[Taisey]

I'm trying to figure out the best way to create MY truck. I want it custom. I want to take a 2002 Chevy Avalance 2500 and gut it. Now starting with the body I like and the Axles/suspension that I need. 2002 because that's when they quit making the 3/4 ton. Not that important though because I can change out the axles, suspension and upgrade the leaf springs. I just like the body I guess I want to drop in the 6.6 LLY but that could be overkill. the 4.5L LMK will get the torque I want, but I don't get the part about not having an intake manifold. Aren't those necessary?

Basic question... How to I take a gas truck and make it diesel other than swapping engines and transmissions. Does anyone know about the mounting brackets and spacing? Which ones line up if any, etc... How much has to be changed for the onboard computer and everything? Is this the right way to go? Or do I buy a functioning diesel and swap bodies with the Avalanche. Most engine work I can do, I don't know anything about body work.

Please Advise

 

[Rustin]

SBC clutch for Duramax (or similar Single Mass)
Duramax factory Motor Mounts. You'll probably need the Dmax frame mounts, too
A normal aftermarket exhaust should work.

Cooling
you can use the stock cooling system.
Gas radiator is 2 inches shorter then the diesel, so that means the gas has les capacity
Use the stock GM LB7or other piping
You'll need the Dmax core support and A-frame (trans cooler) support, too.
Electric fans are not needed unless it's for race applications.

Fuel System
You can reuse factory Gas fuel tank. Just drop it and clean it out really well.
Do not reuse the fuel system. Trans plant the entire fuel system over. The diesel fuel lines are larger and flow better.
Modify fuel tank filler neck for diesel pump filler nozzle

Electrical
You will need the DMax wiring harness
Your PCM or current PCM will need a security re-flash, so that the modules will all have same VIN to "talk" to one another
Upgraded battery and/or go to a dual battery set up

Misc
- 2500HD torsion bars
You will need the electronic (fly-by-wire) throttle (gas) pedal.
the hydro boost and associated plumbing will need to be added -- check if your ABS controller will work with it
Custom driveshaft -- check into using an Ex-cab driveshaft
Tcase may not be up to the task, if its the NV240 series -- may need the nv260 series

This information was pulled from another forum and modified by me. not to say I couldn't answer your question. I just felt that this was more appropriate.
I hope this gives you a sense of what you're doing or getting into.
This guy does exactly what your doing. Mash Motors Inc.com they have done Avalanches.

Your suspension and breaks might be underrated for the extra weight.

 

[In2Trux]

If you do follow throw with the gasser / diesel conversion... Pacific Performance Equipment, PPE has a bisic Duramax wiring harness conversion kit available.
I saw it on an episode of Gearz. on SPEED network

 

[Rustin]

If you do follow throw with the gasser / diesel conversion... Pacific Performance Equipment, PPE has a bisic Duramax wiring harness conversion kit available.
I saw it on an episode of Gearz. on SPEED network

:iagree::repplus:

 

[Taisey]

Thank you for the incredible information. I wish I had come here sooner. Very organized and detailed. How can I find out if there is a deisel engine that will just fit without mods?

 

[Rustin]

Thank you for the incredible information. I wish I had come here sooner. Very organized and detailed. How can I find out if there is a deisel engine that will just fit without mods?

Buy a truck with a diesel?

or you could go 12v 5.9l Cummins or 6.5l idi GM with electronic control... Nope you will need to modify for the 6.5l maybe the 6.2 l GM. you might be better off with a 3.8l 4bt..... To be honest there will always bee a substantial amount of modification!