'Da Chief : 5.3 Gen V / 6L80 Swap

[cu4whln]

On the hood insulation:

so I think it is intended for smooth side to be toward hood
but the other way seems better,.....

P.S. just thought, I bet spray adhesive does better on the smooth side for more contact area as opposed to fuzzy side
and on a Monte Carlo the insulation is held on by large round push in clips, not adhesive,.... so on an FSJ using glue, the smooth Side may stick/hold better ??????

dave in NC

Thanks Dave ...

I agree with you.. the smooth side will adhere better. BUT I do like the smooth side look.
Probably will install it with grey side showing.. I don't want this falling down.
We have all seen old insulation coming apart and falling down!

[cu4whln]

OK.. Did as SOLSAKS suggested ...

Installed the hood insulation the way it was intended... smooth side glued to the hood.
3M must LOVE this adhesive ... NOT cheap. Hood is ready to reinstall now.

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[cu4whln]

Air Intake Prep ...

Have been messing around with how to get an air cleaner in place... and found there isn't really a place to buy a Gen V compatible cold air system.
Or not one that's under 300 bucks.. ouch.

So I am making my own.... Nothing is a bolt on. Turns out the mass airflow sensor for Gen V LTs have a different mounting scheme than the LS series.
So the 5.3 kit I bought wouldn't mount the MAF sensor?

Then, I found a part that can be mounted to the pipe that will work... from ICT billet. I have some ideas for the intake, but am waiting on a 45 degree elbow.
Anyway, I cut the opening for the sensor to stick through, and JB welded the part onto the intake pipe.

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Installed the MAF sensor for a trail fit... and mounted it up.
Note: I will have to make a block off plate for the LS MAF mount.

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During tonight's warm up and test run, I found out the engine runs much better with the MAF sensor working ... Go figure !

[GWNashville]

Da Chief

This thing is looking so good. I have got to get busy, yours is moving along so well.

[cu4whln]

Small Steps . . .

This thing is looking so good. I have got to get busy, yours is moving along so well.

Thank you! I think the key is doing a little every day.. at least something get done, even small steps help. My wife knows where to find me!

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Now, Today's small stuff . . .

Have been working on cleaning up and routing/securing the wires... Lots a zip ties!

Mounted up my ECU mount.. then put the ECU and fuse panel in..

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Adding more underhood components, more wires secured and organized.
All small stuff ...

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Felt the Hydraboost lines were too close to the exhaust.. so I took the original heat shielding from the stock mounts and made a heat guard.

There's actually 2.. one is right under the Hydraboost unit, the other up front,

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[bkilby]

That looks purdy and all, but aren't those plastic zip ties gonna melt before the hoses do? Maybe try some stainless steel zip ties?

https://www.youtube.com/watch?v=Kuf3ByL1IMM

[cu4whln]

Hmm . . . I didn't know there were metal zip ties?

Auto parts store ?

[bkilby]

The company that posted that video sells them. Or maybe try these?

https://www.homedepot.com/p/Gardner-Bender-11-in-Stainless-Steel-Cable-Tie-10-pack-45-312SS/206410938?MERCH=REC-_-pipsem-_-203531940-_-206410938-_-N

[cu4whln]

In Today's News . . .

Thanks Brad.. U so smart ! I will pick some of those up!

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Today... Cleaning up more wiring and securing all the harnesses for long term use. Not super exciting, but this will pay off long term !

Got my new batt terminals today. Reusing the GM leads that come with the wire harness. they are very nice, but need a buss to bolt on like the Yukon it came out of.

So out comes the wire strippers and crimp tool.. Dang it !! Broke BOTH of those today!! Guess I get to buy some new tools !
I went Old School on the crimps... Vise Grips will do a good job if you are careful.
This was tedious, but got it all crimped, routed and secured today.
I think the wiring is done ! Woot !!

Have feeds for headlight harness, starter feed, alt feed, PWM fan with 80 amp fuse, and vehicle power [Removed the AMP meter and yellow feed wire btw]
Found an old rubber cover to protect all the positive feeds.

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Eliminated the fusible link and went to a 50 amp Maxi fuse to protect the vehicle feed. Of course, I'll carry a spare fuse !!

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I had an old ARB headlight harness I never installed on the CJ and decided to use it.
That's the 3 relay block with it's own 30 amp fuse holder.
I have some Cibe headlights and H4 bulbs to install.
Not engine swap related, but I have it all apart now.

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[cu4whln]

More Details . . .

Spent some time getting ready to put the front end back together. I cleaned up and degreased the hood hinges and hood hardware...
Then got the "paint booth" ready ... Spray cans it is!

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Then put the springs back on and stretched them out so I could get paint in between the coils. Also cleaned up the horns as they were kinda skimey ...

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Had to move the horns to make room for my air intake ... So I attached them to the new ECU bracket.

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[cu4whln]

Stress Test . . .

Well, I have run and warmed up the engine 5 times now... all seems reasonably OK.

So, it was another HOT day, and I was wondering if I could get the temps up in the radiator. So I ran the engine in the garage at 3200 rpm for 10 minutes or so... 195, fan turns on, 205 fan ramps up a bit, 212 fans ramps up a bit more, 219 fan is running faster, but no way is it full tilt yet. Can't get temp over 219? So that seems to be max ?

Good news is I now know what the temp gauge vs the scan tool temp is. 219 is in the middle.
The temps? Never could get it over 219... seems the cooling system is keeping the temp OK. Good.

Then I shut it down for 3 minutes to "heat soak" it.. fired right back up at 217 and dropped quickly back to 197 at idle.

I LOVE the fact there was no heat soak issue like the other engine.

[cu4whln]

Today...

I reinstalled the trans tunnel cover. It needed some clean up.. and the gasket was toast.. so cleaned it up first... Don't want water getting in around the cover.
Hmm, exposed bare metal after cleaning .. can't have that. Get the spray paint!

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Painted up the bare metal parts.. Then added some strip caulk around the edges to replace the deteriorated old gasket.
This made it slightly more difficult to install the cover, but it's sealed!

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Also touched up the paint on the floorpan as it also showed some bare metal after cleaning.

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Ready to go. Note the t-case shifter. I added a rubber gasket on the shaft to help keep splash away from the hole in the floor.
Note: The floor will get cleaned up and POR treatment at a later date.

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[toddthewelder]

Man this is a sweet build. After reading all of this I'm glad I went with the LS rather than the new engine, but you are making it look easy.

[cu4whln]

After reading all of this I'm glad I went with the LS rather than the new engine, but you are making it look easy.

I hear ya! LS is a great engine.. I guess I decided to take the road less travelled.

It really hasn't been that much harder... BUT - there have been a few expensive challenges and solutions ! lol

[cu4whln]

Today: Sheet Metal . . .

Running out of things to do.. sort of.

So decided to put the fenders back on.
I am NOT a body guy.. but figured, how hard can it be?

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Well, after some fussing, I got it on!
Not perfect alignment... Oh wait, it wasn't perfect before... lol
Starting to look like a Jeep again.

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Driver side on too.. got hood hinges ready for hood install. Buddy coming over Fri to help me with that.

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Look! It looks like a FSJ engine bay again ! Woot !!

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Note the washer bottle .. It was very stained and dirty .. seemed not to clean up?
Took it to the sink.. scrubbed it with some dawn.. and OXI Clean [ per the wife].
Let the OXI Clean soak overnight.. and it is a LOT better.

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