1992 isuzu to diesel TDI swap

superhl

Veteran Member
Joined
Jul 21, 2017
Location
27534
TDI
2002 new beetle
When I purchased the S10 NV3500 tranny, it came with drive shaft and I did not have to make any modifications to fit the Isuzu. From what I researched, the S10/S15/Sonoma 92 through 97 3.73 differential should fit the NV3500 tranny. However, I will probably need to make modifications to fit the Isuzu. Spent most of the day stripping the paint preparing for a new paint job. Hopefully tomorrow I can find the time to go look. Just hope they have a tag so I can verify that I getting a 3.73. As far as crimping tools, I have all that and what I don't have my cousin who owns a trucking business has. Again, thanks for all the info!!!
 

PickleRick

Veteran Member
Joined
Nov 29, 2017
Location
Greenville sc
TDI
05 GLS BHW sedan 5 speed conversion. BHW Carver SantaCruz in progress
Isuzu is an odd gm venture where i can't keep track of what's shared with the s10/blazer lines and what's Japanese.

You may get lucky and it's bolt in.


I love the old square body late 80 to early 90s troopers. Once I'm done restoring my cabin boat i plan on doing a bhw swap with an nv3500, dana 300 and a dana 44 sas.

I plan on keeping the 4:11 to 4:56 ish gear ratios and doing a large enough body/suspension lift to run 33 to 35 inch tires.
 

superhl

Veteran Member
Joined
Jul 21, 2017
Location
27534
TDI
2002 new beetle
Troopers were well made vehicles. Don't understand why they quite making them. I guess not fancy enough for most people.That will be an awesome build. The Isuzu pickup I have is a solid truck. No rust. Everything manual. Very little to break...I loving this 1.9 ALH swap. Fuel mileage is awesome and plenty of power! I have to confess, it was not easy!
 

PickleRick

Veteran Member
Joined
Nov 29, 2017
Location
Greenville sc
TDI
05 GLS BHW sedan 5 speed conversion. BHW Carver SantaCruz in progress
I'm sure the lack of mpgs plus the competition of the sua when they were introduced had a lot to do with it.

Many times vehicles like the trooper are sold for years elsewhere after being discontinued in the US market.

They are also usually sold with diesel engines elsewhere. Ford 1/4 and 1/2 ton turcks, land cruisers, monteros and land rovers all like oil burners else where. The rovers in the UK military got a 200 or 300 tdi. In Australia the rovers got the 4bd1 or 4bd1t. Im sure there are more that I'm not aware of.
 

superhl

Veteran Member
Joined
Jul 21, 2017
Location
27534
TDI
2002 new beetle
Not had time to get the 30 inch tires yet... I have another issue. Trying to get my heater fan to work. If I remove charge relay it works. Looking at the diagram below, where would I connect the white/blue wire from the charge relay on the generator. It appears this wire powers the heater relay allowing the fan to run??? I am using the VW alternator. Or am I wrong.



http://repairguide.autozone.com/znet...52800627d9.gif
 
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superhl

Veteran Member
Joined
Jul 21, 2017
Location
27534
TDI
2002 new beetle
I replaced my quantity adjuster upper and lower seals on my injection pump last week. It ran fine except takes several rotations (4-5)to start- it has been taking 4-5 rotations in the morning for a while. Once started, it starts on first rotation. Wednesday I replaced IP head seal from Diesel geek. Was very careful although I did drop shutoff solenoid and spring fell out. It took me an hour to find it. Only found a spring and black plunger was still in the housing? Is there more parts? After installing the solenoid it was easy to prime and start. After driving down the road I noticed weak deceleration- turbo lag. Today, ensured all the pipes were tight, drove and black smoke poured out. I checked the timing and appears to be off the charts- advanced. How does changing the IP head seal affect the timing? If a part is missing from the Solenoid, would it cause the black smoke? If I damaged the seal, it should be very hard to prime and if started should see white smoke. Thanks
 

jmodge

Top Post Dawg
Joined
Jun 18, 2015
Location
Greenville, MI
TDI
2001 alh Jetta, RC2 w/.205's 5speed daily summer commuter and 2000 alh Jetta 5spd swap, 2" lift, hitch, stage 3 TDtuning w/.216's winter cruiser, 1996 Tacoma ALh
Cold start injector could be stuck open
 

superhl

Veteran Member
Joined
Jul 21, 2017
Location
27534
TDI
2002 new beetle
Here are the codes

Friday,29,November,2019,21:48:17:09494
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 10 x64
VCDS Version: 19.6.2.0 HEX-V2 CB: 0.4508.4
Data version: 20190930 DS308.0
www.Ross-Tech.com





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--------------------------------------------------------------------------------


Address 01: Engine Labels: 038-906-012-AGR.CLB
Control Module Part Number: 038 906 012 FF
Component and/or Version: 1,9l R4 EDC G000SG 4104
Software Coding: 00002
Work Shop Code: WSC 00066
VCID: 59EF8EE2000B23AFEE9-4B5C
5 Faults Found:

17068 - Glow Plug Control Module (J179)
P0684 - 35-10 - Implausible Signal - Intermittent
16502 - Engine Coolant Temp. Sensor (G62)
P0118 - 35-00 - Signal too High
16491 - Manifold / Barometric Pressure Sensor (G71) / (F96)
P0107 - 35-10 - Signal too Low - Intermittent
17569 - Manifold Temp Sensor (G72)
P1161 - 35-10 - Open or Short to Plus - Intermittent
17656 - Start of Injection Timing Regulation
P1248 - 35-10 - Control Deviation - Intermittent

Readiness: 1 5 0 0 1

--------------------------------------------------------------------------------
--------------------------------------------------------------------------------


Address 01: DTCs cleared
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Address 01: Engine Labels: 038-906-012-AGR.CLB
Control Module Part Number: 038 906 012 FF
Component and/or Version: 1,9l R4 EDC G000SG 4104
Software Coding: 00002
Work Shop Code: WSC 00066
VCID: 59EF8EE2000B23AFEE9-4B5C
Fault Codes have been Erased

8 Faults Found:
17068 - Glow Plug Control Module (J179)
P0684 - 35-10 - Implausible Signal - Intermittent
16491 - Manifold / Barometric Pressure Sensor (G71) / (F96)
P0107 - 35-10 - Signal too Low - Intermittent
17569 - Manifold Temp Sensor (G72)
P1161 - 35-10 - Open or Short to Plus - Intermittent
17656 - Start of Injection Timing Regulation
P1248 - 35-10 - Control Deviation - Intermittent
17068 - Glow Plug Control Module (J179)
P0684 - 35-10 - Implausible Signal - Intermittent
16491 - Manifold / Barometric Pressure Sensor (G71) / (F96)
P0107 - 35-10 - Signal too Low - Intermittent
17569 - Manifold Temp Sensor (G72)
P1161 - 35-10 - Open or Short to Plus - Intermittent
17656 - Start of Injection Timing Regulation
P1248 - 35-10 - Control Deviation - Intermittent

Readiness: 1 4 1 1 1
 

jmodge

Top Post Dawg
Joined
Jun 18, 2015
Location
Greenville, MI
TDI
2001 alh Jetta, RC2 w/.205's 5speed daily summer commuter and 2000 alh Jetta 5spd swap, 2" lift, hitch, stage 3 TDtuning w/.216's winter cruiser, 1996 Tacoma ALh
Check or unplug your maf
 

superhl

Veteran Member
Joined
Jul 21, 2017
Location
27534
TDI
2002 new beetle
MAF is is unplugged. Here after re-seating the CTS and MAP.

2 Faults Found:
17068 - Glow Plug Control Module (J179)
P0684 - 35-10 - Implausible Signal - Intermittent
17656 - Start of Injection Timing Regulation
P1248 - 35-10 - Control Deviation - Intermittent
 
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jmodge

Top Post Dawg
Joined
Jun 18, 2015
Location
Greenville, MI
TDI
2001 alh Jetta, RC2 w/.205's 5speed daily summer commuter and 2000 alh Jetta 5spd swap, 2" lift, hitch, stage 3 TDtuning w/.216's winter cruiser, 1996 Tacoma ALh
Output test cycle the N108. Doesn't appear to be stuck.
They don't necessarily stick stationary, and since I can't see or hear what you do, I have to ask why do you think it doesn't appear stuck?

Have you compared specified and actual timing? Also have you watched the timing while the valve is being cycled to see if the timing comes down to the high 50's low 60's?
 

superhl

Veteran Member
Joined
Jul 21, 2017
Location
27534
TDI
2002 new beetle
The mechanical timing was way advanced. Readjusted and now back to slightly advanced. Runs good but not quite the power as before. No smoke! I will compare late this evening and post....Only codes is
17068 - Glow Plug Control Module (J179)
P0684 - 35-10 - Implausible Signal - Intermittent

Thanks!

Hoping tomorrow morning is will start without 5-6 engine rotations.
 
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jmodge

Top Post Dawg
Joined
Jun 18, 2015
Location
Greenville, MI
TDI
2001 alh Jetta, RC2 w/.205's 5speed daily summer commuter and 2000 alh Jetta 5spd swap, 2" lift, hitch, stage 3 TDtuning w/.216's winter cruiser, 1996 Tacoma ALh
Any idea how the mechanical timing became off the graph?
 

superhl

Veteran Member
Joined
Jul 21, 2017
Location
27534
TDI
2002 new beetle
I don't have a clue. The week before I changed quantity adjuster seals top and bottom. It ran fine other than the 4-5 rotations when starting in the morning. The timing was slightly advanced which is the way I set it. I changed the IP head seal Wednesday and timing way off. Unless losing the bolts moved the IP. They seem rather tight. Now the engine sounds louder and I have what seems like turbo lag. This morning it at least 5 rotations before engine started. It was 60 degrees outside. Did I pinch the seal. The main goal for installing the seal was to help eliminate having the engine rotate 4-6 rotations before starting. Anything I can test the vagcom to verify all is well? Also, not seeing air in the fuel line.
 

superhl

Veteran Member
Joined
Jul 21, 2017
Location
27534
TDI
2002 new beetle
I drove a short distance from the house and it shutoff. It appears the engine has seized. Will remove the valve cover tomorrow evening. First I going to remove the serpentine belt and check the alternator. The brake lights warning appeared shortley before the engine stalled.
 

superhl

Veteran Member
Joined
Jul 21, 2017
Location
27534
TDI
2002 new beetle
Lifters are hosed. Pulling the heads sometimes tomorrow to see how the pistons look. How did changing the IP head seal throw off the timing? Maybe just a consequence. The hard morning starts. The timing belt was still firm. If not fixable may purchase new 1.9 engine.
 

superhl

Veteran Member
Joined
Jul 21, 2017
Location
27534
TDI
2002 new beetle
I removed the valve cover and 1 valve was destroyed. The others looked fine. Timing belt was tight appeared not to have jumped... I need to remove the head. I couldn't find a valve12MM TRIPLE SQUARE CYLINDER HEAD BOLT TOOL locally - autozone, etc. I ordered one online. Should be here Monday.
 

superhl

Veteran Member
Joined
Jul 21, 2017
Location
27534
TDI
2002 new beetle
Heads and Piston-
Still can't determine why there was interference. Sending heads to Frank.

[/IMG]
 

superhl

Veteran Member
Joined
Jul 21, 2017
Location
27534
TDI
2002 new beetle
Frank rebuilt my head. He sent me a new timing belt tensioner stud but no nut. Is it ok to use the old nut or should I use a new one? I picked up some 8x 1.25 at autozone not sure they are same specs.


[/IMG]



 
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3baudios

Veteran Member
Joined
Mar 20, 2008
Location
winston NC
TDI
93 eurovan AHU (almost), 88Fummins, 01 alh golf, 91 toyota alh
something must have made the timing move, otherwise why would valve/piston contact result?
 

superhl

Veteran Member
Joined
Jul 21, 2017
Location
27534
TDI
2002 new beetle
No doubt timing moved... Anyhow, I completed timing belt installation. I quadruple check the timing to ensure timing is correct. I used coat hanger(removed glow plug), crankshaft and harmoic balancer to verify TDC. I wish while I had the heads removed. use the VW tool to place a mark on flywheel. Would make timing much easier... Where does this part go?


[/IMG]
 
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superhl

Veteran Member
Joined
Jul 21, 2017
Location
27534
TDI
2002 new beetle
Truck running fine but taking to long to start. No doubt it is worse. Does not matter cold or hot. In the morning, if I turn on my inline fuel pump and let run for 2 minutes, it will start quick. From the tank to inlet of the fuel filter, fuel doesn't leak down (valve prevents fuel from leaking down to tank). It appears I'm losing prime at the injector pump. Not sure! I replaced the head seal on the injector pump about 2 months ago. It really has been an issue since installing the engine. Is the IP leaking down? No external leaks! Is it an injector? When I bought the car, it had been in a collision that knocked the lift pump bottom off. Later Motohead1 says 2002 vw 1.9 TDi did not come with a lift pump. I thinking they must had trouble starting and installed a lift pump. Looking at the VCDS, should all 4 cylinders specs be similar? Cylinder one is substantially lower than the other cylinder







[/IMG]
 
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superhl

Veteran Member
Joined
Jul 21, 2017
Location
27534
TDI
2002 new beetle
resolved slow starts!

Ever since I completed my swap I've had slow starts. I spent hours testing new fuels line, electric inline lift pump, etc., etc. When I installed the high torque starter, I dropped it cracking the plastic on the solenoid. Nothing appeared broke internally so I glued the plastic back and seemed ok other than slow starts meaning take 4-6 cranks to start. About 6 months ago, the two long starter bolts had become lose and one fell out. . I remove and took to local starter shop. They check it out and said starter was fine replacing the two bolts. Still same issue. Finally starter started dragging. I took it back and they solved the issue. Now the 1.9 starts blistering fast. The other day I checked my fuel mileage and getting 32 mpg around town. Not bad.
 

superhl

Veteran Member
Joined
Jul 21, 2017
Location
27534
TDI
2002 new beetle
With the help of Luk, I as able to locate the correct clutch and disc. The 04-021 is correct.
 
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