5.3L LS swap and overall restoration – Reference photos with descriptions
…arranged newest to oldest…
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nasty rusted rear shocked. Soaked the nuts/bolts in PB Blaster for a couple days and they came right off.

Sanden 508 R57580 compressor and ICT Billet 551494X-3 bracket.

Sanden 508 R57580 compressor and ICT Billet 551494X-3 bracket.

preparing wires and plug for instrument panel

fuel lines and wiring thru firewall loomed up

ebay special ODB2

FIRST START!!!

headlight/wiper switch is in rough condition but works well.

headlight switch

wiper switch

original backup switch will be changed out to include neutral safety switch.

previously unknown disconnected heavy gauge wire under dash... for rear window defroster which I do not have...

in cleaning up the original tank, I cleaned off some solder that was there for a repair and it leaked... alot... So rather than repair it again, a new Spectra Premium replacement was ordered.

in cleaning up the original tank, I cleaned off some solder that was there for a repair and it leaked... alot... So rather than repair it again, a new Spectra Premium replacement was ordered.

no surprise here...

gas pedal cleaned up and painted... had to bend it slightly to take up some slack in the oem truck throttle cable...

gas pedal cleaned up and painted... had to bend it slightly to take up some slack in the oem truck throttle cable...

heater box back together and wiring cleaned up...

heater box back together and wiring cleaned up...

heater box back together and wiring cleaned up...

TV throttle connector painted...

TV throttle connector painted...

another smashed up box... part not damaged.

new AV evap coil arrived and installed... new heater core also...

new AV evap coil arrived and installed...

new AV evap coil arrived and installed...

New AC condenser... damaged in shipping from rockauto...

New AC condenser... damaged in shipping from rockauto...

New AC condenser... damaged in shipping from rockauto...

version two... bracket will change when I put on a new adjustable TV cable...

version two... bracket will change when I put on a new adjustable TV cable...

version two... bracket will change when I put on a new adjustable TV cable...

version two... bracket will change when I put on a new adjustable TV cable...

version two... bracket will change when I put on a new adjustable TV cable...

version two... bracket will change when I put on a new adjustable TV cable...

about to go to version two on bracket...

about to go to version two on bracket...

version two...

version two...

version two...

version two...

version two...

version two...

gonna have to do some adjustment on this...

gonna have to do some adjustment on this...

gonna have to do some adjustment on this...

gonna have to do some adjustment on this...

gonna have to do some adjustment on this...

first version of TV connector installed...

first version of TV connector installed...

first version of TV connector installed...

first version of TV connector installed...

first version of TV connector installed...

This 700R4 trans cover is made to fit small block Chevy, not 5.3L

This vacuum port will be opened and connected for vacuum connection to canister for AC/heater controls

TV bracket install test fit..

TV bracket install test fit..

TV bracket install test fit..

TV bracket install test fit..

compare the smaller pulley to larger truck pulley (installed). Small pulley is Dorman 300-201 (plastic) or 300-202 (metal). Shown is the oem GM small pulley 10166335

compare the smaller pulley to larger truck pulley (installed). Small pulley is Dorman 300-201 (plastic) or 300-202 (metal). Shown is the oem GM small pulley 10166335

Plenty of clearance with the oem truck PS pulley because I have the smaller 605 steering box. So I did not need the smaller pulley that is needed if you have the 800 box.

Simplest thing to do is to change this fitting from o-ring to flare so I can use the oem Gbody replacement I need.

Out with the new and in with the old... To be clear, I used the original Gody replacement hoses which have flared fittings. oem truck 5.3 pump was o-ring, so I switched the fittings...

o-ring style vs flared power steering pump inlet connectors...

o-ring style vs flared power steering pump inlet connectors...
What type of ac condenser did you use ? I see that your lines are on the passenger side of vehicle . Also what did you use for the intake fitting for your power brakes ?
I used the Gbody Cutlass Condenser for AC to keep the install cleaner. It has connections on passenger-side whereas Malibu has driver-side connections. Intake fitting for power brakes? Everything on the brakes, from booster to lines to calipers/wheel cylinders are all OEM replacement. Hard lines and proportioning valve are from inlinetube.com
Do you have any part numbers for the ac hoses along with fittings ?
Hoses are custom fit and made. Even a couple fittings were custom made.
The tv bracket and cable ? Are they custom or replacements ? Do you have part numbers
The TV cable was oem, but I broke the housing and replaced it with an adjustable cable. The bracket was custom fabbed and the connector arm was custom fabbed. There’s a bit if information about how I did this in the write-up. See the menu for the URL.