I finally think I got all the DTC codes taken care of. The oil pressure code (p0522) popped back up, but I found the connector had fallen out of the oil pressure sensor.
Other code I had was p0463 - fuel level sensor. I believe GM does 0-90 ohms, empty to full and toyota does 110-3 ohms (so opposite). This is all speculation at this point from googling around. The yota numbers are in the service manual somewhere.
I know I only have about 7-8 gals in the tank and the Dakota Digital gauge is showing 7/8 full (and getting more full the more I drive). I had the incorrect wire going to the DD VHX module (for gauge cluster). Should pull from connector c13 (combo meter aka "gauges") wire 14, yellow-red. I had wire 11, red and it was not working. I then ran a wire from the terminal on the VHX for the fuel gauge to the GM ECM (green 54). The nice thing about DD is I can correct the fuel gauge as I fill it up and it will tell me the ohms. Pretty slick. I then plan to adjust the fuel tables through hp tuners. I plan to follow this once I get around to it.
98 to 99+ fuel tables to get fuel gauge to read correctly
I'll probably fill up and get the fuel gauge to read properly. Then I can go through the drive cycles to show the EVAP system as ready. I should be able to get my state inspection done and then emissions and then I can get plates back on my vehicle. Once I have the tags, I'll sit at the fuel pump one night and get everything corrected.
The power steering leak should be fixed as well. I have the heidts regulator in there and I thought that was screwing me over, but it looks like a loose connector that I never tightened up is the culprit. I should have power steering back.
I'll probably end up redoing the exhaust (or having the guy at boulder muffler do it). It's warm underneath and I think I need to lower the cats a bit. I also want to be able to flip the drive shaft back around so the double cardan joint is at the tcase like it should be. This will mean moving the cat down and doing some clearancing of the tranny pan. This will be done post emissions.
The 4l80e is a beast and I'm not sure it's the best choice. I need to finish the exhaust so the tail pipe goes out the back, it pretty much terminates at the muffler right now, and I think it's contributing a bit to my exhaust heat problems. This will need to be done before emissions I'm pretty sure.
Other than that, it's nice taking off from the line and actually accelerating faster than some other vehicles. I haven't fully opened her up yet, but she shifts smooth and the power is definitely there. The true test will be vail pass and Eisenhower.