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6.5 repair or replacement options

malkom

malkom

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Hi Everyone. This is my first post. I just discovered this site and forum and will search around on this topic, but thought I would also post my question. My 1994 Chevy K2500 Suburban 6.5 Turbo Diesel has served me well these past several years but just surpassed the 200K mile mark. I heard an exhaust manifold leak on the passenger side right and immediately showed it to a local mechanic who was reluctant to repair it, saying that the 6.5 is at the end of its life, probably has other more serious problems, e.g. head gasket leaks, and suggested an engine replacement is the best way to go, seeing as that vintage 6.5 is notorious for problematic block problems, cooling issues with the rear cylinders, etc.

Up til now, she has been pretty much trouble free, after I relocated the PMD about 70K miles ago. So my question is - is engine replacement the only good option, assuming I want to keep this 20 year old vehicle, (which I do), or are there other measures I can take to squeeze out a little more life from this otherwise very reliable engine?

Thanks for your help.

Mark
 
Actually 94 is one of the better years. Mine has 350k of hard towing and never blew a head gasket. Just replace the manifold,

Check w/ Leroy @ Leroydiesel.com screen name burningoil
 
malkom, spend a lot of time reading stickys, and older threads here. it will pay off in $ saved and a lot less headaches.

The 6.5 has a bad rap for problems that can be taken care of most of the time pretty cheap. just fix the leak and go from there.

When the time comes for a new engine there are options based on $ to put in.
 
Is the mechanic going to pay for it????

Obviously, not. So find another mechanics since this one is probably only good at throwing parts.

My dad has a 95 that is almost 400K, there are issues but it can be fixed.
 
First, Welcome to TTS.

All good advise above. There is likely lots of life left in your engine.
 
Agree that the first step is to find a shop that is 6.5 conversant.

Fix the manifold.

Consider getting an oil analysis *every* oil change so that you find out what, if anything, is wrong with internals. Do not go off of somebody's woulda, shoulda, coulda diagnosis.

As Will mentioned, read through the sticky's and Technical Library as others have already blazed the trail to keeping the motor running. Like any vehicle, decide whether you want to keep it OE, or start planning for upgrade projects as things need fixing.
 
Are you sure its the manifold? Might be the crossover or crossover seal (AKA the doughnut). In comparison the crossover is more likely to rust through. I'd take it to a reputable muffler shop and pinpoint the leak then go from there.
 
I know I'm not saying anything that hasn't been said, but if your 6.5 still runs well, and is reliable, then find the exhaust leak, fix it, and keep on truckin! When the time comes for replacement, there are some great options for updating your current 6.5 with a stronger one, but you can cross that bridge when the time comes. :thumbsup:

Matt
 
Yes, Welcome to TTS. While your searching around the stickies and old threads, please know that a good place to start to get to know your truck is to break out the Diagnostic Check list and run through it. That will give you a base line knowledge of what areas need attention, known weak points and how to address them, what items/areas are key for diagnostics and what to look for to know if the motor is healthy.

Soot around the manifolds, cross over junctions at the right and left manifolds, down pipe and turbo flange are where you need to look as well as inspecting the cross over itself for signs of leakage. I was perusing around E-bay for fun and noticed a half dozen manifolds for sale ranging from $60 to $250 so there are deals to be had.

FWIW, I'm considering a 94 Suburban to add to the stable...it will be long enough for me to sleep in cause that'll be my 'dog house' if I get it.

I think your truck is a long way from the point that you need to consider a new motor so take a breath, run through the checklist and look over that exhaust system before you hit the 'buy it now' button on a new motor.
 
All good suggestions. I'll spend some time with the stickies and older threads. Looks like a lot of good stuff here. Thanks for your advice on this manifold leak. Pretty sure it is the manifold and not the crossover, but not 100% sure. I'll do more research and let you know what I find out.
 
Yeah, I've been checking out the options on eBay and see several options, including this one cast for BMI in Mexico

http://www.ebay.com/itm/6-2-6-5-L-D...Parts_Accessories&hash=item19e26f244d&vxp=mtr

Does anybody here have an opinion on these?

Not a bad price.

And Pavel, that is a good reason to get a 6.5 Suburban - to sleep in it. That, and to haul a bunch of people and their gear long distances with ease and with reasonable fuel economy. But sometimes, you just need to have a place to sleep and it is nice to have the Burb for that option. With the 2nd bench folded down, the 3rd and 4th row bench removed, and a big sleeping bag thrown down for padding and one on top for insulation, it is very comfortable camping set up, and certainly long enough for me (5'10"). I slept in it several times last summer up above Sundance while working late nights in Provo and didn't want to make the long drive home, north of SLC. Lots of spectacular hidden camp sites up there that get almost no visitors, except a few deer and racoons. One of the Suburban strong points--cavernous interior space and room for pretty much everything. I'll attach of pic of my Burb on one of those unplanned campouts last summer, taken the next morning.

View attachment 43215
 
Welcome. As others have said keep it and fix. T has 295K and I drove another 6.5 with over 320K. With good care, no abuse, and proper maintenance these rigs will run a long time. Looks like a nice manifold, I have never bought from this vendor. Someone here might have a used manifold or even a wrecking yard that could save you a few bucks. Good luck with the exhaust leak!
 
Id' buy a new manifold, aftermarket has these now. Used ones almost always require machining on the ports to get a good seal again. Not just anyone can machine the turbo side manifold either.
 
Old manifolds do warp. These engines do not use manifold gaskets as the soot the engine produces in great quantity will seal it up quick. So you should post up a pic of the suspected leak. Replacing a manifold is not fun, but, can be done. As said above find someone else who can do it without pulling the engine. IMO pulling and replacing the engine and replacing the manifolds while you are at it is normal, but, I usually have engine problems first...
 
I would find a new mechanic.

best choice: hire yourself. :) These ol 6.5Ls are pretty easy to work on.

IMO miles dont matter, care does. check for blowby, if it has none or very little, fix the leak and keep rolling.
 
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