Step by step Isuzu diesel conversion

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

As you can see from the picture the compressor housing points downwards and if not rotated gets in the way of just about everything

I love reading about your projects! Keep up the great work mate, you are living the dream for the diesel jims!

A braver man than me Gunga Din (or should that be Bunged Itin? )

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

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

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

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

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.

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

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!

Think ill be going this route with my g13bb jimmy

Watching your right up eagerly