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Russ' Turbo 6.2L build thread - Updated with Pics & a Problem

Russell

Russell

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Hey guys!

I figured I should throw a post up with my turbo 6.2L build I've got on the go right now. I don't have any pictures I can post here yet, but I will as of this weekend :D

What I am up to is taking a very low miles red block 6.2L that I picked up over christmas, polishing it up nicely, turbocharging it, and installing it in my K25 with an NV4500 I have sitting on the shop floor awaiting detailing :)

Anyways, I spent all last week cleaning the engine up, and was able to get every spot of grease cleaned off the block / heads, and get it all painted up nicely. I dropped the oil pan, and installed a DSG main girdle kit after inspecting my block for signs of cracking. Fortunately, I was unable to find any cracks after visually inspecting, then using a torch to warm the mains up to try and draw oil out of any cracks

I also purchased and installed a brand new 97+ 130 gph water pump to go along with my brand new harmonic balancer, and serpentine pulley system. I've got a brand new 105 amp CS alternator, AC pump delete pully, and hydroboost power steering pump.

Before installing the water pump I put in a brand new timing chain, and installed the injection pump as well.

Now, for my first of what will probably a ton of questions:

After installing the timing cover and water pump, I've discovered that my engine makes a noise that sounds like the timing chain rubbing against the side of the timing cover. It only happens within about 1/8th of a turn of the crankshaft, which is making me wonder if my injection pump's timing gear is crooked for some reason, or if it really is the chain hitting the side of the timing cover for some reason...

I also noticed that the water pump impeller slightly rubs the backing plate as well when you rotate it by hand. Should that be something I am worried about, or should I just let it wear itself in?

Thanks!

Russ
 
Can't be good. I would tear it apart and have a look. You using gaskets or rtv to seal everything up?
 
I've got Felpro gaskets sealing everything. If I take it apart again, should I be replacing all the gaskets as well?
 
water pump rub

I've put a cucv surplus in my K5 and replaced the waterpump for ease of pully arangment(lazy) but it had a factory stainless shim plate. Never ran into that befor but it had a high volume pump on it originally. Might need to check with mil-specs could be something to do with high volume impeller. Ive got a Helms manual but it never showed anything about a shim plate, so go figure.
 
i have nothing good to add. I have a banks turbo sitting in my garage that I plan to install once my house is done. I will be following your build closely.
 
Exhaust is for wussies!

Actually, I plan to have a custom 2.5" crossover pipe made up, and run a single 3" straight pipe from the turbo out to behind the rear wheel with a 45 degree angle exit. No need for a muffler on these engines, the turbo does enough muffling to make them sound a lot like a big block with some really nice mufflers on it.

Anyways, I do have an update for you guys, and it isn't particularly good news for me. I was under the assumption that my engine had newer heads on it with short injectors already, however, that isn't the case. After pulling one of my old injectors I was dissapointed to discover it was a coarse threaded injector and is about 1/4 - 1/2" longer than the short rebuilt injectors I have to install. That means that my lines won't fit properly, and the turbo manifold is literally up against the line / nuts of the inner two injectors on the passenger side. While the manifolds do sit close enough that a guy could get away with it after installing gaskets, I don't feel good about leaving the injector lines touching the hot exhaust manifold. While I was working on the engine I also discovered that one of the injectors was badly crossthreaded by my PO, and while I can get the old line on it, there is no way I can install the new lines without stripping something out even worse.

So, that leaves me with three potential options. The first two will have my truck sitting for most of the summer, the third would have me up and running within 2 - 3 weeks:

1. Change the heads out with a set of rebuilt 6.5L heads from DSG at 550 per head (fully assembled ready to bolt on with the coolant passage tube fix done) + the 250 odd bucks for the ARP head studs, and whatever the cost of the 6.5L turbo headgaskets is.

2. Purchase a Banks turbo kit to install, which could potentially cost over a thousand as well

or

3. Replace the injector with the buggered up threads, install my J-code intake and run it N/A until I can afford to install new heads.

What do you guys think I should do?

I see adding the 6.5L heads as a major upgrade to the engine. They flow a bit better, would get me the headgaskets designed for a turbo, the head studs, and have turbo pre-cups installed. They would also be immune to the cracking problems the old ones faced. However, its a ton more money which I don't have at the moment, so the engine would sit on the stand for at least a couple of months before I could finish it. I would probably eventually wind up doing the heads, so the banks turbo would be a bit of a band aid fix.

BTW, here are a couple pictures of where I am at with my engine. As of this afternoon the oil pan and vacuum pump delete are cleaned up, painted and installed. I have my valve covers scrubbed, but still need to strip the old paint off them before I can re-paint them. I didn't bother worrying about it since I may be replacing my heads anyways. I was also planning on changing out the injectors and installing the lines, but as you may have guessed, that didn't happen, lol

001.jpg


002.jpg


003.jpg


004.jpg
 
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I'd read back through Max's engine thread. I seem to recall he had issues with the 6.5 heads he bought. He made them work, but wasn't impressed.

Why not look for some later 'J' code heads and run the more common injectors? Less outlay for better end product, but you'd still get the ARP studs and better head gaskets done which takes care of a few issues right away.

BTW, visually the engine looks really sharp. I know it was a lot of work, because you were describing what a grease pig that one was...but it looks very sharp now!

Rene
 
I've heard that the J-code heads are very hard to find, particularly without big cracks in them, otherwise I'd be happy to go with them.

I know that a dealership would rape you hardcore around here for new OEM heads, but I wonder how much a set would cost down on your side of the border...
 
Last I checked I still lived on the same side of the border that you do... :p:

I wonder why 'J' code heads are hard to find? You'd think every scrapped M1008 would have a set...and with low miles to boot.

Rene
 
Doh, sorry man! Totally forgot you were a Canadian as well! Just used to most of the guys being from south of the border...

And yeah, you'd think they are common, but I've read in a number of places that they are very tough to find in usable condition and are not longer available as NOS.

Regardless, I finally managed to get my cellphone to connect to my computer properly, so here is a picture of the turbo manifold with the injector lines installed.

As you can see, the first injector's line is up against the turbo oil return line, the second injector's nut and line are both against the manifold, and the third injector's nut is up against the manifold as well. I am sure I can just do some custom "tweaking" to get the line off the manifold and return line, but will those nuts being right up against the turbo be a major problem?

As it sits in these pictures, the manifold is close enough to the block that it will seal properly.

005.jpg


006.jpg
 
Well, from experience with a NA 6.2 and a manual tranny I think the power level will be fine. My K5 get's up and scoots as well as my '83 pick-up...but it weighs 2000 lbs more. :doah:.

The K5 has the NV4500 with a doubler behind it, the '83 has the 700R-4 behind it.

Rene
 
I am sure I mentioned it, but this truck will have an NV4500 behind it. It is an early 93 version, so it has the deep gearing too
 
I wouldn't run it like that either...can't you order up a set of short coarse thread injectors and carry on though? I don't recall rebuilt injectors being all that spendy.

Also, maybe i missed it, but what turbo set-up are you trying to use?

Rene
 
I wasn't aware that there was such a thing as short coarse threaded injectors? I thought there was only the one size!

That is a stock 93 GM-3 turbo setup with a mechanical wastegate
 
I thought there were short coarse injectors...specifically for the G vans.

Rene
 
tRustyK5 said:
I thought there were short coarse injectors...specifically for the G vans.

Rene
Click to expand...

That's what I was thinking. It's at least worth checking it out;) Sorry I can't be specific.

Another idea is there is somebody here trying to sell a set of rebuilt heads for $400. Might still have them for sale. Can't remember more on that either:rolleyes:
 
Hey Russell, don't know if I mentioned it but I bought a little 10 gallon pressure pot sandblaster, if you're coming out to my place and you have any small parts you want to clean up bring 'em along . . . . :-)

SHARP looking engine, man!!!!:bow:
 
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