Hey everyone.. so it’s now my turn for a ls swap on my 91. 3FE just isn’t cutting it. So I picked up a DBW 2004 5.3ls with a 4l60E and had relatively low mileage so I couldn’t pass it up. Got everything from the yard to do the swap.. gas pedal, ac and power steering lines uncut so it’ll be easy to mock up what I need and bring to a hydraulic shop to fab it up.
Anyhow engine got delivered last week and promptly started to remove upper intake, exhaust manifolds (yard even left the mid pipe that has the cats uncut.. unbolted everything so those bends and cats could be reused in fabbing up the exhaust). Waterpump on order as well as the tensioners and idler pullies easy to do it now. Rear main seal will be replaced as well as that oil plunger thingamajigger.
Going to go with mechanical fan route that bloc did using a 2014 Chevy Silverado 2500 fan clutch and a 19” fan from the vans.
Things on order:
- Marks 4wd adapter: MFK1195AE
- Muscle car oil pan kit on order: NAL-19212593
- Summit Fan Kit: SUM-380457-SH
- Dirty Dingo LS Street Rod Complete Adjustable Engine Mounts: DD-LS-SR-CM
- ACDelco 15-40520 GM Original Equipment Engine Cooling Fan Clutch: Amazon
- ACDelco 15785087 GM Original Equipment Automatic Transmission Control Lever Cable: Trailblazer Cable - PN 15785087
- Delphi AS10017-11B1 - Delphi Ignition Knock Sensors: DFP-AS10017
- Fel-Pro BS40640 - Fel-Pro Rear Main Seal Cover Gaskets
- Fel-Pro MS98016T - Fel-Pro PermaDryPlus Intake Manifold Gaskets
- Wix Filters 33737 - WIX Filters Fuel Filters
-GMB OE Replacement Water Pumps 130-7340 (Used Gen4 waterpump)
- Melling Oil Pumps M295: MEL-M295
- Corvette Servo: 700R4 4L60E Corvette Servo
- Denso Supra Fuel Pump 950-0155
I know I'll also need some assorted intake hoses and pipes, heater hoses, fuel line and assorted connections..
Will the 91/92 radiator still work as they moved to a 3 core design 93 and up?
So some stuff I need clarity on as I’ve been researching on everyone’s swaps is stuff like the exhaust manifold... seems like in the beginning center exit was the thing and cleared great and now I seen the hooker cast ones with rear exits working best. Opinions?
Going with these exhaust manifolds:
- Hooker LS Cast Iron Exhaust Manifolds 8501HKR
I also read somewhere that the trans cable from like a Trailblazer works best so I plan on getting this one:
- ACDelco 15785087 GM Original Equipment Automatic Transmission Control Lever Cable
I need to find that thread to switch out the brake switch? I saw somewhere someone had used a different one but I can't be sure.
I've seen where the corvette pedal works a lot easier and just need to swap two pins.... colorado pedal same thing. Some have made the truck pedal fit but had to make their own bracket..
I plan on working the harness, been watching tons of youtube videos on cleaning up the LS harness and as long as you lay it out as if it’s on the engine you have a better idea on what you’re doing. I just need to get the EWD for a 91 so if anyone has one saved would be great. I’ve seen 93 on up but nothing for 91/92.
I'd like to give myself 2 months to complete this project as I plan on using this as our travel vehicle so we'll see... 3 young kiddos keeps ya mighty busy lol..
Anyhow I will try to keep this updated best I can...
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Late update (16 Nov 21) to parts I've gone with:
- I ended up going with a 2007 5.3 (gen 4) water pump since the outlet won't interfere with the intake tube. (I believe thatcabledude gave me that tip)
- AC Delco gen 4 thermostat housing
- Holley Terminator Xmax stand alone ECU
- GM Genuine Parts 10379038 Accelerator Pedal with Position Sensor
- Holley EFI 554-121 Air Temp Sensor
- Low Dollar Motorsports 7/16”-20 UNF Female 100 PSI Pressure Sensor PN: 7990100-716
- CJ Tatton 2" front DC drive shaft (so far it's working but order was sloooowww)
- ICT Billet LS Truck Intake Manifold Rear Brake Booster Vacuum Port Plug 4.8L 5.3L 6.0L LQ4 551927-PLUG
- GPI racing aluminum radiator (it's working so far)
- 2003-2017 Chevy Express 2500 Fan Blade AC Delco 99876GS
- Added OEM steam port tube
- Gates K060923HD FleetRunner Micro-V Serpentine Drive Belt
- Gates 20230 Premium Molded Coolant Hose ( works great for lower rad hose just needs a little trimming)
- ACDelco 12588670 GM Original Equipment Timing Chain Damper Kit with Bolt, Retainer, and Spacer
- Cloyes C-3220 Timing Chain Kit
- ACDelco 36299 Professional Idler Pulley with Bolt, 17 mm Insert, Dust Shield, Retainer, and Spacer
- ARP 2342503 Stud Kit for crankshaft balancer
- Belt Tensioner, Industry Number, 38159
- Automatic Serpentine Belt Tensioner and Pulley Assembly - Replaces 38158, 88929140 - Fits Chevy Avalanche, Silverado, Tahoe, Trailblazer, GMC Sierra,
- Sonnax 4L60 4L60E 4L65-E & 4L70-E Pinless Accumulator Piston Kit
- Borgeson 925121 6AN Steering Box Hose Adapter Kit
- Russell 648060 -6AN adapter for power steering pressure side
- Radiumauto 14-0121 (M14x1.5 inverted flare to 6AN male adapter)
Anyhow engine got delivered last week and promptly started to remove upper intake, exhaust manifolds (yard even left the mid pipe that has the cats uncut.. unbolted everything so those bends and cats could be reused in fabbing up the exhaust). Waterpump on order as well as the tensioners and idler pullies easy to do it now. Rear main seal will be replaced as well as that oil plunger thingamajigger.
Going to go with mechanical fan route that bloc did using a 2014 Chevy Silverado 2500 fan clutch and a 19” fan from the vans.
Things on order:
- Marks 4wd adapter: MFK1195AE
- Muscle car oil pan kit on order: NAL-19212593
- Summit Fan Kit: SUM-380457-SH
- Dirty Dingo LS Street Rod Complete Adjustable Engine Mounts: DD-LS-SR-CM
- ACDelco 15-40520 GM Original Equipment Engine Cooling Fan Clutch: Amazon
- ACDelco 15785087 GM Original Equipment Automatic Transmission Control Lever Cable: Trailblazer Cable - PN 15785087
- Delphi AS10017-11B1 - Delphi Ignition Knock Sensors: DFP-AS10017
- Fel-Pro BS40640 - Fel-Pro Rear Main Seal Cover Gaskets
- Fel-Pro MS98016T - Fel-Pro PermaDryPlus Intake Manifold Gaskets
- Wix Filters 33737 - WIX Filters Fuel Filters
-
- Melling Oil Pumps M295: MEL-M295
- Corvette Servo: 700R4 4L60E Corvette Servo
- Denso Supra Fuel Pump 950-0155
I know I'll also need some assorted intake hoses and pipes, heater hoses, fuel line and assorted connections..
Will the 91/92 radiator still work as they moved to a 3 core design 93 and up?
So some stuff I need clarity on as I’ve been researching on everyone’s swaps is stuff like the exhaust manifold... seems like in the beginning center exit was the thing and cleared great and now I seen the hooker cast ones with rear exits working best. Opinions?
Going with these exhaust manifolds:
- Hooker LS Cast Iron Exhaust Manifolds 8501HKR
I also read somewhere that the trans cable from like a Trailblazer works best so I plan on getting this one:
- ACDelco 15785087 GM Original Equipment Automatic Transmission Control Lever Cable
I need to find that thread to switch out the brake switch? I saw somewhere someone had used a different one but I can't be sure.
I've seen where the corvette pedal works a lot easier and just need to swap two pins.... colorado pedal same thing. Some have made the truck pedal fit but had to make their own bracket..
I plan on working the harness, been watching tons of youtube videos on cleaning up the LS harness and as long as you lay it out as if it’s on the engine you have a better idea on what you’re doing. I just need to get the EWD for a 91 so if anyone has one saved would be great. I’ve seen 93 on up but nothing for 91/92.
I'd like to give myself 2 months to complete this project as I plan on using this as our travel vehicle so we'll see... 3 young kiddos keeps ya mighty busy lol..
Anyhow I will try to keep this updated best I can...
View attachment 2326043
View attachment 2326044
View attachment 2326045
Late update (16 Nov 21) to parts I've gone with:
- I ended up going with a 2007 5.3 (gen 4) water pump since the outlet won't interfere with the intake tube. (I believe thatcabledude gave me that tip)
- AC Delco gen 4 thermostat housing
- Holley Terminator Xmax stand alone ECU
- GM Genuine Parts 10379038 Accelerator Pedal with Position Sensor
- Holley EFI 554-121 Air Temp Sensor
- Low Dollar Motorsports 7/16”-20 UNF Female 100 PSI Pressure Sensor PN: 7990100-716
- CJ Tatton 2" front DC drive shaft (so far it's working but order was sloooowww)
- ICT Billet LS Truck Intake Manifold Rear Brake Booster Vacuum Port Plug 4.8L 5.3L 6.0L LQ4 551927-PLUG
- GPI racing aluminum radiator (it's working so far)
- 2003-2017 Chevy Express 2500 Fan Blade AC Delco 99876GS
- Added OEM steam port tube
- Gates K060923HD FleetRunner Micro-V Serpentine Drive Belt
- Gates 20230 Premium Molded Coolant Hose ( works great for lower rad hose just needs a little trimming)
- ACDelco 12588670 GM Original Equipment Timing Chain Damper Kit with Bolt, Retainer, and Spacer
- Cloyes C-3220 Timing Chain Kit
- ACDelco 36299 Professional Idler Pulley with Bolt, 17 mm Insert, Dust Shield, Retainer, and Spacer
- ARP 2342503 Stud Kit for crankshaft balancer
- Belt Tensioner, Industry Number, 38159
- Automatic Serpentine Belt Tensioner and Pulley Assembly - Replaces 38158, 88929140 - Fits Chevy Avalanche, Silverado, Tahoe, Trailblazer, GMC Sierra,
- Sonnax 4L60 4L60E 4L65-E & 4L70-E Pinless Accumulator Piston Kit
- Borgeson 925121 6AN Steering Box Hose Adapter Kit
- Russell 648060 -6AN adapter for power steering pressure side
- Radiumauto 14-0121 (M14x1.5 inverted flare to 6AN male adapter)
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