Been a while and I thought I would update. Been collecting parts for the completion of the turbo install. I had done some mock up on the turbo stuff as shown above but I only had one bolt in the exhaust manifold. When I went back to stick more bolts in to check length I could not get the back bolts to start. So I pulled it back out and found this:
So the gasket fits the block and the old 6.2 manifold perfectly. But look at the gap on the bottom most port. No wonder the bolts would not start. I do not under stand this because I pulled it from my parts 6.5. But that motor was trashed and there is evidence that the manifold was very hot at some point. The sealing surfaces on the manifold were bad and very thin anyway. After looking locally for one I gave up and bought a re-pop off Amazon for $160.
The casting is pretty rough finish (inside and out) but the sealing surfaces are flat, it fits the gasket pretty well, and I can also get all the bolts started in the head. I had just finished tapping the EGT gauge hole. These are ready to go in my blast cabinet and then off to a coworker who sprays Cerakote to get coated on the outside along with the hot side of the turbo to try to cut down on some underhood heat. The manifold spacer to clear the injector lines is designed and just waiting for some free time to cut it out.
I also split the turbo for a rebuild. This turbo was probably usable as is but came off a high mileage truck (150k) and had some bearing play. I opted for a replacement cartridge from Rotomaster. I had some issues getting the clamp bolts out on the hot side and ended up cutting two of them off and welding nuts on and finally got them out.
According to the guy I bought the turbo from for cheap it was not building much boost and now I know why. The wastegate shaft had worn down and was allowing the wategate to sit crooked in the housing and not seal blowing by boost.
I am going to take it to work and either make a new shaft or try to weld up that one. New parts waiting on install.
Yesterday I got the mechanical lift pump removed and installed the turbo drain. That was a messy job as I ended up dumping about 2 gallons of diesel on the shop floor because somehow I started a siphon from the tank.
I removed that weird third battery tray and got the second battery and battery cables installed. Also started prepping to swap the intake manifold.
I decided to remove the 6.5 fuel filter tab on the manifold as shown because it interferes with the vacuum pump location. Bandsaw made quick work of that. After a quick degreasing it is ready to install.
