run a carbd maniold with a tbi adapter, shorty heads with emissions otherwise a vortec head swap would be utterly pointless. where do you live that you need egr and stuff exactly? a little of both, i have friends who have had the money to piss away a new engine and the number sometimes are more than said to be or less. personally if something is labeled as 190hp i would not be looking into swapping that into my truck. id be looking at something with more juice than stated from the factory engine in your vehicle because that means less effort to make your vehicle move, less time on the go go pedal etc. i got the same if not better fuel mileage with my 383 than my old 350, got better with a heads, cam, and stroked 305 than the original 305. you just have to keep your foot off the throttle all the time.
I cannot run a carb. If you meant a carb manifold with the TBI adapter, I'd rather just use the GM manifold.
It has to pass emissions, including having a factory EGR, catalytic converter, etc. That will not change until it is 24 years old, then it's exempt. I want the same/better mileage and the same/better power. While what you say about it working harder/less hard is somewhat valid, I'd argue that the LS05 and Vortec motors have a specific intake/combustion chamber design, in conjunction with a specific cam profile, to promote efficient combustion at low RPM/highway speeds. While the absolute/peak output may be lower than a custom setup, the overall efficiency for normal usage is expressly engineered and balanced, from the airfilter sizing to swirl vaporization, to exhaust pulse/scavenging timing.
I'd prefer a new crate motor over a remanufactured one. The GM recommended crate engine for my truck has a description listing it as 190HP. My OE engine is rated at 210. I'd like to know why it is different.
The only reason I mentioned a vortec motor is that the head design is efficient enough using the GM TBI conversion manifold, one 96 exhaust manifold, and a tubing adapter. The crate vortec motor is cheaper, but the assorted adapted items bump it up to about 300 dollars more than the crate LS05 replacement engine. While it would not have 255hp, it would be at least equal to, if not greater than, the stock engine in output, and it would get equal/better mileage *and* also pass emissions.