The interior was more comfortable and didn't smell like mice, the brakes and
suspension were safe, and the car was lowered an inch and a half.
Interior complete
Washed and waxed
Engine Swap Prep
Engine before
Donor car
Freshening Up the New Engine
New timing set
New oil pump
New water pump
Oil Level Sensor Delete
Pan plug plans
Pan plug comparison
Pan plug installed
Cleaning Up the Intake Manifolds
Upper intake manifold
Lower intake manifold
New gaskets
Intake installed
Exhaust Gas Recirculation Delete
EGR plug plans
EGR plug installed
Brass plugs
I forget why there were holes in the water jacket here, but they needed
to be plugged.
Brass plugs
Brass plugs installed
Rebuilding Injectors
Injectors before
Injectors rebuilt
Injectors installed
Throttle Body Adapter
The engine was a Series 3 3800 while the donor car (PCM, injectors, fuel rail,
throttle body, and such) was a Series 2.
So, the throttle body needed some adapting.
Throttle body before
TBA plans
TBA machined
TBA installed
Throttle body installed
Thermostat Housing Mod
I modified the thermostat housing from the original engine to fit the new one.
The Fiero cooling system is a little unusual: the thermostat housing is the
highest point, so it's important that it have a cap for filling.
Thermostat housing before
Thermostat housing deconstructed
Thermostat housing reconstructed
Thermostat housing installed
Alternator Bracket
I significantly re-arranged the accessory drive as part of the sawp, so I
made a custom alternator bracket.
Alternator bracket plans
Alternator bracket weldment
Alternator bracket installed
Air Conditioning Delete
The Fiero didn't have air conditioning, so I put an idler pulley at an
appropriate place in the accessory drive.
A/C idler bracket
A/C idler pulley
Transmission before
Flywheel
Clutch
Transmission installed
Engine Mounts
End mount mockup
End mount
Rear mount tacked
Front mount
Dog-bone bracket
Engine Bay Prep
Engine bay before
Engine bay after
Trunk Reduction
I removed the lower trunk section to make room for the new exhaust.
Trunk marked
Trunk cut
Trunk patch
Alternator Clearance
The alternator also took a little room from the trunk.
Alternator clearance
Alternator panel
Cradle Installation
Cradle prepped
Cradle rolling in
Cradle installed
Exhaust
Exhaust parts
Exhaust welded
Pillar Pod Gauges
I did get all of the gauges in the original instrument cluster adapted and
working with the 3800 Series 2 PCM, but I also wanted a couple of extra
gauges: a wide-band oxygen sensor for tuning and an OBD2 scanner for
diagnostics and tuning.
Pillar pod idea
Pillar harness
Pillar pod cut
Pillar pod bonded
Pillar pod painted and blended
Pillar pod gauges
Wiring
Body harness
I put the OBD2 connector and wide-band oxygen sensor output in the passenger
footwell, along with a power jack – this made tuning more convenient.
OBD2
A simple adapter allowed the Fiero speedometer and odometer to work with
the Series 2 3800 PCM output.
Speedometer converter
Firewall wiring
I set up the entire engine harness to feed through one big connector.
This made it easy to drop the cradle later when necessary.
Engine harness
PCM mount
For Sale
After a number of fun years, it was time to sell the Fiero.
For sale inside
For sale back
For sale engine