'92 Series I 3800SC into manual Formula - basic questions (Page 1/2)
statue4 MAY 14, 11:01 PM
There are so many 3800 threads out there. I didn't think I would have to make my own, but after (countless) hours of research, I still have some questions I'd like to figure out.
My Fiero: 1988 Fiero Formula 2.8L V6 5-speed Getrag manual transmission
Donor car: 1992 Bonneville SSEi Series I 3800SC automatic
I feel like I must establish that I do not care how much better the Series II engines are (because I know it will be brought up). This is just a "get it in and get it running" swap. The Fiero is currently my daily and is asking for a new clutch badly, so I figured I'll just put in a better engine while I'm at it.

First I have to get my new engine out of the donor car. I haven't done much work on FWD cars before and am trying to figure out the best way to get it out. I will be using the getrag 5-speed my Fiero has, so I don't need the donor transmission. I don't have a car lift. I don't currently have an engine hoist, but could pick one up from Harbor Freight or Craigslist if it would make the job alot easier. I do have jackstands and a floor jack. Is it going to be easier for me to separate engine from transmission and pull it out the top with a hoist, or to just drop the whole cradle? If I do drop the cradle I'll have to remove the engine and put the cradle back in so I can send the car off to the scrapyard - which sounds challenging considering it weighs alot more than I do. If I do drop the cradle, should I remove the bumper cover and radiator too? I apologize for the basic questions - I've pulled engines before, but this Bonneville is the first FWD car I've owned and the Fiero is the first transverse-drivetrain car I've owed.
Removing the wiring harness from the Bonneville looks like it might be a chore. I think the computer is in the cabin under the glovebox.

I've placed an order with FieroRog for a Series I flywheel, lower alternator bracket, engine mount and bracket, and dog bone bracket.

When it comes time to install everything in the Fiero, I do have a few questions:
-Fuel lines. Thinking about what this thread has: https://www.fiero.nl/forum/.../HTML/139530.html#p5 But those little connectors add up in cost fast, so I might try to see if there is something simpler I can do.
-Fuel pump. I've seen EP376 and EP381 recommended. What should I go for? Or, because this is only a 205HP engine, could I use the stock V6 pump? It currently has Bosch 69222 in it.
-Clutch. I saw someone on a Facebook ground recommend a Spec Stage 2+ clutch. If that's the only thing that will work, so be it, but with taxes and shipping I'll be looking at close to $500 for a clutch. It'll be a stock engine, so 260 ft-lb of torque.
-Air conditioning. Best recommendation for getting parts to hook the Bonneville A/C pump to the Fiero?
-I plan on buying new transmission mounts from West Coast Fiero and new rear bushings from The Fiero Store.

[This message has been edited by statue4 (edited 05-14-2021).]

statue4 MAY 17, 03:40 PM
So I've ordered the Spec Stage 2+ clutch kit from Summit. Still have a few more parts to get ordered. I'm planning on spending the rest of the day working on pulling the Bonneville engine.
Dennis LaGrua MAY 17, 07:59 PM
As you pointed out you are only swapping s 205 HP engine. You shouldn't need more than a Spec stage 2 or similar.
The 3800SC series II and series III swap usually uses a 95-95 FWD Camaro/Firebird flywheel cut to .82 thickness and balanced to the flexplate that came on the engine. I am not sure that flywheel will fit the 3800 series I engine so some checking is in order. I would confirm before buying the clutch. The only series I swaps that I have seen have come with autos so again some checking is in order.

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" 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 "

statue4 JUN 17, 02:25 AM
Look at how toasted this clutch was. I literally drove it until it wouldn't drive any longer, then started the swap.
longjonsilver JUN 17, 06:58 AM
What is th redline on a 3800? is my gage for a GT marked correctly for red line and orange line?

jon

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Astronomy says we will find a coded signal from outer space. Then we'll KNOW that life exists there, for coded signals aren't by chance.

Biology says there are coded genetic signals in every cell, but we KNOW that no intelligence created life.

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

statue4 JUN 19, 11:48 AM
This has taken many more hours than anticipated, but I think I am close.
It looks like I need to move the whole engine over about 2 inches to the left to get the alternator on. Or figure out another way to get the alternator in there. I would order the FieroRog low alternator mount, but he said it's two weeks out and I need to get this car running yesterday. When ordering my other parts from him, we discussed the lower alternator bracket, but didn't confirm it. I have seen photos of the Series I mounted in a Fiero using the stock alternator mount and naively assumed it would work for me too. I haven't called West Coast Fiero to see what kind of lead time they have, but if they do have anything on the shelf, they're closer to me so I'd probably be able to get it pretty quick. Their stuff is pricier, but it might be what I have to do.
statue4 JUL 03, 02:06 PM
Update:
I ended up having to make a wiring harness and that took a few days. It is installed and I have gotten it to fire up and idle. The idle speed fluctuates greatly and sometimes even stalls. If I give it any throttle it dies. Where should I look?

[This message has been edited by statue4 (edited 07-03-2021).]

Matthew_Fiero JUL 03, 10:20 PM
I would double check your wiring. Special attention to the idle air control valve.

Edit: don't go by colour when checking the wires to the PCM. always use a multimeter and check the continuity.

[This message has been edited by Matthew_Fiero (edited 07-03-2021).]

statue4 JUL 03, 11:03 PM
Here are the codes the S.E.S. light gives:
31 - I think this is for the canister purge. I did not hook the ECM wire up for this because I frankly wasn't sure where it went.
34 - MAF sensor voltage low. I guess I should follow these wires to the ECM. I made sure my splices were top notch, but perhaps something got pinched when I was putting everything on the engine or installing loom.
43 - Knock sensor. My knock sensor is not hooked up because the connector got damaged. A new one is ordered and on it's way.
56 - ECM quad driver circuit malfunction. I have no idea what this is telling me.
58 - Either trans fluid temp error or VATS error. Trans fluid error would make sense, because I do not have a trans fluid cooler or anything (manual transmission). I am 95% sure I have my VATS module wired correctly, including a chip-key bypass resistor.
I am not sure that these are the correct faults for the codes, but it is what I have found so far.

Also worth mentioning that I am currently using the stock Fiero V6 fuel pump.
statue4 JUL 04, 04:13 PM
Update:
I did find that I didn't connect the MAF ground wire. Oops. Unfortunately fixing it didn't change much.