GM 6.2 diesel swap questions

[Thaddeus]

So after lots of research, I'm torn between 2 diesel swaps for a 60/62, 6.2 gm diesel or Isuzu 4bd1/2T. I think it will be less expensive to swap a 6.2 than an isuzu, but I thought I'd defer to expert opinion on this so let me know what you think and tell me if I'm missing anything.

6.2 Swap list:
$2000 Military blazer or diesel truck, whole and running strong
$800 advanced adapter 700r to 4spd x-case
$200 Jt outfitters engine mounts, might be able to use donor mounts
$200 x-case rebuild kit
$800 rebuilt 700r with torque converter
$500 For the little extras that pop up
$4500 for the complete swap

Maybe I can offset some of these costs by selling the donor truck for parts, th400, transfer case, dana 60's and such. Plus, I'll have a fj60/62 transmission and engine to sell. I'm hoping in the end I can sell some parts get my swap cost down to $3500. Does this seem realistic or am I making some major miscalculations?

IRISH52084,

There is a lot to consider when planning an engine swap.

My original plan was to put a 6.2L into an FJ62, but I came across a really clean FJ80 and decided to upgrade. I did a lot of research before proceeding and a ’91-’93 6.2L diesel is the best option. You don’t have a problem with dimensions or weight and the engine runs more quite than an Isuzu or Cummins. The power band seems a little more compatible as well.

If you have a FJ60, then I would choose a manual transmission. Advanced sells a number of different adaptors and they would know what setup works best. If you have an FJ62, then I would stay with the A440F transmission and use the Marks adaptor. The gear ratios are similar to the GM 700R4 and 4L60.

I wouldn’t purchase a donor vehicle because unlike the newer computer controlled engines, you won’t need to pull much else from the vehicle and most of what you will need (AC compressor, alternator, hydraulic brake system, etc…) you would probably end up replacing them anyway.

Also, the military diesels are 24v and you probably want to stay with a 12v system.

I was able to pick up a ’88 6.2L J-code engine with only 128,000 miles for about $275.00 through a reputable source, and I was also able to find ’91 complete engine with accessories for $500.00 a couple of years ago. This is the one I rebuilt for my purposes. It has the one-piece rear main and the stronger block than the later ones.



--Thaddeus

 

[Thaddeus]

Check out my thread on this topic if you haven't already.

IH8MUD.com - Page Not Found

This might answer some of your questions.
From what I have read the 6.2 with the banks turbo actually puts out more power than the 6.5 turbo, not sure how or why but that is what I read.
Also, there is a clearance problem with the shock tower with the 6.5 that I have heard about also.
The serpentine belt was also available on the 6.2's, if I were doing it again I would definitely go that route.

Feel free to ask any questions, I have sold the vehicle to buy a Mercedes G350 TD, one of only 3 in the country, I couldn't pass it up otherwise I would still be driving the 6.2 Cruiser.

Rusty

Rusty,

I followed your posts earlier this year and I was quite impressed with your journaling of the process of the engine swap. I was sorry to hear that you sold the vehicle.

I would concur with you that a 6.2L with the Banks turbo would probably be the best setup if you can come across such a configuration at the right price.

One of the biggest advantages is that it locates the crossover around the front where there is more clearance, as opposed to under the transmission, which is obstructed by the driveline.

I am using the GM IH turbo because it came with one of the motors I purchased. I had to modify the exhaust manifold of the turbo housing to avoid the shock tower. It was pretty straight forward. Simply cut a 45-degree section out and weld it back together.

However, now I am trying to decide how to run the crossover. Regardless of which route I end up going with, I am going to have to modify the exhaust manifold, and fab up the crossover pipe. I believe I would have been able to avoid this with the Banks system.

--Thaddeus

 

[torfab]

Thaddeus

I ran my crossover pipe around the front, but you have a different setup with your 80. My 60 needed the exhaust to be run inside the framerails, and it had to cross over from pass to driver side. You can run yours on the outside of the frame on the pass side like the stock 80's. The 91 and 92 were on the drivers, and the 93+ were on the pass side.

I tucked mine up to be flush with the frame rails too and used 3" exhaust pipe.

Also, that banks turbo only gives 7-10 pounds of boost, whereas the 6.5 turbo can handle more than 10 because it's a lower compression engine designed for that application.

My next project will be a 80 series with either a 6.2 or 6.5 turbo. My client has decided on options, so now comes the fun shopping part.

 

[Irish52084]

I gotta say, I love this site. I have gotten such good info from people all over the place, 80 series section etc...

I have been looking at lots of options for a swap and have decided that I want an 80 series unless a really nice 60/62 shows up. I have a baby boy due in late February, and the would appreciate the options and amenities of the 80. I have lots of time to decide on a swap, I'm already involved with a frame off fj40 project.

I like the 6.2/6.5 turbo idea because of parts availability and MPG's. I've ruled out Toyota diesels because of cost and parts availability in the USA. I'd love to do a Cummins 6bt and NV5600, but I dont want or need a spring over. A new swap that has popped up is the GM Atlas engines out of the trailblazer and a few others. It's an inline 6 with the SBC bellhousing pattern, so the GM transmission options and adapters are all available. I'm also thinking of going to a mix fuel system with a propane tank where the spare tire is mounted.

Anybody running propane in the Seattle/Tacoma area? I love to see what the set up looks like and know how everbody likes it.

 

[Dougal]

I like the 6.2/6.5 turbo idea because of parts availability and MPG's.

But the 6.2/6.5 have worse MPG than almost any other diesel!

 

[Irish52084]

Should have clarified, MPG's vs original gasser. I do find it kind of funny that the 6.2/5 was introduced as a mileage alternative to the international and Cummins diesels and yet their mileage was either only slightly better or actually worse.
On a related note, I asked my buddy who has a 2008 dodge with the v8 cummins what his mileage was. Before a lift and 35" tires he got 16-20 depending on how heavy he was with the skinny pedal, he does have a lead foot. After lift and 35's he got 12.3, correctly adjusted mileage for tire change, on the same 650 mile trip that my 1994 ford 460 got 14.7 on. The Cummins does produce some awesome power though, if I had to compare the cummins with my dad's ford king ranch twin turbo diesel, I'd say the cummins feels much more fun to drive. Could be the ford's lack of a 6 speed manual, but I didn't feel inspride when I drove it recently. We drove the ford to Spokane and back to pick up a hard top and we average 14.3. I was truly dissapointed in that number, considering we werent pulling anything and it was just 2 of us.

 

[Thaddeus]

Frankenstein 6.2/6.5

Thaddeus

I ran my crossover pipe around the front, but you have a different setup with your 80. My 60 needed the exhaust to be run inside the framerails, and it had to cross over from pass to driver side. You can run yours on the outside of the frame on the pass side like the stock 80's. The 91 and 92 were on the drivers, and the 93+ were on the pass side.

I tucked mine up to be flush with the frame rails too and used 3" exhaust pipe.

Also, that banks turbo only gives 7-10 pounds of boost, whereas the 6.5 turbo can handle more than 10 because it's a lower compression engine designed for that application.

My next project will be a 80 series with either a 6.2 or 6.5 turbo. My client has decided on options, so now comes the fun shopping part.

Thanks for the input torfab!

I did leave some details out relative to my build-up. I have a friend who is an engineer that has a BT4 wedged into an early '70s Satellite that he turbocharged. Its a great engine, and he is getting around 20mpgs, but I still think the GM 6.2/6.5 combo is a slightly better fit for FJ62s and FJ80s with the A440F transmission.

The two primary reasons why I went with this combination is affordability and flexibility. Parts are cheaper with the GM diesel than with most other diesels, they are readily available. Plus the motors are relatively simple to work on, and there is interchange between the 6.2 and 6.5.

I have to preface this by saying that I started researching and shopping for bits and pieces three years ago. I wanted to make sure that I had the time to find what I really needed at affordable prices without an arbitrary deadline pressuring me.

I also decided to do a rebuild the motor because I didn't want to put all that time into an engine swap with a mystery motor. The Military Repair Manuals are the way to go. They're written so that even an idiot such as myself can rebuild a motor correctly. Plus, just take your time.

I spent $500-$600 for the engine, and traded the J-type heads with a machine shop for some of the labor. Then, I built my engine up using a '91 block machined with oversized pistons and purchased a set of '97 6.5 turbo heads for about $700 that were ported from a guy in Minnesota who builds racing engines for circle track and tractor pulls.

Ironically, the turbo setup came from my original engine, an '88 6.2 that was pulled out of a truck which was being hot rodded. I purchased that motor for $275 off eBay, kept the turbo, and sold the motor on later on eBay for $500.

That's the only time I have ever made any money on a deal! This project has been sucking up funds like a Dirt Devil strapped to my wallet, so it feels nice to win one once in a while.

The Hydro Boost came out of a '97 Chevy Suburban, which I converted over last spring. It was challenging, but I am very happy with the results, and I know that once the diesel is in, I won't have to hassle with a vacuum pump.

I haven't installed it yet, but I decided to go with the serpentine belt configuration for late '80s early '90s 6.2J and M20/MT8 models. This keeps the AC Compressor and alternator in the same locations as with the FJ80 and you don't have to run electrical and hydraulic lines all over the place.

The brackets for this setup come available on eBay once in a while. I picked mine up for $50 plus shipping, but if anyone is interested, I can also post part numbers and you might be able to work a deal from a salvage yard.

All my hydraulic lines (oil, AC, etc..) are fabbed up using Aeroquip fittings. Initially it looks expensive, but when you price out what it costs to have a shop do it, you will find that you're actually saving money. Plus the fittings are reusable, so when the hoses wear out, you can simply fab up a new line.

So, as you can tell, I am building a Frankenstein motor. Different models and years, but all tailored to work well in the FJ80.

--Thaddeus

 

[6840]

Currently doing a 6.5td swap into an FZJ80

Thought I'd pipe in on this thread. I am in the middle of swapping a 6.5TD/NV4500 5 speed into a '93 FZJ80. Am using the AA adapter to an FJ60 part time transfer case, with Aisin hubs in place of the drive plates, so that I have true 2 wheel drive.

The engine fits OK with AA engine mounts, it's tight with regard to the passenger side shock tower, and I may end up moving the tower an inch or so once the final fit is determined.

This engine is fitted with an early style mechanical injection system, so no electronics, only 1 wire to make the thing run! ( I did computer my penance with a Vortec conversion and wanted to go for simplicity this time)

Good to see that others are in the process - perhaps we can start a thread dedicated to that...

 

[Irish52084]

The shock tower issue seems to be the big one on the 80 series. How tough of a fix do you think it's going to be? I think the 6.2/6.5 turbo swap is a good one for the $$.

I also like the true 2wd setup. How bad was the change over? If you haven't done a build thread, I'm sure lots of people would find your experience and info useful, including me.

 

[Irish52084]

I forgot to ask, Have you had any fitment issues with the nv4500?

 

[Thaddeus]

6.2 Diesel Banks Turbo

Hey,

I don't know if anyone is interested, but out on eBay there is a fresh rebuilt 6.2L diesel with the Banks turbo setup. It is a complete engine, and "0" miles on the rebuild.

The starting bid is $1500 dollars, and auction ends 6 days from today. I don't know what the reserve is, but you could easily spend over $3000 dollars trying to get an engine in this condition and setup with the Banks unit.

The other advantage of this setup is the turbo avoids conflicting with the shock tower and driveline of the FJ80.

Item number:280454407944

Good luck to anyone searching for this type of engine.

--Thaddeus

 

[dieselcruiser]

6.5TD exhaust in fj80

Irish52084 - I see a few weeks back you inquided about the shock tower vs turbo downpipe on the 6.5TD in an fj80. You can cut and reweld the cast pipe to the correct angle without much problem. It only takes a couple hours to do the work. The drivers side exhaust manifold exit turns to the outside and hits the frame so that needs to be cut and rewelded also to turn to the inside to avoid the frame conflict.

I can't comment on the 2wd fj80 set-up.

 

[Viggen]

Im going to bring this back up as I am thinking about a GM powered Cruiser. TorFab, I sent you a PM.

Yes, the Isuzu or Cummins are better on mileage but they arent as readily available as the GM. Parts can be had all over for the GM and the loudness and vibration are far lower with the GM. If I can get around 20 in town and mid 20's cruising at 65mph, Ill be more than happy.

 

[Viggen]

How does the stock A440F auto trans in the early 80 cope with the diesel? Is it an issue with the shift points or anything? Kind of need to know. Looking at buying one already converted...

 

[fj80404]

Good question on the trani, seems to make things less complicated. not my thread but im going to through out my situation and see if someone can advise and hope others can learn from it.. Mid 80's donor sidewinder turbo out of 6.2, pluss all
the engine components, including 6.2 mechanical injection turned up for the banks and the 6.2 injectors but it is all going in a 1999
6.5 longblock. Does anyone have experience with this issue.
I have these parts together and would prefer not to change to 6.5 injectors if poss. my 6.2 injectors are Bosch 850cc marine is what i was told, not able to comfirm so far... thanks for any input. Insterd of intercooler im methane injecting, i read more power and less heat... true?