Build 1997 FZJ80 Chevy 5.7 TBI build

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88chevota

88chevota

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Jun 5, 2006
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Colorado Springs, CO
Well, I'll am taking off the first week of march to work on this thing. Let's see if I can finish it. (at lest the engine conversion)

I have a 1997 that blew a head gasket.

So I am keeping this really simple. I have done a couple of the 5.7 chevy TBI conversion on 60 series. They are simple, easy to work on and run forever. I know you get more power with a 5.3 vortec but the 5.7 is cheaper to get.

Its a 1991 truck motor with a 700R4
I found a 62 series t-case because the adapter is quite a bit cheaper and by going part time 4WD I'll save on gas!

I will be trying to keep the dash and center console all stock.

It will be getting a lift.

Engine is cleaned up and just about ready. went ahead and resealed things up... gaskets, and such.

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88chevota said:
any recommendations on headers or just use stock manifolds?
Click to expand...

I guess you'll find out what kind of interference is going to surface and that may dictate your choice.

What's your status on this right now?
 
Status: cleaning the garage trying to get ready for it. I'll start working on the tranny-tcase most likely today.
 
Does the 62 Tcase shifter operate the same as the 80 Tcase? I thought it was a vacuum operated or some such thing?
 
It is vacuum for the 4 high, but shifts the same for 4 low. I'll install a 3 way brass ball valve under the dash to control the vacuum for 4-high.
 
Good choice on the TBI, it's a pretty good engine.

My LT1 is using stock shorty headers. The heat shields on them have about two inches of clearance from the steering wheel shaft. Right now I have the driver's side pipe going under the oil pan and joining up with the passenger side at a Y before going back with a 3" pipe. I plan on making some space and routing a true dual exhaust over the frame rails, so I can tuck the mufflers under my running board/sliders.
 
Here you go. Pardon the mess.

One thing that bugs me a bit about the driver's side header is how close it is to the brake lines. I haven't really found a perfect solution for the LT1 yet, so I'm sticking to shielding them for now. IIRC the TBI and LT1 both use 1 5/8" manifolds.


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When I mentioned running the exhaust over top the frame rail, I meant putting it on the outside of each rail. This gets it away from the brake, electrical, and fuel lines and lets you tuck the whole system up higher.

I'm going to dump the exhaust out the sides in front of the rear wheels, just to keep it far clear of the 2nd fuel tank.
 
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Those manifolds are quite different than mine.

Mine look like these. FYI that's not my engine just too tired to go take pics.

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88chevota said:
any recommendations on headers or just use stock manifolds?
Click to expand...

IF the stock manifolds work I would use them as no real benefit to run headers on stock engine.

Otherwise very common to run "rams horn" style mandifolds....70 era corvette manifolds on the 5.7 swaps, at least on the 60s.
 
I know one guy used a late 80's Camaro exhaust manifold on the LHS in a 91 fj80, and the stock 350 tbi exhaust manifold on the RHS.
 
Not sure on the dash. I'll see if the guys who pulled the motor left the ecu.

Getting started.

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No smog here. Block hugger headers look like the cheapest way to go. This is a budget limited deal. Rams horns look pricey. I ran headers before and I get them to seal great. Some people have issues with sealing but I have a trick that works. As long as you get ones with 5/16 flanges.

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I used the factory Toyota brackets modified to fit chevy motor mounts. The pass side was fine jus redrilled some holes. Has to cut off the driver side an weld it back on and drilled holes.
 
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