Well....... This swap has been more of a pain then anything. There has been fitment issues from the gecko, over spending to solve said fitment issues and over due replacement of 24 year old parts. Luckily issues that I had on the 16v have been the opposite. AC compressor fits like a glove has needed zero clearancing or slicing of bracket. It could not fit any better.
Top radiator hose was an issue till I did some google research and found that
Gates 22352 water hose fits as if this would of been a volvo swap part from the factory if they did a LS option.
Steering shaft rubbing was the big issue. I ended up moving the steering rack over an inch to the drivers side readjusting the tie rod ends enough to get me to the alignment guy. Hood is about 1/4" from rubbing on the truck manifold.
Front end is back on and hood latches which was a pain in the ass. Some how manage to adjust the hood pin wrong and took about an hour to get my hood unlatched. Exhaust went in pretty well. Dual 2.5" Y'd into a 3" after the transmission made from 304L stainless with a single SS magnaflow free flowing muffler. No cat this time. Car has one more year on the sniffer and it should pass without and if doesnt I have a guy that will pass it.
Only thing left is finish engine grounds, battery grounds. hook up modified 5.3L harness inside the cab, run 12v to fuel pumps, find out why my brake pedal no longer goes back to zero and whys its making a popping sound. Along with headlights and small **** that will come as I remember.
Was hoping I would be able to trim the stock avalanche coolant hose to work. That wasn't going to happen so I found this hose and worked out great.
About 1/4" of space between 940 efan and water pump pulley
almost there