It has finally moved under it's own 3800 power!
There are issues to work out, on windshield appointment #4 (again, issues with how safelite manages getting the right equipment to the job), and starting to troubleshoot some of the minor issues.
Here's the airbox cover, 3D printed ABS that are acetone vapor smoothed:
Need to do some more work on the snap fit elbow on the throttle body before I call the intake done.
Troubleshooting what ended up being something quirky with the DRL module (incidentally fixed itself somehow?). Started off with a mistake in the '99 CSM that didn't clarify the wiring for the front turn signal on the passenger side. It was the only light not blinking, even the side marker was blinking. Found the ground splice was sealed poorly and led to oxidation in all of the ground wires on that side of the harness. Lots of fun pulling all the grounds, replacing the terminals in the connectors, etc. Got that all fixed with new wires, and it still wasn't working. I figured I'd just grab a used module from the junkyard once I traced the issue to the module, but it started working on it's own again.
Had to modify the A/C line to add the low side port:
Tried something new with the 3D printer while printing fog light mounts. Doesn't look too fancy, but there are three components nested together in a single footprint. This saves a ton of time to be able to print like that (less time printing supports, fit more parts in a single layer, etc.)
Working on the head unit fit to the new dash, I don't intend to leave the wood grain look.
And the Blu Ray player in action!
Lots to do yet though. The power sliding doors are still inop. There's a relay clicking on the PSD module when you trigger the buttons, which should trigger the motor but it's not. Have to dig into that a little more.
Next is an issue I'm not sure how to troubleshoot. We're using the original PCM for the van. The injectors on the 3400 were assigned to different pins on the PCM than what you get with other 3800 applications. Since we didn't overwrite the OS, it should still be using the 3400 pin assignment? Or does that change when you tell it there's a different engine in there? Idle quality is a little off, like a misfire, and it poured smoke out the exhaust when I did a pull in the driveway, though it seems like it's making good power under throttle. I haven't been able to find any specifics about injector assignment.
Looks like the tachometer and the coolant temp gauges are dead. The fuel level was initially not working but then it came back to life, and the low fuel light turned off. There's 5 gallons in the tank and it reads a little over 1/4. Since I changed the needles out it might just be because I didn't get it set right, so I'll have to address that later. Speedometer seems to work, most of the dummy lights are all working.
The head unit had a bunch of burnt out bulbs so I've got that apart to fix it.
And the brake rotors up front will need to be replaced.