thanks: 28 times

Re: 91 Storm Trooper rebuild project

Postby Tentin » Sun May 09, 2021 6:58 pm

Yep any organization you do now will pay off in the long run. Labeled ziploc bags for bolts and smaller pieces helps too
1995 Isuzu Pickup 4WD aka Suzie Q. 3" lift, 32" A/T's
1998 Isuzu Amigo 4WD aka Smeagol The Amigo. 2" Lift, 31" A/T's
User avatar
Tentin
Mi Amigo
 
Posts: 173
Joined: Tue Jun 23, 2020 3:03 am
Location: San Jose
Has thanked: 0 time
Have thanks: 20 times

Re: 91 Storm Trooper rebuild project

Postby Docloucks » Sun May 09, 2021 10:17 pm

Ziplock bags with pre-printed labels tape on hoses and ends with corresponding numbers etc.
biggest current issue is wrestling with a couple mechanical issues like getting the fricking starter out as well as the ac compressor off...!
I know that come rebuild it’s the block and the head that go to the shop so I’m ok taking off extra items during disassembly knowing they either come off while in the engine compartment or off on the engine stand later.
Slow, gradual, no rush steady progress is the mantra. It’s supposed to be FUN is what my wife keeps telling me and I want the fun to last for a while, lol
Docloucks
Drives on Pavement
 
Posts: 9
Joined: Thu Apr 15, 2021 12:34 am
Has thanked: 4 times
Have thanks: 1 time


Who is online

Users browsing this forum: JoeyTrooper and 18 guests