85 Burb Diesel conversion

[AKMark]

Hello folks, thought I'd post up on the development of one of my current projects.

Picked up an 85 Burb hull (planned to give him back the 350, bad tranny, and the t-case) and found myself a 83 Burb to donate it's 6.2L, slightly beefier built 700R4, and NP208. As well as a few other pieces to put it all together.

About a month and a half ago Kev and I parted the 83 and got rid of it.

Today we pulled the 350, tranny, t-case, brake master cylinder (Diesel's cannot use the vacuum style brake setup) as well as the radiator, exhaust, and 350 wiring harness.

I got the Diesel hydraulic master cylinder, and wiring harness in.

We have just the following left to do before we can try to start it; Install motor, trans, T-case, radiator, power steering pump, starter, belts, second battery tray, connect wires on the motor, put in the driveshafts, put on the dual pipes, drop fuel tank and clean it, drop a few gallons of diesel to get to the station with.

After that, it should be a go.

I hope to have everything but the fuel tank done before Saturday.

It's not that hard when everything bolts up. YIPEE!

[sevenslats]

So this is going to be your family DD/tow rig?

Sounds like a good build.

[naturalbornmudder]

I am interested to see how the IM portion goes, when you go for the diesel exempt sticker but the titling shows it being a gas motor.
Kelly, could you shed some light on this one for me?

[ChevyKev]

From what I understand, as long as there was a diesel option for that year / model you can swap one in. Once swapped you have to stop by the Borough IM office (where Kelly works) and have someone make sure it's a diesel and they give you the exempt sticker.

Simularly - any time someone buys a diesel they have to take ti to the same location to ensure it is in fact a diesel and takle that form to the DMV when they title and register it under their name.

[akdsmer]

Any vehicle with a diesel powerplant can get a diesel exemption. The vehicle simply needs to be DRIVEN to our office at 3175 Peger Rd. We type up the certificate, walk outside verify it stinks while idling :rolleyes: and put the window sticker in. You then take the certificate to DMV where they will input the correct I/M designation and WHAM! your a diesel. There is no requirement that it come with a diesel originally, so I can stuff a Cummins into the zuki and snap some more axle shafts if I want!

[AKMark]

The motor is in. We had a little problem today and thanks to it, the tranny and T-case still remain on the floor in Kev's Garage.

Before dropping the motor in, I decided it would be a good idea to yank out the glow plugs while they were really easy to access. Well, there was enough carbon build up on them to make it a challenge. I broke one off. I then pulled the respective head to remove the remains, only to find that I still couldn't get the part out. Finally removing the injector freed the piece, which means the head didn't have to come off.

However, in pulling the head Kevin and I noticed something. Someone has gone through this engine in it's recent history. Fairly new gaskets and other parts were holding it together originally and the head was in perfect shape. (Thank you God for not showing me an obvious crack.) So, we put the engine back together and dropped into the frame. It's bolted to the motor mounts with a jack on the tail to keep it from sagging till the tranny goes in.

If I get off at a decent hour, I will go and throw the PS pump, radiator, tranny cooler, wiring, and fan in as well as finish the ignition cylinder and fuel cable. Those won't take long.

I'm hoping to convince a few folks to give a hand after the meeting to drop the fuel tank, and install the tranny & T-case. I want it to run tomorrow!

[ajpthng]

If I was their mark I'd give ya a hand. Good luck and

:worthless:

[ChevyKev]

These aren't very good, but here's the idea:

83 Burb body, fairly clean with a few minor dents - and someone in past history with a love affair with red spray paint!

http://www.arcticoffroad.com/forum/gallery/files/1/3/IMAG0001_edited.JPG

6.2 diesel picked up for $350 (came in a parts burban that we got engine, trans, t-case, radiator, and other parts needed for this swap)

http://www.arcticoffroad.com/forum/gallery/files/1/3/IMAG0002_edited_116958.JPG

I don't think this is exactly the correct transmition placement - I'll have to read my manual to be sure.

http://www.arcticoffroad.com/forum/gallery/files/1/3/IMAG0007_edited.JPG

Dark picture, but the entire bed of the burb is full of parts.
We can play I-spy!

I spy a... clutch fan, tranmition filter box, t-case, Napa parts bag, Driveshaft, radiator (x2), upper radiator support, battery tray, oil cooler lines, shredded tarp, 208 t-case, Delo Oil container (x2), antifreeze, trim pieces, parts bucket, ...

http://www.arcticoffroad.com/forum/gallery/files/1/3/IMAG0008_edited.JPG

[naturalbornmudder]

all right! The last two pictures are now outdated!

[akram]

Yes most of that stuff is now in it's right place

[ajpthng]

Good to hear! Hope to hear it on the road soon.

[AKMark]

Well....

I got off work early on Friday which is a first in the history of the 355th AMU. I show up a little after 8pm to work on this last night and immediately get called a bum because someone decided to be nice and got a few friends together to put the trans and T-case in. So around 9pm, Nate, Pat and eventually Mel show up and got to work.

We got the tranny in, t-case in, crossmember in (TWICE), rear DS in. Fuel tank out (needs to be cleaned then reinstalled). Radiator and additional trans cooler in, wiring harness trimmed to meet vehicle requirements. Steering wheel is off for install of a new lock cylinder. The fan is on, fuel filter mounted, fuel lines properly routed. Vacuum EGR crap removed.

What's left?

Clean and reinstall fuel tank and flush fuel lines
Pop out unleaded fuel nozzle holder in the tank filler neck
Install transmission cooling lines
Install front driveshaft
Install starter
Install PS pump
Install belts
Wire Glow plug switch (yeah it'll be manually actuated)
Wire Torque Converter lockup switch (It'll be manual too)
Install New ignition lock cylinder
Reinstall Steering wheel and console pieces.
Replace self canceling spring on steering column, (currently if you turn left the blinkers won't cancel.)
Install second battery tray
Install dual exhaust (already have the pipes)
Install both batteries
Drop tranny pan, install new filter and gasket.
Drain T-case and refill
Drain engine oil and change filter
Install air filter assembly
Fill all fluids to the proper specification
Turn over motor without glow plugs installed to prime the injectors
Install glow plugs
Cycle them once
Say a quick prayer
Make sure a charged fire extinguisher is nearby
Attempt to start
Hopefully after only a few seconds of cranking hear it cough to life and give the wonderful diesel rumble that it should create.
run through gears in place, check and top off trans fluid, run through gears in place, check and top off trans fluid, run through gears moving a foot or so back and forth, top off trans fluid, and repeat last process again.

Allow it to get to operating temperature and shut it off
Verify the fluid levels are where they should be
Attempt restart
Take it for a spin
Check and top off trans fluid again
Get ins card and go see Kelly at the DMV for a vehicle diesel reclass and registration

If all goes well, YIPEEE! I got a new DD!

[93hummer]

A quick note on the priming, I have ran my 6.2 out of fuel 4 times now and have it down to a science:

step 1. put some fuel in tank
step 2. prime fuel filter housing and reinstall filter and lid
step 3. crank engine while holding the pedal to the floor, it will prime MUCH faster this way. after a few cranks it should cough and sputter and start. When it starts, keep giving it some pedal until it clears up and runs smooth.

Another way to prime it fast is to crank with one injector line loose to bleed all of the air out. If you have an electric fuel pump, you could loosen one up and jumper the pump to run until fuel seeps out of the loosened line. If a mechanical pump, that step obviously won't work. Mine is electric but I have never had to do that, just the three steps above.

[93hummer]

Just had another thought on priming, if you have the mechanical pump, you could loosen one injector line, put some fuel in the filter housing, close it, then crank for 20 seconds or so, and repeat until fuel seeps out the loose injection line. Probably only take one or two times. Then tighten up injector line, fill filter housing one more time and try to start with the full throttle priming mentioned earlier.

[AKMark]

A diesel tech suggested removing the glow plugs and cranking till fuel came out. After priming the other 6.2 we just got running using the injector method, (just like you mentioned except loosening all 8) I like the glow plug removal because of a few things. By leaving the injector lines tight, you prime the injectors. By removing the glow plugs, you remove compression in the cylinders during priming, releaving the starter a little during the priming sequence.

[ajpthng]

JMO but I helped get many a diesel running in Iraq after they ran out of fuel on a convoy and it fairly easier to just crack an injector line then to remove the glow plugs. They take about the same amount of time to bleed the lines but once one line is bleed you can tighten up that line while the others are still bleeding and its faster to keep cranking and tighten a line then to try and put a glow plug back in.

[AKMark]

Well more progress today.

The only parts left to install are;

Right side Optima Red top
PS pump
belts
Fuel tank and filler neck
Proper air filter (Napa sold me the wrong one)
Exhaust

I'm going to FBNX tomorrow to attempt to find a 6.2L PS pump bracket as the only one we found does not fit. CRAP!!! Go figure MSI is the only place in town that thinks it has one. At least they only want $15 for it.

Also gotta get a fuel tank filler neck. Diesel's use a larger nozzle at the pump than gas and I found the part that makes it smaller doesn't just pop out like I had hoped. Luckily Interior towing has several diesel filler necks for me to choose from.

We are definately getting close though.

[STOMPR]

If you have trouble finding the PS bracket at the junkyard call the Diesel Doctor I know that when I broke mine nobody had one, called them and they had it new on the shelf. They actually carry quite a bit of hard to find diesel parts if you find yourself in a jam.

[AKMark]

Cool thanks!

I'll hopefully be getting with you soon about your 6.2 for sale.

[ChevyKev]

Mark had a good trip to MSI today and we ot the correct filler neck and PS brackets. Tomorrow should be the turn-key moment to see if ti fires up.

[93hummer]

This is so cool... we should start a 6.2 club within Arctic offroad... if I can ever get in!!!

AKMark, once you get that stock burb running, I challenge you to a race, but only up to 55-60, you have overdrive and I dont!!!

[STOMPR]

Your 6.2 does more than 55-60 :eek: I`ll race you with mine. wanna go for pinks? (now I`ll just add propane and a turbo he he) :D

[AKMark]

I do have a shorter 1st and 2nd gear compared to you two. I might get off to a head start. We'll have to see.

[STOMPR]

What axle ratio you running ?

[AKMark]

3.55 or 3.73, dunno which. Also you are running 3/4 ton running gear, I'm running 1/2.

I'm not saying we should race, but it would probably be close.

[STOMPR]

True I am running 3/4 ton gear currently and it may change to 4:10 1 ton stuff soon. Racing any 6.2 I believe would be a turtle race as they are know for being workers not racers although it may be somewhat interesting. Now the new Diesels thats another ball of wax altogether.

[AKMark]

You have to remember the 6.2L came out in 82 amid the fuel crisis. It was developed to produce decent pulling power and good fuel economy. Compared to it's 350 and 305 brothers, it usually got between 2-10 mpg better and during towing operations even better than that. They are loud, slow and a bit on the rough side, however they were fairly reliable, and like I said before, gas mileage was a big plus.

Dad had an 82 C-20 with a SM465 and a 1700 lb veternarian's box in the back and routinely got in the low to mid 20's. Yup, going 0-60 is not something you want to time, but it works for those with a budget in mind.

[93hummer]

mine has 5.24 gearing and 42's. My top speed is somewhere around 70. I have tweaked the injection pump for more power, with 37's it would really go, the 42's really sapped the power though. I would race for fun, but never pink slips. and the winner would have the "fastest 6.2" title....

[akdsmer]

Hmmmm.....Anyone of you boys wanna race a 6 cylinder? :whistle:

<thread hijack over>

[AKMark]

No racing.

Just got her done. Runs and drives, shifts smooth, and even rides pretty well. After only idling for a few minutes the heat was very hot and engine temp sat right at 190. At least that wire is connected right. I still have to wire the oil pressure sender correctly, as it read nothing till it got warmed up and then slowly climbed like I would expect a temp guage to read. In fact it was in the same position (approx 11 o'clock) that the temp guage read. This truck has three different temp sensors. One was supposed to be for the glow plug controller, another one for high idle, and a third for the guage. Only two were used, however the wiring from the 83 burb donor to the 85 gas was slightly different, so I probably have to chase that one down a bit. However it's gutless as they come. I was floored to get to 55 and it took forever.

Hummer if you see this give me a call at 978-9011. I'd like to meet up with you sometime in the next week or so to tune this sucker up. At speed it doesn't spit black, so I'm guessing that it's a bit lean.

However, seeing that this engine has not been running for many months, I'm partially assuming that the injectors are attempting to figure out why they have fuel when they haven't in a long while.

Kelly, I should be up there with it Monday morning bright and early to get it reclassed and registered. If I can have your number to get a hold of you when I get there, that would be cool.

I'm just glad it's running. I might be getting better injectors if tuning it up doesn't give me the zip I'm looking for. At least I can get to mine pretty easy compared to Kevin's 6.5 Turbo.

I still have to completely install the dash, hi-idle switch and of course the radio. A project is never really done is it?

[93hummer]

May I suggest a 6.2 diesel wrenchfest? Stompr was looking to turn his pump up too, so we could kill 2 birds with one stone. I wanna turn mine up some more eventually, but since I have already turned it up once, I am not gonna turn it up anymore until I get an EGT Guage. Maybe we can get some good pics and a writeup for the tech section if anyone has a digtal camera. With enough tools, good lighting and wrench turners, it should take 2 hrs each, maybe faster. I am interested in your high idle switch, mine does high idle on it's own sometimes, but not always, I would like to add a switch to it.

[93hummer]

One other thing we could do is check the injection pump timing, we could advance it a couple of degrees and see if that helps power. They say that with high mileage the timing chain stretches and retards injection pump timing, which can cause lower power. if your engine is above 100K, I would bump it like 2-3 degrees, pretty easy to do.

[ajpthng]

Congrats mark! Glad to hear it's up and running!

[Jackrabbit]

What you need is a turbo.

[akdsmer]

Sweet, another rig out of Kevin's place! 459-1311 is my number there at work, but when you walk up to the counter, you'll see me. To be clear, I don't work at DMV, you'll be stopping by the I/M Office. Turn RIGHT onto Peger road from the Mitchell Expressway. The second building on the left, immediately after the RV/Camper shop.

[AKMark]

Roger that, I'll be by Monday morning around 0900.


George, I agree, I'll be keeping an eye open for a setup that'll work for me.

[AKMark]

Well, didn't get to FBNX today thanks to someone who couldn't find a title. :whistle:

He finally found it right where he thought it was, except it was under the drawer he thought it was in. Oh well. No big deal.

Did drive it around a bit getting ins started and keys made. It's not that bad, quieter than the Jeep, and overall I'm happy. I thought it was a complete turd till I realized the speedo is a little over 20% off, so while I was thinking it took forever to get to 60, I was closer to 75. Whoops! No wonder I was passing so many cars, so the correct gear will be on the shopping list soon.

Of the other notes I have, I need to get a new frost plug heater. I found a wire for the one I have and it just pops circuit breakers, so I'll be fixing that soon.

Also found a slight tranny leak. There's a splice on the line that goes from the tranny to the cooler, and the clamp is maxed out and not holding the fluid in. A couple of small clamps should have it working great, so I'll knock that out tomorrow morning.

Kelly, I should be up there tomorrow, I don't have a reason to not get up there, so hopefully it works out.

I found that with patience and strong batteries it will start at -10 without plugging it in. However, I do hope to get it plugged in to save not only wear and tear on the starter and batteries, but also to the motor itself.

It runs strong and clean, which tells me it's a bit lean, so when Hummer and I tune it up a little, we should get some good results.

Can't wait to get this thing all fixed up and working. It rides great and should be a good vehicle down the road for me and the fam. The best part is that IT'S PAID FOR! The fact I didn't spend a whole lot is nice as well.

[STOMPR]

Project "Black Smoke" at my place, time to be determined.

[naturalbornmudder]

I would like to take a ride in the Suburban Commando once you get it all ironed out Mark. I have a soft spot for diesels.

[AKLJ8]

:worthless:

[AKMark]

Hard to take pics when it's at someone else's house and the wifey has the camera hidden somewhere.

I know, excuses are like armpits.......

My diesel doesn't jump to life, but the groan of the motor had Cassie sleeping in only a few minutes a few hours early for her daily nap. I guess taking her for a ride might be required more often to get her to sleep.

[Jackrabbit]

I have a perk heater you can use untill you get your block heater.

[AKMark]

I'm going to attempt to trade the block heater for the 3.4L I bought for our Buick that I never used for this one. It's worth a shot. I'll just keep it in the garage (if it fits) until then. That'll make the wife want to give me the time to fix it. :whistle: She's gotten used to her vehicle being parked in the garage all the time. :D Getting in a vehicle that's already at 70 degrees and usually warms up fast enough that it doesn't get cooler is nice. I'm never that lucky. The Jeep is too tall, and I'm betting the Burb will be too wide and long to fit in the garage with all our crap. Oh well, if I can get the nose in I can change the frost plug heater in fifteen minutes, as long as I don't strip out the heater screw. Right Mel? GOTTA USE THE ALLEN WRENCH INSTEAD OF THE SCREWDRIVER! :D

I can't wait to bring this home tomorrow.

If someone has a buddy heater or a 12V heater they would sell for cheap, let me know.

[akdsmer]

Oh well, if I can get the nose in I can change the frost plug heater in fifteen minutes, as long as I don't strip out the heater screw. Right Mel?



I know a few people who wouldn't believe me if I said that either....:whistle:

[akdsmer]

I just got a look at the Dieselnator. Looks like a clean install, and I officially proclaim it a Diesel. :cool:

[STOMPR]

I just got a look at the Dieselnator. Looks like a clean install, and I officially proclaim it a Diesel. :cool:
Did you just use the words "Clean" and "Diesel" in the same sentence ?:D

[akdsmer]

What was I thinking....I've been driving Lorna's too much I guess.

I can still give Mark (and company) props for the installation of the engine that appeared to be well done. :D

[akjeep]

Now he's usin' 'props' and 'diesel'.....

[akdsmer]

:silenced:

[ChevyKev]

thanks for the props, but I don't have a boat.

Mask, I tol' you I had a buddy heater. And you've walked past it about 300 times in the past week.

I've even got a deal for you on it.

[AKMark]

I guess I now need to change the username to mask. Hmm........NO!

Yeah I know you had one, however, I thought it was going into your 99. Since yours is used by the wifey, I'd rather you put it in there, I'm not as picky about it being warm when I first get in.


Thie project is now home. It fits in the garage with only an inch or two to spare front and back. The mirrors must be folded in, and it's difficult to get in and out, but it does fit. When I get off work tonight I have 2 block heaters to install, and a transmission cooling line to repair. Hopefully, the rubber patch and eight clamps hold it together till we get the K-5 done and I can pull it apart and have Napa make me a new line.

I also have a CD player and amplifier to install. I might have to scrounge up some speakers as several of the ones in it seem to have had better days. I also need to find another CB antenna for it, as I don't have a spare.

Thanks for the quick inspection Kelly, I have less fear of emissions now.

The wife even approves. It goes down the road with only a little noise, and with the exception of the glow plugs, there are no real tricks you need to know to get it going. I have a wire on the torque converter lock up control, and have found it locks up quickly on it's own without me turning it on. However, it does hold better when I've let off the gas and are slowing down with it on than off. For fun, I left it powered the entire day today and it shifted no different all the way up to speed. I can feel it locking up a little quicker and holding better with it on, however that could be partially because of the leak on the trans cooling line.

All in all I'm happy. I have my first personally owned diesel, and it works great. Hopefully I'll add a second soon and add to the fun.

[ChevyKev]

I guess I now need to change the username to mask. Hmm........NO!

Yeah I know you had one, however, I thought it was going into your 99. Since yours is used by the wifey, I'd rather you put it in there, I'm not as picky about it being warm when I first get in.


I have one for her vehicle, too.