3800sc Swap Complete Parts List (Page 1/4)
AustinH MAR 24, 12:01 PM
Update: The below build worked great (except for random wiring issues) and took me less than 1 month to do. I managed a 13.5 second quarter mile with a 1.9 second 60' time with street tires. I drove this build for nearly two years and MAN IT WAS FUN!!!! It was an extremely easy direct-swap effort, and I would do it to EVERY Fiero in a heartbeat. The total cost for hard parts was around $1700; I bought a car with the engine+transmission+axles in it for $600 and sold the old 2.8. I did use a bonneville torque converter which made me idle around 20mph, so get a different one (listed in build 2). I believe this build generated 280-300 crank horsepower based on air consumption. It is common to put a 3.4" pulley, 180* thermostat+radiator fan temp points changed, and two range colder spark plugs on these stock engines to get an extra 30-60 horsepower out. I have now started a second engine build after buying another lower mile block, primarily because my wiring harness and engine bay are a rat's nest. I decided to rebuild the engine less the short block and shoot for 400 wheel horsepower. You can track my build progress and my other how-to videos (vertical doors, slim headlights, steering wheel, etc) here - https://www.youtube.com/use...4?sub_confirmation=1

I just finished a 3800sc series II swap with a 4t65e-HD automatic into a 1988 fiero GT on a budget. I kept a list of parts I used to do the swap. This list is complete, but keep in mind there are many alternatives to doing this swap.

Here's the parts list of stuff you'll need for the 3800sc swap with a GTP engine. The numbers in ( ) are the quantity. I mostly found the best priced stuff out there. Almost everything can be found at Summit and Autozone.

Heater Hose (for 87-88 fieros, may work for other applications but will need longer hoses) (goes with 5/8" barb, youll have to mount a retaining bracket):
Dayco C87641 - 3/4" 3800sc heater hose elbow (actually 7/8 but can squeeze on) to 5/8" stock fiero heater hose line

Aluminum Heater Hose Elbow:
Dorman 47065HP

5/8-5/8" barb for new dayco heater hose to stock heater hose:
http://www.homedepot.com/p/...903-122501/202254895

T-stat housing to L-side coolant tube (cut a few inches):
Dayco E71082 - 1.25" to 1.25" 3800sc t-stat housing to fiero

Water-pump to R-side coolant tube (cut a few inches):
Dayco E71030 - 1.25" fiero to 1.5" 3800sc water pump hose

Radiator filler neck:
Moroso 63745 1.25"-1.25" hose

Radiator cap:
Stant Products 10203

Trans cooler line barb fitting (2): (replaced in 2nd build below with different parts)
Derale 98104 - 1/4" NPT to 3/8" hose barb trans line

Trans cooler fitting adapter (2): (replaced in 2nd build below with different parts)
Dorman 800-754 - 1/4" NPT to 5/8-18 inverted flare fiero fitting

fittings push lock gas line fittings and hoses: (replaced in 2nd build below with different parts)
Fragola 200106-BL (4) -6 AN push lock fuel hose adapters
Fragola 871006 (10ft) push lock fuel hose

fittings for gas lines:
Vibrant 10229 -6 AN to 14 x 1.5 fiero fuel line return
Vibrant 16619 -6 AN to 16 x 1.5 fiero fuel line
Vibrant 16885 -6 AN to 5/16 fuel rail return 3800sc (replaced in 2nd build below with different parts)
Vibrant 16886 -6 AN to 3/8 fuel rail 3800sc (replaced in 2nd build below with different parts)

Thread sealant for gas line fittings to Fiero:
Permatex Form-A-Gasket No. 2 (Autozone)

air duct flex 4" dia, 41inch long:
Spectre 9751

air filter:
K&N RF-1040

Transmission filter:
Fram FT1129A (replaced in 2nd build below with different parts)

Oil filter:
WIX 51040XP (replaced in 2nd build below with different parts))

Fuel filter:
WIX 33481 (replaced in 2nd build below with different parts)

AC/DRYER:
Four Seasons 33181 (optional)

Muffler 3" right in, 2 2.5" right + left out: - you will have to weld a bend in your own exhaust.
Flowtech 50363FLT (replaced in 2nd build below with different parts)

3-pin Oil pressure sender connector:
STANDARD MOTOR PRODUCTS HP4480

3-pin Oil pressure sender:
AIRTEX/WELLS 1S6635

Supercharger Tensioner Pulley:
DAYCO 305217

1" frost plug for plugging water pump hole:
Dorman 570-005

Accessory Belt:
Gates K060815 81.5", 6 ribs)

Supercharger belt: (replaced in 2nd build below with different parts)
3.7" pulley - Duralast 665k6 (66.5", 6 ribs)
3.4" pulley - Duralast 660k6 (66", 6 ribs)

Supercharger oil (2 bottles):
GM 12345982 (replaced in 2nd build below with different parts)

Fuel pump:
HFP-343 255lpm fiero (quieter, cheaper, higher quality than walbro 255)

Spark Plugs:
Autolite 104 spark plugs, gap to .050 or .055 (6) - two ranges colder than stock plugs (Autolite 606) (replaced in 2nd build below with different parts)

Supercharger Pulley:
Smoothflow 3.4" supercharger pulley: (optional, also see supercharger belts) (replaced in 2nd build below with different parts)
http://www.smoothflowpulleys.com/3800_MPS.html

Thermostat:
180 deg thermostat (drill small hole in):
Duralast 15848

Transmission Fluid:
7.4 quarts (maint.) to 10 quarts (flush) Dexron III trans fluid (replaced in 2nd build below with different parts)

Oil:
4.5 quarts 5W30 oil (replaced in 2nd build below with different parts)

Fierorog brackets:
engine mount
auto trans mount
alternator bracket
dogbone bracket
Find them here http://www.fiero.nl/cgi-bin...orum=4&thread=068855

West Coast Fiero shifter bracket:
http://westcoastfiero.com/p...ion-shifter-adapterx

new driver's side axle:
stock fiero automatic driver's side axle

new passenger's side axle:
Drivers & Passenger GTP axle + any manual fiero axle - see youtube how-to video https://www.youtube.com/watch?v=D_VKktIEaTE

The parts list is much longer if you don't have a GTP engine e.g. 2000+ bonneville/park avenue:
GTP/Regal Steel Oil Pan
GTP Oil Pan Gasket (needs cutting to fit over oil pickup)
Oil Filter Housing Gasket
GTP/Regal oil filter bracket GM 12569219 ; 24508441
GTP/Regal angled coil pack bracket GM 24507211 ; 24504360 (cut dogbone)
GTP Tensioner pulley on coil pack bracket
3-pin Temperature sender & wire - duralast TU178DG

If you are making your own harness:
In-line fuse holders (2) (replaced in 2nd build below with different parts)
computer
fuel pump relay (can use stock) (replaced in 2nd build below with different parts)


-------------------------------------------------------
Not 3800sc swap related parts below -
bigger tires General Altimax RT43: (optional)
225/60R15 rear (on stock 15x7" rims)
215/60R15 front (on stock 15x7" rims - 1988 fronts came with 15x6.5s)

Rear Brake lines:
Autozone M10 to M10 Copper-Nickel line 60" (1) rear
Autozone M10 to M10 Copper-Nickel line 12" (1) rear
Autozone M12 to M12 Steel Line 36" (1) rear
Autozone M12 to M12 Steel Line 60" (1) rear
Autozone M12 to M14 steel line 12" (2) rear
Autozone M12 to M12 coupler (2) rear
Dot3 brake fluid

stock tire size is -
215/60R15 rear
205/60R15 front

I also have 1988 specific parts #'s:
shocks - KYB KG4513 (optional)
struts - MONROE 71814 (optional)
brake pads (optional)
brake calipers (optional)
headlights # H6054 (optional)

Misc body parts: (optional)
Side scoops - http://fierofiberglass.com/...ages/SideScoops.html
5" raised wing stands - Fierowarehouse (message doug on Ebay) http://stores.ebay.com/Fiero-Warehouse

Other misc part number website (not best prices)
http://www.gmtuners.com/fiero/parts.htm


------------------
Austin H.
1988 GT 3800SC Series II 3.4" Pulley
Fiero How-To Videos at https://www.youtube.com/use...4?sub_confirmation=1
Facebook page at https://www.facebook.com/FieroAustinH/
Build thread - http://www.fiero.nl/forum/Forum2/HTML/139530.html
Build pictures - https://drive.google.com/dr...OM2I3THM?usp=sharing

[This message has been edited by AustinH (edited 09-03-2019).]

fieroall MAR 24, 12:46 PM
That's a great list of parts however I think it's a bit misleading. Their are many different ways to do the 3800 swap depending on your abilities and finances. Honestly looking over your list I don''t think I used a single part from it to do any of my swaps.
AustinH MAR 24, 12:49 PM

quote
Originally posted by fieroall:

That's a great list of parts however I think it's a bit misleading. Their are many different ways to do the 3800 swap depending on your abilities and finances. Honestly looking over your list I don''t think I used a single part from it to do any of my swaps.



Thanks for the reply. You are right, there's a lot of other parts out there. But if someone wants to get started, I just finished my swap, and these parts could be used as a quick reference.

------------------
Austin H.
1988 GT 3800SC Series II 3.4" Pulley
Fiero How-To Videos at https://www.youtube.com/use...4?sub_confirmation=1
Facebook page at https://www.facebook.com/FieroAustinH/
Build thread - http://www.fiero.nl/forum/Forum2/HTML/139530.html
Build pictures - https://drive.google.com/dr...OM2I3THM?usp=sharing

[This message has been edited by AustinH (edited 08-10-2018).]

BMTFIERO MAR 25, 10:40 PM
Thanks for your time and contribution to the cause!!
Spadesluck MAR 26, 01:04 AM
Everyone's build will vary for sure depending on wants and needs, however for you to go through the trouble and list what worked for you is greatly appreciated. Thank you. It will, at the very least, give people an idea on what to expect and look for.

[This message has been edited by Spadesluck (edited 03-26-2017).]

AustinH NOV 08, 07:15 PM
removed

[This message has been edited by AustinH (edited 04-30-2018).]

bulldog85043 NOV 12, 05:05 PM
I have my engine (3800 SC) out of a 2002 Grand Prix 40th Ann. so I'll be watching VERY close for those vids...

[This message has been edited by bulldog85043 (edited 11-12-2017).]

AustinH NOV 20, 01:20 PM

quote
Originally posted by bulldog85043:

I have my engine (3800 SC) out of a 2002 Grand Prix 40th Ann. so I'll be watching VERY close for those vids...





Well I am tearing down my 2nd 3800sc engine for a rebuild now and doing a how-to about it.

I decided to launch a Facebook page, as Facebook seems to have replaced some Forums as a modern source of information in many ways. You can find it here:

https://www.facebook.com/pg/FieroAustinH/



------------------
Austin H.
1988 GT 3800SC Series II 3.4" Pulley
Fiero How-To Videos at https://www.youtube.com/use...4?sub_confirmation=1
Facebook page at https://www.facebook.com/FieroAustinH/
Build thread - http://www.fiero.nl/forum/Forum2/HTML/139530.html
Build pictures - https://drive.google.com/dr...OM2I3THM?usp=sharing

[This message has been edited by AustinH (edited 08-10-2018).]

VanGTP5000 NOV 20, 01:53 PM

quote
Originally posted by AustinH:
Well I am tearing down my 2nd 3800sc engine for a rebuild now and doing a how-to about it.

I decided to launch a Facebook page, as Facebook seems to have replaced some Forums as a modern source of information in many ways. You can find it here:

https://www.facebook.com/pg/FieroAustinH/





Great job on the video Austin...I enjoyed watching it. I am sure it will be very helpful to many!!!

-Van
AustinH DEC 24, 12:03 PM
I never included these earlier. Here are pictures of diagrams for my first swap. Just to centralize information.

Coolant lines, fuel lines, and transmission line fitting diagram:


Axle building diagram (these parts are NOT the only ones that will work. Do your interchange parts research.):


Fuel pump hotwire (courtesy of GMTuners / Darth Fiero / Sinister Performance:


Custom fuel rail design (Not included in above parts list. Part #s on diagram):


Harness wiring diagram (For a GTP harness that works manual Fiero trans. For automatic harnesses, you will need to ground the VSS LOW Fiero input pin and add the buffer circuit shown here between the GTP computer and the fiero pin: http://www.gmtuners.com/fiero/fmods.htm ):


------------------
Austin H.
1988 GT 3800SC Series II 3.4" Pulley
Fiero How-To Videos at https://www.youtube.com/use...4?sub_confirmation=1
Facebook page at https://www.facebook.com/FieroAustinH/
Build thread - http://www.fiero.nl/forum/Forum2/HTML/139530.html
Build pictures - https://drive.google.com/dr...OM2I3THM?usp=sharing

[This message has been edited by AustinH (edited 02-18-2020).]