Project Big Blue

IDIBRONCO

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Cam to crank 180 out. RAN IT FOR OVER A YEAR LIKE THAT.
I've seen one guy do that on several 6.2/6.5 Chevys, but they were never run very long. I wasn't too thrilled about it since I was the one who got the "pleasure" of fixing them.
 

Thewespaul

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Got the cooling system finished up and tested it with 20 psi with no drop overnight, so pulled the engine off the stand to prime it. Flywheel and starter on, fresh oil and filter, glow plugs out and rigged up a feed and return into a jug of clean ATF to run the pump on. Cranked until I had oil pressure at the turbo, then plugged the turbo feed line and cranked till I had at all the rockers, telling me the lifters were filled. After that I reattached the oil feed line and teed my gauge in to check pressure with the turbo added and the system primed. 30 psi at cranking with the glow plugs out, ready to run. Next I checked compression in every cylinder with the lowest at 390 psi and the highest at 425 psi, really good for an engine with over 200k. Put all the glow plugs back in and installed the new harness.
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Lastly I pulled the return fitting out of the pump and installed a straight through quick connect to pull a vacuum on and prime the system with the ignition on, this gets 90% of the air out of the fuel system. Connected it back up and..
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Engine sounds great and is ready to go in the truck after a retorque now that it’s been heat cycled.
 

Thewespaul

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Got the engine bay cleaned up, coated the front frame rails with some chassis black, clearanced the body seam for the exhaust and laid some noise/heat insulation along the firewall. This sure is a pretty oem color.
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While I had the room with the engine out, I clearanced the core support for the intercooler and got it mounted. Also got the new light in and aligned nicely.

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Thewespaul

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While I was in the engine bay I noticed the battery trays had started to rust, so blasted both sides and hit them with some chassis black.
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Battery cables are in good shape, but the terminal ends are pretty rough so Im going to cut and crimp copper lugs on to get rid of the fatigued clamp style terminal connectors.
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Engine going in..
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And bolted into its final place. Little bit of a fight to get the torque converter lined up with the sagging body mounts but not too bad. Looks pretty nice in there.
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IDIBRONCO

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I didn't realize that there's enough room to install the engine with the turbo attached. I always removed it before pulling and installed it after the engine was in place. Something else just occurred to me. We all say that we "clearance" the firewall, but in reality, who doesn't enjoy taking a hammer and beating the crap out of something when we're stressed?:Thumbs Up
 

Thewespaul

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I didn't realize that there's enough room to install the engine with the turbo attached. I always removed it before pulling and installed it after the engine was in place. Something else just occurred to me. We all say that we "clearance" the firewall, but in reality, who doesn't enjoy taking a hammer and beating the crap out of something when we're stressed?:Thumbs Up

I prefer to take more time during the install (had to loosen the front cab mounts and tip the cab up less than an inch to line things up) and get the turbo kit installed on the stand where I can be sure everything is air tight and installed perfectly before it’s up against the firewall and you have to stand on your head to reach everything. I use vice grips and a dead blow to bend the seam, if it was my own truck it might be a stress relief but I’m usually more stressed when I have to do it to someone else’s cherry truck.
 

Thewespaul

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Got the lights final installed this morning, was waiting to install the headlights because I was out of the oem clips, don’t know why headlights don’t just come with new clips but they should. While I was in there I pulled the bumper off to fix a bent mount and use some shims to fix the bumper sag, new tail lights also went in with some new stainless hardware, those screws are almost always stripped.
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94bluebeast

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Looks great. It’s amazing how much a fresh set of lights/lenses can change the appearance of the truck so much.


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IDIBRONCO

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I prefer to take more time during the install (had to loosen the front cab mounts and tip the cab up less than an inch to line things up) and get the turbo kit installed on the stand where I can be sure everything is air tight and installed perfectly before it’s up against the firewall and you have to stand on your head to reach everything.
Now that makes perfect sense.
 

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