So,
I am THRILLED and ridiculously ELATED to announce, I have a FULLY and PROPERLY operational 4FB1 diesel motor!!
There is still some fine tuning to do, which will wait until it is safely in the Heep.
Idles nice, crisp throttle. Purrrrrs like a "Cat"! :wink:

And boy. Do those glow plugs and heavy starter drain a small battery FAST!! :shock:
I will definitely be getting a blue top optima or a semi-style battery, if not two. Absolutely.

I had to rebuild the Bosch VE style pump. I have to admit, tearing apart the IP was a bit scary.
Never done one by myself. However, it was actually rather easy.
If you have ever rebuilt a motor with success, or a very very detailed model, you CAN do it, if you approach it like a brain surgeon.
DO NOT screw up, because if you lose parts, or put them together wrong, many diesel shops WILL NOT touch it.

And the French gentleman's pictorial guide there are things that can be done MUCH easier, esp. when reinstalling the throttle levers and pump head.

Biggest thing was to mark EXACTLY where the governor shaft was factory set. I used a small file to mark them.
They were a bit of a pain to get back in place
with the style of locknut Isuzu used, so I couldn't use 2 tools at once. I made a tool from deepwell impact socket.
A VW style reverse metric hex nut will be due on the next one, to be sure. Which I hope will be an I-Mark style IP, eventually.

Anyways, after all the time, grief, money, challenges, obstacles, I couldn't be more relieved, or happy. This motor is AWESOME.

So, as I am finishing up the Heep frame and tub before installing the 4FB1, here is more Polished aluminum.
Remember this is BY HAND, NO wheel.
But I did use the Dremel/carbide to shave the cast pebbles in first step.

Looking at the old pics of the turbo as bought, hard to believe it's the same one:

Attachment 29494

Attachment 29495

Attachment 29496

Attachment 29497
Everything cancerous, holey, or little no structural integrity was cut out, fabricated, and welded in,/replaced my myself. Luckily, the frame was uber sanitary, except a few cracks where some swamper/mudder jackass was launching the old gal. All hat channel fabricated from 1/8th sheet by me. All 14 linear feet of hat channel lined up with mounting holes on frame, which was sitting outside during tub resto.
Attachment 29498
Seat frames to mount @ 1994 Wrangler seats fabbed by me from 2 stock passenger side CJ5 seat mounts.
Attachment 29499

Attachment 29500
The trans access panels are actually nicer than they look, and very restorable. But you get an idea of what I started with.
Attachment 29501
No more of this anywhere on the Jeep. The Yellow is a rocker panel I cut out. You can see where I cut a hat channel to repair it, and decided I couldn't live with what I found.
Attachment 29502

First Mockup. Notice no adapter plates, no weird expensive crap. Bolts together 100% with factory Isuzu and Jeep parts. Even the clutch is 100% Isuzu and Jeep mashup, but the friction plate($65).
Never been done before conversion, far as I can tell. Weighs the same, performs the same as the original "Go-Devil" 4 cyl gas motor that came in almost all CJ5's first 20 years of production. And that is BEFORE I put a turbo back on a motor designed to run with a turbo.
I am good on all those Kabotas, 4BT's and OM617's, overpriced engineering headaches and compromises.
Attachment 29587
Looks factory
Attachment 29588
Only problem I had was a PO installed a lift kit, which created a steeper rear pinion angle. So I had to mount the engine a little higher than I wanted. But still lower center of gravity and roll center than V8 conversions, and @ the same installed height as the "Go-Devil" I found:
Attachment 29589
Right mount:
Attachment 29590
Installing an '83 vintage T5 and D300, I had to move the trans support X member forward till the rear bolt hole in the x member was in the forward most frame hole, then drill a new bolt hole. Still in the reinforcement metal inside the frame. Also had to cut a relief in the xmember. Reinforced, of course.
Attachment 29591
Winch mount/bumper: 3/8" 2"x4" "C" channel, 3/8" plate for 12,000lb winch. Those bolts are only temporary.
Attachment 29593
Getting dang close!! :jump:
Attachment 29592

If you're up and running, how's your gas mileage? Can it get up to 75-80 mph with ease & hold that all day long? Cool build.

Thanx Sir!
Actually, STILL not driving it YET.
Engineering dang near everything, like brackets, wiring, radiator mounts, ect AND actually making things nice and factory appearing takes massive amounts of time. Then replacing everything like lights, lenses, shift boots, ect. takes mad money.
I don't want to just throw parts at it to get it running, because once the wear and tear of driving a vehicle begin, it is harder to get things sanitary and sharp. I really need to take and upload some new pics. Looking awesome.

However, extremely close, as in, turn/marker/headlight wiring, brakes, and clutch line pretty much all that is left before I can drive it!

:jump:

2 1/2" exhaust turnout, with 10" braided flex. Also, notice the inlet of the FlowMaster is inboard of the turndown. Tricky fabbing to have such smooth flow on so many compound curves and angles! BUT perfectly spaced through the hole I had to use!
Attachment 30358
Perfectly spaced @ 3/4" gap, on an compound angle 2 1/2" pipe through a 5 1/2" gap measured at 3/8" above lowest point on body/fender! PLEASE ignore crappy harbor freight welder welds. I couldn't get that thing to weld properly to save my life. Since returned(ALWAYS buy the warranty from them, ppl) full refund. Buddy's identical HF welder worked like a champ after the fact, so not all their welders are junk.
Attachment 30359
Full 2 1/2" exhaust system designed and fabricated by me, with recycled pipes. Very minor surface rust, so after painting with High temp, should last many years after being coated on the inside with oily diesel soot. After the turbo install, this can easily be adapted.
Also, this design can be copied at a later date.
Still have a heat shield for the muffler, but later.
Exhaust system sits higher than Transmission cross member, so will be great for me for a good while.
Attachment 30360

Attachment 30361
In this, we can see the well plotted, and nice smooth fuel tubing bends, mounting to frame. The "E" brake cable mounts I had to make, and still need proper hardware.
Yes, the Fuel tank is only Ratchet strapped in ATM!
Attachment 30362

Attachment 30363
Braided stainless brake lines throughout. Skyjacker 8000 nitrogen charged shocks for 3-4" lift.
Attachment 30364
Front brake line routing and mounting. Semi finished radiator frame. Will not be finalized until after air to air cooler is mounted.
Attachment 30365
Factory alternator bracket modified to use uber common GM style alternator. Still need a semi temporary fan shroud. Summit Racing GM style fully TIG'd aluminum radiator bought from a buddy. Had some minor mods to do, still have some after intercooler install.
Attachment 30366
In this, you can see the blowby vent tube I fabbed on the top of the valve cover. Horizontal line on Firewall is clutch line
Attachment 30367

You can see a lot of engineering and production in this. Fabricated battery mount, hold down, Fuel water separator/hand primer bracket. Modified Isuzu A/C vacuum idle up diaphragm bracket for use with throttle. Saab duct is temporary until after Turbo install.
Attachment 30369
Made these side mirror mounts out of aluminum crutch tubing. Perfect OD!!
Attachment 30370
Less work to do than appears to untrained eye, actually, and jack compared to what I have already done. Seat restoration soon($10 bucks on CL? Absolutely!!)
Yes. That is an actual Browning .50 Cal "dummy" for bench testing weapon action. Primer never drilled from factory. Originally thinly chrome plated.
REAL "pineapple" dummy hand grenade for Transfer case shifter coming soon.
And I tell ya, after all this time, work, money, meditation, etc., it is AWESOME to sit in the driver's seat, and fire up that little Diesel!
Attachment 30371
Still much refinement to be done, but I would venture to say a very much stock appearing conversion!
Attachment 30372
Very proud of my work! REALLY starting to look awesome!
Attachment 30373

what about the turbo?, are you going to run NA

I will be running N/A when it first hits the road. The turbo project will cost @ $500 between the mandrel tubing for the T304 SST manifold, and the turbo overhaul and shaft balance. This motor weighs almost exactly what the Hurricane Go-Devil 4 cyl. motor does, and puts out almost exactly the same HP. So, it should drive N/A about what CJ5's did for the first 20 years of production. The turbo should make it extra fun.

UPDATE: All exterior lights(Head, tail, turn, running/clearance, brake) are wired in and operational!

Only thing left is the headlight high beam circuit!

Transfer case resealed, rears opened up, cleaned out, resealed.

Getting a hose put on the end of the clutch line today.

I should finally be driving the Jeep this week!!

:jump:

So, I have been driving a while now. She has been very reliable, with very few gremlins for being a pile of parts not too long ago, and so much custom engineering and fabrication that has been involved...

Happy to report that I am getting @ 30MPG. I just installed a working fuel gauge, so I will know more accurately soon. I got tired of trying to put @ $10 of fuel in it, and only getting @ $5 in it. However, I haven't put fuel in it in over 3 weeks, and have used slightly over 1/4 a tank, so @ 4-5 gallons. That is ALL of my to and from work, errands, and personal social driving. AWESOME.

She is a "gutless wonder". Rather slow to get to speed, but not dangerously so. REALLY wish I had the rare factory 4.23 ratio. But the turbo will help all of that.

I also scored a old "Kelly Manufacturing" "Safari Full Cab" Steel top, doors, and pre-'68 windshield for less than $140 at the local pick-your part off of a CJ6 rotting away in the back corner. Just got the wipers installed and operational(not shown in this pic). The top will be completely restored this winter.

Although some amusing hateration and indignation from those who thought their SUV or truck is actually kewl, but are mistaken. But mostly she gets smiles, waves, questions, and huge enthusiasm everywhere we go.

Man I love my Heep.

Nice little puddle jumper you have there!

Can you hold 5th on the highway? I wonder what 4.10's would do for your little Heep

Thanks Sir.
Although I would trade it for a small plane on floats! haha

Nope. Not going anywhere near a highway yet. They would help a great deal. I happened to ride in a bud's S10 C223 (NA) Diesel with 4.10's last weekend. Slightly heavier vehicle, .3L bigger motor. Night and day difference. Able to accelerate up a fairly steep grade in 3rd gear.

The Heep is great off road, even in 2WD High. Plows through bramble and brush, mud, over logs excellently barely off idle. Doesn't much care what's in front of it.

The thing is I am working on putting a turbo back on it as it should be. That will cure what ails her. I'll play with ratios after that. That is also cheaper than two ring and pinion sets, and bearing/seal kits. And having someone help me set the lash, as I have never done that myself.

Turns out my spare set of axles is also 3.73's, not the rare and elusive 4.23 factory ratio. But I wasn't surprised.

https://cimg1.ibsrv.net/gimg/www.die...412d2de0f2.jpg
A short crappy phone vid.
Overwhelms my friend's phone mic with all of the diesel clatter and bassy exhaust thump of the Flowmaster in a 2 stall metal building. You can tell the phone is confused what to record.
You can hear the intake sound very well during the rev. Yes, that is probably @ 5,400 rpm, and VERY loud in that small building.
My bud said you can hear the bass note of the exhaust from a good way away, and it'd definitely a diesel.

https://www.youtube.com/watch?v=d4yk...ature=youtu.be

About share some Jeep fun with a youngster this past weekend.
The most rewarding activity for me as an Old Jeep caretaker!
:rocking:
It's Jeep thing. Ya wouldn't understand.
Attachment 30900

So a few years later(6?), she has been crazy reliable. I have been averaging @ 40 mpg or so city all these years, with all the timing and tuning and playing I have done.

YES, It IS STILL that clean.

I drive the snot out of it during warm months. And put fuel in it @ twice a year, so maybe one tank(10-15 gal) of fuel. Off road, chugging @ off idle, I get closer to 60mpg. That is almost every day, driving to and from work, and in the eves just riding in it, with the wife. Often for several hours, because vintage topless Jeep.

With the turbo, it sounds a LOT like a turned up duramax(or modern common rail), accelerates absurdly, and is frying my mostly stock clutch plate at a very low 3-4 psi. SO far, barely turning it up, and so many mods left(like a rare in the USA C223T injection pump to frankenbuild) I am almost embarrassed it's a diesel CJ5. That is ALL on ONE turn of the fuel/smoke screw, after finalized NA pump settings. SO MUCH left power wise that I probably will never explore. Plus who like gritty cylinder walls anyways?

My Izusu guru said 12-15PSI would still be mild. And I am far from even putting that down so far.

So still have the clutch to ponder. Probably headed towards a CJ or mustang T5 clutch, with flywheel drilled for off the shelf, inexpensive, common and much more gripping power. Without a bunch of custom ordering and costs. Prob is, fitting it inside the "bell" of the 4FB1 flywheel.

Also, that is a retrofitted clarke or Hyster brass radiator that was never used after a recore. Used GM truck rubber isolators and made custom frame mounts.
Still have a forklift air filter housing to retrofit for a factory appearance, and be rid of that hokey "tuner" looking garbage filter.

Also, finally swapped the rear axle for a lower time unit, and Tom Woods double cardan driveshaft. Still have front axle and TW DC driveshaft to install. But I have to balance myself with the fleet's demands.

She has all 5 brand new firestone 31's, and a modified late model cj5-cj7 spare tire carrier, with jerry can mount(all built by me).

And btw, the thing, despite PO installed 3+ lift, it still is very balanced and nimble off road with that near M38A1 military design spec weight and balance.

No absurd heavy 5 ton truck motors and dangerous CG, dangerous braking characteristics, and pathetic departure angles for me. Thanks.

Overall, an absolutely AMAZING, PERFECT swap for a Military rooted Cj5.

https://cimg2.ibsrv.net/gimg/www.die...fec9d6920a.jpg
5 years later, and a TD04HL15T
https://cimg6.ibsrv.net/gimg/www.die...a06a013cfe.jpg
fleet has grown...

I forgot to mention (for those considering turbo'ing something that currently is not). I had over $1K into the turbo project.
I used all new parts, avoiding the headache of worn out questionable junk. So between a brand new cartridge, FMIC, ductwork, braided oil supply, coolant line, AN fittings, rad hoses(as the IC was mounted to the rad, so had to mount it) and the cost of making the SST turbo manifold, ect. In my experience the aluminum radiator was not durable enough for serious off road and incessant diesel vibrations. I had different issues pop up several times, and was glad to be rid of it.

Opinion based on my 40 years experience:
I wasn't wasting my time and money on those cheap ebay "turbo kits" made in china that grenade in no time. You can save money trying to half ass, but you WILL pay for it somewhere else. Often at a HUGE loss.

https://cimg7.ibsrv.net/gimg/www.die...37a09b441d.jpg

Needs paint but carrier is built
https://cimg9.ibsrv.net/gimg/www.die...3b5e48858e.jpg

Most impressive Diesel Jeep swap
 

I have a 74 CJ5 Renegade I've completely rebuilt. But I built a 401 AMC rather than the stock 304. Although I certainly wish I would have now with the 6 mpg I average. But she is definitely fun. But this Isuzu turbo diesel swapped CJ is by far the most impressive, most Interesting and most sensible diesel swap I've ever read about or seen and I've seen a bunch in my 20 years of Jeep building, owning and wheeling. Just fantastic in my opinion .

thanks
 

Thanks man! Its been soo reliable, so fun. In service bumping 10 years, and still nfs.
https://cimg8.ibsrv.net/gimg/www.die...dd8358120e.jpg
https://cimg9.ibsrv.net/gimg/www.die...44801380b9.jpg

Excuse me. In service over ten years.
Enjoy the newer pics.