Is Swapping gas for diesel engine feasible?

[BradKW]

I'm still looking hard at box trucks...in fact, I'm going up to the mainland this weekend and visit a few of the big truck/van re-seller lots. 

I would prefer a diesel for mileage reasons, but if you rule out Ford 6.0's, there's fairly slim pickins' so far. One scenario I've seen a number of are high mileage Chevy/Ford gas engines, with very nice "everything else"...talking 220k +. I'm not so sure I'd want to buy that high without factoring in a possible engine replacement at some point.

Which got me thinking, what is involved if you wanted to swap a gas engine for a diesel? I'm not looking for step-by-step details, but more general...like if a normal engine swap cost $4,000, what would swapping to diesel add to that? Or..."you idiot, you can't do that"

Thanks  

 

[rvpopeye]

It happens a lot but don't know the costs vs another gasser.

 

[29chico]

Besides the regulatory issues, a diesel engine can weigh significantly more than a gas motor.  So the front suspension may need to be beefed up to deal with the load.

 

[highdesertranger]

I am doing it right now. but I am doing the easiest of all conversions. replacing a 454 gasser with a 6.2 Detroit Diesel. this is about as close to a bolt in swap you can do. I can give all the details you want. any question ask away. highdesertranger

 

[BradKW]

I am doing it right now. but I am doing the easiest of all conversions. replacing a 454 gasser with a 6.2 Detroit Diesel. this is about as close to a bolt in swap you can do. I can give all the details you want. any question ask away. highdesertranger

I guess my main question would be what gas engine(s) to look for in the Ford/Chevy/GMC options I'm considering, which seem to be in the '08 -'12 E350/3500 range. Not opposed to going E450/4500, just don't feel I need that...but it does seem to open up some different engines.

And I suppose on the flip side, what might I want to avoid because the transition is more difficult?

 

[eDJ_]

As for Diesel Conversions these guys have some interesting ideas.   I'd like to visit their operations HQ some day.

Finding an old pickup that I could put a Kubota Diesel in and get great mileage with is more and more intriguing to me.

Check out this video.

 

[Spaceman Spiff]

Assuming you have the skills, tools, space and know cuss words in at least 6 languages, it is very do-able.

Easiest and least expensive:  finding a diesel from the same make and model of truck that has the gas engine and using original factory parts.

Most difficult and expensive: Sourcing and fabricating individual parts to make a non-stock diesel work in a given chassis.

Installing an engine into a chassis is straight forward.  It's all the pieces that connect everything together that can get difficult if you are not simply copying a factory setup.

It's up to you to do due diligence on the financial desirability of your particular swap.

-- Spiff

 

[NeedAnEscape]

To make it easier, you will want to go with a chassis that was offered with the engine you want to swap in. For van-based vehicles that means Ford or Chevy/GMC, and putting in a 6.9/7.3 in the Ford or 6.2 in a Chevy. You will have to make less changes to wiring if you start with a carbureted gas vehicle and put in a pure-mechanical diesel.

 

[MrNoodly]

You'd need to weigh the cost of doing the conversion against fuel savings. I suspect you'd need to do a LOT of driving in order for fuel savings to make up for the cost of the conversion. If fuel costs are your main concern, just drive less.

As far as engine life goes, you're talking about definitely replacing an engine now versus possibly replacing/rebuilding and engine later. Replacing a gasoline engine with another gasoline engine is plug-and-play, and decent used gas engines are plentiful. A diesel engine swap means changing out a lot of other things, and decent used diesel engines are less plentiful and more expensive.

 

[karl]

Though not a dodge fan- an idling 5.9 Cummins is music to my ears.....and I dream of one in Thirsty.
dieselbombers site is a good reference of oddball swaps.

 

[speedhighway46]

Sometimes I start my diesel just to listen to it; and of course no need to shut it down when fueling, so everyone can be green with envy!

 

[highdesertranger]

I will add a couple of things. like everybody says do a swap with a diesel that was available for your vehicle. I don't like to rely on parts that were never offered from the factory, makes replacement a pain. I would only consider a mechanical diesel, but that's me I don't like electric doo dads. your best bet is to find the same vehicle as yours that has a diesel that's been wrecked and buy that for all the parts. by far the easiest conversion will be a Chevy/GMC. highdesertranger

 

[MrNoodly]

For some, you can't put a price on the sound of the diesel.

Guy

Mmmmmm, the sound of a dryer full of rocks...

 

[ZoNiE]

Mmmmmm, the sound of a dryer full of rocks...

 

[cognitive dissonance]

Veteran of several swaps here.  (LS7 in a BMW M3, small block chevy in an old champ car, 8.3 Cummins replaced a 5.9 in a truck, currently own a GMC 3500 truck with a Cummins 4bt.)

Swaps are a lot of work. My advice is that if you want a newer diesel engine, find a truck with one in it from the factory.

If you're going to do a swap, HDR had sage advice: the only swap I'd do again would be in favor of an old mechanical diesel.

For the reefer truck you're looking at, the Cummins 4bt would be good choice. It originally powered Wonder Bread and Hostess vans, so we know it can move that size of vehicle through the air. Simple injector and injection pump mods will bump HP nicely, and you don't use any extra fuel unless you're making the extra power.

The mechanical 4bt only needs one wire connected to it, and that's for the fuel shut-off solenoid.  (That can be replaced with a mechanical shut-off like on old tractors...)

Likely hurdles: 1) Someone will have to fabricate the mounts. If you can't buy the mounts somewhere, there's some trial and error involved - it's really handy to have a two post vehicle lift and a forklift to move the engine around. 2) You'll need to buy engine/transmission adaptors. I can just about guarantee someone already makes those. 3) Rear end gearing will probably be too high for happy highway cruising. 4) You'll need an aftermarket controller to shift the automatic trans. 5) Noise.  6) Emissions - most jurisdictions take a dim view of swapping an older non-emissions engine into a newer model year vehicle.  Have a non-emissions jurisdiction to register it in, or don't do the swap.

 

[wagoneer]

I miss my old 6.2 Duramax 1987 GMC van. Having never done a conversion only same to same but with lower miles. I would guess staying in brand as stock as possible your 450 will hold a bit of weight. I would go with a pre 1999/or earlier 7.3 stay away from computers pre 1993? You guys correct me
I was a flathead v8 guy Mercury, Fords.

 

[romeosierrabravo2]

It would be far far easier to find a diesel cab and chassis truck and mount a box. CAb and chassis are also at many of the RBAuctions.com They do a lot of oilfield, constructiion, landscape type sales. The box can be had for 2 or 3K from Uhaul salvage or other. The trucks be it dodge cummins, ford, or chevy are a dime a dozen in west tx, oklahoma, nm.

 

[highdesertranger]

I am doing this conversion(gas to diesel) right after RTR. I will document it here for those interested. highdesertranger

 

[Cammalu]

I am doing this conversion(gas to diesel) right after RTR. I will document it here for those interested. highdesertranger

HDR I am truly amazed at all the things you tackle. You must be an ace mechanic. I hope to pick your brain one day.


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[Baloo]

I have done a few Volkswagens, but like others have said, they came with em from the factory, so all the parts were available. Despite the mechanical ability, and it can be done with enough time and money, don't forget about the legal aspect. if you register it in a state or county with emissions testing you will not pass. If the vehicle is newer than 1996 it will have a OBD II connector that they plug into for testing. Swapping out a modern diesel is a huge headache as far as the computer and transmission (newer vehicles are computer controlled) interface go. Unless you are planing an older vehicle with a mechanically injected engine, I would just wait till the right diesel rig came about.


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