M998 HMMWV engine swap to 6.5 turbo

[jdknech]

I recently purchased a cherry m998 with a blown 6.2, after much debate I decided to swap it out for a 6.5 turbo motor I had sitting in a van.
Anyone who has done this swap, please shoot me any advice you see fit! I'm not a stickler for originality, but I do like to keep things looking decent

Yesterday I drove the van around town before pulling the engine out, it ran great! Now it's sitting out on the ground waiting for me to get the 6.2 out of the HMMWV

 

[02smokemaker]

I like your method on getting it out!

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[jdknech]

I like your method on getting it out!

thanks! we decided the van was getting scraped anyways, might as well make it a easy removal!

 

[jdknech]

Started pulling the front of the HMMWV apart last night..

 

[Retiredwarhorses]

Being s civy motor, your gping to need to strip the motor down to a long block and change everything over to mechanical.
unless your going to convert to 12v. That IJ pump might be a DS4, the wastegate is vacuum not mechanical...it's a lengthy list of things to do.

 

[jdknech]

Being s civy motor, your gping to need to strip the motor down to a long block and change everything over to mechanical.
unless your going to convert to 12v. That IJ pump might be a DS4, the wastegate is vacuum not mechanical...it's a lengthy list of things to do.

I know you are very knowledgeable about this swap, I will list the things I know that have to be done or that's different
Please add to the list if I missed something!
The IP on the 6.5 is a ds4, the 6.2 has a DB2 that was just installed 3 weeks ago by the previous owner, the DB2 will be swapped over to the 6.5 and the fuel rate bumped up a tad for the turbo

.injection pump and lines swapped from the 6.2, to the 6.5
.wiring harness swapped from 6.2 to 6.5 (possibly will need different harness, unsure at this time)
.body lift 1" to clear turbo
.air pipe from cleaner to turbo is different (ordered one today)
.Engine cover inside is different (sourced one, haven't ordered yet)
.exhaust down pipe from turbo different (have one sourced, have not ordered yet)
.All front brackets and accessories have to be swapped over
.i will be making a mechanical wastegate actuator (I made one for my civy truck and my old m1009 turbo conversion, it works great)

The following is issues I have come across, but haven't figured out yet.

.the kickdown cable originally ran right through the space the turbo will now occupy
(Might be tricky to re-route, but it's doable)
.not sure if I will have to trim the tunnel for any reason, I've heard that you do, and that you don't have to trim it

If I've missed anything, please chime in! I would rather not come across any major surprises!

 

[jdknech]

Also forgot to add, I will be installing new glow plugs (15g?) and replacing the pan gasket, and rear main seal before install.. And if I find a AC compressor and mount before install I'll be putting it on as well

 

[Action]

I don't see why you wouldn't need to cut the tunnel. When you get the new doghouse put it on, without the engine in. The new opening will be where the bottom of the doghouse sits. You will also need to reinforce the new opening with a lip like the one already there.
There were two different doghouse attachment methods at the top. If yours has 2 dzus fasteners, the new one will fit right in.
You may want to get the entire turbo exhaust system with catalytic converter, or not.
The factory body spacers are more like 1/2" thick. I just measured.

 

[dilvoy]

You need to use an injector pump for a turbo application as well as the injectors. Injector lines from a 6.5 Humvee engine N/A or Turbo will work.

 

[jdknech]

Got the old one out!

 

[simp5782]

Any update on this or dead in the water?

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[jdknech]

I guess I should have done better at keeping up on here. Lol. It's done, and I've been using it a coupe months now! Runs great!

 

[simp5782]

I guess I should have done better at keeping up on here. Lol. It's done, and I've been using it a coupe months now! Runs great!
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Any of the swap pics?

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[jdknech]

This is all I have unfortunately, if you have any questions I'll help the best I can

 

[jdknech]

If you need a hard top, I'm building and selling them

 

[simp5782]

If you need a hard top, I'm building and selling them

What are they running?

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[jdknech]

2600+ shipping. 4man with back wall, all aluminum, REMOVABLE!, and installs with no drilling

 

[ken]

Are you making 2 man hard tops?

 

[ken]

What did you use for exhaust from the turbo down to the tail pipe?

 

[jdknech]

I am only building 4man tops at the moment, and for the exhaust I found the factory crossover/downpipe from the uparmored turbo trucks