diesel motor swap?

[2000jeepxj]

I found a 92 1 ton chevy van with a 6.2 diesel in it, and it only has 25000 miles on it. How hard would it be to swap this motor and transmission, into my 83 waggy? THanks

[supercopjason]

why the 6.2 those things suck !!

[2000jeepxj]

lol Yeah so i hear but i have also heard some good things to. The main reason for the 6.2 is because it has less than 26000 miles on it and runs and it is cheap as hell!!! prolly less that $200, and i believe that it has the turbo400 so i could throw in a np 205 pretty easy. Also i am not a speed freak, and my waggy is going to serve as a offroad vehicle about 99% of the time. O and the van has a 14 bolt so my rear axle will be taken care off.

[Grimjaw]

6.2 are not bad, they just are not the power houses of modern diesels. They get good low end torque and great mileage but not a lot of horse power. If you can find one of the Banks turbos or a turbo off a 6.5 the HP numbers are much better.

Test Results (http://www.bankspower.com/test_results_AC02.cfm)

[ March 26, 2006, 06:22 PM: Message edited by: Grimjaw ]

[The PIG Smith]

There is a user here, OhioJ20, that was running a 6.2L Diesel in his J20 pickup truck.
He had adapter built to use his stock T18 Four Speed transmission to the Diesel.
Her reported the it ran good and the performance was good.
He couldn't hang tough with a Corvette, but neither could the 'vette haul a ton gravel.
Sadly, his father had borrowed his J20 and it was destroyed in accident

He is currently working on installing a 6.2L in a '90 model Grand Wagoneer
My 1990 Grand Wagoneer 6.2 Diesel project (http://www.ifsja.org/ubb/ultimatebb.php?ubb=get_topic;f=3;t=034709#000001)

Basically, the conversion is not that bad.
The 6.2 and 6.5 Diesels share the same motor mounts and tranny bell housing bolt pattern as their gas cousins, SBC and BBC.
So, just pretend your 6.2 is a 350 V8 and swap it in!
There are several Chevy Engine Mount brackets available.
BJ Offroad is a place to start
Small Block Chevy Motor Mounts (http://www.bjsoffroad.com/cartgenie/prodInfo.asp?pid=503&cid=25)

http://www.bjsoffroad.com/cartgenie/images/large/24-6257.jpg

One good thing, there is less wiring to deal with!
That's right! NO COMPUTER!
Even with a late model 6.5TD, you can add the mechanical 6.2 components to the 6.5 to make it super easy swap!

I hope OhioJ20 jumps up and adds more details to my brief comments.

Also, there is another user here, I believe SJDiesel is his screenname, has a 6.5 Turbo Diesel in a Grand Wagoneer.

It is my humble opinion that while the Ford PowerStroke and the Cummins 6BT make much more horsepower, the 6.2/6.5T makes a much easier swap into a FSJ.
Even the Duramax is smaller than both the Ford and the Cummins, making is a better swap candidate.
(The Duramax makes more HP too!)

Do not get me wrong, I like the Cummins Diesel, I just feel that they are much more difficult to swap into a FSJ.
If I remmember someone here has a project of swaping a 24 valve Cummins into a Waggie.

I lust after a 360 horsepower Duramax and it's Allison automatic tranny as a swap into a FSJ.

Something like this:
EBay: 2006 CHEVY DURAMAX (LBZ) COMPLETE DROP IN (http://cgi.ebay.com/ebaymotors/2006-CHEVY-DURAMAX-LBZ-COMPLETE-DROP-IN_W0QQcmdZViewItemQQcategoryZ33615QQitemZ80500457 43QQrdZ1)

http://i22.ebayimg.com/05/i/06/9b/a5/0c_1.JPG

http://i4.ebayimg.com/03/i/06/9b/ba/08_1.JPG

Good Luck and keep us posted with LOTS of pics!

[supercopjason]

dont get me wrong i would love a deisel in my wag and i would even take a 6.2. The thing about the 6.2 is they can be made up nice. Banks offers a lot for the 6.2 and if you can get a newer 6.2 they make a power programer for it that adds a lot to both TQ and HP.

[rustywagoneers_com]

i have a 6.2 suburban, with a banks kit
19mpg pretty much all the time
as much 'power' as about any stock gas v8
runs good,
burns nearly any fuel
weighs about the same as a big block
use the Jeep trans, with a chevy adapter plate,
or get a chevy 700 (then find a diesel governor for it) and use a chevy 208 input gear with a jeep 208

(easiest by far to just adapt the jeep trans and t-case)

my 6.2 setup will absolutely be going into an FSJ, hopefully this summer

it is nice that the van is a 92, because it will not be an electronic engine... the elsectronics for 6.2 / 6.5 engines are not very sophisticated, and not worth the hassle at all... for 1000 bucks peninsular diesel www.peninsulardiesel.com (http://www.peninsulardiesel.com) can build you an injection pump to get 300 to 400 HP out of the 6.2 / 6.5 engines... try to get the fuel tank out of the van, and the fuel filter housing, as much wiring as you can, and the glow-plug controller. if you are not an absolute diesel head, lacking these items will cause enough hassles to make you hate yourself for even getting started on this project... but if you ARE a diesel nut, then go for it... otherwise, clue me in on where it is, i want it!!

peace,
Dave

[2000jeepxj]

Well I think that I am going to try and get it if I don’t end up getting it I will clue you into where it is. Now I have the hard task of convincing my parents to let me get it to part out lol this will be the forth vehicle of mine in the yard and only one runs right now. Lol
How hard is the wiring this is my first motor swap so I’m still a little weary. So on a scale of 1-10 how hard is this? Thanks for all of ya'lls help!!! Is their any write ups that i am missing when i search?

[rustywagoneers_com]

well, get the haynes diesel manual at least,

it does a pretty good job of describing the systems which are special to the various GM and Ford Diesels.. it is at least a 7 or 8 for difficulty, but imho it would be worth it..

as far as your folks go... maybe you should arrange for the van to sit where it is until you clean up 2 piles before you bring yonder van home... if you can, get the whole engine harness from the van, clear back into the cab, so you have the glow plug and water in fuel light wiring... it will be easier to tie main power and charging wires from the wag harness into the diesel wiring, than to add the diesel wiring to the jeep harness.

there is not a LOT of wiring to go with the diesel. but it is fairly unique to those applications.. various sensor and controls on the fuel filter housing, shutoff and cold advance on the injection pump housing, glow plug controller and relay... you need books!

and seriously, get rid of 2 piles before bringing the van home...

peace, Dave

[The PIG Smith]

Another place for help with 6.2L Engines and swapping them is the TheDieselPage.com's forum.
Lot of great information.

The Diesel Page (http://72.22.76.69/tdpforum/index.php)

I am member there also.
Super nice folks, just like here, that would give lot's of advice, tips and help.

I believe SJDiesel is also a member there.

PS: The search engine works great there, just this forum's search engine will after Dome upgrades the software.
WhooooHoooo...I can not wait!

[poolmike]

I'm a member of the diesel page also. Great 6.2/6.5 advice over there.

Does anyone have pictures of Wag/J series engine perches?? I'm curious if/how they are different from my 715. If they are the same, then conversion mounts are a snap for GM motors

[sputterinfuel86]

I second on the pics...also if you have any of the wiring that would rock...

and poolmike, you have a pm...

[Soulman67]

that 92 van should have a mechanical injection pump, the ds2. the electronic pump ds4 came out in 94. the ds2 cand be turned up by turning a screw in the back. Plus for the trans will be a 4L80E with a stand alone system. Perfect for that swap.

Once I swap a duramax/allison combo in my 96K3500 I put its old 6.5TD/4L80E combo in my jeep.

[rustywagoneers_com]

what sort of jeep did you toss the 6.5 TD and 4L80E into? and how did you like it when it was all said and done?

peace,
Dave

[2000jeepxj]

So how much power gain can be expected by turning up the injection pump? Also what are the down sides to turning it up.

[scotty]

more swap info on the 6.2 on this thread:
http://www.ifsja.org/ubb/ultimatebb.php?ubb=get_topic;f=2;t=037189

[2000jeepxj]

Allrighty I have been doing a little more research and I am a little bit confused. From what I have read you have to buy a expensive adapter to be able to put a transfer case (np 205) behind the 4L80E since the van is a 4x2 is this correct I am trying to build this thing on the cheap side of things.

[rustywagoneers_com]

then you need a divorced T-case

search, grass-hoppah

peace,
Dave

[The PIG Smith]

My uneducated guess to your question is Yes.

The 2WD rear tail housing and shaft would need to be replaced with an adapter and input shaft from the 4L80E to the NP205.

Here are my thoughts:

It might be very difficult to find another transmission that has a transfer and/or is set up for your 205 AND is Diesel compatible.
Meaning the Diesel tranny has a different Torque Converter and some have valvebody modifications that are different than a gasser unit.

Now, if you found such a unit and it was in good working order and you did not pay a lot for it, then that would be the easier way, but I doubt you will find such an animal.

Also, keep in mind that if you get an adapter for your NP205, bolt all this 'stuff' in your rig, the drive shafts may not be the correct length.

So, trying to make your 4L80E to work with your NP205 maybe cheaper, howbeit a lot of work, than getting someone else's bag of worms to work correctly.

Maybe other folks here might suggest a better adapter/input shaft/shifter/transfercase to seek out instead of your current NP205.

[Soulman67]

turning up the injection pump will increase power greatly over stock. and your fuel mileage won't change under normal driving, but when you push the pedal to the floor it will use more fuel. the 6.2 diesels came stock with 4,000 rpm governer as where the 6.5's had a 3,400 rpm governer. So you could just use your stock tranny and probably get over 20 mpg. Most 6.2's were used in trucks with low gears and no overdrive.

My diesel truck turns 70 at 2400rpms in overdrive, my stock wagoneer turns 2200rpms at the same speed. I had a 91 1 ton crewcab with the 6.2 4l80e and 4.10s that got 18mpg.

[Grimjaw]

Originally posted by 2000jeepxj:
Allrighty I have been doing a little more research and I am a little bit confused. From what I have read you have to buy a expensive adapter to be able to put a transfer case (np 205) behind the 4L80E since the van is a 4x2 is this correct I am trying to build this thing on the cheap side of things.Chevy offered the 4L80E with the np205 for ONE year. Of course this was in 4x4s. I have this set up in my 1979 K5 Blazer. The adapter is rare and pricey. Good luck.

[rustywagoneers_com]

once again

leave the trans alone

use a divorced t-case

peace,
Dave