S10 V8 Swap Bible, 2nd Gen Options

[MWood]

Last modified 2 May, 2010

Before attempting any swap call your emissions center to discuss the legal aspect of it. You may have to replace the engine in your truck with the same year or newer, some may not let you do the swap period. This is something you need to know before you start.

Make a budget and price out everything you need. Also set aside at least 2 weeks to complete the swap, and another couple hundred miles to work out the bugs.

You will need ample space, basic handtools, engine lift, and a engine stand. Also an engine leveler will help out a lot.

Vortec 5.7 ('96-'00)
The L31 Vortec 5.7 was manufactured from 1996-2000 but was still found in Chevy Express vans up until 2003. It is the easiest, and least expensive v8 to swap into the 2nd gen s10 series truck.

Taken from Wikipedia.
1996-2003 Chevrolet Express/GMC Savana full-size vans
1996-1999 Chevrolet/GMC C/K full-size trucks
1996-1999 Chevrolet Suburban/GMC Suburban full-size long-wheelbase SUVs
1996-1999 Chevrolet Tahoe/GMC Yukon full-size short-wheelbase SUVs
1999-2000 Cadillac Escalade
/Wikipedia

Cooling.
Factory radiator works (if its in good shape) Fans you need depend on the weather in your area. Factory fan and clutch will not work. You can either leave the radiator in the stock position and use 2 12" fans in front of them as pushers (this is what i have). You can move the radiator into the forward position, then move the AC condensor in front of the radiator support and use electrical fans out of a ford taurus, or electrical fans out of a LS1 car. You can also purchase a corvette radiator which is a little smaller than the stock piece.

For the lower radiator hose I used a Prestone Universal hose I found at Autozone with help from bvd80. Part # is 1318.

Motor Mounts.
You can use the weld-in motor mounts, or you can use the stock mounts and use Advanced Adapters motor mount adaptors. With the stock mounts and adapter, you will need either a 2" body lift or you will have to cut some of the core support to clear the AC compressor. This is not necessary when using the weld-in mounts.

If you are using the stock mounts with the AA adapters, then I recommend a pair of energy suspension motor mounts. The stock mounts tear up with just the v6, and energy suspension's mounts are advertised to hold up to 800hp. I bought mine from Jigg and his store Synergy Offroad.

Wiring.
As far as wiring, you need to add a v8 injector pod which can be purchased through Jared at Current Performance.. Then add the 2 injector control wires (6 and 8 I believe) that run to the computer, and 2 switched 12-volt wires that run to the fuse box under the hood. Extend your knock sensor wire, o2 sensor wires, add or remove o2 sensor wiring as needed (depending on exhaust setup). Relocate your knock sensor. I used a 45º npt fitting (Earl's Performance 991502ERL), but you can also drill your motor mount adaptors, or some other spot on the block or accessories bracket and tap and thread it for the knock sensor. Because of the way the engine sits in our trucks, the sensor will hit the frame in the stock position. You also need to extend the coolant temperature sensor wire.

Or you can give Jared at Current Performance a call and he will hook you up as far as the wiring harness (and computer programming).

This wiring setup is used with the black computer. The 0411 (silver) computer may have a different pinout.

(Info on pinout from Shiftit's post in Bvd80's thread)
All wires should be in the red connector, providing the computer is flashed to a 98 or newer.

Inj 1 Ctrl (Blk) Pin 8
Inj 2 Ctrl (Lt Grn/Blk) Pin 11
Inj 3 Ctrl (Pnk/Blk) Pin 32
Inj 4 Ctrl (Lt Blu/Blk) Pin 31
Inj 5 Ctrl (Blk/Wht) Pin 15
Inj 6 Ctrl (Yel/Blk) Pin 16
Inj 7 Ctrl (Red/Blk) Pin 12
Inj 8 Ctrl (Dk Blu/Wht) Pin 9

8 D 7
6 5
4 3
2 1

Maaso's write-up on how to do wiring


Plug wires.
Run heat socks on at least cylinders 1,2, and 3.

Custom build your own plug wires and build them to exact length.

Run some wire loom to separate the plug wires, and keep them off of the headers.

Computer Programming.
Programming for the 2 extra injectors need to be added. And after the swap is completed, you need to visit someone with a Tech II scanner (dealership) and get a CASE (Crankshaft Angle Sensor Error) relearn done. This is because of the slightly different angle of crankshaft the "new" engine will have. There is a procedure to do it by test driving it, but from my research I have found that it never works. My dealership charged me $20 to do it, but most will charge you either an hour or half-hour. It only takes 2-3 minutes to complete. My truck was reprogrammed as a 2000 Chevy Express Van.

Remove the Vats, Passlock, Passlock 2, which ever one you have.

Jared at Current Performance is a great guy, and will work with you to get your project finished.

There is also Wait4Me Performance, and PCM For Less. Among others i'm sure.

Exhaust.
Use a quality header and collector gasket. Also run locking bolts if you don't want to re-tighten header bolts all the time.

Stores.
S10 V8.com Parts Store
Headers, weld in engine mounts, fans, radiators. The headers say they won't fit with a 2" body lift, but they will. 4wd headers atleast.

Summit Racing

Current Performance Wiring
Wiring accessories, wiring services, miscellaneous items.

PCM For Less
Computer tuning.

Wait4Me Performance
Computer tuning.

Synergy Offroad

Tips.
Buy new bolts for matting the transmission to the engine. I believe they are 5/8 standard thread and are about 3" long with hex heads. Get them from any hardware store.

Replace the rear main seal if the engine isn't new.

This is a good time to clean out your radiator and the "new" engine, and run some green coolant.

Either get rid of your oil cooler lines and use an adapter to mount the oil filter directly to the block, or buy a new oil filter relocation kit. Especially if you are replacing a bad motor.

I recommend doing the MFI conversion simply because it is easier with the engine out of the truck, but it is not necessary.

A 2" body lift is not needed, but very helpful with the initial swap, and maintenance.

I did not have any oil pan clearance issues because I used the motor mount adapters which move the engine up about 1.5". When using the weld-in mounts you may have to buy a custom pan to clear the front differential. The oil pan from a box truck will not fit and will need to be notched. A pickup truck oil pan should do the trick. Thanks to civicslayer07 (Chris), this information has come to light.

The 4.3 starter can be used with the 5.7 flexplate. I am not 100% positive if the 4.3 flexplate can be used on the 5.7, but I don't see why not.

All of the front accessories off of the 4.3 can be used on the 5.7. I even used some of my 4.3 sensors.

Stock fuel pump can be used, but you need the engine rails off of a 5.7

I bought the JTR book on v8 swaps, but it really hasn't done anything other than collect dust.

Swap Threads.
MWood
bvd80 Good information on using weld-in mounts, and relocating the radiator/ac condensor.
ZR2 MIKE Good information on relocating the radiator/ac condensor.
02 Wherry

Swap Websites
ZR2 MIKE
S10V8.com




LSx
The 4.8, 5.3, 5.7 and 6.0. Info on years and applications at Wikipedia.

There is an adapter for mating the LSx to the transmission.

There is an adapter for relocating the AC compressor. Without relocating it, you will need to notch the frame to clear it.

Corvette front accessories must be used to clear the power steering gearbox. I think they must be used to clear the radiator also.

If you have completed the swap and have info to share on a 2nd gen, please post up and I will add it and give you credit for it.

Thanks to D, here is some info on a LSx swap by Black X on a 2wd over on the S10Forum.

QUOTE (Black X;3866298)
Hey Guys, I am going to attempt to share all the knowladge I have on these swaps, My parts list and some very good links and usefull information.

--------------------------------------------------------------------------------

Wiring Harness:
Seriously best money ever spent on my truck Current Performance Wiring Approx Cost$750


A/C Setup
(Same as on my truck) Welcome to Street and Performance Approx Cost$ 550


Car-Part.com--Used Auto Parts Market is an excellent resource for finding parts at an auto wrecker.

Cooling
The Upper radiator hose I used was from a 2001 Camaro. GM Part#10271554
LS2 water Pump GM Part#89017457
Conversion Radiatior V8 conversion manuals, parts for V8 S10, Datzun Z, Jaguar, Chevy TPI & TBI, Colorado, Astro Van V8, Volvo 200 & 700
I run (2) 10" electric fans pushing and (1) Pulling. I have no overheating issues.

Misc
Throttle cable is from a 2002 Chev S-10 4.3L GM Part#15010419
Cruise Control Cable GM part # 15045460
Transmission Flexplate Spacer (For use of 700R4 TH 350 TH 400) GM part#12563532 Bolts Part#12563533 (looks like GM just reduced the price on this)

FUEL:
You need a rail pressure of 58-62 psi There is an adapter fitting made by Russel Part#640850 that will adapt the GM rail to #6AN fitting. For guys wishing to adapt #6AN to their existing 5/16" return line use part #640860

FUEL PUMP
My truck was a 2.2L Flex fuel truck. I HAVE MADE NO MODIFICATIONS TO THE FUEL SYSTEM! the factory flex fuel pump has supported 491RWHP and The filter has a built in regulator. Same as the Corvette. I used (2) Russell part# 640850 fittings and a chunk of braided stainless line that was all I needed.
Filter/Regulator Setup is GM Part#10299146

Headers and Mounts
These are available from Current Performance Wiring They fit great I am using them.

The follwing list is part numebers for the C5 Accessory package.
This is also in the 2007 GM performance parts catalog under a single part number but I do not have the number. PEKO??? Any help here.
Alternator (1)10246634 (production) 10316182 (service)
Alternator to bracket bolts (2) 24503609
Alt bracket to head bolts (3) 11516357
Alt bracket to head bolt (1) 11516356
Alt/ P/S mount bracket (1) 12555220 was superceded by part number 12578068.
P/S fluid reservoir bracket (1) 12555222
P/S fluid reservoir (1) 26046502
P/S reservoir hose (1) 26046910
P/S reservoir cap (1) 26022453
P/S pump (1) 26046503
P/S pump pulley (1) 12559890
P/S pump brace (1) 12555693 Same as f-body
P/S pump bolts (2) 14078896 Same as f-body
P/S pump bolts (2) 11515758 Same as f-body
Belt idler pulley (1) 12564401 Same as f-body
Harmonic balancer (1) 12560115
Belt tensioner assembly (1) 12559325
A/C belt tensioner assembly (1) 12560345 Same as f-body
A/C belt idler pulley (1) 12557334
A/C compressor bracket (1) 12556444
A/C compressor (1) 1137031
A/C bracket stud (1) 12556447
A/C bracket bolt (1) 11515768
A/C compressor bolt (1) 11516714
A/C compressor bolt (1) 12552922
A/C compressor bolt (1) 11509202
A/C compressor nut (1) 10255857


OIL PAN
This one is a little bit tough to decide exactly what you should do.
If your willing to notch the GM truck pan from any 4.8 5.3 or 6.0 will fit. It will also hang approx 1.5" below the crossmember.
The LS2 pan is rumored to fit the 4x4 trucks without modification I can't confirm this.

Tuning and ECM calibration.
You can purchace tuning software from a number of locations on the net. The best way for the budget swappers would be the Predator tuner that Jared at Current Performance Wiring offers.

Coil Packs
If you use the round coils from the truck engines and the associated brakets you will not have to relocate the rear 2 coils.
This is a good start for people.. I hope this points a bunch of you in the right direction. I will continue to add to this as I remember things that you might need.

Swap Threads
heliflyer over on www.s10forum.com 5.3 in a 2002 Zr2
Black X LSx swap in a 2wd S-10



Carbed, TBI, LT1/LT4, or Big blocks.......
I have no idea. If you have information on doing these swaps in a 2nd gen S10, feel free to post up and I will add it and give you credit for it.

The guys at "Extreme 4x4" put a crate 502 in a 2nd gen S-10, but it has a custom tube frame, extended front fenders, and rockwell axles.
http://www.powerblocktv.com/sites/xtreme/
http://www.powerblocktv.com/sites/xtreme/e...amp;ep_sea=0801
http://www.powerblocktv.com/sites/xtreme/e...amp;ep_sea=0801




Also, feel free to correct me on any misinformation.
I will continue to add to this post as I become aware of more issues with the swap I had to go through, and when people add their issues to the thread.

This post has been edited by MWood: Apr 30 2010, 06:13 PM

[Keviness®]

(IMG:style_emoticons/default/icon_appl.gif)

I'm going to make this a pinned topic. Nice Job Marcus (IMG:style_emoticons/default/thumup.gif)


Something I think would be a good addition to the post would be a list of good sites geared toward V8 Swaps into S-Platform vehicles, and also a list of any good books of the same topic. I know there are some of both out there, but I don't know exactly what they are (IMG:style_emoticons/default/smile.gif)

[civicslayr07]

Nice, the guide ive been looking for thank you mwood, ur the man. Im serious this rocks!!!!!!!!! (IMG:style_emoticons/default/rockon.gif)

[beedle4]

Not that I plan to do this any time soon but...

Since I have a suspension lift a regulat oil pan would work?
If useing stock motor mounts only trim needed is the hood to clear the AC? I have a 1" body lift would it clear?

[MWood]

Not that I plan to do this any time soon but...

Since I have a suspension lift a regulat oil pan would work?
If useing stock motor mounts only trim needed is the hood to clear the AC? I have a 1" body lift would it clear?

Im not sure if a suspension lift will give you more oil pan clearance. Thinking about it, it makes sense that it would but im not sure.

With a 1" body lift you may get away with clearing the hood without cutting. I'll have to see if I can measure my AA adapters, or get the specs off of their site. I think they raise the engine 1.5".

[MWood]

(IMG:style_emoticons/default/icon_appl.gif)

I'm going to make this a pinned topic. Nice Job Marcus (IMG:style_emoticons/default/thumup.gif)


Something I think would be a good addition to the post would be a list of good sites geared toward V8 Swaps into S-Platform vehicles, and also a list of any good books of the same topic. I know there are some of both out there, but I don't know exactly what they are (IMG:style_emoticons/default/smile.gif)

Thanks Kevin.

I have plenty more to add, I just wanted to get the most important stuff down.

[bvd80]

Good job Marcus! (IMG:style_emoticons/default/drinkbuds.gif) We (everyone who did the swap) are always willing to answer any questions anyone has regarding the V8 swap.

[D]

Here is a write up that a member over at S10forum did for the LSX swap. Hope this help's.

Hey Guys, I am going to attempt to share all the knowladge I have on these swaps, My parts list and some very good links and usefull information.

--------------------------------------------------------------------------------

Wiring Harness:
Seriously best money ever spent on my truck Current Performance Wiring Approx Cost$750
(IMG:http://i72.photobucket.com/albums/i163/dsmacias05/Truck/LSX/01_6A-LS1.jpg)



A/C Setup
(Same as on my truck) Welcome to Street and Performance Approx Cost$ 550
(IMG:http://i72.photobucket.com/albums/i163/dsmacias05/Truck/LSX/DSC00637.jpg)

Car-Part.com--Used Auto Parts Market is an excellent resource for finding parts at an auto wrecker.

Cooling
The Upper radiator hose I used was from a 2001 Camaro. GM Part#10271554
LS2 water Pump GM Part#89017457
Conversion Radiatior V8 conversion manuals, parts for V8 S10, Datzun Z, Jaguar, Chevy TPI & TBI, Colorado, Astro Van V8, Volvo 200 & 700
I run (2) 10" electric fans pushing and (1) Pulling. I have no overheating issues.

Misc
Throttle cable is from a 2002 Chev S-10 4.3L GM Part#15010419
Cruise Control Cable GM part # 15045460
Transmission Flexplate Spacer (For use of 700R4 TH 350 TH 400) GM part#12563532 Bolts Part#12563533 (looks like GM just reduced the price on this)

FUEL:
You need a rail pressure of 58-62 psi There is an adapter fitting made by Russel Part#640850 that will adapt the GM rail to #6AN fitting. For guys wishing to adapt #6AN to their existing 5/16" return line use part #640860
(IMG:http://i72.photobucket.com/albums/i163/dsmacias05/Truck/LSX/rus-640850_w.jpg)


FUEL PUMP
My truck was a 2.2L Flex fuel truck. I HAVE MADE NO MODIFICATIONS TO THE FUEL SYSTEM! the factory flex fuel pump has supported 491RWHP and The filter has a built in regulator. Same as the Corvette. I used (2) Russell part# 640850 fittings and a chunk of braided stainless line that was all I needed.
Filter/Regulator Setup is GM Part#10299146
(IMG:http://i72.photobucket.com/albums/i163/dsmacias05/Truck/LSX/vette_filter_with_fittings.jpg)

Headers and Mounts
These are available from Current Performance Wiring They fit great I am using them.
(IMG:http://i72.photobucket.com/albums/i163/dsmacias05/Truck/LSX/CSLS1.jpg)


The follwing list is part numebers for the C5 Accesory package.
This is also in the 2007 GM performance parts catalog under a single part number but I do not have the number. PEKO??? Any help here.
Alternator (1)10246634 (production) 10316182 (service)
Alternator to bracket bolts (2) 24503609
Alt bracket to head bolts (3) 11516357
Alt bracket to head bolt (1) 11516356
Alt/ P/S mount bracket (1) 12555220 was superceded by part number 12578068.
P/S fluid reservoir bracket (1) 12555222
P/S fluid reservoir (1) 26046502
P/S reservoir hose (1) 26046910
P/S reservoir cap (1) 26022453
P/S pump (1) 26046503
P/S pump pulley (1) 12559890
P/S pump brace (1) 12555693 Same as f-body
P/S pump bolts (2) 14078896 Same as f-body
P/S pump bolts (2) 11515758 Same as f-body
Belt idler pulley (1) 12564401 Same as f-body
Harmonic balancer (1) 12560115
Belt tensioner assembly (1) 12559325
A/C belt tensioner assembly (1) 12560345 Same as f-body
A/C belt idler pulley (1) 12557334
A/C compressor bracket (1) 12556444
A/C compressor (1) 1137031
A/C bracket stud (1) 12556447
A/C bracket bolt (1) 11515768
A/C compressor bolt (1) 11516714
A/C compressor bolt (1) 12552922
A/C compressor bolt (1) 11509202
A/C compressor nut (1) 10255857


OIL PAN
This one is a little bit tough to decide exactly what you should do.
If your willing to notch the GM truck pan from any 4.8 5.3 or 6.0 will fit. It will also hang approx 1.5" below the crossmember.
The LS2 pan is rumored to fit the 4x4 trucks without modification I can't confirm this.

Tuning and ECM calibration.
You can purchace tuning software from a number of locations on the net. The best way for the budget swappers would be the Predator tuner that Jared at Current Performance Wiring offers.

Coil Packs
If you use the round coils from the truck engines and the associated brakets you will not have to relocate the rear 2 coils.
This is a good start for people.. I hope this points a bunch of you in the right direction. I will continue to add to this as I remember things that you might need.

[D]

Also here is a link to someone who put a 5.3 in his 02 Z

heliflyer

I also asked how he made the ZR2 mounts work. here is his answer.

I just welded an extra inch or so the the front side of the engine mount where it bolts to the motor and drilled 4 new holes.

[MWood]

Here is a write up that a member over at S10forum did for the LSX swap. Hope this help's.

Thanks a lot man. (IMG:style_emoticons/default/drinkbuds.gif)

You wouldn't happen to have the link for this thread would you?

[D]

http://www.s10forum.com/forum/f213/parts-l...sx-swap-283608/

[Zr2x350]

Nice job Wood.

If anyone has any questions you can message me anytime you want....I dont mind answering them.

[Jonathan Brock]

Who had the Pin out diagram for 2000 5.3L?

I know i saw it somewhere but cannot find it to save my life today!

[burnedzr2]

That is a great swap!! how hard was the fuel injection to work properly. I would love to do it but in CT. we have a emissions program that we have to pass.And I believe the the test runs the computer some how to check that everything works right.

This post has been edited by burnedzr2: Sep 16 2009, 09:37 PM

[MWood]

It was just a matter of adding the extra wiring (2x control wires, 2x 12 volt wires) for the 2 extra cylinders and having the computer reprogrammed.

[tyhuck]

So has anyone confirmed which oil pan to use for a 5.3 swap? Im just not comfortable cutting and welding something that basically holds the life blood of my engine.

[jrigby]

So has anyone confirmed which oil pan to use for a 5.3 swap? Im just not comfortable cutting and welding something that basically holds the life blood of my engine.

I believe turbotime.us makes LSx oil pans for the syclone/typhoons which should fit our 2nd gen 4x4's. But their product page has been down for a week or so now. (IMG:style_emoticons/default/idunno.gif)

[manyfire]

NYS Emissions Page,this is why im not doin my zr2 http://www.nysdmv.com/vehsafe.htm#einspect

[Zr2x350]

So has anyone confirmed which oil pan to use for a 5.3 swap? Im just not comfortable cutting and welding something that basically holds the life blood of my engine.

Just use a F body oil pan and call it a day. like a f body ls1...camaro, transam.

[Zr2x350]

LSX wiring info here.

http://lt1swap.com/wiringharness.htm

My lsx knowledge has grown a shit ton recently.