That was my swap............. I however removed the 4X4, which involved some welding up a new front end support to replace the axle. With my build I was going for MPG so the 4X4 was dead weight and it did not fit the older style 6.2 oil pan that I had.
To do the swap the easiest way I found to...
I did a swap in a 96 tahoe for the following reasons
#1 Wanted to do it for the fun project that it would be and learning experience.
#2 Get better gas milage
#3 I like the 6.2 6.5 diesels.
With fuel mileage gains I calculate that I save at least $8 every 200 miles even though fuel is more...
I am with Will... I would really like to see a video of this smoke coming out the intake. Air getting in the fuel pump can definitely make them a bugger to start.
I hope your smoke out the intake is not this extreme but it reminds me of a time I was working on a friends Toyota......... It was...
If you are getting fuel out at the injectors, I would look real hard at the glow plugs. These trucks wont start without them. Also X2 on the cranking speed. If the battery got run down just a bit then there is a good chance that it will not fire.
Another thing that can cause SES at 70MPH is a vacuum pump, vacuum line, or waste gate solenoid problem. My truck did this when the vacuum pump went out.... at 70MPH there was not enough vacuum to hold the waste gate, so the under boosted condition would set the code.
When I built the engine for my tahoe I did not have an IP, but I was able to get a 24 Volt from a guy for $100 and got it re-built. I just told the shop that it was a 24V and asked them to change it to a 12V. They talked like that was no big deal.
Is that 13MPG town/city driving? If so that sounds about like mine, I get about 14 in town if I go easy on it and 13 if I listen to the turbo.........don't get 19-20 unless I am out on the interstate. Mine is a 94 K2500 with a steel flatbed on it so it weighs a bit more than stock.
I think I found the culprit on this....... I went out and tried it (had not done anything to it) and it fired right up. So I walked around and started wiggling wires at the injection pump. As soon as I touched the PMD extension harness at the IP end the truck died. I repeated this a couple times...
Is the needle on your gauge out of place? Sounds like maybe you are getting the proper range of motion it is just twisted up to read too high on the scale. I know on my 96 you can pop the needle right off (I don't remember it being keyed on its shaft) so I would think you could just line it up...
My pickup stalled out today. Would not re-start....jumpered the fuel pump and confirmed good fuel pressure to the IP, no air bubbles in the return line, put a known good PMD on it........Nada.... A friend got a roll back we loaded it in the rain at 40 something degrees......... Its been sitting...
Best Timkin P/N I can find is 99282 (Redi Sleeve). Rock Auto Price is about $22. The SKF Speedi Sleeve P/N 99845 from NAPA is about $100. I have not been able to find the P/N by application......just had to measure the shaft and go to a sizing chart
I have a rear seal leak on left side (the drum is full of gear oil). It appears that there are grooves worn into the spindle where the seal rides. I replaced the seal a couple years ago and it seemed to help some but it is starting to leak again pretty good. Is there some kind of repair sleeve...