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There's not a heck of a lot of difference between the 02 and 04. The biggest is the fuel system and I forget what exactly that was. For me the 21,000 mile difference would make the decision. I bought my 02 two years ago with 9,300 miles on it and haven't had a single problem. Good luck...
If you go to the originating dealer who sold the car new, you can buy the GMPP from them. You can renew it through Fitchner here as long as you do so greater than 30 days before expiration.
Differences:
2002
* Z06 Changes:
* Z06 LS6 cam changed to: 0.551/0.547, 204/218 on 117.5
* Less restrictive intake airbox lid
* Descreened MAF
* Removal of pup-cats (total with changes = 405hp)
* Z06 shocks revised with less rebound for better launching
* Z06 brake pads revised for better stopping (generate more dust)
* Lighter, sodium filled valves w/ stronger valve springs
* Higher tension rings installed to prevent oil burning problems
* Slight piston redesign *
* Clutch strength upgraded.
* HUD available on Z06 (not avail '01 model year)
* Wheel supplier changed to Speedline, moved from forged to cast. Weight nearly identical
* Electron Blue color offered
* Steel endlinks changed to aluminum
2003
* Late model-year new fuel system design from C6's
2004
* Z06 shocks further refined. Accompanying upper front control arm bushing, and rear swaybar bushing changes.
02 will have external combination fuel filter and pressure regulator, which is about $60 cost to replace. Believe the 04 has fuel filter in the fuel tank, much more hassle and expense to replace, but may not need replacement as often?
Price seems a little steep on both cars, but that may be negotiable. And with the years and milage it is a tough toss up between the two.
I would start nit-picking the two cars for the options each one has for the ones you want. <also check the rear end gears to see if it is the standard 2.7? <I think>, or the optional 3.15.
Also do the hose test...close the windows and put the top up and hose the car down, paying special attention to make sure you get around the seals to see if the dang thing leaks.
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