Transcript Chevy Astro / GMC Safari

Chevy Astro / GMC Safari
The V8 Swap
This is a photo documentary on
how to install a small block
Chevy V8, such as a 350, in
place of the little 4.3 that the
vans came from the factory.
The Beginning…
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The first thing that you need to find is of
course a V8. My personal choice was a
350 from a 89 up full size Chevy/GMC
pickup. These engines are virtually a bolt
in, and are very easy to do.
The van I am using for this show is my 86
Astro, which has served me faithfully for
years, so its time to have some fun.
Parts List
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1) V8 engine
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2) motor mounts (from JTR or Racecraft Conversions)
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3) TB bracket, may not be necessary depending on the engine choice.
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4) V8 fuel injectors
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5) 7747 computer with V8 program
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6) Headman 68600 headers, or stock manifolds.
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7) V8 distributor
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8) V8 Flexplate, I am not sure if the V6 is the same or not.
First, you need to remove most of the front end.
This means simple stuff like the grille, headlight
buckets, upper radiator support, the radiator
itself... Here Mike removes the lower fill above
the bumper.
Advice on the upper radiator
support…
IMPORTANT
 There are two bolts that are on the back
of the upper support on each side at the
top. It is very easy to overlook these and
have a problem removing the support. In
fact, one is actually a chassis ground. At
least it was on my Astro. The picture on
the next page points to their locations.
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Remember, they are on the BACK
of the main support
More stuff to remove
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This is what the van
SHOULD look like with
the radiator, ac
condenser, bumper,
fill panel all removed.
We also removed the
hood as well, since it
was really beat and
will be replaced.
Now the fun begins
Out with the old!!!

Make absolutely sure that you disconnect all the
wiring from everything attached to the engine. If
you miss something… You’ll know it all too fast.
Also, make sure you take off the TBI off the top
of the engine, as you will need all the room to
hook the engine crane up to it. It has to be
extremely close in order to get the engine out of
there. We even removed the distributor.
Please Remember!

Don’t forget to have the front of the van
on ramps… We DID forget this little touch
and thankfully we were able to lift the van
with my old 1955 Hein Werner jack, and
shove the ramps under the front wheels…
You more than likely will not get the
engine out without the body being in the
air.
Trans too???

In our case, since the
transmission was toasted
too, we decided to pull it
too. It actually seemed a
little easier to do it this
way. Again, remember to
unhook
everything…cause the
one thing forgotten WILL
hold that puppy in there…
Remember…CLOSENESS
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As you can see, the crane has to be close to the
intake…
Time to Tug (or really Yank)
Be Careful!
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Again, double check yourself here. Make
sure everything is disconnected, the chain
is correctly hooked to the engine, all
harnesses are out of the way of the
engine being pulled. And have a few extra
hands around in case, as the engine is
heavy enough by itself, let alone with the
trans on it.
Remember the Harness! We
goofed!
Its Free!!!
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Its free and hanging
there… Now to get it
off the crane and
onto the tire outside.
This whole combo of
the 4.3 and toasted
tranny weighs upward
of 1000 lbs combined!
Don’t drop this on
your toes!
Ready and waiting! Time to clean it
up a little before the new resident
moves in!
Rest in Peace, Old friend…
Boltin’ It Together
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Here we see Mike and
Ryan tightening the
transmission down.
We later decided to
install the engine and
transmission
seperately.
Before We Forget…The Chips!
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In order for the V8 to function correctly, you must replace the chips
in the computer. If you got the computer from the donor truck, you
are already set. If not, just get these from the junkyard and install
them in the computer. Make sure your computer is service number
7747. Without these, it may run, but not the proper way!
Closer view of Motormount

This shows the
drivers side motor
mount and header
clearance. We had no
issues there
whatsoever.
On its way home!
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Here goes our 350,
heading to its new
home. Without the
trans attached, it was
very easy to slip it in
there. Surprising GM
never offered these
factory issue. If you
want one, gotta do it
yourself!!!
Almost In!
Getting it Together!
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The top picture shows
how the engine and
trans lined up initially.
A little maneuvering,
preferably with 2 or
more people, ends up
with the result on the
bottom picture. A nice
hookup!
She’s Home!!!
Putting it all back together
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Here we see the front of
the engine, complete with
the 350 serpentine
accessory brackets now
in place. Power pulley
installed on the
crankshaft too at this
point. Coming along slow
but sure
Cant wait to hear her run!
The time is closing in!
Some Points To Remember
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Check Fuel lines for leaks
Double check all hose fittings
Check the ignition wire order for proper
location on the cap…
I can stress these because I didn’t do
these things and wound up with a minor
fire and more damage to repair.
Another Thing
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In this 86 van, You will
notice that the alternator
and the AC compressor
have switched sides. This
is not a issue, as simple
lengthening of a couple
of wires is all that’s
needed here.
Looking Great!
Make sure the steering
pulley is on the whole
way! Otherwise, you will
chew up belts…
Right Side Rear Wires
Drivers Side Rear Wires
Radiator Back In…
No AC For me…want to keep it cool!
Looking Good! Almost Done!
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The reason for no AC
is because of the big
filter…Its actually
from a 88-95 Chevy
truck!
So Far, So Good!
Project Complete!