Another SAI thread?!?!?!

Corprin

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Aug 20, 2012
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MLPS
Yay!

I pulled my upper plenum off to hunt down my slow coolant leak out of the rear of the engine. Turns out to be the rear end of the passenger side head gasket. No big shocker there.

During the removal of all the crap on top of the motor, I managed to break one of the very brittle SAI lines, specifically the one between the cross-pipe and the pump. Couple that with the broken mount/isolator for the pump and I am quite frustrated with this system.

Checked out AB and Rovers North and the hose I broke is a $130 item. I then started researching on ripping out the damn thing all together and found the ECU wouldn't be very happy with me. Every thread I find on the subject seems to end in people getting in a pissing contest about OBDII and emissions crap. But, it does seem as though I can swap out matched non-SAI ECU/BCM and tear the system free of my truck. I have found such a set in known working order for cheaper than the one plastic pipe mentioned above.

Has anyone swaped over the ECU/BCM, and if so what will need to be done to make it run in my truck?

Can I simply swap in a non-SAI ECU and have it synched to my current BCM, what would the advantage be?

What is the average cost of having the ECU/BCM synched, and can this be done by someone with one of the aftermarket systems, or must it be done at the dealer with the testbook?

Is there a way to have the ECU programmed with my VIN when ordering, to save me a trip to the stealership?

I am sure I will come up with some other questions, but this will do for now.
 

seventyfive

Well-known member
Jan 3, 2010
4,280
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over there
Op,

Next time, spray Rostoff or PBS blaster at the four nuts and plugs. Hose them down really well.
Run engine at idle for about 10 minutes.
Squirt them down again.
Pull all your plugs.
Put an open end 17 wrench on the flat spots on the standoff plugs. Use a four way 27 mm open end wrench on the compression nuts. Work them back and forth, and they will come right off.

Otherwise, contact www.buckhornimports.com and order new pipes. I'm not perfect, but I have never busted one of those pipes.

OR, contact www.buckhornimports.com and see if they have a complete ecu/bcu/slabs module, fuel pump, and evap canister, from a non-lev D2. Swap everything over, run new wires to the ecu, find someone with a T4 or autologic to flash your shit to a non lev four six.
I know some 'parts guys' say its impossible to convert....
 

Corprin

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Aug 20, 2012
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MLPS
It wasn't the metal lines that broke, it was the damn plastic one between the pump and y-pipe over the coils.

Looks like I'll be rocking some 5/8 heater hose then.
 

distrovol

Active member
Oct 10, 2011
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ga
Corprin said:
It wasn't the metal lines that broke, it was the damn plastic one between the pump and y-pipe over the coils.

Looks like I'll be rocking some 5/8 heater hose then.

That's what I used when I snapped mine during my rebuild. It slips right over the remaining sections of plastic. To remedy the kinking that happens where it bends to the section going to the metal pipes use a screw hose clamp to keep the hose wall from collapsing.
 

Durt D1ver

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Jan 14, 2008
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Jersey Shore
When I broke the plastic hose during my head gasket install, I just cut a few inches on either end of the break, then stuffed a piece of 3/4" copper tube in it, and taped it together. True CB shit, but it's worked that way for 2 years.
 

Corprin

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Aug 20, 2012
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MLPS
seventyfive said:
OR, contact www.buckhornimports.com and see if they have a complete ecu/bcu/slabs module, fuel pump, and evap canister, from a non-lev D2. Swap everything over, run new wires to the ecu, find someone with a T4 or autologic to flash your shit to a non lev four six.
I know some 'parts guys' say its impossible to convert....
What is the functional differences between an NAS non-LEV fuel pump and evap canister, and those from the NAS LEV trucks? RAVE gives no differences for these parts in the descriptions.... maybe I need to dig further?

Is the SLABS needed for the truck to function, I was under the impression that only the ECU and BCM needed to be a matched pair, or have the sync done. I understand this will disable my key-fob use and alarm system until they are synced, and I am fine with that.

Why do I need the ecu flashed to a non-LEV 4.6, when the ECU will already be flashed to a non-LEV 4.0?

What wires will need to be run to the ECU for the swap? I can't find any pin differences between the LEV and non-LEV sans the extra wires for the SAI system.
 

Corprin

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Aug 20, 2012
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I think there are some wires crossed here, I have no idea where the 4.6L discussion came from.

My truck is a '00 SE7, LEV 4.0L w/ACE, fully optioned sans SLS

I found a donor truck in the JY yesterday '00 SE7, non-LEV 4.0L w/ACE, fully optioned, SLS has been removed for coils.

ECU/BCM are already in my possession. Going back with my shopping list this afternoon.

With some guidance from the heavens (or PMs) I spent a few more hours with RAVE and found the mechanical differences between the two systems, and have nearly all the wiring changes that will need to be made planned out.

Once concern presented was the mismatched VIN in the ECU/BCM vs the truck's actual VIN. There was mention about stolen truck/parts when this deviation was present... but I just don't see that ever happening on a 13yo truck, known for washy electronics, and the parts having traditional JY markings, backed with receipts.

The other concern was the possibility of someone contacting the police about having non-LEV parts in a LEV truck. Is this common for people to do in this community? I guess that is a rant for another day.

EDIT:
I found a couple threads about upgrading the SLABS to that of a '04 to acchieve the CDL parameters of the later year. The posters both stated the revisioned SLABS units were reverse compatable, and the only programming required on the new units was the setting of the recipient truck's option list. Otherwise, the swap was plug-n-play. When reviewing RAVE 0.65.01 it only states "Programme[sic] the new SLABS ECU using TestBook." I read over the description for the SLABS and it does not specifically state that the unit requires sync to the ECM or BCU. The only sync related comments are found in the BCM descriptions stating, "For immobilisation, the BCU disables the starter motor relay. When the engine is cranking, the ECM looks for a coded signal from the BCU. If the signal is not received within one second of cranking, the fuel supply to the engine is stopped and the injectors are disabled. This also prevents unburnt fuel from entering the catalyst." I am assuming this coded signal is what requires a sync.

What am I missing here?
 
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Corprin

Well-known member
Aug 20, 2012
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MLPS
Asked in another thread, but got no response. For those in the know, should I be finding these parts in a SAI truck?

2013-03-05192947_zps5d580562.jpg


2013-03-05192859_zpsffba5e6b.jpg


VIN shows "49-state emissions." Is there any possible way a non-LEV truck was issued with a SAI? ...or is this just a situation where an SAI motor was swapped in, and the SAI bits retained for some reason?
 

seventyfive

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Jan 3, 2010
4,280
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over there
^thats a good question.

contact Randy Williams http://www.britishboneyard.com he has a 4 liter lev truck. he should be able to give you a definitive answer, regarding the charcoal canister and canister valve.

seeings how it doesnt have a DTML at the charcoal canister, you already have the proper bits in that truck and shouldnt need to run any additional wiring.

keep in mind fuel tank/EVAP leak detection is a completely separate system. secondary injection's sole purpose is to pump fresh air into exhaust, more oxygen at the front oxygen sensor makes the ECU fatten mixture, thus getting the cats hotter faster. DTML simply does a self test to verify there are no leaks in the fuel system.

i could only assume CaliforniaAirResourceBoard required air injection AND DTML, which is why you commonly see 49 state instead of 50 state.

to answer your question, yes it is very possible to HAVE secondary air and NOT HAVE fuel tank leak detection.
 

Corprin

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Aug 20, 2012
260
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MLPS
Mike,

Thanks again. When I get a moment I am going to pop the fuel-tank inspection plate and check from the sensor on the pump. If that is there, and all the rest of the bits are in place as well, I am simply going to unplug the SAI pump and run it for a month or two to see if I toss a code. If the SAI code comes up, I may have discovered something for all to know... and I will swap in the non-SAI/LEV ECU/BCU/SLABS I have sitting in the garage now.

I'll contact Randy as well and see what he says.

seventyfive said:
^thats a good question.

contact Randy Williams http://www.britishboneyard.com he has a 4 liter lev truck. he should be able to give you a definitive answer, regarding the charcoal canister and canister valve.

seeings how it doesnt have a DTML at the charcoal canister, you already have the proper bits in that truck and shouldnt need to run any additional wiring.

keep in mind fuel tank/EVAP leak detection is a completely separate system. secondary injection's sole purpose is to pump fresh air into exhaust, more oxygen at the front oxygen sensor makes the ECU fatten mixture, thus getting the cats hotter faster. DTML simply does a self test to verify there are no leaks in the fuel system.

i could only assume CaliforniaAirResourceBoard required air injection AND DTML, which is why you commonly see 49 state instead of 50 state.

to answer your question, yes it is very possible to HAVE secondary air and NOT HAVE fuel tank leak detection.