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nickd's new 6.5 engine install

nickd

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Newport, Delaware
The process has begun!

Most of the work is done in preparation to remove the old 6.2 making way for the 6.5. The overhead gantry is once again a life saver! the remaining steps to remove the old motor include disconnecting the starter from the wiring harness, and removing the torque converter bolts. Since the engine is not turning over, I will need to drop the oil pan to access the bottom end to be able to turn the flywheel. Once the torque converter bolts are removed the gantry will be used to pull the old clunker out. I am in the process of securing a military engine removal fixture to make the job easier since I will be doing most of the work alone. Here are some pictures of the progress so far.

The first picture is what the magnet on the oil pan plug picked up. I will have one more of the parts and shavings I find in the oil pan once it is removed.

The second is the front of the work space. The bay is 30' deep and there is more room inm the back for parts storage and the rest of the tools are back there as well. The soft top was protected by rags and plywood before the hood was placed up there for safe keeping.

The third picture is an old progress picture, a few more items have been removed

Picture 4 shows the green box hanging at the height required to drive out from under it in order to unload it from my pick up it weighs 1200 lbs

Picture 5 its on the ground ready to be unwrapped AHH merry Christmas to me!

The last picture is the rebuilt 6.5. all new parts all bolts painted and torqued almost ready to put in.

More to follow.

Nick
 

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emmado22

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Install the winch... Now is the perfect time. It's also a good time to boil the radiatior, andf change all the heater lines.
 
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jcappeljr

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Good luck,Keep your old parts I might need them,I have a brand new transfer case for the 6.5 turbo humvee.
 

nickd

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Location
Newport, Delaware
NickD's engine install part2

Spent some garage time today. Got the starter out and the exhaust cross over pipe out of the way. I dropped the oil pan and found lots of shavings as shown in the picture. I had to remove the connecting rod nuts on cylinders 7&8 to turn the motor for access to the torque converter bolts. I just need to disconnect the power steering lines before I disconnect my new boat anchor from the transmission, I will remove the power steering pump, bracket and the generator bracket for installation on the new motor while it is in the can
 

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m38inmaine

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Maine USA
Good progress Nick. I lost the 6.2 in my M1009 last year 15 miles from home, crank snapped in half. Is that a mule transmission I see being used as a jack stand? HI HI
 

m38inmaine

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Mine gave me 20 seconds warning it was about to go. It sounded like the exhaust had broke and got noisy and losing power then she shut off like turning the key. Pulled the pan and the crank was snapped near the center bearing. Took out a few connecting rods and broke parts off the block. Engine had 90k on it, from what I have read a bad harmonic balancer is the common cause. I bought a 93 GMC mini bus with a 6.2 and pulled the engine for a replacement. I stripped the dead engine and sent it to the metal pile. Good luck with the install Nick.
 

nickd

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Location
Newport, Delaware
I had oil pressure all the way to the end. the bearings may be dry because they are not there. the shavings in the bottom of the pan are the bearings. the oil was drained on the 14th of January and it has been sitting in the garage since. i dropped the oil pan to disconnect the connecting rods to turn the fly wheel and disconnect the torque converter. It is possible the shavings were sucked up by the oil pump. I need to flush out the oil cooler and lines before i put the new 6.5 in.
 

foxtrot

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france
Wow! the "bearings" in the pan.
It may be interesting for you to redo the 6.2?
It seems that the heater is located at this level.
Let us know your laying 6.5.8)
Friday 13 is not so bad.
 

readyman

Member
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Location
Elk Grove Village, Illinois
NickD,
Brings back memories. My crank broke in half at 4500 miles. It was a 'military rebuild' tho. With friends from my MV club the engine came out and went in pretty good(at just the perfect angle). I put the Milemarker hydraulic winch in while everything was apart up front.
 

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nickd

Active member
862
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28
Location
Newport, Delaware
Nick D's 6.2l engne taken out today

Spent the day in the garage with the torpedo heater keeping me warm as the outside temperature was in the 20's. The military lifting sling really made the job easy as it angles the engine at the right angle for removal. With the sling and the overhead gantry I was able to do the job alone with out any issues. Here is a picture of the engine hanging on the hook disconnected from the transmission ready to be scrapped. The second picture shows the stripped block upside down and the damage to the bearings on the rod bearings for cylinders 7&8.

The new 6.5 is out of the can and on the engine stand ready to have the starter inatalled along with the wiring harness and the exhaust manifold heat shield.
 

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nickd

Active member
862
37
28
Location
Newport, Delaware
Put some time in the garage today. I "dressed the motor" with the alternator, starter, power steeriing pump, belts and wiring harness. The 6.5l is now in the engine bay. It slid in with ease. The engine sling along with the gantry and chain fall really made this a one man job. I still need to install all new hoses, fuel lines, low pressure power steeering lines and plumb the new mile marker hydraulic winch. The radiator/oil cooler/transmission cooler and transmission cooler will be flushed and cleaned before they get installed.

There were no pictures taken today!
 
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