Having just messed with a few, here's what I remember:
- Federal uses a glow plug relay and bus bars, no diagnostics. CA uses a fancy controller with diagnostics, and each plug has a dedicated wire. The one part of the CA motor I like. You can run the CA glow plug setup on a federal OS and it works awesome. I do this on both my LB7s.
- CA has an EGR riser on the passenger up-pipe, and an EGR cooler. Heater lines are different to accommodate.
- CA has a different Y-bridge, actually a 2 piece unit with a butterfly valve to force the motor to draw exhaust in when required. Federal is a one piece, and uses a shorter wire to the intake air heater since it's closer to the motor.
- The MAP sensor is on a tube on the CA motor, and directly plugs into the Y bridge on federal. It is held down with a different bracket CA vs. federal.
- CA has a vacuum pump to run the EGR crap, and a longer belt to make that work. A bunch of solenoids tucked up near the fuel filter head. Additional wiring in the harness too.
- CA head has different intake ports than federal, but they look bigger to me. SoCal Diesel once told me the CA heads flow better stock (barely), but you can't really open them up, so federal heads are better if you're porting them.
- The PCV system on the CA motor is routed over the Y bridge to clear the EGR, with a stupid Y pipe bracket, whereas the federal system is simpler and tucked in the valley nicely. Both go to a phase separator on the front accessory bracket then vent to atmosphere.
- The turbo exhaust housing bolt pattern and downpipe are different. Probably to clear the EGR riser?
There's probably more I don't remember or haven't noticed.
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