2002 S10 Vortec V8 Swap Build.

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2002 S10 Vortec V8 Swap Build.

Postby ApproachMedium » Tue Jul 02, 2013 9:27 pm

So it starts, I finally came thru with buying a 5.7L Vortec V8 to swap in to my crew. The donor vehicle is a 1997 2wd Chevy C1500 pickup. It was in good shape but the frame rotted out and split, and was horribly repaired so its junk. The owner of the vehicle seemed to keep it fairly clean otherwise so it looks like I should have a good and able motor for the swap. Has 125k original miles on it.

For now here is a list of items I have gotten towards the job already besides the motor:

Wire harness from the donor vehicle.

3 inch in and out offset Magnaflow muffler

2.8L Motor mounts and 2.8 to 5.7 adaptors.

Sanderson 4x4 shorty headers.

2 inch Performance Accessories body lift kit.

New oil pan and pickup EDIT: used Canton Racing 7qt pan and reused 4.3L pickup.

New Oil pump

Revised Fuel Injection spider

All new top end gaskets

All new oil pan and pump gaskets

New water pump and timing chain


More to come, if anyone feels they have any suggestions here please give me a shout! I plan to work this thread in such a way where as items are added or moved around the lists I will update the original post to make it easier for anyone in the future to reference this information. Photos of progress etc. will be added in new posts below this one by either me or Dave who will be doing the dirty work for me.
Last edited by ApproachMedium on Sat Aug 10, 2013 9:26 am, edited 3 times in total.
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Re: 2002 S10 Vortec V8 Swap Build.

Postby ApproachMedium » Tue Jul 02, 2013 9:28 pm

Here are the first two items of the photo variety. Please excuse the crappy video quality as it was shot to send via text message. I will take some more photos Sunday when I pick the motor up.

Image

Click for video.
Image
Last edited by ApproachMedium on Wed Jul 03, 2013 7:55 pm, edited 1 time in total.
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Re: 2002 S10 Vortec V8 Swap Build.

Postby mars2878 » Wed Jul 03, 2013 2:39 pm

sounds good so far
keep the pics coming
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Re: 2002 S10 Vortec V8 Swap Build.

Postby ApproachMedium » Sun Jul 07, 2013 10:25 pm

Friday mounts and body lift kit arrived.
Image


Today I ventured back out to Lehighton PA today to pick up the engine. Sat it down in the bed of the truck and it dropped a few inches. No problem for the F150, it hauled it away and hit the highway with no trouble. Of course between getting it and going home a lot more stuff happened. Went to visit a good friend of mine who lives in that same town and spent the afternoon driving around and discussing railroad stuff in his jeep. Later on when we parted ways, I saw a train leaving town I decided to go chase. Well that was fun and dandy.

Image

Until this happened on my way out:
Image
This folks is why you should never ever mess with a phone or other distraction while operating a vehicle. I was only going 5-10 mph here. I had sent my friend the same photo of the train passing while i was stopped of course. Then proceeded to exit the location along the tracks up a rarely traveled dirt/gravel road. The two seconds I took my eyes off the road to see why the phone buzzed the truck pulled to the left quick and went off. Since its only 2wd it pretty much was stuck. The tow truck wouldnt have at it, but got a chain and hooked it to my buddys Jeep Wrangler and yanked it out. 350 in the bed and all. Goes to show them little straight six wranglers can pull 3x their weight! I had the frame rail buried in the dirt and the one wheel ready to slide off the embankment and roll the whole truck down on to the tracks. I am glad it worked out and I am safe but ill tell you thats something I will NEVER do again!

Anyhow, here are the motor pictures!

Image

Image

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Re: 2002 S10 Vortec V8 Swap Build.

Postby ApproachMedium » Sat Jul 20, 2013 3:37 pm

Parts have arrived!

Image

Oil pan, pump, Sanderson headers, 4x4 stock oil pan, oil pickup and rear main seal.

Heres the top end taken apart ready to install some of the new goodies.

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Re: 2002 S10 Vortec V8 Swap Build.

Postby ApproachMedium » Wed Jul 24, 2013 9:12 pm

All the parts were dropped off at the shop today, and the front end is already starting to come apart to get the old engine out. So much excitement. The only thing that I see so far that may be a snag is the oil pan. The one I bought is a 4qt supposedly for a 4x4 fullsize pickup, but it doesnt look like it will fit in my S10. Hopefully someone can help me out with a pan that fits in the 4x4 S10 so I am not too delayed.
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Re: 2002 S10 Vortec V8 Swap Build.

Postby paintballrocker » Wed Jul 24, 2013 9:59 pm

i read on s10forum about people using hummer h3 pans to clear the diff n crossmembr. Im looking foward to this, keep posting the info!! I have been researching and plan on doing the 350 vortec swap once i get back to the states in a few months
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Re: 2002 S10 Vortec V8 Swap Build.

Postby ApproachMedium » Wed Jul 24, 2013 11:08 pm

Nice. Where will you be when you return to the states? Can you link me to something about this H3 pan? I dont understand how that would work since they dont even use a 350 SBC in the H3?
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Re: 2002 S10 Vortec V8 Swap Build.

Postby paintballrocker » Thu Jul 25, 2013 2:55 am

sorry for the bad info, the h3 pan is for ls engines.

but i know you can use the stock 350 pan if you have a body lift because you can make the engien sit a bit higher.

If not there are a few 4x4 s10 v8 swap oil pans made to clear the diff n xmemeber.

also here is a link for info on moding your own 350 pan or 4.3 pan

http://www.jagsthatrun.com/Pages/Parts_ ... Parts.html
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Re: 2002 S10 Vortec V8 Swap Build.

Postby paintballrocker » Thu Jul 25, 2013 2:59 am

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Re: 2002 S10 Vortec V8 Swap Build.

Postby ApproachMedium » Thu Jul 25, 2013 3:55 am

The JTR pan is not available anymore for some reason, I know Dave looked in to it and told me that, which is why we were just going to modify a stock 4x4 pan which seems to be no different than the 2wd one lol

Summit Racing also has that same pan for a lot less.
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Re: 2002 S10 Vortec V8 Swap Build.

Postby ApproachMedium » Mon Jul 29, 2013 4:58 pm

Bought the canton pan and got it to the shop, dave really likes it, and I really like it too. Gonna just stick that on there and forget about the whole 7 quarts thing. Oil changes will be expensive, but maybe running synthetic I can go further between changes.

Anyhow, here are some photos from today. Got the core support ready to come out, just have to remove the oil filter from the bottom of it and its good to go. Body lift parts have been installed on the bed section, and all body mount bolts etc have been removed from the cab section so its just resting on the frame at the moment.

Image

Image
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Re: 2002 S10 Vortec V8 Swap Build.

Postby Horsehammerr » Tue Jul 30, 2013 5:54 am

ApproachMedium wrote:So it starts, I finally came thru with buying a 5.7L Vortec V8 to swap in to my crew. The donor vehicle is a 1997 2wd Chevy C1500 pickup. It was in good shape but the frame rotted out and split, and was horribly repaired so its junk. The owner of the vehicle seemed to keep it fairly clean otherwise so it looks like I should have a good and able motor for the swap. Has 125k original miles on it.

For now here is a list of items I have gotten towards the job already besides the motor:

Wire harness from the donor vehicle.

3 inch in and out offset Magnaflow muffler

2.8L Motor mounts and 2.8 to 5.7 adaptors.

Sanderson 4x4 shorty headers.

2 inch Performance Accessories body lift kit.

New oil pan and pickup

New Oil pump

Revised Fuel Injection spider

All new top end gaskets

All new oil pan and pump gaskets


More to come, if anyone feels they have any suggestions here please give me a shout! I plan to work this thread in such a way where as items are added or moved around the lists I will update the original post to make it easier for anyone in the future to reference this information. Photos of progress etc. will be added in new posts below this one by either me or Dave who will be doing the dirty work for me.

I look forward to studying your post all the way through. It's always great when a member details a mod. of this extent. I'd like to suggest laying a tape measure in where you can to show dimensions as clearly as possible. I've been in dream mode for some time about this mod. for the simple understanding of better gas miles. :rock:
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Re: 2002 S10 Vortec V8 Swap Build.

Postby ApproachMedium » Tue Jul 30, 2013 7:07 am

Thanks what exactly would you like measured? I am not going to be the one installing the new motor
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Re: 2002 S10 Vortec V8 Swap Build.

Postby Horsehammerr » Tue Jul 30, 2013 12:44 pm

ApproachMedium wrote:Thanks what exactly would you like measured? I am not going to be the one installing the new motor

Front , Back, Sides of engine clearance to radiator , firewall , wheel well liners , and do you really need body lift , or will a 2" or 4" popup hood work just as well ?
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Re: 2002 S10 Vortec V8 Swap Build.

Postby ApproachMedium » Tue Jul 30, 2013 1:13 pm

Well from what I understand the body lift makes maintance much easier. Like spark plugs wires sensors etc. Without a body lift the AC will not clear the hood on a 4x4. So you would then need a bigger hood. Most of this info is out there actually on v8s10.org. NOT s10v8.com/org that site is halfway useless.
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Re: 2002 S10 Vortec V8 Swap Build.

Postby ApproachMedium » Wed Jul 31, 2013 5:26 pm

Well the core support is finally out, all the wires etc that I could possibly get to without it being on a lift have been disconnected from the body. Now to pull the thing out.

Soon.

Image
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Re: 2002 S10 Vortec V8 Swap Build.

Postby ApproachMedium » Mon Aug 05, 2013 5:52 pm

Well Dave got the engine out today! heres some photos of the progress. The body lift parts are in place so now the cab is where it should be for when the motor goes in. Now it looks like a rollerskate.

Image

Image

Cab lifted.
Image

Here she comes.
Image

Image

Gone!
Image

Out.
Image

I now decided I am going to call this truck the LOLERSKATE Lets see who remembers what those are lol.
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Re: 2002 S10 Vortec V8 Swap Build.

Postby ApproachMedium » Wed Aug 07, 2013 11:22 pm

Tuesday the frame was powerwashed and cleaned very well by Dave, I then came over and proceeded to apply the POR 15 to it. The results were incredible. I wish I took a photo before i started though. The frame cleaned up very well and once all of the undercoat was off the frame it looked like it did the day it left the factory. You could still see the burn marks clearly in the welds like they were just done. Anyhow, heres the photos.

Image

In the backround you can see the 5.7 on the floor while Dave worked on putting in the gaskets, fuel injector, new oil pump and pan. It was then determined that the water pump and timing chain should also get replaced before putting the motor in.
Image

Image

I am amazed at how well this stuff goes on. I will say, do not waste your time with any of the cheaper stuff. This stuff paints right on over rust, and very well. All you need to do is power wash any grease and grime off first. I tried to apply it to places where it had not been cleaned yet and did not work so well. It definitely does NOT come off. I got it on my skin and I am now going to wear it for the next few days. I have tried many many things, old wives tails you name it nothing takes this stuff off. It is activated by moisture and basically once you get your skin wet, or its a hot sweaty day it dries right away. Best thing to do is wear a long sleeve shirt with no holes in it and some kitchen gloves. I used regular latex gloves and it came right thru.

When it dries though, it has a very nice glossy black finish. However they recommend that any part you paint that may have contact with UV light be topcoated, because UV light will break it down and destroy it.
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Re: 2002 S10 Vortec V8 Swap Build.

Postby ApproachMedium » Fri Aug 09, 2013 6:42 pm

Well the engine is in! Dave got it in with plenty of clearance from the front axle. The Canton racing pan seems to work excellent with clearance. The motor however is mounted as far forward as it can go and as far up as it can go on the mounts. We used 2.8 mounts on the frame with 2.8-v8 adaptor brackets from advanced adapters. The stock V8 oil filter is currently placed on the motor, however Dave is not sure if the oil filter will be able to be serviced once the headers are installed. More to come on that one. For now heres a few photos showing the clearances.

Image

Image

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Re: 2002 S10 Vortec V8 Swap Build.

Postby _STUCKY » Fri Aug 09, 2013 9:36 pm

Can you swap over the oil filter relocation junk from the 4.3?
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Re: 2002 S10 Vortec V8 Swap Build.

Postby ApproachMedium » Fri Aug 09, 2013 10:55 pm

No unfortunately that "junk" is exactly that lol, it doesn't fit the oil filter hole on the 5.7L. I'm gonna have to buy one from Canton if the headers end up being in the way. Right now it looks like the exhaust might block it requiring the front drive shaft to be removed to get the filter out.

Id rather buy the canton product anyhow, it will probably last longer without pissing oil all over my engine bay which is clean now.
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Re: 2002 S10 Vortec V8 Swap Build.

Postby HenryJ » Sat Aug 10, 2013 6:36 am

Good thread 8) you are gathering up some good information.

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Re: 2002 S10 Vortec V8 Swap Build.

Postby ApproachMedium » Sat Aug 10, 2013 9:24 am

HenryJ wrote:Good thread 8) you are gathering up some good information.


Thanks! I am trying to include anything that became an issue for me that I could not find the answers for. Believe it or not its extremely rare for someone to do a V8 swap on a stock 4x4 S10. I am also cross posting this thread in v8s10.org.
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Re: 2002 S10 Vortec V8 Swap Build.

Postby paintballrocker » Sun Aug 11, 2013 6:44 pm

nice thing about when i do my swap is......no IFS crap in the way!! haha
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Re: 2002 S10 Vortec V8 Swap Build.

Postby ApproachMedium » Sun Aug 11, 2013 10:25 pm

paintballrocker wrote:nice thing about when i do my swap is......no IFS crap in the way!! haha



Nope, but unless you lift the oil filter might still be blocked by the pumpkin and drive shaft like mine is.
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Re: 2002 S10 Vortec V8 Swap Build.

Postby ApproachMedium » Tue Aug 20, 2013 1:20 pm

Progress. I have been getting my ass kicked down at engineer school for the past week and a half. I have not had time to go back up to the shop. Dave finished up putting everything together for me and just waiting on the computer. For the moment the mechanical fan blades have been cut shorter so that the fan will fit the truck properly Not sure yet if that will be sufficent for cooling the engine or not. Burn in testing when the computer arrives will have to see what happens. All accessories have been retained including the AC!

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Re: 2002 S10 Vortec V8 Swap Build.

Postby ApproachMedium » Fri Aug 23, 2013 5:49 pm

Well the computer finally came and it fired right up! Progress is so sweet! I cant wait to drive it. It sounded real good with just the open headers on it. I would have put up a video but with the open headers and not all the coolant in yet I could not have it on long. At least another week or so before its street ready. Some more work to be done on the minor stuff, plugging things back in and building the exhaust.

At least my hood and fenders finally line up for once!
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Re: 2002 S10 Vortec V8 Swap Build.

Postby _STUCKY » Fri Aug 23, 2013 5:57 pm

I expect to see a video by Monday at 5 pm :lol:
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Re: 2002 S10 Vortec V8 Swap Build.

Postby ApproachMedium » Fri Aug 23, 2013 6:14 pm

Hahah Well Dave is going to be busy the rest of the weekend and I am going to see some vintage war birds tomorrow before I head back to delaware. Video may just have to wait till the exhaust is done. I am psyched about this I cant wait to post a video of it dont worry. :)
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Re: 2002 S10 Vortec V8 Swap Build.

Postby paintballrocker » Tue Aug 27, 2013 1:57 pm

any worries about the little 2.8 mounts holding up to the 350? Does the steering shaft interfere with the headers with the body lift, i know the website says it might? and what was the mod to the fuel spider, i know the stocks ones dont offer much performance.

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Re: 2002 S10 Vortec V8 Swap Build.

Postby ApproachMedium » Tue Aug 27, 2013 3:27 pm

Zero worries on the 2.8 mounts, Dave tells me has been very confident in them on any 4.3L to V8 swap he has done in the past with many many other lowered 2wd trucks. Often they have no issue holding up a 6.0LS motor so they should be fine with my 350. The 2.8 mounts are a much safer, stronger design than the 4.3l mounts. I have read about others doing it this way too.

As for the headers there does not seem to be an issue with the steering shaft so far. I will let dave chime in on that one as far as what he had to do but as i was told the 2nd gen trucks are not an issue because the shaft is different and something else. Also when you order the headers from Sanderson you specifiy that you have a 4x4 with 2 inch body lift and they know what to do. Most other header companies will not work with you in such situation which is why it was suggested to me to buy nothing but the Sandersons.

I did not modifiy the fuel spider other than replaced the factory one with the recalled upgraded model that Delphi made for these trucks. Its the same issue the 4.3L engine had with sticking injectors or something. It does not gain any performance as far as HP etc goes. I mean as it is headers, intake exhaust i am looking at pretty much 300HP out of the box here. For me, thats more than enough power. I will have to see what HP gains adding the hypertech may add.
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Re: 2002 S10 Vortec V8 Swap Build.

Postby AVTekk » Wed Aug 28, 2013 5:53 am

There were no issues with the steering shaft at all. The 2.8 mounts are much stronger than the 4.3 mounts, which is why I always try to use them, but they are not a direct bolt-on to the frame. One hole in the frame needs to be tapped, and the holes in the mounts themselves need to be elongated, not a big deal.
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Re: 2002 S10 Vortec V8 Swap Build.

Postby _STUCKY » Wed Aug 28, 2013 8:51 am

Out of curiosity, what do you use to elongated the holes? I was trying to make a oval out of a circle the other day, and it wasn't working out too well haha.

I am glad to see such quick progress. Looks good!
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Re: 2002 S10 Vortec V8 Swap Build.

Postby ApproachMedium » Wed Aug 28, 2013 5:59 pm

Super awesome Y pipe is all done! 2.5 to 3 inch and all 409 stainless. I cant wait to drive this thing. Whenever I get a picture texted to me like this I get real excited.

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Re: 2002 S10 Vortec V8 Swap Build.

Postby Jongo88 » Wed Aug 28, 2013 10:51 pm

NICE!!!!!
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Re: 2002 S10 Vortec V8 Swap Build.

Postby AVTekk » Thu Aug 29, 2013 8:00 am

_STUCKY wrote:Out of curiosity, what do you use to elongated the holes? I was trying to make a oval out of a circle the other day, and it wasn't working out too well haha.


I use a die grinder with carbine bits. If it needs more precision, then I'll put it on the Bridgeport ;)
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Re: 2002 S10 Vortec V8 Swap Build.

Postby paintballrocker » Mon Sep 02, 2013 6:43 pm

i might of missed it by skimming quick, but are you re-pinning the stock harness or splicing in a donor v8 harness?
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Re: 2002 S10 Vortec V8 Swap Build.

Postby ApproachMedium » Mon Sep 02, 2013 8:01 pm

Ill let Dave answer that one as to what exactly he did. I took the stock V8 harness from the donor truck because we needed it for certain plugs like the fuel injector.
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Re: 2002 S10 Vortec V8 Swap Build.

Postby ApproachMedium » Tue Sep 03, 2013 6:25 pm

Latest update from the shop: Intrepid fans are in and working good, the stock fan kept hitting the shroud. Needs crank relearn and cat-back piping installed. Dave says i can drive it friday when i go home. I am like a little kid right now. :thumb:
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Re: 2002 S10 Vortec V8 Swap Build.

Postby AVTekk » Tue Sep 03, 2013 8:10 pm

paintballrocker wrote:i might of missed it by skimming quick, but are you re-pinning the stock harness or splicing in a donor v8 harness?


I repinned the ECM connectors with the wires from the V8 injector plug. The only 2 wires that are spliced are the pink wires providing power to the 7 and 8 injectors. Knock sensor is repinned and efan control was added and pinned.
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Re: 2002 S10 Vortec V8 Swap Build.

Postby ApproachMedium » Sat Sep 07, 2013 8:47 am

Here it is the moment you all been waiting for. Video! Theres a few oh shoot moments in there so please excuse the bad language. :)

http://youtu.be/L2Tk9ZoPbek
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Re: 2002 S10 Vortec V8 Swap Build.

Postby AVTekk » Sat Sep 07, 2013 1:20 pm

Ya she goes good
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Re: 2002 S10 Vortec V8 Swap Build.

Postby HenryJ » Sat Sep 07, 2013 1:37 pm

Nice. I had that dream a long time ago. Very nice to see it done for real.

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Re: 2002 S10 Vortec V8 Swap Build.

Postby paintballrocker » Sat Sep 07, 2013 3:45 pm

glad to hear it man! Makes me jealous I have to wait a few more months till i move to do it haha
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Re: 2002 S10 Vortec V8 Swap Build.

Postby ApproachMedium » Sun Sep 08, 2013 12:05 am

Thanks! I can't believe I made this dream a reality myself! I couldn't have done it without the help from Dave at Afterhours who's done most of the major work for me and suggested all of the right stuff for me to get
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Re: 2002 S10 Vortec V8 Swap Build.

Postby _STUCKY » Mon Sep 09, 2013 7:45 am

:thumb:
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Re: 2002 S10 Vortec V8 Swap Build.

Postby ApproachMedium » Fri Oct 11, 2013 10:22 pm

Progress report! Its been a while but its running now, and the exhaust is finally installed. I will get to take it for a week so I can move back from Delaware to NJ in two weeks. Hope to bring the GoPro with me for some in cab video on the highway.

http://www.youtube.com/watch?v=ZEUnKwIcwUM

http://www.youtube.com/watch?v=Cx9ootYfsAo
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Re: 2002 S10 Vortec V8 Swap Build.

Postby F9K9 » Sat Oct 12, 2013 9:23 am

Sweet! You've got some good looking sliders too!!
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Re: 2002 S10 Vortec V8 Swap Build.

Postby ApproachMedium » Sat Oct 12, 2013 9:32 am

Thanks. How do you think it looks with the body lift? I wasnt so sure about it at first. I really liked the look of them snug up against the rocker panels. Its starting to grow on me though. They certainly help with the handling though!
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Re: 2002 S10 Vortec V8 Swap Build.

Postby F9K9 » Sat Oct 12, 2013 10:08 am

ApproachMedium wrote:Thanks. How do you think it looks with the body lift?.......................................
Can't really comment until I see a side view with the final "look" but, when you compare the amount of work to modify them, versus "as is", I believe that they will look very good to me! I recently talked with Chris, the builder of those sliders, and he was quite proud of them. He's moved on from the S-10 platform and is running an ultra4 car now. That's the unlimited rigs that race in the King of the Hammers, in Johnson Valley, CA and other locations.

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Re: 2002 S10 Vortec V8 Swap Build.

Postby ApproachMedium » Sat Oct 12, 2013 11:04 am

Cool! Did you tell him how far these things have traveled? lol

Anyhow here's one side shot of the truck.
Image
Image

And the other side.
Image


In other news I also ordered some 30 inch tires for it today. And _STUCKY sold me his ZR5 wheels which are being shipped today also. Now all I need is a new windshield and as far as driveable goes, it will be complete.
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Re: 2002 S10 Vortec V8 Swap Build.

Postby _STUCKY » Tue Oct 15, 2013 6:23 am

There is an auto dimming mirror in the box too :D

I have been seriously considering going to a solid front axle so no need to keep the wheels. I've got my axles, and if/when I put them under an s10, I will be using 8 lug wheels :rock:
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Re: 2002 S10 Vortec V8 Swap Build.

Postby F9K9 » Wed Oct 16, 2013 5:46 pm

ApproachMedium wrote:Cool! Did you tell him how far these things have traveled? lol.......................
Actually I did mention the miles that they have traveled! Now you just have to hammer on them harder than I have. By the way, Chris, I and everyone else, put too much emphasis on the powder coating. If, a product has an option to come "naked", and you plan to use the product for it's intended purpose..........settle on rattle can finishes. They're easy to touch up and PC is a PITA to work with. My PC is a PITA to clean up on the CC. Might be nice for the "mall crawler" crowd but, not for wheeling.
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Re: 2002 S10 Vortec V8 Swap Build.

Postby ApproachMedium » Wed Oct 16, 2013 6:07 pm

Yea the most these things are going to do is defend against idiots in parking lots, shopping carts at the grocery store and random objects that may be along railroad rights of way/abandoned ROWs lol. I live in NJ, which means I am within 20 mins driving to 4 major malls, and I cant stand them id rather stay home. The powder coating has already shown some issues with small metal flashing's that got on it during modification. I should be able to polish them out. Worse comes to worse I can just plasti dip the whole damn thing, so when it gets messed up just peel it off and start over again!

Cant wait to get home friday so I can mount my new wheels and tires on this thing and start driving it. My friends are already trying to wager how many tanks of gas I may burn up in the first week. Im wagering how long the rear axle will hold up till I blow it apart and need to bring it back to Dave for a ZR2 swap.
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Re: 2002 S10 Vortec V8 Swap Build.

Postby _STUCKY » Wed Oct 16, 2013 7:14 pm

bring it back to Dave for a ZR2 swap.


Do it in the driveway.
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Re: 2002 S10 Vortec V8 Swap Build.

Postby ApproachMedium » Wed Oct 16, 2013 7:40 pm

Not at my house. Dont have the tools, dont even have a jack! its only a 15 minute drive to the shop anyhow. Plus I dont even know what the hell I am doing with leaf springs and an axle lol.
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Re: 2002 S10 Vortec V8 Swap Build.

Postby ApproachMedium » Fri Oct 18, 2013 5:51 pm

Got the truck back home tonight. First installed the 30 inch tires and the ZR5 wheels. It looks a thousand times better now.

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Re: 2002 S10 Vortec V8 Swap Build.

Postby ApproachMedium » Sat Oct 19, 2013 10:17 am

Some more as completed photos.

Image
Image
Image

Why the ramps you ask? Well the rear already started making noises. Checked fluid levels and they were OK. Getting ZR2 rear hopefully this week.
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Re: 2002 S10 Vortec V8 Swap Build.

Postby F9K9 » Sat Oct 19, 2013 11:40 am

Looking good and a nice residence, as well!!! :thumb:
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Re: 2002 S10 Vortec V8 Swap Build.

Postby AVTekk » Sat Oct 19, 2013 2:42 pm

Lol burning tires out of the shop didn't help any, who knows what other mischief you got into last night...
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Re: 2002 S10 Vortec V8 Swap Build.

Postby ApproachMedium » Sat Oct 19, 2013 3:07 pm

Lol yea I was bad. When I went to quick chek today for lunch I saw skidmarks and it took me a few minutes to figure out they were mine.
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Re: 2002 S10 Vortec V8 Swap Build.

Postby ApproachMedium » Sun Oct 20, 2013 8:16 pm

Logged about 250 miles on it this weekend so far. Just arrived back in Wilmington Delaware for the final week of my training. Judging by the trip computer vs fuel gauge I get about the same MPG highway with this as I did with the V6 so far. Around town/being silly with it the calculation on my first tank came to 13. something, almost 14mpg which is about what the v6 was doing after I modified the intake and was wailing on it for a few weeks. However with the V6 programmed my speedo was off by 3mph at 70mph. The V8 its dead on, checked from 45-55-70-75 and its on the money with my phones GPS.

I fiddled with the diff on saturday, took the fill nut off and checked for fluid, i added a little in there but it didnt take much. After that the squeaking went away from the rear and its been fine ever since. Still gonna do the ZR2 rear though. Hopefully everything is fine this week.
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Re: 2002 S10 Vortec V8 Swap Build.

Postby _STUCKY » Sun Oct 20, 2013 10:35 pm

The wheels look great on there. Much better than collecting dust in the shed. They will look even better after you get the wider zr2 axle swapped in. Be careful doing burnouts though, you will be replacing a transmission sooner than later.
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Re: 2002 S10 Vortec V8 Swap Build.

Postby ApproachMedium » Tue Nov 05, 2013 4:31 pm

Well I think thats it, its pretty much done. For now. Most of the bugs have been worked out except for the shift indicator. The truck gets about the same MPG so far with the V8 as it did with the V6, so for gaining over 100 more HP, being able to pass inspection, and actually being able to maybe tow things now it was pretty worth it. As we all know no car project is ever really "done" so expect to see some updates on the thread about any add ons etc related to the swap. For now I leave you with some fancy fall photos and one of the finished product under the hood.


Image
Image
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Re: 2002 S10 Vortec V8 Swap Build.

Postby _STUCKY » Wed Nov 06, 2013 8:13 am

Looks great! :thumb:
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Re: 2002 S10 Vortec V8 Swap Build.

Postby ApproachMedium » Wed Mar 05, 2014 7:32 pm

Welp, looks like it may finally be getting a ZR-2 rear axle! Possibly getting one from MA out of a ZR-2 blazer. I wanted the sway bar too for the better handling (I dont really wheel as some of you may know) Should know by the end of the day tomorrow if ill be getting it or not.
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Re: 2002 S10 Vortec V8 Swap Build.

Postby F9K9 » Tue Mar 11, 2014 6:42 pm

:thumb: Woot, Woot!!!!!!!
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Re: 2002 S10 Vortec V8 Swap Build.

Postby ApproachMedium » Wed Mar 12, 2014 3:44 am

As long as the junkie pulls it Thursday, picking it up Saturday.
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Re: 2002 S10 Vortec V8 Swap Build.

Postby ApproachMedium » Wed Sep 03, 2014 10:09 pm

In case anyone is interested the truck is just about a year in on the V8 swap, and is still going strong. I had it at Afterhours fab for some suspension work most of the summer. Had the ZR-2 rear axle installed, ZR-2 torson bars up front, bilstein shocks and energy suspension bushings up front. So far drives and rides like it really should. Handling is good but its still not my little hot hatch, but thats fine. I can still scare people on the cloverleafs for the interstates. :)

Dont have any pics yet of it with the front done. I'll take some this weekend maybe if the PCM gets back from Current Performance. Having my gauge cluster properly set up in the PCM so my shift indicator works.
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Re: 2002 S10 Vortec V8 Swap Build.

Postby HenryJ » Thu Sep 04, 2014 5:02 am

Awesome build. :clap:

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Re: 2002 S10 Vortec V8 Swap Build.

Postby ApproachMedium » Thu Mar 19, 2015 12:57 am

Well after a long and hard winter, the truck finally died two weeks ago. It was running good, then the RPM needle started to randomly flutter. The snow melted a bit and we had some rain, and BIG puddles. It began to misfire badly that same day after some spashing. Replaced the rotor and cap, ran better for a few days and then would not spark at all. No RPM input to the computer and reported P0335 Crankshaft Position Sensor A Circuit Malfunction. Replaced the sensor, still crank no spark. I gave up and towed it back to AVTekk who did the V8 swap. The ICM was bad, and so were the wires to the ICM and the Coil. He replaced those and now it runs great again!

Just turned 279k. Its been offically 20k since the V8 swap and other than this failure, its been quite flawless. I have had countless hours of enjoyment with this truck since then and hope to have many in the future. I will have to post some pics when it hits 280k. Only another 20k more and it will be the first vehicle I have owned to hit 300k on the clock! And probably the first S10 crew to do the same.
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Re: 2002 S10 Vortec V8 Swap Build.

Postby ApproachMedium » Tue Mar 31, 2015 3:48 pm

I guess I spoke too soon. Having misfire issues now. Most likely a bad fuel pressure regulator. Doing alot of research and trying to source a MerCruiser Vortec intake. 29lb injectors. Possible 50HP gains. The project never ends.
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Re: 2002 S10 Vortec V8 Swap Build.

Postby ApproachMedium » Mon Jul 20, 2015 5:05 pm

Have had it sitting at my friends shop for almost 6 months now with a bad misfire issue. The truck runs fine in "open loop" but not in closed loop. Stinks of fuel at the tail pipe, wont idle right and when you take it on the road drives like crap. The pass side exhaust manifold is hot as hell and driver side cold (same temp as engine). Plugs looked just a little wet but not soaked. The computer showed an extreme fuel trim of -31 on bank 1 and bank 2 normal. Checked the compression and that was good. good fuel pressure. Good vacuum.

Turns out a mechanic buddy said unplug the upstream O2 sensors and see what happens. That fixed the problem. Truck runs and drives perfect now but with the SES light on. I frankly could care less. Do you know how tough it is to go 6 months without a pickup truck? LOL Anyhow, gonna troubleshoot the sensors/wiring/computer another day as its been way too hot out here. Either my driver side sensor is bad, the wire is bad or i have a computer problem. What else is interesting is there were no codes at all being set or pending for the o2 sensor. Then again the trucks been sitting with a dead battery for a while now.
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Re: 2002 S10 Vortec V8 Swap Build.

Postby LoneWolf04 » Tue Feb 28, 2017 12:22 am

Thinking about making the plunge into the V8 world. I think the biggest question I had I got the answer from your pics on here. My '02 doesn't have an EGR valve and couldn't find if people were just having it deleted out of the ECM when it's flashed or not. I am assuming this is what you had done since I see you have the EGR still attached to your engine but it doesn't appear to be hooked up with a harness. I really did not want to deal with running wires and hooking one up. Was thinking of just buying a blockoff plate.
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