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Old 25th March 2009, 13:09   #1
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Default Gypsy Powering up with ISUZU 1800 cc Petrol engine

Hi all,

After a setback in Munnar off roading this january, was seriously thinking of powering up my gypsy MG 410 W. The first culprit was the balding tyres - Bridgestone H/T run over 70 k kms on road and off road. Changed the tyres to Yokohoma AT/S 235 75 R15, which raised the gypsy ground clearance of about 1.5 inches. Yoko's performed very well in Chikkathore OTR.

Next was powering up the gypsy heart, meaning transplant. choices were;

1) Gypsy King engine and gearbox
2) Esteem Engine and gypsy King gearbox
3) Baleno engine with gypsy king gearbox
4) ISUZU 1800 cc Petrol engine with isuzu 5+1 gearbox

First 3 options were scarce and improbable. 4th option seem more viable. Hunt started to identify an Isuzu 1800 cc engine at Shivaji Nagar Scrap Yard, Bangalore. Jammy Anand and Shakir Ahmed have helped me lot in identifying the right engine.

Scrap dealer had Isuzu engines of petrol -Carb, Petrol - Mpfi and Diesel engines. My preferance was only petrol engine. Here we were to decide between carburator and mpfi version. After debate of pros and cons of mpfi over carb version , I decided to pick Mpfi version. The dealer had one engine with MPFI with all wirings and ECM, 2007 make and 5+1 speed imported gearbox. Negotiations began on pricing and finally closed the deal at Rs. 23k. Now for the comfort talk. The dealer showed the Superking AC kit too. Temptation took over, Finally bought the AC kit for another 6 k with condensor and pipings.

First set of pictures posted here
Dwarak
Attached Thumbnails
Gypsy Powering up with ISUZU 1800 cc Petrol engine-image_703.jpg  

Gypsy Powering up with ISUZU 1800 cc Petrol engine-image_704.jpg  

Gypsy Powering up with ISUZU 1800 cc Petrol engine-image_705.jpg  

Gypsy Powering up with ISUZU 1800 cc Petrol engine-image_706.jpg  

Gypsy Powering up with ISUZU 1800 cc Petrol engine-image_707.jpg  

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Old 25th March 2009, 13:21   #2
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great going dwarak !

what are you gonna name your ride , its no longer gonna be a gypsy !, lol
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Old 25th March 2009, 13:38   #3
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Wonderful sir. Look forward to this mod.

Few questions:

1. What would be required to mate the engine/gearbox to 4x4 t-case? Would you retain the existing 410 t-case?

2. From pictures, it looks like that the combined length of the engine + gearbox would be quite long. Would it fit in or some body alteration be required?

Cheers,
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Old 25th March 2009, 13:49   #4
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Quote:
Originally Posted by khan_sultan View Post
1. What would be required to mate the engine/gearbox to 4x4 t-case? Would you retain the existing 410 t-case?
If there's an easy answer to this then lot of people will shower flower on dwaraka.
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Old 25th March 2009, 14:17   #5
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Interesting project, I have only had the chance to see one such Gypsy with a Isuzu engine on it, a olive green one if I remember right from Conoor. It was just a rear wheel drive.
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Old 25th March 2009, 14:25   #6
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All the best for the project Dwaraka. Any specific reason for going the MPFi way? The carb version makes 11bhp more and should be easier to install and work on right?
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Old 25th March 2009, 14:26   #7
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Why would you want to convert a 4x4 to 4x2, esp since you do offroading. the power advantage somehow doesnt ring a bell for me, and a diesel would have atleast given you good low end torque compared to petrol? am confused.
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Old 25th March 2009, 14:36   #8
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Quote:
Originally Posted by Jaggu View Post
and a diesel would have atleast given you good low end torque compared to petrol? am confused.
13.3 Kg at 3000 r.p.m. Not bad for that light weight Gypsy Jaggu.
Interesting part is 4/4 TC mating. I'm going to disturb dwaraka regularly from now on.
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Old 25th March 2009, 14:36   #9
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The Carb version would have been better and would have had better tuning options too, but I hope you don't go overboard like GTO did and switch back to stock engines, also what was the problem in sourcing a 1.3 or 1.6 engine and wouldn't it have been easier to mesh the Transfer case to a Suzuki's clutch housing and hence retain the 4 X 4 ?
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Old 25th March 2009, 14:53   #10
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Hi,

Have engaged Shabbir-Mechanic and expert in engine modifications for the task. Engine and gearbox transplant for my gypsy has already begun. Mods, involved extracting 1000 cc engine , changing the engine bedding fixture, gearbox bedding fixture, alligning the power train, fixing the connecting rods to transfer gearbox, etc. Very time consuming task indeed.

In the bargain, I learnt that the gypsies are easy to modify on power train. Reason being, the transfer gearbox is divorced one and supports mods. Positioning the T-Case (transfer gearbox) changes.

More report to follow.

Dwarak
Attached Thumbnails
Gypsy Powering up with ISUZU 1800 cc Petrol engine-image_708.jpg  

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Gypsy Powering up with ISUZU 1800 cc Petrol engine-image_720.jpg  

Gypsy Powering up with ISUZU 1800 cc Petrol engine-image_721.jpg  

Gypsy Powering up with ISUZU 1800 cc Petrol engine-image_722.jpg  

Gypsy Powering up with ISUZU 1800 cc Petrol engine-image_723.jpg  

Gypsy Powering up with ISUZU 1800 cc Petrol engine-image_724.jpg  

Gypsy Powering up with ISUZU 1800 cc Petrol engine-image_725.jpg  

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Old 25th March 2009, 14:55   #11
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All the best Sir, we are eager to witness the outcome of this project.
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Old 25th March 2009, 14:58   #12
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dwaraka, if there is no issue please let me know when you're working on TC bit. I want to see the process/progress.
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Old 25th March 2009, 14:59   #13
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Quote:
Originally Posted by siddartha View Post
great going dwarak !

what are you gonna name your ride , its no longer gonna be a gypsy !, lol

Thanks Siddu,

How about isuzuki gypsy

Dwarak
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Old 25th March 2009, 15:04   #14
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Quote:
Originally Posted by khan_sultan View Post
1. What would be required to mate the engine/gearbox to 4x4 t-case? Would you retain the existing 410 t-case?

2. From pictures, it looks like that the combined length of the engine + gearbox would be quite long. Would it fit in or some body alteration be required?

Cheers,
Suzuki T-case will be retained. connecting rod from gearbox will drive the t-case for 2 WD and 4 WD.

Yes, the overall length of the powertrain is more than MG410 by about a foot from bedding point. Shabbir-Mechanic is fixing the bedding in different places matching the Isuzu. Gear lever and 4 WD lever positioning will change a few inches backwards. Levers will get bent for usual position after the work is completed.

Dwarak
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Old 25th March 2009, 15:04   #15
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Quote:
Originally Posted by khansultan&others
1. What would be required to mate the engine/gearbox to 4x4 t-case? Would you retain the existing 410 t-case?
Since it has a divorced Transfer case, it should be a matter of aligning prop shaft and adjusting length, i assume.
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