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Diesel Conversions Convert gas to diesel, or convert to a 6.2/6.5/Duramax/Cummins/Navistar/Isuzu/Perkins/Detroit/or ... diesel engine. Go here to see completed projects, works in progress, share your conversion or ask the experts.

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  #1  
Old 05-17-2007, 02:32 PM
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Arrow Duramax Diesel Conversions

A 2004 article on TDP's Duramax Conversion is available on Truck Trend magazine's web site.

You can also read more about it here on TDP.

Jim
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Old 12-26-2007, 03:13 PM
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Default More info & questions answered.

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In your conversion truck, how did you get the climate controls and radio to work, I know that your conversion guide mentions that it includes information to produce a running and drivable truck. So, are there any manuals or wiring diagrams for those kind of things in the truck? Also what kind of unforeseen problems further down the road have you run into? Any electrical or drive train problems or other little things? Any help is very appreciated thank you-Robert


I installed the complete under dash/inside cab wiring harness, fuse block, and electrical junction blocks matching the engine/trans package. I also installed a matching dash. This allowed me to use the matching audio system, light switch, pushbutton 4WD switch and instrument panel gauge cluster. I retained the original 1989 control panel for the HVAC system by interfacing it with the new harness. This is covered in the Conversion Guide (HVAC system).

No problems with the drivetrain have come up, except that if doing it again, I would install a matching model year steering column, which would simplify the conversion. The Guide shows how to retain the original steering column and get the cruise, turn, horn and wiper system integrated into the new electrical system.

Jim

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For this conversion, how much would the approximate cost be? I've read all the articles I can find on the conversion you did with the '89 however I can’t find a build cost. I'm looking to do it to my 1996 and was wondering about an approximate build cost to just get it running and drivable. Thank you -Robert


Assuming you did all the work, the total cost would depend on what you pay for a conversion package. I've heard of packages going for $5k to $12k. Many almost-new low mileage salvage trucks go for somewhere in the $7500 range, but you'd need a salvage license to bid on insurance vehicles. Ebay can also be a good source for engines and parts.

Jim

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You mentioned a conversion kit, aside from taking the parts out if a salvage truck what do you mean?
Thank you Robert
I referred to a conversion parts package that was assembled from a salvage truck. A package will contain the complete engine/transmission, all related wiring harnesses, computer modules, fuse blocks, electrical center, intercooler/hoses, radiator, steering column, etc.

There have been a few "packages" sold on eBay. I urge people to buy a complete package or a complete salvage truck. The little bits & pieces can really run the cost up if you have to buy them over the counter.

Jim
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Old 02-23-2009, 12:22 PM
Margo_325 Margo_325 is offline
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Im doing conversion on a 1995 Suburban. Donor car is 2001 Silverado. I have the book "Duramax 6600 Conversions&Repower Projects"

My Suburban does not have an HVAC like in the book, I took all the wiring out behind dashboard (I want to keep the old dashboard), that included all heater wiring as well. Do I just have to compare two car wiring diagrams and search for right wires to connect to heater plugs?
I only left the wires, that came out from drivers door and went behind dashboard to passenger door. How did you get your power windows and central locking to work, I didnīt find anything from the book, how to connect them.

Margo, Estonia
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Old 02-23-2009, 01:25 PM
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Originally Posted by Margo_325 View Post
Im doing conversion on a 1995 Suburban. Donor car is 2001 Silverado. I have the book "Duramax 6600 Conversions&Repower Projects"

My Suburban does not have an HVAC like in the book, I took all the wiring out behind dashboard (I want to keep the old dashboard), that included all heater wiring as well. Do I just have to compare two car wiring diagrams and search for right wires to connect to heater plugs?
I only left the wires, that came out from drivers door and went behind dashboard to passenger door. How did you get your power windows and central locking to work, I didnīt find anything from the book, how to connect them.

Margo, Estonia
I also have a 95 SUBURBAN and am in the process of finding an 01-02 donor truck. From what I have found, most all of the 95's sub systems work as a stand alone from the factory. And the 01-02 DMAX can be made to work a s a satand alone as well. I plan on keeping everything inside of interior stock including the dash and cluster. The 01-02 uses seperate drivers for the wait to start and check engine, and the tach can be hooked up to the newer alternator just like on a 6.5. EFILIVE or a PPE will take care of the ECM not having the other modules. You'll need a wiring diagram to seperate the low and high pressure switches to the HVAC control in a 95. From what I have found the A/C in the 95 works without the ECM control, it just uses one wire to trigger the fast idle to the ECM. The DMAX uses seperate inputs for the switches and compressor, so some wiring will need to be done there. And the locks should be on there own circuit as well in the 95 from what I have found. The windows work without any controllers, just a circuit breaker if I'm not mistaken.

Several people out there have done CUMMINS conversions, and the biggest pain is the gear shift indicator. The 01-02 ALLISON uses a switch like that of the 95 4L80E, so I believe with some diodes and maybe a few relays you could make the stock gear indicators work as well.
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Old 02-24-2009, 12:17 AM
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Quote:
Originally Posted by Margo_325 View Post
Im doing conversion on a 1995 Suburban. Donor car is 2001 Silverado. I have the book "Duramax 6600 Conversions&Repower Projects"

My Suburban does not have an HVAC like in the book, I took all the wiring out behind dashboard (I want to keep the old dashboard), that included all heater wiring as well. Do I just have to compare two car wiring diagrams and search for right wires to connect to heater plugs?
I only left the wires, that came out from drivers door and went behind dashboard to passenger door. How did you get your power windows and central locking to work, I didnīt find anything from the book, how to connect them.

Margo, Estonia
Your complete HVAC system & control panel should work just like mine does, meaning it'll operate as a standalone system. You'll just need to tap into DMax HVAC under-dash wiring for power/ground/AC clutch engage. I recommend using the Dmax HVAC power and lighting circuits so the correct the fuses are being used. The 88-94 diagram in the book can be used as a guide for your 95 system, but you will likely need the 95 wiring diagram to double-check it.

As was mentioned by THEFERMANATOR, the ECM will be looking for the Dmax HVAC controller. I didn't need to delete that function in the ECM using EFI-Live, but it wouldn't hurt.

If you want to maintain 4-wheel ABS, I would transfer the Dmax truck's ABS controller and related hardware to the Suburban.

And by the way, I consider the Dmax instrument panel essential for the best conversion (the gauges are right and you'll have the DIC).

Jim
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  #6  
Old 02-24-2009, 04:56 AM
Margo_325 Margo_325 is offline
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I did put the Dmax instrument panel cluster in a Suburbans dashboard and fabricated a plastic cover around it. Also I did put a Dmax dip switch, that fitted almost perfectly. So for the HVAC I need just to connect 3 wires to make it work correctly (power, ground, A/C Clutch)? Unfortunately, I dont have Suburban wiring diagram, only the Silverados one.

Last edited by Margo_325; 02-24-2009 at 05:43 AM.
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  #7  
Old 02-24-2009, 10:24 AM
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The pickup wiring diagrams should be virtually identical to the Suburbans.

The HVAC package under the dash should have its own wiring harness - that connects to the HVAC control panel and the vehicle's original under-dash harness.

I connected the original 1989 HVAC harness to the new Dmax harness connections for power/ground and Ac clutch engage. Works great.

Jim
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  #8  
Old 03-17-2009, 09:40 PM
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Well, 1st off, mine was an OBD II & you guys, fortunately are dealing w/OBD I.
My Opinion:
You need to get the GM FACTORY MANUALS!! It has all of the wiring diagrams.
The A/C..As I recall, youall are on the right track-LOOK AT THE "a/c Request" wire.
The 95-99(2000 for some) A/C wiring is the same. The control head is a computer.
I'm not sure how you can get the 95 dash to work with the 01(DMAX) since all of the inputs(outputs?) are different & changed again several times.
I used the 01(actually 01-03 I think)DMAX dash & it is usable/fitable(if that's a word)
I need to read the posts again.......
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64 Biscayne 409 NSS
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Old 03-17-2009, 09:47 PM
GordonMarks GordonMarks is offline
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OH, the 95-99 A/C system controls are DEFINITELY different! They changed the controls & the dash. The basic system(box) is the same but the control head is alltogether different as is the wiring.
The ducts are better too. The air flow/cooling(for those down here)is much better on the 95-99's but not as good as the later 2000's +.
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  #10  
Old 03-23-2009, 09:41 AM
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I have an ALLDATA membership for my 95 and 01 for my conversion. If you need any particuliar wire colors or such let me know and I can look them up for you.
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