Why doesn't it add up?
You built a hybrid engine and are trying to run it with hybrid settings. But the settings have not been configured for your type hybrid.

Your firmware is fine the problem seems to be a classic case of PEBCAK

Exactly my point. I built a hybrid engine with the same sensors from the old engine, used the same settings that worked previously from old engine, and the car hardly ran. There's no way to simplify it further.

The only variable left is the move to the OEM '03 COPs, hence the title of the thread.

If you want to try to help me productively troubleshoot this, I would appreciate it. If not, don't waste any more of our time by posting petty insults.

I discovered that my rear coolant temp sensor was broken so I replaced it.

I got new BKR6EIX spark plugs and left the gap as-is at .040. The plugs that came out have me worried. See attached (#1 on left, #4 on right). #2 is the obvious stand-out and it's the same cylinder that failed on my last engine so now I'm paranoid as fuck. I checked through my injector sub-harness wiring and connectors, but I cannot see any problem areas without cutting into the outer sleeve.

I am not a mechanic and I don't pretend to be one. I have not tried to start the car again yet - I'd like to spend more time looking through the wiring. I'm stuck on where to go next, so if this makes sense to anyone I'd appreciate any help I can get.

Haven't read through much of this, but did you check your injectors recently? As in sent them out for flow testing?

I was running FIC 650's when the last motor died. I put in the NB2 265's to try to test that same theory.

I sent out the FIC's to be checked and just got them back. Total overkill since I'll likely be staying N/A, but at least I will know they aren't the problem. I'll put them in tomorrow.

Anything else to check while I'm in there?

Put in the tested 650cc injectors and new plugs, switched req fuel to 4.7, adjusted deadtime and voltage correction to values provided with injectors and surprise surprise, this fucking piece of shit wont start. Catches barely after cranking about 5-7 times, then dies.

Verified coil wiring. It's correct. Verified timing. It's correct.

Attached composite log of no throttle start attempt and my current tune. I am using the '96 TPS, CAS, crank wheel, crank trigger, and all the old settings that ran great on my previous '00 motor.

Pulled the plugs to see what's going on since they were brand new:

1 & 4 are black
2 looks brand new still
3 has a little discoloration

Note the bronzing of the top of the plugs.

What is going on? I just re-wired the COP's with heat-shrink crimps to make sure the wiring is solid since it was soldered before, but no change.