chevy 6.5 turbo diesel swap thoughts

[FL cruiser]

mechanical injector pump, which is a grand PITA to deal with, being underneath the intake manifold.

Even if you've never worked on one before, the intake will be off in 20 minutes.
It takes maybe 15 to 30 min more time to change one out on a 6.2 than it does on an Isuzu and just as easy.

 

[Combat Chuck]

The GM 6.2 6.5 blocks had a history of problems. Then in about 2000 Navistar took over and re-engineered the block, which is the 6.5 motor that the military currently is using and has been proven to be a much better block.

The military-isse blocks can be had for cheap if you know where to look, and generally come with a maintenance record a mile and a half long, which is alot more comforting than getting one from a friend of a friend who knew somebody who had this thing in his fish tank for a decade, or some such.

Navistar does good things with diesels, I would trust anything with their nameplate on it before anything that rolled off a Give us Money assembly line. I don't know how they do it, but GM is the undisputed master of starting with a good design, and ruining it.

 

[Fast Eddy]

Even if you've never worked on one before, the intake will be off in 20 minutes.
It takes maybe 15 to 30 min more time to change one out on a 6.2 than it does on an Isuzu and just as easy.

Maybe if you're a shop pro. It took me some hours, including beer drinking.

 

[jluck]

I'd like to give a rebuttal to this post. Please don't think of this as a put down of your feelings, just some thing I have found out about this motor.

If you let GM do your thinking then yes this is the big chance you take. GM shot themselves in the foot with their cost cutting measure, the bean counters won the skirmish but GM lost the war.

All motor manufacturers have had their share of problems. The early 7.3 had head bolt problems, the early cummins the killer dowell pin problem and the IP killing lift pump problem, and you're well aware of the 6.0 problems. The point I'm getting to is how the parent company faced the problem. Some of these motors reputations have survived because of how the problem was taken care of. Others have gone down the tube because of how they weren't taken care of.

The GM 6.2 6.5 blocks had a history of problems. Then in about 2000 Navistar took over and re-engineered the block, which is the 6.5 motor that the military currently is using and has been proven to be a much better block.

If you pay attention to the aftermarket parts suppliers enough has been learned that it is possible to find a good undamaged block, or maybe even a military take out, and build a reliable motor.
"blown head gaskets" Use ARP head studs and not the torque to yield bolts, make sure the deck and heads are clean and flat.
"roached turbo" The Gm turbo was notorious for too much back pressure, there are now other turbos already proven to be much better, and others currently in the process of being proven.
"bad IP's" The electronic IP had a problematic Stanadyne fuel system driver and many IPs were changed without checking the FSD first. Flight Systems came out with an aftermarket FSD that recently has been proven reliable.
"junk injectors" Genuine Bosch injectors have been proven reliable, other brands are hit and miss.
"cracked heads (GM says that's "normal")" GM was just trying to stay out of hot water, there are now some aftermarket suppliers, not chinese, that so far seem to have taken care of this problem, time will tell.
"cracked piston skirts" GM added piston squirters to cool and lubricate which helped, but this was eventually a cooling system problem, particularly around # 7 & 8 pistons. There are now cooling system upgrades that have taken care of most of the problem. Still some concerns, especially in the area of fan clutches that don't come on at low enough temps.

The 6.2 and 6.5 has had more than its' share of problems which can all be traced back to GMs' bean counters. The aftermarket suppliers have stepped up to give solutions to many of the problems. Overall, this motor CAN be made into a reliable one IF you spend some time learning about these aftermarket fixes.

This motor is cheaper to buy parts for than others such as Cummins and Fords' Powerstroke.

Will it ever be as powerfull as others? No, but it CAN be as reliable and give the others a run for their money in the power area.

I'm full aware of the shortcomings and am constantly searching and learning of ways to improve the motor. I can afford this motor and vehicle, where with any of the others it would be very questionable considering the prices of even used ones.

Don

Fair enough. but I guess when I think diesel I want a good reliable unit not something that could be made good. I will take that 12v cummins and put a 20 cent tab of metal over the killer dowel pin and flog it for 300K. also the KDP issue "might" happen whilst the 6.5 problems will.
This personal banter is formulated by real personal experience not hear say or "forum engineers" opinions. I have had allot of diesel pick-ups (and suburbans) and done a few diesel conversions
In a nut shell If you had to pick one factory diesel full size pick-up to put your family in would it be the 6.2/6.5 powered trucks?

 

[Combat Chuck]

In a nut shell If you had to pick one factory diesel full size pick-up to put your family in would it be the 6.2/6.5 powered trucks?

I would get a 7.3 Powersmoke.

 

[RAYJON]

Take a look at the small Isuzu diesels easy swap and there are several different ways to adapt them, the 6.5 isn't bad but the trouble is finding a good one cheep. Which you seem to be finding out,

 

[Elbert]

never seen a 7.3 swap into a 60 or 80? Has anyone done that?

 

[Combat Chuck]

never seen a 7.3 swap into a 60 or 80? Has anyone done that?

I have not, and I'm skeptical it would work. If it did, there would be gobs of noise and vibes into the cabin.

I was referring to the poster's question about what I would choose if I were looking for a fullsize diesel truck I'd trust, and IMO, the 7.3's one of the best.
I like the longevity of the Cummins better, but wouldn't want to have to eat a POS Dodge with it, so that was the reasoning behind my explanation.

FWIW, I'm sure the 60 has room for a 7.3 under the hood with some jockeying...

 

[handcannon]

Fair enough. but I guess when I think diesel I want a good reliable unit not something that could be made good. I will take that 12v cummins and put a 20 cent tab of metal over the killer dowel pin and flog it for 300K. also the KDP issue "might" happen whilst the 6.5 problems will.
This personal banter is formulated by real personal experience not hear say or "forum engineers" opinions. I have had allot of diesel pick-ups (and suburbans) and done a few diesel conversions
In a nut shell If you had to pick one factory diesel full size pick-up to put your family in would it be the 6.2/6.5 powered trucks?

I fully understand where you are coming from and I appreciate your experience and opinions.

Your post came across to me as saying that the 6.2/6.5 could never be a good reliable motor. If a person does not have the knowledge or needed skills to maintain, work on, and modify one of these motors you are very accurate in your assessment.

However, if a person is on an extremely tight income and has the knowledge and skills to work on and modify this motor it can be a viable, and economical alternative.

Due to circumstances beyond my control I've had to go on disability, which is less than half what I used to bring home. Consequently, I've had to start driving vehicles that are within my means. I have the background to easily be able to do the mechanical work for this and I know there are others out there like me who have chosen this route, for whatever reason. With your information, my information, and others information those who look into the 6.2 and 6.5 can make an informed decision.

As to your question, what would I choose? I like the 12v Cummins, simple, no electronics, easily modified (yep, I'm an incurable modifier), and they can give real decent fuel mileage for a truck. But, their suspension is so harsh that it is very hard on my back. My wife will only drive a pickup if she is forced to, so there is no real choice here. My back and my pocketbook says my 94 K2500 6.5TD fills the bill.

Don

 

[Fast Eddy]

the KDP issue "might" happen whilst the 6.5 problems will.
This personal banter is formulated by real personal experience not hear say or "forum engineers" opinions.

My "real personal experience" is a 6.5td in a 3 ton dually with 190000 trouble-free miles, other than regular maintenance. This is true of the entire truck, not just the engine.

I've fixed:
rear pinion seal
brake hydro-booster
injector pump
glow-plug relay
o-ring on the fuel-filter housing
radiator
power door-lock relay
brakes and tires

Needs work:
stereo speakers
driver's power window
A/C recharge

Mods:
Banks kit, turbo-back exhaust, waste gate mod, fuel-pump tune
Water-to-air intercooler (needs work)

 

[handcannon]

My "real personal experience" is a 6.5td in a 3 ton dually with 190000 trouble-free miles, other than regular maintenance. This is true of the entire truck, not just the engine.

I've fixed:
rear pinion seal
brake hydro-booster
injector pump
glow-plug relay
o-ring on the fuel-filter housing
radiator
power door-lock relay
brakes and tires

Needs work:
stereo speakers
driver's power window
A/C recharge

Mods:
Banks kit, turbo-back exhaust, waste gate mod, fuel-pump tune
Water-to-air intercooler (needs work)

Sweet looking rig!! I just wish mine was a four door.

Sounds like you started with it from new. The care given to the 6.5 from new seems to have a lot to say about how they hold up. I know there are exceptions to this also.

The only history I have of mine is from about 160K and on. The PO to me had real good service while he drove it. Prior to that I know only that it was used to tow a 5th wheel trailer, RV or utility is not known. It already had the snorkle delete and Turbomaster prior to my PO purchasing it. It currently has 239K miles. Runs good, but has blowby, probably because of the towing.

Don

 

[BJ74Guy]

You can find Jeep Liberty CRD engines in eBay and other places. Dont discount it. Mine makes 335ft pounds of torque and will spin both rear tires on dry pavement.

 

[Fast Eddy]

You can find Jeep Liberty CRD engines in eBay and other places. Dont discount it. Mine makes 335ft pounds of torque and will spin both rear tires on dry pavement.

Was thinking about this just today. v10 VW tdi would be a pretty interesting swap too.

 

[Combat Chuck]

Was thinking about this just today. v10 VW tdi would be a pretty interesting swap too.

I've read about the smaller VW TDIs being swapped into minis and Hiluxes.
They're more of a "revvy" motor with a short throw and not alot of torque output, and need to be geared down to match.

I doubt a small VW TDI would produce enough power to move a 60 comfortably without overworking it, and negating both the economy and reliability of a diesel, but the CRD diesel is probably about golden with the right gearing.
I think funky electronics and relative obscurity might put the kybosh on the V10 at present.

For the offroader, I honestly thing a truck diesel is the best option, be it Ford, GM or Cummins, because the torque output and power will be there to spare. Personally, I would rather have the extra power and not need it often, than need the extra power, and not have it.

 

[shelfboy1]

my kid runs a 6.5 diesel in his gmc 4x4 tows a trailer with his big mud truck on it several times a summer .150 thou and no problems yet.

 

[rmag757]

my brother has a 6.5 turbo diesel in his Fj60. He got rid of the electronic pump went with the manual, but you have to get the manual injection pump lines.

His only problem with the build was running the exhaust off of the manifolds and the down pipe and drive shaft get in the way.

His exhuast runs all over the place!

He also has split two rearends doing burnouts I think it was the carrier that cracked or what ever you call the housing the spider gears sit in

 

[mookie]

At work we have three bucket trucks with the 6.5 and there is literally always at least one of them in the shop, all are on their 3rd or 4th engine. I personally wouldn't take one of those engines even if someone gave me a brand new one.

 

[DWitcher]

How heavy are those bucket trucks? Trucks based on the HD chassis are usally overloaded and driven hard. Constant abuse dose'nt help either.

 

[mookie]

Yep they are heavy, overloaded, driven hard, and run all day.....the older fords we've had have been tough as nails though, hardly ever any proplems

 

[uglyoinker]

I have procured a 6.5 with an nv4500 for pretty darn cheap and should be stabbing it into my 60 that sits on a 80 series chassis soon.