It was a good weekend. Lots of frusteration but overall a good weekend.

First up we finished up replacing the gaskets I mentioned above. Course that didn't fix the problem. First we had one leak, after replacing the gasket we had two. Here is where the first leak was...

The leak we were fixing was better, but still leaking. The timing cover stayed on but the water inlet and water pump had to come back off. The gaskets were cleaned and inspected. This revealed the problem. Looks like when the previous owner of the caddy replaced the water pump, they over torqued a couple of the bolts. Since the 4.9 water pump is made out of stamped steel, it made some leaks appear. Here is what the gasket looked like...

We confirmed and fixed the problem with a feeler gauge on the steel table. Stamped steel may be cheap but at least its easy to fix.

We put everything back together and decided not to take any chances. Some of you tractor motor guys ( ) might get a kick out of this.

Cat Red liquid gasket maker.

Both sides or every gasket were covered as everything was stuck back together. This stuff works great.



I will never change another 4.9 waterpump without this stuff. We put a little on the thremostat gasket also since we were seeing some blow-by there.
We pressure tested the system yet again (#8 I think. ). This time we got it up to 16lbs. Cooling system is done. It took almost 4 hours but its done. Whew.


Next up I had to figure out why the fuel pump was not working. I added the wire I had forgot last time and tried it again. Nothing. I started running checks to find where the problem was. Basically it lead me to think that there was a dead short at the tank so.... I had to drop the tank yet again. While it was out we tested the fuel pump by connecting it directly to a battery. It worked and seemed to be puting out good pressure. We went back to the wiring. Everything had continuety (sp?) and the ground was good. The relay, fuse, and all the wiring is good. After scratching out heads for about 5 min we find the problem...


Aparently when I had to fix the patch job the previous owner did to the power wire for the fuel pump, I didn't get them secured well enough and the one wire was pinched between the tunnel and sending unit. Oops.

I got it put back together. I did a few other things too get it ready to start. Just the final details, I don't remember all of it. That was it for friday.


It runs and I have 4 videos to prove it. Are you guys ready for this????

.... To be continued....

[This message has been edited by Fieroseverywhere (edited 04-22-2008).]

Post Post Post Post!!!

Glad to hear you got the problems fixed. I didn't get near as much done as you did. My trans colling tubrs are giving me fits still, but oh well. Here's the trunk removed, looking all toothless.



I have an exhaust question that you might be able to answer. I have never done an exhaust system, and don't know a lot about them. What is the stock size of the outlet on the caddy? Is there an aftermarket part that can bolt on to that hole? The hole is dead center in the pic on the rear echaust manifold. These are 91 Deville manifolds. If so is that what is called a collector? Or is that just a term used on headers? Is a stock manifold a type of header?? I'm so confused!! If there isn't an aftermarket part that could be bought, do you have the original part that came off the manifold you could sell me as well as a foot or so of the pipe that is connected to it, and I will just start my system from there. I had thought of going around the front of the engine in more the way that you are to keep it more in the stock location, but going out the back will be easier for me and since I have the trunk out, I have the room.

Thanks in advance for any info.

And now back to the Continuing saga of Fiero Argento Signora,

Darren

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quote Originally posted by Darren's 87 coupe: Post Post Post Post!!! Glad to hear you got the problems fixed. I didn't get near as much done as you did. My trans colling tubrs are giving me fits still, but oh well. Here's the trunk removed, looking all toothless. I have an exhaust question that you might be able to answer. I have never done an exhaust system, and don't know a lot about them. What is the stock size of the outlet on the caddy? Is there an aftermarket part that can bolt on to that hole? The hole is dead center in the pic on the rear echaust manifold. These are 91 Deville manifolds. If so is that what is called a collector? Or is that just a term used on headers? Is a stock manifold a type of header?? I'm so confused!! If there isn't an aftermarket part that could be bought, do you have the original part that came off the manifold you could sell me as well as a foot or so of the pipe that is connected to it, and I will just start my system from there. I had thought of going around the front of the engine in more the way that you are to keep it more in the stock location, but going out the back will be easier for me and since I have the trunk out, I have the room. Thanks in advance for any info. And now back to the Continuing saga of Fiero Argento Signora, Darren

I only wish I had all the problems figured out. Actually it kept getting worse as the weekend progressed. The good thing is it runs. Once it get a few other things figured out it will run good. It sounds really good when it working.

Ok. I'll answer what I can.

-Stock size of caddy outlet... 2.5"
-You could probably find what you need at an exhaust shop to bolt it up. All you really need is a flange to fit the manifold. Or if you can wait a couple weeks I do have the original caddy one that I can send to you. Maybe I can get it out sooner. Its has about a foot of pipe on it.
- A collector is the point where both manifolds or headers meet. Usually in the "Y" pipe. I guess in this case that manifold is also the collector.

I have to run to work. I'll be back later to post some vids and help with what I can. Later Darren.

[This message has been edited by Fieroseverywhere (edited 04-22-2008).]

[This message has been edited by Fieroseverywhere (edited 04-23-2008).]

Ok. I'm sure some of you are ready to see some videos. I know I was ready to be taking them.

For those what want to skip ahead and watch them all...
http://www.youtube.com/resu...=caalon&search_type=


The first vid was the first real start of the engine since the rebuild. It had been fired up once before for about 10 sec so technically the second start.

Dad forgot to tighten the water pump pully bolts (well, two of them). That was most of the racket you could hear. Exhaust sounds suprisingly good though. It ran for about a minute before we had to shut it down. The idle never came down. We needed to brake in the cam at a high idle anyway.


The second video was for the third start. The waterpump pully bolts are now tight. She fired right back up. See if you can spot the fire.

Still idling high. Lots of high temp paint, zinc primer, and steam coming out on top of the engine bay on top of the smoke. I remembered that the screw for the ISC was not the original. It was too long and had to be shortened. I don't know how the previous owner could have made it work. If you didn't see it the fire was just a papertowel on the under car pipe. Oops. No burned wires of any other problems. We also set the timing with a light while it was running.

About 5 minutes after we shut it off my daughter showed up with her grandmother. She got to hold the camera at the beginning of this vid. Dad went over to his shop to fix the ISC screw.

She's funny. The car is idling now and sounds much better.
Shortly after this video the temporary fuel lines decide they are done. We tried to fix them a couple of times but those alluminum fittings are worthless IMO. Saturday was nearing the end anyway. I replaced the trunk carpet with some out of an early coupe. I packed up everything that needed to go with the car and called it a day. I also temporarily attached the gauges, installed the inner fenderwells and did a few other odds and ends to start getting the car ready to move.


I took sunday off and took my daughter to do some lazer tag. We had a blast.

Monday morning it was time to get this car moving. We remade the fuel lines. Dad did the fittings and I bend the lines where I wanted. I routed them between the ISC and alternator bracket. Looks very clean now. I also relocated the MAP sensor so I could use the stock intake for a while. The tube is from an 85 2.5 fiero. The EGR silinoid was moved also for a cleaner look. I put on most of the loom for the wiring. I still have some work there to finalize everything but it came out very good. It was time to take the first test drive. When we fired it up again It sounded like we lost a cylinder. It had to be moved out of the shop so I drove it like that around the building and backed it in. I could tell it is going to be a fun car even with only a 15 sec test drive. Eventually we found the ground wire for the ECM had broken at the loop. Not completely, but enough to cause a problem. Once I replaced it everything worked great again. It was running very near perfect.

But it was short lived. It developed another problem.

Time was short and I had to start the drive home. So here is where I'm stuck at the moment. Maybe someone can help me out?

Car starts and idles perfect. When you give it gas though it bogs down and tries to die. It won't take ANY throttle. Everything was working perfectly for a little while. I'm leaning towards the loss of the MAP or possibly another sensor. I really don't know for sure right now. I can't run any tests since the car is so far away either. I didn't get a chance to check it again once it cooled so I don't even know if its heat related. Anyone have any ideas?


All in all it was a good weekend. It sounds great and its running. I'll get the rest figured out later and finally get my test drives. I'll get more pics and vids later when I can make it back down. Hopefully have the first real test drive on video also. We'll see. Later.

[This message has been edited by Fieroseverywhere (edited 12-08-2009).]

quote Originally posted by Darren's 87 coupe: Glad to hear you got it figured out. And I am also really glad to see the videos. That was really cool. I let my son watch them and told him that you were doing the same thing that we are doing and that is what ours is going to sound like. He got really excited and wanted to know if it was going to be silver like that one. I told him no, that ours was going to stay blue and look really cool. Then he said could we paint it like a rainbow.................. I think I'll take him hunting this weekend and up his rations of beef jerky and pork rinds. I hope that knocks that rainbow idea out of his head once and for all. you never know whats going to come out of a 4 year olds head. Seriously he cracks me up all the time. Keep the videos coming. Especially of a good launch when you get it out. Later, Darren

I still can't believe the pump died right after we finally got it all running right. It figures!
Rainbow. Hehe. Thats great. Have someone photoshop a really bad rainbow fiero for you. I'm sure that will stop that idea in its tracks.
I actually think yours will sound better. The much shorter exhaust will make a big defference. I can't wait to hear it fire up. Your gonna take a video right?

I'm gonna do some thing different with the exhaust tips. Looking at the videos I realize how restrictive they actually are. Supposedly dual 2.5 tips but the exhaust doesn't get to use the 2.5 at all. That center hole is way to small. I'll try opening up the ends a bit and help the flow. Then we'll see what it sounds like.

I'm gonna fix this thing into submission I swear it. I have the days (well day and a 1/2) off of work planed out already. I'll be heading down again on friday 5-2. I should have a few hours to replace the pump that day and until monday evening to test drive and work out any other bugs that come up. Wish me luck. Later Darren,
Caalon

[This message has been edited by Fieroseverywhere (edited 04-24-2008).]

She runs well and drives!

First thing I did was pull the O2 sensor. It turned out to be a Bosch. In the trash it went. I picked up a new Delco one at a local dealership. Then all of a sudden it wasn't running nearly as rich as it used to be. Imagine that.

Once the O2 was replace I had to pull all of the spark plugs and clean them. Most of them had fouled out at that point and I couldn't tell which ones were still good. Once cleaned they were re-installed. It fired right up.

Then the next problem showed its ugly little head. It wouldn't idle right. It just kept hunting and still wouldn't take much throttle. After a few hours of looking I found the problem..... I missed a wire. And a pretty important one at that. The power wire for the EGR silonoid. Actually I only missed part of the wire. From the caddy C225 to the PCM. Thats why I had such a hard time tracking it down. I added it in a presto. Runs like a champ and finally sounds like it should.

We adjusted the timing and idle again and I did a few other touches to the car. Then I took it for a little test drive. Felt good. Tons more power then the 2.8. The clutch is pretty touchy being new and all but everything else felt good. Brakes worked better then I had hoped. I only put my foot in it once in first gear. Wow! Me likes!

I got a couple more clips. Much better IMO.

The squeeling is a bad bearing in the alternator. It will be replaced later.

Exhaust clip.


There are still some bugs to work out but overall its much better. Still a touch on the rich side but not to the point that is fouling out plugs anymore. I'll keep you guys posted on the progress.

[This message has been edited by Fieroseverywhere (edited 12-08-2009).]