I just bought a 94 chevy pickup with a blown 6.5TD and DewEze bale unroller for $3500 and I have the option of buying a 6.2 diesel for $200 and was thinking about transplanting it in the truck. How hard would it be to swap them over. Would I have to get something to make the transmission shift? Could I take the turbo off the 6.5 and put it on the 6.2 and make it work along with the injectors and intake? Would it make enough power to pull a 27ft trailer occassionally and do some general hauling and occassionally a load of cattle? I know they arent real powerhorses but just looking to get something to get me by. Thanks ahead of time for any help

 

I would put the 6.2 long block in and swap over all the electronics including the IP and turbo,exhaust and intake manifolds and drive accessories.

Not sure if you would need the 6.2 injection lines or have to swap injectors?

If you get the electronic timing set properly you should not notice much if any difference between the 6.2 and 6.5.

The 6.5 is a slightly bored out 6.2,otherwise they are identicle engines.
The turbo versions have a ceramic coating on the pistons so if using the 6.2,install a pre turbo EGT gauge and limit EGT temps to 1100F,the turbo side exhaust manifold has a boss for drilling and tapping for the EGT probe.

 

Im new to chevy diesel and truck diesels all together. Im just a missouri farm boy and didnt know i this was even possible. Basically he just wanted 3000 for the bale unroller which runs for about 10k new which made the truck 500 dollars and I figured if I could get it running and going that would be a cheap truck all together.
When you say switch over the electrionics what exactly all do you mean? Do i switch them from the 6.5? When I get done will it even have enough power to haul two 1500 pound bales of haul and about 15 to 20 times a year a trailer? Or am I just wasting my time? Thanks and sorry for all the noobish questions I just really have no Idea

 

Basically take all the parts off the 6.5 and put them on the 6.2.
Everything will work the very same as if it were a 6.5 turbo diesel.

The tricky part of the whole deal is setting the timing with the computer controlled injection pump.

Only 3 scan tools will do the timing on a 94/95.

The GM dealers can do it with a tech 1 or tech 2 with OBD1 expansion pack,or an aftermarket laptop program called Gmtd ScanTech pro version.
The program license and cable are about $250 and well worth the money if you intend to keep the truck.

The 6.5 exhaust manifolds and crossoverpipe,the intake manifolds,the timing cover and timing chain set and all electrical sensors ect need to be installed on the 6.2 and perhaps even the oil pan to make the 6.2 long block work as the 6.5 did.

Depending on what injectors the 6.2 came with you might need to swap the 6.5 injectors over or have the 6.2 injectors rebuilt to turbo specs and re-use the 6.2 injector lines on teh electronic IP and perhaps need high pressure fuel line adaptors?

In the end it should do what you want pretty decent depending on what gear ratio the axles are?

The towing ability is a combination of power and axle ratio.

 

with the injector timing is that something a beginner can do or should i just take it to the dealership?

 

It takes patienec and the scan tool to set timing but can be done by anyone willing to learn-most dealers don't know how to do it either.

If you don't buy GMTD ScanTech yourself along with the cable I could try and put you in touch with someone in your area willing to help out if they exist.

Still better to buy the pro versiion of the laptop based scan tech for yourself though.

The rest of the help will be here or other 6.5 sites when the time comes that you need it.

As far as the injectors go it depends what 6.2 you have,they had long and short injectors installed depending on the year-the long ones are 6.2 only while the shorts interchange between 6.2 and 6.5 naturally aspirated engines-they are the same as turbo injectors except that the turbo ones have a higher pop pressure.

 

Mark the position of the Injection pump before you swap it. re-install it in the same position on the other engine. Hopefully this will get you close enough to time, to start and drive to the dealer or a shop to get the truck timed correctly.

Injectors should be changed about every 100,000 miles. You can use either set, if they are both the same length. Whichever set you use, I'd take them in and have them pop tested. Do not pitch the other set. I or the shop you take them to would buy them off you. I could use a spare set.
I am in the process of changing injectors on all of my vehicles.
I take out a set and send them in to be re-built and do another vehicle. I send the injectors off, so It's easier to have a set ready to go when I want to swap them.

When we switched from the 6.2 in my 89 to a 6.5 we had to swap injector lines. There was something different. I do not remember what it was. That was in year 2000 I think.

Pull the glow plugs and check them. If they are an older style or cheap glow plug, they can swell and become stuck in the engine. Use only AC Delco 60G or Bosch Duraterm glow plugs.
Do not use any different number of AC Delco, no matter what anybody tells you or any different glow plugs than those 2 brands.
I just recently had a shop trying to tell me that the AC Delco 60G's were not the right glow plugs for the truck and I should change them. I took that as a good sign to take my business elsewhere.

 

NA injectors are set to pop @ 1750psi,turbo injctors are set to pop @ 2150psi.

They are not interchangeable due to that difference-timing is affected as well as fuel quantity especially on the turbo engine.

Some 6.2's came with long body injectors with coarse threads where they screw into the head,the rest of the 6.2's and 6.5's all have short body injectors with fine threads in the head.

The other difference that can require adaptor fittings is when you swap an electronic IP onto an engine that came with a mechanical IP and you wish to keep the mechanical IP injectors lines-the length is different IIRC,I could however have that backwards and the changeover is viceversa?

If you swap IP,injectors and lines together there should be no problems that I can see.