from 3.8 (1995) to 3.9 (2004) engine swap (fuel rail diference)

jorgeflores · August 9th, 2011, 03:34 AM

well, iam installing a 3.9 in my old 95 stang... it used to have the 3.8 singleport (150hps).... so i wanted a lil more power and a newer engine... so i buy a 3.9 splitport 2004....

first i found that it haved de IMRC and i didnt know how to make it work so i delete de IMRC.... so NO PROBLEM...

but now i found this problem...
the 95 engine haved 13conectors and a return line and also like a fuel regulator..
and the 3.9 2004 doesnt have return line and have 14 conectors (so i have 1 harness free :/)

so i was looking for fuel rail diagrams from the 95 and the 2004 to check out how to make them compatible but i dont find nothing!!!

so please help me, i need a cheap way to solve this problem...

some questions
-why i cant just install the 3.9 2004 fuel rail? what would it happend if i dont have a return line in my old 95 stang?
-if it have any problem instaling de new rail, can i solve this problem if i change de fuel pump or something?

please help dudes!

ESG-642T · August 9th, 2011, 03:40 AM

You have to mod the fuel rail....

jorgeflores · August 9th, 2011, 04:08 AM

and what about the wiring? thanks for the photo, very ilustrative!

the fuel regulator is in the nut iosnt?

ESG-642T · August 9th, 2011, 04:11 AM

What do you mean connectors, on what exactly?

jorgeflores · August 9th, 2011, 04:16 AM

let me take some pictures and upload them for best info for ilustrative data

jorgeflores · August 9th, 2011, 04:23 AM

i mean harness...

ESG-642T · August 9th, 2011, 04:31 AM

Use your stock harness, no need to swap them.

jorgeflores · August 9th, 2011, 04:42 AM

mmmm are u sure? sorry for aswing, but i was seeing the harness and the 95 have more pins than 04 :S

ESG-642T · August 9th, 2011, 04:46 AM

Yep I'm sure.

Loki · August 9th, 2011, 03:17 PM

No need to mod a fuel rail & the 04 harness WILL NOT work, use your old one. You may have to swap some connectors over, though..

As for the fuel rail, pull one off of a Windstar van or an E-150 truck. Mine is from an E-150. The lines will connect on the drivers side towards the back, so you'll have to extend them

jorgeflores · August 18th, 2011, 01:23 PM

Hey kyle, how i have to modify my fuel rail to fit o0n the new motor? Where is the return line in that picture?

Loki · August 18th, 2011, 04:47 PM

Oh, that's cool. Completely ignore my post and do it the hard way. Lol, enjoy!

qwiksilvermustang · August 18th, 2011, 07:42 PM

TOp right of photo you'll see the regulator and return line coming off of it, easy mod to pull off esp for the guys with NE's wanting to put down some huge numbers

jorgeflores · August 26th, 2011, 11:14 PM

dudes iam just at the final of my project and i coesnt know how to make the mod for the fuel rail, can i re-use de FRP shit from the 95 fuel rail of my old 3.8?
how can i reconnect the return hose to the FRP?

Mr. Red Pony · August 27th, 2011, 01:37 AM

Split port use returnless. So you have to put a different pressure regulator on it with a return built in. Or make a 'T' in the soft part of the rail and use that as your return.

jorgeflores · November 19th, 2011, 12:51 PM

well, this old topic its going to be alive because now i have a very BIG question....

now i run out of clutch ):

or at least i think so, because like for a month start making horrible friction noises and yesterday morning it only doesnt move in any direction because the transmition its not engagging... anyway... so the most common answer is to change me clutch... but thats tmy question.... should i get a 1995 3.8 clutch? or a 2004 3.9 clutch? when i swap the motors y swap them completely, but i left the original 1995 5sped transmition on it.... soooo what clutch i most choose? or what the hell you reccomend?

thank you dudes
!

Green_6er · November 19th, 2011, 09:55 PM

04

SON1C · November 20th, 2011, 10:28 PM

Originally Posted by jorgeflores

well, this old topic its going to be alive because now i have a very BIG question....

now i run out of clutch ):

or at least i think so, because like for a month start making horrible friction noises and yesterday morning it only doesnt move in any direction because the transmition its not engagging... anyway... so the most common answer is to change me clutch... but thats tmy question.... should i get a 1995 3.8 clutch? or a 2004 3.9 clutch? when i swap the motors y swap them completely, but i left the original 1995 5sped transmition on it.... soooo what clutch i most choose? or what the hell you reccomend?

thank you dudes
!

english class

Skargon · November 20th, 2011, 11:20 PM

Originally Posted by SteeD43

english class

Rude much?

Green_6er · November 21st, 2011, 09:33 AM

use the clutch from the year flywheel that you have.

August 9th, 2011, 03:34 AM	#1
jorgeflores Newbie Join Date: Jun 2011 Posts: 20 iTrader: 0 reviews	from 3.8 (1995) to 3.9 (2004) engine swap (fuel rail diference) well, iam installing a 3.9 in my old 95 stang... it used to have the 3.8 singleport (150hps).... so i wanted a lil more power and a newer engine... so i buy a 3.9 splitport 2004.... first i found that it haved de IMRC and i didnt know how to make it work so i delete de IMRC.... so NO PROBLEM... but now i found this problem... the 95 engine haved 13conectors and a return line and also like a fuel regulator.. and the 3.9 2004 doesnt have return line and have 14 conectors (so i have 1 harness free :/) so i was looking for fuel rail diagrams from the 95 and the 2004 to check out how to make them compatible but i dont find nothing!!! so please help me, i need a cheap way to solve this problem... some questions -why i cant just install the 3.9 2004 fuel rail? what would it happend if i dont have a return line in my old 95 stang? -if it have any problem instaling de new rail, can i solve this problem if i change de fuel pump or something? please help dudes!

August 9th, 2011, 03:40 AM	#2
ESG-642T [8MINUS2] 2002, Ford, v6 Join Date: Feb 2007 Location: TEXAS Posts: 12,319 iTrader: 0 reviews	You have to mod the fuel rail.... __________________ Hi, You can call me Kyle Random ESG fact: Had a prochamber on his v6 before it was popular. WTB: v6 BBK valve covers

August 9th, 2011, 04:11 AM	#4
ESG-642T [8MINUS2] 2002, Ford, v6 Join Date: Feb 2007 Location: TEXAS Posts: 12,319 iTrader: 0 reviews	What do you mean connectors, on what exactly? __________________ Hi, You can call me Kyle Random ESG fact: Had a prochamber on his v6 before it was popular. WTB: v6 BBK valve covers

August 9th, 2011, 04:31 AM	#7
ESG-642T [8MINUS2] 2002, Ford, v6 Join Date: Feb 2007 Location: TEXAS Posts: 12,319 iTrader: 0 reviews	Use your stock harness, no need to swap them. __________________ Hi, You can call me Kyle Random ESG fact: Had a prochamber on his v6 before it was popular. WTB: v6 BBK valve covers

August 9th, 2011, 04:46 AM	#9
ESG-642T [8MINUS2] 2002, Ford, v6 Join Date: Feb 2007 Location: TEXAS Posts: 12,319 iTrader: 0 reviews	Yep I'm sure. __________________ Hi, You can call me Kyle Random ESG fact: Had a prochamber on his v6 before it was popular. WTB: v6 BBK valve covers

August 9th, 2011, 04:08 AM	#3
jorgeflores Newbie Join Date: Jun 2011 Posts: 20 iTrader: 0 reviews	and what about the wiring? thanks for the photo, very ilustrative! the fuel regulator is in the nut iosnt?

August 9th, 2011, 04:16 AM	#5
jorgeflores Newbie Join Date: Jun 2011 Posts: 20 iTrader: 0 reviews	let me take some pictures and upload them for best info for ilustrative data

August 9th, 2011, 04:23 AM	#6
jorgeflores Newbie Join Date: Jun 2011 Posts: 20 iTrader: 0 reviews	i mean harness...

August 9th, 2011, 04:42 AM	#8
jorgeflores Newbie Join Date: Jun 2011 Posts: 20 iTrader: 0 reviews	mmmm are u sure? sorry for aswing, but i was seeing the harness and the 95 have more pins than 04 :S

August 9th, 2011, 03:17 PM	#10
Loki Enthusiast 1996 V6 Join Date: Feb 2011 Location: Connecticut Posts: 632 iTrader: 0 reviews	No need to mod a fuel rail & the 04 harness WILL NOT work, use your old one. You may have to swap some connectors over, though.. As for the fuel rail, pull one off of a Windstar van or an E-150 truck. Mine is from an E-150. The lines will connect on the drivers side towards the back, so you'll have to extend them __________________ 1996 3.8L.. Split Port Swap, CAI, True Dual Exhaust, the car accident mod. Need cheap parts? CLICK MEEEEEEEEE!! =]

August 18th, 2011, 01:23 PM	#11
jorgeflores Newbie Join Date: Jun 2011 Posts: 20 iTrader: 0 reviews	Hey kyle, how i have to modify my fuel rail to fit o0n the new motor? Where is the return line in that picture?

August 18th, 2011, 04:47 PM	#12
Loki Enthusiast 1996 V6 Join Date: Feb 2011 Location: Connecticut Posts: 632 iTrader: 0 reviews	Oh, that's cool. Completely ignore my post and do it the hard way. Lol, enjoy! __________________ 1996 3.8L.. Split Port Swap, CAI, True Dual Exhaust, the car accident mod. Need cheap parts? CLICK MEEEEEEEEE!! =]

August 18th, 2011, 07:42 PM	#13
qwiksilvermustang Enthusiast 1999 Mustang Pony Not even currently moving Join Date: Mar 2010 Location: Ft. Bragg Posts: 631 iTrader: 2 reviews	TOp right of photo you'll see the regulator and return line coming off of it, easy mod to pull off esp for the guys with NE's wanting to put down some huge numbers __________________ lt's,o/r h, flow 40's, egr delete,windstar w/65mm tb,UDP, sniper tuned Need to install: 4.2 crank,.030 silvo's,268hr112 cam,RR's,comp 915's

August 26th, 2011, 11:14 PM	#14
jorgeflores Newbie Join Date: Jun 2011 Posts: 20 iTrader: 0 reviews	dudes iam just at the final of my project and i coesnt know how to make the mod for the fuel rail, can i re-use de FRP shit from the 95 fuel rail of my old 3.8? how can i reconnect the return hose to the FRP?

August 27th, 2011, 01:37 AM	#15
Mr. Red Pony Resident badass 01 Built V6 (3.9) 13.91 @ 99.1 N/A Join Date: Jan 2010 Location: Lawton, Oklahomo Posts: 6,789 iTrader: 10 reviews	Split port use returnless. So you have to put a different pressure regulator on it with a return built in. Or make a 'T' in the soft part of the rail and use that as your return. __________________ 271rwhp N/A V6 The Name is Danny. I'm a GM Technician. Suck it.

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November 19th, 2011, 12:51 PM	#16
jorgeflores Newbie Join Date: Jun 2011 Posts: 20 iTrader: 0 reviews	well, this old topic its going to be alive because now i have a very BIG question.... now i run out of clutch ): or at least i think so, because like for a month start making horrible friction noises and yesterday morning it only doesnt move in any direction because the transmition its not engagging... anyway... so the most common answer is to change me clutch... but thats tmy question.... should i get a 1995 3.8 clutch? or a 2004 3.9 clutch? when i swap the motors y swap them completely, but i left the original 1995 5sped transmition on it.... soooo what clutch i most choose? or what the hell you reccomend? thank you dudes !

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