Our plan is to fit an AFE...
Our plan is to fit an AFE open-element air cleaner to the turbo inlet. But as you can see, the turbo isn't going to hook up to the intake manifold the way we have it now. We'll solve that problem when we install a Turbonetics intercooler kit for GM 6.5L truck applications to reduce intake air temperatures.
Why Swap in the 6.2/6.5L?
Often in life what's "popular" and what's "cool" aren't always the same thing. Since the 6.6L Duramax hit the scene in 2000, the 6.5L has lost appeal with enthusiasts who are in search of the ultimate in diesel power. To be honest, if a 500hp diesel is what you're after, the 6.5L isn't the engine for you. But if you're interested in swapping a diesel into your truck, car, or boat for fuel economy and simplicity, there isn't another diesel on the planet that will be as easy a conversion as the 6.5L transplant.
The key to the 6.5L swap is that its overall size and shape were largely dictated by the Chevy 350 and 454 gas engines that GM produced. While it shares almost nothing with those two engines, dimensionally it's very similar. Because of this family resemblance, the 6.5L is easily swapped in place of a Chevy V-8. And let's face it, the small-block Chevy is the world's most popular engine swap. So the 6.2 and 6.5L are readily adaptable to dozens of vehicles by simply using commonly available motor mounts, bellhousings, and conversion pieces for Chevy V-8s. Need more convincing? Let's compare the 6.5L to the Duramax and 5.9L Cummins engines.
6.6L Duramax
Donor vehicles: '01-present GM 3/4- and 1-ton pickups, '06-present GM vans, '06 Hummer H1 Alpha, and GM medium-duty trucks.
Engine bellhousing pattern: Standard 90-degree Chevy V-8.
Engine mounts: Unique to '01-and-later GM trucks.
Size: Taller, wider, and heavier than 6.5L. Weighs about 860 pounds.
Electrical complexity: Significant. Duramax swaps almost always require a complete donor vehicle in order to swap over the engine, transmission, dashboard, vehicle computers, and wiring harness.
Cost of a usable engine on eBay at press time: $4,500 (long-block) to $10,500 (used engine, transmission, and all computers).
5.9L Cummins
Donor vehicles: '89-present Dodge 3/4- and 1-ton pickups, Ford F-650 cab and chassis trucks, various Freightliner medium-duty trucks, various Case construction equipment, numerous boat, motor home, and school bus applications.
Engine bellhousing pattern: Varies. Can be adapted to 90-degree Chevy V-8 with Cummins parts.
Engine mounts: Unique to Cummins B series engine.
Size: Taller, longer, and heavier than 6.5L. Weighs about 1,100 pounds.
Electrical complexity: Varies. The '89-'98 engines are the most basic. The '03 would be the least complex common-rail engine swap.Cost of a usable engine on eBay at press time: $3,500 (12-valve long-block, no turbo) to $9,650 (24-valve with VP44 injection pump rebuilt drop in engine).
6.2/6.5L
Donor vehicles: '82-'98 GM 1/2-, 3/4-, and 1-ton pickups, SUVs, vans, and Hummers.Engine bellhousing pattern:Standard 90-degree Chevy V-8.
Engine mounts: Traditional Chevy small-block. Can be adapted to fit many engine compartments with aftermarket pieces designed for small-block Chevy swaps.Size: Approximately the size of a Chevy big-block. Weighs about 700 pounds.
Electrical complexity: Varies. The mechanical-injected 6.2Ls are the most basic. The electronically controlled 6.5Ls have a computer-controlled injection system. Cost of a usable engine on eBay at press time: $2,700 (rebuilt 6.2L long-block) to $5,895 (6.5L with side-mounted turbo, rebuilt drop-in engine).
Original 6.2/6.5L
Applications
Chevrolet and GMC
'82-'98 Pickups (up to '02 in 3500 HD cab and chassis)
'82-'98 Suburbans
'82-'98 Blazers/Jimmys/Tahoes/Yukons
'82-'02 Vans
'83-present Hummers/HMMWVs
 Fitting an exhaust to the...  Fitting an exhaust to the side-mount turbo could prove a little tricky, considering the 6.2L K5 Blazer we're going to put this engine in was never available with a turbo. We'll figure it out. |  Here's where our hot rodded...  Here's where our hot rodded 6.5L will end up. This '82 Blazer was born with a 6.2 between the framerails, but there have been more than a few engines (including a gas guzzler) in there since. Three years ago, we even tried to fit the truck with a Duramax and Allison 1000 but found there just wasn't enough room in the engine compartment. | |