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Thread: Isuzu 4BD2T diesel swap into Suburban

  1. #1
    LeroyDiesel.com Burning oil's Avatar
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    Default Isuzu 4BD2T diesel swap into Suburban

    Ive been gathering parts and now its time to dive in. I'll be installing an Isuzu 4bd2t 4cyl into my 1994 Suburban.
    I removed the 6.5 diesel today.
    Im hopeing to have better performance than the 6.5 and get close to 30mpg.
    The 4bd2's are sourced from the Isuzu NPR trucks and the Chevy W4000.
    Also available is a 6bd1 cyl. They are mechanicaly injected.
    I'll be using the 4L80E trans with a OptiShift controller.

    More pictures as they come.

    4bd2t removal
    4bd2t engine swap 004.jpg4bd2t engine swap 006.jpg
    Leroy.
    www.leroydiesel.com <<< CLICK
    We sell pmd extension cables and the FS PMD or the new Stanadyne PMD with available 7 year warranty.Turbo Boost Bolts and lots of 6.5 turbo diesel parts. Check out the web site.
    Be sure to update your signature with products you bought from me.
    1 ton, crew cab, 6.5 diesel w/DB2 4911 IP. srw.
    1994 2wd Suburban.
    I like it alot. https://www.youtube.com/watch?v=NH9t44iOiA4

  2. #2
    LeroyDiesel.com Burning oil's Avatar
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    Got the 6.5 out and into an old military crate.

    Attachment 30297
    DSCN2951.JPG
    DSCN2949.JPG
    DSCN2953.JPG
    Leroy.
    www.leroydiesel.com <<< CLICK
    We sell pmd extension cables and the FS PMD or the new Stanadyne PMD with available 7 year warranty.Turbo Boost Bolts and lots of 6.5 turbo diesel parts. Check out the web site.
    Be sure to update your signature with products you bought from me.
    1 ton, crew cab, 6.5 diesel w/DB2 4911 IP. srw.
    1994 2wd Suburban.
    I like it alot. https://www.youtube.com/watch?v=NH9t44iOiA4

  3. #3
    Stand Your Ground 3500GMC's Avatar
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    You're pulling a big heart and installing a small one.
    '93 GMC Sierra SLE K3500 RCLB 4L80E 4.10 axles, lockers, JB8 13x3.5 brakes, 4X4 SRW 1TON, 6.5TD now a fully ported big valve '82 6.2 turbocharged, mandrel straight pipe w/ warpspeed x-over, Fluidampr, tweeked DB2-2831-4911 IP, Battery relocation, H/O W/P, CDR elim custom vent, PYO wheels w/285-75 Dick Cepek FC-II's - Quasar Blue and Argent Silver two tone.

    ...and other various GM cars and trucks


  4. #4
    LeroyDiesel.com Burning oil's Avatar
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    Yea, but the little one has a big heart. It should be capable of 300hp easily and still up around 30mpg.
    I know a guy with a 4bd1 that is putting 500hp and 850#s of tq to the ground and the long block is stock!!
    Im getting ready to go work on it some more today.
    Leroy.
    www.leroydiesel.com <<< CLICK
    We sell pmd extension cables and the FS PMD or the new Stanadyne PMD with available 7 year warranty.Turbo Boost Bolts and lots of 6.5 turbo diesel parts. Check out the web site.
    Be sure to update your signature with products you bought from me.
    1 ton, crew cab, 6.5 diesel w/DB2 4911 IP. srw.
    1994 2wd Suburban.
    I like it alot. https://www.youtube.com/watch?v=NH9t44iOiA4

  5. #5
    Brain Damaged Diesel Junkie dangerousdave's Avatar
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    Still no nibbles on the sale of the 6.5?
    Not as Dangerous as I used to be Dave

    http://www.silent-warriors.com/ Veterans of America Club, member #25
    1994 Suburban 6.5TD C2500 "F", 3.73 gears, 4L80E, 265K+ miles. Heath clone bumper mount fsd, custom S&B 5x9 intake, home grown TM, Flowmaster DP and X-over, hollow soot trap, Biodiesel rated fuel lines, http://leroydiesel.com/ (Burning Oil) OPS ext. hose kit, oil cooler kit, Walbro LP. Racor pre LP filter, removed tank sock, Fuel press and boost gauges, fuel pressure gauge isolator, moved PS battery to fender, Lubrilon engine treatment, 21.2 average mpg, added air dam to improve cooling and mpg; .6mpg better now. 1 qt ND30 per 20 gallons of fuel, PS gray bottle per instructions for maintenance; keeps the injectors clean

  6. #6
    LeroyDiesel.com Burning oil's Avatar
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    Nope, it was running so good too. I'll just keep it for another project.
    Leroy.
    www.leroydiesel.com <<< CLICK
    We sell pmd extension cables and the FS PMD or the new Stanadyne PMD with available 7 year warranty.Turbo Boost Bolts and lots of 6.5 turbo diesel parts. Check out the web site.
    Be sure to update your signature with products you bought from me.
    1 ton, crew cab, 6.5 diesel w/DB2 4911 IP. srw.
    1994 2wd Suburban.
    I like it alot. https://www.youtube.com/watch?v=NH9t44iOiA4

  7. #7
    Registered User deejaaa's Avatar
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    subscribed.....
    Prediction is very difficult, especially about the future. Niels Bohr Danish physicist (1885 - 1962)
    93 1 ton 4 door, 2WD, 6.5, 4L80E, w/ Gear Vendors OD unit, 1800 rpm at 67 mph, TCC manual switch, straight pipe, GP manual mod, fuel pressure/boost gauge, spin-on 10 micron fuel filter pre-FFM. Installed ATT on 6-12-2011. Brought home 9/4/08, has '99 engine, daily driver,avg 600 miles/week. Now with a manual controller for the 4L80 transmission (Jakes PCS/EPC eliminator plug and controller).
    96 ¾ ton, 6.5, 2WD, stock, ext cab, long bed. Down but not out.....
    12-21-2012: "Year of the Crying Mayan"
    2002 Jetta GLS, TDI, 5 speed, white, 50 mpg. Brought home 4-22-2012.
    *****Homemade Welders, The Life You Lose Could Be Your Own*****

  8. #8
    Recruit
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    This is a project I always hoped to do with a manual transmission. Don't think it's ever going to happen here.
    98 GMC Suburban 2500 6.5 4x4 235,000 mi, FS2500, new timing chain, gears, Fluidamper & remote PMD, braided stainless oil cooler lines

    96 GMC 6.5 Suburban 1500 4x4 240,000 mi; Amsoil bypass & remote transmsision filters
    new timing chain, gears, fluidamper & remote PMD, braided stainless oil cooler lines

    95 Tahoe 2 door 4x4 6.5 240,000 mi;
    Stainless mandrel 3" exhaust, Amsoil Bypass filter, new timing chain, gears, Fluidamper, transmission, 3.73 rear end & remote PMD, braided stainless oil cooler lines

    1989 GMC Sierra 2500 2wd 5 spd get-rag trans had 108,000 mi. in 92 when the odometer broke. 7-800,000 miles on the truck. Installed a GM crate 6.5 non-turbo & FS 2500 in 2000 about 400,000 miles on the motor
    new timing chain, gears, Fluidamper & IP
    locked up and sold.

    95 Chevy C2500 xtra-cab 2wd 6.5 240,000 miles, remote PMD

    91 international 4700 low pro, spicer 6 speed, DTA 360 with 18' van box 500,000 miles plus.

    NRA Life Member for over 30 years
    Vote Freedom First

    1994 chev K3500 crew cab SRW 5 speed 4x4 230,000 miles
    PMD with heat sink. FS2500 bypass filter, The engine oil cooler lines are not leaking, Knock wood

  9. #9
    Jack of all, Master of none 12ga diesel's Avatar
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    Good luck with this swap Leroy! I'll definitly be following this thread. Can't wait to see more pictures and following your progress.
    David
    '04 Ram 3500 SRW/HO Cummins 5.9L, 48RE Auto Trans
    QC/SB, Smarty Jr. set at 70hp, FASS Fuel Pump 95 Series, AEM BruteForce CAI, MBRP 5" Turbo-Back Exhaust (Homemade Flat Black), Recon LED Smoked Cab Roof Lights/3rd Brake Light, BFG All-Terrain T/A KO 285/70/17, Liquid Metal Gatlin 17x9 Wheels, Line-X bed, Sirius Satellite Radio, Mobil1 fuilds
    Fuel Pump out at 70,500; Front u-joints and driveshaft replaced at 76,775; Rear u-joints at 78,000; Rebuilt Transmission at 95,600
    132,200 miles (78,644 miles driven by me)
    He is not MY President!

    BAD AMERICAN #21

  10. #10
    LeroyDiesel.com Burning oil's Avatar
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    Got alittle done. Had to remove the bushing on the end of the crank. The autos have them, but with use of the engine adaptor it has to go. It was a PITA to.

    DSCN2955.JPG
    I tried using a slide hammer, but that did not even budge it.
    DSCN2958.JPG
    Finally had to cut the bushing almost flush with the crank. Then I cut a slit in it to a point just before the saw could contact the crank. This weakend the bushing enough that the slide hammer could pull it. Its the two round parts laying on the plywood.
    DSCN2960.JPG
    Next I cleaned up the crank bore with some emery cloth and taped a bearing into the spot where the old bushing was. The hub adapter centers on the crank.
    DSCN2962.JPG
    Isuzu flywheel gets bolted back on and the hub adapter bolts to the flywheel and rides in the bearing in the picture above.
    DSCN2963.JPG
    The 4L80E flex plate will bolt to the hub adaptor. This pic shows the Bell housing adapter. It converts the Isuzu pattern to a Chevy Bell housing.

    DSCN2964.JPG

    Thats all I got done today.
    Leroy.
    www.leroydiesel.com <<< CLICK
    We sell pmd extension cables and the FS PMD or the new Stanadyne PMD with available 7 year warranty.Turbo Boost Bolts and lots of 6.5 turbo diesel parts. Check out the web site.
    Be sure to update your signature with products you bought from me.
    1 ton, crew cab, 6.5 diesel w/DB2 4911 IP. srw.
    1994 2wd Suburban.
    I like it alot. https://www.youtube.com/watch?v=NH9t44iOiA4

  11. #11
    Registered User
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    Looking good, cant wait to see it completed
    1995 yukon 4wd, Buddys 6 banger chip, HIDs hi and low beams with high 4 kit, custom front bumper, 33x12.50/17s no lift, FSD in bumper, custom CAI, FASS HPFP 95gph LP, Turbomaster,3 gauge pillar with boost, egt, trans temp, ARP studs, .010 thicker gaskets, 14 bolt 9.5inch semi-floating rear, 3"downpipe to dual 3" out the back. Eventually... SAS with Dana 60's on both ends.

  12. #12
    LeroyDiesel.com Burning oil's Avatar
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    Default Few more pictures

    4L80E Flex plate bolted on.
    DSCN2965.JPG
    Engine to trans line up dowel pins in adaptor.
    DSCN2967.JPG
    Getting ready for first fitment.
    DSCN2968.JPG
    DSCN2969.JPG
    Engine fits in the hole, but will need modifications to set down far enough.
    DSCN2970.JPG
    Comp will have to be relocated.
    DSCN2971.JPG
    The oil pan has this extra volume that will have to be removed OR I would like to find a 4bd1 oil pan as they did not have the extra volume.
    Anyone have a 4bd1 oil pan for sale?
    DSCN2972.JPG

    Im also going to move the trans back a few inches so the engine sits further back behind the front axle line. It will also sit lower. One problem I have now is I will have to buy/build a drive shaft as the Burban is a composite material.
    Leroy.
    www.leroydiesel.com <<< CLICK
    We sell pmd extension cables and the FS PMD or the new Stanadyne PMD with available 7 year warranty.Turbo Boost Bolts and lots of 6.5 turbo diesel parts. Check out the web site.
    Be sure to update your signature with products you bought from me.
    1 ton, crew cab, 6.5 diesel w/DB2 4911 IP. srw.
    1994 2wd Suburban.
    I like it alot. https://www.youtube.com/watch?v=NH9t44iOiA4

  13. #13
    FRANKENBURBAN THEFERMANATOR's Avatar
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    I've never seen anything but a steel driveshaft in all of teh BURBS of this generation myself, so composite is a new one on me. At least it's a 2WD so you can move the trans back and not have to deal with the torsion bar crossmember.
    WHO SAYS YOU CAN'T HAVE IT ALL, JUST BUILD IT

    1995 GMC 2500 SUBURBAN powered by 01 DURAMAX/ALLISON, little of this, a little of that,
    DIAMONDEYE 4" exhaust, CORSA muffler, AFE stage 1 dry filter, custom tuning by me, KENNEDY single pump and pump rub kit.


  14. #14
    LeroyDiesel.com Burning oil's Avatar
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    I'll get a pic of it tomorrow.
    Leroy.
    www.leroydiesel.com <<< CLICK
    We sell pmd extension cables and the FS PMD or the new Stanadyne PMD with available 7 year warranty.Turbo Boost Bolts and lots of 6.5 turbo diesel parts. Check out the web site.
    Be sure to update your signature with products you bought from me.
    1 ton, crew cab, 6.5 diesel w/DB2 4911 IP. srw.
    1994 2wd Suburban.
    I like it alot. https://www.youtube.com/watch?v=NH9t44iOiA4

  15. #15

    Default

    Quote Originally Posted by Burning oil View Post
    Also available is a 6bd1 cyl. They are mechanicaly injected.

    I'll be watching with great interest also.
    Just for clarification, is it the 6bd that is mechanically injected or both the 4bd and 6bd? Also approx costs on the adapters?
    Last edited by CtChevy427; 11-06-2011 at 01:13 PM. Reason: fix quote
    1994 K3500 Crew Cab Dually. Round about 300K miles (drove three years with inop odometer) Manually controlled 4L80E via switched solenoids, 4.10 gears, DS4 eliminated, DB2-4911 installed, homemade TM, Vac pump eliminated, Warpspeed X-pipe, 3" downpipe, 3" strait exhaust, Hayden severe duty fan clutch w 10 blade fan, Racor series 230 fuel/water separator currently with 10 micron element before twin lift pumps (FRB-5 primary, stock Delphi 3309 secondary, parallel) each manually switched with relays, Fuel pressure, boost, EGT and trans temp gauges. 22 gallon auxiliary tank in cab plumbed to main tank on frame.

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