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Project Pissed Wife Phase II 5.3L Vortec and 4L60e install!

212K views 1K replies 66 participants last post by  august4936 
#1 ·
This is the second phase of my original build ( in my sig) that I finished in 2010. Everything has been great with the rig except for one thing. The power level of the 4.0 has always left me wanting more. Which brings us up to today.

So I stoped by the junkyard to talk with a buddy of mine that runs the sales department. He made me bring this home:


and this:

and these:


It is a 2001 5.3L with a 4L60e and some Tj front drive shafts to elimanate the front disco crap.

I spent a few hours tearing a bunch of crap off the engine along witht the wiring harness and ECU.



The wiring harness is getting sent of tomorrow to get torn apart and a bunch of unneeded emissions sensors deleted. The ECU will also get programed.

Today I ordered an Advance Adapters kit to adapt the 231J to the 4l60e and to add a VSS sensor between the tranny and transfer case.

More to come In the next few weeks. I plan to cover everything with the install.
 
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#159 ·
Uuuummmmm No! They hit the motor mounts. I'm not pulling the motor to clearence the mounts. So I sold the C6 manifolds and bought some 2012 Camero SS manifolds. They dump straight down at cylinder 4. Plenty O room.
 
#163 ·
I purchased them on Ebay but I don't have them yet. They just shipped out yesterday from AZ.

You can see them installed in the Dookey Reverenge build on Pirate in the hardcore section.
 
#165 ·
Lookin good!:thumbsup:

I got word this morning that my wiring harness is inbound. Ill send you that stuff early next week.

I was out of town all weekend. Took the family to a cabin in the Smokey Mtns near Pigeon Forge. Needed the rest.

I did some work yesterday after getting back. Got the trans mount from AA installed. It was easy,and looks like it set the trans and tcase at the same height as the ax15/231. So that works out well. This allowed me to get the belly pan in and finalize the trans shifter and to get the trans cooler line run. So over all it was a productive day.

My radiator showed up today, really nice item. And my fuel lines should be here Tuesday. Exhaust manifolds are inbound and should be here by weeks end. So I feel like I am getting close, exhaust is the only thing I haven't nailed down yet but everything else needs to be in so that I can route that. :thumbsup:

I don't have any pics right now that I can post up at work. I get that on here shortly.
 
#168 ·
I an running a GM stock line that I will cut at the end of the block and then run rubber trans cooler lines. The stockers are only $20 a piece.

GM Part #'s
15773661
15809053

I picked these up at my local dealer. Cheaper and cleaner route than running my own lines.
 
#174 ·
:thumbsup:any ideas what your going to do about a fan? im stuck between an electric or using a mechanical fan. im leaning much more towards mechanical as it's so simple...it's there and works. just build a cheap shroud. hmmm... i totally thought that was a sigma...it looks like my range pistol..i carry a smaller keltec pf-9 ... under 13 oz with full mag.... in it's soft case it's like the size of my friends smart phones...but no one knows :)

i didn't see the steam port on the rad you mentioned... u sure it has one? im going to use an inline upper hose adapter for mine i think..
 
#175 ·
BionicOnion said:
:thumbsup:any ideas what your going to do about a fan? im stuck between an electric or using a mechanical fan. im leaning much more towards mechanical as it's so simple...it's there and works. just build a cheap shroud. hmmm... i totally thought that was a sigma...it looks like my range pistol..i carry a smaller keltec pf-9 ... under 13 oz with full mag.... in it's soft case it's like the size of my friends smart phones...but no one knows :)

i didn't see the steam port on the rad you mentioned... u sure it has one? im going to use an inline upper hose adapter for mine i think..
Mechanical. I have never had trouble with a mechanical fan. KISS.

The 4.0 shroud fits the GM mechanical fan.

Yea it has one if you look at my pics there is a green piece of tape over it.
 
#177 ·
USMCBuckWild said:
I miss my Glocks.......

Cool idea with the filter and the conduit clamp!

I miss my Glocks......
Man I probably have yours. 3 G22s, 2 G23s and 1 G27

I love them and couldn't ever sell one. In fact I have a strict rule of never selling a gun.
 
#180 ·
Glock 19 Gen 2
19 Gen 3
21sf RTF2 Gen 3
29 Gen 3
30 Gen 3

The electric fan is reliable and easier in my opinion. Yes a Mechanical fan can be less headaches to attach and run, but making a decent shroud can be a pain. Plus, if the homemade shroud fails and makes contact with the fan, you can kiss the radiator goodbye and you are dead in the water. I would run the electric, possibly in front of the radiator and then if you really wanted too a mechanical without a shroud as a backup. I learned the hard way about the shroud thing not too long ago.

Just my $.02.
 
#179 ·
Meh. I don't think it would matter. I have seen guys block it off, tap it into a heater hose, tap it into a radiator hose and even tap it into the water pump. As long as it goes in the system it should be fine. The whole system is pressurized so it should work anywhere.
 
#181 ·
USMCBuckWild said:
Glock 19 Gen 2
19 Gen 3
21sf RTF2 Gen 3
29 Gen 3
30 Gen 3

The electric fan is reliable and easier in my opinion. Yes a Mechanical fan can be less headaches to attach and run, but making a decent shroud can be a pain. Plus, if the homemade shroud fails and makes contact with the fan, you can kiss the radiator goodbye and you are dead in the water. I would run the electric, possibly in front of the radiator and then if you really wanted too a mechanical without a shroud as a backup. I learned the hard way about the shroud thing not too long ago.

Just my $.02.
The 4.0 shroud will work with the GM mech fan. No need to make one. Only to make some brackets for my rad and it will be good to go.

I had my harness guy leave a wire for fan control if I go elec later.
 
#182 ·
Unfinished up my fuel system last night. I pressure tested it and have. I leaks with good pressure at the rail.

I went with AN from the rail to the frame just over the trans skid to hard lines. Put the new filter, Fram G15 $4.99, and filter mount, conduit holder $2.50, in the stock location. Ran some fuel injected hose on back to the pump.

Over all it was a pain dealing with the hard lines. If I did it over again I would go all AN.







Apparently my sexy man legs got in a few of those pics. They are terrible pics but it was 2am and I was exhausted!
 
#797 ·
Unfinished up my fuel system last night. I pressure tested it and have. I leaks with good pressure at the rail.

I went with AN from the rail to the frame just over the trans skid to hard lines. Put the new filter, Fram G15 $4.99, and filter mount, conduit holder $2.50, in the stock location. Ran some fuel injected hose on back to the pump.

Over all it was a pain dealing with the hard lines. If I did it over again I would go all AN.







Do the fuel rail fittings you used have metal clips in them or how do they connect to the fuel rail? The russell ones I got have plastic clips in them.
 
#183 ·
Hey got a question. Why did you go with different exhaust manifolds? Did it have anything to do with performance or was it a fit issue? Curious if my truck manifolds will work. I know they will clear my homemade motor mounts but I am thinking about an aftermarket camshaft. Thanks
 
#184 ·
snail81 said:
Hey got a question. Why did you go with different exhaust manifolds? Did it have anything to do with performance or was it a fit issue? Curious if my truck manifolds will work. I know they will clear my homemade motor mounts but I am thinking about an aftermarket camshaft. Thanks
The trucks will work. But my understanding is that it requires cutting the body and making a sharp 90 degree turn with the tubing to clear the frame.

The Corvette manifolds hit the Novak motor mounts like Novak said they would.

Honestly I sold my truck manifolds on EBay for what I bought the corvette manifolds for. Then I sold the Corvette manifolds for what I paid for the Camero manifolds.
 
#186 ·
HARLEYX2 said:
Have you tried the camero manifolds yet? Any pics?
I got them on Thursday. I left for a vacation as soon as I walked in the door. I was able to hold one up and I think it is going to work out great

I'll put up some pics on Tuesday when I get back.
 
#188 ·
Very little. Went on a house boat from last Thursday thru Monday. Everyone including the kids got some kind of stomach thing. So I have been down for a few days.

I got my ECU and harness today! I have some pics of the trans lines, manifolds and a few other things that I need to get up. I plan on working
 
#190 ·
So after much delay. I have been on vacation, sick and building handicapped ramps and a shower in my buddies garage so he can wash his dirty ***.

So I made a Gin and tonic and got to work tonight.

The 2012 Camero SS manifolds arrived last week. They work much better than the Corvette manifolds. They dump straight down in the back .


They clear the mounts by a mile, clear the fire wall and fit between the rails with Novak mounts.

I went with stock 2001 1500 Silverado HD with a cooler trans cooler lines. I have already posted the part numbers. If not let me know and I will repost them. I had to bend them a tad at the bellhousing to clear the exhaust, but not much. I also wondered down to the machine shop today and made a mount to replace the flimsy stock part. I could have used the stock by part by flipping it backwards but I was bored at work. It just a block of alum that has 2 3/8" holes and a clamp.


Pass side, manifold clearance and trans lines.


GM drawing of trans lines.


They dump out right at the end of the block where I plan to cut them and splice in some trans hose thats connected to my rad trans cooler.


I also installed my harness tonight, just need to make the connections to the Jeep and wire in the fuse block. Wayne's harness is awesomeness. Labeled and ready to go. Not to mention it is about 10 lbs lighter than stock. Took an hour to install on motor. I should be able to mount the ECM in the stock Jeep location.
 
#192 ·
HARLEYX2 said:
Do the Camaro manifolds have o2 sensor holes like the corvette ones?
No they do not.

But I was able to find someone else that is also doing a 5.3 swap and used the Camero manifolds. They built the exhaust and then realized that his custom 4 link was not going to work with the Camero manifolds. So bought his exhaust for $150 shipped. SCORE! He has done all the work for me and has welded in the O2 bungs.
 
#193 ·
Why J? said:
No they do not.

But I was able to find someone else that is also doing a 5.3 swap and used the Camero manifolds. They built the exhaust and then realized that his custom 4 link was not going to work with the Camero manifolds. So bought his exhaust for $150 shipped. SCORE! He has done all the work for me and has welded in the O2 bungs.
How many exhausts you buyin? Haha lookin good though.
 
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