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Post Info TOPIC: 1991 V3500 Engine Rebuild/Upgrade



- Erik -
Snohomish, WA


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Posts: 446
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1991 V3500 Engine Rebuild/Upgrade
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So I finally found time after Elk hunting was finished to strip down my Gen V 454 to see what damage the rod knock caused.

 

#3, 6 & 7 rod bearings had some scoring.  #3 had a little groove in the crank that you could feel with your fingernail, but the others were pretty light!  #4 main bearing had some heavy scoring in the bottom half, but the crank looked pretty good!

 

I've been trying to work with a wrecking yard for about a month on a deal for a Gen VI 454, but they haven't wanted to come down on price.  After much looking I might end up paying them what they want for it.

 

My plan is to build a Gen VI 454 and use the 0411 pcm to put coil near plug and dbw throttle body on it.  Essentially make a L21 454.  I entertained an 8.1L, but everybody wants so much for them and the front drive brackets are hard to come by without spending a fortune to make it work.

 

Next order of business is to grind the rivets off to remove the front crossmember and install the ORD crossmember.

The Gen V I will probably slowly rebuild to something that can either go in the Chevelle, or sell.



-- Edited by ehjorten on Saturday 19th of November 2016 09:31:32 PM

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Erik
'69 Chevelle Sport Coupe, EFI355, TH350
'68 Chevrolet C10 Stepside Project, 292, t-56, C4 IRS (project)
'77 Chevrolet K20 Silverado LWB, 400CI, TH400
'91 Chevrolet V3500, TBI Gen V 454, 4L80E, Lifted


- Durand -

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Personally I'd stick with a MIV or GenVI.

The GenV's make good Buoy anchors.

Head gaskets problems, minimal part swapping, no fuel pump boss, etc.

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- Erik -
Snohomish, WA


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Posts: 446
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Yeah, the Gen V with it's low compression, mild cam, poor flowing heads and Throttle Body early GM FI with UV erasable PROM isn't much to write home about. Plus my '91 is a single year PCM that there is zero support for! I am gonna put AC 241 pumps in my tanks and thankfully the stock switching valve is rated for 65 psi, so no changes other than FI rated rubber fuel lines and FI rated hose clamps. The rest is a cluster of electrical harness. Gonna go with a Howell engine harness to minimize the pain.

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Erik
'69 Chevelle Sport Coupe, EFI355, TH350
'68 Chevrolet C10 Stepside Project, 292, t-56, C4 IRS (project)
'77 Chevrolet K20 Silverado LWB, 400CI, TH400
'91 Chevrolet V3500, TBI Gen V 454, 4L80E, Lifted



- Erik -
Snohomish, WA


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Posts: 446
Date:
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I was kind of surprised at how loud the rod knock got with how little of wear was showing on the bearings. Yes, there was some scoring on 3 rod bearings and one main, but I was expecting to see a lot more damage! Good thing I parked it so things didn't get worse!

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Erik
'69 Chevelle Sport Coupe, EFI355, TH350
'68 Chevrolet C10 Stepside Project, 292, t-56, C4 IRS (project)
'77 Chevrolet K20 Silverado LWB, 400CI, TH400
'91 Chevrolet V3500, TBI Gen V 454, 4L80E, Lifted


- Beemer Brett - Redmond, WA

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Where are the pics?

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1966 Chevelle, 1972 K20, 1967 GTO, 1955 210 Coupe, 1969 Chevelle




- Erik -
Snohomish, WA


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Posts: 446
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Picked-up a low mileage 6.0L LS out of a 2004 Yukon Denali XL2500 today! Slightly different route now. Hope I will be satisfied. I don't think I'll be making 410 lb-ft of torque at 1,600 RPM anymore! I'd really like to put some L92 heads and an LS3 intake manifold on it, but the cost of those things along with a new camshaft really isn't in the cards right now.



-- Edited by ehjorten on Tuesday 29th of November 2016 01:50:27 PM

__________________
Erik
'69 Chevelle Sport Coupe, EFI355, TH350
'68 Chevrolet C10 Stepside Project, 292, t-56, C4 IRS (project)
'77 Chevrolet K20 Silverado LWB, 400CI, TH400
'91 Chevrolet V3500, TBI Gen V 454, 4L80E, Lifted
Ben


- RAMBO -Mill Creek, WASite Administrator

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Oh no... does that put me in Jepardy of not getting my car running before your truck?



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Ben R.

1968 Chevelle 300 - 454 / 4spd




- Erik -
Snohomish, WA


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Posts: 446
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Don't know! LOL! I have fuel tanks to deal with, fuel pumps and fuel line routing. I'm replacing my radiator support with a good used one. Need to get that stripped and painted. Then I have miles of wiring and PCM programming to deal with!

__________________
Erik
'69 Chevelle Sport Coupe, EFI355, TH350
'68 Chevrolet C10 Stepside Project, 292, t-56, C4 IRS (project)
'77 Chevrolet K20 Silverado LWB, 400CI, TH400
'91 Chevrolet V3500, TBI Gen V 454, 4L80E, Lifted



- Erik -
Snohomish, WA


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Posts: 446
Date:
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Brett, you wanted pictures of the bearings...here they are! Quite a few with wear down to the babbit in places.

w9uxm2zNAzaG26qjUqGaRBD__ufXoYGv__1vH_i5
#1 Main

xzGIrreOFvgjy2Cn8B3QKt2xLuUVbuZr14at0Cg2
#2 Main

t4ktSI-fKla2Tl2bAtUavOqHTCOyYjGt2MUOR0u0
#3 Main

OVrJn4lST9e8wmVBlxBHbzQp3KR_HirqUgYIs7S5
#4 Main - Heavy Scoring

LXKPeYq4zC9yspZXSs2SHz7tN-gzPGWbYhjUowCT
#5 Main

_3rWFpHbc8QP4ho1nsVOUMJIklMrth_2aFMFpKsf
#1 Rod

KrITnLtYpnkASeNAtzU3yp_A5nz5Dpa7x4D8hKGV
#2 Rod

icF0b8aCjFtTFIpoSnlPZ5bs4ABxNuT6oNoa-412
#3 Rod - Light Scoring...Wrist Pin is a little sticky

i1b3_ilSyQ-UbV6VMR_ba6O2bjoN5Ao48vcwYEVP
#4 Rod

tmptriSS4Es_xs23HQ2Ss6UCyejO1dlyoiyO2UXi
#5 Rod

PfSVb9_JWS2qZb4djgQWxiixdIpbbRlOVsI7wU0F
#6 Rod - Scoring

c1kF6Q7i8Lkkef9BEOZl9RRJfNMop48kkzFQ4ALZ
#7 Rod - Light Scuffing


9LyBJG0dakSWrQsJg_gPYBqpo8gaik8zNFCtm1es
#8 Rod



-- Edited by ehjorten on Saturday 3rd of December 2016 01:57:32 PM



-- Edited by ehjorten on Saturday 3rd of December 2016 01:59:18 PM



-- Edited by ehjorten on Saturday 3rd of December 2016 02:47:30 PM

__________________
Erik
'69 Chevelle Sport Coupe, EFI355, TH350
'68 Chevrolet C10 Stepside Project, 292, t-56, C4 IRS (project)
'77 Chevrolet K20 Silverado LWB, 400CI, TH400
'91 Chevrolet V3500, TBI Gen V 454, 4L80E, Lifted


- Beemer Brett - Redmond, WA

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Cool thanks! Yeah good thing you tore it down. Are you going to sell the parts?  I'm surprised that was knocking, I guess it doesn't take much!



-- Edited by Brettd85 on Saturday 3rd of December 2016 02:52:50 PM

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1966 Chevelle, 1972 K20, 1967 GTO, 1955 210 Coupe, 1969 Chevelle




- Erik -
Snohomish, WA


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Posts: 446
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Me too! As loud as it was, but it doesn't take much to ruin the hydrodynamic wedge of oil that it rides on. Then you have a very small clearance that is hammering metal on metal.

__________________
Erik
'69 Chevelle Sport Coupe, EFI355, TH350
'68 Chevrolet C10 Stepside Project, 292, t-56, C4 IRS (project)
'77 Chevrolet K20 Silverado LWB, 400CI, TH400
'91 Chevrolet V3500, TBI Gen V 454, 4L80E, Lifted



- Erik -
Snohomish, WA


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Posts: 446
Date:
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yjhoLfjSppIvbTB9tbCgwxYLB1Dn4G7yJnCksa7f

Got the ORD crossmember mocked-in!  Pulled it and the front motor mounts out for cleaning and painting along with the rear transfer-case crossmember.



-- Edited by ehjorten on Monday 12th of December 2016 11:50:42 AM

__________________
Erik
'69 Chevelle Sport Coupe, EFI355, TH350
'68 Chevrolet C10 Stepside Project, 292, t-56, C4 IRS (project)
'77 Chevrolet K20 Silverado LWB, 400CI, TH400
'91 Chevrolet V3500, TBI Gen V 454, 4L80E, Lifted



- Shane -
Graham, WA


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Posts: 1035
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gotta love ORD.. i used to have alot of ORD on my K5

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- Beemer Brett - Redmond, WA

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Cool! Is that crossmember required to clear the pan?

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1966 Chevelle, 1972 K20, 1967 GTO, 1955 210 Coupe, 1969 Chevelle




- Erik -
Snohomish, WA


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Posts: 446
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You can notch the stock one on the driver's side to clear the pan or install this one. This one gives a little better access and more or less just bolts in. Removing my stock one I found that it had a broken rivet and the frame side engine mount on the drivers side was loose.

__________________
Erik
'69 Chevelle Sport Coupe, EFI355, TH350
'68 Chevrolet C10 Stepside Project, 292, t-56, C4 IRS (project)
'77 Chevrolet K20 Silverado LWB, 400CI, TH400
'91 Chevrolet V3500, TBI Gen V 454, 4L80E, Lifted



- Erik -
Snohomish, WA


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Posts: 446
Date:
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Just love conversion stuff! The LS adapter plates that I got don't fit to a stock LQ4 worth a shit! Sure it would work with a carbed LS without any oil-cooler lines, but GAWD!!! Looking for another set of adapter plates; maybe Dirty Dingo ones?!

__________________
Erik
'69 Chevelle Sport Coupe, EFI355, TH350
'68 Chevrolet C10 Stepside Project, 292, t-56, C4 IRS (project)
'77 Chevrolet K20 Silverado LWB, 400CI, TH400
'91 Chevrolet V3500, TBI Gen V 454, 4L80E, Lifted



- Mike -
Olalla, Wa


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Posts: 3616
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I have the dirty dingo plates on my LQ, but I'm not using the oil cooler lines to comment on the clearence.

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'66 SS Chevelle LQ4/4L80E

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'65 GTO 455/th400




- Erik -
Snohomish, WA


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Posts: 446
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Got BRP Hotrods LS engine mounts the other day and test fitted them to the block last night. Looks like it solves all of the interference issues and might even allow the stock A/C compressor to work! They weren't a cheap setup, but I am definitely happy that they fit without any issue! This weekend I will test fit the engine to make sure I have good clearance to the firewall with it in the stock location. I did call and talk to BRP and pick their brain about any issues with the Gen. 3 truck install. Very friendly and willing to provide information, not just sell parts.

__________________
Erik
'69 Chevelle Sport Coupe, EFI355, TH350
'68 Chevrolet C10 Stepside Project, 292, t-56, C4 IRS (project)
'77 Chevrolet K20 Silverado LWB, 400CI, TH400
'91 Chevrolet V3500, TBI Gen V 454, 4L80E, Lifted



- Erik -
Snohomish, WA


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Posts: 446
Date:
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Not quite a slam dunk! I didn't realize that there was a difference between SBC and BBC motor mounts when it came to the clam shell truck style. The BBC mounts are 0.100" narrower, but the clamshell is bigger and the bolt pattern is different! The BRP Hotrods mounts are designed around a 1985 K10 that had a SBC in it, so needless to say the frame-side mount doesn't fit to my truck! I reverse-engineered the brackets and designed my own set from that and am having our fab shop at work make them up.

Also, the A/C Compressor won't fit, but just barely!  The compressor interfers with the frame mounts, but maybe only by an inch.  I think if I wanted to make it fit I would have to cut, notch, weld and modify the passenger's side engine mounts.  I am trying to actually keep this a bolt-in operation as much as possible, so I guess I will have to get a high-mount compressor kit to get the A/C back to working.  I think that will be a follow-on project after it is back on the road.  I'll just cap off the A/C system for now.



-- Edited by ehjorten on Monday 23rd of January 2017 08:08:25 AM

__________________
Erik
'69 Chevelle Sport Coupe, EFI355, TH350
'68 Chevrolet C10 Stepside Project, 292, t-56, C4 IRS (project)
'77 Chevrolet K20 Silverado LWB, 400CI, TH400
'91 Chevrolet V3500, TBI Gen V 454, 4L80E, Lifted



- Erik -
Snohomish, WA


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Posts: 446
Date:
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Couple of questions...

1) What kind of spring pressures are decent for a performance engine with a hydraulic roller cam that gets driven regularly?  The reason I ask is that the stock LS 6.0 has beehive springs with 76# @ 1.8" installed height and 220# @ 1.32".  I am seriously considering the Vinci VHP080 cam swap before I install the engine.  It looks like they want you to go with double springs that have 155# @ 1.8 and 380# @ 1.18".  This cam has 0.551 lift with with stock 1.7 rockers so I won't be going quite to 380#.  My concern is that it is seems like so much more spring pressure.  I know I will need stiff push rods as the stock LS ones are fairly flexy.

2) Does anyone have any LS engine tools?  Specifically the alignment tools for the front and rear covers, and/or a Comp Cams Crankshaft socket for an LS so I can mount my degree wheel?

 

Thanks!

 

-Erik



-- Edited by ehjorten on Thursday 9th of February 2017 01:03:45 PM

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Erik
'69 Chevelle Sport Coupe, EFI355, TH350
'68 Chevrolet C10 Stepside Project, 292, t-56, C4 IRS (project)
'77 Chevrolet K20 Silverado LWB, 400CI, TH400
'91 Chevrolet V3500, TBI Gen V 454, 4L80E, Lifted
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