My Series II 3800 SC Conversion
Here are a few links I have found to be most helpful
http://www.terranexus.com/fieroman/
http://home.earthlink.net/~chriswest/
http://chartermi.net/~gene.down/
http://www.americancustomeng.com/
http://www.grandprixstore.com/
http://www.thrasher-ep.com/
http://www.ramairtech.com/
I would appreciate any links or information to add here.
I will be including pictures and progress along the way as time allows. I will not be using any form of a kit. This Fiero will be left as a manual and I have decided to go with the modified Camaro 3800 flywheel (part # 24503285) instead of modifying the 2.8 flywheel or having one custom made.
Progress
2/12/2000
Picked up the 1996 Series II 3800 SC from a Bonneville. Included were all accessories, engine harness, and PCM.
2/19/2000
Have the engine mounted on a spare cradle. I chose to use a common 3800/3300 front (right) engine mount (a b) which is similar to the 2.5 engine mount and to use the more common 3800/3300 oil filter extension (part # 25522641) which puts the filter out beside the crank pulley instead of down between the oil pan and cradle where I wanted the engine mount. I lost the oil cooler hookups doing this and will add an aftermarket cooler later on. I extended the stock cradle bracket forward and used the stock rubber mount with the rear stud in the front stock bracket hole, the front mount stud is in the extension which I added. The shift cables for a Getrag or Isuzu should clear the stock x-over pipe just fine, but I had to make up a new bracket for my 4-speed. I made nylon inserts for the front cradle mounts and used aluminum spacers for the rear. Removed power steering pump, which leaves the tensioner doing almost nothing, but a 670K6 or 5060670 belt fits tightly enough that it must be turned onto the idler by turning the crank. The tensioner will allow for some, but not much stretch.
3/1/2000
Just completed my dogbone brackets and coil pack relocation. Also dropped the original drivetrain out of my 86 SE. I am keeping the right decklid hinge, but have moved the pin to the front hole and have cut off a section of the hinge and mount. Modified 2.8 thermostat housing for 3800.
3/4/2000
It's in with fuel and coolant lines run. It will have to come back out when I get the flywheel turned down and balanced, no machine shops open on Saturday and I couldn't blow two full days. I put it together with a 2.8 flexplate so I'll at least be able to fire it up, or try, before I have the finished flywheel.
3/5/2000
It's alive but my Pass Key Bypass seems to vary with temp, sometimes enough to not work. Without 40-60 Hz to the PCM, and without the donor relays, the engine will start and run for about 6 seconds then die.
3/10/2000
Picked up my flywheel from the machine shop, dropped the engine, installed flywheel and clutch, bolted everything back in the car.
3/12/2000
It's been one month, it runs rich until going closed loop and it begins cutting out under hard acceleration.
3/18/2000
Just built most of my exhaust, waiting for resonator tips and downstream O2 sensor. Completed exhaust, found that the downstream O2 sensor really isn't necessary other than preventing an MIL light. Update to previous statement: the 2nd O2 sensor is also used for long term fuel trim so it will affect fuel mileage if not present or faked.
up to 4/7/2000
Bought Helms for the Bonneville hoping it would help, but the few unknown wires I had are not important. Fuel pressure checks out. Sensors check out from what I can tell with a multimeter. The cutting out problem disappears with the MAF disconnected, but that causes other problems. Helms doesn't give enough info on what things are ignored in certain modes etc.
1996 3800 SC firewall connector pin-out
Note: The above pin-outs are not yet updated.
5/26/2001
After a new job, a new house, and a long family crisis, it's done. I recently ordered another PCM from a junkyard online. This was from a Supercharged Riviera. With the "original" PCM, my scanner was showing incorrect vaccum from the MAP . Plugged in the Riviera PCM and the they were correct. But no MIL light with the ignition on, thus no go. Luckily a friend had sent me copies of schematics for the 96 G cars (Aurora/Riviera) back before I bought the Helms for C/H cars and the G car PCM has one additional IGN wire to the PCM that's not on the C/H cars. Moved an unneeded pin in C1 for the new IGN wire, got the MIL light with ignition on, and then it fired right up. Runs perfect. I am 95% certain that the PCM I picked up with my engine was from a non-SC car and they knew enough to put a knock sensor in it, but didn't know that it wouldn't work with a 2 bar MAP. For this reason, I strongly advise you see the complete package in the donor prior to removal so you can be sure to have all the correct parts. This "mistake" cost me $105 for a new MAF (didn't need), $400 for an OBDII scanner (although it's nice to have it now), and $100 for a SC PCM, not to mention all the time wasted. I likely would not have purchase the Bonneville Helms manual either at $120. Not including time, the wrong PCM cost me over $725, which is nearly what I paid for the 3800 SC, wiring, and PCM to start with. Would I do it again even with all the trouble I had due to the wrong PCM ? Definately :-)
