3500 (LX9) swap into a Fiero

[flimbob]

That's what I meant regarding the A/C hose, you'll need one from each car in order to join the ends. The Fiero hose is a little unique in it's old age and turned out not to be as simple as removing the hose from the line connection end to the car to expose the barbs, the tubes barely have barbs for the later hose to grip, the center of what would be the barbed area on the Fiero fittings are slightly undercut sort of like a coke bottle and it did not appear the hose from the new compressor would be able to maintain its seal under pressure.

Whatever the case, I wound up dealing with what's probably the best hose and line tech (at Amazon Hose) in Tampa Florida and he explained to me his concerns about the differences and made me a pretty sophisticated piece with a combination of welding, butt barbs and threaded connections. I can unscrew the hoses in the middle. You may do fine since you'll be cutting the hoses in the middle, I completely removed the hose from one of the ends and found something different than what I was expecting. You may also need to purchase the low/high cutoff switch like the one I just purchased to make the system work properly since there is no pressure sensor on the new compressor like that found on the Fiero's compressor. There's no sensor on it to turn the coolant fan on either.

Joseph,

Do you have pictures and/or part numbers for the cutoff switch you used? I believe I picked up a cutoff switch that was on a mid to late 90's pontiac. It was mounted in a small tube which was I believe was headed to the condensor. I can provide a picture of it if that helps. What kind of price did Amazon charge for your modified hose? Also, I was under the impression that the 7730 controlled the fan. Am I missing something here?

The idler pulley is mounted on Malibu/G6 vehicles where the power steering pump normally mounts. My engine was out of an Uplander which has a normal PS pump in that location. I chose not to use the PS pump, so I reverted to the design used on the Malibu/G6. Thanks for the location of the knock sensor. I am indeed using the new style compressor. Instead of modifying the newer style flex hose, I intend to modify a Fiero flex host to connect to the newer style flex hose. I would think it would be cheaper, since the hose just needs to have male connectors installed on a short piece of the Fiero flex hose.

That's what I meant regarding the A/C hose, you'll need one from each car in order to join the ends. The Fiero hose is a little unique in it's old age and turned out not to be as simple as removing the hose from the line connection end to the car to expose the barbs, the tubes barely have barbs for the later hose to grip, the center of what would be the barbed area on the Fiero fittings are slightly undercut sort of like a coke bottle and it did not appear the hose from the new compressor would be able to maintain its seal under pressure.

Whatever the case, I wound up dealing with what's probably the best hose and line tech (at Amazon Hose) in Tampa Florida and he explained to me his concerns about the differences and made me a pretty sophisticated piece with a combination of welding, butt barbs and threaded connections. I can unscrew the hoses in the middle. You may do fine since you'll be cutting the hoses in the middle, I completely removed the hose from one of the ends and found something different than what I was expecting. You may also need to purchase the low/high cutoff switch like the one I just purchased to make the system work properly since there is no pressure sensor on the new compressor like that found on the Fiero's compressor. There's no sensor on it to turn the coolant fan on either.

[flimbob]

Why do you need an idler pulley to replace the power steering pump? The timing covers are the same across the 3500s and since the G6 3500 does not use a power steering pump thanks to the electric rack it shouldn't be a problem unless an extra pulley is the difference between the motors. The knock sensor goes in the coolant drain plug hole on the side of the block. You'll need A/C hoses from both cars and a good hose shop to connect the ends if you intend to use the newer style A/C compressor. It will also need to be a little longer than the stock Fiero A/C hose from the compressor.

The idler pulley is mounted on Malibu/G6 vehicles where the power steering pump normally mounts. My engine was out of an Uplander which has a normal PS pump in that location. I chose not to use the PS pump, so I reverted to the design used on the Malibu/G6. Thanks for the location of the knock sensor. I am indeed using the new style compressor. Instead of modifying the newer style flex hose, I intend to modify a Fiero flex host to connect to the newer style flex hose. I would think it would be cheaper, since the hose just needs to have male connectors installed on a short piece of the Fiero flex hose.

[86FieroSEv6]

Cannot "knock retard" be "tuned" out of the equation? If not, shouldn't the KS be mounted closer to the head deck?

Decided to use an idler pulley mounted to the same location as the malibus and g6s. Installed the belt from a 2004 malibu and everything functions perfectly. I'm in the process of wrapping up some loose ends such as the CTS. I acquired a CTS from a 96 Pontiac grandam which is the 3 prong type. This will allow me to send info to the gauge and the ecu. Also ordered a 12MM-6FP adapter so I won't have to drill and tap the original CTS location. My ECU is from a 92 Cavalier, so I obtained a knock sensor from that vehicle. Not sure where it needs to be installed. In the process of obtaining the ac flex tubing from a V6 Fiero so I can have an adapter created that will plug and play the 3x00 flex tubing to the Fieros hard tubing.

Starting to think about exhaust creation. Will need a cat here in Texas. Looking at possibly using a Magniflo high flow unit with some flex tubing and some radical 180 and 90 degree bends. Space is tight, so I will consider smaller cherry bomb type mufflers for each output pipe. I intend to reuse my original tips. Will use clamps initially, but eventually get the system welded. I want to keep me trunk completely intact as there is very little storage space on a Fiero as it is. I would like to use 2 1/4" tubing as it is pretty close to stock for the LX9( I think ). Please chime in if you have any input on exhaust ideas, and/or knock sensor location.

Why do you need an idler pulley to replace the power steering pump? The timing covers are the same across the 3500s and since the G6 3500 does not use a power steering pump thanks to the electric rack it shouldn't be a problem unless an extra pulley is the difference between the motors. The knock sensor goes in the coolant drain plug hole on the side of the block. You'll need A/C hoses from both cars and a good hose shop to connect the ends if you intend to use the newer style A/C compressor. It will also need to be a little longer than the stock Fiero A/C hose from the compressor.

[flimbob]

Decided to use an idler pulley mounted to the same location as the malibus and g6s. Installed the belt from a 2004 malibu and everything functions perfectly. I'm in the process of wrapping up some loose ends such as the CTS. I acquired a CTS from a 96 Pontiac grandam which is the 3 prong type. This will allow me to send info to the gauge and the ecu. Also ordered a 12MM-6FP adapter so I won't have to drill and tap the original CTS location. My ECU is from a 92 Cavalier, so I obtained a knock sensor from that vehicle. Not sure where it needs to be installed. In the process of obtaining the ac flex tubing from a V6 Fiero so I can have an adapter created that will plug and play the 3x00 flex tubing to the Fieros hard tubing.

Starting to think about exhaust creation. Will need a cat here in Texas. Looking at possibly using a Magniflo high flow unit with some flex tubing and some radical 180 and 90 degree bends. Space is tight, so I will consider smaller cherry bomb type mufflers for each output pipe. I intend to reuse my original tips. Will use clamps initially, but eventually get the system welded. I want to keep me trunk completely intact as there is very little storage space on a Fiero as it is. I would like to use 2 1/4" tubing as it is pretty close to stock for the LX9( I think ). Please chime in if you have any input on exhaust ideas, and/or knock sensor location.

[flimbob]

The PS pump does not appear to be serviceable. I was able to remove the reservoir, but the pump itself looks like the only way to open it is to remove the wire clamp which holds the bottom of the pump to the pump case. Is this the correct way to get at the vanes? I'm making an assumption that the pump is a vane type.

Addendum: I found info on how to get the pump apart, so it looks like I'm moving ahead on the PS pump. I'm assuming the reservoir is needed only to lubricate the pump. I might look into leaving the reservoir off and putting a short piece of hose filled with fluid. The reason for leaving the reservoir off is that it looks like it may cause height problems.

[86FieroSEv6]

What scrabblegod said about "idling" the power steering pump is the correct method. The only other thing I would mention is to use synthetic fluid due to the heat.

[flimbob]

Got the tranny and engine mated. Both are mounted on the cradle. Mounted the alternator, starter, and ac compressor. Ordered a crank sensor and evap solenoid valve. Still haven't decided what to do about the ps pump. Rewired the fuel injector harness to eliminate the cam sensor. I will need to have an ac hose extension created that will mate between the Fiero long tubes and the 3x00 dual compressor lines. I figure the small extension will allow me to quick change hoses if needed. I also need to get the ac hose sensor installed. I need to research where the sensor need s to be ( high or low side ). Things left to do before removing my existing engine/tranny:
1) Create return style fuel regulator.
2) resolve 440t4 issues.
3) Resolve CTS issue.
4) Obtain a 96 EGR tube.
5) Start exhaust design.

[flimbob]

If the high pressure side of the ps pump was connected to the low pressure side, wouldn't the pressure relief valve bleed the pressure off?

[scrabblegod]

On my wifes 3.4DOHC Fiero, I wanted to keep the stock belt, so I opened up the pump and removed the pump vanes so there would be no pressure. This allowed me to plug the lines and keep the pump full of fluid for lubrication.

Gene

[CNCguy]

If you were to leave a PS pump on there, I would suggest running a short hose from the pressure side to the return. If you plug the holes it will operate at max pressure, create more hp loss and reduced pump life.

[flimbob]

Received the alternator late yesterday afternoon. Starter is the only missing piece except for PS delete pulley. None of the Pick-n-Pulls around here have vehicles with LX9 engines. Anyone have an idea how much horsepower is robbed by the PS pump? I'm wondering if I could just leave the pump hooked up and plug the tube. That way if I ever decide to modify my Fiero for power steering, I'll have the pump ready to go.

[flimbob]

Picked up an ac compressor from the local pick-n-pull. The top 2 bolts work fine, but the bottom bolt does not fit correctly. Others have posted this should not be a problem. Got an alternator and starter from Ebay. They should be here next week. Received and installed the TCE crank trigger. Making good progress.

[flimbob]

I obtained an alternator bracket and found that I will not be able to swap the valve covers around. It appears the bracket interferes with the valve cover vacuum connector. Well I guess going back to the stock location won't be so bad. I won't have to worry about all the interferance issues I';m having now.