I have a 1996 "S"engine k1500. I want replace the "S" intakes with a set off a 2000 "F" engine. First of all, with my truck have an EGR valve and the F intake not have an EGR, will I run into EGR code issues? What all do I need to do to not throw nuisance EGR codes? Can I just leave the egr solenoids in place and cap off the port that feeds the valve? Should ditch the vac pump all together (it seems to be weak, only 20" HG at 200 rpm) and go mechanical with the WG? I know that this is a lot of questions, but this is a major step in making this 6.5 "right". I appreciate all the information that this site gives and I hope to be able to return the favor someday.

1st of all what you propose is illegal, so make sure it is something you are willing to deal with if caught fines can be stiff, you would be better off coming acrosss the border as an illegal alien.

That said it can be done, but in order to make the sensors not code you will need a F PCM also or your S reflashed to F programming, once going F upper/lower & PCM your vac pump can be removed 20" at 200 or 2000rpm??? 20" is good vac, so I'd stay with vac pump until it dies then go TM

TD. thought is would be-the only real reason that I was even considering the swap was I am having boost issues-I believe I have a WG solenoid going bad-I lose boost and I can see that the WG actuator is not pulling the WG fully closed at idle. I tested the vac before and after the WG solenoid. I got an erratic reading (15-20") after the WG and a least erratic (19-21") coming into the solenoid. I have the upper intake off, cleaning up the egr tower flashing. Once I get it back on, I am going to test to vac at the vac pump. Am I on the right track.

Does Indiana have an emmisions testing program for trucks? If they do not I would do all of the modifications you listed in your first post. If you are required to do emissions testing there I woold consider gutting the S intake so it appears that all of the emmisions crap is still intact.

Then with the EGR out of the way you might as well ditch the vacuum pump and factory boost controller system.

I would think that a couple of resistors would fool the ECM into thinking that all is well with the disconnected EGR system.

Indiana is emissions test free, so I would have at it and get it done the way you like.

Does anyone kow if Kentucky is an emissions-free state? I am going to be moving there (no Kentucky jokes please-oh well, just one-someone told me that by me moving to Kentucky I am raising the IQ of both states). Shold I wait until I get the truck inspected, if I do this at all.

If you are having boost issues that is not a reason to eliminate EGR, need to troubleshoot boost system for WG, also remember with S truck EGR solenoids are part of the vac system and will need to be troubleshot as well if boost system checks out; what indications do you have that you have boost issues, did you go through the WG operation thread in FAQ

This is a little off the subject, but can anyone tell what the real difference in air flow is between the F and S intakes if the webbing around the EGR port is removed on the upper. Can anything be done to the lower to help airflow?

The problem with the lower 'S' intake is not really in the restriction of the EGR passage, its the heat that is in that passage....