Fuel system setup diagram for E85 conversion in Build 1
Fuel system setup diagram for E85 conversion in Build 1
Posted inCardiagtech

Car Engine Parts List: Essential Components for a 3800 Fiero Swap

No Comments

Embarking on a 3800 engine swap for your Pontiac Fiero? This comprehensive Car Engine Parts List, originally designed as BUILD 1 for a budget-friendly conversion, provides everything you need to get your project started. Whether you’re aiming for a straightforward engine replacement or looking to enhance your Fiero’s performance, this guide details the essential car engine parts and components required for a successful swap. This list is meticulously compiled for enthusiasts and DIY mechanics focusing on optimizing the 3800 Series II or Series III engine for your Fiero.

Donor Car Essentials

To begin your 3800 Fiero swap, sourcing the right donor car is crucial. Ideally, a 1998-2002 Pontiac Grand Prix GTP or Regal serves as the perfect candidate. These models provide the most compatible engine and supporting components. Extract the following car engine parts directly from the donor vehicle:

  • Engine: The heart of your swap, ensure it’s a complete 3800 Series II or III engine.
  • Transmission (Optional): While you can reuse your Fiero transmission, the donor’s transmission (especially if automatic) might be beneficial.
  • Wiring Harness: Obtain the engine wiring harness up to the firewall, including the OBD II connector from inside the donor car. Remember to also keep your Fiero wiring harness for integration.
  • Computer (PCM/ECU): The engine control unit is vital for managing the 3800 engine’s functions.
  • MAP Sensor Vacuum Lines: These vacuum lines are specific to the 3800 engine’s manifold absolute pressure sensor.
  • A/C Hose: The air conditioning hose up to the firewall can be adapted for your Fiero’s AC system.
  • 3″ Exhaust Flange: Cut this from the donor car’s exhaust system – it will be essential for custom exhaust fabrication.
  • Extra Fuses and Relays: Gather these from the donor car’s fuse box as spares or for direct use.
  • Power Washer Fluid Pump, Tank, and Hoses (Optional): For a budget methanol injection setup (not detailed in this guide).
  • Electronic Cruise Control Module and Cruise Cable (Optional): If you plan to retain or upgrade your cruise control.
  • CV Front Axles (GTP): Crucial for ensuring compatibility with the 3800 engine and potentially the donor transmission. Axles from a GTP model are recommended.

A junkyard search is highly recommended to find these donor car components. Websites like Junkyard Search can be invaluable.

Air Intake and Supercharger Components

Optimizing the air intake system is key for the 3800 engine, particularly if it’s supercharged. Here’s a list of car engine parts for the air intake and supercharger system:

  • Supercharger Pulley Belt (3.7″ or 3.4″): For the supercharger, a 3.7″ pulley belt (66.3″, 6 ribs) like Roadmax 6k663AP (Amazon Link) is needed. For slightly increased boost, consider a 3.4″ pulley belt (66″, 6 ribs) such as Gates K060660 (Amazon Link). Belt sizes may need adjustment for perfect fitment.
  • Optional: Supercharger Modular Pulley System (MPS): Consider ZZPerformance 3.4 MPS (Ebay Link) or Smoothflow 3.4 Polished Finish Pulley System MPS (Smoothflow Pulleys Link). Ensure you order the complete system with the hub.
  • Optional: Supercharger Pulley Puller: For pulley swaps, a dedicated puller (Ebay Link) may be necessary.
  • Optional: Flexible Air Duct: To replace stock Fiero/3800 air intakes, a 4″ dia, 41inch long flexible duct like Spectre SPE-9751 (Amazon Link) is a convenient universal option. Alternatives include Walker 42423, Walker 43381, UCREATIVE U-SH-45-102-T, or GM GENUINE 25173861 / Dorman 696-426.
  • Optional: Air Filter: Upgrade to a performance air filter like K&N RE-1040 (Amazon Link) for better airflow.
  • Optional: Air Filter Wrap: For added protection, use a filter wrap like FILTERWEARS K298K (Amazon Link) to keep out water and debris.

Fuel System Parts

Upgrading the fuel system is critical to support the increased power of the 3800 engine. Here’s what you’ll need for the fuel system:

  • Fuel Pump: A high-flow fuel pump is essential. Consider the Walbro 255 LPH F20000169 (Amazon Link) or the quieter Quantum 255 LPH HFP-343 (Amazon Link). Be cautious with Quantum pumps and ensure proper fuel flow, trimming the bottom lip may be needed.
  • Fuel Tank Lock Ring and Seal: Replace these with a new Dorman 579-001 set (Amazon Link) when accessing the fuel pump.
  • Stock Fuel Rail Hose Release Tools: Performance Tool W83148 (Amazon Link) are necessary for disconnecting the stock fuel lines.

For plumbing the fuel system, especially for ethanol compatibility, consider these components:

  • Push-Lok Ethanol Fuel Hose 3/8″: Fragola 871006 (10ft) (Amazon Link) is recommended for ethanol fuels.
  • Fuel Filter: Wix 33481 (Amazon Link) with welded 16mm x 1.5 female inlet/outlet is a suitable choice.
  • M16 x 1.5 Adapter to -6 AN: Edelbrock Russell 648060 (Amazon Link).
  • 90° -6 AN Female swivel Push-Lok Barb Male: EVIL ENERGY CS00465D90 (Amazon Link).
  • Stock 3800sc Fuel Rail 3/8″ & 5/16″ Supply/Return Line Adapters: Vibrant 16886 (3/8″ – Amazon Link) and Vibrant 16885 (5/16″ – Amazon Link).
  • 1/4″ barb to 3/8″ barb: Beduan 1yf-02920-srb (Amazon Link).
  • 1/4″ Fiero Ethanol fuel tank return hose: UCREATIVE U-FH-30R7-5-14 (5′) (Amazon Link).
  • 5/8 ID molded Ethanol hose with a right angle: Gates 28467 (Amazon Link).
  • 1.5″ Fiero Ethanol Fuel tank filler neck hose: Gates 21660 (Amazon Link).
  • 180° bend -6AN to Pusk Lock 3/8″ Barb: Dexepe OCH-AN6-180#1-BK-LC (2x) (Amazon Link).

Ignition System Parts

For a robust ignition system, especially when considering performance enhancements, these parts are essential:

  • Spark Plug Wire Kit for Custom Lengths: Taylor Cable 83253 (45 degree boots) (Amazon Link) for creating custom-fit spark plug wires.
  • Spark plug wire crimper: MSD 3503 (Amazon Link) needed to crimp the wires using a vise.
  • Optional: Colder Spark Plugs: Autolite 104 (Amazon Link) are recommended, gapped to 0.035″-0.040″, to prevent knock and improve performance.
  • Optional: Spark Plug Gap Tool: Performance Tool W80540 (Amazon Link) for precise spark plug gapping.

Exhaust System Components

A custom exhaust system is usually necessary for a 3800 Fiero swap. These are the parts to consider for your exhaust setup:

  • Muffler (3″ inlet, dual 2.5″ outlet): Options include Spintec 343SC (Ebay Link), Flowtech 50363FLT (Ebay Link), Magnaflow 12158 (Amazon Link), or Walker 18375 (Amazon Link).
  • Donor Car Exhaust Flange: Crucial for welding to the new exhaust system to connect to the 3800 headers.
  • 90° bend 3″ diameter: X AUTOHAUX a22111700ux0403 (Amazon Link).
  • 180° bend 3″ diameter: X AUTOHAUX a22111700ux0413 (Amazon Link).
  • 90° bend 2.5″ diameter (2-PACK): X AUTOHAUX a22111700ux0402 (Amazon Link).
  • Straight 2.5″ diameter, 1 ft: X AUTOHAUX a22111700ux0435 (Amazon Link).
  • 2.5″ diameter generic exhaust hanger U-bolts (2-pack): PALOZO EC-2.5 (Amazon Link).
  • 2.5″ diameter Exhaust Tips: Reuse stock Fiero tips or choose aftermarket options.
  • Optional: 96-02 Camaro/Firebird Oil Pan & Pickup Tube: Spectra Premium GMP46A (Amazon Link) and Melling 292S (Amazon Link) for stock Fiero exhaust routing.

Coolant System and Hoses

Managing the cooling system effectively is vital in a mid-engine car like the Fiero. Here’s a parts list for the coolant system:

  • 3800 Thermostat housing to drivers’ side coolant hose (1.25″ to 1.25″): Dayco 71082 (Amazon Link).
  • Radiator filler neck (1.25″ inlet and 1.25″ outlet): HCHCSPEED JP2826-SL (Amazon Link).
  • 3800 Water pump 1.5″ to Passengers’ Fiero coolant hose 1.25″: Gates 21205 (Amazon Link).
  • Barb coupling for heater hose (5/8-5/8″ ID): ICT Billet AN627-10A (Amazon Link).
  • Heater Hose (for 87-88 Fieros): Continental 63113 (Ebay Link, Amazon Link) or DAYCO C87641 (Autozone Link).
  • Aluminum Heater Hose Elbow: Dorman 47065HP (Amazon Link).
  • Optional: 180° Thermostat: Gates 33428S (Amazon Link) or MotoRad 239-180 (Amazon Link).
  • 1″ expansion frost plug: Dorman 02600 / 570-005 (Amazon Link) or Dorman 555-018 (Amazon Link).
  • Hose clamp kit: (Amazon Link) for securing all coolant hoses.
  • Coolant/Antifreeze: Peak PXA0B3 (2 gallons of concentrate) (Amazon Link).
  • Optional: Bigger Radiator: Champion 166-CC828 (Amazon Link) or cheaper alternatives available on Amazon.
  • Optional: Better Radiator Fan: Proform 67016 (Amazon Link) or Permacool 19115 (Amazon Link).
  • Optional: Hood vents: GM 10030564 & 10030565 (Ebay Link) or Paul Angel’s vents (Angelonearth Link).

Wiring Harness, Sensors, and Computer (ECU/PCM)

Electrical integration is a significant part of the swap. Here’s a breakdown of the electrical car engine parts:

  • Harness from the donor car: Essential for the 3800 engine.
  • Harness from the Fiero: Needed for integration with the car’s systems. Avoid 1984 harnesses due to differences.
  • 3-pin Oil pressure sender: STANDARD MOTOR PRODUCTS PS245T (Amazon Link) if not already present on your Fiero (typically for 1988 V6 models).
  • 1/4″ NPT Male to Female Elbow: Legines 3420*BB (Amazon Link) for oil pressure sender relocation if needed.

For those building their own harness, these parts are necessary:

  • HPTuners + 2 credits: (HPTuners Link) for ECU programming and tuning.
  • 3-pin Oil pressure sender connector: Standard Motor Products HP4480 (Amazon Link).
  • 4t65e-HD/4T65e/4T60e Transmission Speed Sensor to Fiero Speedometer Buffer Circuit: (Reddevilriver Link).
  • In-line 20A fuse holders (2x): Bussmann BP/HHG (Amazon Link).
  • 1998-2002 Computer (ECU/PCM): GM 09357440 (Amazon Link) or from a junkyard.
  • Fuel pump relay: (Amazon Link).

Transmission Components

Depending on whether you choose a manual or automatic transmission, different parts are needed:

Manual Transmissions:

4t65e-HD/4T65e/4T60e Automatic Transmission:

  • 4t6x Transmission Cooler Line Fittings:
    • 1/4″-18 NPSM to -6 AN male (2-pack): ICT Billet 551114 (Amazon Link).
  • Transmission line elbow -6AN to 3/8″ 90 deg barb (2-pack): EVIL ENERGY EV01111D90 (Amazon Link).
  • Transmission Hose to Fiero Steel Hose: Derale 13016 (5ft) (Amazon Link).
  • 4t65e-HD/4T65e/4T60e Shifter bracket: Contact Chuck Peterson (Facebook Link) or West coast Fiero (West Coast Fiero Link).

Transmission Axles

Axle selection depends on your transmission choice:

Manual Transmission Axles:

4t65e-HD/4T65e/4T60e Automatic Transmission Axles:

Building 4t65e-HD/4T65e/4T60e Passenger’s Axle (DIY):

  • Re-use Driver’s side GTP Axle OEM: GM 26054707 / Cardone 60-1255 (Amazon Link).
  • Re-use Passenger’s side GTP axle OEM: GM 26073392 / Cardone 60-1256 (Amazon Link).
  • Re-use any manual Fiero axle OEM.
  • Axle Boot Inner with grease: Dorman 614-004 (Amazon Link).
  • Axle CV Boot Clamps: MIKKUPPA QAT094 (Amazon Link).
  • Axle CV boot clamp tool: ABN 8542034855 (Amazon Link).

Accessories, AC, and Miscellaneous Parts

These components cover additional functionalities and convenience:

Mounting and Brackets

Engine and transmission mounts are crucial for a secure and vibration-free swap:

Rubber Cradle Side Motor/Transmission Mounts:

  • Engine Cradle Mount for 84-85 4cyl, 86-87 4cyl manual, 85-87 V-6: Westar EM-2472 (Amazon Link).
  • Engine Cradle Mount for 86-87 4cyl automatic, 1988 4cyl & 1988 V-6: Westar EM-2548 (Amazon Link).
  • Front Transmission Mount: DEA A2466 (Amazon Link).
  • Rear Transmission Mount: Westar EM-2467 (Amazon Link).
  • ALTERNATIVE POLY ENGINE CRADLE MOUNT: (fierospace Link).

Engine/Transmission Side Brackets:

Parts Needed if Not Using a 1998-2002 GTP/Regal Donor

If your donor car is not a 1998-2002 Pontiac Grand Prix GTP or Regal, you’ll need these additional car engine parts:

  • 2-Bar MAP sensor: Standard Motor Products AS4 (Amazon Link).
  • GTP/Regal External Transmission Gear Selector Neutral Safety Switch / Range Sensor Switch: Standard Motor Products NS122 (Amazon Link).
  • GTP/Regal External Transmission Gear Selector Neutral Safety Switch / Range Sensor Switch Connectors: ZOOKOTO 88862288 (Amazon Link).
  • GTP/Regal Steel Oil Pan: SPECTRA PREMIUM GMP11B (Amazon Link).
  • GTP/Regal Oil Pan Gasket: Apex AOP356 (Amazon Link).
  • GTP/Regal Oil Pan Pickup Tube/Gasket: Melling 256S (Amazon Link).
  • GTP/Regal oil filter bracket: GM 12569219 ; 24508441 (Amazon Link).
  • Oil Filter Housing Gasket: MAHLE B31639 (Amazon Link).
  • GTP/Regal angled coil pack bracket: GM 24507211 ; 24504360 (Ebay Link).
  • GTP/Regal Supercharger Tensioner Pulley: Dayco 89367 (Amazon Link).
  • GTP/Regal Supercharger Idler Pulley: Gates 38009 (Amazon Link).
  • Optional: Torque Converter: DACCO B21JXFM (Amazon Link).
  • GTP/Regal 3-pin Temperature sender: Standard Motor Products TX66 (Amazon Link).
  • GTP/Regal 3-pin Temperature sender connector: Standard Motor Products HP4440 (Amazon Link).

Maintenance and Wear Parts for a 3800SC Engine

Proactive maintenance ensures longevity and performance. Consider these wear parts for your 3800SC engine:

This comprehensive car engine parts list ensures you are well-prepared for your 3800 Fiero swap, covering everything from essential components to maintenance parts, helping you achieve a successful and powerful engine conversion.

Comments

No comments yet. Why don’t you start the discussion?

Leave a Reply

Your email address will not be published. Required fields are marked *