3.4 swap into 91 Trooper

[Ed_Mc.]

It Lives!

Way Cool !

Please keep us updated with driving impressions.

Then you're gonna need to start a swap writeup for the rest of us power-hungry Trooper Dudes!

Enjoy!........ed

[Canyonero]

Sure thing. It was a pain, but with what I learned I'm sure the next SFI swap could go much easier! We haven't decided what to do with that $500 blue Trooper I just bought. Probably keep the TBI, and maybe SUPERCHARGE IT! That would be awesome.

[IsaacHayes]

3900 like you were thinking. It should fit if a 3400 does.

[Canyonero]

I somehow installed the clutch release incorrectly. The release fork is not in the right position. I don't know what I did, but I guess it doesn't matter. It doesn't work. Time to drop the transmission... again.

[Ed_Mc.]

Maybe the clutch fork popped off of its pivot. Before you pull the tranny, try pulling back the clutch boot to see if you can tell what's going on. You may want to drop the slave cyl first so it won't interfere with handling the clutch fork. You're going to have to drop it anyway if the tranny does need to come out!

[Canyonero]

+ 1 MSD Tach Adapter for DIS Ignition Systems. Will it ever end?

Still haven't looked at the clutch. Busy weekend. Maybe tomorrow.

[Canyonero]

A friend lent me a hand working on my Trooper yesterday. Some steps forward, some steps back...

Turns out I did assemble my clutch incorrectly. The plate was in backwards. Brilliant 'eh? That has been corrected (in my defense, the plate wasn't labeled, but I still should have been able to figure it out considering the OEM one was). The clutch feels much better now.

But, I have an oil leak. My first guess would be the intake manifold gasket. It's the same place my old engine leaked before I got that replaced.

I'm suspecting that I have a leaking injector rather than a blown head gasket. That is somewhat comforting. I have spare injectors that I can switch around, and I'll probably get a set reconditioned eventually.

So, to sum up. I still have some things to sort out, but the rig might FINALLY be on the road tomorrow. Yeah, I've never said that before...

[Canyonero]

I meant it this time. I drove my Trooper today. Definitely still have some kinks to work out, but it did make it the seven miles to the exhaust shop without too much trouble. Having a real exhaust system on there will make me happy (maybe not so much when I have to write the check).

Oh, and my clutch works great.

[Canyonero]

I'm sure everyone has lost interest in this project by now, but I think the Trooper is finally running as it should. Ran into several more snags, but I'm able to drive the rig now.

Bought a new set of Accel injectors, and it runs again (my spare set was worthless).

New Flowmaster exhaust system. That's just what the shop worked with and had on hand. Sounds decent, but I'll pick something else next time (Magnaflow?).

At least couple quarts of gas that was being pumped out the stuck injector made it's way into my engine oil. Yeah, not cool... Changed that. My oil filter was dry, haven't checked back to see if that's being used yet.

I must have fouled a plug or something when it was running super rich. They look alright, but I swapped 'em all and put on some Accel 8mm wires this morning, running smooth now.

Also installed my MSD DIS Tach driver this morning, but still not working.

So, I'm making progress. I want to take it on a trip in a couple weeks,so I'm going to try to get the wiring cleaned up so I can have a passenger in the front seat. All the ECU wiring is spilling out the glove box now, and the ECU is on the floor.

[Canyonero]

I was wrong, changing the plugs and wires didn't fix it. But I think I got it today. I unplugged my O2 sensors and took it for a good drive. Seems to be all cleared up. I'll be doing betterthanyou's Heated O2 Sensor Swap soon as I get the parts.

[geoffinbc]

Sounds like you are working it out anyway. Does the exhaust seem rich? Your injectors may be too big or the pressure may be off.

[Canyonero]

Doesn't seem rich. I put in a new set of 17lb Accel fuel injectors, I understand 17lb is the stock flow. Be another week or so before I get my new O2 sensors. We'll see what happens when I get those in. It was also suggested to me that the coolant temp sensor might have something to do with it. I'll replace that when I do the manifold gasket.

Oh salvage yard engines...

[KellyTTE]

Doesn't seem rich. I put in a new set of 17lb Accel fuel injectors, I understand 17lb is the stock flow. Be another week or so before I get my new O2 sensors. We'll see what happens when I get those in. It was also suggested to me that the coolant temp sensor might have something to do with it. I'll replace that when I do the manifold gasket.

Oh salvage yard engines...

So whats the status on this project any movement forward? Backwards?

--
Kelly
1990 2.6l I4/M5/4X4 Trooper
Western US Editor and Writer:
http://www.ttellc.net Cool, no bs gear reviews and news
kellyb@ttellc.net

[Canyonero]

I had misread the labels on my wiring harness and plugged my O2 sensors in backwards. I hooked them back up correctly and it's been running fine. Still chronic clutch problems. I'm going to have to pull the tranny again to clean the clutch up, I wasn't as careful as I should have been last time around, think I contaminated it. The worse problem is the hydraulics. Seems my new slave cylinder started leaking after a few weeks of driving. Can't get my clutch to stop dragging. I bled it on a couple occasions and that seemed to help at first, but not anymore.

Still planning to do the HO2S swap. I have to tweak, reroute, and reloom my harness anyway, so I'll do it then.

Still have an oil leak (intake manifold gasket), it's small enough that I just don't care enough to fix it right now.

Still haven't figured out how to make my ventilation fans work (originally triggered somehow off the oil pressure switch).

The flowmaster exhaust is starting to irritate me. I think I'm going to have a cat put on to mellow it out some. If the guy will give me some credit on the flowmaster he used, I'll have it switched for a magnaflow.

I mounted a fire extinguisher in the back. Just in case...

My tranny is noiser than it used to be. What weight of oil should I be using in it? My Chiltons manual says 5W-30 engine oil, which is what I used.

Well, that's the update. Overall, it's been running and driving nice right up until the clutch issue.

[geoffinbc]

Your right on the blower fan. It gets grounded by the oil pressure switch. Hook it up again and it should work fine.

The Isuzu trans does use 5W30.