Gen IV LS swap in a G20 Chevy van. Ep 1. overview and teardown.

[@BeardedPortland]

“I love this little van, don’t know why…it’s not worth that much” a finished 78’ 4x4 LS swapped van dura just sold for 30k…🤯 I have a 76 gmc van dura 35, posi dually rear end long frame, with the 21 foot Canada born RV box with 27k original, 350 with 4 barbell edelbrok* and dual flow masters, upgraded the points to a dizzy, ngk plugs and wires, k and n filter, Alluminum radiator, all original billet grill and valance, original cummi….ONAN 3000kw generator….. and more to list as it comes… it too is my favorite rig….. Awesome video

[@BrokenWrenches]

you and me both my friend!!!! people have never had one or driven one just dont get it. appreciate ya.

[@timjefferson2137]

Had to turn my '76 G30 Pathfinder 4x4 van into a '94 because the old body was rotten. I have a junk '96 G30 long wb van too. Can't stop driving mine either. I'm kind of looking for an older body for my 4x4 again...

[@youroldfriendev]

Can't believe I stumbled upon these videos this morning. I did a 6.0 swap into my 71 g10 back in March, and actually just finished turbocharging it. Fantastic job, main points are very much what I did

[@BrokenWrenches]

Thats awesome man !!!!! I would love to see a turbo setup. Thanks for watching my stuff.

[@makevelicustoms]

@Evan any vids on it? Sounds cool AF bro.

[@youroldfriendev]

Check the g10 Facebook groups, haven't had time to make a KZbin video

[@dexterlecter7289]

I want to do that to my G30 .... Any tips at all are appreciated, even if you just say do research lol. Anything.

[@BrokenWrenches]

@@dexterlecter7289 yes, research!! And give yourself a lot of time to do it, it takes a minute. Also order the parts you will need in advance.

[@itchy-scratchy]

I just did an 86 g20 extended top. Not a lick of rust.....totally Westcoast all its life. Put a 6.0 4l80e. Gen3 drive by cable Replaced the tank just used a regular van tank with a 2022 camaro assembly ac delco pump. With a Hummer radiator. Used dirty dingo universal mounts.Kept my stock power steering just replaced the pully. Mine had the 305 and th350......3:08 gearing in the 10 bolt rear-end. Goes in the shop tomorrow getting Geared to a 4:10 LSD I went all the way.

[@BrokenWrenches]

Thats sounds awesome!!! Nothing like a nice modernized classic van. The mileage on mine just killed me, not to mention oil fouling plugs in 500 miles !!

[@itchy-scratchy]

@@BrokenWrenches yea my trans went out and it's needed all seals intake you know the drill. It had 98k on it. I didn't hook up air. Being a short body class b. I ditched the air-conditioning. Portable 12v units ran cheaper. So loosing the air-conditioning system I was able to get way more room and put the Savanah air cleaner and housing in. Believe it or not. It was totally easier plenty of room by doing the engine and trans. Just moved the mount back. Granted the gearing has to be changed. Drive by cable is the way to go too. No modifications to the pedal. Now mine gets 26mpg.

[@custersecservice4276]

hello, did a LS swap on my 1981 G20 shorty. You do not have enough room in the engine bay. I used a camaro exhaust manifold to get it fitted. Also made room for the alternator. ( so had to move the gas pedal a little bid. Engine is also more to the front because there is no room. I Used a stock oil pan. So i couldn't lower the egine. but everything is in now, and it run's great.

[@BrokenWrenches]

Thanks for watching man. Vans are sweet

[@peterzinia3767]

Last year I took an L96 ( the 6.0 with the

[@peterzinia3767]

An L96 (6.0 w/aluminum heads steel block)with the 4L90 trans out of a 2014 Isuzu NPR & stuffed it in an '81 G30. What a fun job that was. The engine & trans fit a little tight. Had to do the mount adapters,notch the frame so the A/C lines would fit,shorten the front drive shaft(2 piece w/carrier bearing)& modify the trans cross member as well as move the mount for the carrier bearing forward to keep the D.S angles within specs. The owner wanted me to use as much of the stock harness as possible. That was the biggest pain in the ass. All the lights in & out,radio,door locks all upgraded for power as well as the windows & mirrors. Spent alot of time it. More that I wanted but was well compensated. I had planned on the 4 wire setup,but figured it would be cool to upgrade all the accessories. Had to do some banging on the body so the exhaust manifold cleared w/3/4 inch on both sides. Cut out the top off both gas tanks tossed the mechanical pump and welded the high pressure pump section on after welding a baffle in the tank so it always gets fuel. It turned out great,but Never again.

[@Imdeadpool]

Currently rebuilding my drivetrain out of my 79 Chevy van (transmission went bad, found a lifter in the oil pan) and I need to get my engine out so this video showing how to disassemble the front end helped a lot! Thanks

[@sunsolatx]

I'm so glad I found this video. I began working on my 82 G20 last weekend. Looking at an engine swap later but first, all the suspension replacement. Thanks for this video.

[@BrokenWrenches]

AWESOME. thanks for watching

[@ricusserfontein1086]

My 1984 G20 is my favourite vehicle ive ever owned.

[@BrokenWrenches]

Im pretty fond of this one as well !!! Thanks for watching

[@timjefferson2137]

You obviously never had a 'Cuda lol but yeah, they're pretty cool. I still like mine after all these years!

[@benstanley449]

Mine is an 82 as well! I put a video up but that was almost a year ago. Documented most of the process but haven’t uploaded any of it. 9 months of body work, new rebuilt 350 to replace the inline 6, 4l60 to replace 3 speed manual, and posi and gear set in the rear end. New gas tank to accommodate efi. Going to be keeping up with your progress here. Love to see it!

[@BrokenWrenches]

get busy uploading it. i will watch them.

[@kasems1536]

Hi, nice jobs & thanks for your VDO, I really love G20 & I have one 1992 hi roof tiara conversion 350TBI,,,,greeting from Bangkok, THANKS again.

[@BrokenWrenches]

thank you very much for watching!!

[@Salmon_Rush_Die]

Wow I haven't seen an A.I.R. system for many years. Brings back a foul memory.

[@stoweby]

Glad to see this can be done. Once I complete the restomod on everything else in my 93 G20 my plan will be to swap a c5 engine/trans when the old tbi dies. I get to start on it over the winter finally

[@watch9604]

Where are you getting parts? I just bought a 90 G20. Looking to replace the transmission and rear diff to get it running first then maybe do an engine swap later.

[@dieselmechanic9824]

I wrecked my hot rod 3 years ago. Still pulling glass out my self. I feel your pain.

[@BrokenWrenches]

Yep, good times. Im doing a video of that car soon along with my history with it.

[@nobullshiit5682]

i love these van a nd also love the astro vans cant wait to swap mine to an ls

[@BrokenWrenches]

Me to, not many running around anymore! Thanks for watching

[@funkart2011]

love it keep us updated

[@BrokenWrenches]

thanks for watching!!! that build series is done already. im loving it.

[@pedrovalentin6658]

so glad to see this project

[@BrokenWrenches]

Thanks !!

[@MetalTentDiaries]

Great video! That gas tank/sending unit is super helpful. I have a 5.3 and a 4x4 G30 roller, going to try to mate them together over the winter. Definitely subscribing and following along with the swap for tips and references.

[@BrokenWrenches]

Thanks for watching man…. The last episode in the swap series is coming out this week. Im including a list of parts used in it. Most of the major component part numbers.

[@davidoswald2155]

Looking do something similar with my kids real soon myself except with a 95 G20 conversion van instead and possibly a LT1 engine for the upgrade. So I will.be watching for inspiration good luck with your build.👍

[@BrokenWrenches]

That would be cool!

[@davidoswald2155]

@@BrokenWrenches I hopefully found the van , looking at It this weekend.

[@WNCworks]

I had a 73 GMC Vandura with a 350 in it that was also tired. I had a .030 over 327 (331) at the time that had a small cam and aluminum heads, so I swapped them out one Saturday. Bolted a 400 turbo transmission up, and it ran great. Sure do miss that old van, we had a lot of fun!

[@WNCworks]

Ps I pulled my engine out of the passenger door...

[@BrokenWrenches]

Gotta love that van life. I drove an 88 g20 conversion van to HS 20 years ago.

[@darrencatenacci2737]

Well that looks like fun. They must’ve put the driveline in before the body went on. Looks like it’s gonna be a fairly tight fit. But I know it should fit that’s basically a small block Chevy so it is the same measurement wise isn’t it? That van is gonna be a beast with that engine in it.

[@BrokenWrenches]

Yea, its real close dimension wise, gonna find out tomorrow. It will bolt right up to the trans, probably have to add some different holes to the LS flexplate. Im not optimistic the cool headers will work tho. Stay tuned.

[@Stephen-ou4sy]

Should be an interesting series. I think on a par with The Skid Factory fitting a Barra in an old Bedford van. Good luck

[@BrokenWrenches]

Gonna be fun.

[@BrokenWrenches]

your welcome. they can also be pulled out the interior if you pull all the seats, i prefer out the front.

[@izaacciro]

Looking forward to this one

[@BrokenWrenches]

Me to my friend

[@madKURTmaxxx]

Keep it up man! I’m looking to do the same on my 1985 Chevy G20 “Ivory Coach”

[@BrokenWrenches]

It hasnt really been to bad really

[@baldeaglegarage]

Nice video! A G20 is on my list of vehicles to get. Good info on changing to a newer tank that has a larger opening for the different pump thats needed. Great planning ahead for a 4L60 if you change your mind later on.

[@theofficialdiamondlou2418]

Fixin to get into my 87’ g20 Starcraft Custom , but I think I’m going to rebuild the existing 350 if it’s not cracked. As it is a 4/bolt 250 hp truck motor. But with 367,000 + miles it may be done. Then I’ll go with a crate motor. Great stuff good luck with the swap. New sub 🤠🎸🎶🤙

[@BrokenWrenches]

Thats a lot of miles. I really appreciate ya watching and subscribing !!

[@danielburke4351]

Can’t wait to see the process of you dropping the LS in! 😀

[@BrokenWrenches]

It is now in the van, stayed tuned for this weeks video on Wednesday.

[@ashleyjessee5953]

That van is the same year as me lol

[@peterzinia3767]

You gain an inch of space in front of engine because you have to move the motor back w/adapter plates so the oil pan doesn't sit on the cradle. Which means modifying the trans cross member or getting one from an older Impala. Shortening the driveshaft or getting one that fits the new length. If you have power assist steering you can drill a second hole in the back of the P.S pump & weld a nut there for the 2nd line out or pick up one that is has 2 out & 1 return already. Older chevys have them but the mount doesn't line up with the old pattern & the shaft is different length for pulley so belt doesn't line up right. Should be an insane ride when you finish. Think about stuffing a turbo in there. It can be done.

[@BrokenWrenches]

I love it now !!!! Appreciate you watching!!!

[@CR7659]

Worth noting that a 1988-up van may be a better candidate for this swap. That year they made the doghouse and firewall opening larger and the big block 454 became an option. 1992-95 have an electric speedometer also (4L60E or 4L80E trans), so you won't need the cable sensor. Plus they run a TBI so already come with an EFI fuel sender. A good donor vehicle for this swap would be an Express work van. They don't typically have power windows and so forth leaving a fairly simple stock harness that could be adapted. Like this generation of van the power window and lock harness is an add-on piece (at least it is on 97-02). My 88-up vans also have a two piece fan shroud. Although 95% of the time the bolts are broken or break when you try to remove them.

[@BrokenWrenches]

agreed. This engine bay is quite tight. I worked on a mid 90's G30 recently that had the diesel,,, lots more room.

[@SheDreamtSheWas]

Add this to your own personal sacrad text "Radiators have magic powers"

[@MattKapp-y4e]

Thank you for posting the G20 LS swap videos! I just finished binge watching all of them. Do you have any air compressor bracket kits left for sale on EBay? Couldn’t find any. Thanks so much!

[@BrokenWrenches]

thank you very much for watching. I have a batch ready to sell as soon as an order of pulleys show up. should be on ebay by the end of the week. my seller account is brandoman68

[@tommavrakos]

I would like to find some to rebuild my motor. 350 cubic inch.92 g30. 377 miles. Tom in tarpon springs Florida

[@basilmacgill]

I have the 92 definitely waiting to do my swap my question is what is rear coil shocks model numbers or brand

[@BrokenWrenches]

I just get on rockauto.com and pick something about medium priced. They have a lot of selection.

[@frankenmnster_75]

What are the part numbers for all the fuel fittings you used? 😅

[@BrokenWrenches]

Check out the final video of the series, I think I got the major fittings in the description. Thanks for watching!

[@sugarskulllyfe5890]

thanks for the video

[@BrokenWrenches]

Welcome

[@HaroldBrown-sd2iv]

I have a 89 g20 that I actually purchased as a family van. Headed to the dentist knowing my muffler was fully slip. Had it hauled off to the local muffler place. They said I blew my engine. Yet he offered me 400 for my van. My rear end cost 7... yet he's said he can't fix it that it don't crank again Why? I need help. Truck in great shape. That's our family traveling van... Really! It went from muffler to no cranking to buying. All new parts. Help? in Danville,Virginia originally from Obion Tn.

[@BrokenWrenches]

hello. thats bad news. my first step would be to try to turn the engine manually. usually it will spin without to much effort. there is a big nut in the middle of the big balancer that the belts go on. if it spins freely then the “no crank” is electrical and likely not a complete engine failure. if it turns ok i would find a local DIY mechanic that works from home like i do. generally these guys are the most honest and cheapest. good luck. engines for these aren’t that expensive so don’t get to discouraged.

[@justushunter8465]

Just curious, why is it better to not have displacement on demand?

[@BrokenWrenches]

Main reason is the DOD function causes catastrophic camshaft failure, sometimes at low miles. I changed one at 67,000 miles.

[@justushunter8465]

@@BrokenWrenches Thanks, that makes more sense

[@Trikekid84]

Clean vans like this can go for $6000-10,000 all day in WI. Now add the LS swap thats what people will pay for.

[@BrokenWrenches]

i bought this one from my wife’s aunt 8 years ago for 300 dollars !!!! been in the family since the early 90’s.

[@alanshepard1561]

My G30 was a forest service rig from 1982 to 2019 some how. I’m basically the first owner. I’m not sire what they did to the motor but it’s at least been rebuilt. The th400 had a sticker that said it had been “utility reprogrammed”. It has 373 rear gears. I’ve had other 350s but for some reason, perhaps the gears, this one can haul a#$. I’d rather throw vortec heads, a good intake, headers, magnaflow, cam, etc maybe even bore out to 355 or whatever, then put in a 5.3ls. But if I could find a 6.0l ls with 4l80e that i could start working on to have on hand when time or necessity allows I’d do it in a heart beat. I’ll be towing a large camper trailer around for trips that’ll mostly be hollowed out and open living space. I’d love to hear your final reviews when done. I’ll watch every minute of the process too especially considering this is my first automotive project.

[@alanshepard1561]

Posted before i watched lol. Still curious about the 4.3.

[@BrokenWrenches]

my 350 was totally pooped.

[@peterzinia3767]

Have you started on your g30 yet? I've done one & maybe give you some advise on what not to do.

[@PaulyStax]

please tell me what size rim and tire you are running front and back. Are those 15x8 rims or 10"? What size tires are those? Van looks dope. Thanks for sharing.

[@BrokenWrenches]

wheels are 15x7 I think, or maybe it was 15x8.....front 235/60r15,,rear 255/60r15

[@iancoleman9341]

What engine transmission combo was in it?

[@BrokenWrenches]

It had a carbureted 350 and th350…. Still has the th350 but whenever it dies i will put a 4l60e in it. ECM is already setup for it.

[@iancoleman9341]

@@BrokenWrenches I have a 6 3 on the tree 81 im putting a 350 and muncie 3 speed in

[@literallyalwaysthejews5397]

I got a G30 that's my daily for my business. I'd love to do something like this instead of getting a new van.

[@BrokenWrenches]

I highly recommend this. Im really enjoying it. Almost done shooting the last of the swap series. Its turned out great. Totally worth it.

[@literallyalwaysthejews5397]

@@BrokenWrenches Awesome glad to hear. There's just something about the old vans.

[@peterzinia3767]

Did one last year. Alot of modifying. Your going to run into alot of bumps,but it's doable if you plan before you dive in. Almost every step requires tweaking cutting grinding reinforcing or rerouting. It's a big job but if you have the time & the tools it will be an awesome ride.

[@jimmywarledo4930]

Could a 5.3 fit in also? I have a 95 G20, that I'm going to engine swap

[@BrokenWrenches]

Yes sir. Same dimensions

[@VintageSpeedwerks]

I noticed your plate, near OKC?

[@BrokenWrenches]

thanks for watching man. north of tulsa a little ways.

[@VintageSpeedwerks]

@@BrokenWrenches ahh darn, I'd like to checkout the van, I'm halfway through episode 2. I'm messing with a 1975 right now.

[@BrokenWrenches]

if your ever in my area holler at me .

[@ThePerfectSeason1972]

Does the van have a frame or is it a unibody?

[@BrokenWrenches]

Unibody. Built like a tank really.

[@ThePerfectSeason1972]

@@BrokenWrenches - can I ask you a question about your van? It's about the wiper blades, how in the world does one disconnect the blade assembly from the tab, I have spent 2 hours researching it and not 1 single person has a video on how to remove it. Not the entire lever, but the part that snaps onto the tab that has the actual rubber blade on it. I can't figure it out and don't want to force it or damage it. Thanks or anyone else ever done it?

[@ThePerfectSeason1972]

@@BrokenWrenches - I figured it out on the wiper blades, you’re changing a motor and I can’t figure out how to remove wiper blades. kzbin.info/www/bejne/ombIYnqbd8-ehtU

[@jadalindegren3061]

Hey! Thanks so much for making these videos! I have watched them all and they have been incredibly helpful. I have a 1976 G30 Ambulance with the original 5.7 in it. I am looking at an engine swap mainly because I can't get over 75 mph with a gutted cab. I do have to smog it in California as well, so I have been researching what LS would work best. I am curious as to why you chose the 4.8. If I buy the 5.3 trans, motor, and harness (or even something bigger) will it fit? Will it be enough torque/hp? I am converting it into a self sustaining camper van so I intend to load it down pretty well. I want to make sure whatever I put in there will fit, hold up, and last a while. Any advice would be greatly appreciated.

[@BrokenWrenches]

Hey, thanks for watching. Main reason i went with the 4.8 is because it was what was available. The 4.8 is the most affordable of the LS engines typically. As far as pulling that ambulance you need as much low end torque as possible, this means you need to find a 6.0L at a minimum. As far as fit goes it should be the same more or less. Another thing you need to figure out if your speed is limited to 75 due to the engine being worn out, or is the rear gear axle ratio so high the engine is running out of oomph??? My van still has the TH350 3 speed trans. You will need to upgrade to a 4 speed automatic with overdrive. This will allow you to get a little better highway speeds. I would say a good donor vehicle for you would be an early 2000’s silverado 2500.

[@jadalindegren3061]

@@BrokenWrenches Thank you! I will look into that rear axle ratio for sure. Also funny you should say that, I am considering a fully functional 2002 silverado, it is sitting at 174,000 mi. I have to check in and see if it would be worth investing in asking is 5000.

[@AbcXyz-rn2lz]

TH400 with cooler would make it an awesome hauler

[@ethan2868]

I just inherited an 83 not sure what to do with it

[@BrokenWrenches]

Drive that thing my friend!!! Such a unique experience compared to all the plastic blobs people drive everyday

[@kentcarr160]

What was your gas mileage before and after?

[@BrokenWrenches]

thanks for watching. my super tired old 350 was getting 5mpg at best. the new engine i would guess at least 15mpg. it was such a drastic difference that i thought my gas gauge quit working because the fuel use dropped so much 😂

[@kentcarr160]

@BrokenWrenches That's amazing. My 1978 Chev Van G20 with 350 engine maybe gets 7 or 8 mpg. I always thought it was due to the big Rochester 4MV carburetor that sucks gas like a vacuum.

[@jimmywarledo4930]

How tall is your ceiling?

[@BrokenWrenches]

in the van i would guess 4.5 feet or so. in the shop 12.5

[@ThePerfectSeason1972]

Nice van, are those rally sport rims?

[@BrokenWrenches]

Honestly not sure what they actually call them, thats what all the locals call them. Square body truck rims or fancy G vans came with them.

[@JohnSnowden-s9b]

What's ur mpg ..

[@BrokenWrenches]

it’s probably around 15mpg or so.

[@ludvigsensworkshop4908]

do anybody know where to find the chassis number on a G20 1995?

[@michalob21]

Throw two 300 watt solar panels on the roof

[@mrnobody8540]

Oh yeah - with the front cross and trans member out - great time to modify them and remove a little bit of weight as you rebuild your front suspension

[@BrokenWrenches]

The suspension will come later. Thanks for watching.

[@mrnobody8540]

@@BrokenWrenches You can drop the front by pancaking the front crossmember - 1and 1/2" with ease ; ( two inches max - but will require some more steering system mods )... Shave a little bit of weight doing it.... This does requires a lot of welding skill - but is cheaper than buying a aftermarket tube frame cross member or drop spindles. You could go a couple of other ways - but I think it's something that most could definitely do --- however I would spend my money on a aftermarket tube A-arms as it's worth the money if you was to buy a tube cross member later... Making a tube trans member is not hard - but boxing the factory cross member... Again something most could definitely do if they are able to weld. Not needed - but it does clean up the under chassis looks... If you was to take the one ton 3" rear spring perch and replace the stock G20 and add the c notch with the fiberglass Astro rear leaf spring - the rear could be lowered and shave a few pounds... But going to a 4 link system or early truck @ 63-72 rear suspension set up would be nicer then the factory leaf spring stock setup on the cool looks side of things. Just something to think about... If money was not an issue - a IRS Corvette front and rear suspension set up would be my personal choice. Hard to bet aluminum A-arms, - big brakes with a lot of big wheels to choose... Good luck - I personally plan on putting a Ford motor in mine if I stay with a gas motor. I know - but I would like to have the distributor up front... Makes tuning the engine easy when your on your own. Besides the Ford motor is lighter then the Chevy and their are lots of little 302's in the scrap yards... Who's going to know? It's lighter, easy to work on and cheep...

[@mrnobody8540]

@@BrokenWrenches A link kzbin.info/www/bejne/aWTOeolpdtVla6c

[@invisableobserver]

I'd like to get a shorty to LS swap, it sure is a lot of work at my age though, and there is not many hot women out there to pick up with it anymore.

[@bnorby213]

Why not use inline pump and keep ur original tank setup. Personally I don’t want my pump in the tank

[@BrokenWrenches]

Valid question. There are two main reasons. 1st and foremost is that the in tank fuel pumps are submerged in fuel and will run cooler and therefore in theory they last longer. 2nd would be the noise of an in tank pump is substantially less.

[@bnorby213]

@ totally get that. I’m just starting my LQ4 swap into my 86 G20. Thanks for taking the time to share all of this man!

[@jimmywarledo4930]

LS that Econoline

[@flyfly3456]

авто тех времён

[@BrokenWrenches]

Yep

[@flyfly3456]

@@BrokenWrenches мне такие авто нравятся

[@mrnobody8540]

Your doing things the hard way - cut your fluid line's and hose's.. remove the fan blade and fan shroud - then the radiator... Then you can remove the grill and other front end part's.... Now it's a free for all on the rest of the engine. The best way to remove the engine and trans is by dropping them from the bottom by removing the front cross member and the trans member after dropping the drive line. You have a lift - no reason not to do the engine removal by the bottom route. Saves a lot of time - but does require that the front suspension can be taken care of...

[@waynepierce7305]

I have a 1985 Chevy 20 to sell somebody..