ZZP Intercooler on L32 3800SC (Page 1/1)
TurboGN JUL 20, 04:48 PM
I have a 1988 Fiero GT with a L32 swapped in. I purchased an intercooler from ZZP and was watching installation videos when I came across a video of one being installed in a Fiero. He ran into issues with having to cut into the hood structure just to clear the supercharger. Is there any way around having to cut up the hood?
olejoedad JUL 20, 05:32 PM
If the engine is mounted low enough in the cradle there are no clearance issues.

There was a rather lengthy thread about this very topic within the past year.

If the bottom of your oil pan is within 1/2 inch of your rear cradle side frame rails you will have no issues.

Most aftermarket mounts will not position the drivetrain that low, so notching the rails on the underside of the decklid is necessary.

Question - What size supercharger pulley are you using and what modifications have been done to the engine?
(Cam, rockers, headers, etc)

If your engine is stock, the intercooler really isn't needed.....

[This message has been edited by olejoedad (edited 07-20-2025).]

Dennis LaGrua JUL 20, 06:55 PM
If I may add to what Joe has said.
My install is the 3800SC series III that uses the Eaton Gen V supercharger that was reworked (2003-up) to be more efficient to put out higher and cooler boost. My powertrain is mounted with West Coast Fiero trans and motor mounts. The position of the powertain with WCF mounts will not allow installation of the full size ZZ Performance intercooler without notching the deck lid. The short stack IC that I use fits fine.
My signature shows my mods and with a 3.4" pulley on the later supercharger it is like running a 3.2" pulley. The max boost is 11 PSI that IMO is quite aggressive.
Before the addition of the intercooler we could not tune (program out) the KR's. Now all is fine with the mods and the stock timing table. However, the larger cable operated N* TB and LS1 MAF that my engine uses required rescaling the MAF table. We did not use drive by wire so operation is handled by a 2003 Grand Prix PCM. Be careful choosing PCM's so you don't end up with the tap shift option used on the optional 4T65eHD trans.
Note that with 3800 Grand Prix PCM's the fueling is calculated from the MAF sensor readings. The "main" fuel tables that are there are only used for default if the MAF fails..

------------------
" 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 "

[This message has been edited by Dennis LaGrua (edited 07-20-2025).]

TurboGN JUL 20, 10:49 PM

quote
Originally posted by olejoedad:

If the engine is mounted low enough in the cradle there are no clearance issues.

There was a rather lengthy thread about this very topic within the past year.

If the bottom of your oil pan is within 1/2 inch of your rear cradle side frame rails you will have no issues.

Most aftermarket mounts will not position the drivetrain that low, so notching the rails on the underside of the decklid is necessary.

Question - What size supercharger pulley are you using and what modifications have been done to the engine?
(Cam, rockers, headers, etc)

If your engine is stock, the intercooler really isn't needed.....




I'll have to check the measurements tomorrow if it's not raining again.
TurboGN JUL 20, 11:04 PM

quote
Originally posted by Dennis LaGrua:

If I may add to what Joe has said.
My install is the 3800SC series III that uses the Eaton Gen V supercharger that was reworked (2003-up) to be more efficient to put out higher and cooler boost. My powertrain is mounted with West Coast Fiero trans and motor mounts. The position of the powertain with WCF mounts will not allow installation of the full size ZZ Performance intercooler without notching the deck lid. The short stack IC that I use fits fine.
My signature shows my mods and with a 3.4" pulley on the later supercharger it is like running a 3.2" pulley. The max boost is 11 PSI that IMO is quite aggressive.
Before the addition of the intercooler we could not tune (program out) the KR's. Now all is fine with the mods and the stock timing table. However, the larger cable operated N* TB and LS1 MAF that my engine uses required rescaling the MAF table. We did not use drive by wire so operation is handled by a 2003 Grand Prix PCM. Be careful choosing PCM's so you don't end up with the tap shift option used on the optional 4T65eHD trans.
Note that with 3800 Grand Prix PCM's the fueling is calculated from the MAF sensor readings. The "main" fuel tables that are there are only used for default if the MAF fails..



I bought mine with the swap already done and I believe it is mostly stock. I have the Northstar TB also with cone filter, colder plugs, 50 lb/hr injectors, modified exhaust, and ZZP coil packs. I wanted to cool down the boost charge so I could run a 3" pulley and keep it running safe.
Dennis LaGrua JUL 22, 05:24 AM

quote
Originally posted by TurboGN:


I bought mine with the swap already done and I believe it is mostly stock. I have the Northstar TB also with cone filter, colder plugs, 50 lb/hr injectors, modified exhaust, and ZZP coil packs. I wanted to cool down the boost charge so I could run a 3" pulley and keep it running safe.



Running a 3" pulley on the Gen V supercharger is like running a 2.8" pulley on the earlier units. My guess is that its going to put out 13-15 psi of boost. IMO, you will need the full stack intercooler but call ZZ Performance to verify the additional mods needed. The full stack IC adds over 2" in height to where the supercharger sits. . You can measure if you have the room but many aftermarket powertrain mounts do not lower the engine sufficiently to provide clearance. Take out the right engine cooling vent, close the deck lid and measure the distance between the supercharger snout and the right hinge support.

------------------
" 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 "

TurboGN JUL 22, 07:30 AM

quote
Originally posted by Dennis LaGrua:


Running a 3" pulley on the Gen V supercharger is like running a 2.8" pulley on the earlier units. My guess is that its going to put out 13-15 psi of boost. IMO, you will need the full stack intercooler but call ZZ Performance to verify the additional mods needed. The full stack IC adds over 2" in height to where the supercharger sits. . You can measure if you have the room but many aftermarket powertrain mounts do not lower the engine sufficiently to provide clearance. Take out the right engine cooling vent, close the deck lid and measure the distance between the supercharger snout and the right hinge support.




Thanks for the info.
TurboGN JUL 24, 10:58 AM

quote
Originally posted by Dennis LaGrua:


Running a 3" pulley on the Gen V supercharger is like running a 2.8" pulley on the earlier units. My guess is that its going to put out 13-15 psi of boost. IMO, you will need the full stack intercooler but call ZZ Performance to verify the additional mods needed. The full stack IC adds over 2" in height to where the supercharger sits. . You can measure if you have the room but many aftermarket powertrain mounts do not lower the engine sufficiently to provide clearance. Take out the right engine cooling vent, close the deck lid and measure the distance between the supercharger snout and the right hinge support.




It looks like I would have just barely enough room to put the intercooler in and clear the hood, but the hinge rod only has about a 1/4" clearance now, so it looks like that would have to be removed completely.