its hard to see in the picture f7 would be on the bottom row

 

if the egr solinoid was stuck open you would have a real rough idle.

 

Yeah, thats definately it....or lack thereof. The manual I have list others next to it that are missing as well.

Regarding the EGR, if stuck open = rough idle. Im quite confident my idle is good and smooth. Opposite of that it qouldnt re-circulate gasses back through to be burnt again....leading to slightly higher HC/NOX readings...?? Maybe this is the last piece of the puzzle?

Opinion on advancing timing up to 8*.....

 

I was hoping the high hc was from the ccp . Although hooked up correct to a ported vacuum signal too much vapor was entering the engine. Timing may help the hc but the nox I always think egr operation or passages being plugged first than a cat.

 

You're probably right there and I realize its a symptom of a more serious issue, but I need a bandaid fix to pass this.

Then, Id have another year and hopefully get a build done in that time.

 

seafoam I bet they would love you at the test station if you suck it throug the pcv hose in the parking lot.

 

Still getting to that EGR....keep getting side tracked with other things:

Pulled the old - dirty - broken - mismatched interior trim and dash...







The dash had a molded cover on it, po did a sheety job putting it on and was seperating:







Only thing wrong with cover:



I was able to seperate them without any further damage.

 

I washed everything down and went over it all with 60g. After compemplating on what color and paint to use I decided to think out of the box. Use my left over Rustoleum bedliner.

Here is an old piece of trim I used as a sample. What you see is 2 coats of the bedliner, wiped down with 400g...just go over it easy. The oe trim has a slight texture to it and the painted surface has the same feel and look...



Compared to the dash bezel:



Final product with dash mocked up for photo:

 

Also took the single - window switch out and swapped in a dual switch from a Burban'

On the Burban' top switch is still window, bottom is rear ac fan lo-off-hi

Since pretty much every chevy truck-k5-burban from 83-91 is the same all I had to do was make the extra hole in the dash.









Pre-wired it for cab roof lights....coming soon. Ill run these up the A-pillar when I re-install trim:





This thing is coming in handy....still need to fish for that dropped nut.......

 

What kind of connector would I use to plug into the ecm...?

 

If you want some relay holders and ecm pigtails send me a pm Ill take a few pictures just pay the shipping my contribution to project tpi blazer. I get the ends form mouser under the delphi 12089660-L. the pins are used on almost any mid 80's to earlt 90's gm ecms

http://www.mouser.com/ProductDetail/...3QJrZl7LJUsw==

 

This doesnt look good:



I drained the oil though, and while a bit dirty, it didnt appear to be contaminated with anything.

 

sent you a pm, man thats nasty looks like cappuccino. thats alot of blow bye and you even have the passenger side vented ;(

 

What's going on there??

 

Yeah, you got some sealing issues for sure. Bummer.

 

Ouch.

 

Hi. Nice build. Mine is similar, but I am using a Megasquirt ECU and Ford EDIS ignition instead of GM stuff. I was wondering why you didn't just use Firebird parts for the air intake?

Here's some pics of what I did:







So this attaches directly to the stock air intake hole in the radiator support. The tubing is the old carb air cleaner snorkel tube cut up, so it snaps right on.







The two Firebird duct pieces are just tied together with a piece of 3" exhaust tubing, which they clamp right on to.

These are old pictures. Since then I swapped those e-fans for the Windstar setup and got rid of all the V-belts for serpentine stuff with dual alternators, but you get the idea.

 

I like that..You can go to the passenger side too. I have plenty of room on that side with no charcoal cannister. Do you think it makes a big difference compared to an open element in front of the factory opening in the grill??

 

I tried GT 5.7 and LT1 boots, not the Firebird...look interesting. I do have Windstar fan in the garage, was in the process of putting them in when I noticed that goo. I found templates on CK5.com to use and had just finished pre-wiring and making my brackets:







Once the fans were in I would have more options for an intake.

 

I never tried that configuration, but my first round was that simple filter that bolts to the throttle body. I had big heat soak problems leaning everything out. With the CAI the truck pulls harder, but the cooler air was always confounded with poor IAT measurements.

I honestly could never get the "copper slug" TPI plenum temp sensor to work. Once the engine warms up, it tracks almost exactly with CLT temp. Hot restart was the worst and it would go to like 17:1 open loop. The stock ECU must ignore it or compensate somehow with a timer. I tried the little cage sensor in there and it worked better, but it was still a problem. My temp sensor is now in that tube before the air filter and the ECU hardly has to adjust anything as the engine warms up now. Some disagree with this setup, but IMO if the ECU can calculate correct fueling (open loop) then the sensor inputs are good.

Anyway, back to intake, why not just build a 5-sided box around the filter, open to the front? For a truck, water is a big issue and a wet filter can stall the engine. I can soak the engine compartment in a mudhole while the grill stays almost dry.

 

It seems like the heat soak to the mat sensor is a problem after shutting off...with my setup I was reading only about 20* warmer then the outside temperature while cruising with the engine at 180*..I was suprised it didn't read warmer.

 

If that was asked of me, I just dont have the room. The KN element barely fits in there as it is. Thats why Im working on getting the Windstar fans in.

Looking at your motor, you're alt and AC are on opposite sides of mine. Especially with the CS144, that thing is huge, no way go go around it. Same trying to go around the AC, the shroud is the biggest obstacle here:

 

The Ford fans should free up about 8"...plenty of room to make a CAI.

Im still bent of getting this thing to pass emissions. Was so close last time. Swapped out the EGR:



Coolant was a bit low, not uncommon, oil fill cap was clean as was dipstick. Im hoping alot of it was due to condensation.

We'll see if putting this on the pass side pcv helps:

[/

 

Here are a few newer pics I found, since I went to the serpentine, so the setup really is a lot like yours. With the Windstar fans there is plenty of room in there. (You can save another 1.5" or something with the Corvette pulleys and accessories, but a square nose has so much space underhood it's not needed. Plus the Corvette setup is annoying.)





As you can see, I don't have the CS144, I have a pair of the smaller CS-series. I have a battery on each side and the charcoal canister on the DS, but there would still be room for the air intake on the DS, but it would have to rub on the rad hose. You may have come up with a better rad hose solution than I did, so it might work OK with an air intake. I have the stock K5 hose, just shortened a couple of inches.

If I had to come up with the ultimate intake, I would build a filter box into the underside of a cowl induction hood. TPI is so low profile that there's all kinds of room up there.

 

What year of Windstar are you guys pulling fans from? How well do they keep the engine cool? Need to keep my C10 cool while towing.

 

And thats where Im heading. Once that shroud is out of the way....

I already removed the plugs in each side of the core hoping that would allow just a little more air inside:

 

Will that let a lot of rain in?? I was afraid to take mine out.

 

Mid - late 90's

Both together pull 4400cfm.

Something like 2275 for the 15" and 2125 for the 13"

 

I'm really liking this Square thread...

 

I thought about that too after taking them out. I bought some screen, like in your home windows or door, and cut a small section. I used the best quality duct tape I could find and affixed it to the core. Then I did the same on the back and off-set that one just a tad.

Kinda cheesy, but you cant even tell unless you stick your eyes right up to the grill. I figure the screen will keep debris out and at least break the rain drops down enough that not that much should get in......not that we get that much rain out here....

 

Thanks man, I'll have to pick up a couple (one for my malibu as well). Need to make more room for my supercharger.

 

Should run you about $25-30 at the yard, $100+ new from Rock Auto....grab the pig tails too. Ive got links to several wiring diagrams, depending on how you want to run them. Mine will be manual, 1 on - off - 2 on, at first.

 

Just to double check, I searched and could only come up with diagrans for 89' - earlier.....

...do I have my CCV routed correctly?

 

I'm going to run them off the ECM using the factory diagrams.

I like the paint you used on the plenum, is it satin?

 

Matte Silver BBQ paint.

 

Looks good, but you put throttle body top. The Line can go to the ported egr line under the tb or the small one on the rh side of the tb.

 

It does go to the TB under the pvc line..

 

That's the one

 

I kept the plastic intake piece in the core support because it's a nice way to attach. I had one that was open in front (not sure if that's original or if it was cut off). Then by re-using the end of the carb air cleaner snorkel hose - it snaps right on to the core support. I've never had a problem with rain or snow getting in there that I know of. It seems like it would rust if water was ever pooling and I've never seen that. It probably depends on what kind of intake setup you have. I have the 89-91 small quad headlights, so the intake hole is kind of behind the headlights.

 

Last test:

HC 4.03
CO 22
NOX 5.8

Tested today:

HC 8.15
CO 35.5
NOX 7.1

Time to pull the plug on this project. K5 as is with motor and motor only going on CL....

 

did you try running it on 6 cylinders instead of 8? You should be able to put dummy plugs in, and I would think that would help reduce emissions.

 

WTF.....too bad you have to have something that old tested..mine was last tested in 2002

 

Sad way to end the tpi blazer thread

 

Just glanced through this. I agree.
Was loving the work done.

 

Bummer. You put a ton of effort into this.

 

This has been a very interesting thread! Thanks for shareing.

 

That sucks. GLWS.

 

Parted with her today....guy from Florida out here trying out for the Texas Rangers will be taking her back home with him.
No rush to get into anything soon, but thinking I may pick up either an early 70's Scout II or Jeep Wagoneer....?
Learned a lot here in a short amount of time and hopefully passed some info on along the way too.
Anybody ever comes across this build thread and has questions: azg1164@yahoo.com

 

You need to get a scout there cool, I miss mine and of course I put a chevy drive train in it.

 

Man, all that work only to get rid of it, that sucks.


I'm sure it will be full of sand and having fun in florida though.