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Step by step Isuzu diesel conversion

  • Dave cc
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28 Feb 2013 22:40 - 02 Mar 2013 09:33 #64245 by Dave cc
Step by step Isuzu diesel conversion was created by Dave cc
Have started to get engine ready to go into Blue Jim so thought would start a step by step guide into what you need to do in case any others fancy going the same route


Engine out take all the ancillaries header tank starter motor and altenator and as may hoses as you can grab if early type altenator you will also need charge relay located in the drivers side kick panel forget the glow plug relay as its a arse to get to and a sod to get working a Pug 106 unit you can get for a tenner and are far easier to wire in also forget the astra radiator as well you will need a 300tdi discovery unit



Remove tin manifold covers




Turning the turbo housing to point north
Unbolt manifold and all the rest of the pipes remove manifold unbolt actuator and housing if garret turbo you can simply turn housing to point north and put bolts back in if IHI then you can only get 2 of the 5 bolts in the others wont line up so you will need to drill and tap 3 holes M5 and idealy replace the Torx screws with allen bolts
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Last edit: 02 Mar 2013 09:33 by Dave cc.

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  • Dave cc
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28 Feb 2013 22:44 - 28 Feb 2013 23:04 #64246 by Dave cc
Replied by Dave cc on topic Step by step Isuzu diesel conversion
As you can see from the picture the compressor housing points downwards and if not rotated gets in the way of just about everything


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Last edit: 28 Feb 2013 23:04 by Dave cc.

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  • Beano
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01 Mar 2013 09:25 #64263 by Beano
Replied by Beano on topic Step by step Isuzu diesel conversion
I love reading about your projects! Keep up the great work mate, you are living the dream for the diesel jims! B)

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  • JivingDaddy
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01 Mar 2013 10:52 #64268 by JivingDaddy
Replied by JivingDaddy on topic Step by step Isuzu diesel conversion
A braver man than me Gunga Din (or should that be Bunged Itin? :-))

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  • Smoggy
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01 Mar 2013 11:38 #64272 by Smoggy
Replied by Smoggy on topic Step by step Isuzu diesel conversion
Many thanks for doing this thread Dave. I will be having a go soon myself

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  • Sponnie
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01 Mar 2013 18:15 #64292 by Sponnie
Replied by Sponnie on topic Re: Step by step Isuzu diesel conversion
Nice one Dave, its on my to do list after the lockers. Keep up the good work.

Sent from my GT-I9300 using Tapatalk 2

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  • ne-crock
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01 Mar 2013 20:39 #64312 by ne-crock
Replied by ne-crock on topic Step by step Isuzu diesel conversion

Smoggy wrote: Many thanks for doing this thread Dave. I will be having a go soon myself


and if it goes well you may be doing mine also ;)

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  • Dave cc
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01 Mar 2013 22:32 - 01 Mar 2013 23:39 #64319 by Dave cc
Replied by Dave cc on topic Step by step Isuzu diesel conversion
Thanks Guys for your comment and also to Martin for putting it on the front page :)

Have turned turbo compressor housing and reffited manifold you will need to replace the dump valve acuator pipe as will not be long enough. Found a piece of blue silicon hose to reconect it and some M5 socket head cap screws to replace the god awfull Torx screws fitted on the IHI turbo housing. Whole job realistically took just over an hour to do luckily Isuzu use metal laminated gaskets that you can just re use them so the cost of doing this mod was virtually nothing :)


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Last edit: 01 Mar 2013 23:39 by Dave cc.

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  • gaz3359
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01 Mar 2013 23:16 #64331 by gaz3359
Replied by gaz3359 on topic Step by step Isuzu diesel conversion
Keeping an eye on this,good thread,i love the 1.7 td izuzu motors,my last van was a 51 plate astra dti,the dti gave up so dropped a 1.7 td in with 200k on and was sweet,went well after fettling the pump and boost,and ran 50/50 veg oil.cant go wrong with them.

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  • Dave cc
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02 Mar 2013 09:31 - 02 Mar 2013 09:32 #64345 by Dave cc
Replied by Dave cc on topic Step by step Isuzu diesel conversion
Quick update on costs so far as weighed the Vauxhall Astra shell in this morning im doing this conversion on a budget so here are the figures so far
Car £300 inc delivery from Bridgewater not bad considering that 120 miles from Denmead :)

Sold wheels and tyres for £50
Tail gate gas struts for a £10
Pumped 40 litres of diesel out of the tank a rite bonus £56
2 Brand new wiper blades now residing on my Hilux must be worth £10
Scrap value from EMR £141.50

Total £267.50 back for car and bits sold giving a spent cost so far of £32.50 for the engine and ancillaries i think that has panned out fairly well :)
Last edit: 02 Mar 2013 09:32 by Dave cc. Reason: spelling

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02 Mar 2013 13:18 #64355 by j999pre

Dave cc wrote: Quick update on costs so far as weighed the Vauxhall Astra shell in this morning im doing this conversion on a budget so here are the figures so far
Car £300 inc delivery from Bridgewater not bad considering that 120 miles from Denmead :)

Sold wheels and tyres for £50
Tail gate gas struts for a £10
Pumped 40 litres of diesel out of the tank a rite bonus £56
2 Brand new wiper blades now residing on my Hilux must be worth £10
Scrap value from EMR £141.50

Total £267.50 back for car and bits sold giving a spent cost so far of £32.50 for the engine and ancillaries i think that has panned out fairly well :)


At this rate you'll be making money!

Gold Jimny the best colour (sold) :(

Big red Jimny 32" tyres, arbs, cage 5:1 transfer etc. (Sold)

Grey pick up Jimny
Turbo m13a, arbs, floating rear shafts, disc conversion rear, vented front conversion. 245 70 16. Winch, 3" lift, 4:16 trans hd shafts and CVS

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  • adamjimny
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14 Mar 2013 21:28 #65709 by adamjimny
Replied by adamjimny on topic Step by step Isuzu diesel conversion
Think ill be going this route with my g13bb jimmy

Watching your right up eagerly

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