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Thread: 95 5.7 Liter TBI swap to 2002 5.3 Liter

  1. #1
    Super Moderator dave w's Avatar
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    95 5.7 Liter TBI swap to 2002 5.3 Liter

    Below is an engine conversion plan I've put together for a 1995 Tahoe with a 5.7 liter TBI engine to a 2002 Drive by Cable LM7 5.3 liter engine. The basic plan is to keep the 16197427 PCM as a stand alone transmission controller for the 1995 4L60E with PWM TCC.

    The 16197427 PCM wiring requirements for Stand Alone 4L60E/80E are listed below.
    VSS (already in the vehicle)
    TPS
    RPM (distributor reference Hi / Lo pulses)
    Ignition
    Battery
    Ground

    Keep the 16197427 TBI PCM wiring listed below.
    Transmission
    Grounds (the distributor reference Lo black / red wire is a ground)
    Ignition (On / Start)
    Battery +
    TPS
    VSS

    Re-purpose the 16197427 wiring listed below:

    The Fuel Pump control wire F6, from the 16197427 PCM removed and spliced into the '0411 Red 9 pin to use the existing Fuel Pump Relay.

    Re-purpose the HEI pink ignition wire to power the '0411 injectors and coils for Bank 1 / Bank 2.

    Re-purpose the 16197427 Injector ignition pink wires to power the '0411 sensors.(HO2S's and MAF).

    Splice into the 16197427 PCM ignition & battery + wiring to power the '0411 PCM ignition & battery + wiring.

    Connect the '0411 ground wires to the exact same ground source being used by the 16197427.


    The Transmission fuse is already in the vehicle.

    Optional - splice into the VSS wiring already in the vehicle to supply the '0411 with a VSS input and re-program the '0411 gear ratio / tire size to match the Tahoe.

    Remove the E6 wire from the 16197427 PCM and splice with '0411 Red 46 wire for the M.I.L.

    Use the '0411 Red 10 wire to supply the 16197427 PCM A4 purple / white wire with a distributor reference HI input. (reprogram '0411 as required)

    Connecting all three TPS wires to both the 16197427 PCM and '0411 using a custom built TPS adapter cable, similar to the one in the attached picture. I'm thinking with both the 16197427 PCM and '0411 sharing the same ground, ignition, and battery wiring the TPS 0v - 5v gray wires will balance and provide a strong signal to both computers.

    Use two ALDL connectors one for the 16197427 and one for the '0411.

    Custom program the 16197427 PROM chip to eliminate engine error codes.

    Custom '0411 Flash as required.

    Luckily, the 1995 Tahoe has a higher pressure fuel pump (DELPHI FG0038).

    Thoughts?

    dave w
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    Last edited by dave w; 04-08-2017 at 11:33 AM.

  2. #2
    Fuel Injected!
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    I thought for about $100 or so you could get a newer valve body to put the 96+ solenoids in a 95 4L60e transmission. If you could, then it gets rid of running 2 PCM's.

  3. #3
    Super Moderator dave w's Avatar
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    Quote Originally Posted by lionelhutz View Post
    I thought for about $100 or so you could get a newer valve body to put the 96+ solenoids in a 95 4L60e transmission. If you could, then it gets rid of running 2 PCM's.
    That is certainly a very doable option. The labor cost associated with installing the 96+ solenoids into the 95 4L60E might be budget factor. Even if the labor charge for solder splicing wires was $10 per wire, that might be a better budget option?

    Maybe there is a website link to information for a similar engine conversion using the 96+ solenoids?

    dave w

  4. #4
    Fuel Injected!
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    I don't have a link to a site. How about this?

    http://www.ebay.com/itm/4L60E-VALVE-...-/201771845802

  5. #5
    Carb and Points!
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    Could you do this same thing with a 4l80e truck? Leave the factory computer in place and run a carburated engine? As long as you had a tps mounted on the carb and a rpm signal?
    1993 K2500 Suburban
    350TBI/4l80e

  6. #6
    Super Moderator dave w's Avatar
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    Quote Originally Posted by 1badeagle View Post
    Could you do this same thing with a 4l80e truck? Leave the factory computer in place and run a carburated engine? As long as you had a tps mounted on the carb and a rpm signal?
    Yes, with TPS, RPM, and a Vehicle Speed Sensor Input.

    dave w

  7. #7
    Carb and Points!
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    The vss should still be intact if the original harness is hooked up correct?
    1993 K2500 Suburban
    350TBI/4l80e

  8. #8
    Fuel Injected!
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    Quote Originally Posted by 1badeagle View Post
    Could you do this same thing with a 4l80e truck? Leave the factory computer in place and run a carburated engine? As long as you had a tps mounted on the carb and a rpm signal?
    Yes you can. The TPS I would consider the aftermarket remote mounted TPS or set it up yourself (have a look). The RPM signal is easy if you run HEI large cap. The HEI will support triggering TWO Ignition modules. I Took the two wires from the pick up coil and soldered wires to the Pick-up coil connector. Ran the wires thru a small hole in the bottom of the HEI base. I used a 1987 or so 5.7 TBI truck Delco Ign module. Mounted to the flat HEI base under side. (Or you may elect to mount it to an alum plate with Di-Elec Grease very close near the lower part of the dist.) I powered up the Module as it would have been. The 4 wire connector the module has I only used the Ground plane or Ign Low or Reference Low and the Engine Reference High or RPM. You must power the module and I ran another Ground wire to the module screw. The Module Reference High is the TCM RPM signal. 4 pulses per revolution and the TCM understands this in the 427 PCM. ( Water will kill the pick-up coil signal if it floods between the two pins. Seal it in the way you are comfortable. But only the pick up coil connector is exposed as the other connections are in GM Sealed terminals.) Power only needs the one pink wire at the two pin sealed connector. )
    You will need to run the DRAC and have it set correctly so the PCM/TCM side will have the correct signals.
    It is difficult, I found, to have a TPS mounted to the Carb. I used a Rochester and fabbed a bracket on the cable side to mount the TPS. But the remote mount TPS is easier and you don't have concern about the air cleaner can clearance on your TPS bracket. It does work well.

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