Chevy Astro / GMC Chevy Astro / GMC SafariSafari

TheThe V8 SwapV8 Swap

This is a photo documentary This is a photo documentary on how to install a small on how to install a small

block Chevy V8, such as a block Chevy V8, such as a 350, in place of the little 4.3 350, in place of the little 4.3 that the vans came from the that the vans came from the

factory.factory.

The Beginning…The Beginning…

The first thing that you need to find is The first thing that you need to find is of course a V8. My personal choice was of course a V8. My personal choice was a 350 from a 89 up full size Chevy/GMC a 350 from a 89 up full size Chevy/GMC pickup. These engines are virtually a pickup. These engines are virtually a bolt in, and are very easy to do.bolt in, and are very easy to do.

The van I am using for this show is my The van I am using for this show is my 86 Astro, which has served me faithfully 86 Astro, which has served me faithfully for years, so its time to have some fun.for years, so its time to have some fun.

Parts ListParts List

1)  V8 engine 1)  V8 engine

2)  motor mounts (from 2)  motor mounts (from JTRJTR or or RacecraftRacecraft Conversions Conversions))

3)  TB bracket, may not be necessary depending on the engine 3)  TB bracket, may not be necessary depending on the engine choice.choice.

4)  V8 fuel injectors4)  V8 fuel injectors

5)  7747 computer with V8 program5)  7747 computer with V8 program

6)  Headman 68600 headers, or stock manifolds.6)  Headman 68600 headers, or stock manifolds.

7)  V8 distributor7)  V8 distributor

8)  V8 Flexplate, I am not sure if the V6 is the same or not.8)  V8 Flexplate, I am not sure if the V6 is the same or not.

First, you need to remove most of the front First, you need to remove most of the front end. This means simple stuff like the grille, end. This means simple stuff like the grille, headlight buckets, upper radiator support, headlight buckets, upper radiator support, the radiator itself... Here Mike removes the the radiator itself... Here Mike removes the

lower fill above the bumper.lower fill above the bumper.

Advice on the upper radiator Advice on the upper radiator support…support…

IMPORTANTIMPORTANT There are two bolts that are on the There are two bolts that are on the

back of the upper support on each back of the upper support on each side at the top. It is very easy to side at the top. It is very easy to

overlook these and have a problem overlook these and have a problem removing the support. In fact, one is removing the support. In fact, one is actually a chassis ground. At least it actually a chassis ground. At least it was on my Astro. The picture on the was on my Astro. The picture on the next page points to their locations.next page points to their locations.

Remember, they are on the Remember, they are on the BACK of the main supportBACK of the main support

More stuff to removeMore stuff to remove

This is what the van This is what the van SHOULD look like SHOULD look like with the radiator, ac with the radiator, ac condenser, bumper, condenser, bumper, fill panel all removed.fill panel all removed.

We also removed the We also removed the hood as well, since it hood as well, since it was really beat and was really beat and will be replaced.will be replaced.

Now the fun beginsNow the fun begins

Out with the old!!!Out with the old!!!

Make absolutely sure that you disconnect all Make absolutely sure that you disconnect all the wiring from everything attached to the the wiring from everything attached to the engine. If you miss something… You’ll know engine. If you miss something… You’ll know it all too fast. Also, make sure you take off it all too fast. Also, make sure you take off the TBI off the top of the engine, as you will the TBI off the top of the engine, as you will need all the room to hook the engine crane need all the room to hook the engine crane up to it. It has to be extremely close in up to it. It has to be extremely close in order to get the engine out of there. We order to get the engine out of there. We even removed the distributor.even removed the distributor.

Please Remember!Please Remember!

Don’t forget to have the front of the Don’t forget to have the front of the van on ramps… We DID forget this van on ramps… We DID forget this little touch and thankfully we were little touch and thankfully we were able to lift the van with my old 1955 able to lift the van with my old 1955 Hein Werner jack, and shove the ramps Hein Werner jack, and shove the ramps under the front wheels… You more under the front wheels… You more than likely will not get the engine out than likely will not get the engine out without the body being in the air.without the body being in the air.

Trans too???Trans too???

In our case, since the In our case, since the transmission was transmission was toasted too, we toasted too, we decided to pull it too. It decided to pull it too. It actually seemed a little actually seemed a little easier to do it this way. easier to do it this way. Again, remember to Again, remember to unhook everything…unhook everything…cause the one thing cause the one thing forgotten WILL hold forgotten WILL hold that puppy in there…that puppy in there…

Remember…CLOSENESSRemember…CLOSENESS

As you can see, the crane has to be close As you can see, the crane has to be close to the intake…to the intake…

Time to Tug (or really Yank)Time to Tug (or really Yank)

Be Careful!Be Careful!

Again, double check yourself here. Again, double check yourself here. Make sure everything is disconnected, Make sure everything is disconnected, the chain is correctly hooked to the the chain is correctly hooked to the engine, all harnesses are out of the engine, all harnesses are out of the way of the engine being pulled. And way of the engine being pulled. And have a few extra hands around in case, have a few extra hands around in case, as the engine is heavy enough by as the engine is heavy enough by itself, let alone with the trans on it.itself, let alone with the trans on it.

Remember the Harness! We Remember the Harness! We goofed!goofed!

Its Free!!!Its Free!!!

Its free and hanging Its free and hanging there… Now to get it there… Now to get it off the crane and off the crane and onto the tire outside.onto the tire outside.

This whole combo of This whole combo of the 4.3 and toasted the 4.3 and toasted tranny weighs tranny weighs upward of 1000 lbs upward of 1000 lbs combined!combined!

Don’t drop this on Don’t drop this on your toes!your toes!

Ready and waiting! Time to Ready and waiting! Time to clean it up a little before the clean it up a little before the

new resident moves in!new resident moves in!

Rest in Peace, Old friend…Rest in Peace, Old friend…

Boltin’ It TogetherBoltin’ It Together

Here we see Mike Here we see Mike and Ryan and Ryan tightening the tightening the transmission down. transmission down. We later decided to We later decided to install the engine install the engine and transmission and transmission seperately.seperately.

Before We Forget…The Before We Forget…The Chips!Chips!

In order for the V8 to function correctly, you must replace In order for the V8 to function correctly, you must replace the chips in the computer. If you got the computer from the the chips in the computer. If you got the computer from the donor truck, you are already set. If not, just get these from donor truck, you are already set. If not, just get these from the junkyard and install them in the computer. Make sure the junkyard and install them in the computer. Make sure your computer is service number 7747. Without these, it your computer is service number 7747. Without these, it may run, but not the proper way!may run, but not the proper way!

Closer view of MotormountCloser view of Motormount

This shows the This shows the drivers side motor drivers side motor mount and header mount and header clearance. We had clearance. We had no issues there no issues there whatsoever.whatsoever.

On its way home!On its way home!

Here goes our 350, Here goes our 350, heading to its new heading to its new home. Without the home. Without the trans attached, it trans attached, it was very easy to was very easy to slip it in there. slip it in there. Surprising GM Surprising GM never offered these never offered these factory issue. If you factory issue. If you want one, gotta do want one, gotta do it yourself!!!it yourself!!!

Almost In!Almost In!

Getting it Together!Getting it Together!

The top picture The top picture shows how the shows how the engine and trans engine and trans lined up initially. A lined up initially. A little maneuvering, little maneuvering, preferably with 2 or preferably with 2 or more people, ends more people, ends up with the result on up with the result on the bottom picture. the bottom picture. A nice hookup!A nice hookup!

She’s Home!!!She’s Home!!!

Putting it all back togetherPutting it all back together

Here we see the front Here we see the front of the engine, of the engine, complete with the 350 complete with the 350 serpentine accessory serpentine accessory brackets now in place. brackets now in place. Power pulley installed Power pulley installed on the crankshaft too on the crankshaft too at this point. Coming at this point. Coming along slow but surealong slow but sure

Cant wait to hear her Cant wait to hear her run! The time is run! The time is closing in!closing in!

Some Points To RememberSome Points To Remember

Check Fuel lines for leaksCheck Fuel lines for leaks Double check all hose fittingsDouble check all hose fittings Check the ignition wire order for Check the ignition wire order for

proper location on the cap…proper location on the cap…

I can stress these because I didn’t do I can stress these because I didn’t do these things and wound up with a these things and wound up with a minor fire and more damage to repair.minor fire and more damage to repair.

Another ThingAnother Thing

In this 86 van, You will In this 86 van, You will notice that the notice that the alternator and the AC alternator and the AC compressor have compressor have switched sides. This is switched sides. This is not a issue, as simple not a issue, as simple lengthening of a couple lengthening of a couple of wires is all that’s of wires is all that’s needed here.needed here.

Looking Great!Looking Great! Make sure the steering Make sure the steering

pulley is on the whole pulley is on the whole way! Otherwise, you way! Otherwise, you will chew up belts…will chew up belts…

Right Side Rear WiresRight Side Rear Wires

Drivers Side Rear WiresDrivers Side Rear Wires

Radiator Back In…Radiator Back In…

No AC For me…want to keep it No AC For me…want to keep it cool!cool!

Looking Good! Almost Looking Good! Almost Done!Done!

The reason for no The reason for no AC is because of AC is because of the big filter…Its the big filter…Its actually from a 88-actually from a 88-95 Chevy truck!95 Chevy truck!

So Far, So Good!So Far, So Good!

Project Complete!Project Complete!