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3800sc Swap Complete Parts List by AustinH
Started on: 03-24-2017 12:01 PM
Replies: 88 (40350 views)
Last post by: AustinH on 02-01-2023 06:02 PM
AustinH
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Report this Post03-24-2017 12:01 PM Click Here to See the Profile for AustinHSend a Private Message to AustinHEdit/Delete MessageReply w/QuoteDirect Link to This Post
MOBILE PHONES - CLICK AND HOLD HERE TO VIEW THIS PAGE THIS WEBPAGE IS BEST VIEWED ON A DESKTOP COMPUTER. NOT A MOBILE PHONE. TO SEARCH THIS PAGE, PRESS ctrl F (PC), command F (mac), or tap ••• and "Find In Page" (mobile)
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.
CLICK HERE TO VIEW MOST OF THESE PARTS ON AMAZON

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 Fiero Repair Guide
-A 3800 Repair Guide
-Perfect

All videos available in this playlist here - https://www.youtube.com/pla...IM_4I2qJnkff2RlPWB_O

VIDEO GUIDE TO THIS BUILD THREAD:


CONTENTS:
1. 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

2. BUILD 1: COMPLETE PARTS LIST FOR A CHEAP AND EASY DIRECT SWAP SERIES II SUPERCHARGED 4T65E-HD TRANS BUILD
-CLICK TO VIEW MOST OF BUILD 1 ON AMAZON
-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
-PARTS THAT WEAR OUT ON A 3800SC


3. 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
-CLICK TO VIEW MOST OF BUILD 2 ON AMAZON
-Air
-Fuel
-Spark
-Exhaust
-Cylinder Heads/Valvetrain/Pushrods/Lifters
-Camshaft, timing chain, and balance shaft removal
-4t65e Transmission

4. 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
-FUEL RAIL SETUP OPTIONS
-HOW A PCV SYSTEM WORKS WITH A NORTHSTAR THROTTLE BODY ON A SERIES III 3800SC
-EXHAUST SETUP FOR BUILD 2
-4t65e Transmission

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

6. 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)

7. Other Helpful Fiero Parts While You're At It
-CLICK HERE TO VIEW MY FIERO MODS ON AMAZON
-A Fiero Repair Guide
-Good parts to change while the engine is out

8. EXTREMELY Useful Links

9. MY BUILD
-CLICK HERE TO VIEW MOST OF THESE PARTS ON AMAZON
-Anything else I put on my car that is not necessary for the engine swaps.

10. MY TOOLBOX
-PART 1: CAR TOOLS
-PART 2: SHOP TOOLS
-PART 2.1: DISPOSABLE CAR HARDWARE
-PART 2.2: CAR WASHING
-PART 2.3: ELECTRICAL TOOLS
-PART 3: HOUSE PROJECT & OUTDOOR TOOLS

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. If you would like to contribute your content to this page or report a broken link, please contact me at http://facebook.com/fieroaustin

All videos available in this playlist here - https://www.youtube.com/pla...IM_4I2qJnkff2RlPWB_O

Consulting, support, and donations
Please consider supporting my YouTube channel by subscribing here - https://www.youtube.com/fie...n?sub_confirmation=1
My Fiero/3800/tool Amazon Store https://amzn.to/3hNViaa
eBay affiliate (use & I get paid) https://ebay.us/4gTj2A
Donate to support future vids https://www.paypal.com/dona...VSKTJ&no_recurring=0
Join channel for perks https://www.youtube.com/FieroAustin/join
Consulting on Facebook https://www.facebook.com/FieroAustin/

------------------
FieroAustin
1988 GT 3800SC Series III 2.8" Pulley
Fiero/3800sc Swap Parts/Tools at https://amzn.to/3hNViaa
Youtube https://www.youtube.com/Fie...n?sub_confirmation=1
Facebook https://www.facebook.com/FieroAustin/
3800sc Swap Instructions //www.fiero.nl/forum/Forum2/HTML/139530.html
eBay affiliate https://ebay.us/4gTj2A
Join Youtube Membership https://www.youtube.com/FieroAustin/join
Donate https://www.paypal.com/dona...VSKTJ&no_recurring=0

[This message has been edited by AustinH (edited 02-01-2023).]

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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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Report this Post03-24-2017 12:49 PM Click Here to See the Profile for 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, Click Here

Data pulled from here
//www.fiero.nl/forum/Forum1/HTML/070670.html
http://www.thechicagogarage...rchive%2A%2A%2A.html
http://www.3800pro.com/forum/fwdquarter.php
http://www.3800pro.com/forum/rwdquarter.php
http://www.3800pro.com/foru...-5-hp-cam-chart.html
http://www.clubgp.com/newfo...e=&smode=&s=#5178946
http://www.clubgp.com/newforum/tm.asp?m=1550443
http://www.clubgp.com/newfo...sp?m=5178946&mpage=1

---------------------Common Modifications-----------------------
All videos available in this playlist here - https://www.youtube.com/pla...IM_4I2qJnkff2RlPWB_O

CHECK OUT THIS VIDEO SERIES FOR LOTS OF TESTING AND MODS!!!:
https://www.youtube.com/pla...BG8VcIqUr0BNWyaLt8Qu

This video shows in-depth modifications to the 3800 engine from this build thread:


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------------------
There are many variations of 3800 engines. There are 3 different series, supercharged and non-supercharged (NA). Virtually every engine has a different wiring harness and different parts between years, makes, and models.
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.

Read up:
https://en.wikipedia.org/wiki/Buick_V6_engine

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.

----------------------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 (comes with 3800s) - will only withstand ~200hp - https://en.wikipedia.org/wi..._4T60-E_transmission
4t65e 4 speed auto (comes with 3800s)- will only withstand ~250hp - https://en.wikipedia.org/wi..._4T60-E_transmission
4t65e-HD 4 speed auto (comes with 3800sc) - 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 5 speed manual (stock fiero) - 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
Alternatively I copied the data from the above link to this post: https://www.fiero.nl/forum/...HTML/139530.html#p14

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--------------------------
All videos available in this playlist here - https://www.youtube.com/pla...IM_4I2qJnkff2RlPWB_O


------------------
FieroAustin
1988 GT 3800SC Series III 2.8" Pulley
Fiero/3800sc Swap Parts/Tools at https://amzn.to/3hNViaa
Youtube https://www.youtube.com/Fie...n?sub_confirmation=1
Facebook https://www.facebook.com/FieroAustin/
3800sc Swap Instructions //www.fiero.nl/forum/Forum2/HTML/139530.html
eBay affiliate https://ebay.us/4gTj2A
Join Youtube Membership https://www.youtube.com/FieroAustin/join
Donate https://www.paypal.com/dona...VSKTJ&no_recurring=0

[This message has been edited by AustinH (edited 12-18-2022).]

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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 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
-CLICK TO VIEW MOST OF BUILD 1 ON AMAZON
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 to delete EGR codes and functionality.
-Catalytic Converter and Rear O2 Sensor - For non-emissions compliant states. Requires programming the computer and deleting emissions codes and functionality.
-EVAP System/Stock Fiero vacuum lines - requires plugging hole with freeze plug and JB weld. Requires reprogramming the computer.
NOTE: Deleting EVAP requires you vent the gas tank and plug the extra EVAP hose on the tank header. You can easily do this by removing the valve in the gas tank filler cap.
-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.
-All Fiero vacuum lines except brake booster and cruise control
-Alternator bracket/coolant circuit (relocated and cooling circuit bypassed)
-You must swap the valve covers so that the oil fill cap is on the other side so it is accessible from the Fiero engine bay.

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 $1850; 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 SPE-9751 - https://amzn.to/3AQOpfR

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 RE-1040 - https://amzn.to/3PdVoUu

Oil filter (1x):
ACDELCO PF47E - https://amzn.to/3Pweipj

Supercharger oil (2x):
GM 12345982 - https://amzn.to/3RBV6bC

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 also from an autoparts store:
https://zzperformance.com/p...harger-pulley-puller
NOTE: Re-installing the pulley can be difficult. I put an ice bag on the shaft and the new pulley hub in the oven and used a hammer to pound it on. There may be better tools for this installation.

Supercharger belt - may have to go up or down a size in 0.5" increments to ensure tight fitment - final fitment may vary:
3.7" pulley - 66.3", 6 ribs (1x):
ACDelco 6K663 - https://amzn.to/3IEJRuZ
3.4" pulley - 66", 6 ribs (1x):
ACDELCO 6K660 - https://amzn.to/3yMujAA
NOTE: THESE ONLY FIT THE FIEROROG BRACKETS WITH A 3.4" PULLEY. IF YOU GET OTHER PARTS, YOUR REQUIRED BELT LENGTHS WILL VARY.

-----------------------FUEL------------------------

Fuel filter (1x):
WIX 33481 - https://amzn.to/3RGOkkH

Push-Lok Fuel Hose 3/8" (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://amzn.to/3OcT4Mb

-6 AN to barb Push-Lok hose adapter (4x):
Fragola 200106 - https://amzn.to/3PaVRqw

Stock fuel rail hose release tools (1x) - These are a pain to use, see this video - https://youtu.be/uVlHx1veJN8?t=33:
Performance Tool W83148 - https://amzn.to/3cipRSP

Stock Fiero Fuel Supply Hose M16 x 1.5 Adapter to -6 AN (1x):
EAR-991955ERL - https://amzn.to/3z6ovn1

Stock Fiero Fuel Return Hose M14 x 1.5 Adapter to -6 AN (1x):
EAR-991954ERL - https://amzn.to/3RDgnl5

Stock 3800sc Fuel Rail 3/8" Supply Line To above -6AN Push-Lok adapter (1x):
Vibrant 16886 - https://amzn.to/3yNlQNP

Stock 3800sc Fuel Rail 5/16" Return Line To above -6AN Push-Lok adapter (1x):
Vibrant 16885 - https://amzn.to/3cbxZ7j

Optional: Thread sealant for Metric Fiero return/supply to -6AN adapters above (1x):
Permatex Form-A-Gasket No. 2 80016 - https://amzn.to/3Pxynvy

Fuel pump (1x):
If you do not need 340LPH for E85, consider the Walbro 255 - https://walbrofuelpumps.com...-pump-6cyl-2-8l.html
I have not tested this part yet but if you are planning E85 or any ethanol this is a must:
AEM 340lph 50-1200 - https://amzn.to/3RCxy6p (untested by me)
NOTE: IT IS A GOOD IDEA TO HOTWIRE THESE FUEL PUMPS, DIAGRAM IN THE HARNESS SECTION.
NOTE: BE CAREFUL WITH THESE PUMPS. THE INLET MAY BE TOO CLOSE TO THE BOTTOM OF THE FUEL TANK AND WILL SUCK AGAINST THE TANK, NOT ALLOWING FOR FUEL FLOW AT HIGH FUEL DEMANDS. ON A SIMILAR ONE, 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.

-------------------------SPARK----------------------
Spark Plugs - two ranges colder than stock Autolite 606 plugs, gap to .050" or less (6x):
Autolite 104 spark plugs - https://amzn.to/3PsvZpK

Spark Plug Gap Tool (1x)
Performance Tool W80540 - https://amzn.to/3aFr6Lc

Spark Plug Wire Kit for Custom Length Spark Plugs (1x) - you need a vice and a spark plug crimper below:
Taylor Cable 83253 (45 degree boots) - https://amzn.to/3O9mcnx

Spark plug wire crimper to use with bench vise (1x):
ACCEL 170040 - https://amzn.to/3ciuH2l

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

NOTE: This exhaust system mates to the stock exhaust headers, which allegedly 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. Pictured in Assembly Diagrams section below.
Flowtech 50363FLT - https://amzn.to/3o7fkfG
stainless options - you will have to do a search for a dual 2.5" offset outlets on opposing sides 3" offset inlet (just like the Flowtech above) - Summit Stainless Mufflers

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) - https://amzn.to/3O5Cy0k
180° bend 3" diameter (1x) - must be VERY TIGHT bend radius, likely needed custom weld job. FieroRog may also offer this exhaust pipe bend. You will have to cut and re-weld this at a sharper angle - https://amzn.to/3od5dpz
90° bend 2.5" diameter (2x) - https://amzn.to/3yJPKlV
Straight 2.5" diameter, 1 ft (1x) - https://amzn.to/3uSvrS3
2.5" diameter generic exhaust hanger U-bolts (2x) - could use the stock Fiero rubber exhaust hangers to hang these from - https://amzn.to/3s6ygNA
2.5" diameter Exhaust Tips (2x) - Re-used stock Fiero exhaust tips

-------------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 Video
DAYCO/Continental 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
NOTE: Instead of fabricating a retainer bracket, some choose to tap the coolant hole in the lower intake manifold with threads and put a pipe fitting in. I do not recommend as the hole is undersized for the proper sized tap and would ideally be honed out/machined larger before a proper tap can fit.

Barb For above heater hose to stock Fiero heater hose, 5/8-5/8" (1x):
https://amzn.to/3z7kVck

Aluminum Heater Hose Elbow (1x) - These CRACK if they are plastic! REPLACE when doing engine!!!:
Dorman 47065HP - https://amzn.to/3PsTTl1

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 - only to fill coolant. need to plug the nipple.(1x):
Moroso 63745 - https://amzn.to/3IFDgjM

Radiator cap (1x):
Stant Products 10203 - https://amzn.to/3PsC99i

1" frost plug for plugging water pump hole that used to go to the alternator coolant circuit (1x):
Dorman 570-005 - https://amzn.to/3D8vzBw

180° Thermostat failsafe (1x):
MotoRad 7239-180 - https://amzn.to/3PmOrA6

Coolant/Antifreeze (14qt, 4x 1 gallon) - you can really use whatever you want, as long as you don't mix two colors and flush the system properly:
PRESTONE AF2000 universal antifreeze - https://amzn.to/3AkE5M1

Optional: 3/4" to 3/4" barb ball valve shutoff (1x):
Sharkbite 22462LFA - https://amzn.to/3tyZcGy

Optional: Bigger radiator install, may want for build 2 (1x):
Champion 166-CC828 - https://amzn.to/3bIcprb
Radiator install video - https://www.youtube.com/wat...QL4pabfi1DyA&index=1

-----------------SENSORS/HARNESS/COMPUTER (ECU/PCM)-----------------
NOTE: See Harness section for more detailed instructions, diagrams, and parts - https://www.fiero.nl/forum/...HTML/139530.html#p11

3-pin Oil pressure sender (1x) - comes from a 1988 Fiero V6:
WVE by NTK 1S6635 - https://amzn.to/3UBr2Ol

3-pin Oil pressure sender connector (1x) - if building your own harness:
ACDELCO PT121 - https://amzn.to/3UZS5Te

2-Bar MAP sensor (1x) - ONLY if you bought a 3800 NA block/harness and you don't already have a 2-bar MAP sensor:
Standard Motor Products AS4 MAP Sensor - https://amzn.to/3Oh48JU

In-line 20A fuse holders (2x) - if building your own harness:
Littlefuse 0FHA0030XP - https://amzn.to/3Gn3nNj

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 1998-2002 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----------------------
Transmission line fitting, transmission side (2x) - 1/4" NPS Male to 5/8-18 Inverted Flare
Dorman 800-754 - https://amzn.to/3EAzg3I
NOTE: I can not remember if these came on the transmission already or not. Check your transmission line fittings first.

Trans line fitting adapter (2x) - 5/8"-18 MALE INVERTED FLARE TO UNF MALE -6AN:
Vibrant Performance 16436 - https://amzn.to/3EEcBnd
Note: Instead of the 2 above fittings, you may be able to find an adapter to go directly from 1/4" NPS Male to -6 AN male, and then use a -6AN elbow below.

Trans line elbow (2x): - -6AN to 3/8" 90 deg barb to mate with above fitting :
Fragola 209006-BL - https://amzn.to/3geLBBg

Transmission Hose to Fiero Hose (1x) - Replaces steel transmission lines:
Derale 13016 - https://amzn.to/3o3QH3r

Transmission oil filter (1x):
ACDELCO TF304 - https://amzn.to/3tUotLL

Transmission Oil Pan Gasket (1x) - if above filter does not come with one - AVOID CORK GASKETS!:
ACDELCO 24204624 - https://amzn.to/3EyUNsv

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
Amazon - https://amzn.to/3RGhvVi

Transmission Fluid:
7.4 quarts (maintenance) or 10 quarts (total drain) Dexron III Transmission fluid (2x-3x gallons):
VALVOLINE 773636 - https://amzn.to/3V7yUHn

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

Optional: OBD2 Bluetooth Scanner to be used with free phone app - REALLY helps with troubleshooting -
OBDLink MX+ - https://amzn.to/3nZm7It

Valve cover seals (2x):
MAHLE VS50332 - https://amzn.to/3uW0M6m

Accessory Belt Tensioner Pulley from a 1995 Ford Taurus, if using FieroRog's engine mount brakcets (1x):
DORMAN 419202 https://www.rockauto.com/en...belt+tensioner,11659

Supercharger Tensioner Pulley - comes on a 3800sc GTP unless coil pack bracket is missing (1x):
Gates 38365 - https://amzn.to/3EDUAoX

Accessory Belt - 81.5", 6 ribs (1x):
Gates K060815 - https://amzn.to/3OeneQT

Oil 5W30 high mileage (4.5 quarts):
VALVOLINE 881163 - https://amzn.to/3gddSZ0

Magnetic Oil Drain Plug for extra safety factor to pick up metal shavings in the oil (1x):
Dorman 090091 (65372) - https://amzn.to/3Ajkjk8

AC/DRYER if doing A/C (1x):
Four Seasons 33181 - https://amzn.to/3gauHUf

Custom A/C hose made by a radiator shop (1x) - I had a radiator shop make one. You need an R12 style port for the AC Pressure sensor. I cut one off of a 2001 Pontiac Bonneville AC hose and had it braised onto the Fiero side. I also used the 2001 GTP compressor side AC hose fitting for the compressor that came with the GTP. 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

NOTE: If you do want to utilize the AC system, you will need to charge it with R134a or newer refrigerant. The Fiero did not come equipped with this, so you will need to swap all your AC System O-Rings with Hydrogenated Nitrile (HNBR), and your orifice tube:
AC Seals (3800 side) (1x)
Four Seasons 26728 - https://amzn.to/3cfKT4c
AC Seals (Fiero Side) (1x)
Four Seasons 26735 - https://amzn.to/3uPXMsd

AC Orifice Tube - YOU MAY NEED DIFFERENT ONE DEPENDING ON YOUR CLIMATE (1x)
FOUR SEASONS 38902 - Under 105 Degrees - https://amzn.to/3V3WRz7
FOUR SEASONS 38904 - Over 105 Degrees - https://amzn.to/3XaMKKQ

Knock Sensor (2x) - a good idea to replace these, especially if they wiggle:
Delphi AS10009 - https://amzn.to/3Gkjzif

Longer 45" battery ground cable (1x):
Schumacher BAF-445S - https://amzn.to/3EE8R59

ALTERNATOR - You need a year 2000+ alternator for any 3800 car to fit with FieroRog brackets. Below is from a Bonneville.
ACDelco 334-2525 - https://amzn.to/3tzWJeX

Lots and lots of hose clamps of all sizes!!! - https://amzn.to/3zgYdOn

Some sort of engine hoist if removing the transmission, two jacks, and two jack stands for engine removal and installation...

----------------MOUNTING AND BRACKETS-----------------
I use FieroRog brackets. There are alternatives (like West Coast Fiero), but many parts from this build thread including axles may not fit up if you use alternatives. Order from FieroRog/Roger here //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:
If using a manual Fiero transmission, get these from FieroRog:
-Custom Flexplate / flywheel (1x)
-Flexplate bolts (8x) (yields) - GM 24505092 (call FieroRog to verify) NOTE: DIFFERENT THAN AUTOMATIC TRANSMISSION FLYWHEEL BOLTS!
-manual transmission mounts instead of automatic transmission mounts above (2x)
-Clutch bolts - GM 24571667
Get in touch with FieroRog here - https://www.fiero.nl/forum/Forum4/HTML/068855.html

Fiero engine and transmission mounts to frame - I would highly recommend NOT re-using the stock Fiero engine and transmission mounts.
WARNING: IF YOU DELETE THE BALANCE SHAFT, THESE POLY MOUNTS WILL MAKE THE CAR VERY SHAKY! INSTEAD CONSIDER RUBBER!
Poly:
Transmission Mounts - bolts to FieroRog's 3800 bracket (1x) - http://rodneydickman.com/pr...o.php?products_id=35
Engine Cradle Mount - bolts to FieroRog's 3800 bracket (1x) - http://rodneydickman.com/pr...o.php?products_id=73
NOTE: I do NOT recommend the poly mount from Rodney if you remove your balance shaft. Instead consider the Fiero Store rubber - https://www.fierostore.com/...20%20%20%20AFTERMARK
Adjustable 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 ARE FOR 4T65E-HD ONLY. 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.
https://www.youtube.com/watch?v=D_VKktIEaTE

3800 Fiero driver's side axle - Use a Stock automatic Fiero driver's side (rear left automatic trans driver's side) axle. (1x):
GSP NCV10509 - https://amzn.to/3ECVX7i

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
NOTE: YOU MUST USE JUNKYARD OEM PARTS/DONOR CAR FOR THE MOST EASE. OTHER MANUFACTURERS PARTS WILL NOT FIT TOGETHER!

Axle Boot Inner with grease (1x):
Dorman 614-004 - https://amzn.to/3geH1TA

Generic Axle CV Boot Clamps
https://amzn.to/3aGWtVM

Axle CV boot clamp tool
https://amzn.to/3z4SkEo

------------------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 External Transmission Range Gear Selector Neutral Safety Switch / Range Sensor Switch (1x):
Standard Motor Products NS122 - https://amzn.to/3AUnxLK

GTP Range Sensor Switch Connector for above:
Standard Motor Products S795 - https://amzn.to/3uRdWSk

GTP/Regal Steel Oil Pan (1x):
SKP SK264124 - https://amzn.to/3c78cgy

GTP Oil Pan Gasket (1x) (needs trimming 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 trimming this gasket):
FEL-PRO OS 30767R - https://amzn.to/3o9cSoU

GTP/Regal oil filter bracket (1x):
GM 12569219 ; 24508441 - https://amzn.to/3PzZqGf
More info at http://www.gmtuners.com/swap/3800.htm


GTP Oil Pan Pickup Tube/Gasket (could instead cut down oil pan gasket to fit the other style pickup tube) (1x):
MELLING 256S - https://amzn.to/3gh34J4

Note: I could not make any bracket BUT a GTP/Regal style work with the FieroRog brackets. Find one in a junkyard.
Note: If you install a 5% overdrive balancer pulley, this will not work. You will need the oil filter spacer to make it work. https://zzperformance.com/products/oil-neck-spacer

Oil Filter Housing Gasket (1x):
ACDELCO 25534742 - https://amzn.to/3ObrEGk

GTP/Regal angled coil pack bracket (1x) - cut engine mount dogbone off, shown here - https://youtu.be/mmfWbG37Bys?t=178 . Get at junkyard including the GTP Tensioner pulley on coil pack bracket:
GM 24507211 ; 24504360 - https://www.gmpartsbin.com/...l?partner=googlebase

GTP/Regal torque converter (JTFM) might be OK, or a higher stall (JZFM or JXFM) Converter. JXFM was highest stall. Works great in a 3800 Fiero. (did NOT come on supercharged 3800s) - (1x):
DACCO B21JXFM - https://amzn.to/3tUn4ot
NOTE: See here for stalls - https://atracom.blob.core.w...al/2013/2013-049.pdf
NOTE: DO NOT PUT A JSFM TORQUE CONVERTER IN A FIERO FROM A BIG CAR LIKE A BONNEVILLE; IT IDLES AROUND 20MPH.

GTP 3-pin Temperature sender & wire (1x):
ACDELCO 213-815 - https://amzn.to/3eJGKav

-----------------------------------------PARTS THAT WEAR OUT ON A 3800SC-------------------------------------

NOTE: These are highly recommended to change out because they do wear. To reduce redundancy, most of these parts are already listed elsewhere in Build 1 or 2.
CLICK HERE TO VIEW PARTS THAT WEAR OUT ON A 3800SC ON AMAZON
* = especially susceptible on a 3800:

*Timing chain tensioner (deleted in build 2) - https://amzn.to/3AogJFn
*STOCK Timing chain (build 2 includes upgraded timing chain) - https://amzn.to/3SD93GI
*Supercharger Coupler - https://zzperformance.com/p...supercharger-coupler
*4t65e-hd shift solenoids
Fuel Injector O-rings

Listed in build 1 (above):
*Coolant Elbows
*Flywheel Bolts/Flexplate Bolts (Yield)
*Valve Cover Seals
Transmission Fluid
Transmission Fluid Filter
Transmission Oil Pan Gasket
Spark Plugs / Wires
Oil
Oil Filter
Supercharger Oil
Knock Sensors

Listed in build 2 (below):
*Intake Manifold Gasket Set
*Required for Intake Manifold: Supercharger Gasket
Head Gasket
*Required for head gasket: Head Bolts (Yield)
*Camshaft Bolt (Yield)
*Crankshaft / Balancer Bolt (Yield)
*Rocker Bolts (Yield)
*Timing chain (replaced with double roller with no tensioner in build 2)
Required for Timing Chain: Front Cover Gasket
Water Pump
Required for Water Pump: Water Pump Gasket
Rear Main Crankshaft Seal
Front Main Crankshaft Seal

------------------
FieroAustin
1988 GT 3800SC Series III 2.8" Pulley
Fiero/3800sc Swap Parts/Tools at https://amzn.to/3hNViaa
Youtube https://www.youtube.com/Fie...n?sub_confirmation=1
Facebook https://www.facebook.com/FieroAustin/
3800sc Swap Instructions //www.fiero.nl/forum/Forum2/HTML/139530.html
eBay affiliate https://ebay.us/4gTj2A
Join Youtube Membership https://www.youtube.com/FieroAustin/join
Donate https://www.paypal.com/dona...VSKTJ&no_recurring=0

[This message has been edited by AustinH (edited 12-18-2022).]

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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 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
THIS BUILD IS IN ADDITION TO BUILD 1, MEANING YOU MUST ORDER ALL OF BUILD 1 PARTS TOO, UNLESS SPECIFICALLY MARKED OTHERWISE.

CLICK TO VIEW MOST OF BUILD 2 ON AMAZON

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 for use with the XPZ camshaft, by cutting down valve guides by 0.0410" (0.050" to be safe) with 1.6 rockers or 0.0587" (0.060" to be safe) with 1.65 rockers. More information in the Assembly videos section

NOTE: THIS BUILD IS TO MAXIMIZE THE POWER OF YOUR 3800 AT A HIGH RPM WITH THE ZZP XPZ CAMSHAFT. IF YOU WANT MORE COMFORTABLE A DAILY DRIVER, CONSIDER DOING YOUR OWN RESEARCH INTO A LOWER RPM CAMSHAFT/VALVETRAIN AND AVOID A TIMING CHAIN/BALANCE SHAFT REMOVAL. MAYBE ONLY PUT 1.9 RATIO ROCKERS ON, OR TRY A ZZP XP-RPM CAMSHAFT FOR GOOD PERFORMANCE GAINS WITH MINIMAL EFFORT.

NOTE: THIS BUILD IS MATCHED AND BALANCED EXCLUSIVELY FOR A ZZP XPZ CAMSHAFT. NOTES INDICATE WHAT PARTS ARE REQUIRED FOR THIS CAMSHAFT.

NOTE: THIS BUILD ASSUMES YOU DELETE the balance shaft/tensioner spring/balance shaft gear (to fit the double roller timing chain)

Note: I believe that I spent ~$4500 total on this build, and ~$7,000 including the parts from build 1. These is NOT A PRICING GUIDE; I encourage you to shop around for the best deals on each part. RockAuto is usually the best place to go.

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://www.summitracing.com/parts/ado-12603871
You will need to find one at a junkyard.
https://www.car-part .com/cg...serIntSelect=1145748

Series III/GENV Supercharger Upper Intake Manifold Plenum Gasket Set (1x) - upgrading from Series II / Gen 3:
https://zzperformance.com/p..._sid=ecdfe73d9&_ss=r
Note: The ZZP Phenolic Spacer comes with 2 gaskets included, so this is not necessary if you order that.

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):
JBWeld Cold Weld Steel Reinforced Epoxy - https://amzn.to/3z4WJqU

LQ4 MAF from a 2000 6.0L Chevrolet Silverado 2500 (1x):
Delphi AF10043 - https://amzn.to/3zcrday

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
or for cheaper:
https://ebay.us/hKl1bh

Gasket Maker for throttle body adapter (1x):
Permatex Ultra Black RTV Gasket Maker 82180 - https://amzn.to/3Pe4lx6
Note: You can get a different form factor of this, such as one that fits in a caulk gun for ease.

Intake Manifold Gasket Set (1x):
ACDelco 89017825 - https://amzn.to/3OczYpd
Note: DO NOT CHEAP OUT ON THIS. GET GENUINE ACDELCO. FEL-PRO's LEAKED WHEN I TRIED THEM. YOU GET WHAT YOU PAY FOR!

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 or maybe Ace Hardware.
See supercharger upgrade instructions in Assembly Diagrams section - https://www.fiero.nl/forum/.../HTML/139530.html#p9

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. Instead of a smaller than 2.8" pulley, consider an overdrive balancer pulley.:
SmoothFlow Pulleys - http://www.smoothflowpulleys.com/3800_MPS.html

One 1/2" freeze plug (1x) - use with JB Weld for EVAP Delete shown here - https://youtu.be/dT3Hwe8S4X...ZQL4pabfi1DyA&t=1159
Dorman 557-001 - https://amzn.to/3PvT3UD

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://amzn.to/3AX63ia

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

MAF/IAT Connector Adapter for Northstar Throttle Body (Optional depending on setup and harness. James Brown can probably put the correct connector on depending on your needs. Length needs to be extended on some applications, especially LQ4 MAF/IAT and Northstar Throttle Body) (1x):
https://zzperformance.com/p...riant=12623053619311

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


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, but it will look messy. If it is not around $50 per injector, it is probably a fake.
Series 2 - Siemens DEKA EV1 80# Injectors - ‎110324 / FI-114992 - https://amzn.to/3RKpuke
OR
Series 3 - Siemens DEKA EV6 80# Injectors - 109991 / FI114991 - https://amzn.to/3PvTIp5

Optional: Alternative recommended fuel rails instead of custom or stock (1x):
Aeromotive 14131 - https://amzn.to/3IK7OAR
Note: If you do buy this, you will need to use the same push-lok hose and push-lok fittings from build 1

Optional (if you get custom fuel rails above) - Fuel Pressure Regulator and gauge (1x) - for custom fuel rail setup:
Evil Energy KT01568BA-AMZ1 - https://amzn.to/3zcg5KI
Note: I have not used or tested this but it has a lot more fittings included than the one I have.
Note: You will likely need more fittings, elbows, and adapters depending on your fuel rail setup. Diagrams in the Assembly Diagram section.

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

Optional: This is MY CUSTOM FUEL RAIL SETUP. I had a friend who is a machinist make rails out of these. These need to be drilled for injector holes and tapped for fittings on either end. Injector holes must be countersunk at an ANGLE:
https://rossmachineracing.c...-fuel-rail-extrusion
1 - Push-Lok Hose Fragola 871006 10' (1x)- https://amzn.to/3OcT4Mb DUPLICATES BUILD 1
2 - Fuel Pressure Regulator AFPR1, 400lph, 35-70psi (1x) - https://amzn.to/3zcg5KI
NOTE: This regulator DUPLICATES some fittings listed here.
3 - Fuel Filter 16mm by 1.5 (M16-1.5) female inlet/outlet Wix 33481 (1x) - https://amzn.to/3RGOkkH DUPLICATES BUILD 1
4 - -6 AN Male to 16mm by 1.5 (M16-1.5) Earl's 991955ERL (1x) - https://amzn.to/3z6ovn1 DUPLICATES BUILD 1
5 - -6 AN Male to 14mm by 1.5 (M16-1.5) Earl's 991954ERL (1x) - https://amzn.to/3RDgnl5 DUPLICATES BUILD 1
6 - -6 AN Female to Push-Lite Hose Fragola 200106 (4x) - https://amzn.to/3PaVRqw DUPLICATES BUILD 1
7 - -6 AN Male to -6 AN ORB Fragola 495100 (4x) - https://amzn.to/3EUh1pT
8 - -6 AN 37° JIC Male, -6 ORB Male 90° Elbow 6801-06-06 (1x) - https://amzn.to/3grlY04
9 - -6 AN 37° JIC Female, -6 ORB Male Swivel 6402-06-06 (1x) - https://amzn.to/3gxmHwY
10 - Ross Machining -6 extrusion 1' aluminum (2x) - https://rossmachineracing.c...-fuel-rail-extrusion
NOTE: The injector counterbores must be drilled at proper spacing AND ANGLE for the injectors. I do not have the dimensions for fuel injector counterbores or spacing.
NOTE: You must tap the ends of the fuel rails with 9/16-18 thread to fit the -6 ORB fitting (#7,8,9 above).
11 - -6 AN Female to 45° to Push-Lok Hose barb Fragola 204506 - https://amzn.to/3hZxgJj
12 - Right-angle mounting bracket to original 1/4" stud holes. Custom made to fit.
NOTE: You must drill and tap holes into sides of fuel rails in order to mount these brackets.


-------------------------------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 - https://amzn.to/3yPBKXM REPLACES SPARK PLUGS BUILD 1

-----------------------------Exhaust(ENTIRELY REPLACES BUILD 1 EXHAUST)-----------------------------
NOTE: This exhaust setup is pictured in the Assembly Diagrams section below - https://www.fiero.nl/forum/.../HTML/139530.html#p9
NOTE: The exhaust I have is not equal length. It does not sound like a professional exhaust, but it is practically straight-piped. The muffler is VERY loud, extra bottle mufflers do help it.

90 Degree 2.5" Mandrel Bent Stainless Steel Exhaust Bends (2x):
SUM-622118 - https://amzn.to/3yJPKlV DUPLICATES BUILD 1

Muffler (1x) - REQUIRES CUTTING OUT BOTTOM SECTION OF TRUNK TO FIT!:
Vibrant 10632 - https://amzn.to/3GnHHkg

OPTIONAL Mini bottle Mufflers (2x)
TOTALFLOW 6644 - https://amzn.to/3uObGeu
NOTE: Get the 4" long muffler with 2.5" dia. 7" long would be very difficult to work with.

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://ebay.us/jebzk1

Exhaust wrap Titanium (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://amzn.to/3uMFmbK

Stainless Tie bands for exhaust wrap (~30x):
https://amzn.to/3ARRBb0

2" exhaust clamp for exhaust headers crossover pipe (2x):
https://amzn.to/3IC1Zp8

3" v-band flange and clamp (1x) - https://amzn.to/3cfGFtB

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

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

OPTIONAL but HIGHLY RECOMMENDED (REQUIRES TUNING AND CUSTOM WIRING) - Air to Fuel Ratio Gauge / O2 Sensor (1x):
AEM 30-4110 - https://amzn.to/3z7zqww

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

Re-using stock valves and porting Series III 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 build 2 video section on custom porting heads. NOTE: EXCLUSIVELY MATCHED FOR XPZ CAMSHAFT

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 0.040" quench + 0.025" out of hole = 0.065" 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): NOTE: EXCLUSIVELY MATCHED FOR XPZ CAMSHAFT. ANY HIGHER RATIO ROCKERS ARE NOT EVER RECOMMENDED FOR NON-FACTORY CAMSHAFTS.
ZZP ZZ-165RA - https://zzperformance.com/p...zzp-1-65-rocker-arms

Valve Springs (12x) - 130# @ 0.050” installed height valve springs, 0.600" lift max NOTE: EXCLUSIVELY MATCHED FOR XPZ CAMSHAFT. COULD GO HIGHER BUT THIS WEARS OUT PARTS FASTER.
PAC 1218 - comes with 16 - https://amzn.to/3V4SrYG

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 NOTE: EXCLUSIVELY MATCHED FOR XPZ CAMSHAFT
GM 10166344 - https://amzn.to/3giV76h

Intake Valve Stem Seals (6x):
MAHLE SS45910 - https://amzn.to/3PEdAa9

Exhaust Valve Stem Seals (6x):
MAHLE SS45911 - https://amzn.to/3OqLf5s

LS7 Hydraulic Roller Lifters (12x): NOTE: EXCLUSIVELY MATCHED FOR XPZ CAMSHAFT
INTENSE Racing GMH-VVL - https://amzn.to/3OjDtdD

Head Studs (1x) - factory head bolts YIELD and need replaced:
APR 193-4001 - https://amzn.to/3v2lAcu
Instructions for installing ARP Head Studs - https://tech.arp-bolts.com/...uctions/193-4001.pdf

HEAD BOLT SEALANT (1x) - DO NOT USE ARP THREAD SEALANT!
Permatex Ultra Black RTV Gasket Maker 82180 - https://amzn.to/3Pe4lx6 Duplicated above for throttle body adapter
Note: Be sure not to get ANY on the head deck surface. Clean it off with a rag sprayed with brake clean if you do.
Note: You can get a different form factor of this, such as one that fits in a caulk gun for ease.
Here is my how-to video on sealing the head bolts - https://youtu.be/z4XB0vyGkz...uvZQL4pabfi1DyA&t=26

ARP 7/16"-14 Thread Chaser (1x) - do NOT use a tap to clean out your head bolt threads:
ARP 911-0004 - https://amzn.to/3cbLnZe

High Strength Threadlocker for Rocker Bolts and plastic Lifter Retainers (1x):
Loctite 272 - https://amzn.to/3O9yKep

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, LIFTERS, AND HEAD GASKET SETUP! Detailed in video section - https://www.fiero.nl/forum/...HTML/139530.html#p12

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 - https://www.fiero.nl/forum/...HTML/139530.html#p12

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

Harmonic Balancer Puller; you can rent these from an auto parts store for free instead (1x) -
ZZP https://zzperformance.com/p...3800-balancer-puller

ZZP XPZ Camshaft (1x): NOTE: EXCLUSIVELY MATCHED FOR XPZ CAMSHAFT
XPZ-1 - https://zzperformance.com/p...ts/supercharged-cams

Camshaft Installation/Assembly Lube (1x):
GM 12345501 - https://amzn.to/3IT2trj

Aluminum Water Pump Gasket (1x):
Fel-Pro 35804 - https://amzn.to/3copQfO

Water Pump (1x):
ACDELCO 251-718 - https://amzn.to/3CCHnKS

Double Roller Rollmaster Timing Chain Set (1x) - Needed for 130# valve springs: NOTE: EXCLUSIVELY MATCHED FOR XPZ CAMSHAFT. IF NOT USING A DOUBLE ROLLER/DELETING BALANCE SHAFT/DELETING TENSIONER, THIS WOULD BE A GOOD IDEA TO REPLACE ANYWAYS (WITH A SINGLE ROLLER) ALONG WITH TIMING CHAIN SPRING TENSIONER AS THESE WEAR OUT. THIS DOUBLE ROLLER REQUIRES BALANCE SHAFT/TENSIONER/GEAR DELETION.
Rollmaster CS6150 - https://zzperformance.com/p...riant=12623144747119

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) - ONLY IF CHANGING CAMSHAFT - yields:
INTENSE GMH-BCM - http://intense-racing.com/M...Product_Code=GMH-BCM

Crankshaft / Harmonic balancer Bolt (1x) - yields, required for removing the balancer/front cover/timing chain/camshaft/balance shaft:
GM GENUINE 24504736 - https://amzn.to/3aOyfsz

Balance shaft delete - use a chrysler 440 camshaft bearing to seal oil hole (1x) - POUND THIS IN TO BLOCK OIL PASSAGE LEFT OPEN BY REMOVING BALANCE SHAFT, WITH OILING HOLES ON OPPOSITE SIDES SO ITS PLUGGED. DETAILED IN VIDEOS BELOW - https://youtu.be/17L58Zk-VTo?t=333
ENGINETECH CC476 - https://www.rockauto.com/en...amshaft+bearing,5208

Crankshaft Seal (1x) - REAR:
ACDELCO 12582320 - https://amzn.to/3OgnHQC

Crankshaft Seal (1x) - FRONT:
ACDELCO 12582313 - https://amzn.to/3AWOvlV

Engine Break-In Additive Oil (2x):
Comp Cams 159 - https://amzn.to/3RC9v7q

Camshaft Bearings:
NOTE: It is very difficult to replace camshaft bearings without completely disassembling the bottom-end (not detailed in this build). Some people choose not to change them.
MAHLE / CLEVITE SH1812S - https://amzn.to/3PvD2hq

Optional - 5% overdrive harmonic balancer (equal to taking a 2.8" pulley down to a 2.66" pulley to overdrive the supercharger even more). (1x):
5% overdrive balancer/AC pulley bypass install video - https://www.youtube.com/wat...QL4pabfi1DyA&index=1
NOTE: Need a SPECIALIZED harmonic balancer puller and a new crankshaft/harmonic balancer bolt above to remove and reinstall.
DAYCO PBO81461SC5 - https://amzn.to/3ogcLb7
NOTE: You will need a ZZP oil neck spacer bracket - https://zzperformance.com/products/oil-neck-spacer
NOTE: I only get a GTP oil filter bracket to work with this.

Optional: If you install the above pulley, you need GATES 8-rib plastic smooth pulleys (2x)
Gates 38023 - https://amzn.to/3Bwo86i

---------------------------------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. Modification of this transmission is not highly detailed in this build, but there is a video covering it in the video section.

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):
GM Genuine Parts 19258573 - https://amzn.to/3uXbVUK
Note: Could get more expensive kits with clutch packs if you choose to change those. No instructions for that here.

Flywheel Bolts (8x) - yields - Duplicated in Build 1:
GM # 24501365 - https://www.gmpartsdirect.c...s/gm-s-bolt-24501365
Amazon - https://amzn.to/3RGhvVi

Torque Converter (1x) - Duplicated in Build 1:
DAACO B21JXFM - https://amzn.to/3tUn4ot

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
Note: This LSD works great but his website does not always work. Contact him directly: https://www.facebook.com/jeff.ianitello
Alternative (untested by me) - https://phantomgrip.com/sho...-venture-4t65e-hd-2/

Optional: 3.29 Gear Set, 7/8" chain and sprockets (1x)
ZZ-GRCK-3.29 - https://zzperformance.com/p...ratio-conversion-kit
Note: I asked around about this gear set and it does not necessarily improve quarter mile times depending on your setup. It will increase your engine RPM to maintain the same speed as before, so cruising on the highway might be unpleasant.
------------------
FieroAustin
1988 GT 3800SC Series III 2.8" Pulley
Fiero/3800sc Swap Parts/Tools at https://amzn.to/3hNViaa
Youtube https://www.youtube.com/Fie...n?sub_confirmation=1
Facebook https://www.facebook.com/FieroAustin/
3800sc Swap Instructions //www.fiero.nl/forum/Forum2/HTML/139530.html
eBay affiliate https://ebay.us/4gTj2A
Join Youtube Membership https://www.youtube.com/FieroAustin/join
Donate https://www.paypal.com/dona...VSKTJ&no_recurring=0

[This message has been edited by AustinH (edited 12-18-2022).]

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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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Report this Post12-24-2017 12:03 PM Click Here to See the Profile for 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 build 1. New diagrams below in this post.


-------------------------------------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 3 Supercharger and hose routings:


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:


Crankshaft and Camshaft Timing Gear TDC Alignment:


----------------------FUEL RAIL SETUP OPTIONS-------------------
SEE BUILD 2 FUEL SECTION FOR PARTS AND DIAGRAM OF MY SETUP
NOTE: This assumes you get rid of stock fuel rails and run something similar to the Aeromotive fuel rail and the Evil Energy Fuel Pressure Regulator
NOTE: I recommend setup #2, but the routings would be quite complicated in the engine bay. My setup (bottom) is a very simply routed return-style, however it may not be the most effective. I do not recommend returnless, or #1 or #3 that dead-head one rail.


----------------------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.


Here is the same exahust with the extra TOTALFLOW Bottle Mufflers and AEM O2 sensor port welded on:


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

Check out 4t65e-HD upgrades. These guys will also rebuild your 4t65 transmission for you:
https://tripleedgeperformance.com/online-store

Good 4t65 disassembly video here:


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

------------------
FieroAustin
1988 GT 3800SC Series III 2.8" Pulley
Fiero/3800sc Swap Parts/Tools at https://amzn.to/3hNViaa
Youtube https://www.youtube.com/Fie...n?sub_confirmation=1
Facebook https://www.facebook.com/FieroAustin/
3800sc Swap Instructions //www.fiero.nl/forum/Forum2/HTML/139530.html
eBay affiliate https://ebay.us/4gTj2A
Join Youtube Membership https://www.youtube.com/FieroAustin/join
Donate https://www.paypal.com/dona...VSKTJ&no_recurring=0

[This message has been edited by AustinH (edited 12-18-2022).]

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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 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 guys:
James L. Brown - https://www.facebook.com/Fiero3800harnesses
Dan McIlmoyle - https://www.facebook.com/danny.mcilmoyle
West Coast Fiero (expensive!) - https://westcoastfiero.com/...r-engine-conversions

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--------------------------
See build 1 harness section for a parts list - https://www.fiero.nl/forum/.../HTML/139530.html#p5
NOTE: For sensors and some wire connector part #s, refer to build 1.

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.

Go to http://www.alldatadiy.com/ and buy a subscription to your donor car's information. You can find a PCM pinout diagram of PCM Connectors C1 (Blue) and C2 (Clear) that will be critical in aiding you with building the harness. Below is an example of the PCM pinout diagram of a 2001 Bonneville SSEi. DO NOT USE THIS DIAGRAM IF YOU DID NOT BUY AN ENGINE FROM A 2001 BONNEVILLE SSEi; THEY WILL VARY SLIGHTLY!




Many great wiring harness pin out charts already exist at GMTuners: http://www.gmtuners.com/files/index.htm
Consult gmtuners for pinout list (this guide BELOW is specifically for a 1998-2002 GTP engine and transmission harness):
http://www.gmtuners.com/fil...o_L67_PCM_wiring.pdf




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


C203 and C500 connector pinouts, courtesy of http://www.gmtuners.com/files/index.htm


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


External Transmission Range Selector Switch for a 4t60/4t65/4t65e-hd transmission:
Note: You will need to purchase one of these and put it on your gear selector if you did not buy a GTP. You may also need the connector for it, available at Rockauto. See above build 1 Parts List.


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:


Here is a homemade spliced harness:


Here is my engine bay with James Brown's harness

------------------
FieroAustin
1988 GT 3800SC Series III 2.8" Pulley
Fiero/3800sc Swap Parts/Tools at https://amzn.to/3hNViaa
Youtube https://www.youtube.com/Fie...n?sub_confirmation=1
Facebook https://www.facebook.com/FieroAustin/
3800sc Swap Instructions //www.fiero.nl/forum/Forum2/HTML/139530.html
eBay affiliate https://ebay.us/4gTj2A
Join Youtube Membership https://www.youtube.com/FieroAustin/join
Donate https://www.paypal.com/dona...VSKTJ&no_recurring=0

[This message has been edited by AustinH (edited 12-18-2022).]

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AustinH
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Report this Post03-01-2018 11:05 AM Click Here to See the Profile for AustinHSend a Private Message to AustinHEdit/Delete MessageReply w/QuoteDirect Link to This Post
Disassembly, Reassembly and Final Fiero Installation Videos

All videos available in this playlist here - https://www.youtube.com/pla...IM_4I2qJnkff2RlPWB_O

----------------------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:


Boost bypass valve setup:


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


Transmission Line hookups and POSI diff (found in build 2 only)


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:


Optional Bigger Radiator Install Video:


----------------------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.).:


Installing a Phenolic Spacer instead of Intercooler:


Removing and Reinstalling harmonic balancer crankshaft pulley:


Installing optional 5% overdrive harmonic balancer, crankshaft front cover oil seal, oil spacer bracket, AC compressor bypass pulley, and lightweight pulley system:


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:


ZZP How to install a camshaft and double roller timing chain:


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


Sealing Head Bolts:


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 HIGH TEMP NON-HARDENING RTV SILOCONE.


HOW I MEASURED PUSHROD LENGTH WITH A PUSHROD LENGTH CHECKER (This only applies to engines with non-adjustable rocker arms):
Buy the pushrod length checker here - https://zzperformance.com/p..._sid=b9d18327f&_ss=r
1 - have your heads and head gasket on and torqued to spec, and valves/springs, camshaft and lifters installed
2 - put the length checker on a valve lifter through the hole in the head.
3 - Rotate the crankshaft with a 24mm socket and wrench, while pushing the pushrod length checker firmly down firmly to ensure that the lifter is making contact with the camshaft lobe, until the lifter is at its lowest point (when it is contacting the base circle on the camshaft).
4 - Bolt on the rocker arm and its pedestal until it is snug. do not over torque.
5 - unscrew the length checker until it makes firm contact with the rocker arm and has no play at all in it. make sure it is seated in the rocker arm cup and not binding on something else!
6 - take the rocker arm off and take the pushrod length checker out. measure the pushrod length checker on a caliper from end to end, careful not to twist it and change its length.
7 - repeat steps 2-6 several times on both heads for both intake valves and exhaust valves. Record each value and take and average for both intake and exhaust. EXHAUST AND INTAKE CAN BE DIFFERENT, DEPENDING ON YOUR CAMSHAFT!!!
8 - add the half of the lifter "squish," or the amount that the lifter preloads to each of your measured lengths. I am not sure what half of your squish/preload length is, but it will probably be between .025" and .075". Call the manufacturer for info or look up the specs.
9 - find a pushrod that is closest in length to your intake and exhaust pushrod measurement calculation and order them. I would advise getting a pushrod of no different length within 0.010" from your measurements if you can find one. As far as pushrod diameter goes, that is up to you. I run two different ones: One is a 3/8" thickness and the other is a 11/32" thickness, because that is what sizes i could find the right lengths for. You want a good balance of strength and lightweight pushrods, depending on how aggressive your camshaft is. You can't go wrong with anything ZZP sells although expensive:
https://zzperformance.com/p.../zzp-custom-pushrods
keep in mind that stock pushrod length is 7.029" if that is closer to your measurements than a 7.000" or a 7.050" pushrod. Do NOT re-use pushrods if you are changing your rockers. If you plan on keeping your stock rockers/pushrods/lifters, make sure to keep them matched to each other and each cylinder, to keep each with its respective wear patterns, and mark which direction the pushrod went. If you change ANY part (cam/lifters/pushrods/rockers), buy all new parts. Stock pushrods are 11/32" thick for a 3800.

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.
NOTE: Assuming you have 1.65 rockers and not the stock 1.6 rockers
1. Machine 0.060" off top of 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", but to be safe this is not accounted for in my calculations.
2. Machine 0.030" off top of 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 0.0247" (or 0.030" to be safe).
3. Redrill and replace valve guides with Bronze oil lite guides (optional)
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.

------------------
FieroAustin
1988 GT 3800SC Series III 2.8" Pulley
Fiero/3800sc Swap Parts/Tools at https://amzn.to/3hNViaa
Youtube https://www.youtube.com/Fie...n?sub_confirmation=1
Facebook https://www.facebook.com/FieroAustin/
3800sc Swap Instructions //www.fiero.nl/forum/Forum2/HTML/139530.html
eBay affiliate https://ebay.us/4gTj2A
Join Youtube Membership https://www.youtube.com/FieroAustin/join
Donate https://www.paypal.com/dona...VSKTJ&no_recurring=0

[This message has been edited by AustinH (edited 12-18-2022).]

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Report this Post03-01-2018 12:24 PM Click Here to See the Profile for AustinHSend a Private Message to AustinHEdit/Delete MessageReply w/QuoteDirect Link to This Post
Other Helpful Fiero Parts While You're At It

-CLICK HERE TO VIEW MY FIERO MODS ON AMAZON

-A Fiero Repair Guide

Replace end links and sway bar bushings

Replace all rear bushings:
POLY 1984-1987 - https://www.fierostore.com/...%20%20%20%20%20BLACK
POLY 1988 - https://www.fierostore.com/...%20%20%20%20%20BLACK
RUBBER Rodney's 1988 rear bushing kit - http://rodneydickman.com/pr....php?products_id=358
How-to video - https://www.youtube.com/wat...4dL8ruvZQL4pabfi1DyA

Camber Bolt: https://amzn.to/3O83vjS

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

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


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


1988 Fiero alignment specs TSB


1988 rear suspension torque specs
https://www.fiero.nl/forum/...130314-2-087857.html

Excellent Fiero brake upgrade video

------------------
FieroAustin
1988 GT 3800SC Series III 2.8" Pulley
Fiero/3800sc Swap Parts/Tools at https://amzn.to/3hNViaa
Youtube https://www.youtube.com/Fie...n?sub_confirmation=1
Facebook https://www.facebook.com/FieroAustin/
3800sc Swap Instructions //www.fiero.nl/forum/Forum2/HTML/139530.html
eBay affiliate https://ebay.us/4gTj2A
Join Youtube Membership https://www.youtube.com/FieroAustin/join
Donate https://www.paypal.com/dona...VSKTJ&no_recurring=0

[This message has been edited by AustinH (edited 01-17-2023).]

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Report this Post03-01-2018 06:41 PM Click Here to See the Profile for AustinHSend a Private Message to AustinHEdit/Delete MessageReply w/QuoteDirect Link to This Post
EXTREMELY useful links:

CLICK HERE TO VIEW MOST OF THESE PARTS ON AMAZON
-A Fiero Repair Guide
-A 3800 Repair Guide
-CLICK TO VIEW MOST OF BUILD 1 ON AMAZON
-PARTS THAT WEAR OUT ON A 3800SC
-CLICK TO VIEW MOST OF BUILD 2 ON AMAZON
-CLICK HERE TO VIEW MY FIERO MODS ON AMAZON

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:
//www.fiero.nl/forum/A...100421-1-053213.html

Fiero Focus tech tips:
http://fierofocus.com/tech_tips.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://tripleedgeperformance.com/

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

Cow S. Patoot Fiero information:
http://www.fieroinfo.com/

Other M90 supercharger specs


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.


Gen III M90 Specs
Delta T

Flow

Power

------------------
FieroAustin
1988 GT 3800SC Series III 2.8" Pulley
Fiero/3800sc Swap Parts/Tools at https://amzn.to/3hNViaa
Youtube https://www.youtube.com/Fie...n?sub_confirmation=1
Facebook https://www.facebook.com/FieroAustin/
3800sc Swap Instructions //www.fiero.nl/forum/Forum2/HTML/139530.html
eBay affiliate https://ebay.us/4gTj2A
Join Youtube Membership https://www.youtube.com/FieroAustin/join
Donate https://www.paypal.com/dona...VSKTJ&no_recurring=0

[This message has been edited by AustinH (edited 12-18-2022).]

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1MohrFiero
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Total ratings: 157
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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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AustinH
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Report this Post04-09-2018 10:09 AM Click Here to See the Profile for AustinHSend a Private Message to AustinHEdit/Delete MessageReply w/QuoteDirect Link to This Post
-------------------------------MY BUILD---------------------------
CLICK HERE TO VIEW MOST OF THESE PARTS ON AMAZON
Here are the extra parts not included above that I also have on my build. NOT NECISSARY FOR THE ENGINE SWAPS!

This video shows in-depth modifications to the 3800 engine from this build thread:


CLICK HERE TO VIEW MOST OF THESE PARTS ON AMAZON
Note: I do run the build 2 list above, with the below in addition:
Balancer 5% Supercharger overdrive 8-rib - https://amzn.to/3QzWBFp
Alternative 10% Underdrive Accessory Belt balancer (not explained in this video) - https://amzn.to/3Bb0r1X
A/C Compressor Bypass Pulley (CHECK FITMENT) - https://amzn.to/3RUQtZA
5% overdrive balancer & A/C Compressor bypass pulley install video - https://www.youtube.com/wat...QL4pabfi1DyA&index=1
ZZP 8-rib pulley set (WITH STEEL PULLEY) - https://zzperformance.com/p...onversion-pulley-set
ZZP Modular Pulley System - https://zzperformance.com/p...odular-pulley-system
Alternate Smoothflow Modular Pulley System (LET HIM KNOW YOU NEED IT MADE SPECIFIC FOR THIS BALANCER - HE NORMALL MAKES PULLEYS WITH TWO EXTRA RIBS ON END INSTEAD OF ONE ON EACH SIDE) - http://smoothflowpulleys.com/3800_MPS.html
Alternate Smoothflow Aluminum 8-rib Pulley Set (If you want to mix and match for lightest setup, you only need the ribbed aluminum pulley from this set. Message him and he will make you a single aluminum ribbed idler, LET HIM KNOW YOU NEED IT MADE SPECIFIC FOR THIS BALANCER - HE NORMALL MAKES PULLEYS WITH TWO EXTRA RIBS ON END INSTEAD OF ONE ON EACH SIDE) - http://smoothflowpulleys.com/8_rib_L67_idlers.html
GATES 8-rib plastic smooth pulleys (If you want to mix and match for lightest setup, you need 2 of these) - https://amzn.to/3Bwo86i
Chin spoiler video - https://www.youtube.com/wat...4dL8ruvZQL4pabfi1DyA
Slim popup headlights (parts in description) - https://www.youtube.com/wat...4dL8ruvZQL4pabfi1DyA
1988 Headlight Rebuild Kit - https://www.fierostore.com/...%20%20PAIR&d=273&p=1
Radiator - Champion 166-CC828 - https://amzn.to/3bIcprb
Radiator install video - https://www.youtube.com/wat...QL4pabfi1DyA&index=1
S10 Brake Booster Upgrade (parts in description) - https://www.youtube.com/wat...4dL8ruvZQL4pabfi1DyA
Stainless steel brake hoses - https://www.fierostore.com/...px?s=56098&d=379&p=1
Windshield Wiper Video (parts in description) - https://www.youtube.com/watch?v=1ga8LR3zO-Q
22" Trico wiper on Drivers' side
20" Trico wiper on Passengers' side
Front Tires - 195/65R15 98H Continental - https://amzn.to/3o9kgRg
Tire Paint Video - https://www.youtube.com/wat...4dL8ruvZQL4pabfi1DyA
Tire Letter paint - https://amzn.to/3PEeSS3
KYB Gas-A-Just front shocks for 1988 (NOTE: These ARE stiffer than stock, could result in more understeer) - https://amzn.to/3RIEQ8x
KYB 234005 Excel-G Rear Struts for all years - https://amzn.to/3oahsTQ
KYB SB103 Strut Boot and Bump Stop - https://amzn.to/3zizTMs
1" Lowering Ball Joints for 1988 - http://rodneydickman.com/pr....php?products_id=158
1" (closer to 7/8") longer sway bar end links - https://amzn.to/3RFAfUJ
Poly Front Sway Bar Bushings - https://amzn.to/3odTC9O
Poly Rear Sway Bar Bushings - https://amzn.to/3yLhgQ5
Mud flaps - not available
Vertical Door Kit video (parts in description) - https://www.youtube.com/wat...4dL8ruvZQL4pabfi1DyA
Steering wheel installation video - https://www.youtube.com/wat...4dL8ruvZQL4pabfi1DyA
Turbo Tachometer from a sunbird video (link in description) - https://www.youtube.com/wat...4dL8ruvZQL4pabfi1DyA
Speakers from Rodney Dickman - http://rodneydickman.com/pr....php?products_id=300
Brighter Interior and Exterior Lighbulbs - http://rodneydickman.com/ad...hp?keywords=brighter
Ground effect - no idea where its from.
Side scoops - discontinued
Rear Tires - 235/60r15 98T Mickey Thompson - https://amzn.to/3PfLkKL
Sail Panel - https://www.fierostore.com/...20%20CLEAR&d=228&p=1
Foxbody mustang hood scoop - was from ebay.
5" Wing stands - unavailable.
Tail Lenses from Keith Goodyear - unavailable now but you could find on ebay.
Blue PONTIAC lens - unavailable but it's just a piece of blue plexiglass of some sort.
Trunk Shock Mount Kit from Rodney Rickman - http://rodneydickman.com/pr....php?products_id=113
Automatic Shifter Cable End Repair Kit (for Fiero shifter, can mate up to 4t65e-hd with West Coast Fiero shifter bracket in the first link above) - http://rodneydickman.com/pr....php?products_id=338


------------------
FieroAustin
1988 GT 3800SC Series III 2.8" Pulley
Fiero/3800sc Swap Parts/Tools at https://amzn.to/3hNViaa
Youtube https://www.youtube.com/Fie...n?sub_confirmation=1
Facebook https://www.facebook.com/FieroAustin/
3800sc Swap Instructions //www.fiero.nl/forum/Forum2/HTML/139530.html
eBay affiliate https://ebay.us/4gTj2A
Join Youtube Membership https://www.youtube.com/FieroAustin/join
Donate https://www.paypal.com/dona...VSKTJ&no_recurring=0

[This message has been edited by AustinH (edited 12-18-2022).]

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AustinH
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Report this Post04-22-2018 01:08 AM Click Here to See the Profile for AustinHSend a Private Message to AustinHEdit/Delete MessageReply w/QuoteDirect Link to This Post
--------MY TOOLBOX----------

CLICK HERE TO VIEW MY NEW AMAZON STORE



PART 1: CAR TOOLS
PART 2: SHOP TOOLS
PART 2.1: CONSUMMABLE CAR HARDWARE
PART 2.2: CAR WASHING
PART 2.3: ELECTRICAL TOOLS
PART 3: HOUSE PROJECT & OUTDOOR TOOLS

EVERY TOOL IN THIS VIDEO, IN ORDER:

* = essential
** = My favorite & essential

PART 1: CAR TOOLS
Click Here to jump to Youtube timestamp
**DeWalt 3/8" impact https://amzn.to/3uVaOVh
**DeWalt 1/2" impact https://amzn.to/3uZbMQJ
*3/8" drive screwdrivers https://amzn.to/3hArxcS
*3/8" drive allen hex bits https://amzn.to/3Abw77W
*3/8" drive Torx bits https://amzn.to/3EtXnkv
**Head lamp https://amzn.to/3Eu6mlT
**OBDLink MX+ OBD2 Bluetooth Scanner https://amzn.to/3nZm7It
*DeWalt Drill https://amzn.to/3E2qSso
Gator Grip universal socket https://amzn.to/3hSmTa4
*Wire Wheels https://amzn.to/3WW8Qk2
*Step Drill bits https://amzn.to/3cqIOCP
**Drill bits https://amzn.to/3A7yjNJ
*Drill to Screwdriver Adapter https://amzn.to/3g2DdER
*Screwdriver tips https://amzn.to/3Ew36GF
Drill bit gauge https://amzn.to/3WXU9wQ
*Hole Saws https://amzn.to/3TAyvM6
*Tool chest top (alt) https://amzn.to/3EtwCg9
*Tool chest bottom https://amzn.to/3g9vVPw
**Toolbox Labels https://amzn.to/3E4Yjub
**Vampliers w/hardened teeth https://amzn.to/3QndRy0
**Side Cutters https://amzn.to/3SKoihh
**Needle nose pliers & cutters https://amzn.to/3TwUUtJ
Long pliers https://amzn.to/3O5fyA1
Thin profile ratchet (alt) https://amzn.to/3US4atB
**Swivel/Flex Ratchets https://amzn.to/3X1jK7Y
**Socket extension, swivel, adapters https://amzn.to/3UO2lhg
Wobbler extensions https://amzn.to/3YOxOmb
*Wrenches https://amzn.to/3UU6CQl
*Wrench Organizers https://amzn.to/3EqIY8K
**Ratchet Wrenches https://amzn.to/3hFwjpB
*Swivel/Flex Head wrenches https://amzn.to/3ttev3s
Ratchet open end wrenches (tooth) SAE https://amzn.to/3zB8LY5
Ratchet open end wrenches (tooth) Metric https://amzn.to/3ErgZ8O
Line/Flare Nut Wrenches https://amzn.to/3JIMrjZ
*Sockets (alt) https://amzn.to/3URvQ1F
*Socket Organizers https://amzn.to/3Af8f3m
3/8" drive impact sockets https://amzn.to/3hyJsAB
1/2" drive impact sockets https://amzn.to/3X2fp4L
*Screwdrivers https://amzn.to/3A8CEjC
*Mini-screwdrivers https://amzn.to/3WZOvKD
Hooks/Pokers https://amzn.to/3WYNX7T
Nut drivers SAE https://amzn.to/3GiC7Qd
Nut drivers Metric https://amzn.to/3UX1Npi
**Endoscope bluetooth camera https://amzn.to/3Ag2D8P
Magnetic/hook work light https://amzn.to/3O4x087
**Flex head Magnet retrieval tool https://amzn.to/3EvUMqs
**Magnet retrievers https://amzn.to/3g30uGI
**Snake/claw retriever https://amzn.to/3E6ejMp
**Thermometer laser https://amzn.to/3ErKuYi
Flare tool for brake/transmission lines https://amzn.to/3AdjR7r
Ethanol Tester https://amzn.to/3UUjeag
Compression tester https://amzn.to/3UAQP9d
Greaser https://amzn.to/3E3K3BW
Adjustable ball joint/tie rod remover https://amzn.to/3g1aBvA
Riveter https://amzn.to/3AbUX7J
Torque Angle Meter https://amzn.to/3Aas3oc
*3/8" drive torque wrench https://amzn.to/3TzPdLQ
*1/2" drive torque wrench https://amzn.to/3Dh7wAQ
Thread Chaser for 7/16 head bolts https://amzn.to/3UVYXkH
Bolt extractors https://amzn.to/3UUaL6R
Better Bolt extractors https://amzn.to/3AepTnD
*Antifreeze freezing point tester https://amzn.to/3DZwBz0
Pump https://amzn.to/3hGltzB
**Oil Filter Wrench https://amzn.to/3QCbRlf
**Small Oil Filter Wrench https://amzn.to/3dbaufK
*Funnels/Oil Pan https://amzn.to/3UB4Cg3
Radiator funnel https://amzn.to/3bDVara
*Hose clamps https://amzn.to/3UNTkok
Spark plug crimp tool https://amzn.to/3ciuH2l
Balancer puller/installer (NON-3800) https://amzn.to/3DiNMNp
Balancer puller (3800) https://amzn.to/3d6W9kh
Balancer installer (3800) https://amzn.to/3BAkl7W
*Spark plug gapper https://amzn.to/3EwdNch
Automotive fuses https://amzn.to/3Ad8uvG
**HPTuners w/credits https://amzn.to/3Tsw4LK
**HPTuners scanner only https://amzn.to/3WY2xfI
**Flashlight, magnetic https://amzn.to/3g8T1G1
**Trim piece remover https://amzn.to/3fZGuF4
Snap ring tool https://amzn.to/3UQL8nx
Pipe/Line cutter (small) https://amzn.to/3bAyCYl
Pipe/Line cutter https://amzn.to/3A3XUHN
Boot Clamp Installer https://amzn.to/3z4SkEo
**Vise Grips https://amzn.to/3WX3GV0
**Vise Grip C clamp https://amzn.to/3hGtIvx
*Heat gun https://amzn.to/3E1VFWd
*Tape measures https://amzn.to/3UR72qH
**Saws-all reciprocating saw https://amzn.to/3GrIAIF
**Angle Grinder https://amzn.to/3EvXAns
Nylon Bottle Brushes https://amzn.to/3EwmiEd
Wire brushes https://amzn.to/3Ev4WHE
Steel Wool https://amzn.to/3EwTB9Y
Scotch-Brite abrasive pad https://amzn.to/3UXbGDr
Markers https://amzn.to/3g9fp21
*Metallic Markers https://amzn.to/3TzxFPX
Paint markers https://amzn.to/3UR7PIb
Wax Pencils https://amzn.to/3TARt5g
Sparker https://amzn.to/3tsOGkc
Lighters https://amzn.to/3UxHhvD
**Deburr Tool https://amzn.to/3TAiF4n
Velcro https://amzn.to/3AeewMF
**Punches & cold chisels https://amzn.to/3E2qSbL
Wood chisels https://amzn.to/3OaB9Y8
*Files https://amzn.to/3fZ8SHp
Small Files https://amzn.to/3TzzrAk
**Allen Hex wrenches https://amzn.to/3tpWljl
**Magnet Bowls https://amzn.to/3AckMUY
Tap & die https://amzn.to/3O1Vvm4
*Metal Hacksaw https://amzn.to/3E3prKg
Wedge https://amzn.to/3O7lCbi
*Wood hammer https://amzn.to/3X07yo1
**Deadblow Hammers https://amzn.to/3TsFHKo
**Pry bars https://amzn.to/3p0QdM1
Crow bar https://amzn.to/3O0Lg1y
*1/2" drive breaker bar https://amzn.to/3G8ncb8
**C clamps (use on brake calipers) https://amzn.to/3E8JM0N
**6" caliper https://amzn.to/3vMaBEl
**12" caliper https://amzn.to/3WRD9s2
Oiling Can https://amzn.to/3Ezwpbh
*Slide hammer https://amzn.to/3TDbkko
*Spray bottles https://amzn.to/3hHuuIv
*Hot glue https://amzn.to/3X1ALPo
Blade Sharpener https://amzn.to/3UzvmxD
**Utility Knife https://amzn.to/3E8tOn6
*Razor Blades https://amzn.to/3TtiV5b
Plastic Razor Blades https://amzn.to/3OewnIZ
**Tin Snips https://amzn.to/3hDRQ1M
*Crescent Wrenches https://amzn.to/3tKMF37
*Channel locks https://amzn.to/3TOsDiN
Pipe Wrenches https://amzn.to/3UEPeiP
Bolt Cutters https://amzn.to/3EwDYiX
Torx Screwdrivers https://amzn.to/3hHUcNn
Safety/Tamper Torx bits https://amzn.to/3UWoWsi
O-rings https://amzn.to/3AcNGnV
Fuel line remover https://amzn.to/3cipRSP
Valve grinder https://amzn.to/3trJ6hX
**Oil Pan/Funnels https://amzn.to/3BK7vVm
Oil dry/absorbent https://amzn.to/3bIixQd
**Torch https://amzn.to/3G9FCIB
**Torch Fuel https://amzn.to/3Ge0lLs
**Dremel https://amzn.to/3UBi3wv
**Jack https://amzn.to/3JB48lk
*Jack Stands https://amzn.to/3PedjK0
**Creeper https://amzn.to/3Vb44xB
**Stool https://amzn.to/3UWhb5g
Engine Stand https://amzn.to/3hFOb3F
Wheel dollies https://amzn.to/3ErwIES
Cherry picker/hoist https://amzn.to/3hxYzdv
*Shop vac https://amzn.to/3GdgEb7
Shop light stand https://amzn.to/3X02ujB
**Shop light https://amzn.to/3USowD1
**Ultra bright bulbs https://amzn.to/3E3xTJi
Light bulb plug adapter https://amzn.to/3AmU8ZF
Light Socket Splitter/Twin Adapter https://amzn.to/3E9V84E
**Bench light https://amzn.to/3O6MMiF
*Battery Charger https://amzn.to/3TEdj89
*Jumpers https://amzn.to/3Tymk2y
*Car Toolbox https://amzn.to/3UE3Yyn
*5gal Gas Tank https://amzn.to/3tB2lpb
Propane Heater https://amzn.to/3TA8f4D
Bug lantern https://amzn.to/3E1BGXH
Radio https://amzn.to/3UA50eM
*Air Compressor https://amzn.to/3hJLuy4
Compressor Dryer https://amzn.to/3Evd62X
Compressor Dryer Hose 1 https://amzn.to/3tsjoK8
Compressor Dryer Hose 2 https://amzn.to/3EtCUMD
*Hose Reel https://amzn.to/3Euj43Q
**Tire Filler https://amzn.to/3US6tgk
*Tire Gauge https://amzn.to/3UXUbmu
**Air sprayer https://amzn.to/3TEfxV3
**1/2" right angle ratchet https://amzn.to/3Eymgf5
Air impact hammer/chisels https://amzn.to/3hOaBiY
**Bench vise https://amzn.to/3E8Dga9
Plastic draining bin w/wheels https://amzn.to/3TA2x2Q
Car fender mat https://amzn.to/3US8vwY
Drill press
Lathe
CNC Mill
Majax mobile car lift
Welder multipurpose 120/240 https://amzn.to/3g8MoUg

PART 2: SHOP TOOLS
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**Extension cord reel https://amzn.to/3tnP3fX
*Extension Cord https://amzn.to/3g8TisM
Chain https://amzn.to/3X2x1NL
**Blower https://amzn.to/3Ty7k4F
*Zip Ties https://amzn.to/3UXH2tW
Bungee cord https://amzn.to/3ExxFvC
Come along winch https://amzn.to/3tuBrzn
*Tape dispenser https://amzn.to/3O3jTE9
*Sandpaper low grit https://amzn.to/3g0GowV
*Sandpaper high grit https://amzn.to/3UDQz9t
*Duct Tape https://amzn.to/3AjjMhV
**Collapsible folding table https://amzn.to/3X47jsk
**Parts organizer https://amzn.to/3hJWThn
**Storage shelves https://amzn.to/3V0PN6x
**Storage Totes w/wheels & handles https://amzn.to/3gcCfWu
Sawhorses folding https://amzn.to/3AbHcpq
*Broom https://amzn.to/3GgUNje
*Trash bin https://amzn.to/3EwvYyh
**Neodymium Magnets https://amzn.to/3BdlFfX
Magnifying Glass https://amzn.to/3Ag43QD

PART 2.1: CONSUMMABLE CAR HARDWARE
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Gloves https://amzn.to/3tr2Wdj
*Dust mask https://amzn.to/3UE6sN9
**Cut resistant gloves https://amzn.to/3UyEy5g
*Ear muffs https://amzn.to/3UUQUEv
**Ear plugs (band) https://amzn.to/3UHXYET
**Kroil penetrating oil https://amzn.to/3UZoNUC
MAF Cleaner https://amzn.to/3AfaOT4
**Brake Cleaner https://amzn.to/3BA4J4H
Penetrating Oil https://amzn.to/3vOcEYO
*Penetrating Oil/lube (stays wet) https://amzn.to/3bAybNH
**Anti-seize lube https://amzn.to/3PrgAGs
**Shop Towels Lint Free https://amzn.to/3exyWrO
*Gasket/epoxy remover https://amzn.to/3qxcwJX
Grey Gasket Maker https://amzn.to/3hE2FB0
**Black Gasket Maker https://amzn.to/3EyH6Ll
**5 minute epoxy https://amzn.to/3hHeS8b
Red Loctite https://amzn.to/3USscW1
Blue Loctite https://amzn.to/3V1Ce6B
Valve Grinding Compound (progressive) https://amzn.to/3TFFvr8
Pipe thread/lock compound https://amzn.to/3U3wUzZ
**Super Glue https://amzn.to/3EfGby2
Moly Powder https://amzn.to/3eiOVd3
Camshaft/Lifter lube https://amzn.to/3Ew1xsh
Air tool oil https://amzn.to/3hB6KWt
Grease for assembly https://amzn.to/3UEQrqg
Engine break-in oil https://amzn.to/3O6vfY4
**Isopropyl Alcohol https://amzn.to/3UN15Ls
**Acetone https://amzn.to/3USt6kM
*Fuel injector cleaner https://amzn.to/3Gy6Wk3
*Brake Fluid Dot 3/4 https://amzn.to/3EbiczF
2 cycle oil https://amzn.to/3O5RxZE
*Power steering fluid https://amzn.to/3GeeoR5
Antifreeze Universal https://amzn.to/3AkE5M1
Lighter fluid https://amzn.to/3Gd94xn

PART 2.2: CAR WASHING
Click Here to jump to Youtube timestamp
**Duster for shows https://amzn.to/3g3lIEk
*Scratch free cloth https://amzn.to/3hE4EVY
*Wash mitt https://amzn.to/3TCzCLi
**Wax/grease remover https://amzn.to/3b6AojA
*Goo gone https://amzn.to/3onOa4p
**Iron remover https://amzn.to/3O3Upq8
*Rubbing Compound https://amzn.to/3UG8vjW
*Wash & Wax https://amzn.to/3Gghsfm
Metal polish https://amzn.to/3UYkw3S
*Car Polish https://amzn.to/3X4Ikou
Ice spray wax https://amzn.to/3AcXw9C
Tire shine https://amzn.to/3PH8d97
**Vinegar https://amzn.to/3g6KWBU
Buffer/waxer/polisher https://amzn.to/3tt8sMz

PART 2.3: ELECTRICAL TOOLS
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Function generator https://amzn.to/3UUCoge
Oscilloscope https://amzn.to/3g6LeJ0
*Wire nuts https://amzn.to/3txQSae
**AC Voltage tester https://amzn.to/3AeNUuV
**Helping hands soldering station https://amzn.to/3g7ofgI
**Flux/braid https://amzn.to/3EbWcFb
Flux https://amzn.to/3E9SYlg
**Solder Vacuum https://amzn.to/3UGJiG7
*Electrical tape https://amzn.to/3AfDNps
**Wire strippers/crimpers https://amzn.to/3B7Td0x
Wire stripper https://amzn.to/3g3o8mo
*Wire stripper https://amzn.to/3X0iHW6
*Needle nose pliers/cutters https://amzn.to/3TwUUtJ
**Crimp connectors https://amzn.to/3PtPejf
*14ga wire https://amzn.to/3O5O5OK
Electrical components, breadboard https://amzn.to/3hMaCEj
*Parts organizer https://amzn.to/3hL8M6N
*Heat shrink https://amzn.to/3UEcCNh
**Soldering station https://amzn.to/3EwBrFm
**DC Power Supply https://amzn.to/3X74dUy
**Digital Multimeter https://amzn.to/3X2jdCZ
**Multimeter probe/clips https://amzn.to/3tujIrX

PART 3: HOUSE PROJECT & OUTDOOR TOOLS
Click Here to jump to Youtube timestamp
Concrete hammer drill https://amzn.to/3EylFd8
**Nail pullers tack hammer https://amzn.to/3E7adDS
**Circular saw https://amzn.to/3tw4eUk
**Orbital sander https://amzn.to/3g6vgys
*Electric Nailer/Stapler https://amzn.to/3O4F0pB
Hand stapler https://amzn.to/3Qsaiqa
Staple Remover https://amzn.to/3vLSJtz
9/16 Staples (divergent with point) https://amzn.to/3A2OnR6
*Caulker https://amzn.to/3UYp8qI
*C clamps https://amzn.to/3GhUxAy
**Quick wood clamps https://amzn.to/3UEXkb6
Square https://amzn.to/3O4xLhj
**Combination square https://amzn.to/3AhuK7L
Drywall square https://amzn.to/3UAzqO0
Laser level https://amzn.to/3TBlmCH
*24" level https://amzn.to/3X5dWug
48" level https://amzn.to/3USzU1O
Drywall rasp https://amzn.to/3ts78cK
Paint scrapers/putty knives https://amzn.to/3Oaczqo
Wood rasp https://amzn.to/3AhvbyV
Wood hacksaw https://amzn.to/3tvLtQT
Coping Saw https://amzn.to/3UWBLmh
Wire brushes https://amzn.to/3Ex4tEZ
**String Trimmer/Weed Eater https://amzn.to/3V0Wi9n
*Tire/Ball pump https://amzn.to/3EyoBqa
**Pump sprayer https://amzn.to/3USBaTb
Seed spreader https://amzn.to/3O83UV5
*Electric Power washer https://amzn.to/3X6xw9t
**Folding ladder https://amzn.to/3OlL79f
**Step Stool https://amzn.to/3O7o7ur
Oscillator Tool DCS354B https://amzn.to/3hG4iOJ
Chainsaw DCCS677B https://amzn.to/3tsFQTC
Leaf Blower DCBL772B https://amzn.to/3WXgwT0
*Snow shovel https://amzn.to/3E7KBqC

Not Mentioned:
Honing Tool https://www.brushresearch.com/brushes.php?c1=1
Dust/paint respirator https://amzn.to/3TA7fxy
Painting/Drywall equipment
Drywall saw https://amzn.to/3UPDhXu
Sledgehammer, pickaxe, hoe, garden rake, rake, pitchfork, shovel, lawnmower, snowblower
Torque Screwdriver https://amzn.to/3B2PksO
Jigsaw https://amzn.to/3WHYYK7
Flexible Extensions https://amzn.to/3jJc4Z1
Car Ramps https://amzn.to/3jKMz9P
Router https://amzn.to/3WFsJLP

------------------------------
FieroAustin
1988 GT 3800SC Series III 2.8" Pulley
Fiero/3800sc Swap Parts/Tools at https://amzn.to/3hNViaa
Youtube https://www.youtube.com/Fie...n?sub_confirmation=1
Facebook https://www.facebook.com/FieroAustin/
3800sc Swap Instructions //www.fiero.nl/forum/Forum2/HTML/139530.html
eBay affiliate https://ebay.us/4gTj2A
Join Youtube Membership https://www.youtube.com/FieroAustin/join
Donate https://www.paypal.com/dona...VSKTJ&no_recurring=0

[This message has been edited by AustinH (edited 01-02-2023).]

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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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0z
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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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Shho13
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Report this Post03-17-2019 12:40 PM Click Here to See the Profile for Shho13Click Here to Email Shho13Send a Private Message to Shho13Edit/Delete MessageReply w/QuoteDirect Link to This Post
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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AustinH
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[This message has been edited by AustinH (edited 05-28-2020).]

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LornesGT
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Report this Post05-09-2019 06:52 PM Click Here to See the Profile for LornesGTSend a Private Message to LornesGTEdit/Delete MessageReply w/QuoteDirect Link to This Post
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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AustinH
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Report this Post05-09-2019 08:26 PM Click Here to See the Profile for 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.

[This message has been edited by AustinH (edited 01-24-2021).]

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AustinH
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[This message has been edited by AustinH (edited 01-13-2020).]

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DimeMachine
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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 - //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

957 posts
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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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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Dennis LaGrua
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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 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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Report this Post08-27-2019 07:43 PM Click Here to See the Profile for AustinHSend a Private Message to AustinHEdit/Delete MessageReply w/QuoteDirect Link to This Post
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[This message has been edited by AustinH (edited 05-28-2020).]

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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 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/Fiero3800harnesses
Danny - https://www.facebook.com/danny.mcilmoyle

[This message has been edited by AustinH (edited 12-18-2022).]

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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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