3400 swap begins - 56k = maybe

[IsaacHayes]

Nice! It looks good in the bay!

[Superdave]

lmao...




Saw that tube on the rad support and guy here at work thought it was KY at first...


Nice swap!

[Kardain]

Spent the better part of the day unstringing the 2.2 harness to seperate out the wires coming from the C100 connector and underhood fuse box so that I can integrate them into the 3400 harness... the harness is seperated into 2 sections, those wires coming from the C100/Fuse panel and those that don't...
the C100 connector has the stuff like ABS, engine to body power disconnects and the like..

Free zip ties FTW





After I did that, sat down and started working on what wires that come from those connectors go to the PCM plugs on the 2.2 computer.. Have all but 4 narrowed down. I'm also sure that 1 or 2 wires may not have made it into the right bundles... From there tried to match 'em up to existing locations on the 3400 harness, got lost at the 3400 fuse panel plug...



@ Superdave, now thats funny Almost makes sense w/ that big ol' engine going into that tiny engine bay. Its silicone grease in case your co-worker was wondering

Ok, off to play w/ more wires

[IsaacHayes]

Good luck! This may be the most time consuming part of the swap!

[Kardain]

Couple updates, non-engine swap related:

June 4:

Finished mapping out the c100 connector to the J PCM and cross referenced that to the LA1 PCM.

I still need to map out the underhood fuse panel for the J's and the connector built into the LA1 harness, also there's what appears to be an engine/body disconnect in the LA1 harness as well as BCM outputs... more later.

June 7:

While the front end is off, might as well do a facelift while I'm at it.

03+ crush guard came in, so I removed the other one… UPS tracking said 64 lbs, well it was revenge for the size of the box... (sorry, no pic of the crushguard... its just a boring, styrofoam piece)



As did the turn signals (they compliment my LED bulbs nicely)



There was another box, but I’ll save that one for later.

Think I finished mapping out the wiring on the all harnesses… I refuse to do that again

Just need to double check it all on paper before I get to the hack 'n' splice part...

Also ordered the 3400 throttle cable (GM part # 22619740 -- in case anyone searches for it, $20-ish from GMPD) and an 03+ hood striker.

June 8:

Mmm… Free stereo stuff is nice. Alpine 400w Class D Amp (while yes, this is not part of the engine swap, I promised progress). Work bought this one for me (via Crutchfield giftcards). Previously, through gift cards, they bought me a JVC HD Stereo Receiver. I'm gonna see how much stereo stuff I can get on their dollar.



Strung the harness to the engine. It appears that in 2002, a couple things may have changed… EGR valve plug is different (99-2001 is the same, 2002+ is different).

Ordered 2k3 Sunfire headlights, should be here this week... still need grilles, bumper and hood

Worked more on the paper verification process on the harness (check and double-check and triple check...)

June 9:

Put the harness on hold for a day (rain = ick) since there's a missing roof panel on my carport/garage thingy.

Started a new speaker box (ditching the dual subs for a single for now since I only have 1 amp), ran out of MDF though... cut all the pieces for one, but it didn’t fit (too tall)… so I’m going to finish it up and sell it locally… 1.7 cubic foot ported... the new one is 4 inches shorter, but 4.5" wider.

And an amp rack (still need a ˝” plexi piece and a filler for the rear part)



Need to secure the rack and get some carpeting for it.

----

Now from here, the updates are going to be a little less frequent Its down to running all the wires from where the 3400 PCM connectors are currently (under the brake booster) to where the stock J computer was - behind the passenger fender... as well as waiting on a couple parts for the tranny to get in so I can finish the lower engine mount. Oh, and before I put the engine in, in my excitement I forgot about the spacers for the AC compressor, so those are on the list as well...

[Kardain]

1) start on harness extension (now that its not raining, I've started that)

I've had to pick at this during the week because of the weather



My heat gun grew legs and walked away. I have 70 or so wires (I lost track) that I need to heatshrink and no heat gun. (I took this before I got the last couple wires soldered up). Its just long enough to span the lower rad support and I rerouted the harness thats on the engine to where the PCM plugs are on the driver's side of that support.

Here’s what’s left of my donor harness when I got done





tomorrow I start on:

2) once complete finish mapping out J PCM, C100, and underhood fuse panel to LA1 PCM/Fuse connector and start splicing

(I made a to-do list so I don't get ahead of myself, hense the quotes)

Oh, and can a mod move this to the engine swap forum

[Superdave]

Damn, that looks fun.. I guess i was lucky b/c mine had a V6 in it allready.

Good luck man!

[Kardain]

oh... yes... its fun... i can... hardly... contain... my... excitement

[Kardain]

June 19

Started on the harness extension part

First though, these 2 made sure that I was entertained for the 5 hours that I was working on the 1 plug extension:





Actually 5 hours, 41 minutes, but who’s counting….



And a test fit:



Oops. Too long, but that’s coo. I’d rather have it be too long than too short

I really gotta find that heat gun now…

June 20

Harness extension pt 2 done. Found the heat gun too . Took me 3 hours for this part (had a groove thing going)



Had a couple extra wires in the 2k2 harness… I’ll ID those later.

So that’s it for now… I’ll check back with more

[IsaacHayes]

(wheres the popcorn eating smiley?)

[Kardain]

(wheres the popcorn eating smiley?)

Right here:



Hmm.... bad news.

I have to remap out the wiring @ the LA1 fuse panel connector.

For some reason, it doesn't match up with the pinout I have

Possible bad news....

Now I have to reverify that the PCM pinouts are the same, which means I may have to redo the whole harness extension. After cross-referencing years on the fuse panel plug, its quite possibly a 2003 harness, not a 2002

[Kardain]

June 23:

Fuel lines hooked up

PCM outputs verified as OK.

June 25:

Here’s the mess of wiring:



Got out my trusty laptop. Oh, look... more wires:



Only got 5 wires done before I got a tad frustrated (I still need to prune the harness and run all the J stuff where it needs to go – ABS, various PCM wires, etc).

So, what do I do when I’m frustrated? Something destructive. Removed the dash. This pic reminds me that I really need to give her a bath..



I have a few more goodies up my sleeve, revealed later though….

[Kardain]

Front bumper arrives



Pruned out everything from the J harness that I don’t need, leaving this (a couple sensor plugs and a few to the PCM as well as a couple grounds):



Also got to listen to the new night DJ play Big and Rich: “Save a Horse (Ride a Cowboy)" back to back to back for 3 hours (I’m not kidding either…..)

[Rhedalert]

now this is a swap worth watching!!! Good luck!

[Kardain]

June 28:

Test fit of front bumper (its just the upper studs on each side holding it up). Still need to get the center brackets:



Got the shipping notice for the throttle cable and hood latch.

June 29:

On the agenda for tomorrow:

Finish up the last bits of wiring, install downpipe and start wiring in the gauges.

Also, the new LSD insert is shipped, should be here tomorrow, Monday or Tuesday. Throttle cable is being shipped, should be here on the 6th. I'm on pace with my planned pre-completion date of July 20th.

June 30:

Ok, there was a change in plans... the diff insert came in today



So, finished up the last bits of wiring (save a random sensor/ground wire) and started work on reassembling the trans.

July 1:

Got the trans back together. When I went to move it to clean it up some, there were bits of the input shaft bearing laying on my workbench, so get to take it apart again….



July 2:

$97 later from GM, the input bearing, seal, and rear cover seal are on order, should be here friday or monday. also included are the fascia brackets.

Decided to test some of the wiring starting with the starting system. took a few tries, but got the starter to tap (didn't try to fire it up since 1: I don't have the fuel pump feed hooked up yet, 2: no trans, and c: no downpipe installed yet).

nothing burned up, so I guess thats a good thing

July 3-6
Tried to troubleshoot why the fuel pump isn’t kicking on… “last good, first bad” leads to the PCM. Either a) the PCM is toast or 2) the theft protection is kicking on. I'm banking on the latter and working on other stuff till I get the BCM wired in.

Since I’ve been working on wiring, nothing new in the picture department.

July 6: Got the new throttle cable, so I get to mark another thing off my list Disassembled the trans in prep for the new input shaft bearing.

that's it for now... (oh and as for the rest of the non-engine swap stuff, I'm just copy/pasting from a word doc)