Top 5 Mods 6.5l Detroit Diesel Reliability - Bulletproof

These are the top 5 Detroit Diesel Mods to bulletproof the truck and fix most of the problems GM caused, in my personal opinion. I know my preference for manual injection is controversial, but it is much cheaper, more reliable, and you don't have the headache of wondering which stage of "update" your electric injection pump is has, not that they really solved much anyways.
1972 Chevrolet K10 Long Bed 6.5l Detroit Diesel Swap
1999 Chevrolet K3500 Crew Cab Long Bed SRW
1. PMD Relocation/Cooler Kit
2. Upgrade From Stock Fuel Lift Pump
3. Delete Vacuum Pump - Serpentine Belt from '93
4. Manual Fuel Injection Pump
5. Straight Pipe Exhaust and Intake
Bonus: Head Studs

[@joelaidler]

Glad there’s more 6.5 guys out there now than there was before

[@davidbrunner4413]

My best guess is it's cause of the cost with all these retired HMMWVs hitting the market and therefor 6.5 turbo diesels without all the emissions crap

[@dand33911]

Because they're just turning 25 years old recently. 25 yrs old = emissions exempt in most states.

[@LTNasty]

I just bought my first one

[@RightFootRacing]

This is an awesome video. I had a 96 6.5 suburban I really liked and I’ve still been thinking about getting another one but an earlier model with preferably a 5 speed trans. They definitely aren’t fast but they sound good and get good fuel mileage and the simplicity is a awesome !

[@BOVAction]

Heck yeah man, thanks for watching! There's definitely not much that can beat the fuel economy of a 6.5l, even in today's market! Many people don't like V8 Diesels, but this is a great platform for those that can't quite afford a Cummins and are looking to get into and learn about their first diesel. I certainly wouldn't mind seeing ya' whip a manual Suburban around like that TA you've got there 😂👍🔥

[@casperhoss2952]

I'm a big 6.2 and 6.5 fan. They are great platforms. Awesome video, thanks for sharing.

[@SWBjr15]

Your truck is like the fleet side version of mine! Sweet 6.5 brother!

[@BOVAction]

Oh man you weren't kidding it really is, color and all! That's one heck of a rig you've got yourself!

[@SWBjr15]

@@BOVAction much obliged brother! Love seeing other 6.5s running And looking good! Keep it going!

[@BOVAction]

@@SWBjr15 Thank you so much! You do the same man! Not enough 6.5 guys out there these days!

[@davidbrunner4413]

I went with a 6.5 for my 86 C30 because when I was looking for a 5.9 12v, I realized very quickly that I didn't have 5.9 12v money...

[@BOVAction]

Yeah, sadly the Detroit's are cheaper than the Cummins and the Cummins are cheaper than the Duramax which is what I'd probably go with if it wouldn't put such a dent in the ol wallet lol

[@VincentMMoore0]

Nice video. I appreciate the focus on reliability. Thanks for the video.

[@LobbsTrucking]

Great video, I have a 96 c3500 4 door long bed 6.5, trying to restore it now and I didn’t realize how much it is gonna cost 😂 but I’d rather have it then a new truck

[@BOVAction]

Thanks man! I can't blame ya' there, these new trucks are so unbelievably overpriced its not even funny!

[@LobbsTrucking]

@@BOVAction yeah exactly!

[@J-Rod7]

Super cheap in the scope of all diesel trucks. $3,700 in parts got me every reliability update + some performance stuff and that's insanely cheap. Guys who spent $10,000 to delete their Duramax or $8,000 replacing their tranny in their 2nd Gen Ram will shit on these trucks but they're super underrated.

[@eternalfalls]

def, EGR, and all the electronics kills all the fun. looking for a 6.5 smog exempt van for my mom. i hate dealing with these sobs 😅

[@ItsPeek]

Wow it’s like this vid was sent from the heavens to me. I’m trying to bring back to life my dads 00 3500hd with a dump bed and damn it needs a miracle. It has sat for about 8-10 years. Rough idle, black smoke most likely injection pump. He got a mechanic to look at it and he said injectors a long time ago but he called bs. I’ve been doing research and this vid is what I need. He got quoted 800 for a injection pump rebuild and right now I’m looking for the best option

[@BOVAction]

Sounds like a darn good truck to me, I'm glad you found some of this info to be of some help, I'm sure you'll get it figured out; these trucks are pretty fuel efficient so even if you have to put some money into it, it'll pay for itself in no time! Good luck my friend, I hope everything goes smoothly!

[@ItsPeek]

@@BOVAction thanks a lot. The truck only has 80,000 miles it’s literally mint besides a fender,misaligned bumper and ripped seat on driver side. I hope to get it running soon and when I do I’ll update ya

[@therambler0001]

Did you ever get the truck running? Just inherited a 94 with the same issues.

[@ItsPeek]

yes we took it to a local mechanic recommended to us by friends. we installed a new crank sensor, installed a used injection pump that was working prior, new rear fuel tank, im not sure if he did a coolant flush as it was couple months ago. he cleaned the motor in and out he took the manifold out and made sure everything was good. since then the things been a beast hauling our skid steer and bringing 4 yard of topsoil (not at the same time lol). really glad we got it back running tip top shape @@therambler0001

[@ItsPeek]

i forgot to mention we also relocated the pmd to a less hotter location. 9 times out of 10 its the injection pump or the pmd that gets overheated.@@therambler0001

[@birdmannichols939]

Awesome channel dude love your setup Ive opened a vw diesel jetta tdi for the past 3 years trying to get a cheap diesel truck myself lol can't find a lot of 6.5 or old cummins here in florida they aren't $20,000 running or parted out lol

[@jerkey]

How hard are the upgrades? I found. 1994 k1500 6.5l diesel turbo and its a z71 but ive never worked on a diesel. Ive heard mixed things about this truck and am fine with doing some work but dont want to be repccuring. The thing only has 190k on it, is pretty clean and only $2800

[@johnnygeorgopoulos4072]

I'm just here for those 8 lug heavy wheels and those Interco Trxxus tires.... how are those tires in the snow, I've heard they're pretty damn good. I've got a 6" lifted 97 GMC RCSB K1500, currently on 15x10 polished Pro Comp 69's and 35x12.5 Patagonias, but have always digged the look of those wheels and tires

[@BOVAction]

Sounds like a hell of a rig you've got yourself there, kudos! The tires are actually phenomenal in the snow! I'm in Colorado and liked them so much I got an identical set of wheels and tires on my lifted (6in) LBZ Duramax too! Can't go wrong with these older Chevrolets!

[@johnnygeorgopoulos4072]

@@BOVAction yeah that's what I've heard about those TrXus tires, and I'm way up in North Dakota, so definitely need something that's got traction in snow and ice 😅 What I'd "like" to do, is get those specific 8 lug GM HD wheels you have on the OBS (don't think they ever named them, there is a part number for them), get them cut and widened to 12", powder coated a satin black, run the chrome GMC centers, and run a 36x14.5R16 TrXus on my current rig, as I've got room to go up slightly from the 35 currently on there and they don't touch anything from lock to lock. Now if I actually had the funds (and time), I'd be searching for a wrecked 06/07 2500 Classic and swapping the LBZ into my 1500 regular cab short bed, second option would be a 6v53t Detroit, but that's a ton of work just for some glorious sound, so a close 3rd would just be a 6BT Cummins and an NV5600 (I can stay auto with the Duramax if necessary, but a manual Cummins just sounds too good) 😅

[@mojo1965]

What about installing a Fluidamper balancer and a solid crank pulley?

[@donnasingleton6320]

I had done all these except for the mechanical pump and battery top posts. After those fixes a huge tree fell on the cab of my much loved 95 Silverado 2500 4x4....😢

[@BOVAction]

I'm so sorry to hear that! Were you able to buy it back from insurance and swap the cab out? Sounds like an awesome truck!

[@donnasingleton6320]

@BOVAction I have the truck. Insurance didn't cover it. The cab replacement, IDK if that's a project I can afford anymore as a senior on a very limited income. It was supposed to outlive me

[@BOVAction]

@@donnasingleton6320 I see, that is very unfortunate. If I ever get the chance I'd love to help get that done for ya'! I've done my fair share of cab/chassis/body swaps that were far less straight forward than that would be and the way I see it the more of these trucks on the road the better! The hardest part would be finding another cab that is titled and not too rusted, depending on where you live. I've seen quite a few candidates here in Colorado with minor rust in the rockers depending on whether it's a regular, extended, or crew cab. There are ways to use untitled cabs if necessary it can just be a pain dealing with the DMV sometimes and I don't really condone simply swapping out the vin plates yourself, but I have definitely seen people get away with it.

[@donnasingleton6320]

@BOVAction That's a very kind offer ❤️ I see this bodystyle in movies and, most recently featured in the TV show the Peripheral. I was the second owner of the truck. It was 5yrs old then and originally from Texas. An extended cab, 2-door. I'm here in Kentucky and there are as many here I suppose as anywhere. I'm looking for one. Don't have much money to spend, but maybe I'll find one. I would love to find another from a more arid part of the USA. That being said, people everywhere have replaced those rusted out cab corners and rockers. I just need to wait for a unicorn or raise some more $$. This truck is my third chevy pu. My first was a 'white '83 manual gasser which I later traded for a 91 Volvo 240. I later bought a 1987 black w/ red interior 1/2 ton gasser from a farmer in Brandenburg. I sold it in 2000 and drove back down to Brandenburg and bought my green diesel dawg.

[@BOVAction]

@@donnasingleton6320 Yes! I've been seeing them everywhere in the media as well! The good thing is those extended cabs are much more common than the crew cabs are! It sounds like you're pretty loyal to the Chevy brand much like myself; can't go wrong, especially with the older ones in my opinion! I wish you the best of luck getting your diesel back on the road and I'll keep my eyes peeled for candidates; I actually have another project coming up soon in which I'll be putting an older body style on the newer 90's chassis and if my donor happens to be an extended cab I'll happily bring it out to ya' and get 'er swapped out! My wife and I are always up for a road trip and I'd be happier putting it to use rather than seeing it go to scrap anyways!

[@MickeyMishra]

Nice thing with a non electronic pump? It will work even after EMP & WW-III

[@BOVAction]

My thoughts exactly!

[@Victorsvolkswagens]

My 6.5 has 240k miles and still runs like brand new

[@landonjohnson2199]

Got a 95 6.5L with 225 and I would put it up with any newer truck as far as reliability and ride quality.

[@Jean_1999]

I found a 97 6.5 for sale it got 134k Miles. Since I heard so much bad things about these engines Im not sure if I should still get one. People say the engine blocks and heads tend to crack, pmd fails, they overheat. I have a feeling people make these Problems way bigger than they actually are.

[@12yearssober]

​@@Jean_1999 Are you still driving it?

[@Texasmule]

Would this bolt up to the GM NV4500? I would love to swap or buy a truck with a 6.5 as it will be my first diesel ever. But i dont know much about them and giving how you explained and showed parts that makes it less reliant on electronics and smog stuff it makes me more confident to get one.

[@BOVAction]

Yes, you can find trucks that already have the NV4500 in them here and there. Some people have pulled out the 4l80e and put in an NV4500, I have a parts list for doing so if that's the route you plan on going.

[@geoffreyb3337]

I loved my 6.5 too

[@jacobhammer7389]

You should stick with the 6.5l platform in my opinion. I see way too many people giving up on the 6.5l and in my opinion it's worlds more interesting than a 12 valve setup don't get me wrong I love a good 12 valve but it's like a Ls swap it's overplayed!.

[@BOVAction]

I have to agree with you that is why I'm putting the 6.5l Detroit into my 1972 K10 they get a lot of hate but I can't help myself I love them and haven't had anywhere near as bad an experience with them as other claim. The OBS in the video actually had a 454 in it, not a 6.5l so either way I would have to motor swap which is why I'm going all out with the 12v

[@dylanslade683]

Build on buddy

[@webbsb.4847]

A family relative had a bulletproof tahoe, the early 2000s model, and i was alway uncomfortable riding in cause i cant get the thought of getting trapped in it out of.my head, if something goes wrong.

[@brendanmitchell3545]

Any changes on the 2000 year 6.5l? I may be looking at one soon. Did they change the PMD location on the last year of production? 2000 GMC 2500 6.5L

[@herrapingviini2024]

i am converting from mecanical to electric pump with super charger becouse turbos make a lot of heat and i am putting it in g20

[@trentmyson61]

I really want to go to a db2 pump I just not sure how to do the whole transmission controller thing

[@BOVAction]

@@trentmyson61 You have a couple options for the 4l80e, one is to source an entire trans and computer from a 92-93 6.5l with the auto trans. These earlier 6.5l 4l80e's had a different valve body so you're not able to simply switch the computer, you'd have to swap the entire trans and computer. You used to be able to get a TCM from Optishift or Leroy Diesel used to have one I believe, you could follow this guide: www.kozykalpacas.com/DIESEL/DB2%20Conv%20Guide.pdf

[@trentmyson61]

@BOVAction so what about a 1995 could I do the swap on that year

[@grovesiderabbit]

just got a 94 6.5 and have no clue on these things. so thank you for explaining. Do you recommend any particular website?

[@BOVAction]

A1Customs.com has a lot of really useful information

[@Patryk24k]

what do you do if you have a electric injection pump and you put the manual injection pump. Do you have to do any upgrades to the 4160e transmission to work?

[@BOVAction]

It's a lot easier if you have a manual, but some people modify the pedals and cable to make the automatic work however this guy did it much simpler and honestly probably more reliably by using a TCM from a different model GM www.google.com/url?sa=t&source=web&rct=j&opi=89978449&url=www.dieselplace.com/forum/attachments/63-gm-diesel-engines/20-6-2l-diesel-engine/320770d1426374115-ip-timing-db2-conv-guide.pdf&ved=2ahUKEwjomKmdx8qGAxUlweYEHcnCBw0QFnoECA8QAQ&usg=AOvVaw2dpK7ndFC58Ocpt8TBd-8K

[@Patryk24k]

@BOVAction oh man, thanks a lot for that link. It's very helpful.👍

[@bladenrexroth2555]

Can I use these same tips for an 8.2 turbo detroit?

[@0.0.0.0.1]

So if I understand correctly 6.2 longblock or 6.5? Then use the 6.5 turbo, with the manual pump plus aftermarket lift pump is the best setup. If adding injectors add head studs. How about the crank? Use the 6.2 or 6.5? My 1995 6.5 has a broke crank.

[@BOVAction]

You can swap a 6.2 bottom end (pistons, crank, rods) in in place of your 6.5 turbo bottom end and have an electronic 6.2 turbo diesel, using the 6.5 block. The crank would have to match whichever bottom end you decide to use, but you can basically swap any and all of the parts other than the bottom end freely. So you can take the injection pump off a 6.2 and have a mechanical 6.5 turbo diesel.

[@GreenMtForgeFarrier]

I'm also swapping out a 6.5 detroit for a 92 5.9 cummins. Are you also gathering swap parts from Jonesy's? Their attention to detail and support via email is superb.

[@doughboy1966]

I’m looking for a crew cab 4x4 6.5 because I like the 6.5 diesel also.

[@KlashingKiller]

Recently got a 98 extended cab dually 4x4, awesome truck

[@theduke672]

Information on that snorkel. I want to add this on my suburban diesel

[@BOVAction]

Its for a '90-'97 Toyota Land Cruiser, pretty sure Dobinson makes a kit I believe you can get off Amazon. If you use a heat gun you can mold it over closer to the cab

[@user-be9ii9ut4t]

Jumped my 96 fuel solenoid wrong, can't find fuse, please help

[@BOVAction]

Left side of fuel injection pump, opposite from the shut off solenoid. The photo here should help. www.dieselplace.com/threads/6-5-diesel-injection-pump-fuel-solenoid.738474/

[@BOVAction]

I think the fuse is in the block on the drivers side fender under the hood, the diagram on the cover should tell you exactly which one is the IP fuse

[@Patryk24k]

Can you put a H1 motor into a 1996 Chevy 6.5l k3500 dually? My motor blew up so I'm trying to put the H1 motor or a 6.2 in it. Is it possible without to much modification?

[@BOVAction]

It is possible to use an H1 6.5l, yes. You'll need to go with an older one (2004 or older) as they started using the Duramax shortly after. You can also build a mechanical 6.5l or an electronic/turbo 6.2l if you decide to combine parts from your blown 6.5l and a sourced 6.2l; there are a variety of ways to combine the two. A lot of guys like to over bore the 6.2l block to that of a 6.5l due to the 6.2l block having a higher nickel content, making it stronger than a stock 6.5l block while still being able to interchange most parts from an actual 6.5l.

[@Patryk24k]

Ok, thanks for the fast reply. I'll definitely look into that. Keep up the good work. 👍

[@natty_ice414]

If the vacuum pump gets deleted, is there a manual wastegate kit that is serviceable separate from the whole turbo?

[@ericbrown2666]

Heath used to sell a “turbo master”. I think Leroy sells one as well as Quad star. You’ll need to install a boost gauge because you’ll manually set peak boost.

[@cowsauce9099]

What is the best form for these trucks?

[@Jean_1999]

I have read much about these 6.5 V8 Diesel engines. I drive a Opel Vectra and Im familiar with GM and cant believe that people say these 6.5 engines are unreliable, the engine Blocks and heads tend to crack, they overheat, the pmd always fails. What from all of that is true and what not. I feel like people give this engine more bad Reputation for small problems because they are too lazy to fix them or is that wrong?

[@BOVAction]

I would have to agree with you on that one; I think most people are just very unfamiliar with the motor so when something does go wrong they have no idea where to start and just give up, kinda like the younger generation these days with the DSM's it's like everyone wants one until something goes wrong and then noone seems to have the patience to deal with it lol

[@Jean_1999]

@@BOVAction Yep totally like that and people that actually can work on a car that cannot make up their mind if its worth getting the Car because people talk more shit about it then it really is

[@jorgefonseca9225]

Great vedeo and great explanation 👍 you have a new subscriber 👍👍 I have a 95 suburban 6.5TD but I removed all fucking electronic diesel pump, fucking PMD and automatic transmission now I put a manual transmission NV4500 with a mechanical diesel pump but still use a standard turbo I would like to replaced for a bigger turbo 🤔 because I pulled heavy trailer and caravan not driving faster the maximum speed here in Norway it's 62mls/h = 100km/h so I need good torque 🤔 anyone have suggestions!!? some fellas said a HX35 or HX40 anyone knows what is a best for 6.5detroit? my engine have all most 920.000kms (560.000mls) thanks mate for showing us that beautiful Silverado 4doors 👏👏👏👌👌👍 cheers from Norway 🇳🇴 👍 👋👋

[@BOVAction]

Sounds like you've got a pretty nice rig there! The HX35 is going to give you more throttle response because the 40 takes a while longer to spool. Some guys take the cold side housing and wheel off the 35 and re-install a housing and wheel from an HX40 to create a decently reliable HX35/40 hybrid. Until the truck is tuned, the regular HX40 is likely to make it fairly laggy. The 35 also requires less fabrication than the 40 as far as the install/conversion goes, hopefully this helps. Thanks for watching, I'm happy to have ya' subscribed; you can never have too many Detroit guys these days!

[@jorgefonseca9225]

@@BOVAction thanks mate 👍 I appreciate your helpful information 👍 👍👏👏 I wants keeping my suburban alive for more time this is a great engine 😀 👍 cheers from Norway 🇳🇴 🤗👋👋

[@jadinzack9271]

Do you not have vacuum boost brakes

[@BOVAction]

No, they don't utilize the vacuum they use the power steering pump/hydro boost, the vacuum only runs the EGR components, Turbo Wastegate, and AC Controls in some of the van models on these 6.5l's

[@jadinzack9271]

@@BOVAction word my 6.9 has vacc boosted brakes so don’t think removing the pump is an option

[@BOVAction]

@@jadinzack9271 I've seen a couple guys add hyrdoboost brakes to their 6.9 and delete the vacuum pump but they had added a dorman electric vacuum pump from a super duty to run the hvac stuff

[@jadinzack9271]

@@BOVAction wonder how that job goes

[@mick5740]

What kind of mpg do they usually get?

[@BOVAction]

Depending on the year, type of fuel injection (mechanical or not), mods, and driving habits, they can easily get 21+ MPG.

[@mick5740]

@@BOVAction how bout all stock 4x4 long bed regular cab

[@BOVAction]

@@mick5740 If it's got 4.10 gears I would say somewhere around 17-18

[@mick5740]

@@BOVAction is there some certain years that suck ? The guy was saying there is and this truck isn’t it either yesr or two newer or older Looks to me like maybe a 93-95 but not sure

[@BOVAction]

@@mick5740 Every motor has had its issues, but it really comes down to preference. A lot of guys prefer the earlier years because they are simpler (less electrical stuff to go wrong, including fuel injection). That's why a lot of guys take the 6.2l blocks and combine them with 6.5l parts to wind up with a more mechanically solid turbocharged 6.5l. There are so many different directions you can go with them in my opinion you almost can't go wrong as long as you're familiar with them.

[@Жоржсанд-о1ц]

Чётенький аппарат 💪💪🔥

[@gentilejoshsaved1646]

You forgot about snorkels!!!!

[@jhsevs]

Nice quick video, straight to the point 👍