Project Polar Bear: '89 V2500 Suburban

[Kay86K5]

What year 8.1 did you end up putting in this thing? I know you said multiple pages back that you had a couple motors that your were making into one, but what year block did you end up using? Also, and more what I'm interested in, what fuel rail/fuel lines did you end up using (01-03 or 04-up)? And did you use your factory 89 TBI fuel lines?

I'm sorry for all the questions, but this is something I didn't see mentioned before in the thread.

Thanks!!

 

[y5mgisi]

Kay, I wonder if you can help the rest of us out and ask these questions in the 8.1 swap resource thread? This way, when we go to look that thread up later, these technical questions are answered there also! No big, just a thought.

 

[Smokinthehippies]

I was wondering if these were maybe already answered in the swap thread.

 

[Larry]

What year 8.1 did you end up putting in this thing? I know you said multiple pages back that you had a couple motors that your were making into one, but what year block did you end up using? Also, and more what I'm interested in, what fuel rail/fuel lines did you end up using (01-03 or 04-up)? And did you use your factory 89 TBI fuel lines?

I'm sorry for all the questions, but this is something I didn't see mentioned before in the thread.

Thanks!!

Yeah, that is buried in this thread way back on post 291 of this thread. The engine itself is a later one….I’m thinking 2005 to 2008, maybe even 2009. It looks older because I didn’t like the bare aluminum valve covers and put 2002 valve covers on it.

Everybody has a preference, and my preference is the earlier style return type fuel rail as I like having the ability to adjust the fuel pressure up on the rail whereas returnless gets more complicated where you must rely on aftermarket BS to regulate the fuel pressure. I just purchased a brand new return type fuel rail for it through work (pn 12575055). As far as fuel lines, I do use the factory TBI lines up to the fuel filter area on both the supply and return side. As far as the fuel lines themselves I am also running Workhorse fuel lines (pn W0000540 Return, W0000539 Supply) then I use a Napa 3623, which has a threaded connection on the tank side and a quick connect fitting that perfectly matches the Workhorse fuel line. The return line gets a little more complicated where you need to cut off a piece of the quick connect tubing from something at the junk yard so it will fit in the Workhorse return line. I find the return line at the fuel rail on 1999-2003 LS engines work great. Just cut it off a donor fuel rail and use it. Hard to explain. If you’re ever down in this area I can show you.

Hope that helps.

BTW, I just fired it up about an hour ago after the cam swap. We pulled the engine the day after Christmas, swapped the cam and stuffed the engine back in Monday night. It starts and idles perfectly just like the K10. I so much DO NOT miss the horrible hunting idle and crazy idle flare up during starting with the Raylar cam and dickweed tune. I haven’t driven it yet there are some other loose ends to tie up but it’s alive and well! It keeps getting hotter than a pistol….think I have an air bubble in the system. This was the shop view Saturday while Rob was working on his ZooK5.3 and I was tearing the engine down

Kay, I wonder if you can help the rest of us out and ask these questions in the 8.1 swap resource thread? This way, when we go to look that thread up later, these technical questions are answered there also! No big, just a thought.

I agree, but in this case it works out in either forum

 

[Smokinthehippies]

So did you go back to a stock tune?

 

[Larry]

So did you go back to a stock tune?

Yep, stock cam and clone of the tune in the K10. The two should run identical as they have the same gear, tires, trans, etc. The only difference is the Burb has headers and a Spectra air filter whereas the K10 has manifolds and K&N air filter. Other than that, they are identical.

 

[Smokinthehippies]

I'm still kinda sad you didn't like the cam, but I definitely understand going with a proven combo that gives you the exact results you want. You gonna save the cam for a different project later on or sell it off?

 

[Kay86K5]

Kay, I wonder if you can help the rest of us out and ask these questions in the 8.1 swap resource thread? This way, when we go to look that thread up later, these technical questions are answered there also! No big, just a thought.

That's a good idea. Maybe tomorrow when I have some time I will bring my questions and some of Larry's responses over to that thread since it's a fantastic resource (right now I have some kids to put to bed )

 

[Kay86K5]

Yeah, that is buried in this thread way back on post 291 of this thread. The engine itself is a later one….I’m thinking 2005 to 2008, maybe even 2009. It looks older because I didn’t like the bare aluminum valve covers and put 2002 valve covers on it.

Everybody has a preference, and my preference is the earlier style return type fuel rail as I like having the ability to adjust the fuel pressure up on the rail whereas returnless gets more complicated where you must rely on aftermarket BS to regulate the fuel pressure. I just purchased a brand new return type fuel rail for it through work (pn 12575055). As far as fuel lines, I do use the factory TBI lines up to the fuel filter area on both the supply and return side. As far as the fuel lines themselves I am also running Workhorse fuel lines (pn W0000540 Return, W0000539 Supply) then I use a Napa 3623, which has a threaded connection on the tank side and a quick connect fitting that perfectly matches the Workhorse fuel line. The return line gets a little more complicated where you need to cut off a piece of the quick connect tubing from something at the junk yard so it will fit in the Workhorse return line. I find the return line at the fuel rail on 1999-2003 LS engines work great. Just cut it off a donor fuel rail and use it. Hard to explain. If you’re ever down in this area I can show you.

Hope that helps.

That does help out a lot. It will all depend on what motor I find for what fuel lines I end up using. If I find a earlier year motor, then the fuel lines will be easier to deal with, if I find a later one, this is perfect info. Maybe one of these days I will come down to your neck of the woods just to check out your sweet rigs!!

 

[Larry]

I'm still kinda sad you didn't like the cam, but I definitely understand going with a proven combo that gives you the exact results you want. You gonna save the cam for a different project later on or sell it off?

I tell ya, I don’t miss that cam one bit. I still haven’t driven it yet tonight because the clutch pedal is out to replace bushings and the return spring (need to go on a parts run in the morning) but it’s been sitting here idling while Rob and I worked out the air bubbles and it idles so smoooooth! It starts nice, idles nice and raps up nice. The exhaust even sounds better without the wide lobe separation cam although it does sound a bit more poppy than I’d like. The cam is already gone to its new home. A buddy from Denver came down Monday too help stab the engine and take back the cam. You might know him, Alex Santiago...he has a sweet 95 2-door Tahoe, SAS'd, etc. that was in Peterson's 4 Wheel & Off-Road a while back. His truck is going through an 8.1L swap right now as well but he doesn't participate in forums much so there is no build thread on it. Actually, his Tahoe looks just like Russell's except gas instead of Duramax.

My wife and daughter went to Florida to spend Christmas with the in-laws while I stayed home this year to use my week off work to fix this damn Suburban once and for all. They left Christmas morning and I’ll pick them up tomorrow night at 8 PM. I’ve been working on this pig the entire time they’ve been gone and should have my entire Suburban bucket list cleaned off (except for adjusting the driver’s door) before I clean up and head to the airport. I might even put the baby seat in it and pick them up at the airport with it (that will piss the wife off ). A 100 mile round trip would be a good test drive. …..And if I can get a day pass, a buddy is putting together a rescue mission to pluck several stuck Jeeps out of the snow Saturday down in Northern New Mexico. Might just run the Burb down there if I can get a day pass.

That does help out a lot. It will all depend on what motor I find for what fuel lines I end up using. If I find a earlier year motor, then the fuel lines will be easier to deal with, if I find a later one, this is perfect info. Maybe one of these days I will come down to your neck of the woods just to check out your sweet rigs!!

Sounds good!

 

[campfire]

My wife and daughter went to Florida to spend Christmas with the in-laws while I stayed home this year to use my week off work to fix this damn Suburban once and for all. They left Christmas morning and I’ll pick them up tomorrow night at 8 PM. I’ve been working on this pig the entire time they’ve been gone and should have my entire Suburban bucket list cleaned off (except for adjusting the driver’s door) before I clean up and head to the airport. I might even put the baby seat in it and pick them up at the airport with it (that will piss the wife off ). A 100 mile round trip would be a good test drive. …..And if I can get a day pass, a buddy is putting together a rescue mission to pluck several stuck Jeeps out of the snow Saturday down in Northern New Mexico. Might just run the Burb down there if I can get a day pass.

Either one sounds like a good test run.

 

[campfire]

That's a good idea. Maybe tomorrow when I have some time I will bring my questions and some of Larry's responses over to that thread since it's a fantastic resource (right now I have some kids to put to bed )

Good on ya for keepin' the priorities straight.

 

[Larry]

How she looks tonight….Much better than a couple nights ago in the picture above! The ECM is not secure and tidy yet though. Need to make a run to the hardware store for some stainless bolts to secure the ECM as the ones I used a few months ago rusted up just sitting in the driveway.

 

[Kay86K5]

The cam is already gone to its new home. A buddy from Denver came down Monday too help stab the engine and take back the cam. You might know him, Alex Santiago...he has a sweet 95 2-door Tahoe, SAS'd, etc. that was in Peterson's 4 Wheel & Off-Road a while back. His truck is going through an 8.1L swap right now as well but he doesn't participate in forums much so there is no build thread on it. Actually, his Tahoe looks just like Russell's except gas instead of Duramax.

I know Alex. He actually helped me with my TBI wiring when I swapped a TBI motor into my Blazer about a year and a half ago. He is a really good dude. I also wheeled with him (he was riding along in Brandon Watson's buggy) at Blazer Bash this year. He is a really cool dude. I know Craig (clstolten on here) really well as he lives right down the road from my dad's place. Craig and Alex work together (kinda), at least at the same place. Craig and I are trying to head over to Alex's house within the next couple weeks to check out his Tahoe.

 

[Larry]

I know Alex. He actually helped me with my TBI wiring when I swapped a TBI motor into my Blazer about a year and a half ago. He is a really good dude. I also wheeled with him (he was riding along in Brandon Watson's buggy) at Blazer Bash this year. He is a really cool dude. I know Craig (clstolten on here) really well as he lives right down the road from my dad's place. Craig and Alex work together (kinda), at least at the same place. Craig and I are trying to head over to Alex's house within the next couple weeks to check out his Tahoe.

It’s a small world we live in….especially if you’re a GM off-roader type guy

Alex is a good dude. Smart sumbish too!

 

[Larry]

Whelp, I got to test drive it 0 miles today. Got the ECM secured and all tidy as well as the clutch pedal bushings and spring replaced but there is absolutely zero clutch. The slave is moving fine, it’s like there isn’t even a clutch in there at all. Has me thinking I put the clutch disk in backwards or something mechanical in the clutch/pressure plate. Sumbish! The not so funny thing is the first time I put this 8.1L in earlier in the year I had to pull the trans out then as well because we forgot to install the rear main seal. The other pisser is my trans jack died and my buddy’s is tied up. Looks like I’ll be making a trip to Harbor Freight shortly. Finding time to do this is another challenge as the ladies will be home tonight.

Errrrr! Always something

It sure starts and idles nice though!

 

[Larry]

Well, well, well! I popped the trans out Friday night and found that I had indeed installed the clutch disk in backasswards. Not sure how in the hell I did that….flippen idiot! LOL The release bearing was a casualty of the disk being in backwards, as a few pieces of it got broken off where it clips on to the fork. It was a cheap plastic bearing anyway. Not sure if it is a good thing or a bad thing but I got the trans out in under an hour. That is a bad thing because I shouldn’t need to know all the short cuts to get it out so quickly! LOL

Anyway, I was finally was able to take it on a test drive this morning and I am a completely satisfied camper! It runs identical to the K10 as I had hoped! Tons of power with Cadillac drivablity manors. No more idle flares, hunting idle, dying, jerky jerk operation…. blah, blah blah…. Ah, and having the low-end grunt to let it lug itself around is so nice. Best of both worlds. Sucks it took 6 months to get here but it was worth it in the end.

You’re all probably tired of pictures but these are the latest pictures with the final hose/harness routing and clipping. It is now DONE under the hood with respect to the 8.1L swap. Speaking of the hood, that is the last thing that needs attention….the hood needs adjusted badly! I’ll try to get some videos soon.

Made stand off brackets for the hydroboost hose from the pump to the booster. This is a GMT400 booster hose (those hose with the blue clamp).

Made another stand off bracket for the hose going to the pump. It has a p-clip holding to the stud to prevent the metal portion of the hose from vibrating resulting in fatigue cracks

Might have a leak here at the pump. Got to keep my eye on this. Didn't drip any over night after I wiped it off

Final Final!

This should be the end of the engine swap reporting for a while. Next up I need to adjust the hood, driver’s door and get after the horrible driveline angles causing major highway vibrations. Aiming to take it on a long roadtrip in May to the Overland Expo

 

[82355]

Never tire of looking at your pictures.

Martin

 

[y5mgisi]

Tired of pictures! You're funny Larry! Glad it's getting to where you like it now!

 

[Big Ray]

tired of pictures Blasphemy!!!!