Engine/Trans Swap LQ4 - 4L80e into bone stock 1971 Chevy C20 camper special
 

My stock 350 motor is burning its fair share of oil these days...
So I bought a wrecked 2006 Chevy van 3500 for the motor, transmission and related electrical parts.

I read a few of the swaps here and found some great info, figured I would add the knowledge.

I've owned the truck for at least 10 years. It's bone stock but has power steering, power brakes, front disc brakes, and air conditioning.
I like the look of the truck in stock form and two tone paint. Currently Orchid and White.

My plan is to clean up the engine bay, fix a couple minor rust issues and do the engine and trans swap.

I will need to figure out where to host images, so I can post pictures. Any good places?

Re: Engine/Trans Swap LQ4 - 4L80e into bone stock 1971 Chevy C20 camper special
 

Tried adding photos but they were huge. I will resize and repost.

I'm removing the all front sheet metal for access and minor rust repair.

Re: Engine/Trans Swap LQ4 - 4L80e into bone stock 1971 Chevy C20 camper special
 

Photobucket is what I use and works well, plus free. I'm currently in the swap process myself and I see your in Sac. I'm in Rocklin, you're more than welcome to come by and take a look and I can share what I've learned.

Re: Engine/Trans Swap LQ4 - 4L80e into bone stock 1971 Chevy C20 camper special
 

Resizing and using the site's capability is better. Seems when folks use photobucket, you eventually see a cat and photo not available, or something like that. Quite annoying... The site's attachment function works fine. Sometimes big pics need to be shrunk a bit. Interested in your swap, looking fwd to pics and progress.

Re: Engine/Trans Swap LQ4 - 4L80e into bone stock 1971 Chevy C20 camper special
 

ok lets see how these work.

https://lh3.googleusercontent.com/1F...E=w800-h453-no

https://lh3.googleusercontent.com/rs...s=w800-h453-no

https://lh3.googleusercontent.com/FV...v=w800-h452-no

https://lh3.googleusercontent.com/oe...O=w800-h452-no

Re: Engine/Trans Swap LQ4 - 4L80e into bone stock 1971 Chevy C20 camper special
 

It looks like its pretty easy to move the motor mounts back to fit the LQ9. I'm hoping this will make room for the A/C compressor.

https://lh3.googleusercontent.com/rD...5=w800-h453-no

Re: Engine/Trans Swap LQ4 - 4L80e into bone stock 1971 Chevy C20 camper special
 

With it being so cold outside when I get home, clean up and paint can wait.
Decided to figure out how the engine sits between the frame.
Started hooking up a chain to the motor when I noticed both rear exhaust bolts are broken. Goggle confirmed common LSx issue.

They look to be flush with the head too

https://goo.gl/photos/mfQ6RDR5YQ6GFJBU7

Re: Engine/Trans Swap LQ4 - 4L80e into bone stock 1971 Chevy C20 camper special
 

try this photo.

https://lh3.googleusercontent.com/jg...=w1294-h862-no

Re: Engine/Trans Swap LQ4 - 4L80e into bone stock 1971 Chevy C20 camper special
 

Notice how Chevy gave the exhaust manifold a larger hole lateral, but none in the vertical axis.
Reading else where, people are drilling out the manifold one drill bit size bigger to allow movement. Another option is studs, but I don't think studs will work well in my application as the manifolds are going to be close to the frame as it is. i.e cant take the manifolds off without lifting the motor.

Re: Engine/Trans Swap LQ4 - 4L80e into bone stock 1971 Chevy C20 camper special
 

I might take you up on this when I get a bit farther.

Been busy with holiday stuff, time to get back at it. I removed the exhaust manifold and noticed that just the rear ear hole is smaller then the rest of the holes. Once I get the broken bolt out of the head, I will drill the exhaust manifold out to match the other holes. I assume GM made the rear hole smaller for assembly reasons.

Re: Engine/Trans Swap LQ4 - 4L80e into bone stock 1971 Chevy C20 camper special
 

It's been over a year, and finally getting back on this project.

I removed the broken exhaust bolt and bought some Camaro exhaust manifolds.
Started on the wiring harness, got everything removed that was not part of the PCM.

https://lh3.googleusercontent.com/AO...=w1319-h989-no
https://lh3.googleusercontent.com/M6...=w1319-h989-no

https://lh3.googleusercontent.com/LE...=w1319-h989-no

https://lh3.googleusercontent.com/W6...=w1319-h989-no

https://lh3.googleusercontent.com/Ow...=w1319-h989-no

https://lh3.googleusercontent.com/CH...z=w742-h989-no

https://lh3.googleusercontent.com/Ql...M=w882-h989-no

https://lh3.googleusercontent.com/r6...H=w773-h989-no

Re: Engine/Trans Swap LQ4 - 4L80e into bone stock 1971 Chevy C20 camper special
 

I got lucky and the 3 bolts that were broken in my 6.0l came out with an ez out. See my thread, my project is very similar to yours. You may be slightly ahead of me tho.

Re: Engine/Trans Swap LQ4 - 4L80e into bone stock 1971 Chevy C20 camper special
 

What bolts or studs are you going to use on exhaust manifold?

I'm comfortable with the harness mod, LT1Swap.com posted some great videos
click here

Re: Engine/Trans Swap LQ4 - 4L80e into bone stock 1971 Chevy C20 camper special
 

Dropped of the exhaust manifolds at the powder coat place.
Ceramic coat should help with under the hood temps.

Re: Engine/Trans Swap LQ4 - 4L80e into bone stock 1971 Chevy C20 camper special
 

I have an 06 van harness and they are way different then a truck harness. Much longer, and different connectors.
So I started at the PCM, removing the wires from the blue connector. You need to unwrap all the way to the plastic harness holder that bolts to the engine. Similar to the truck several pink wires make a U turn and go to a large electrical connector. Its a long way from the PCM to the block with pink wires, maybe 12'

https://photos.app.goo.gl/A91prptr1dsCqtML8

https://photos.app.goo.gl/7WHCAK2cnXvEQJ3C9

Re: Engine/Trans Swap LQ4 - 4L80e into bone stock 1971 Chevy C20 camper special
 

Finally back working on the truck.
Ordered a ton of parts.

Got the firewall painted and the tranny tunnel primed

http://67-72chevytrucks.com/vboard/p...ictureid=25799

Re: Engine/Trans Swap LQ4 - 4L80e into bone stock 1971 Chevy C20 camper special
 

Got the fire wall insulated

http://67-72chevytrucks.com/vboard/p...ictureid=25800

Re: Engine/Trans Swap LQ4 - 4L80e into bone stock 1971 Chevy C20 camper special
 

That’s going to be a nice ride with that drivetrain.
What are you using for the insulation?

Re: Engine/Trans Swap LQ4 - 4L80e into bone stock 1971 Chevy C20 camper special
 

I bought Design Engineering floor & tunnel shield on summit racing. Its pretty tough stuff as you need tin snips to cut it. 14 sq feet. still have a bit left over.

With everything out it was easy to install.
I will add more after the engine is in.
I looked at my brothers new Chevy pickup and it has something similar, the OEM stuff looks a bit thicker on insulation. This stuff has a thicker aluminum shield.
I've used this on a different truck and it made a huge difference on inside cab temps during the summer.

Re: Engine/Trans Swap LQ4 - 4L80e into bone stock 1971 Chevy C20 camper special
 

Ok, the truck is getting some love after like 5 years.

Pic of the painted fire wall.
https://lh3.googleusercontent.com/pw...-gm?authuser=0

The engine and trans are mounted and I started on the radiator and fan shroud install.
Not many seem to use the stock engine driven fan. I pick up a fan shroud on ebay for a newer C10 and it fits the larger 19.5 " fan. Working on hoses

Since parts are always slowing me down, I switch gears a lot and work on other items.
I got the hydro boost brakes installed and working.
Got the exhaust started, need to order more stuff.
Switch over to working on fuel, got some old gas lines out that went to the aux tanks. Looking for adapters to take every to -6 AN and use Aeroquip PTFE Racing, Braided Stainless Steel. Pick up an inline pump bracket from a 1986 Ford Bronco at the junk yard. They hold the pump and keeps it quite and its easy to convert to -6 AN.

https://lh3.googleusercontent.com/pw...-gm?authuser=0

https://lh3.googleusercontent.com/pw...-gm?authuser=0

Re: Engine/Trans Swap LQ4 - 4L80e into bone stock 1971 Chevy C20 camper special
 

Ok this is turning into the longest build thread.

• Engine moved back as far as possible, with dirty dingo sliders.
As luck would have it the stock trans cross member lined up with factor holes
in the frame.
• Put all the sheet metal back on.
• Finished up the power steering and hydro boost brakes.
• Radiator is installed, still need to figure out a fan shroud.
• Replaced the fuel tank and added a return line.
• Fuel lines are done
• Driveline is installed

Working on the exhaust.
Ordered a harness from BP automotive. (Nice looking harness and staff was very helpful in answering all my questions)
Right now trying to decide on a good spot for the ECM.
Need to mount the DBW gas pedal.

I installed a lift, which is making my life way easier.

https://lh3.googleusercontent.com/pw...-gm?authuser=0

Re: Engine/Trans Swap LQ4 - 4L80e into bone stock 1971 Chevy C20 camper special
 

Hey, these things take time! Nice work, Rg

Re: Engine/Trans Swap LQ4 - 4L80e into bone stock 1971 Chevy C20 camper special
 

-
Glad to see you are back on it.

As far as the DBW pedal There is a guy on the board that sells a bracket to mount the DBW pedal to the firewall but I can't remember his board name. I made my own.

https://67-72chevytrucks.com/vboard/...829820&page=10

Starting with post #235

Pictures of it mounted in post #238
.

Re: Engine/Trans Swap LQ4 - 4L80e into bone stock 1971 Chevy C20 camper special
 

Thanks, but that bracket uses a different pedal then the one I took from the 2006 chevy van. So I will need to fab up what ever it takes.

Re: Engine/Trans Swap LQ4 - 4L80e into bone stock 1971 Chevy C20 camper special
 

That is the cheapest way if you can pull it off. It shouldn't be too hard. Keep us posted on what you come up with for it.

Re: Engine/Trans Swap LQ4 - 4L80e into bone stock 1971 Chevy C20 camper special
 

I made a cardboard template for the gas pedal and then made it out of some 12ga metal. But found the pedal stroke from the van was too long. Went to the JY and got a 2004 pedal from a truck. I tried using the existing bottom hole in the bracket, but then the pedal was a bit sideways. So I welded those holes closed with a copper backing plate and re drilled the holes, using the stock bracket as a template.
Next is to cut off most of the truck arm and use the stock pedal arm, by drilling a 3/8 hole and welding that where it should be. I spent a lot of time trying to figure stuff out that I push that to the back burner for now.

https://lh3.googleusercontent.com/pw...-gm?authuser=0

https://lh3.googleusercontent.com/pw...-gm?authuser=0

Moved on to the harness. I bought a BP automotive harness, the length was about 4" short to mount under the seat. I just wrapped tape 4" farther up the harness and that worked.
Drilled the 2 1/8 hole for the grommet and used a hand held Bur tool from Lowes to remove any sharp edges. I ran the wires along the transmission and up the back of the engine. I will make a holder to bolt to the back of the trans to hold wires closer to the floor. I was able to get 1/2 of the connectors plugged in. :bann::bann:
My brother said to attached them to the floor pan, I said why all the wires are attached to the engine :D
https://lh3.googleusercontent.com/pw...-gm?authuser=0

That is about it for at least a week as I'm heading to the Mojave Desert to watch some racing in the desert. King of the Hammers.

Re: Engine/Trans Swap LQ4 - 4L80e into bone stock 1971 Chevy C20 camper special
 

I took the original gas pedal bracket off and used it as a template to drill holes in the 2004 truck bracket.

I then cut off part of the 04 peddle assembly. Then drilled a 3/8 hole in it
I then cut my stock peddle arm and inserted into the 04 peddle and it's very close to where the stock pedal was located.


Original position.
https://lh3.googleusercontent.com/pw...-gm?authuser=0


Peddle in place.
https://lh3.googleusercontent.com/pw...-gm?authuser=0

The peddle is in the stock location.
https://photos.app.goo.gl/gjd3A4KBLmcib5127

Sitting about 2" below the brake peddle
https://lh3.googleusercontent.com/pw...-gm?authuser=0

Re: Engine/Trans Swap LQ4 - 4L80e into bone stock 1971 Chevy C20 camper special
 

Got a to do list and knocking things off. Made a bracket to mount on the back of the transmission which will hold the wire harness up.

I cut out a cardboard template and then looking at it I remembered I had some gussets from another project that would fit nicely, added some flat bar and bent the end over 90 degrees and drilled holes to add a ty-rap.

https://lh3.googleusercontent.com/pw...-gm?authuser=0

Re: Engine/Trans Swap LQ4 - 4L80e into bone stock 1971 Chevy C20 camper special
 

I'm still waiting on parts, so I'm just finding other stuff that needs to be done.
I decided I wanted to use the transmission neutral safety switch. That is not controlled by the ECM with my harness.
I read some other post and they added a Relay to the transmission neutral safety switch to control the starter solenoid.

I went to the JY and cut a harness connector off a 2005 Tahoe today.
used ls1nova71 diagram to wire it up.

https://lh3.googleusercontent.com/pw...-gm?authuser=0

https://lh3.googleusercontent.com/pw...-gm?authuser=0

Re: Engine/Trans Swap LQ4 - 4L80e into bone stock 1971 Chevy C20 camper special
 

Got the Vintage air A/C compressor installed, fan belt and upper radiator hose.

Had to do a cut and turn on the upper hose to make it work
.
https://lh3.googleusercontent.com/pw...-gm?authuser=0

https://lh3.googleusercontent.com/pw...-gm?authuser=0

https://lh3.googleusercontent.com/pw...-gm?authuser=0

Re: Engine/Trans Swap LQ4 - 4L80e into bone stock 1971 Chevy C20 camper special
 

This past week felt like one step forward and five steps back. Every modification I made seemed to create new problems. ��

The A/C install ended up interfering with the radiator hose, the new hose fix the issue with the belt, but now occupied the same space I needed to route the air filter ducting to the passenger side.

Today, I decided to switch things up. Originally, I had planned to mount the air filter on the driver’s side, but that setup required electric fans—and I’m not ready to go that route just yet. I still want to run the stock LQ4 fan.

Then I came across a post by ls1nova71, where he modified the battery box and moved it to the driver’s side. That sparked an idea.

So, I pulled the battery and box today, then grabbed some parts off my Suburban to mock up the ducting for the air filter. It actually worked! After that, I headed to the junkyard to grab the parts I needed and fabbed up a bracket to secure the air filter box in place.

Tomorrow will be working on the battery box move to the drivers side, and adding a second bracket for the air filter box.
I felt better after solving some issues.

Re: Engine/Trans Swap LQ4 - 4L80e into bone stock 1971 Chevy C20 camper special
 

These trucks had an option for an Auxiliary battery. The second battery box is available on the forum sometimes. I made my own.

Re: Engine/Trans Swap LQ4 - 4L80e into bone stock 1971 Chevy C20 camper special
 

Air box and battery relocation done.
I almost bought a battery box from an offroad shop. But decide to cut up my brand new one. :mm:

The move was a bit more then I thought it would be.
Had to install some Rivet Nuts, had to buy yet another tool because there is not room for the bigger install tool. $6.99 at Napa

Got the shifter linkage extended, and the new brake light switch to control the torque converter installed too.


Next will be to clean up the wiring with the battery move.
While at the junk yard, I grabbed some relays for future electrical changes too.

https://lh3.googleusercontent.com/pw...-gm?authuser=0

https://lh3.googleusercontent.com/pw...-gm?authuser=0

https://lh3.googleusercontent.com/pw...-gm?authuser=0

https://lh3.googleusercontent.com/pw...-gm?authuser=0

https://lh3.googleusercontent.com/pw...-gm?authuser=0

Re: Engine/Trans Swap LQ4 - 4L80e into bone stock 1971 Chevy C20 camper special
 

I'm working on a similar swap. I may have missed it but what did you use for the radiator and hydra boost? I bought an Escalade for a donor and would like to use the hydra boost from that if I can make it fit.

Re: Engine/Trans Swap LQ4 - 4L80e into bone stock 1971 Chevy C20 camper special
 

Hydra boost was from the donor. I modified the rod as the ends are different. I just cut off the truck side brake rod and added it to the hydra boost rod. My friend has a lathe so he tapered one piece and drilled a hole in the other piece, then I welded them together.
I also remove the large 4 sided nut and added my homemade adapter plate.
It has a master cylinder off of an early year GM diesel truck circa 1985 that came with Hydro boost. Painted with brake spray paint from Eastwood.
That is a PSC reservoir, worth every penny and comes with a filter too.
I ran the Aeroquip PTFE hoses as they are rated at 3,000 psi.

Edit: You need to measure the stock rod length. You also need to know how far it sticks out into the engine bay as the "new" rod needs to be that exact length but with using hydro boost unit. The mounting plate will affect this length/ Hope that make sense.

The radiator is a Cold Case LS replacement radiator.
If I had to do it again I would just use the donor radiator and modify the support. They cut the bottom mounting plate off the donor and add it to the stock support. Then its all stock hoses too.

https://lh3.googleusercontent.com/pw...-gm?authuser=0

https://lh3.googleusercontent.com/pw...-gm?authuser=0

https://lh3.googleusercontent.com/pw...-gm?authuser=0

Re: Engine/Trans Swap LQ4 - 4L80e into bone stock 1971 Chevy C20 camper special
 

I finished up the battery wiring, routing the wire along the oil pan to the driver’s side.
I used new wire from battery to starter, while the donor fusible link connects the battery to a terminal block from a circa 1990's chevy pickup. From the terminal block it feeds into the cab through a 50-amp circuit breaker. I added new relays to manage the purple starter wire and installed an ignition fuse block to support additional ignition power connections. I also used the donor ground cable from the battery to the engine and to the frame and from the battery to the fender too.

Before startup, I removed the spark plugs and added about a teaspoon of Marvel Mystery Oil to each cylinder. After letting it sit for a few hours, I turned the engine over by hand to get things moving.

Once everything was double-checked, I started the engine and let it run for about a minute. After checking the fluid levels, I ran it a few more times to verify everything was functioning properly.

However, the transmission seems to be slipping. The dipstick shows no fluid, and I'm starting to wonder if I order the correct one.
The donor was a van and those dip sticks are like 6 feet long. I added 2 qt's and it still no show. Was hoping to drive it to the lift for an transmission oil change.

Re: Engine/Trans Swap LQ4 - 4L80e into bone stock 1971 Chevy C20 camper special
 

[QUOTE=binford;9395338]Hydra boost was from the donor. I modified the rod as the ends are different. I just cut off the truck side brake rod and added it to the hydra boost rod. My friend has a lathe so he tapered one piece and drilled a hole in the other piece, then I welded them together.
I also remove the large 4 sided nut and added my homemade adapter plate.
It has a master cylinder off of an early year GM diesel truck circa 1985 that came with Hydro boost. Painted with brake spray paint from Eastwood.
That is a PSC reservoir, worth every penny and comes with a filter too.
I ran the Aeroquip PTFE hoses as they are rated at 3,000 psi.

Edit: You need to measure the stock rod length. You also need to know how far it sticks out into the engine bay as the "new" rod needs to be that exact length but with using hydro boost unit. The mounting plate will affect this length/ Hope that make sense.

The radiator is a Cold Case LS replacement radiator.
If I had to do it again I would just use the donor radiator and modify the support. They cut the bottom mounting plate off the donor and add it to the stock support. Then its all stock hoses too.

Nice, I was thinking I could use the Escalade brake booster. I have a 13-48 lathe, so the push rod is no problem. Thanks.

Re: Engine/Trans Swap LQ4 - 4L80e into bone stock 1971 Chevy C20 camper special
 

I decided to make a radiator fan shroud.

I had considered using a 2005 Suburban/Truck radiator support, radiator, and fan setup so I could run the stock hoses and overflow tank. Link here However, I realized it would require a fair amount of work with minimal benefit. The Suburban radiator and fan assembly is wider than the opening in a stock radiator support. I could have used a radiator from a 4.8 engine, which is the same width as the stock radiator, but the 2005 fan assembly would not mount to it directly.

After discussing it with a friend, he said use what you have and build one. I found an old sheet of .080 aluminum and decided to make the shroud in two halves so it can be removed without taking the radiator out.

It has been years since I welded aluminum, so it was some helmet time.
My brother now wants one as well. Next time, I will use 5052 marine aluminum instead of 6061, since it is easier to bend.

https://lh3.googleusercontent.com/pw...-gm?authuser=0

https://lh3.googleusercontent.com/pw...-gm?authuser=0

Re: Engine/Trans Swap LQ4 - 4L80e into bone stock 1971 Chevy C20 camper special
 

Bought a temp sensor for analog gauges and hook it up. I removed the plug from the passenger side head and screwed it in. I belive its made by Holley as it had a Holley sticker on the package.
Classic Instruments SN12MM Temperature Sensor - 12mm LS


Works great, except I need to add a resister to it as the gauge reads a bit high. To be expected as an LS engine runs hotter around 92c or 195 degrees.


https://lh3.googleusercontent.com/pw...-gm?authuser=0