'94 Burb 6.5TD into '97 K3500 6.5TD Dually?

[tankertoad]

My dually has a bad knock and haven't yet torn it apart to figure it out. Want the dually running, so I bought a rolled '94 burb for the engine, only 40K on reman with new injector pump 6 mo. ago. What are the things to look out for on this swap? Thanks.

[diesel65]

94 used black standard thread bell housing bolts, The 97 may use the silver metric bolts.
The oil cooler ports on the block will be different sizes, 1/2" on the 94 and 3/4" on the 97.
You need to use the injection pump from the 97 unless the 94 has been updated already. Just strip all of the accessories off the 94 block and swap the 97 stuff over.
Put in a fresh crank sensor.

[tankertoad]

One thing I forgot to bring up was that the Burb is auto matic , but Dually is a 5 speed. The Burb had injection pump done 6 months ago. Can't wait to get dually running! Thanks, John.

[diesel65]

Don't forget to install a pilot bearing in the crankshaft.

I just remembered, The oil pressure sensor will be in different locations. The 97' is in the valley behind the intake manifold and the 94' is located behind the block below the glow plug relay.
The 97' harness should reach the new location.

[Jim Faire]

The 94 burb is OBD-I, the 97 dually is OBD-II ..

--keep all the sensors and electronics off the new one and install them all on the 94 engine.

[Robyn]

You will need to run the IP from the later engine as the older rigs pump will probably not get along well with the newer ECM.
The swap is easy but you will have to do a TDC learn on it once it running.

Good luck

Robyn