LS4 / F40 swap - fieroguru (Page 189/216)
Will JUN 19, 06:49 AM
Since you're into wiring right now... Do you run 22ga wires to the alternator control terminals?
Fieros have 18ga wires to the F/I and L terminals, while the 2006 Corvette that's volunteering my engine management has 22ga. I'm just trying to make sure I can drive the voltage light with 22ga without problems.

Edit: Are you using DR25? What sizes do you run with various wire bundles? E.g. 1/4" tubing with a 3 wire bundle?

[This message has been edited by Will (edited 06-19-2023).]

fieroguru JUN 19, 07:46 PM
I kept the stock LS2 wiring from the ECM to the alternator terminals (22ga) and spliced in the stock Fiero wire from the 500 connector for the light.

Yes, I am using DR25 heat shrink.
I have 25+ ft in each of the various sizes from about 3/16 up to 1 1/2".
I just see if the sleeve will go over the bundle with ease, if not I move to the next larger size.
Will JUN 19, 09:01 PM

quote
Originally posted by fieroguru:

I kept the stock LS2 wiring from the ECM to the alternator terminals (22ga) and spliced in the stock Fiero wire from the 500 connector for the light.



So you have the L terminal on your alternator is connected to both the ECM terminal AND the Fiero voltage light (C500-B3)?
I will be running a 2006 Corvette .bin with table updates by Sinister. He told me that unless both of the ECM alternator connections were connected, the ECM would not be happy. I had not gone so far as to ask if he's ever known one to be run with BOTH connected.


quote
Originally posted by fieroguru:

Yes, I am using DR25 heat shrink.
I have 25+ ft in each of the various sizes from about 3/16 up to 1 1/2".
I just see if the sleeve will go over the bundle with ease, if not I move to the next larger size.



Well that sounds way too easy. I was about to order a collection (well... really just a couple of sizes to civilize my small bundles) and wondering if I should order 3/16" or if 1/4" should be the smallest. I'm thinkin 1/4" would be fine for 3x 22ga bundles

[This message has been edited by Will (edited 06-19-2023).]

Will JUN 19, 09:18 PM

quote
Originally posted by fieroguru:

Finished up a couple of details:

Welded a nut to the exhaust to support the cutout boost line:





What's the temperature rating on that P-clamp?
fieroguru JUN 20, 07:04 AM

quote
Originally posted by Will:
So you have the L terminal on your alternator is connected to both the ECM terminal AND the Fiero voltage light (C500-B3)?



Yes.


quote
Originally posted by Will:
Well that sounds way too easy. I was about to order a collection (well... really just a couple of sizes to civilize my small bundles) and wondering if I should order 3/16" or if 1/4" should be the smallest. I'm thinkin 1/4" would be fine for 3x 22ga bundles



The smallest connection would be 2 wires so I use of 3/16 for all those. I normally put 6" to 12" on those before I start combining multiple connectors.



quote
Originally posted by Will:
What's the temperature rating on that P-clamp?



-30° to 180° F.
fieroguru JUN 25, 05:55 PM
I have been out of town since Friday and taking advantage of the hotel time to get the base tune updated for all the various changes (2 Bar OS, MAF, IAC, MAP, Injectors, Flex Fuel, F40 VSS, unused DTCs, and much more).

Overall there were 114 changes to the various cells and tables in the calibration. This should allow the engine to start and all fiero gauges to work, but a lot more tuning will be needed to dial in the new parts to the changes made in the engine and the addition of flex fuel and the turbo.

I am planning to get back to the harness work on Monday afternoon.
fieroguru JUN 26, 09:51 PM
Got home about 2 PM and loomed up a few more circuits... but didn't take any new pictures. I did load the baseline tune into the ecm. A year or so back I made a bench tuning device, so I can tune the ecm while sitting on the couch. It works like a charm. It sure beats waiting to do this until everything is in the car and powered up!

[This message has been edited by fieroguru (edited 06-26-2023).]

zkhennings JUL 12, 04:48 PM
Looking really good, what tubing are you using for the coolant crossover? I did not have much luck trying to find some stainless tubing in a similar diameter to the stock coolant lines that run under the car.
fieroguru JUL 12, 09:08 PM

quote
Originally posted by zkhennings:

Looking really good, what tubing are you using for the coolant crossover? I did not have much luck trying to find some stainless tubing in a similar diameter to the stock coolant lines that run under the car.



https://www.mcmaster.com/8989K308-8989K31/
fieroguru JUL 13, 04:47 PM
While I really wanted to have my LS4/F40/Turbo swap completed before the 40th Fiero Anniversary Show, that isn't going to happen. I have been on vacation this week and made some significant progress with the swap and it is nearly ready to go in the chassis. I still need to add the coil ends to the plug wires and remove the gold paint from the plug wires and make some refinements to the PCV system.

Not sure why the text on the plug wires was gold, but I don't like it. Did some experimenting and brake clean will remove it, so I will take the time to remove all the gold (if I don't then it will annoy me every time I look at the engine). In this picture the TALYLOR to the left was gold and now is not!


Here is how the Fiero will be viewed when installed in the Fiero. The engine is fully wired and hosed in this picture. Nothing additional will be added to the top side of the engine at this point.


Much of the turbo and exhaust stuff will be hidden as well. Here is a picture showing everthing that will be under the stock truck area (no modifications to the trunk performed).


For reference, here is what the swap looked like when NA. I really liked the presentation of this engine in the bay, so I didn't want to screw that up.


Here is the rear view of the drivetrain/exhaust/cradle:


Accessory side:


Front side. This is the side that is up against the firewall and not really visible. So it becomes the business end for the majority of the harness, hoses, ecm and fuse box.


Here is what the harness to the ecm and fuse box looks like:



Completed several modifications to the Fierostore fuel sending unit. The picture also shows the flex fuel sender/bypass and filter assembly.
- Added a sealed ground stud. This will allow me to use 2 of the existing wires (vs. 1) for the fuel pump (Walbro 450 lph).
- Added -6 AN fittings and then an adapter to -8AN - all fuse hoses and fuel rails are -8AN
- Modified the pump support so the larger fuel pump would fit - cut the stock one off, rotated it, then welded it back in place and added a brace.



I am taking the rest of the extended weekend off to attend the 40th Fiero Anniversary Show.