I'm done, sort of. The install went pretty well. There are a few things that are not how I would of done it , but its a universal kit so bitching will do no good.
First off is the 02 sensor, pretty easy, mark placement, drop your exhaust, drill hole and weld in bung, let cool and paint weld, set aside. Next is the fuel pump. My first problem. Instructions say close to the tank and below the tank. This is where I was wishing I had an in tank pump, but I dont. I installed the pump on the lowest part of the frame. I did not want it to be below the frame so its on the side frame rail. Parts were easy to assemble and there is enough High pressure line line in the kit to go from the tank to the engine and back to the tank ( Return system) So none of my steel line that was for the carb worked so I took it all out along with the manual fuel pump. Ran my feed and return lines, mounted the pump. I am done under the truck so I put my exhaust back up and install my 02. Next is taking off the carb and installing the TB. Wow that was hard, not. Next comes the wiring harness, wow. This is the second thing I did not like. I pull this harness out of the bag and it looks like a 10 year old put it together. The plugs and terminations are good it just finished off really messy. I took some time and re did what I could and got it looking better. Every thing plus in easy and the few other hookups I had to do were easy. Next I have to drill a hole in the fire wall to get the harness into the dash area where I will mount the ECU. here is where they try and trick you. In the bag there is a big rubber grommet. Dont just measure the grommet and drill. First off the ECU connector is bigger than the grommet hole and second you dont need a hole that big. I used a 1 3/8'' hole saw, drilled a hole, took all my wires off ot the TB where I had already installed them. Took the harness inside the truck and pushed each connector ( biggest first) thru the hole. They will all fit. Then I made all the TB connections again. Tied up and secured my wires under the hood. Next I mounted my fuel regulator and ran my fuel lines on the engine. Good parts here , pretty easy. Next I went under the dash and mounted the ECU, ran the wires just like the instructions said. Mounted and tied up the wires and ran my last 2 wires to the battery. I'm done with the install.
Now to start it. I cycle the key and check the fuel pressure. It is low and I have to adjust to 43 pounds. The regulator is nice and this is easy. Jump the relay on the pump so it wont shut off, I do this so I can check for leaks. No leaks. Take apart the jumper. I hook up the hand held programer and enter set up. It walked me thru the general information about the engine. Next I set my TPS, closed then WOT. Done with that it was now time to set target RPM and start the truck. yeah right , like it's that easy. About 4 revolutions and she starts up. Runs kinda shitty but never stalls. I adjust the idle at the TB. the engine likes that and runs better. When I changed the low setting on the TB. I then had to go back and re-calibrate the TPS. Not a big deal with the handheld programer. I set the closed position and then had to turn it off to reset the WOT. Restarted and just went thru the live data info it see hoyw it was doing hitting the targets. A/F was way fat but you could watch it take fuel out to get to the target. It took about 5 min but it got there. The engine was warm, the IAC was working holding the preset idle at 800. I decided to lower the idle to 700 just to see if it would do it. made the adjustment on the hand held and down it came to 700. Now the lumpy cam is singing an song I like. Well I set a rev limit at 6k and go for a ride. Instructions say to drive at varying distances at different speeds / different loads. I put about 20 miles on her and started to hear the fuel pump wine. So I head for the shop. By the time I get home the pump is singing. Park the truck, the pump is hot. Now here is where I said I could not get the pump low or close enough in relation to the tank. The pump is either bad, cavitating, or starving. I called tech and they said drive it some more, if it keeps making noise they will send me a better pump. The guy explains that the pump in the kit is not that good and he could send me a better one. So I take a drive and the pump still squeals. Call tech again and their closed. I will call tomorrow. An in tank pump would be nice for the broncos. You cant really put the pump where you need to.
Some pictures.
