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Old 11-08-2022, 11:02 AM   #1
lookforjoe
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Default 1991 740 pickup LR4 V8/4L60e Swap

This thread will be to document my V8 swap thread. Pickup conversion thread
I like to review everything I do, so this will be a lengthy thread with much fitment & revision minutia.
I will update this post with page summaries as time goes by

Gathering parts at this stage.

Areas to cover:
Physical Drivetrain fit - JTRmount kit
Accessory Drive
Exhaust - LS generic manifolds, 2.5" SS exhaust
Chassis/body mods
EMS (standalone harness relocate)
Driveshaft (hybrid w/ Chevy forward section?)
Cooling System (rad (Be Cool 35223) / hoses, heater hoses, surge tank)
Front Suspension/Brakes (DIY coilovers, 302 brakes)
Fuel supply (6AN lines, regulator, adaptor fittings)
HVAC - adapt lines
Power Steering - adapt lines
Rear Axle (how to address pulse wheel?) Mount ear kit
Other stuff I haven't thought about yet...

Tach mod?

Flexible trans dipstick to reduce bulkhead mods?
Intake manifold (cathedral port, 3 bolt TB) compatible with LS1,2,LS6

Reference threads -
What current V8's...
Rear Axle Choices

Corivus's 740SE V8
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Old 11-08-2022, 02:06 PM   #2
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What made you pick the JTR kit?
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It says so on the lens.
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Old 11-08-2022, 02:23 PM   #3
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Originally Posted by doucheNozzle View Post
What made you pick the JTR kit?
STS never replied to my emails about the mount brackets they made (out of stock).

JTR came up looking at other swaps. They also don't stock the kits anymore, but... he answered the phone, and had one partial set he said he would finish up for me. He said he is weighing whether or not to make more. Spoke with him again this morning, actually.
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Old 11-08-2022, 07:12 PM   #4
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Originally Posted by lookforjoe View Post
STS never replied to my emails about the mount brackets they made (out of stock).

JTR came up looking at other swaps. They also don't stock the kits anymore, but... he answered the phone, and had one partial set he said he would finish up for me. He said he is weighing whether or not to make more. Spoke with him again this morning, actually.
did he talk to you about how pacific bell was spying on him?
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Old 11-08-2022, 08:47 PM   #5
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did he talk to you about how pacific bell was spying on him?
Is that a thing? I don't know the guy. He seemed 'normal' during our conversations.

So, Drivetrain arrived

jeesh this thing is heavy. I have zero experience with American automotive hardware. What is the best way (lift points?) to lift the drivetrain? There are no hooks supplied, as with any European or Japanese motors...







not much space left


EMS stuff - hopefully not trashed - this was all stuffed under the pan


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Old 11-10-2022, 10:17 PM   #6
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Originally Posted by cosbySweater View Post
did he talk to you about how pacific bell was spying on him?
what's this story?
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Old 11-12-2022, 08:03 PM   #7
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Coilover (Bicknell) sleeves (2.080" bore), seats & jam nuts & (BNE) strut plates, weld rings. 12" 250lb Eibach XT springs coming.



302mm brakes. I modified the caliper casting so I can still use my 15" (new) snows

hanger bracket corners cut back


hanger bracket is spaced 1/4" outward - others have noted the bracket then contacts the ABS tooth wheel. Mine clear


grinding back the caliper in stages




clears the outer step of the 15"wheel now. Took about 4mm off the outer lip, to a depth of about 32mm, then tapered into the rear area




2nd caliper went much quicker








self etching primer


silver enamel

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Old 11-12-2022, 08:40 PM   #8
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Quote:
Originally Posted by lookforjoe View Post
STS never replied to my emails about the mount brackets they made (out of stock).

JTR came up looking at other swaps. They also don't stock the kits anymore, but... he answered the phone, and had one partial set he said he would finish up for me. He said he is weighing whether or not to make more. Spoke with him again this morning, actually.
There is also the giffin motor mounts which are the cheapest out of all the available mounts.

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Originally Posted by lookforjoe View Post

EMS stuff - hopefully not trashed - this was all stuffed under the pan

Unless you want to keep the pcm in the engine bay, you won't be using any of it. Aftermarket harnesses are cheap(amazon or ebay) and they relocate the pcm to the inside of cabin(just makes for a much cleaner setup).
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Old 11-12-2022, 11:29 PM   #9
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Originally Posted by white855T View Post
There is also the giffin motor mounts which are the cheapest out of all the available mounts.

Unless you want to keep the pcm in the engine bay, you won't be using any of it. Aftermarket harnesses are cheap(amazon or ebay) and they relocate the pcm to the inside of cabin(just makes for a much cleaner setup).
Giffin also never responded when. I enquired about the mount brackets.

- Yes, I bought the DBW relocation harness based in your recommendation - it is the modules I'm concerned about, but they don't seem too have suffered any physical damage.
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Old 11-15-2022, 10:26 AM   #10
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Took a couple hours to rearrange the garage & move the drivetrain to a sturdier cart. This sucker is HEAVY. Going to be fun moving this thing around & test fitting :(




also purchased an LS6 intake with injectors & fuel rails. This is adding up quickly. I'll need a larger rad, and a number of other $$$ items


Mount kit arrived

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Old 11-19-2022, 11:58 PM   #11
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Collecting parts...

LS6 mainfold & rails


new gaskets Felpro MS 96718 (edit - these are wrong for the LS6 intake, correct set ordered (Felpro MS 92438)


exhaust - 2 cats


"flex" couplers - it's annoying that they expanded the outlet side - makes no sense, since inserted exhaust junctions should always be following the exhaust flow. I'll probably just cut it off since I'm going to butt-seam the welds anyway


misc exhaust sections, mandrel bends


28" Be Cool 35223 rad - 24" Volvo efan shroud will work


Made the missing V8 mount adaptor plate - using 3/4"x4"x6" flat stock - retapped the provided one from 3/8" & 5/16" to metric - M10x1.5, M8x1.25






Started stripping stuff off the drivetrain. Have to order the tensioners, idlers, water pump, etc.


Wiring & truck intake. I have NEVER worked on an American V8 product , so this is all new to me


No idea what the two plugs/caps are for in the valley, have to research that


Have to remove the coils & brackets & clean all that up.


Several variants of coils apparently - I ordered new coil wires & plugs appropriate for the 19005218 (D585) coils.

Last edited by lookforjoe; Yesterday at 10:25 AM..
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Old 11-21-2022, 09:40 PM   #12
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Started a reference thread to discuss accessory drive & other issues related to using the LS6 intake manifold (12573572) on the truck 4.8L

Back & forth with a number of things. Trying to determine the best way to deal with the heater line fittings at the pump. I need them to make a 90º right off the pump. I wanted to use quick connect fittings, as those allow much vibration resistance & can rotate if needed. But... I can't find a source for 3/8" & 1/2" NPT male fittings with 5/8" & 3/4" male quick connects, to match the available Dorman heater elbows (800-416 & 800-418).

So, I'm just going to go with the readily available Male NPT-to-Male AN fittings, with AN to barb 90º fittings.

The other thing is the 90º fuel feed at the rail, which interferes with one of the coils. No way to readily reposition the one coil, and the various coil pack brackets are not meant for the D585 coils, and/or won't necessarily move it where I need it to be, whilst still using stock coil/plug wires.



So, I decided to cut the fuel feed & silver solder a new straight feed that runs parallel to the rail. This makes more sense anyway, as it keeps the fuel lines away from the exhaust manifold

removed the pressure damper for the job - just need to add a support brace to the rail for it



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Old 11-22-2022, 11:47 AM   #13
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That's the fuel pressure regulator . On a returnless system, it's at the rail.

Those two plugs are the knock sensor covers.
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Old 11-22-2022, 11:56 AM   #14
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Originally Posted by Broke4speed View Post
That's the fuel pressure regulator . On a returnless system, it's at the rail.

Those two plugs are the knock sensor covers.
Aha - when I looked up 2002 Camaro fuel system it showed a pulse damper in the rail, so that was the basis for my assumption. I'll replace it with a pulse damper, since I'm going to be using a remote filter/regulator with -6 fittings.
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Old 11-22-2022, 12:18 PM   #15
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I just got some cheap eBay fuel rails, didn't worry about the car rail not fitting with the truck coils on mine.
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Old 11-22-2022, 01:54 PM   #16
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Quote:
Originally Posted by Broke4speed View Post
That's the fuel pressure regulator . On a returnless system, it's at the rail.

Those two plugs are the knock sensor covers.
thats a fuel damper to keep noise down at the rail. the regulator is in the filter on corvette returnless systems
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Old 11-22-2022, 07:01 PM   #17
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My mistake...I confused the end of the rail for a return. Pulse damper it is!
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Old 11-22-2022, 07:03 PM   #18
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Originally Posted by lookforjoe View Post
Aha - when I looked up 2002 Camaro fuel system it showed a pulse damper in the rail, so that was the basis for my assumption. I'll replace it with a pulse damper, since I'm going to be using a remote filter/regulator with -6 fittings.
I was wrong...it is a pulse damper. I made a mistake, sorry.
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Old 11-22-2022, 08:46 PM   #19
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Originally Posted by Broke4speed View Post
I was wrong...it is a pulse damper. I made a mistake, sorry.
No worries!

Moving forward with small things whilst I'm waiting on parts.

Drilled & tapped (1/8" NPT) the back of the intake for the left valve cover breather - found the only place where there is meat, and not open to mount flange area

Used the stock 10mm nitrile line, cut & set into the elbow


Removed the exhaust manifolds - first I had to heat the block to get the dipstick tube out of the way
one broken stud on the right - going to be a PITA to get the remnants out - I snapped off an easy-out in here :(

two broken studs on the right - first & last, but those I got out without any damage


Stock injectors 25317628 (25lb@58psi) . For some reason the LS intake had 16lb(@43psi) 0 280 155 890 Bosch. I'm going to use 0 280 155 832 (from Volvo 960), since I have a refurbished set, and they will also run 25lb@58psi.

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Old 11-23-2022, 12:59 PM   #20
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hey just wanted to also say I ended up using the LS3 exhaust manifolds, even the vette c4 manifolds put the exhaust into the steering joint. you can modify that but I prefered to just modify the manifold to get it to fit better. I'll update my thread later next week when i'm back at work and can get it up on the racks to take a proper photo.
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Old 11-23-2022, 10:25 PM   #21
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hey just wanted to also say I ended up using the LS3 exhaust manifolds, even the vette c4 manifolds put the exhaust into the steering joint. you can modify that but I prefered to just modify the manifold to get it to fit better. I'll update my thread later next week when i'm back at work and can get it up on the racks to take a proper photo.
Are those the same as the "LS Swap" cast iron ones below?


After about 90 minutes I finally got the bolt remnants out - 3 carbide bits & 2 concrete bits later. Drilled & tapped for M8x1.25 helicoil.



block sanded the exhaust flange surface


test fitting the aftermarket manifolds - waiting for MLS gaskets & proper length bolts.


Cut the water junction off the TB - don't need it, and it's in the way of the water pump


had to grind a recess into the TB to clear the water pump flange




new t/stat already has the jiggle pin, so no need to drill a vent


removed heater hose pipes & tapped 3/8" & 1/2" for the NPT/AN fittings


Stock tensioner would actually clear the hose outlet , but I already ordered the Camaro tensioner to go with this pump


ICT Billet relocation kit for PS & Alt. Only problem is unless you buy an additional $100 bracket (not mentioned in the kit description) for the alternator when kit is used with a steel block, it only has two mount points....


...and the 2 provided 120mm bolts only sit about an inch into the block




have to order a new pressure pipe for the PS pump, doesn't come with new pump
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Old 11-24-2022, 10:34 AM   #22
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that looks similar to it and your ps pump looks a bit different then mine. it would be nice if ict mentioned you needed an additional bracket if you wanted to keep all your accessories.
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Old 11-24-2022, 11:07 AM   #23
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The stock truck mount only has two mount points for the alt, I have the same ICT kit and have no worries at all.
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Old 11-24-2022, 07:00 PM   #24
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Originally Posted by Broke4speed View Post
The stock truck mount only has two mount points for the alt, I have the same ICT kit and have no worries at all.
It does, however the cradle has much more support - using just the provided bracket means it's hanging off the two bolts, with no counter support. I'm going to order the extra base support, I'm not comfortable leaving it as is.

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Old 11-24-2022, 09:23 PM   #25
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What base support are you referring to? I've looked all over the site and can't find anything.
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