04 Colorado V8 swap (Lot's of pics!)

Discussion in 'Photo & Video Gallery' started by TRPLXL2, Jan 18, 2013.

  1. TRPLXL2

    TRPLXL2 New Member

    I have been gone for a while I know, but this thread will show you what I have been doing for the last year. Ralph (Seffieldvillage) is also a member on here, this is his truck but I am posting it for him. He did all the mechanical and paint and body work, and I did all the electrical/troubleshooting of this build. Mostly It will be pictures with a little bit of info, If you have any questions feel free to ask me or Ralph. Here is what we started with:

    2004 Chevy Colorado 3.5 liter, 4l60e, 2wd 77,xxx miles
    Donor engine- 2000 Camaro LS1 5.7 stock (aluminum block and heads)

    Drilled all the spot welds on core support
    removed and painted side winders and misc. parts (single stage ppg)
    LS1 120,xxx miles (missing ecm, harness, oil pan, coils, accessorie drive)

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    I should say that the truck is completed as of a few months ago, but I is getting a complete overhaul which I will explain later. More demolition pictures, Ralph is 65 years old and I'm 30 years old lol. Broad spectrum ha ha!!

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  2. silverhobey

    silverhobey New Member

    I have barely checked out the pics, but let me tell you....awesome pics
    for those of us in any learning phase(s)....thanks a bunch...Brian
  3. Enkeiavalanche

    Enkeiavalanche Moderator

    Very nicee.. Waiting for more....
  4. TRPLXL2

    TRPLXL2 New Member

    We took the front fenders off to avoid damaging them, we were going to remove the inner fenders but they were welded to the frame so we didn't want to mess with that.

    The fusebox comes apart in sections, a 7mm bolt holds each section in place. We removed C2 which is the engine block, C1 is body, and C3 is miscellaneous other stuff.

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    Pulled the drive shaft out, which was relatively easy. The 5 cylinder didn't have very good pulling points, so we undid some bolts on the block and used the child safety restraint brackets to pick the engine out.

    The ratchet wrench with a ton of extensions and an 18mm socket, Is what we had to use to get to the bellhousing bolts on the back of the transmission.

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    We had to remove the header, because the engine would not clear with that on there. We ended up selling the engine, dual stainless exhaust and k&n intake for $1,000. This gave us more money to move forward, the motor never skipped a beat and served us well for the 77,000 miles it was in service.

    ​The 4l60e was kept, and later you will see what we did with that.

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  5. TRPLXL2

    TRPLXL2 New Member

    Once we got the engine out, we realized how dirty and nasty the engine bay was. We spent several days cleaning, and then Ralph painted the frame gloss black and clear coated it. He also sanded the whole engine bay down, and repainted and clear coated it to match the truck. We also removed that nasty insulation mat on the firewall, It was filthy and all ripped up anyways.

    The big blob of wiring behind the fuse box, Is all of the aftermarket wiring in this truck. Lights, lights, and more lights.
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  6. Enkeiavalanche

    Enkeiavalanche Moderator

    Holly :gasp: Spiderweb Batman!!!! Look'in good....
  7. TRPLXL2

    TRPLXL2 New Member

    Sanded and painted the fuel rail, sanded the intake manifold and prepped it for paint. We used price tag dots to cover the valley bolt holes, sanded and painted coil pack mounts.

    We bought the coils and brackets off of ebay for $105.00, engine harness & ecm from 2000 Camaro wth 40,000 miles for $400.00. While the injectors were out I cleaned them with brake cleaner CRC non chlorinated, and got an injector rebuild kit which included new upper and lower orings.

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    Firewall all degreased, cleaned, sanded, primed, painted, and clear coated. Valve covers painted to match truck. first time they cracked pretty bad so they had to be stripped and redone. LS1 intake was a real challenge to paint and clear, many many hours of sanding lol!!

    ​Aftermarket wiring pulled under the truck, and out of the engine bay. Later this will be explained.
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  8. silverhobey

    silverhobey New Member

    the results are looking awesome....thanks for the updates and pics.
  9. TRPLXL2

    TRPLXL2 New Member

    We reused the Colorado 4l60e, but it had to have several modifications to make it bolt up to the LS1. As you can see the Colorado bellhousing has a flat top, with two bolts on each corner. The LS1 style housing is called a 12 o' clock bellhousing as it has a single hole right in the middle at the top. We bought the LS1 bellhousing on ebay for $50.00 shipped, also the front pump and input shaft had to be changed as It has a different splined shaft. We also had to buy an LS1 style stall converter, we opted for a 2800 stall for good daily drive ability.

    Engine pics will be explained later, some how these finished pics got in here first lol!!

    ​Thanks guys for the compliments!! I figured posting these pics, would give people an idea of what is really involved in an LS swap. It was our first LS swap, and I learned a TON about them.

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    The sanded cover in the second picture is the engine cover from ZOOPS, It is designed to hide all the wiring and coil packs giving it a clean look. The ecm mounting bracket is out of a 98-04' S10, got it at pull a part for $1.37.

    The engine mounts are from Current Performance, they are made for bolt in installation of LS engine into Colorado/canyon platform.

    Finally got the engine mounted in the truck for a test fit, very tight clearance but it fits perfectly.

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  10. Sierraowner5.3

    Sierraowner5.3 New Member

    man i would LOVE to drive that thing!

  11. Enkeiavalanche

    Enkeiavalanche Moderator

    That is looking sweet... GREAT write up....:great:
  12. aloxdaddy99

    aloxdaddy99 New Member

    Really NICE!! I like the detail. Not many people would clean the engine bay with the motor out much less paint it. How is the hood clearance?
  13. TRPLXL2

    TRPLXL2 New Member

    Alex It is a blast to drive, especially when you stop at a stop light and it's thumpin away and everyone's trying to figure out what's making all the rucus lol!

    Enkei- You will get a real treat when you get to see the truck in person, I am trying to get Ralph to let me do the burnout contest but I don't think he trusts me ha ha!! A friend of mine gave us a set of Hoosier drag radials for the rear, I just have to buy rims for them.

    Alox- It shocks me how many guys don't clean the engine bay while the motor is out. Ralph is a perfectionist with the paint and cleaning of the paint. The underside of the truck looks just like the engine bay, It is spotless. As far as under the hood clearance, there is at least a foot of clearance from the top of the intake to the underside of the hood.

    Here are some clearance pics for ya!! The heater hoses literally lay right on top of the passenger side valve cover, drivers side coils are real close to the brake booster. The worst clearance issue is the back of the engine, you can't even get your finger in between the intake and the firewall.

    Pics from underneath show our first problem of the swap, we had a 5" suspension lift already. Well the bellhousing sat to high on the firewall, there was no access to the top 3 bolts of the transmission. We ended up doing a 3" body lift to get the transmission bolted up, pics of the engine mounts too!!
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  14. Sierraowner5.3

    Sierraowner5.3 New Member

    wow,maybe while you have it all apart, you should make it a 4x4! lol.....

  15. Enkeiavalanche

    Enkeiavalanche Moderator

    I may be out there in a Booth again... Talking to a new Sponsor now.... [​IMG] you may see something new to Top off all my Acc's soon....
  16. TRPLXL2

    TRPLXL2 New Member

    LOL! No 4x4, I have had too many problems with previous 4x4's.
    Enkei- I think you got a Bestop soft cover for your truck??
    Got the engine cover painted and cleared, 4l60e stock servo removed.
    ​Picture of the P/N switch, It is externally mounted, we also have the LS1 bellhousing bolted up.

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  17. Enkeiavalanche

    Enkeiavalanche Moderator

    (LOL! No 4x4, I have had too many problems with previous 4x4's.
    Enkei- I think you got a Bestop soft cover for your truck??
    Got the engine cover painted and cleared, 4l60e stock servo removed.
    ​Picture of the P/N switch, It is externally mounted, we also have the LS1 bellhousing bolted up.)

    Close but no Cigar.......
  18. TRPLXL2

    TRPLXL2 New Member

    Some pics of the valve body, and the new transmission filter and gasket. We added an HD-2 shift kit, and a billet corvette servo. It shifts extremely HARD, and FAST and thats what we wanted. We also replaced the 3rd and 4th shift bands while we had it apart, after we put the 31" tires on the truck it had a hard time staying in final gear. It was doing a lot of down shifting, and you could see it on those 2 bands especially. $20.00 worth of parts. Shift kit was $127.00, corvette servos $40.00.

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  19. Sierraowner5.3

    Sierraowner5.3 New Member

    good lord that thing is gonna be fast. gonna run some quarters with it? See what kind of time you can get out of it. my guess is low 12s.

    run it on a dyno yet?

  20. TRPLXL2

    TRPLXL2 New Member

    Well as it sits right now, It just has a mail order tune from frost on the ecm. It is 90% correct, but it is not completely dialed in. I am going to take it to big 3 performance this spring and have it dyno tuned. We have no idea how fast it is as of right now, but I will make sure to post the dyno results good or bad lol!!! We are also going to do some 1/4 mile passes in it this summer, I am planning on buying a GoPro camera this summer to capture some good times.

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    We had to swap to an LS1 style input shaft and front pump, different diameter and different spline count. Pic of one of the bands, and the sunshell was also upgraded to the revised piece. We are also running the f-body accessories for the serpentine setup, this was for clearance issues mainly. You can run truck accessories which are the cheapest, f-body which are middle pricey, corvette accessories which are the tightest clearance but are 3 times as much.

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