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There are a few possible solutions.
A. Bolt on the smog parts that originally came in your truck(air line to back of heads) and plug the manifolds or install the ones from your motor, the air to the head portion won't function but it will look good, and since sniffer tests are performed on a warmed up vehicle where air is injected downstream of the O2 sensor it won't affect the sniffer test.
B. Use whatever combo of parts necessary to make the air to exhaust manifolds function, the system will work the same as factory so sniffer tests won't be affected but it will look slightly different to anybody that looks closely.
C. Swap cylinder heads so the system both looks and functions as per it's factory release.
Thanks , There is no place to bolt the old air valve on the new motor's head. I was thinking about doing just what you said. Using some of the parts from the donor. to connect the air pump to the exhaust manifold and making it look hooked up. From what I have read I think it will be ok?
The air to head motor should also have a crossover tube/s across the back, you could connect that to the factory valves from your truck and be good to go. The donor motor you have is from a HD truck and for whatever reason the air injection system was different but functionally it works the same as the 1/2 ton version.
Are your original heads worn out or freshly done? No sense in putting the crusty old heads on your replacement engine.
Since your F-150 truck has an additional solenoid versus the F-250 system, I'd consider getting a valve job on your old heads and swapping them. Everything will work as intended with your original equipment then.
If you are less ambitious, then use the AIR in manifold system completely with whichever parts you may need scrounged off the F-250. You may have an additional solenoid behind the ignition coil. I would just leave it plugged in and discretely capped.
Are your original heads worn out or freshly done? No sense in putting the crusty old heads on your replacement engine.
Since your F-150 truck has an additional solenoid versus the F-250 system, I'd consider getting a valve job on your old heads and swapping them. Everything will work as intended with your original equipment then.
If you are less ambitious, then use the AIR in manifold system completely with whichever parts you may need scrounged off the F-250. You may have an additional solenoid behind the ignition coil. I would just leave it plugged in and discretely capped.
My engine burnt a valve on a road trip. I got a junk yard head and about 40 miles later it overheated bad. When I got home I got the an engine off a 96 f250 5.8 with less then 100k miles. I would like to use it without taking too much apart. I was thinking reseal timing cover and oil pan and rear main seal. I would like the emissions system to work as original but its old and the secondary air system from what I have read will work fine either way. Let me know if you have any more advice. Thanks Bruce
All you have to do then Is use the exhaust manifolds off the donor as well as all the smog plumbing. Just leave the third solenoid plugged in but capped off. Should work as intended and appear original to anyone not on this forum.