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6.2 turbo swap

M

MOcummins-farmboy

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Location
Rock Port, MO
To start off the project truck is an 81' GMC Sierra Classic RC LB 1-ton with an 83' 6.2l diesel that my dad put in the truck in place of the original big block. He had the engine decked before he dropped it in, this is the only thing done to the engine. Yesterday i just picked up a 93' 6.5 engine that i found on craigs list for $500, he also threw in an AD 100 and 2 more sets of bosch injectors. Now the engine was startin to smoke white but that doesnt pose a problem cause im just pullin the turbo and all the manifolds. I plan on having the bosch injectors pop tested and hopefully have 8 good ones outa the 16. before i start the swap this summer i hope to get some more parts such as-head studs, main girdle, turbo master waste gate, AFE intake, prolly more i just dont remember. The only problem i fore see is the turbo oil supply and return. If any one has any pointers or ideas from past experiences id sure appreciate it. Im always open to knowledge.

Also forgot i wanna change the timing chain for a gear setup made by the Diesel Service Group and put in some autometer gauges to keep track of vitals, boost, pyro, and fuel pressure.

Shipped the extra 15 injectors off today to get em pop tested, hopefully ill have 8 good ones to use.
 
oil supply and return are relatively easy. ditch the mech lift pump that's where the return goes then t into the ops for supply. save your money on the afe aircleaner and get a k47 box out of a 97+ 6.5 truck. I thought I heard the gear drive was no longer available
 
I planned on gettin rid of the mech one, thats what the AD 100 is for, i just need to get the block off plate. What kind of lines do you use for the oil supply? I know lots of people dont like AFE air cleans but personally i dont like the restricitve air boxes. Ill do some investigating on the k47 air boxes. i jst recently read that about the gear drive too which sucks cause id rather have that than the timing chain.
 
watch your fuel pressure with the AD100. I am running one on my 6.2 and I had to crank it almost as low as it would go. You'll need a fuel pressure gauge for sure.
 
It should be set for 8 psi. How much do you run? Fuel press. gauge is a must for sure along with boost and pyro.
Spring break is the 18th till the 30th so I hope to start workin on it then and I'll post some pics that I take along the way.
 
You are putting a 6.5 turbo setup in this? Does it have AC? I recall the 6.5 turbo setup will hit the HVAC box on the OBS trucks.
 
I read about the AD for the 5.6's and they said they were set a 8 psi. but ill have to check. yes i am taking a 5.6 turbo setup off a 6.5 engine that i bought and puttin it on my 6.2. I know theres clearance problems with the A/C unit. Im pretty sure that it doesnt have A/C but if it does it will be coming off cause it doesnt work any ways. Im anxious to see what problems im gonna have with the exhaust, im gonna try to keep it between the fram rails.
 
turbonator said:
if your 6.5l has the oil return plate you just use that in place of your mech. fuel pump as the blockoff plate
Click to expand...

I took all the manifolds and turbo off the engine this evening and saw the oil drain tube the went to the side of block and was wondering if it would bolt into place of the mech lift pump so thatll be pretty easy.
 
Heres some pics i snapped today while i was taking off all the manifolds and turbo.

Complete Engine-
http://i1237.photobucket.com/albums/ff472/cummins-farmboy/DSC00006.jpg
http://i1237.photobucket.com/albums/ff472/cummins-farmboy/DSC00009.jpg

Exhaust Manifolds-
http://i1237.photobucket.com/albums/ff472/cummins-farmboy/DSC00010.jpg

Intake Manifolds-
http://i1237.photobucket.com/albums/ff472/cummins-farmboy/DSC00011.jpg

Turbo-
http://i1237.photobucket.com/albums/ff472/cummins-farmboy/DSC00012.jpg

When i pulled the turbo and laid it on the floor some oil ran out of the pressurized intake side of the turbo, i think this is a problem any input?
 
MOcummins-farmboy said:
Heres some pics i snapped today while i was taking off all the manifolds and turbo.

Complete Engine-
http://i1237.photobucket.com/albums/ff472/cummins-farmboy/DSC00006.jpg
http://i1237.photobucket.com/albums/ff472/cummins-farmboy/DSC00009.jpg

Exhaust Manifolds-
http://i1237.photobucket.com/albums/ff472/cummins-farmboy/DSC00010.jpg

Intake Manifolds-
http://i1237.photobucket.com/albums/ff472/cummins-farmboy/DSC00011.jpg

Turbo-
http://i1237.photobucket.com/albums/ff472/cummins-farmboy/DSC00012.jpg

When i pulled the turbo and laid it on the floor some oil ran out of the pressurized intake side of the turbo, i think this is a problem any input?
Click to expand...

IMO it is part bad CDR and bad design.... gm used an oil supply that has no restriction and oil builds up inside the turbo and pushes past the brass bushings into the cold side.....
 
turbonator said:
IMO it is part bad CDR and bad design.... gm used an oil supply that has no restriction and oil builds up inside the turbo and pushes past the brass bushings into the cold side.....
Click to expand...

So the turbo its self is alright? thats the main thing im worried about. Theres is very minimal side to side shaft play and none in and out.

Now that were on the CDR subject. Is it required for the engine to operate?
The CDR on th 6.2 has 2 hoses running into the intake manifold.
The 6.5 CDR has one tube goin to the turbo.
What do i need to do with this swap?
 
You can use the stuff off the 6.5 and run it to the turbo or you could run a draft tube.
 
Some may call it a road tube.

You just run an open tube from the cdr to below frame level, it's just vented to atmosphere. Off road equipment used to be this way, some may still be.

You would then plug the cdr inlet at the turbo.
 
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