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Unread 02-10-2013, 10:06 PM   #1
myke88
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Join Date: Jul 2007
Location: Texas
Posts: 20
91yj 5.3 swap

I bought this jeep last year, I've had a blast wheeling it but it always lacked power on the street. The PO said the motor was a 4.6L but to me it didn't feel like it, so I decided it was time for some chevy love. I've been collecting parts for a few months now, and just this weekend I decided I had enough to begin the swap. I am using Advance Adapters headers and motor mounts with the novak gmax15 adapter, and pilot bearing to keep the ax15.

motor specs:
LM7 5.3L vortec
stock bottom end with arp rod bolts, all new gaskets, bearings, and rings
comp cam .581/.581 224/224 114LSA
LS1 806 heads, ported and polished
LS7 lifters
hardened pushrods 7.350"
patriot dual gold valve springs with titanium retainers
arp flywheel and pressure plate bolts
168 tooth billet flywheel

I am doing all this myself at the auto hobby shop on Camp Pendleton, so I'm only able to work on it 8 hrs/day on the weekends, and what ever time I have left after work on weekdays. I'm hoping to have it done by the end of this month, but we'll see how that goes....and sorry for the crappy cellphone pictures

here's a pre-build pic, the last one I have of it running. this was up in big bear back in november:


motor:


and here is the start of the swap:

pulled the front clip and got to work pulling the 4.0





gmax15 adapter on

old motor mounts gone and ground smooth, GM bellhousing on




I dropped the tranny/tcase today, it was difficult to line the trans input up to the pilot bearing, even without a clutch so I'm going to drop it in as one piece. If ya'll wanna see any more let me know and I'll keep the thread updated.

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Unread 02-10-2013, 10:31 PM   #2
SeanB95YJ
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1995 YJ Wrangler 
 
Join Date: Nov 2009
Location: Schenectady, New York
Posts: 1,184
always interested in seeing v8 swaps... keep it coming.

good luck
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[FONT="Comic Sans MS"][COLOR="Blue"]Sean B. - Schenectady, NY - 95 YJ, 350/700r4/NP241, JB Shorty SYE, 8.8 rear, 2" BDS, 1" homebrew shackles, Daystar 1" BL, TJ flares, 35x12.50 General Grabber AT2 on 15x10 Bart D-Truckers, Polyshield polycarbonate windshield, HD over/under crossover steering
[/COLOR] [COLOR="Red"]swap/build thread: [url]http://www.jeepforum.com/forum/f22/after-almost-4-years-finally-my-own-build-swap-thread-1542284/[/url][/COLOR][/FONT]
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Unread 02-11-2013, 05:22 PM   #3
Sprungover
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Join Date: Mar 2005
Posts: 388
Keep the pics coming. I'm doing the same swap soon.
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Unread 02-14-2013, 07:02 PM   #4
myke88
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Join Date: Jul 2007
Location: Texas
Posts: 20
small update, I found out that the bell housing was actually for a 153 tooth flywheel... I have a 168 tooth. So instead of trying to find one I just ordered a brand new one.

For anyone trying to use a manual trans with a chevy motor, the easy way to tell if the bell housing is for a 153 or 168 tooth flywheel is by the starter boss, which is flush with the rest of the bell housing on the 153 tooth version. On the 168 tooth it sticks out about an inch or so. The bell housing I bought is casting number 3899621, which has the 4 5/8" bore I needed to fit the gmax adapter.



I also cut down the jeep harness last night, I trying to keep all the body/lighting wiring intact, as well as the starter, charging system, and the oil/water temp gauges. I will eventually replace all the gauges with autometer units, but for now to save money I will keep the speedo, oil psi, fuel, water temp, and voltmeter.

heres the harness, kind of hard to see in the box I know but its nothing exciting.



and here's the wiring I cut out. basically all the engine sensors, and injectors.



I will hopefully get the engine mated to the tranny tomorrow and maybe have the motor mounts welded in if there's time. sucks working in a place that's only open 8hrs/day 5 days a week.
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Unread 02-14-2013, 10:24 PM   #5
rinking
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2000 TJ Wrangler 
 
Join Date: Sep 2008
Location: michigan
Posts: 411
Cool build! Your finish time might be a little agressive! My 5.7 swap took me a couple months. I was doing it by myself, 4-5 days a week. I did an 8.8 swap at the same time. A lot of the time I was waiting on parts to be shipped to Me. I ran into alot of little stuff that had to be ordered, but didnt know it till I needed it. Have fun, dont cut any corners! Keep us up to date.
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Unread 02-16-2013, 09:14 PM   #6
myke88
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Location: Texas
Posts: 20
Got the motor dropped in today and the mounts baked in . Looks like there wont be any clearance issues either. The power steering pump is a little close but it should be fine, the hoses are going to be moved and routed under the steering shaft. Firewall clearance is about 2.5", should be enough. I wanted the motor placed as far back as possible for weight distribution. The transmission is only moved up about 3/4" from where it was previously. Gonna have to have the rear drive shaft extended.... heres the pics











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Unread 02-18-2013, 10:42 PM   #7
myke88
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Location: Texas
Posts: 20
Got the fuel lines run, -6 AN through a corvette fuel filter/pressure regulator, all the way to the fuel rail. Jumped the fuel pump and didn't find any leaks, the stock yj pump is putting about 55 psi at the fuel rail, so it might be sufficient for the vortec. If not I have a walbro standing by, I'm just interested to see how the stock pump does.

Also installed 2/3 of the wiring, all except the front harness for the headlights. Everything still works though radio, wipers, blinkers, hazards, brake lights, and running lights, which doesn't sound like much but this was my first wiring harness cut/mod I've done so I'm glad to see I didn't mess anything up.

Forgot to take pics, but I'll get some this week. I'm gonna have the engine harness plugged in and hooked up pretty soon, along with a starter. Then all I'll need for a test start is the pcm flashed and vacuum/pcv lines run.

Also forgot to mention, the power steering pump lines are a perfect fit, the high pressure side threaded in just fine, had to bend the line but that was it. The low pressure has to be extended but the hose is the right size. Thank you GM and Chrysler!!
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Unread 02-23-2013, 09:12 AM   #8
USMCBuckWild
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1991 YJ Wrangler 
 
Join Date: Apr 2012
Location: Sneads Ferry, NC
Posts: 976
Lookin good
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Unread 03-01-2013, 10:58 PM   #9
myke88
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Location: Texas
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ITS ALIVE!!!! I just fired it up for the first time tonight, there's still a few small things to iron out, but I should be driving it this weekend. I'll get some pics and maybe a video or two soon.
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Unread 03-02-2013, 06:10 AM   #10
linusb
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1994 YJ Wrangler 
 
Join Date: Aug 2009
Location: Lexington,SC
Posts: 1,775
Wow! Impressively done in very short order!
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1994 YJ Wrangler, 4.0, AX15, NP231, 35x12.50x15 BFG KM2s, 4" RC lift, 1" lift Boom Shackles, 1" BL, 4.10 gears, 8.8 LSD in rear and D30 Aussie Locker in front, on-board air conversion, Ramsey RE8000 winch.
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Unread 03-02-2013, 06:45 AM   #11
MI_JEEPER
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1995 YJ Wrangler 
 
Join Date: May 2012
Location: Baroda, Michigan
Posts: 90
Great job!! I'd really like to see a video of it!
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1995 YJ 2.5 cyl. 4 inch Zone Offroad suspension lift on 32x11.5x15 M/T Poison Spyder Customs Hood Louver
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Unread 03-02-2013, 08:34 AM   #12
rinking
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Very impressed!
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Unread 03-02-2013, 10:21 AM   #13
myke88
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Location: Texas
Posts: 20
These are the pics I have from last week after I put the front clip back on. I'm about to go to the shop once they open and hopefully I'll be driving her home today







I'll try to get a video today, it's hard to remember though being so excited to have it running
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Unread 03-02-2013, 02:55 PM   #14
Fuzzy_Wuzzy
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1991 YJ Wrangler 
 
Join Date: Jan 2010
Location: Arizona
Posts: 62
looks real good. I like the idea of the 5.3 with the AX15.
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Unread 03-02-2013, 09:25 PM   #15
snail81
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1988 YJ Wrangler 
 
Join Date: Aug 2011
Location: jackson, ms
Posts: 319
Hey how does that camshaft sound? Im running the comp cams 0.607 0.614 219 227. Im a few weeks out from starting mine for the first time. Really ready to run this thing
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