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TBI conversion, exhaust issues, etc.

jms

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...another one of the "Can't make up my mind" posts.

Background: '85 K5, 350, vortec heads (7 years ago...), Q-Jet, Edelbrock TES headers, AIR injection, EGR pipe (from vortec manifold to O2 sensor port on DS collector). Needs to be compliant w/ AZ emissions, due next August. And they do a visual in addition to the sniffer.

I've had a TBI setup in a box for about a year now. Here are a bunch of random points I think I need to address:

When (If...?) I convert to TBI, I believe I need to retain the smog pump as it was original emissions equipment on the truck. AIR injection with the current headers happens upstream of the O2 sensor port - not sure how that would affect the computer and the fuel metering. Also, AIR injection is currently vacuum-controlled, so I need to find a similar port on the TBI/manifold in order to leave that alone.

Currently, the headers leak. Could be solved by a new gasket on each side, and then installation of an O2 sensor port in the passenger collector (since the driver's side is currently used for EGR.

However, I don't like headers anyway. A manifold from Pace could solve the driver's side issue of EGR + O2 ports; I'd still need a way to connect the smog pump. But that could possibly be done downstream of the O2 sensor port.

Question then remains what to do on the passenger side. A stock-ish manifold with AIR would be one possibility. It would allow me to keep the EFE unit on the passenger side, which is currently present but disabled due to the lack of an exhaust crossover passage in Vortec heads. And it would probably fit with the exhaust Y-pipe, well, sort of.

The current Y-pipe is another issue. It runs below the front driveshaft - which rubs on the Y-pipe when the front axle droops. Not that this is really a problem, it has been like that for a few years now. And the current Y-pipe wants to be close to the DS spring shackle bolt - to the point that it has pushed a nice indentation into the pipe just before the Y. This is despite several attempts to change it. It's not worn through, but...

The thought has occurred that if I go back to manifolds (which means I could actually get at the spark plugs again...) I could use a manifold (with AIR injection...?) that dumps in the center (like this...), and I could have a Y-pipe made to cross over in front of the oil pan sump (?). Not sure how much of a headache that would be, but it would get the Y-pipe away from the front driveshaft. Not sure how I'd fit the EFE unit in there, if only for the visual effect.

I'm aware that it all sounds pretty incoherent; I'm in the planning stages using my current motor. While a entire 5.3/4L65E swap would be certainly be nice, it's too involved with respect to time, space, and resources. Anyways, comments would be appreciated.
 
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If you were to go to a yard ( or look online for pics ) you could find a TBI motor with air , and copy the routing and see the port location . early 90's Camaro/Firebird comes to mind right off the bat . Trucks , most didn't get a.i.r , well at least in the states you reside . California may have a.i.r trucks .

As for manifolds and y-pipe , just have a y made for you . A local shop did my K5 years ago ( less than 350 with all new tube and turbo muffler and stock cat ) , and all was perfect until the lift , and then it only rubbed a little at full droop .
 
Yardwalk is not in the cards.... A little reading suggests I first need to find out whether the ECM I have came from a vehicle with a.i.r. - I don't believe that's the case, and that'll mean the ECM won't like my current headers that have air from the smog pump coming in upstream of the O2 sensor.

I also have to find out from the emissions people what I have to do to stay compliant - that is, will I need to keep the smog pump if the 'motor' is from a newer truck with an injection system that didn't use a smog pump, and what documentation is required.
 
Call your local referee station and tell them what you want to do and they will tell you what you need to have or can delete. I'm pretty sure the EFE valve can go and possibly the AIR system as well since most TBI rigs don't have it (some do though but not sure from what part of the country and why). I'm pretty sure the AIR system for a carbed rig wouldn't work with a TBI engine though.
 
The funny thing in all this is that looking for info on conversion to fuel injection was how I found ColoradoK5.com in the first place - nearly 10 years ago. That carb has held up pretty good over God knows how many trail rides...

If I need to ditch the headers anyways, I think the exhaust x-over under the motor is something to explore...
 

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