Ok I recently ruined my engine in my 02 OZ, and now I just got and engine out of and 05 ES. Visually it looks exactly the same but upon further inspection I noticed that the fuel rails are different. On the 02 engine it has of course the line where the fuel is delivered and also one on the opposite end of the rail where it returns to the tank, where as the 05 doesnt have the return. Im sure over the years Misu must have made slight improvements but I dont see how this could be one. Also trying to simply swap the two rails isnt as simple as it would seem for the injectors didnt line up right, they all went in at a horrible angle and Im sure would leak if it were to be left that way.

So my question is do I need a fuel return line? What would I do with the line if I didnt use it? or is there a different type of return line somewhere that Im missing?

 

Did you also ruin the IM? Use what's good from the '05 motor, minus that "returnless" fuel system. You should be fine...

 

what exactly happened to the 02 motor.

 

Stick to the original rail. Returnless perfoms the same as returned. You are right that is the only external difference. Fuel rail and intake manifold is different on th 04-06. It is not interchangable with the 4G93 family.

ROAD/RACE

 

Well what happened to my stock engine was to say the least, supercharge + hard driving + no wideband air fuel ratio gauge = car ran lean and burnt hole in pistion. so it was cheaper to buy a new engine and install it which is all done now.

But on that note now that its all installed and running I have only one issue, when I first press on the gas the engine hesitates as if its about to cut off but once it revs up its fine, does anyone know what could be the problem?

 

It could be a number of things but I don't know how you'd be able to just eyeball it and determine what's causing the hesitation. My first thought would be it's running too lean during idle.

And as for what happened to your last engine, I'd suggest getting an EGT to monitor engine safety over an AFR.

 

maybe my mind isnt working right now but could you let me know what an EGT is and where could i get this?

 

Exhaust Gas Temperature... It should be installed approximately 3 inches from the engine block into the header. Anyone know which runner tends to run the hottest? This EGT gauge will tell you gas temps that will in turn tell you valuable info...

 

Ok I solved the problem now or at least had help in doing so. I ended up having to use the manifold of the 02 engine and basically using only the head and block from the 05. So for future reference there is a difference between the two manifolds although visually the only thing that looks different is the fuel rails.

 

does anyone know what the difference between a intake manifold from an 02 engine and one from an 05 engine?

 

Fuel rail and a couple vaccuum holes, I believe. Nothing major.