Isuzu 4BD2T diesel swap into Suburban

Discussion in 'Diesel Engine Conversions' started by Burning oil, Nov 1, 2011.

  1. Burning oil

    Burning oil LeroyDiesel.com

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    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.jpg 4bd2t engine swap 006.jpg
     
  2. Burning oil

    Burning oil LeroyDiesel.com

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  3. 3500GMC

    3500GMC Stand Your Ground

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    You're pulling a big heart and installing a small one.
     
  4. Burning oil

    Burning oil LeroyDiesel.com

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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.
     
  5. dangerousdave

    dangerousdave Brain Damaged Diesel Junkie

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    Still no nibbles on the sale of the 6.5?
     
  6. Burning oil

    Burning oil LeroyDiesel.com

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    Nope, it was running so good too. I'll just keep it for another project.
     
  7. deejaaa

    deejaaa Active Member

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    subscribed.....
     
  8. jrsavoie

    jrsavoie 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.
     
  9. 12ga diesel

    12ga diesel Jack of all, Master of none

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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.
     
  10. Burning oil

    Burning oil LeroyDiesel.com

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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.
     
  11. 1995yukon65

    1995yukon65 New Member

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    Looking good, cant wait to see it completed
     
  12. Burning oil

    Burning oil LeroyDiesel.com

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    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.
     
  13. THEFERMANATOR

    THEFERMANATOR FRANKENBURBAN Staff Member

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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.
     
  14. Burning oil

    Burning oil LeroyDiesel.com

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    I'll get a pic of it tomorrow.
     
  15. Yachtcare

    Yachtcare Recruit

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    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 a moderator: Nov 6, 2011
  16. Burning oil

    Burning oil LeroyDiesel.com

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    Both.
    Cost is $680

    6bd1 would be an absolute beast.
     
  17. Burning oil

    Burning oil LeroyDiesel.com

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    Heres a couple of the drive shaft. Definatly a composite shaft with aluminium ends.
    It wieghs maybe 7-8 pounds.

    DSCN2976.JPG
    DSCN2975.JPG
     
  18. dangerousdave

    dangerousdave Brain Damaged Diesel Junkie

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  19. deejaaa

    deejaaa Active Member

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    Leroy, i think it just might be coated. have you tried scraping any part of it to see any fiber? what does it sound like when you tap on it with a hammer?
     
  20. Burning oil

    Burning oil LeroyDiesel.com

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    I'll look again tomorrow. I did tap on it, it is not metalic sounding. Looks like carbon fiber.
     

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