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3800sc Swap Complete Parts List by AustinH
Started on: 03-24-2017 12:01 PM
Replies: 51 (13383 views)
Last post by: AustinH on 10-02-2020 03:57 PM
AustinH
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From: Waterloo, Iowa; Fort Wayne, Indiana; West Lafayette, Indiana
Registered: Jun 2014


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Report this Post03-24-2017 12:01 PM Click Here to See the Profile for AustinHClick Here to Email AustinHSend a Private Message to AustinHEdit/Delete MessageReply w/QuoteDirect Link to This Post
Welcome to the One-Stop-Shop for swapping a 3800sc engine into a Fiero! You will likely not come across a more thorough collection of 3800sc fiero swap information, parts, diagrams, or videos than here.

What this thread is: A suggestion for a complete 3800sc Series II or Series III supercharged swap guide with a 4-speed automatic 4t65e-HD transmission. There are TWO COMPLETE ENGINE BUILDS detailed here:
-A cheap and easy Series II direct drop-in swap (Build 1)
-An all-out Series III supercharged build including changing camshafts, but not changing pistons/crank/bearings/rods (Build 2)

What this thread is NOT:
-A pricing guide
-A 3800 NA swap guide, though you will find much overlap
-A 3800 turbo swap guide, though you will find much overlap
-A computer (PCM/ECU) reprogramming or tuning guide
-A bottom-end machining/assembly guide (pistons, connecting rods/bearings, piston rings, crankshaft/bearings)
-An automatic to manual transmission swap guide
-An all-encompassing Buick 3800 engine guide for any car but a fiero
-A transmission rebuilding guide
-A detailed manual transmission guide
-Perfect

CONTENTS:
How to pick out parts for your build: 3800 Performance and Specs of historical swaps
-Modification Selection Chart
-Camshafts
-Quarter Mile Times
-Dyno Wheel Horsepower
-Common Modifications
-Differences between 3800 Engines
-Transmission Options
-M90 Gen 3 and Gen 5 supercharger specs
-Motivational Previews

BUILD 1: COMPLETE PARTS LIST FOR A CHEAP AND EASY DIRECT SWAP SERIES II SUPERCHARGED 4T65E-HD TRANS BUILD
-Air
-Fuel
-Spark
-Exhaust
-Coolant/Hoses
-SENSORS/HARNESS/COMPUTER (ECU/PCM)
-4t65e Transmission
-ACCESSORIES/AC/OTHER/MISC
-Mounting and Brackets
-Axles
-PARTS NEEDED IF YOU DO NOT BUY A PONTIAC GRAND PRIX GTP DONOR CAR

BUILD 2: Complete Parts List for an all-out Series III Supercharged 4T65E-HD build, excluding bottom end (connecting rods/pistons/crank), IN ADDITION TO BUILD 1
-Air
-Fuel
-Spark
-Exhaust
-Cylinder Heads/Valvetrain/Pushrods/Lifters
-Camshaft, timing chain, and balance shaft removal
-4t65e Transmission

3800sc Assembly Diagrams and Torque Specs
-Firing Order
-Coolant and Fuel Lines
-SUPERCHARGER, CONNECTIONS, AND ROUTINGS
-HOW TO HOOK UP THE 4t65e TRANSMISSION
-Exhaust Setup for Build 1
(below here is for build 2 only)
-Torque Sequences
-ENGINE EXPLODED VIEW ASSEMBLY DIAGRAMS
-HOW A PCV SYSTEM WORKS WITH A NORTHSTAR THROTTLE BODY ON A SERIES III 3800SC
-EXHAUST SETUP FOR BUILD 2
-4t65e Transmission

WIRING HARNESS AND COMPUTER/ECU/PCM PROGRAMMING
-Buying a harness
-Building a harness

Disassembly, Reassembly and Final Fiero Installation Videos
-Required for both Build 1 and Build 2
-Required for Build 2
-Engine Tear-down and rebuild instructions
-Porting Heads
-INSPECTING THE BOTTOM END (crank/bearings/connecting rods/bearings/pistons/piston rings)

Other Helpful Fiero Parts While You're At It

EXTREMELY Useful Links

Disclaimer: If you follow any instructions here, you assume 100% liability for your own build. NOTHING is guaranteed to work. If you blow up your engine, it is YOUR FAULT. Do not blindly follow this guide and buy parts until you feel you understand for yourself why and how everything about a 3800 engine works. This build thread is NOT BASED ON THE FACTORY INSTRUCTION MANUAL, but rather years of accumulated modification knowledge from across many companies, personal experience, and the internet. It might be helpful for you to buy a Buick 3800sc factory service manual.

NOTE: I do have the pricing recorded of ALL parts purchased for both builds. Also, if you would like to contribute your content to this page or report a broken link, please contact me at http://facebook.com/fieroaustinh. Please consider supporting my by YouTube channel by subscribing here - https://www.youtube.com/use...4?sub_confirmation=1
------------------
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 06-03-2020).]

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Report this Post03-24-2017 12:46 PM Click Here to See the Profile for fieroallSend a Private Message to fieroallEdit/Delete MessageReply w/QuoteDirect Link to This Post
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.
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AustinH
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Report this Post03-24-2017 12:49 PM Click Here to See the Profile for AustinHClick Here to Email AustinHSend a Private Message to AustinHEdit/Delete MessageReply w/QuoteDirect Link to This Post
How to pick out parts for your build: 3800 Performance and Specs of historical swaps
All options for your engine swap will come down to cost and effort. This build thread details two specific paths. Use the charts and videos below to decide what power you want out and how much effort and money you are willing to invest into the project.

----------------------Modification Selection Chart-------------------
The below chart shows the dyno wheel horsepower numbers AND quarter mile track times from different people's 3800 supercharged build setups found posted across the internet. The chart shows the modifications for each person's setup (camshafts, superchargers, cylinder heads, fuel type, boost, compression, etc.). The top of the chart also lists all available supercharged 3800 camshaft design specs. Generally, red colored cells indicate either bad performance or hard to achieve (expensive or lots of other supporting mods required), This chart shows ALL M90 3800sc build track times that are on various forums that I could find, which are linked.

If you want a spreadsheet file, you can download from here https://drive.google.com/op...BhWo_-7onmDaVip8EFwo


---------------------Common Modifications-----------------------

Here my video indicates most common modifications available for the Fiero:


Here ZZP makes a short summary video of common modifications you can make to your 3800sc:


----------------Differences between 3800 Engines------------------
Read up:
https://en.wikipedia.org/wiki/Buick_V6_engine

NOTE: The ideal donor car or motor to buy is a 1998-2002 Pontiac Grand Prix GTP. If you do not get an engine from a GTP, there are many parts listed below that you will need in addition, just to make it fit in a Fiero.

NOTE: DO NOT SWAP A SUPERCHARGER ONTO A 3800 NA (Naturally Aspirated) BLOCK UNLESS YOU KNOW EXACTLY WHAT YOU ARE DOING. THE COMPRESSION, PISTONS, AND RINGS ARE DIFFERENT.

Short Summary of Differences between L26/L27/L67/L32/L36/L67 3800 Series II or Series III Supercharged or NA (Naturally Aspirated) engines:


----------------------Transmission Options------------------
NOTE: Many transmissions will work with this car. Here are a few common ones that can handle the 3800 power.
http://www.fastfieros.com/t...06_transmissions.htm
4t60e 4 speed auto - will only withstand ~200hp - https://en.wikipedia.org/wi..._4T60-E_transmission
4t65e 4 speed auto - will only withstand ~250hp - https://en.wikipedia.org/wi..._4T60-E_transmission
4t65e-HD 4 speed auto - will withstand ~300hp, and up to ~400hp with light modifications - already comes on 3800sc cars. EASIEST TO USE - https://en.wikipedia.org/wi..._4T60-E_transmission
Getrag 282 - will only withstand ~250hp - https://en.wikipedia.org/wi...rag_282_transmission
4t80e 4 speed auto - will withstand ~400hp but is big and heavy - https://en.wikipedia.org/wiki/GM_4T80_transmission
F23 5 speed manual - will allegedly withstand ~500hp - https://en.wikipedia.org/wi...rag_F23_transmission
F40 6 speed manual - will allegedly withstand ~600hp - https://en.wikipedia.org/wiki/GM_F40_transmission

----------------------M90 Gen 3 and Gen 5 supercharger specs------------------
Relevant M90 Supercharger Design and Performance Information:
http://www.mscperformance.com/specpg2.html


NOTE: The pulley sizes here are for a mustang engine and do not apply to 3800's, but the rest of the info can be helpful. This is for a Series II/Gen3 supercharger. For Series III/Gen5, subtract approx. 40°F to temperatures here.


Here is a quote from Eaton about the performance of an M90 Gen5 supercharger:
The 90-cubic inch Gen V supercharger is very compact. Its housing includes the throttle-body adaptor, crankcase ventilation plumbing,
coolant passages, the evaporative emissions purge valve and the rotor
drive mechanism. The drive mechanism is sealed and permanently
lubricated, obviating the need for oil connections and eliminating a
potential source of leaks. Moreover, the Gen V features all-cast
components and a larger, low-restriction outlet port. The tuned inlet
port is also less restrictive, compared to previous-generation
superchargers, allowing a larger (75 millimeter) throttle body. As a
result, more air is pumped by the supercharger through the Series III’s
induction system. The Gen V’s rotor is finished with Abraidbable Powder
Coating (APC) rather than epoxy. APC is a patented material containing
graphite that is electrostatically applied to the rotor and baked on. As
a result, the rotor requires less clearance within the supercharger
housing, resulting in less leakage around its edges, greater airflow at
a given operating speed and lower operating temperature. The Gen V’s
rotor bearings have been enlarged to increase durability and reduce
operating noise and vibration.

As a result, the Gen V operates at considerably higher efficiency than
its predecessors. At wide open throttle, the Gen V turns at 700 fewer
rpm (a 9 percent reduction), draws 13 percent less power from the
crankshaft, decreases operating temperature 15 percent and increases
volumetric efficiency 9 percent. For the customer, that means a 9
percent increase in horsepower (see product specifications), and best-
in-class acceleration times for the Grand Prix.


--------------------------Motivational Previews--------------------------


------------------
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 05-29-2020).]

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Report this Post03-25-2017 10:40 PM Click Here to See the Profile for BMTFIEROClick Here to Email BMTFIEROSend a Private Message to BMTFIEROEdit/Delete MessageReply w/QuoteDirect Link to This Post
Thanks for your time and contribution to the cause!!
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Report this Post03-26-2017 01:04 AM Click Here to See the Profile for SpadesluckSend a Private Message to SpadesluckEdit/Delete MessageReply w/QuoteDirect Link to This Post
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).]

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Report this Post11-08-2017 07:15 PM Click Here to See the Profile for AustinHClick Here to Email AustinHSend a Private Message to AustinHEdit/Delete MessageReply w/QuoteDirect Link to This Post
BUILD 1: COMPLETE PARTS LIST FOR A CHEAP AND EASY DIRECT SWAP SERIES II SUPERCHARGED 4T65E-HD TRANS BUILD
NOTE: THIS BUILD 1 LIST IS COMPLETE AND INDEPENDENT OF BUILD 2, BUT BUILD 2 INCLUDES BUILD 1 LIST!

Preface: The output of this engine is expected 280-300 crank horsepower with easy, minor modifications. Those modifications are:
-3.4" supercharger pulley - for slightly increased air
-180 degrees thermostat - for slightly cooler combustion
-Re-program radiator fan setpoints - for slightly cooler combustion
-Tune the computer (ECU/PCM)
-Autolite 104 Spark Plugs (2 heat range colder than stock spark plugs) - for slightly higher knock resistance
With these modifications, an extra 30-60hp is expected out of the otherwise totally stock series II motor.

This build thread also assumes you optionally delete the following:
-EGR system - requires welding and sealing shut holes in exhaust and lower intake manifold, detailed in Build 2. For non-emissions compliant states. Requires reprogramming the computer.
-Catalytic Converter and Rear O2 Sensor - For non-emissions compliant states. Requires programming the computer.
-EVAP System/Stock Fiero vacuum lines - requires plugging hole with freeze plug and JB weld. Requires reprogramming the computer.
-Stock Fiero intake - requires new intake mounted.
-"coffee can" vacuum accumulator canister for stock cruise control - stock Fiero cruise control allegedly works by hooking the vacuum line directly to the supercharger port, since the 3800 has more vacuum than the stock Fiero engine.
-balance shaft/tensioner spring (build 2 only)

NOTE: The ideal donor car or motor to buy is a 1998-2002 Pontiac Grand Prix GTP. If you do not get an engine from a GTP, there are many parts listed below that you will need in addition, just to make it fit in a Fiero.

There is no need to separate the 4t65e-HD transmission from the engine. If you do, get new flywheel bolts listed below.

Update: The below build worked great (except for custom wiring issues) and took me less than 1 month. I ran a 13.5 second quarter mile without modifying the tune, and 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 $500 and scrapped the body to get back $125.

THE LIST:
The numbers in (x) are the quantity of parts you need to order. Almost everything can be found at Summit/RockAuto/Autozone/Advanced/Oreillys/ZZPerformance

---------------------AIR--------------------
Flexible air duct flex 4" dia, 41inch long (1x):
Spectre 9751 - https://www.summitracing.com/parts/spe-9751

Air filter (1x) - this entirely replaces the stock air intake and water separator. Air filter is fastened under fenderwell behind drivers' seat and behind the stock intake:
K&N RF-1040 - https://www.summitracing.com/parts/knn-rf-1040

Oil filter (1x):
ACDELCO UPF47R -https://www.rockauto.com/en/parts/acdelco,UPF47R,oil+filter,5340

Fuel filter (1x):
WIX 33481 - https://www.rockauto.com/en...481,fuel+filter,6200

Supercharger oil (2x):
GM 12345982 - https://www.amazon.com/GM-P...r-Gear/dp/B00CFH3BZM

Supercharger Pulley (1x):
Smoothflow 3.4 Polished Finish Pulley System MPS (Modular Pulley System) - optional, also see supercharger belts - DON'T JUST ORDER A BARE PULLEY! ORDER THE PULLEY SYSTEM WITH THE HUB THAT IS PRESSED ON TO THE SUPERCHARGER SHAFT!:
http://www.smoothflowpulleys.com/3800_MPS.html

Supercharger Pulley Puller (1x) - can rent:
https://zzperformance.com/p...harger-pulley-puller

Supercharger belt - may have to go up or down a size in 0.5" increments to ensure tight fitment:
3.7" pulley - 66.5", 6 ribs (1x):
Duralast 665k6 - https://www.autozone.com/co...e-belt-665k6/66396_0
3.4" pulley - 66", 6 ribs (1x):
Duralast 660k6 - https://www.autozone.com/ig...-660k6/315419_0_8239

-----------------------FUEL------------------------
Note: The fuel fittings in this section do not represent any fittings in the custom fuel rail diagram posted below TBD. These are bolt-on for an easy, direct swap.

Push-Lok Fuel Hose (1x) - heat this up in a pot of hot water before pushing the below barb fitting on. Cut into 2 appropriate length sections for both supply and return fuel hoses.
Fragola 871006 (10ft) - https://www.summitracing.com/parts/fra-871006

-6 AN to barb Push-Lok hose adapter (4x):
Fragola 200106-BL - https://www.summitracing.com/parts/fra-200106

Stock fuel rail hose release tools (1x) - These are a pain to use, see this video - https://youtu.be/uVlHx1veJN8?t=33:
Advance Auto Parts W83148 - https://shop.advanceautopar...-8-w83148/11962912-p

Stock Fiero Fuel Supply Hose M16 x 1.5 Adapter to -6 AN (1x):
EAR-991955ERL - https://www.summitracing.com/parts/ear-991955erl

Stock Fiero Fuel Return Hose M14 x 1.5 Adapter to -6 AN (1x):
EAR-991954ERL - https://www.summitracing.com/parts/ear-991954erl

Stock 3800sc Fuel Rail 3/8" Supply Line To above -6AN Push-Lok adapter (1x):
Vibrant 16886 - https://www.summitracing.com/parts/vpe-16886 (replaced in 2nd build below with custom fuel rail parts)

Stock 3800sc Fuel Rail 5/16" Return Line To above -6AN Push-Lok adapter (1x):
Vibrant 16885 - https://www.summitracing.com/parts/vpe-16885 (replaced in 2nd build below with custom fuel rail parts)

Thread sealant for Metric Fiero return/supply to -6AN adapters above (1x):
Permatex Form-A-Gasket No. 2 80016 - https://www.summitracing.com/parts/ptx-80016

Fuel pump:
Quantum Fuel Systems 255LPM Fuel Pump HFP-343 (1x) - quieter, cheaper, claimed higher quality than walbro 255 - BE CAREFUL WITH THIS PUMP. THE INLET IS TOO CLOSE TO THE BOTTOM OF THE FUEL TANK AND WILL SUCK AGAINST THE TANK, NOT ALLOWING FOR FUEL FLOW AT HIGH FUEL DEMANDS. I TRIMMED THE BOTTOM LIP OFF OF THIS FUEL PUMP TO GIVE MORE CLEARANCE FOR DRAWING FUEL FROM THE BOTTOM OF THE TANK, WHILE STILL ALLOWING ROOM FOR THE SCREEN TO FIT - REMOVE SCREEN BEFORE TRIMMING. - https://www.highflowfuel.co...8-2-5l-tbi-2-8l.html

-------------------------SPARK----------------------
Spark Plugs - two ranges colder than stock Autolite 606 plugs, gap to .050" or less (6x):
Autolite 104 spark plugs - https://www.summitracing.com/parts/atl-104

Spark Plug Gap Tool (1x)
Advance Auto W80540 - https://shop.advanceautopar...ge-w80540/10075900-p

Spark Plug Wire Kit (1x) - you need a vice and a spark plug crimper below:
Taylor Cable 83253 (45 degree boots) - https://www.summitracing.com/parts/tay-83253

Spark plug wire crimper to use with bench vise (1x):
Accel 170040 - https://shop.advanceautopar...mm-170040/10717178-P

-------------------EXHAUST (Upgraded Entirely in Build 2)-----------------

NOTE: This exhaust system mates to the stock exhaust headers, which can support up to 300hp. You will have to custom-weld your exhaust. There is no bolt-on exhaust for an engine swap (does someone want to start making these?). See pictures of exhaust for this setup in the Assembly Diagrams section. Final fitment can vary between year models of Fieros, engine mount setups, etc. Best advised to go to an exhaust shop and get one welded up after the engine is in the car.

Muffler (1x)
3" right in, 2 2.5" right + left out: - you will have to weld a bend in your own exhaust.
Flowtech 50363FLT - https://www.summitracing.com/parts/big-50363flt

Exhaust pipes - The best types are mandrel bent stainless steel, but those can be hard to find and expensive. For a lower cost option, go to an auto parts store and pick up the below pipes:
90° bend 3" diameter (1x)
180° bend 3" diameter (1x) - must be VERY TIGHT bend radius, likely needed custom weld job
90° bend 2.5" diameter (2x) - https://www.summitracing.com/parts/sum-622118
Straight 2.5" diameter, 1 ft (1x)
2.5" diameter Exhaust Tips (2x) - Re-used stock Fiero exhaust tips
2.5" diameter generic exhaust hanger U-bolts (2x) - use the stock Fiero rubber exhaust hangers to hang these from.

-------------COOLANT AND HOSES--------------
Heater Hose (1x) - for 87-88 Fieros, may work for other applications but will need longer hoses. Goes with 5/8" barb, you'll have to fabricate and mount a retaining bracket detailed in LostNotForgotton's videos below:
Dayco C87641 - 7/8" 3800sc heater hose elbow, can squeeze on to 5/8" stock Fiero heater hose line - https://www.autozone.com/co...se-c87641/315787_0_0

Barb For above heater hose to stock Fiero heater hose, 5/8-5/8" (1x):
https://www.homedepot.com/p...ing-800089/300096112

Aluminum Heater Hose Elbow (1x):
Dorman 47065HP - https://zzperformance.com/p...minum-coolant-elbows

Thermostat housing to drivers' side coolant tube (1x) - cut a few inches off the small end:
Dayco E71082 - 1.25" to 1.25" 3800sc thermostat housing to fiero - https://www.autozone.com/ig...2/886135_16004_10495

Water-pump to Passengers' coolant tube (1x) - cut a few inches off the small end:
Dayco E71030 - 1.25" fiero to 1.5" 3800sc water pump hose - https://www.autozone.com/co...hose-e71030/886077_0

Radiator filler neck 1.25" inlet and 1.25" outlet (1x):
Moroso 63745 - https://www.summitracing.com/parts/mor-63745

Radiator cap (1x):
Stant Products 10203 - https://www.summitracing.com/parts/snn-10203

1" frost plug for plugging water pump hole (1x):
Dorman 570-005 - https://www.oreillyauto.com...-plug/570005/4180960

180° Thermostat (1x - drill small hole in the outside plate):
Duralast 15848 - https://www.autozone.com/co...ostat-15848/615480_0

Coolant/Antifreeze (14qt) - you can really use whatever you want, as long as you don't mix two colors and flush the system properly:
PRESTONE AF3000 (AF3000/F) universal antifreeze - https://www.amazon.ca/Prest...freeze/dp/B000KKNBVU

Optional: 3/4" to 3/4" barb ball valve shutoff (1x) - for shutting off coolant into the heater circuit in the summer: https://www.walmart.com/ip/...selectedSellerId=282

-----------------SENSORS/HARNESS/COMPUTER (ECU/PCM)-----------------
NOTE: See Harness section for more detailed instructions, diagrams, and parts.

3-pin Oil pressure sender (1x) - comes from a 1988 Fiero V6:
AIRTEX/WELLS 1S6635 - https://www.rockauto.com/en...sender+/+switch,4588

3-pin Oil pressure sender connector (1x) - if building your own harness:
STANDARD MOTOR PRODUCTS HP4480 - https://www.rockauto.com/en...witch+connector,2603

2-Bar MAP sensor (1x) - if you bought a 3800 NA block or harness:
ACDELCO 2131520 - https://www.rockauto.com/en...e+(map)+sensor,11207

In-line fuse holders (2x) - if building your own harness:
Oreilly Auto FHA1BP - https://www.oreillyauto.com...8/pontia c/grand-prix

Computer (ECU/PCM) (1x):
If you don't have one, get at junkyard for $25 from ideally a 1998-2002 Grand Prix GTP. - Junkyard Search

Harness from the donor car (1x):
Again best harnesses and engines are from a 1998 Pontiac grand prix GTP.

Harness from the Fiero (1x)

Fuel pump relay (1x) - if building your own harness
-Can use stock Fiero relay or any modern generic car relay that you pull out of the fuse box from the donor car.

-----------------------4t65e-HD TRANSMISSION----------------------

Trans line fitting (2x) - 5/8"-18 INVERTED FLARE TO UNF -6AN:
SUM-220667B - https://www.summitracing.com/parts/sum-220667

Trans line elbow (2x): - -6AN to 3/8" 90 deg barb to mate with above fitting :
209006-BL - https://www.summitracing.com/parts/fra-209006-bl

Transmission Hose to Fiero Hose (1x) - Replaces steel transmission lines:
Derale 13016 - https://www.summitracing.com/parts/der-13016

Transmission oil filter (1x):
ACDELCO TF304 - https://www.rockauto.com/en...utomatic,filter,8600

Transmission Oil Pan Gasket (1x) - if above filter does not come with one - AVOID CORK GASKETS!:
ACDELCO 24206182
Or
ACDELCO 24204624
https://www.rockauto.com/en...,oil+pan+gasket,8612

Flywheel Bolts (8x) - ONLY NECESSARY if you take off the automatic flywheel. NOT NEEDED if you have a manual transmission. These bolts YIELD and need to be replaced if you take off the flywheel. However if you do install a manual transmission, you will need different flex plate bolts listed in the Mounting and Brackets section.:
GM # 24501365 - https://www.gmpartsdirect.c...s/gm-s-bolt-24501365

Transmission Fluid:
7.4 quarts (maintenance) or 10 quarts (total drain) Dexron III Transmission fluid
https://www.rockauto.com/en...smission+fluid,11387

-----------------------ACCESSORIES/AC/OTHER/MISC----------------------

Accessory Belt Tensioner Pulley from a Ford, if using FieroRog's engine mount brakcets - (1x):
DAYCO 305217 - https://www.rockauto.com/en...belt+tensioner,11659

Supercharger Tensioner Pulley - comes on a 3800sc unless coil pack bracket is missing:
GATES 38365 -https://www.rockauto.com/en/parts/gates,38365,belt+tensioner,11659

Accessory Belt - 81.5", 6 ribs (1x):
Gates K060815 - https://www.rockauto.com/en...es,K060815,belt,8900

Oil, conventional preferred (4.5 quarts):
5W30

Magnetic Oil Drain Plug (1x):
Dorman 090091 (65372) - https://www.rockauto.com/en/parts/dorman,65372,,

AC/DRYER if doing A/C (1x):
Four Seasons 33181 -https://www.rockauto.com/en/parts/four+seasons,33181,a/c+receiver+drier+/+accumulator,6972

Custom A/C hose made by a radiator shop (1x) - I had a radiator shop make one. You need an R12 port for the sensor. I cut one off of a Bonneville AC hose and welded it onto the Fiero side. I also used the GTP compressor side AC hose fitting. Beware, there were at least 2 types of compressors/AC hoses on 3800 engines. LostNotForgotton has a video, and people on Facebook fiero pages make the hoses. See LostNotForgotton's video - https://youtu.be/ZyPZkCPJzNk?t=530

Knock Sensor (2x) - a good idea to replace these, especially if they wiggle:
STANDARD MOTOR PRODUCTS KS45 - https://www.rockauto.com/en...tonation+sensor,5108

Longer battery ground cable from Advance Auto (1x):
https://shop.advanceautopar...k-ac129hs/11142544-P

ALTERNATOR - You need a year 2000+ alternator for any 3800 car. Below is from a Bonneville.
https://www.rockauto.com/en...tor+/+generator,2412

Lots and lots of hose clamps of all sizes!!!

Some sort of engine hoist, two jacks, and two jack stands for engine removal and installation...

----------------MOUNTING AND BRACKETS-----------------
I use FieroRog brackets. Order them from Roger here http://www.fiero.nl/cgi-bin...orum=4&thread=068855
-engine mount
-4t65e-HD automatic transmission mounts (2x) - see below if you are using a Fiero manual transmission
-alternator relocation bracket
-dogbone engine mount bracket
-bolts

Manual Transmission Brackets:
If using a manual Fiero transmission, get these from FieroRog:
-Custom Flexplate (1x)
-Flexplate bolts (8x) - GM 24505092 (call Roger to verify)
-manual transmission mounts (2x) - instead of automatic transmission mounts above
-Clutch bolts - GM 24571667

Fiero engine and transmission mounts to frame - I would highly recommend NOT re-using the stock Fiero engine and transmission mounts.
New Fiero Transmission Mounts - bolts to FieroRog's 3800 brackets (1x) - http://rodneydickman.com/pr...o.php?products_id=35
New Fiero Engine Cradle Mount - bolts to FieroRog's 3800 brackets (1x) - http://rodneydickman.com/pr...o.php?products_id=73
New Fiero Engine Dogbone Mount - bolts to FieroRog's 3800 bracket (1x) - http://rodneydickman.com/pr...o.php?products_id=72

West Coast Fiero shifter bracket:
NOTE: It is not difficult to construct your own. Some manage to simply unbolt the shifter arm and bolt it on in the reverse direction with other minor modification. Some choose to reverse the linkage action on the fiero side shift lever itself.
http://westcoastfiero.com/p...ion-shifter-adapterx

Throttle cable mounting to a 3800 Series II motor - see http://www.gmtuners.com/swap/3800.htm

-------------------AXLES----------------------

Want to buy axles? Stephen Poe will make axles for you. You must supply him the following information:
-Your Transmission Type
-Your Engine Type
-Your Fiero Type (make/model)
-Your engine mount/transmission mount type
-Measurements from both transmission output shaft surfaces to the inside surfaces of the Fiero hubs with no axles installed, with wheels on ground.
Contact him here: https://www.facebook.com/stephen.poe.5011

Building axles yourself? See LostNotForgotton's axle building video posted below. THESE AXLES REQUIRE YOU USE THE FieroRog/Rodney Dickman ENGINE AND TRANSMISSION MOUNTS LISTED IN THIS BUILD THREAD AND IN LostNotForgotton's VIDEO. FINAL FITMENT CAN VARY. If you do not have a GTP, go get a 1998 GTP passenger's and drivers' side axle from a junkyard. Below are the parts required for building axles.

3800 Fiero driver's side axle (1x):
Use a Stock automatic Fiero driver's side axle

3800 Fiero passenger's side axle (1x):
Drivers & Passenger GTP axle + any manual Fiero axle - see how-to video https://www.youtube.com/watch?v=D_VKktIEaTE

Axle Boot Inner with grease (1x):
Oreilly Auto Parts 614-004
https://www.oreillyauto.com...t-kit/614004/4251654

Generic Axle CV Boot Clamps
https://www.amazon.com/gp/p...07_s00?ie=UTF8&psc=1

Axle CV boot clamp tool
https://www.amazon.com/gp/p...09_s00?ie=UTF8&psc=1
Or
https://www.oreillyauto.com...liers/w83013/4614564

------------------PARTS NEEDED IF YOU DO NOT BUY A PONTIAC GRAND PRIX GTP DONOR CAR----------------------

NOTE: Some of these parts can be found at junkyards.

GTP/Regal Steel Oil Pan (1x):
ULTRA-POWER 264124 {#12512670, 12563240} - https://www.rockauto.com/en...,engine,oil+pan,5562

GTP Oil Pan Gasket (1x) (needs cutting to fit over non-GTP oil pickup tube; Depending on your car, you can get either get a GTP oil pickup tube or get a non-GTP oil pan gasket to avoid cutting):
ACDELCO 12587964 - https://www.rockauto.com/en...,oil+pan+gasket,5436

Oil Filter Housing Gasket (1x):
ACDELCO 25534742 - https://www.rockauto.com/en...adapter+gasket,10649

GTP/Regal oil filter bracket (1x):
GM 12569219 ; 24508441 - More info at http://www.gmtuners.com/swap/3800.htm

GTP/Regal angled coil pack bracket (1x) - cut engine mount dogbone off, shown in videos posted below. Get at junkyard including the GTP Tensioner pulley on coil pack bracket:
GM 24507211 ; 24504360 - https://www.gmpartsbin.com/...l?partner=googlebase

GTP or Oldsmobile Torque Converter (1x):
DACCO B21JXFM - https://www.rockauto.com/en...orque+converter,8668

3-pin Temperature sender & wire (1x):
Duralast TU178DG - https://www.autozone.com/en...178dg/625841_71058_0
------------------
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 10-02-2020).]

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bulldog85043
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Report this Post11-12-2017 05:05 PM Click Here to See the Profile for bulldog85043Click Here to Email bulldog85043Send a Private Message to bulldog85043Edit/Delete MessageReply w/QuoteDirect Link to This Post
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).]

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AustinH
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Report this Post11-20-2017 01:20 PM Click Here to See the Profile for AustinHClick Here to Email AustinHSend a Private Message to AustinHEdit/Delete MessageReply w/QuoteDirect Link to This Post
BUILD 2: Complete Parts List for an all-out Series III Supercharged 4T65E-HD build, excluding bottom end (connecting rods/pistons/crank), IN ADDITION TO BUILD 1
Preface: This build is expected 400+ wheel horsepower if you run E85 and a good tune, non-intercooled. THIS BUILD IS IN ADDITION TO BUILD 1, MEANING YOU MUST ORDER ALL OF BUILD 1 PARTS TOO, UNLESS SPECIFICALLY MARKED OTHERWISE, but it has a few additional or upgraded parts from Build 1. This list assumes you buy a Series II engine and convert to a Series III supercharger. It would be easier to buy a Series III to begin with. The bottom end is not modified for this build. This build requires modifying the cylinder heads for the increased lift, by cutting down valve guides by .060". More information in the Assembly videos section.

THE LIST:
The numbers in (x) are the quantity of parts you need to order. Almost everything can be found at Summit/RockAuto/Autozone/Advanced/Oreillys/ZZPerformance

----------------------Air------------------------

Series III/GENV Supercharger (1x):
Get at junkyard or private seller from a 2004+ Pontiac Grand Prix GTP or flat out buy a Series III engine - upgrading from Series II / Gen 3 -
https://www.car-part .com/cg...serIntSelect=1145748

Series III/GENV Intake Manifold (1x) - upgrading from Series II / Gen 3:
ACDELCO 12603871 - https://zzperformance.com/p...en-5-intake-manifold

Series III/GENV Supercharger Alumimum Lower Intake Manifold Gasket Set (1x) - upgrading from Series II / Gen 3:
FEL-PRO MS96847 - https://www.rockauto.com/en...+plenum+gasket,10394

Year 2000+ Cadillac DeVille/Seville throttle body (1x) - upgrading from Series II / Gen 3 :
Get at junkyard - https://www.car-part.com/cg...userIntSelect=679348

JBweld and 3 dimes (2 must be ground down with a file to fit) for sealing throttle body coolant holes and EGR delete (1x):
https://www.amazon.com/J-B-...forced/dp/B0006O1ICE

LQ4 MAF from a 6.0L Silverado 1500 (1x):
https://www.rockauto.com/en...air+flow+sensor,5128

Northstar Throttle Body Adapter Plate (1x) -available on eBay for cheaper. They sell a whole kit including MAF and TB too:
ZZP ZZ-NSAP - https://zzperformance.com/p...thstar-adapter-plate

Gasket Maker (1x):
Permatex Ultra Black RTV Gasket Maker 82180 - https://shop.advanceautopar...2180-82150/7160059-P

Intake Manifold Gasket Set (1x):
ACDelco 89017825 - https://www.rockauto.com/en...manifold+gasket,5424

Valve cover seals (2x):
MAHLE VS50332 - https://www.rockauto.com/en...e+cover+gasket,10710

Supercharger Bolts for upgrading from Series II / Gen 3 to a Series III / Gen 5 (1x of each):
Re-use all GENIII Supercharger bolts, but in addition:
1x M8x1.25x120mm bolt
1x M8x1.25x140mm bolt
Can get from Menards.
See supercharger upgrade instructions in Assembly Diagrams section

2.8" Supercharger Pulley (1x) - modular pulley system also needed from Build 1. NOTE: If you go below 2.8", it is required to machine down the supercharger snout. INTENSE Racing suggests this is pointless, as smaller pulleys beyond this point make exponentially increased temperature compressed air:
SmoothFlow Pulleys - http://www.smoothflowpulleys.com/3800_MPS.html

One 1/2" freeze plug (1x) - use with JB Weld for EVAP Delete:
Advance Auto Parts
https://shop.advanceautopar...s-557-001/22140398-P

Throttle Body Adapter Cables for Northstar Throttle Body to LQ4 MAF (1x):
ZZP ZZ-MAFADP-SIII-LQ4 - https://zzperformance.com/p...dapter-with-iat-plug

Optional ZZP 1" Phenolic Spacer for gen 5 supercharger (1x) - NOT COMPATIBLE WITH INTERCOOLER, instead opt for 1/4" if you intercool:
ZZ-M90HNSPC-G5-1 - https://zzperformance.com/p.../m90-phenolic-spacer

Cable stop end for throttle/cruise cable (1x):
Dorman 03336 - https://www.oreillyauto.com...rtment/03336/4526846

Northstar Throttle Cable Bracket Adapter (1x):
ZZ-NSCB - https://zzperformance.com/p...rottle-cable-bracket

-----------------------------Fuel--------------------------

TBD COMING SOON: Custom Fuel Rails and Fittings - See part numbers for fuel line fittings for custom rails in diagram below TBD. Also see original parts list. REPLACES STOCK FUEL RAIL ADAPTER FITTINGS IN BUILD 1.

Optional: Alternative recommended fuel rails instead of custom (1x):
Aeromotive 14131 - https://www.summitracing.com/parts/aei-14131

Optional: You can get a custom fuel rail made by people on Facebook.
https://www.facebook.com/gr...37910286395192&rt=11

Injectors (6x) - DO NOT BUY ON EBAY - THEY'RE FAKES. You can tell by the DEKA words on the injection molding; fakes do not have DEKA on them. Series III harnesses came with EV6 connectors and Series II harnesses came with EV1 connectors. Your harness provider should be able to put whichever connector on. If you end up with the wrong ones, it is possible to get an adapter.
Siemens DEKA EV1 80# Injectors
Intense FIS-840-x - http://intense-racing.com/PROD/FIS-840-x.html
or ZZP 110324-6 - https://zzperformance.com/p...-deka-80-injectors-6

Fuel Pressure Regulator and gauge (1x) - for custom fuel rail setup:
Tanks, Inc. AFPR1 - https://www.summitracing.com/parts/tnk-afpr1

-------------------------------Spark--------------------------
Spark Plugs (6x) - Autolite Racing Plugs; last longer and burn better (according to marketing). Have a back cut electrode. They are 3 ranges cooler than stock plugs (Autolite 606). Gap to .035” to .045”.
Autolite AR103 - http://intense-racing.com/PROD/ARP-xxx.html REPLACES SPARK PLUGS BUILD 1

-----------------------------Exhaust(ENTIRELY REPLACES BUILD 1 EXHAUST)-----------------------------
NOTE: This exhaust setup is pictured in the Assembly Diagrams section below.

90 Degree Mandrel Bent Stainless Steel Exhaust Bends (2x):
SUM-622118 - https://www.summitracing.com/parts/sum-622118

Muffler (1x) - REQUIRES CUTTING OUT BOTTOM SECTION OF TRUNK TO FIT!:
VPE-10632 - https://www.summitracing.com/parts/vpe-10632

Stainless Chinese exhaust headers for a Pontiac Grand Prix GTP (1x) - on eBay search "GTP Exhaust" - REQUIRES CUTTING BOTTOM SECTION OF TRUNK TO FIT! Also, Since the Grand Prix GTP headers will likely not fit out of the box, the cross-over pipe will require cutting and re-welding, and the EGR will require welding shut.
https://www.ebay.com/sch/i....gtp+exhaust&_sacat=0

Exhaust wrap (1x) - exhaust wrapping the Chinese headers sucks but is a MUST, the exhaust headers get extremely hot, especially in the tight Fiero engine bay. Wear gloves when wrapping and watch the how-to video at https://www.youtube.com/watch?v=LWHHMTVHv7w
Design Engineering 010130 (2" by 100' roll) - https://www.summitracing.com/parts/dei-010130

Stainless Tie bands for exhaust wrap (50x):
https://www.amazon.com/gp/p...02_s00?ie=UTF8&psc=1

2" exhaust clamp (2x):
https://www.amazon.com/gp/p...06_s00?ie=UTF8&psc=1

3" v-band flange and clamp (1x) - https://www.amazon.com/gp/p...06_s00?ie=UTF8&psc=1

Generic Exhaust Hanger (2x):
https://www.napaonline.com/en/p/BK_7321015

Exhaust Tips (2x):
Re-used stock Fiero exhaust tips.

----------------------Cylinder Heads/Valvetrain/Pushrods/Lifters---------------

Re-using stock valves and porting GENIII heads. Stock Series III valves (1.83") are .030" larger than stock Series II valves (1.80").

Cylinder Head Modification: Machining off .060" off of valve guides, valve job, gasket match intake runners, widened exhaust runners (maintain D shape). Head surface was decked. Performed at machine shop. See below how to videos on custom porting heads.

Head Gasket (1x right and left side) - My cylinders measure out of hole ~0.025". You want .038"-.046" of quench according to INTENSE, so I am going .040" quench + .025" stock = 0.65" thick gasket.
NOTE: The arrow and the "L," or Left-Hand Side (LHS) gasket goes on the cylinder 1/3/5 side of the engine. If you look at the rear cover, it goes on the left hand side.
INTENSE HGP-0xx - http://www.intense-racing.com/PROD/HGP-0xx.html

Rockers Arms (12x) - light 1.65 rockers with re-usable rocker bolts (yields):
ZZP ZZ-165RA - https://zzperformance.com/p...zzp-1-65-rocker-arms

Valve Springs (12x) - 130# @ .050” installed height valve springs, .600" lift max
PAC 1218 - comes with 16 - https://www.summitracing.com/parts/rsc-pac-1218-16

Valve Spring Retainers and locks (12x) - They allow for ~0.005” more valve guide to retainer clearance!
Use LS1 Spring retainers reused from another engine - https://zzperformance.com/p...lve-spring-retainers
Or
https://www.rockauto.com/en...pring+retainer,10022

Intake Valve Stem Seals (6x):
MAHLE SS45910 - https://www.rockauto.com/en...valve+stem+seal,5800

Exhaust Valve Stem Seals (6x):
MAHLE MAHLE SS45911 - https://www.rockauto.com/en...valve+stem+seal,5800

LS7 Hydraulic Roller Lifters (12x):
INTENSE Racing GMH-VVL - http://www.intense-racing.com/PROD/GMH-VVL.html

Head Studs (1x) - factory head bolts YIELD and need replaced:
APR 193-4001 - https://arp-bolts.com/kits/...ail.php?RecordID=727
Instructions for installing ARP Head Studs - https://tech.arp-bolts.com/...uctions/193-4001.pdf

TEFLON TAPE HEAD BOLT THREAD SEALANT (1x) - DO NOT USE ARP THREAD SEALANT!
Advance Auto AC561 - https://shop.advanceautopar...-600-ac561/5014298-P

ARP 7/16"-14 Thread Chaser (1x) - do NOT use a tap:
ARP 911-0004 - https://www.summitracing.com/parts/arp-911-0004

High Strength Threadlocker for Rocker Bolts and Lifter Retainers (1x):
Loctite 272 - https://shop.advanceautopar...red-37480/16160014-p

ZZP Pushrod length Checker (1x):
ZZP ZZ-PRDLCKR-3800 - https://zzperformance.com/p...shrod-length-checker

Ignore this: Intake Pushrod (stock size 7.029") - MELLING MPR605 (MPR-605) - MEASURE YOURS! YOURS WILL BE DIFFERENT DEPENDING ON CAM, DECKING, VALVES, VALVE RETAINERS AND HEAD GASKET SETUP! Detailed in video section.

Ignore this: Exhaust Pushrod - 7.00" - ZZ-CUSPRD-7.00-5/16-12 - MEASURE YOURS! YOURS WILL BE DEFERNT DEPENDING ON CAM, DECKING, VALVES, VALVE RETAINERS, AND HEAD GASKET SETUP! Detailed in video section.

--------------------------Camshaft, timing chain, and balance shaft removal--------------------------

ZZP XPZ Camshaft (1x):
XPZ-1 - https://zzperformance.com/p...ts/supercharged-cams

Camshaft Assembly Lube (1x):
GM 12345501 - https://www.summitracing.com/parts/nal-12345501

Aluminum Water Pump Gasket (1x):
Fel-Pro 35804 - https://www.rockauto.com/en...ter+pump+gasket,2148

Double Roller Rollmaster Timing Chain Set (1x) - Needed for 130# valve springs:
ZZP CS6150 - https://zzperformance.com/p...ollmaster-timing-set

Machined oil pump cover (1x) - required for rollmaster double timing chain clearance - I surface grinded the non-oil pump side of the cover down by grinding off .023", or buy ZZP's:
ZZP # ZZ-OILPCVR - https://zzperformance.com/p...hined-oil-pump-cover

Extra thick front cover gasket (1x) - needed for double roller timing chain:
ZZP ZZ-FCGG - https://zzperformance.com/p...k-front-cover-gasket

Camshaft Bolt (1x) - yields:
INTENSE GMH-BCM - http://intense-racing.com/M...Product_Code=GMH-BCM

Crankshaft Bolt (1x) - yields:
INTENSE GMH-BCR - http://intense-racing.com/PROD/GMH-BCR.html

Balance shaft delete 440 camshaft bearing (1x) - POUND THIS IN TO BLOCK OIL PASSAGE, WITH OILING HOLES ON OPPOSITE SIDES SO ITS PLUGGED
ENGINETECH CC476 - https://www.rockauto.com/en...amshaft+bearing,5208

Crankshaft Seal (1x) - REAR:
ACDELCO 12582320 - https://www.rockauto.com/en...crankshaft+seal,5604

Crankshaft Seal (1x) - FRONT:
ACDELCO 12582313 - https://www.rockauto.com/en...crankshaft+seal,5604

Engine Break-In Additive Oil (2x):
Comp Cams 159 - https://www.summitracing.com/parts/cca-159

Camshaft Bearings:
NOTE: It is very difficult to replace camshaft bearings without completely disassembling the bottom-end.
MAHLE / CLEVITE SH1812S - https://www.rockauto.com/en...amshaft+bearing,5208

---------------------------------4t65e Transmission--------------------------------
NOTE: I had a professional disassemble my transmission and install the below parts. This is a very complicated process and can be very easy to mess up.

Hardened Input Shaft (1x) - needs GM J-tool and complicated disassembly to be installed properly, must take off valve body to access and replace gaskets. This shaft is to support over 350 whp:
ZZP 4340 - https://zzperformance.com/products/input-shafts

Chrome Moly Pump Shaft (1x) - needs same install as above. This shaft is to support over 350 whp.:
ZZP ZZ-CMPS-4T65E - https://zzperformance.com/p...rome-moly-pump-shaft

Hardened 4th Clutch Shaft (1x) - must take off chain to access, to support over 350whp.:
ZZ-HRD4CLSH - https://zzperformance.com/p...ned-4th-clutch-shaft

Gasket and Seals Kit for above assembly (1x):
PIONEER 750240 - https://www.rockauto.com/en...240,rebuild+kit,8512

Flywheel Bolts (8x) - yields - Duplicated in Build 1:
GM # 24501365 - https://www.gmpartsdirect.c...s/gm-s-bolt-24501365

Torque Converter (1x) - Duplicated in Build 1:
DAACO B21JXFM - https://www.rockauto.com/en...orque+converter,8668

Engineered Performance Positraction Differential (1x) - There are a few options out there for differentials. This one is affordable and does the trick.
http://www.engineered.net/eplsd.htm

Optional: 3.29 Gear Set, 7/8" chain and sprockets (1x)
ZZ-GRCK-3.29 - https://zzperformance.com/p...ratio-conversion-kit
------------------
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 07-28-2020).]

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VanGTP5000
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Report this Post11-20-2017 01:53 PM Click Here to See the Profile for VanGTP5000Click Here to Email VanGTP5000Send a Private Message to VanGTP5000Edit/Delete MessageReply w/QuoteDirect Link to This Post
 
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
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AustinH
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Report this Post12-24-2017 12:03 PM Click Here to See the Profile for AustinHClick Here to Email AustinHSend a Private Message to AustinHEdit/Delete MessageReply w/QuoteDirect Link to This Post
3800sc Assembly Diagrams and Torque Specs
------------------------------------------FIRING ORDER---------------------------------------



----------------------------COOLANT AND FUEL LINES----------------------------
Ignore transmission lines here, I simplified them with parts in the build lists. New diagrams in transmission section.


-------------------------------------SUPERCHARGER, CONNECTIONS, AND ROUTINGS-----------------------------------
Excellent Gen 3 to Gen 5 Supercharger Upgrade Guide:
http://www.grandprixforums....en-five-gen-5-a.html

Another Gen 3 to Gen 5 Supercharger Upgrade Guide:
https://www.instructables.c...n-V-M90-Swap-on-L67/

ZZP's 3800 NA to Gen 3 supercharger installation instructions:
http://s3.amazonaws.com/zzp...rger+Kit+Install.pdf

Diagram of Gen 5 Supercharger and hose routings:


----------------------------HOW TO HOOK UP THE 4t65e TRANSMISSION------------------------

How to connect 4t65 transmission lines to Fiero:


-------------------------EXHAUST SETUP FOR BUILD 1---------------------------

NOTE: Refer to Build 1 parts list. This setup is for mating with the stock exhaust headers, which can support up to 300hp.


EVERYTHING BELOW THIS POINT IS FOR BUILD 2.
--------------------------------------TORQUE SEQUENCES-----------------------------------------
NOTE: The Torque Sequence refers to the order in which you torque bolts. Head bolt torque sequencing can require multiple steps. Please refer to the torque guide website below for these steps, or to the guide from head stud your manufacturer.
For example, Instructions for installing ARP Head Studs - https://tech.arp-bolts.com/...uctions/193-4001.pdf

3800 Engine Torque Specs (helpful to print this off):
NOTE: THE TORQUE SPEC CALLING OUT 74 ft-lbs FOR A/C COMPRESSOR BRACKET/STAY IS INCORRECT. SUGGEST TO USE 30 ft-lbs INSTEAD.
http://www.torkspec.com/tor...?KI=12-3.8L-231ci-V6

ZZP's Instruction Manual for swapping 3800 superchargers:
http://s3.amazonaws.com/zzp...rger+Kit+Install.pdf

Supercharger Torque Sequence:


Series II Supercharged Lower Intake Manifold Torque Sequence:
NOTE: #5 is not shown, but it is directly below #11.


3800 Cylinder Head Torque Sequence for both sides (follow torque values in the torque spec website for stock or follow the head stud manufacturer's torque specs. ARP Head stud torque specs found here: https://tech.arp-bolts.com/...uctions/193-4001.pdf


-------------------------------ENGINE EXPLODED VIEW ASSEMBLY DIAGRAMS------------------------------
You can find most of these diagrams and the part #s of the parts labeled at many GM parts websites. These diagrams were taken from here:
https://www.wholesalegmpart...x-GTP-4DR-parts.html

Fuel Rail, Supercharger, Lower Intake Manifold, Exhaust, Throttle, EGR diagram:


Cylinder Head, Valve Train, Coil Pack, Lifter, Pushrod, Rocker, and Valve Cover Assembly.


Water Pump, Front Cover, Alternator Bracket, Thermostat, Balancer diagram:


Front Cover, Oil Pump, Oil Pan, Dipstick diagram


Camshaft, Rear Cover, Flywheel, Crankshaft, Timing Chain, Balance Shaft, Piston, Connecting Rod diagram:


Transmission to Engine Mating Diagram:


----------------------HOW A PCV SYSTEM WORKS WITH A NORTHSTAR THROTTLE BODY ON A SERIES III 3800SC-------------------
All you do is attach a hose from the Northstar TB nipple (before butterfly valve but after MAF) to the nipple on the supercharger by the PCV. The air goes from the throttle body, through the supercharger nipple, through the intake manifold, through the heads to the crank case, back up through the heads, back through the intake manifold, through the PCV valve, and back into the supercharger intake. There is no way to run a catch can without bypassing the actual PCV in some way, since it sits directly in the Gen 5 Supercharger intake.


-------------------EXHAUST SETUP FOR BUILD 2-----------------
Note: See build 2 parts list in conjunction with this picture. This exhaust mates with the ebay chinese exhaust headers. REQUIRES CUTTING OUT BOTTOM PORTION OF FIERO TRUNK TO FIT! ALSO REQUIRES GRAND PRIX GTP HEADERS FROM EBAY! Since the GTP headers will likely not fit out of the box, the cross-over pipe will require cutting and re-welding, and the EGR will require welding shut.


--------------------------------------4t65 Transmission--------------------------------

Check out 4t65e-HD upgrades:
https://shop.tripleedgeperf...T65E-Upgrades_c2.htm

These guys will also rebuild your 4t65 transmission for you:
https://tripleedgeperforman...rformance_4T65E.html

Good 4t65 disassembly video here:


4t65 transmission diagram, parts available here:
https://www.transpartsonlin...TransPartsType=4T65E

------------------
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 06-03-2020).]

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Curtisk1060
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Report this Post12-25-2017 10:07 PM Click Here to See the Profile for Curtisk1060Click Here to Email Curtisk1060Send a Private Message to Curtisk1060Edit/Delete MessageReply w/QuoteDirect Link to This Post
I have not heard of most people re-designing the existing fuel pump circuit. I believe most have utilized the original circuit, especially the oil pressure switch and just upgraded the fuel pump fuse to a 15 amp. Some have replaced the original relay with a newer model, but the wiring has remained the same.. curtis
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Report this Post12-25-2017 10:47 PM Click Here to See the Profile for AustinHClick Here to Email AustinHSend a Private Message to AustinHEdit/Delete MessageReply w/QuoteDirect Link to This Post
WIRING HARNESS AND COMPUTER/ECU/PCM PROGRAMMING
NOTE: There is no actual tuning guide here, although it is REQUIRED to reprogram your 3800 computer.

------------------------------------Buying a harness----------------------------------

Want to buy a harness and PCM tune? I highly recommend this. Contact one of the below two guys:
James L. Brown - https://www.facebook.com/pr...p?id=100010340077920
Dan McIlmoyle - https://www.facebook.com/danny.mcilmoyle

And supply them with the following information, including programming:
Ship them your donor harness and donor computer (PCM/ECU)
Fiero Year/Model?
Year/Make/Model of donor car engine?
Transmission type?
Keep or delete EGR?
Keep or delete Boost Bypass valves/solenoid?
Throttle Body and MAF type?
Keep or delete rear O2 sensor after catalytic converter?
88 fiero oil pressure sender 3-pin (only center pin used)
Keep or delete EVAP system?
3 pin temp sensor (use the center pin for fiero gauge)
Keep or delete A/C pressure sensor connector near compressor connector?
Keep or delete Electronic cruise control?
Speedometer sensor buffer circuit
External or Internal transmission gear selection range switch?
MAP sensor type? (1-bar or 2-bar?)

Programming:
Delete ABS
Radiator fan activate at low temp (185?) and turn off at 180
Accommodate for type of MAF/TPS/IAC tables
Vehicle Speed Sensor programmed at:
24,713.7? ppm if using stock 215/60R15 rear tires (double check this)
24,327.5 ppm if using specific 225/60r15 rear tires
VATS Security delete
Rev Limiter? (Up to ~7000RPM)
Amount of timing to add? Determined by below
Camshaft type?
Supercharger type?
Thermostat type?
Supercharger pulley size?
Spark plug type?
Fuel type? (87/89/91/93 octane or E15 or E85?)
Cooling type if added? (Methanol injection, nitrous, intercooled?)
Head Gasket Type?
Compression Ratio?
Other modification type? (ported heads, ported supercharger, fuel injectors, exhaust system, valve springs, rocker ratio)
custom ported heads

------------------------------Building a harness--------------------------

Want to build your own harness instead? Below are diagrams for doing so. This thread does not supply any wire loom dimensions for laying out the harness - that is owned by harness makers above. It is possible to simply splice all of the connections that you need and lay out your own harness routings, but this is unreliable and messy. This guide will not help with that, but it will help with the final wiring diagram.

Many great wiring harness pin out charts already exist at GMTuners: http://www.gmtuners.com/files/index.htm

NOTE: For sensors and some wire connector part #s, refer to Build 1.

Harness wiring diagram (For a GTP harness that works manual Fiero transmission. For automatic harnesses, you will need to ground the VSS LOW Fiero input pin and add the buffer circuit shown below between the GTP computer and the fiero pin):


Speedometer Buffer Conversion Circuit (the input signal to the Fiero speedometer is incompatible with the 4t65e-HD transmission Vehicle Speed Sensor (VSS) output signal) :
http://www.gmtuners.com/fiero/fmods.htm


Stock Fiero C500 connector in engine bay:
A good pinout is located here: http://www.nathanbittinger....roaddiction/c203c500


Stock Fiero C203 Connector under center console


OBDII Connector Pinout:
NOTE: The 3800sc Fiero only uses the "VPW" configuration on pins 2, 4, 5, and 16.


Optional: 3800 Electronic Cruise Control (can instead rig up the Fiero vacuum cruise to work)


Optional: Fuel Pump Hot Wire, for supplying slightly more voltage to your fuel pump in high performance applications - http://www.gmtuners.com/fiero/hot_wire.htm


How To Repin Or Replace Wires On The Main Engine Harness Connector:

------------------
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 05-28-2020).]

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AustinH
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Disassembly, Reassembly and Final Fiero Installation Videos

----------------------Below this line is required for both Build 1 and Build 2---------------------

Fiero Engine Removal:


How to replace the Fuel Pump :


How To Change The Supercharger Pulley Using The ZZP Pulley Puller:


How to change Supercharger Oil:


How to Install oil sending unit, Thermostat & plugging water pump:


How to install FieroRog Engine Brackets, Belts & Accessories in a 3800 Fiero:


How to Install A Custom Fuel Rail & Swapping Valve Covers:


How to build your own 3800sc Fiero Swap Axles:


How to install Transmission:


How To Mount Engine to Trans/Install supercharger Belt


How To Install an Injection Technology Wiring Harness


How to hook up fuel lines, AC lines & hoses:


Fiero Engine Bay for 3800 Swap Overview


How to install engine in car and hook up exhaust:


Engine Bay Routings/Hookups 1:


Engine Bay Routings/Hookups 2:


Engine Bay Routings/Hookups 3:


----------------------Below this line is only required for Build 2-----------------------

IMPORTANT: BEFORE TEARING DOWN THE ENGINE, PLEASE WATCH THESE FACTORY SERVICE VIDEOS TO SAVE YOU SOME HEADACHES!
Buick 3800 Engine Noise and Repair Techniques:


Buick 3800 Engine Mechanical:


Why you don’t want to disassemble the bottom end (rods/pistons/crankshaft/bearings):


-----------------------Engine Tear-down and rebuild instructions-----------------------

How to tear down and rebuild the Lower Intake Manifold:
NOTE: I THOROUGHLY CLEANED OUT THE INSIDE OF MY LOWER INTAKE MANIFOLD BY SOAKING IN BRAKE CLEANER AND THEN TAKING IT TO A CAR WASH AND MANUALLY SPRAYING DOWN THOROUGHLY, INSPECTING, AND DRYING.


How to tear down the "long block" (accessories, supercharger, intake, water pump, etc.).:


Servicing your 3800 Supercharger:


Installing a Phenolic Spacer instead of Intercooler:


How to remove front cover, balance pulley, timing chain, balance shaft, camshaft, etc.:


How to remove front cover, balance pulley, timing chain, balance shaft, camshaft alternative:


How to disassemble cylinder heads with a valve spring compressor:
NOTE: You should drop your cylinder heads off at a machine shop, detailed at the end section of this post. BE CAREFUL WITH THE CYLINDER HEAD DECK SURFACE. DO NOT SCRATCH THE BOTTOM OF THE HEADS. PLACE ON A LINT FREE CLOTH AND DO NOT PUT THEM ON THE GROUND OR A HARD SURFACE UNLESS YOU INTEND TO DECK THEM.


FACTORY SERVICE GUIDE for installing heads, valve train, balance shaft, intake manifold, valve covers, etc.:


How to prepare deck surfaces and assemble cylinder heads


ZZP Installing Heads:


How to assemble cylinder heads, valve train (lifters/rockers/pushrods), intake manifold, supercharger, and throttle body:
NOTE: DO NOT USE ARP THREAD SEALANT SHOWN IN VIDEO. INSTEAD USE TEFLON TAPE + HIGH TEMP NON-HARDENING RTV SILOCONE.


How to assemble valve train alternative:
NOTE: I DO NOT AGREE WITH THE METHOD USED HERE FOR MEASURING PUSH ROD LENGTH. INSTEAD WATCH ABOVE VIDEO.


How to assemble Custom Exhaust, Custom Fuel Rails, Accessories:


How to wrap your exhaust:


--------------------------------PORTING CYLINDER HEADS-----------------------------

PREFACE: According to INTENSE Racing, stock cylinder heads will out-flow ANY M90 supercharged 3800 engine setup. There is virtually NO NEED to modify cylinder heads, UNLESS YOU RUN LIFT HIGHER THAN 0.525, DETEAILED BELOW.

NOTE: I would NOT attempt performing ANY of this at home. Take your cylinder heads to a machine shop. That being said, below is a collection of information about porting 3800 cylinder heads.

Here are the instructions I supplied a machine shop for porting my cylinder heads:
NOTE: Maximum valve lift on a stock 3800sc (NOT NA) block and pistons is ~0.600" before running into piston-to-valve clearance issues. Over 0.525" lift REQUIRES machining down valve guides.

1. Machine .060" off intake valve guides to support XPZ Camshaft lift.
a. 1.65 rocker arm * 0.354 XPZ camshaft intake lift = 0.5837" lift. Stock lift max is 0.525" before intake valve runs into valve guide with stock retainers. 0.5837"-0.525" = 0.0587". Therefore, cut down top of valve guide by 0.0587" (or 0.060" to be safe). NOTE: LS Retainers add about .005" clearance, meaning max intake lift would be 0.0530".
2. Machine .060" off exhaust valve guides
a. 1.65 rocker arm * 0.335 XPZ camshaft exhaust lift = 0.5528" lift. Stock lift max is 0.528" before exhaust valve runs into valve guide with stock retainers. 0.5528"-0.528"= 0.0247". Therefore, cut down top of valve guide by .0247" (or 0.060" to be safe and consistent with intake).
3. Redrill and replace valve guides with Bronze oil lite guides
4. Valve job
a. widen valve seats for 1.83" intake valves (on heads now) (stock is 1.80"), 1.52" exhaust
b. Replace seats with hardened seats at custom 3 angle cut.
c. Back-cut valves with same 3 angle cut. Lap valves if necessary.
d. If not replacing seats with hardened seats, don't grind seat, but grind right up to it, without touching it, to maintain factory hardened seat.
5. Blend bowl smooth - remove casting mark and lips on radius
a. Street/strip port, Polish combustion chambers
b. Smooth short side radius
c. Don't drop port floor
6. Gasket Match Intake runners and Lower Intake Manifold
a. Don't gasket match exhaust. Keep the D-shape of exhaust ports (can widen a bit)
b. Polish runners
c. Blend in short side of intake
d. Be careful not to grind through walls.
7. Deck head surfaces and record thickness decked by. Need at least 50 Roughness Average (RA) on deck surface to properly seal Cometic Head Gaskets.
Valve job video:


Head Porting 1:


Head Porting 2:


Head Porting 3:


Head porting example:


How to lap / grind / regrind valves and valve seats:


------------------------------INSPECTING THE BOTTOM END (crank/bearings/connecting rods/bearings/pistons/piston rings)------------------------------

In addition to porting cylinder heads, on the engine block, measure each cylinder “out of hole” clearance, or the amount which a piston sticks out above the block deck when the crankshaft is at top dead center. Stock piston height should be between 0.012” to 0.025”. If the out of hole measurements for each piston are significantly different than one another, then consider decking the block. At this point, you will need to disassemble the bottom end. If re-using stock bottom end parts, keep every bolt/bearing/rod/piston/journal/cylinder matched with where it came from, including direction. Consider getting the engine inspected and blueprinted, the crankshaft ground, the rods conditioned, the rotating assembly balanced, having new oversized bearings installed afterwards, honing cylinders, and replacing piston rings with correct gap for your boost. This is how to properly tear down the bottom end which is not covered in this guide. Here are the instructions I would provide a machine shop with for working with the bottom-end:

If the rotating assembly is in good shape, re-use all factory items and don't recondition.
1. Measure if block needs decked. .003" out of flat and 50 microinch RA surface or more required for decking. If not leave it. If so, deck block/heads and continue.
2. Disassemble pistons/rods.
3. Keep rods, rod bolts, rod bearings, crank bearings, and journals, etc matched to each other.
4. Clean pistons and rings with oil based solvent.
5. Check rings. Leave stock rings and don't hone if rings are OK. If rings are seized:
a. Replace rings (oversized?)
b. Gap rings. Adjust gap for 12-14.5 psi roots style supercharger boost (350 deg. Max)
c. Hone cylinder bores.
d. Oil and install pistons and rings.
6. Measure rods/bearings. If good, leave stock. If rods are worn:
a. Recondition rods, bore and find matched bearings (oversized?)
b. Clean rod bearing seats with alcohol
c. Oil inside of bearings but not in seat, work in oil to crank
d. Assemble rods to torque spec with matched bolts
e. Measure play (plastigauge) to verify correct size bearing
f. Also do replace crank bearings (below).
7. Measure crank bearings for wear
a. If crank or rod bearings worn, replace with new bearings (oversize?)
b. Plastigauge new bearings once torqued and seated to verify correct size
c. Clean main seats with alcohol.
d. Oil inside of bearings, torque mains down and rotate crank with oil in inside of bearings.
8. Measure main seats. If round, leave. If out of round:
a. Re-bore mains. Select appropriate bearings
9. Measure crank journals. If out of round:
a. Machine journal to round
b. Replace bearings (oversized?)
10. Measure crankshaft thrust bearing play. Recondition if necessary
11. Check assembly for balance
a. If out of balance for 6,700RPM, then re-balance rotating assembly
i. Flexplate
ii. Torque Converter
iii. Crank
iv. Pistons
12. Replace front and rear main seals and covers, reinstall everything and torque

Here is a decent video on inspecting the bottom end
NOTE: This video does not describe matching and conditioning rods parts. Before disassembling anything for yourself, if you're not an expert, JUST TAKE IT TO A MACHINE SHOP AND HAVE THEM DO EVERYTHING.


Here is a in-depth video about measuring crankshaft and connecting rod journals.

------------------
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 08-16-2020).]

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AustinH
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Other Helpful Fiero Parts While You're At It

Bigger tires General Altimax RT43 (2x of each size):
225/60R15 rear on stock 15x7" rims (stock rear tire size is 215/60R15)
215/60R15 front on stock 15x7" rims - 1988 fronts came with 15x6.5" rims (stock front tire size is 205/60R15)

Replace end links and sway bar bushings (2x of each):
Go to an auto parts store and buy generic end-links and sway bar bushings after having measured your end-link length on your car, if it is equipped with a rear sway bar.

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

Stainless steel brake hoses - https://www.fierostore.com/...px?s=56098&d=379&p=1

Headlights:
H6054

Rear Decklid Scoop - buy a Mustang Fox Body Hood scoop and mount reverse on your decklid.

1988 only Front shocks (2x):
KYB KG4513 - https://www.rockauto.com/en...,shock+absorber,7556

1988 only Rear struts (2x) - VERY EASY TO REPLACE WHEN ENGINE IS OUT OF CAR:
ACDELCO 503143 - https://www.rockauto.com/en...uspension,strut,7584


How to install and upgrade bushings for 84-87 Fieros:


How to install a stock looking boost gauge for your 3800sc Fiero dashboard:

------------------
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 05-28-2020).]

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AustinH
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Report this Post03-01-2018 06:41 PM Click Here to See the Profile for AustinHClick Here to Email AustinHSend a Private Message to AustinHEdit/Delete MessageReply w/QuoteDirect Link to This Post
EXTREMELY useful links:
Playlist for hundreds of 3800 related videos:
https://www.youtube.com/pla...y06RXVNmLuiX2rw4OJfz

Good 3800 modification and suggestion forum:
https://www.fastfieros.com/3800faq.htm

Another 3800sc swap step-by-step build thread:
http://www.fiero.nl/forum/A...100421-1-053213.html

FastFieros technical pages:
http://www.fastfieros.com/tech/

GMTuners.com:
http://www.gmtuners.com/

GMTuners Technical Articles:
http://www.gmtuners.com/tech/index.htm

GMTuners wiring and other information:
http://www.gmtuners.com/files/index.htm

GMTuners 3800 Swap guide (not as thorough as above, but used as inspiration):
http://www.gmtuners.com/swap/3800.htm

GMTuner's parts list for swaps (not as thorough as above, but used as inspiration):
http://www.gmtuners.com/fiero/parts.htm

Triple Edge Performance - they will rebuild your 4t65e-HD transmission for you:
https://tripleedgeperforman...rformance_4T65E.html

The Ogre’s Fiero Cave:
http://fierocave.shorturl.com/

Cow S. Patoot Fiero information:
http://www.fieroinfo.com/
------------------
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 05-29-2020).]

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Report this Post04-09-2018 09:10 AM Click Here to See the Profile for 1MohrFieroSend a Private Message to 1MohrFieroEdit/Delete MessageReply w/QuoteDirect Link to This Post
I dont know how I missed this before. Thanks for the huge effort in documentation.
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longjonsilver
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Report this Post05-17-2018 09:36 PM Click Here to See the Profile for longjonsilverClick Here to visit longjonsilver's HomePageClick Here to Email longjonsilverSend a Private Message to longjonsilverEdit/Delete MessageReply w/QuoteDirect Link to This Post
Thanks Austin: lots of good information here. Everybody's swap is different, so the more info we get the more options we have to choose from and the better decisions we make. The electrical diagrams you posted are especially helpful, as are your videos on youtube.
thanks again
jon

------------------
I'm the original owner of a white ' 84 2M4 purchased Dec 10, 1983 from Pontiac. Always garaged, no rust, 4-wheel drifts are fun! 3800 SC swap to come!

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Report this Post03-14-2019 09:52 PM Click Here to See the Profile for 0zSend a Private Message to 0zEdit/Delete MessageReply w/QuoteDirect Link to This Post
How did it turn out?
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Amazing post and lots of valuable information here. Thanks for documenting your swap and all the information so well!

------------------
"Discord"
Red 1988 GT under restoration!

Let's Go Mets!

( ͡° ͜ʖ ͡°)

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It’s not like I am an expert but the crank becomes positive so I believe the flow will be opposite of your explanation.
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Report this Post05-09-2019 08:26 PM Click Here to See the Profile for AustinHClick Here to Email AustinHSend a Private Message to AustinHEdit/Delete MessageReply w/QuoteDirect Link to This Post
 
quote
Originally posted by LornesGT:

It’s not like I am an expert but the crank becomes positive so I believe the flow will be opposite of your explanation.


Air through the PCV valve can only travel the direction shown. Intake vacuum sucks air directly into the blower through the PCV from the crank case.

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 01-16-2020).]

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Report this Post06-18-2019 06:30 PM Click Here to See the Profile for DimeMachineSend a Private Message to DimeMachineEdit/Delete MessageReply w/QuoteDirect Link to This Post
 
quote
Originally posted by AustinH:

Today's video is everything you need to know about a 3800sc.

Part 4 of the swap coming soon!



Austin H.
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


Fantastic thread young man! I'll be watching as you seem to be doing a fine job!

------------------
84/87 NB, 3800SC, E-85, VS Cam, 2.8 Pulley, 4T65E-HD, HP Tuners, AEM Wideband, Regal GS Gauges, S-10 Brake Booster. 1/4 mile -11.85 at 114mph

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DimeMachine
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Report this Post06-18-2019 06:33 PM Click Here to See the Profile for DimeMachineSend a Private Message to DimeMachineEdit/Delete MessageReply w/QuoteDirect Link to This Post

DimeMachine

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Member since Sep 2011
You seem to be very analytical in your approach - researching and then making informed decisions. Curious what your conclusion was regarding the Gen 3 M90 ported vs Gen 5.

Thanks!
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AustinH
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DimeMachine
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Report this Post06-18-2019 09:19 PM Click Here to See the Profile for DimeMachineSend a Private Message to DimeMachineEdit/Delete MessageReply w/QuoteDirect Link to This Post
 
quote
Originally posted by AustinH:


Hey Dime.

I honestly picked up my Gen V + the two series III heads + the Lower Intake Manifold for $150 total... maybe got lucky.

The hype online is that a ported Gen III blower is equal airflow to a Gen V blower.

I think that the 13% less HP parasitic and 15% less heat would remain with the Gen V blower however.

Here are the exact numbers from Eaton found here: http://www.grandprixforums....en-five-gen-5-a.html
The 90-cubic inch Gen V supercharger is very compact. Its housing includes the throttle-body adaptor, crankcase ventilation plumbing,
coolant passages, the evaporative emissions purge valve and the rotor
drive mechanism. The drive mechanism is sealed and permanently
lubricated, obviating the need for oil connections and eliminating a
potential source of leaks. Moreover, the Gen V features all-cast
components and a larger, low-restriction outlet port. The tuned inlet
port is also less restrictive, compared to previous-generation
superchargers, allowing a larger (75 millimeter) throttle body. As a
result, more air is pumped by the supercharger through the Series III’s
induction system. The Gen V’s rotor is finished with Abraidbable Powder
Coating (APC) rather than epoxy. APC is a patented material containing
graphite that is electrostatically applied to the rotor and baked on. As
a result, the rotor requires less clearance within the supercharger
housing, resulting in less leakage around its edges, greater airflow at
a given operating speed and lower operating temperature. The Gen V’s
rotor bearings have been enlarged to increase durability and reduce
operating noise and vibration.

As a result, the Gen V operates at considerably higher efficiency than
its predecessors. At wide open throttle, the Gen V turns at 700 fewer
rpm (a 9 percent reduction), draws 13 percent less power from the
crankshaft, decreases operating temperature 15 percent and increases
volumetric efficiency 9 percent. For the customer, that means a 9
percent increase in horsepower (see product specifications), and best-
in-class acceleration times for the Grand Prix.




Ha. Makes it an easy decision when a deal like that falls into your lap....
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TexasT
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Report this Post06-19-2019 08:48 AM Click Here to See the Profile for TexasTClick Here to visit TexasT's HomePageClick Here to Email TexasTSend a Private Message to TexasTEdit/Delete MessageReply w/QuoteDirect Link to This Post
Just wanted to add my "keep on moving forward"!
You are doing FINE work, so keep it(the work), the posts, and vids on youtube coming. I'm sure I'm not the only one taking it all in.

How are you doing the computer? We are looking at hptuners and efilive for a programmer for our sc gtp swap into an 85 Fiero.
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Report this Post06-19-2019 09:01 AM Click Here to See the Profile for Dennis LaGruaClick Here to Email Dennis LaGruaSend a Private Message to Dennis LaGruaEdit/Delete MessageReply w/QuoteDirect Link to This Post
 
quote
Originally posted by TexasT:

How are you doing the computer? We are looking at hptuners and efilive for a programmer for our sc gtp swap into an 85 Fiero.


I would recommend that the OP use HP Tuners to tweak the program as there is a long history with that software. It takes a while to learn how to use editing software but if you add any mods, having it is essential.

------------------
" THE BLACK PARALYZER" -87GT 3800SC Series III engine, custom ZZP /Frozen Boost Intercooler setup, 3.4" Pulley, Northstar TB, LS1 MAF, 3" Spintech/Hedman Exhaust, P-log Manifold, Autolite 104's, MSD wires, Custom CAI, 4T65eHD w. custom axles, Champion Radiator, S10 Brake Booster, HP Tuners VCM Suite.
"THE COLUSSUS"
87GT - ALL OUT 3.4L Turbocharged engine, Garrett Hybrid Turbo, MSD ign., modified TH125H
" ON THE LOOSE WITHOUT THE JUICE "

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AustinH
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Report this Post06-19-2019 09:47 AM Click Here to See the Profile for AustinHClick Here to Email AustinHSend a Private Message to AustinHEdit/Delete MessageReply w/QuoteDirect Link to This Post
 
quote
Originally posted by TexasT:

Just wanted to add my "keep on moving forward"!
You are doing FINE work, so keep it(the work), the posts, and vids on youtube coming. I'm sure I'm not the only one taking it all in.

How are you doing the computer? We are looking at hptuners and efilive for a programmer for our sc gtp swap into an 85 Fiero.


Thanks! The above post is correct, I have a friend with HPTuners. James L Brown (who manufactures 3800sc swap harnesses) also programs the PCM for you.
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AustinH
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AustinH
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Fiero Ron
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Report this Post11-21-2019 03:18 PM Click Here to See the Profile for Fiero RonClick Here to Email Fiero RonSend a Private Message to Fiero RonEdit/Delete MessageReply w/QuoteDirect Link to This Post
I have been subscribed for a while, I love the videos, they are very informative. When I saw the part about the A/C compressor, I was laughing because I did the same exact thing torquing the nuts to 74 ft-lbs because of how it was described in the list of torque specs. I pulled the threads right out of the compressor bracket, I ended up tapping to the next size with the same thread pitch and using a Time-Sert. Glad to have you and LostNotForgotten giving tips with the 3800 Supercharged install, it definitely helps many of us a lot. I hope you get over 1,000 subscribers soon, you definitely deserve it. Keep up the good work!

Ron
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AustinH
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VROOMZ28
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Report this Post02-14-2020 12:03 AM Click Here to See the Profile for VROOMZ28Send a Private Message to VROOMZ28Edit/Delete MessageReply w/QuoteDirect Link to This Post
AustinH,

Thank you for the updated video. I am in the process of getting all my parts required to perform my 3800sc swap and I have been watching your videos and “LostbutNotForgotten’s” videos. You guys are my inspiration and my guides in doing this swap. I can’t thank you enough for sharing the information.

I have a 3800sc Series II L67, but I’ve aquired a Gen V M90 and L32 lower intake manifold.

Do you know is there any VATS or PASSKEY on the Gen II that needs to be disabled in the ECU? I’d like to test run my engine before I mount it in the Fiero.

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AustinH
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Report this Post02-14-2020 10:11 AM Click Here to See the Profile for AustinHClick Here to Email AustinHSend a Private Message to AustinHEdit/Delete MessageReply w/QuoteDirect Link to This Post
 
quote

Do you know is there any VATS or PASSKEY on the Gen II that needs to be disabled in the ECU? I’d like to test run my engine before I mount it in the Fiero.


You are welcome! Glad to hear.
Yes, there is VATS you must disable. You can do that with a programming tool like HPTuners. I have a friend handle all that stuff for me. If your harness came from Danny (Canada) or James Brown, then they would have disabled it already. You can send out your PCM to one of them or take it to a shop to have done otherwise. What are you doing for a harness?
James Brown - https://www.facebook.com/pr...p?id=100010340077920
Danny - https://www.facebook.com/danny.mcilmoyle
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VROOMZ28
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Report this Post02-22-2020 10:53 PM Click Here to See the Profile for VROOMZ28Send a Private Message to VROOMZ28Edit/Delete MessageReply w/QuoteDirect Link to This Post
I wasn’t sure if I should try to use the existing harness and splice into the Fiero wiring or try to get a harness made. The harness is really the only thing I am missing to perform my swap. My engine is from a 1998 Grand Prix GTP so hopefully its not too challenging. What are your recommendations? I pretty handy, but I’d be willing to buy one too save me some headaches...
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