The 1997 has a fuel return system with pressure regulator at the fuel rail.
The 2000 has a returnless fuel system with pressure regulator and return line built into the fuel filter which is back in the back near the fuel tank.
While it would be preferable to have the complete 1997 fuel system swapped over to the 2000 I was not in a position to add the additional labor to make that happen in the time I had available.
The simple solution then was to simply plug off the return line at the fuel rail.
That required a hunt for and obtaining the parts to do so.
Specifically, a 5/16" quick connect to 6AN flare adapter along with a cap to close it off.
This plugs right into the fuel regulator in place of the fuel return line.
A search of Jegs, Summit and others pointed me in the right direction.
Had to go to Amazon to find it; no local hardware or autoparts store carries this.
This part is frequently used as part of an LS swap to connect to the fuel system.


1997 fuel supply and return lines

return line plugged off.

 

As for everything else, the wiring harness had to be rerouted to reach the locations of the components on the 1997 engine.
Amazingly everything did reach, nothing needed to be cut and spliced to add length.
The throttle cable was able to be rerouted and connected to the new SOHC throttle body on the 1997 intake.
The vacuum lines from the throttle body as stated previously had to be modified to reach the associated ports.
I used a little heat to reform one of the plastic lines so it was going in the right direction along with a cut and splice on the other.
The rest of the plumbing was able to be rerouted and fit without extensions.
I did have to cut some length out of the heater core hoses but I could have just bought new 1997 heater core hoses and they would have fit fine.
The bracketry is a little different between the 1997 and 2000 power steering pumps. There was no issue swapping the 2000 pump onto the 1997 engine.
I did have to swap the 1997 intake duct and airbox over to the 2000.
Airbox is a little tight against the battery now but workable. The sensor on the duct is the same and didn't need swapped.


original 2000 air duct and box

1997 Air duct and box in 2000 SW2

 

You know someday they will think this was a factory install! I love doing custom work and making it look factory.
very nice as usual Janmar.

 

Thanks for this write up, it has really helped with my project of putting a low mile '96 into my '00 wagon.

I am nearing completion and looking at the fuel lines. As far as the original fuel line that connects to the fuel rail, did you need to modify that or were you able to re-orient the line to fit the '97 fuel rail? As you stated earlier, the orientation of fuel rail and fuel lines are different.

I picked up a '96 fuel line connector and some length of the fuel line thinking I would splice into my existing '00 fuel line and make the connection to the fuel rail that way. However, I would love to avoid putting weak points in the fuel line.

 

The original fuel line in the 2000 wagon connected right to the 1997 fuel rail no problem. Just ended up with the test port upside down.


Arrow points to fuel supply line to rail

 

Okay, that makes sense! I did need to modify my fuel line. But i just cut off a section and reattached the connector to the fuel line.

I finished up and took it for a test drive -- it runs and drives with no check engine light! I'm pretty excited to have this lower mile engine now. Thanks again for your write up, I followed it closely.

I did notice that I lost cruise control. I wonder how I can go about fixing that.

 

Isn’t the cruise control a separate unit with it’s own cable to the throttle body? That is how my L200s are, my L300s are drive by wire so they are a function of the ecm.

 

Hello guys I have a 99 Saturn SC2 I'm trying to swap over to an 01 motor needs some help but figuring out what to do with connections and hoses and what not, I know that it's not exactly the same motor. And it's my first engine swap so looking for a little bit of help because you guys seem know what the **** you're talking about I don't.
I'm more of a visual learner so if we can maybe video chat to help. And I can show u what I'm dealing with