92 Olds LSx Swap

As some of you may or may not know, I picked up a 92 OCC last fall that pretty much went right into winter storage.  The car rides nice and all but after owning almost exclusively LT1 B-bodies (with the exception of a 305 powered olds) this car's 170k L05 leaves much to be desired.  Being an Olds I was more than willing to drive it as is and always though an LS swap would be cool.  
Well, shortly after going away for the winter I came into a junk 2000 Suburban for scrap value.  It had 140k on it and came with a 5.3l.  I yanked the engine with some help of my coworkers and sold off the rest covering the cost of the truck and making a few bucks along the way.  This swap just became a reality   

The donor truck as I got it:


What was left of it:


LS comes home:


Over the course of the winter I had torn the engine apart and inspected everything and was happy to find a very clean engine both inside and out.  I'm pretty sure this thing was rebuilt at some point in it's life, there's now way this thing has 140k on it.  I decided to leave the lower end alone as everything was in such good shape.  Spent my time cleaning and painting parts, and acquiring parts for the swap.

Engine before the tear down, test fit the LS1 intake:


Spaced out the Camaro pump's pulley to match the truck drive.


The truck intake had to go, so I bought a used LS1 intake off a member on LS1tech cheap.  Would like to have done an LS6 intake, but this is a budget build and those go for crazy money.  For the time being the cam will stay stock, but down the road I can upgrade it once I figure out how to choose a cam   .  For the pan I also went with an F-body pan from a 98-02.  The water pump is also from an F-body as well, some say the water neck can be bent on the truck one to fit, but I got this pump cheap.
For motor mounts I'm going with a custom set someone on the SS forum makes, they allow me to use this F-body pan, and the stock trans mount location.  I'll be using an LT1 cross member so I can run duals.
For wiring I'm modifying the harness myself and will be splicing it into an LT1 harness.  That way I can use the underhood fuse box that the LT1 cars got.  The under dash wiring looks to use the same connectors, just have to repin most of them.
Exhaust is still up in the air right now.  I found some 2010 Camaro exhaust manifolds that should clear the frame and cross member, hopegfully they will fit.
For the trans I picked up a low mileage 96 B-body trans.  I bought an adapter to bolt it's TCC up to the LS flywheel.
I plan to keep the AC, found a nice mount kit that uses the old R4 compressor and positions it just like the old L05.
I still have a few small details to work out, some of which I can't work on until the motor is in the car.

And now some pics:





The car:



More to come!

Awesome,cant wait for more!

After you finish your OCC I will be glad to let you do mine and I will even supply the engine!LOL
Seriously thanks for documenting everything you do to make it work as economically as possible.

Economically is the goal here, plus being as cheap as I am helps keep the costs down.

Your driveway picture hardly says you're a cheapskate,just likes the classics.This place makes some great AC compressor relocation brackets for the LS engines,www.kwikperformance.com.

Hmmm. Perhaps I should LS my WB4 that needs an engine.

Nice

Flasheroo wrote:

Your driveway picture hardly says you're a cheapskate,just likes the classics.This place makes some great AC compressor relocation brackets for the LS engines,www.kwikperformance.com.

Considering my fleet is comprised mostly of Craigslist rejects that no one else would buy, I'm either cheap, nuts or love a money pit   
I looked at their brackets, but they look to only work with the Sanden compressors. I'd rather reuse my good R4 unit and keep the AC system intact.

Geterdun for Wagonfest

I used a bracket of of a 4.3 TBI Chevy pickup out of the junkyard to keep my AC intact on my swap. Worked great. Make sure you get one that didn't have a smog pump. There is a writeup on it somewhere on ls1tech.

Very cool! Easy swap, and the wiring is fun!    

halffast wrote:

I used a bracket of of a 4.3 TBI Chevy pickup out of the junkyard to keep my AC intact on my swap. Worked great. Make sure you get one that didn't have a smog pump. There is a writeup on it somewhere on ls1tech.

I've been searching but keep finding ones with the smog pump. I also looked at the one Holly makes, but it ends up costing way too much once you buy all the install kits for it.

check out http://lsbrackets.com/5_1999-13_r4_truck_a_c_compressor_bracket.htm

Also, you can use a 1998 Camaro 3-wire CTS to provide an output for the stock temp gauge. In case you where wondering how to hook that up as well.

MalibuSSwagon wrote:

check out http://lsbrackets.com/5_1999-13_r4_truck_a_c_compressor_bracket.htm

Also, you can use a 1998 Camaro 3-wire CTS to provide an output for the stock temp gauge. In case you where wondering how to hook that up as well.

That's the same bracket I'm going with, he has them on ebay for a little less. And I already bought the 3 wire sensor   

95BRMW wrote:

That's the same bracket I'm going with, he has them on ebay for a little less.  And I already bought the 3 wire sensor   

Nice! The 3-wire sensor works great, I used it for a 94 Camaro 6.0L swap.

Small update, got the engine together and started over the weekend on the engine stand.  Aside from it not idling which I think is a bad IAC, it ran good.  Wiring is for the most part squared away on the engine side, vehicle side is still a mess.  Integrating a 96 Roadie fuse box into this car is proving do be a pain, but will looks clean and factory once it's done.
Video of the engine start:

What part of the Roadmaster side is giving you trouble?

Great progress, looks like a big hurdle getting that running.

Tom

loweredd wrote:

What part of the Roadmaster side is giving you trouble?

I have to repin the connectors under the dash and repurpose a bunch of wires. While the TBI cars and LT1 cars use the same connectors, nothing electrically is the same between the 2. I got it mostly there, just have a few mystery wires to figure out. The FSM describes each connector in the large connector under the dash, but nothing in the small one for the gauges is labeled. I had to go through each diagram in the book for mention of which pin did what. It's very time consuming but will be worth it in the end.

silverfox103 wrote:

Great progress, looks like a big hurdle getting that running.

Tom

It was a huge relief knowing it's a runner.

Not that I'll be doing this type of swap anytime soon, but I hope you have cataloged which wires swap where to make it easy for a future swap

Great work so far, can't wait to see it in person one day.

A little progress; got the wiring on the engine cleaned up and here's what I'm left with. Just have to join it with the harness I pulled out of a Roadmaster.

Coming along good Dave. Spending more time flipping through those FSM pages than actually working on the car?

Gastt wrote:

Coming along good Dave. Spending more time flipping through those FSM pages than actually working on the car?

Sure seemed that way!

Some updates on this project.  I took Friday off from work to start this project and cram it into a 4 day weekend.  Lynol came up from NJ to give me a hand with this (big thanks for that!)  Friday I managed to get the old L05 out of there and began work Saturday.
Saturday we got a late start and got the holes drilled out for the LT1 trans cross member (which ended up being wrong) and got the fuel line plumbed up.  Not much done for that day.  Sunday we got the LS mounted in the car and started work on getting the cross member in place.  Ran into problems with lining it up and eventually got it mounted.  It was difficult getting the bolts in the right spot but Lynol eventually got it mounted in the right spot.  The drive shaft is in and the shift linkage, all lined up well.
Today we started adding all the accessories.  The LS1 intake went in, and then the exhaust manifolds.  That's when all the problems started.  On the Driver's side one bolt snapped off (new grade 10 or something metric bolts), and the passenger side just doesn't fit.  The flange hits the frame, but with some grinding it went in.  It's still to close to the frame for my comfort and I don't think I could get anything bolted up to it with the way it sits.
We moved onto the power steering pump from there.  I had read the TBI lines will work with this so out came the new set.  With a lot of bending they fit very tight, but do fit.
So this is where it's at now:

Accelerator cable from the truck needs to be modded to fit
Wire harness is on the engine, but needs to be soldered to the car harness.  I gotta find a spot to shove the LT1 fuse box (The AC accumulator is in the way of everything)
Exhaust manifolds need to be modded or find ones that fit
Fuel pump has to be swapped (hoping the TBI one makes enough pressure to at least start this thing)
Need a new alternator (140a is too tall to clear hood)
Cooling system has to be constructed, heater core is blocked by #8 coil
Bunch of small things

If anyone wants to try one of these, don't try to cram it into a 4 day weekend.  It's WAY too much work to do all at once.  After working at this for 4 days I was hoping to have at least a running engine, but am ways away from that.  It's pretty discouraging I gotta say.

Old engine out!



Holes for new cross member


Bolted in place

Wow, looking good. I can't believe how clean your new car is on the underside. Best of luck in getting it going. I'm assuming after all this work this one will be a keeper?

Mark 96 Roady wrote:

Wow, looking good. I can't believe how clean your new car is on the underside. Best of luck in getting it going. I'm assuming after all this work this one will be a keeper?

Absolutely    What's funny about this car is for the most part it's very clean, but in some spots it's pretty bad looking. All the seams under the car by the frame where the sheet metal was tacked together is almost rotted! I guess GM didn't protect the edges of the steel when they built it. Also found an old rotted brake line just shoved up in the frame rail. What was also interesting was once I got the old engine out I noticed 2 of the bell housing bolts weren't even screwed in all the way.

Here's where it sits this morning:

Looking good,very inspiring. Did you use prefabb custom engine mounts?

Coming along nicely,mines next!

Sorry to hear this is becoming a pain, but great work and am enjoying the write-up!

That motor sure looks small in there compared to the TBI setup. Guess it's the low-profile valve covers and intake.

Can't wait to see how this all comes out. Good luck!

-Mike

dont get fustrated u got a lot done so far. that was a lofty goal to do all that in a weekend. how is the accessory bracket working out for you?

I'm watching this build very closely as its an idea for what I may finally do when I get a wagon.

Andebe wrote:

Looking good,very inspiring. Did you use prefabb custom engine mounts?

I didn't, I bought these off someone on the SS forum that makes them, his username is Beertestr

81X11 wrote:

Sorry to hear this is becoming a pain, but great work and am enjoying the write-up!

That motor sure looks small in there compared to the TBI setup.   Guess it's the low-profile valve covers and intake.    

Can't wait to see how this all comes out.   Good luck!

-Mike

The block does measure shorter than the old SBC did, it looks kind of out of place in there.

mtrhead79 wrote:

dont get fustrated u got a lot done so far. that was a lofty goal to do all that in a weekend. how is the accessory bracket working out for you?

A lot did get done, now just on to the small stuff   
I picked up a 105A alternator today and with that one the hood closes with a little space to spare. The 145A looked way too big.

I have a couple videos uploading that I'll post tomorrow.

First and second videos are up. First is an overview second is the engine in the car

Nice videos. Gives a very good look of the " minor" problems you run into. Best of luck and get it running...
Pete

It's alive!!!

Its alive,awesome work David!I am curious what are you using as a air filter on the throttle body?

SWEET! That's alot for just over a week. good job!

Flasheroo wrote:

Its alive,awesome work David!I am curious what are you using as a air filter on the throttle body?

Haven't gotten there yet, might stick the cheap ebay "hot air" dual intake I have on there for now.

Sprocket wrote:

SWEET!  That's alot for just over a week.  good job!

It sure was, felt good to hear it run.

Wont be long now,awesome...

This thread is relevant to my interests.

Hmmmm....

congrats dave

I watched your videos yesterday. Very impressive work. Any new progress to report?

Very Nice Dave. Kudos to all the hard work. It looks awesome.

Nice job! mileage should by amazing.

Thanks guys, I'm happy it's gotten as far as it did. Hopefully it'll make it to wagon fest   

Time for a much overdue update. After weeks of ordering and returning stuff the Olds finally drives! I had to modify the AC accessory bracket I bought to clear the coolant tank, but it fits. The company I bought it from makes another bracket they just released that looks to clear everything better though. But for the time being it works
Cooling system is together and filled, had to use a flexible hose from summit and an elbow off an LT1 hose for the lower one, used a stock lower hose from an LT1 for the upper too. The heater lines were formed using those goodyear springs that let you bend hoses.
I ended up buying the water pump spacers and a Camaro pump, the one I had with the bolt on pulley is junk and near impossible to get.

Exhaust is on, I ran stock LT1 on the back for now, and used some flex pipe to mate up the headers to it. One thing I found out is the driver's header dumps perfectly in line with the shift linkage, I had to smash one side of the flex pipe flat to clear it. I'm sure its restricting it but it will work until I can find a shop to do it right.

With all that I finally got to take the car out for a drive, what a great feeling that was! It sounds good and pulls hard. All my gauges work, the climate control works but the F* next to the outside temp keeps flashing, not sure what that means.

I have some issues to tend to, one major one being either a problem with the starter or the alternator. It's always cranked kind of slow and labored, and after my drive today barely turned over at all. I let it sit for a while when I got back and it cranked over like it did before. I'm getting 14v when the alternator is hooked up so I'm leaning towards a failing starter, or maybe the headers are throwing too much heat at it. Another issue is at least my primary fan doesn't come on. The relay clicks but the fan doesn't spin, hopefully just a loose connections somewhere. The next is possibly related to the fan not working, but the AC doesn't work. I charged it, compressor engages but I don't get cold air and the readings on both the high and low side pin on the high side. Hopefully a lack of cooling on the condenser is causing that. Beyond that I gotta put an intake together, no biggie there.

And now a couple pics

The LS picking up it's first meal


The all important badge I made at work

Congrats Dave.....Now post up some new vids

Wow, this got on the road pretty quick! Glad you're enjoying it!

Got to be exciting to drive it and congrats!

Good job Dave, you're going to be a popular guy at WF.

Tom

Nice work! I'm sure you'll have the bugs worked out soon. Hey it's on the road, and that's the big win! Keep the posts coming!

-Mike