Will the swap be the same on a 91?
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.
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 ?