Will the swap be the same on a 91?
How to swap a Vortec 350 into a 4.3 S10/Sonoma
Doing a little write-up while it is fresh on my mind. This will be specific to 2000-2003 s10 with the 0411 silver computer and 2wd......but a lot of info will cross over into other years.
First, the engine:
You want 1996-2003 350 out of a full-size truck or an express/savanna van. If it is out of a 2500 or larger pickup, you must change the oil pan to 1500. It will not clear the cross-member.
Things you want to do before install to the 350:
Well, make sure it is a good engine. If it has too many miles on it, I will rebuild it just for peace of mind, even if it is a good running motor. You do not want to be pulling this motor again in 20k miles.
AT THE VERY LEAST, change the intake gaskets.
I would also recommend changing the spider injector to the updated version.
Check the distributor gear for wear and the shaft for side-to-side play.
Change the water pump. They are $40 for a brand new one. Again, peace of mind.
PAINT IT. This will make it look much, much better when installed.
Things you will need before you start this:
Motor mounts.
Many different companies make them, including JTR and Current Performance. I went with the JTR.
Headers.
Four options here. Hedman, Sanderson, eBay stainless.....all shorties. Or, if you dare(you will have to move your fuel lines), long tubes. I used the Heddmans. You have to specify bigger flanges with the heddmans. They come with 2".
Radiator.
Most people use the 1986-ish Corvette radiator. This requires cutting on the core support. And requires an adapter for the lower radiator hose. I used the stock 4.3 radiators. I figured if I had to cut, I might as well make my stock one work. That way, I could use the stock tranny cooler and oil cooler. There are other options that do not require cutting. Current Performance makes one that fits in the stock location. But it was 500 bucks. I will post pics of the stock radiator frenched later in this post.
Fan.
I used the stock clutch fan that was on my 350. My 350 came out of 1996 2500HD. You may want to go with an electric fan...I will be later when money allows.
Here are the electric fan options.
Using the stock radiator(16x26 inches), a 2000-ish Dodge Intrepid fan will fit PERFECT. And I will keep it cool. Also only pulls 14-16 amps. Also, a mid 90's Volvo fan will fit perfectly.....but pulls around 40-50 amps. You can also use an early-mid 90's Nissan Quest fan. It fits like stock and pulls only 20 amps.
If you go with the Corvette radiator(16x23 inches), your options change. A ford Taurus fan fits it perfectly. The 1995 and below single fan dual speed ones. You can also mod the Nissan Quest fan and make it fit.
The biggest thing to remember here is 1 or 2 aftermarket fans without a shroud WILL NOT COOL IT WITH AC. You must run a shrouded setup to get maximum airflow over the radiator.
AC condenser.
No matter what, when you move the radiator forward, your stock condenser will not work anymore. Some people modify the hood latch bracket and move it to the front of the core support. Another option is the Current Performance one. It will fit behind the core support.
Computer.
With a 2000 and up, you can use your factory 0411 computer. It will need to be reflashed. Many places do this. I tried Wait4me and got screwed. It did not work. Engine only ran on five cyl. I now have a Current Performance computer, and it runs great.
Companies that do this:
Pcmforless
Current Performance
Black Bear Performance
And many others...
Harness.
From 2000-2003, use your 4.3 harnesses. You only have to add the two injector wires, a one-wire knock sensor, and separate the low side ground for the O2 sensors. I will get into wiring specifics later.
Tranny.
The 4L60E will work fine. I am sure the 5-speed will work fine too. You will have to get different bell housing bolts. The 4.3 are metric, and the 350 are not.
Starter.
The stock 4.3 starters will work fine on either flexplate as long as the 5.7L was from a 1500 truck with 4L60e. My engine was from 2500 with 4L80e, so I could not use the flex plate. Again, the bolts on the 4.3 are metric, and the 350 are not.
OK......next post will concern installation. More to come.
First, the engine:
You want 1996-2003 350 out of a full-size truck or an express/savanna van. If it is out of a 2500 or larger pickup, you must change the oil pan to 1500. It will not clear the cross-member.
Things you want to do before install to the 350:
Well, make sure it is a good engine. If it has too many miles on it, I will rebuild it just for peace of mind, even if it is a good running motor. You do not want to be pulling this motor again in 20k miles.
AT THE VERY LEAST, change the intake gaskets.
I would also recommend changing the spider injector to the updated version.
Check the distributor gear for wear and the shaft for side-to-side play.
Change the water pump. They are $40 for a brand new one. Again, peace of mind.
PAINT IT. This will make it look much, much better when installed.
Things you will need before you start this:
Motor mounts.
Many different companies make them, including JTR and Current Performance. I went with the JTR.
Headers.
Four options here. Hedman, Sanderson, eBay stainless.....all shorties. Or, if you dare(you will have to move your fuel lines), long tubes. I used the Heddmans. You have to specify bigger flanges with the heddmans. They come with 2".
Radiator.
Most people use the 1986-ish Corvette radiator. This requires cutting on the core support. And requires an adapter for the lower radiator hose. I used the stock 4.3 radiators. I figured if I had to cut, I might as well make my stock one work. That way, I could use the stock tranny cooler and oil cooler. There are other options that do not require cutting. Current Performance makes one that fits in the stock location. But it was 500 bucks. I will post pics of the stock radiator frenched later in this post.
Fan.
I used the stock clutch fan that was on my 350. My 350 came out of 1996 2500HD. You may want to go with an electric fan...I will be later when money allows.
Here are the electric fan options.
Using the stock radiator(16x26 inches), a 2000-ish Dodge Intrepid fan will fit PERFECT. And I will keep it cool. Also only pulls 14-16 amps. Also, a mid 90's Volvo fan will fit perfectly.....but pulls around 40-50 amps. You can also use an early-mid 90's Nissan Quest fan. It fits like stock and pulls only 20 amps.
If you go with the Corvette radiator(16x23 inches), your options change. A ford Taurus fan fits it perfectly. The 1995 and below single fan dual speed ones. You can also mod the Nissan Quest fan and make it fit.
The biggest thing to remember here is 1 or 2 aftermarket fans without a shroud WILL NOT COOL IT WITH AC. You must run a shrouded setup to get maximum airflow over the radiator.
AC condenser.
No matter what, when you move the radiator forward, your stock condenser will not work anymore. Some people modify the hood latch bracket and move it to the front of the core support. Another option is the Current Performance one. It will fit behind the core support.
Computer.
With a 2000 and up, you can use your factory 0411 computer. It will need to be reflashed. Many places do this. I tried Wait4me and got screwed. It did not work. Engine only ran on five cyl. I now have a Current Performance computer, and it runs great.
Companies that do this:
Pcmforless
Current Performance
Black Bear Performance
And many others...
Harness.
From 2000-2003, use your 4.3 harnesses. You only have to add the two injector wires, a one-wire knock sensor, and separate the low side ground for the O2 sensors. I will get into wiring specifics later.
Tranny.
The 4L60E will work fine. I am sure the 5-speed will work fine too. You will have to get different bell housing bolts. The 4.3 are metric, and the 350 are not.
Starter.
The stock 4.3 starters will work fine on either flexplate as long as the 5.7L was from a 1500 truck with 4L60e. My engine was from 2500 with 4L80e, so I could not use the flex plate. Again, the bolts on the 4.3 are metric, and the 350 are not.
OK......next post will concern installation. More to come.
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Hello, I am new to the forum and I am considering an engine swap once my engine craps out. I have a 03 Sonoma with the 2.2l and I know that this will be much more involved than say a swap with a V6. This will be a project to keep me out of the house and out of the wife's hair lol. The OP made a very impressive write up for this conversion, so my question is? Since I have the I4 would I need to obtain an ECU, as well as harness, and obvious accessories to fit in the frame? I am pretty sure that I will have to modify the I4 motor mounts which is not a huge issue for me, but if not then that’s icing on the cake. I am thinking about a Chevrolet or GMC 1500 motor as my donor. I know that I have the 4l60e trans and that it will be a direct bolt up, I am not trying to make a track car out of this just something to tool around in and have a little extra oomph... to say pull something if need be. I was considering a GM 10 Bolt, but after tons of reading it sounds like a Explorer 9" is the safe bet option. This is a budget build, but I am not in a massive hurry to have a transformed truck in a few days or even a couple of weeks. I had a ford falcon that was on its last leg and traded a friend for the 03 Sonoma; I got the better deal at the time! But the 2.2l I4 is a gutless turd and I may bump up the conversion sooner than waiting for the motor to blow...
Any advice, recommendations on power plant, Trans, ECU, etc would be greatly appreciated!
Any advice, recommendations on power plant, Trans, ECU, etc would be greatly appreciated!
The Vortec 5.7 will provide both more oomph and be a relatively simple swap. Since it basically uses the same accessories as the 4.3. With 82 to 90 something 2.8 frame mounts and a pair of simple aftermarket engine mounting adapters the SBC and 4L60E will bolt right in. I'd recommend buying them already together. Best to use 98 to 02. 96 and 7 had a less compatible trans. That's the easy part.
Exhaust will be simplest with a pair of swap headers. You'll have to fab the rest. Cooling will usually require a 4.3 radiator support and the easiest is a stock 4.3 rad. It will need to be recessed somewhat into the support to clear a pair of electric fans.
The trickiest part is the wiring. You are lucky in that your 03 already has an 0411 PCM. Just need to build or buy a harness. Run an 02 Express van tune, unless you mod the engine for mo power. If you do that you'll need to get it on a dyno.
A stock 4.3 air intake system is nearly a bolt on, but you'll want to use the 5.7 MAF. It's a hair bigger and will match the tune.
I'd keep the rearend if you stay stock. They hold up pretty well to under 300HP. If you beat on it and blow the rear, then look for one from an Explorer. A lot of S10's on the road with a V8 and stock 7.5. You might try to find one from a Blazer with LSD for cheap.
Final product won't be a dragon wagon, but it will be a lot more fun to drive with 2-1/2 times the power of the Tutu.
Of course there are a 1000 other ways to do any or all of it. It's your truck.
The forum doesn't list every post ever made in the V8 section. It helps to use Search this Forum on the 1st page of the V8 section for things like radiator, wiring, harness, muffler, etc to see some of the newer posts on a subject.
Exhaust will be simplest with a pair of swap headers. You'll have to fab the rest. Cooling will usually require a 4.3 radiator support and the easiest is a stock 4.3 rad. It will need to be recessed somewhat into the support to clear a pair of electric fans.
The trickiest part is the wiring. You are lucky in that your 03 already has an 0411 PCM. Just need to build or buy a harness. Run an 02 Express van tune, unless you mod the engine for mo power. If you do that you'll need to get it on a dyno.
A stock 4.3 air intake system is nearly a bolt on, but you'll want to use the 5.7 MAF. It's a hair bigger and will match the tune.
I'd keep the rearend if you stay stock. They hold up pretty well to under 300HP. If you beat on it and blow the rear, then look for one from an Explorer. A lot of S10's on the road with a V8 and stock 7.5. You might try to find one from a Blazer with LSD for cheap.
Final product won't be a dragon wagon, but it will be a lot more fun to drive with 2-1/2 times the power of the Tutu.
Of course there are a 1000 other ways to do any or all of it. It's your truck.
The forum doesn't list every post ever made in the V8 section. It helps to use Search this Forum on the 1st page of the V8 section for things like radiator, wiring, harness, muffler, etc to see some of the newer posts on a subject.
Thanks for all the information, I'm really excited to see how this build turns out. I'm happy to know that the ECU won't need to be swapped just adjusted for the new vortec 5.7l.
Building the wiring harness will be the most difficult part, but since you were/are an ASE tech you shouldn't have too much trouble. Just time consuming and a brain teaser.
If you search the V8 section I seem to remember a couple threads on building the S10 - Vortec SBC harness. Since most were swapped from 4.3's you still will need to figure out some of it.
Sometimes it's easier and cheaper to swap PCM's than do the re-programming. Unless you have access to a Tech2 and TIS2000
Ideally you can find an 02 Express with a 5.7 and just grab the 0411 PCM. It would be plug and play to your new harness and already programmed. You'd just need to do the 30 minute security re-learn.
If you search the V8 section I seem to remember a couple threads on building the S10 - Vortec SBC harness. Since most were swapped from 4.3's you still will need to figure out some of it.
Sometimes it's easier and cheaper to swap PCM's than do the re-programming. Unless you have access to a Tech2 and TIS2000
Ideally you can find an 02 Express with a 5.7 and just grab the 0411 PCM. It would be plug and play to your new harness and already programmed. You'd just need to do the 30 minute security re-learn.
I was thinking exactly that just swap for an Express ecm and plug and play so to speak
Hi, here's my question I have a 2003 Sonoma w/the 2.2. I have a great 97 5.7 Vortec out of a full size suburban. Can my 2.2 harness and ecm be tweaked to be able to utilize on the 5.7? And is there any significant difference between these two ECM's 12202203 vs 12200411?I haven't checked yet as this is my daily driver right now. But everything I've read says it's the 2203, any ideas outside of pulling up my ECM? Probably not, but shot in the dark.
I've been trolling this conversion in various forms but this page is by far the most informed and we'll versed.
This will be put into action during the winter months as the south is too hot during the summer.
I've been trolling this conversion in various forms but this page is by far the most informed and we'll versed.
This will be put into action during the winter months as the south is too hot during the summer.
Mine isn't the 4.3 mines the 2.2 so is ecm, harness still viable or am I going to have to get a 4.3 harness?The Vortec 5.7 will provide both more oomph and be a relatively simple swap. Since it basically uses the same accessories as the 4.3. With 82 to 90 something 2.8 frame mounts and a pair of simple aftermarket engine mounting adapters the SBC and 4L60E will bolt right in. I'd recommend buying them already together. Best to use 98 to 02. 96 and 7 had a less compatible trans. That's the easy part.
Exhaust will be simplest with a pair of swap headers. You'll have to fab the rest. Cooling will usually require a 4.3 radiator support and the easiest is a stock 4.3 rad. It will need to be recessed somewhat into the support to clear a pair of electric fans.
The trickiest part is the wiring. You are lucky in that your 03 already has an 0411 PCM. Just need to build or buy a harness. Run an 02 Express van tune, unless you mod the engine for mo power. If you do that you'll need to get it on a dyno.
A stock 4.3 air intake system is nearly a bolt on, but you'll want to use the 5.7 MAF. It's a hair bigger and will match the tune.
I'd keep the rearend if you stay stock. They hold up pretty well to under 300HP. If you beat on it and blow the rear, then look for one from an Explorer. A lot of S10's on the road with a V8 and stock 7.5. You might try to find one from a Blazer with LSD for cheap.
Final product won't be a dragon wagon, but it will be a lot more fun to drive with 2-1/2 times the power of the Tutu.
Of course there are a 1000 other ways to do any or all of it. It's your truck.
The forum doesn't list every post ever made in the V8 section. It helps to use Search this Forum on the 1st page of the V8 section for things like radiator, wiring, harness, muffler, etc to see some of the newer posts on a subject.
I have the opportunity to buy a 99 K 2500 for work I was wondering if that would be a direct bolt over to my 99 Sonoma? The K 2500 has a Vortec 5.7 automatic. buy direct pulled over and wondering if the wiring harness would need to be swapped etc etc
I have a 99 sonoma amd at work there is a 99 k2500 with a vortec 5.7L. What can i take out of the donor 2500 to make the swap easier, wiring harness, computer etc ? Will i be able to use the same fuel hook ups and will the 4.3 fuel pump fit the new engine delivery wise pressure and volume ?
You should start your own thread. This one is dead.I have a 99 sonoma amd at work there is a 99 k2500 with a vortec 5.7L. What can i take out of the donor 2500 to make the swap easier, wiring harness, computer etc ? Will i be able to use the same fuel hook ups and will the 4.3 fuel pump fit the new engine delivery wise pressure and volume ?
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