High Feature V6 Swap

[draven]

Still trying to figure out the OneDrive pic issue for older pics in this thread..

Quick update and question for everyone....

Camaro ZL1 fuel module mounted and installed in Fiero fuel tank with fuel ring installed, lots of pics to come...
Good o'le V8Archie Front battery mount tray installed
Running pos and neg cables to ecu in trunk and block respectively. (Obtained OEM ATSV battery cable available from ebay and it's a rear mount battery setup stock)
Built in shoulder harness mounts fabricated and mounted behind firewall AND frame rail under rear window so no harness bar in cabin, I'm not Will height, but 6'3" 200lbs I do need all the leg room I can get...
DEI tunnel insulation over firewall 16g aluminum skin over WestMarine insulation

Wish to be much further along but getting divorced with three kids puts a damper on finances... ka-ching

So..... the carrier bearing I'm using is for the late 2000's Saab 9-3 Aero V6 turbo with F40, see below:

https://www.esaabparts.com/static/image ... 795185.jpg


This bolts right up the LFX/LLT etc.. but not exactly to the LF3 / LF4 due to the turbo oil return being offset behind the lower right bolt hole in the bracket. I removed the lower right bolt mount from the bracket but not sure if I need to tie in another support to the block. The only 'easy' way would be to tie in the two bearing retainer bolts(longer of course), one is visible on the right side of the image back to the block. Although my tig skills are improving I've never welded cast aluminum which is pulling me down the bolt / tie-in path.

I'm not too familiar with the forces exerted on a carrier bracket / bearing.

My only other option would be to cannibalize the XTSV carrier bearing bracket, which does bolt to the block but is way out of alignment and much further offset from the block than what the F40 intermediate shaft requires, and tie that into the block.

Thoughts?

[Series8217]

Camaro ZL1 fuel module mounted and installed in Fiero fuel tank with fuel ring installed, lots of pics to come...

Very interested in seeing this. I was thinking the "easiest" way to do a modern swap is to reuse the entire sending unit from the donor car, plus you get the benefit of the built in "sump" and can get away better with broken Fiero tank baffles.

[draven]

First off, Onedrive has changed the URL format for embedded photos invalidating most of my photo links... I'll correct them over time as it's rather tedious to correct.
Series, if there are any posts you want to see specifically as you are researching your LF3/LF4 solution, let me know and I'll tackle those first.

ZL1 fuel module pics..

FUEL SAFE fuel ring and gasket parts (gasket is just cork and butyl rubber)






OE ZL1 pump with nylon plastic top removed. Both springs can come right out and one pin as well.


Vapor Works pickup kit (slightly customized tube lengths)


Fuel module with aluminum top bracket with tig'd gun barrel drilled round stock with set screws


Tig'd rods onto OE fuel tank hat





Preassembled Fuel module and pickup layout





Vapor Works fuel pickup. Have one in the front of the tank and another in the rear. The pickups close if no fuel is present and reopen when fuel floods the filter screen.






In tank fitting (note stainless magnetically held down brackets for fuel pickup and Boeing fuel line clamps)


Deutsch connectors (with rubber gasketing removed)







Have to bandsaw cut fuel ring to get it inside tank. This voids the warranty but FuelSafe stated to me that they have many racers who do the same thing.



All fuel pickups work on the venturi principal from the pickup bung coming out of the bottom of the fuel module with a capped pickup on top of the module that would normally pull from the sibling saddle tank in a modern setup, i.e. Camaro, ATS, etc... What you cannot see is the pickup on the bottom of the fuel module allowing pickup against the very bottom of the tank.


All baffling forward of the fuel tank ring was removed and the rear baffling kept in place for the fueling and air ports.

Short of the aluminum bracket, FuelSafe ring, and removing the nylon screw in plate everything here is effectively a VaporWorks setup.

The ultimate solution for a modern Fuel Module in a fiero would be a full stainless tank with as wide a rear fuel tank top as one could go with a weld on / bolt on fuel module screw ring. Theres just not enough fuel tank width, although close, in the rear of the fiero fuel tank to do so.

[draven]

Finally found a GM pigtailed connector for the ATS/ATSV - Camaro fuel pump control module (FPCM). Although not wired "for" the ATSV harness and needing to be re-pinned. Below is the disassembly of the connector as it wasn't apparent to me how this one came apart.













Once the inner shell is removed the pins can be repositioned as necessary to match your specific wiring harnes...

[draven]

Steering rack universal cleaned up, painted, and rag joint replaced with solid aluminum. This was a kit for the 80s Camaro/Firebird that matched up nicely with our racks.

[ericjon262]

Good to know about the rag joint eliminator, on my suburban I used a Jeep XJ steering shaft, it has a nice feel to it.

[The Dark Side of Will]

Finally found a GM pigtailed connector for the ATS/ATSV - Camaro fuel pump control module (FPCM). Although not wired "for" the ATSV harness and needing to be re-pinned. Below is the disassembly of the connector as it wasn't apparent to me how this one came apart.



https://1drv.ms/i/c/c954ad43d971b902/IQ ... eight=1024

https://1drv.ms/i/c/c954ad43d971b902/IQ ... eight=1024

https://1drv.ms/i/c/c954ad43d971b902/IQ ... eight=1024

https://1drv.ms/i/c/c954ad43d971b902/IQ ... eight=1024

https://1drv.ms/i/c/c954ad43d971b902/IQ ... eight=1024

Once the inner shell is removed the pins can be repositioned as necessary to match your specific wiring harnes...

Is this a new style of Aptiv (formerly Delphi) connector or is it from a different manufacturer?

[draven]

Does anyone know if the curved sheet metal that separates the engine bay and left rear fender well between the oem intake resonator and filter box is structural /necessary?

Id like to utilize the oem atsv filter box with its multifunction sensors but it's too large to fit in the fender or in the bay with the rest of the setup.

[FieroWanaBe1]

As thin as that area is, I doubt it. The thicker material by the strut tower I wouldnt touch though.

[draven]

Nevermind... the ATS-V intake box is just too large overall and the two air intake tubes go off into different directions whereas I need them to merge back into one in the limited space available.

Luckily it's ABS so I'll be dissecting the stock box and fabricating a semi-custom setup.... ABS slurry time.. lol