Well since the other thread went to hell because of a few I have decided to start a new one. Please if anyone has any comments to make to me about anything other than the title of this thread please contact me by way of email. With that being said lets get to the install.
[imghttp://members.accesswave.ca/~z24/swap/eb/engbay16.jpg
For anyone who does not know the history, my car is a 1998 Z24. The engine is a 3800 SC V6 with a 2000 5-speed getrag muncie tranny mated to it. I'm using a custom aluminum flywheel (9.5lbs) with a Bully stage 3/4 clutch package (stage 4 pressure plate and stage 3, 4 puck clutch disc.) The PCM has been custom tuned to remove the govenor, readjust the timing and fuel curves for use with a 3.4" SC pully (stock is 3.8") and some other minor things. I'm also running a wet NOS nitrous system using 150hp jets. I also plan on running an MSD DIS-4 before it hits the track this summer.
The parts that were used are as follows;
3800 supercharged series 2 V6 (from a 99 Regal with 40,000kms)
SC 3800 wiring harness (from a 99 Regal)
Custom tuned 3800 PCM (done by Digital Horsepower)
2000 2.2l getrag muncie 5-speed transmittion
Custom tubular subframe (2" square tubing with 1/4" wall thickness)
Custom fabricated lower engine mount (using a mount from a 3800 and some flat steel)
Stock front transmittion mount (filled with polyeurethane)
Custom Dog Bone mounts (made with 1 1/2" steel tubing) with aluminum bushings
Custom aluminum flywheel (9.5lbs) made by Racetech
Bully stage 4 pressure plate
Bully stage 3 clutch disk (4 puck design)
Fuel pump from a Grand Prix GTP
3.4" Supercharger pully
160 degree thermostat
N.O.S. wet nitrous system (using 100hp jets)
Thrasher N20 install kit (also acting as a TB spacer)
Custom cold air intake (using an Ractive intake for a 2002 Ford F150)
This swap is a lot of work. First some of the old subframe had to be removed. We built a whole new subframe out of 2" square tubing. We used the stock front tranny mount and made a custom lower engine mount from an old mount from the 3.8 and some flat steel. The front stock tranny mount was filled with polyurethane and used to support the tranny. With a lot of messuring the engine lined up great in the engine bay. Two custom dog bones had to be made for the top mounts as well as custom brackets on the upper rad support. The dog bones were made out of 1 1/2" tubular steel and we had aluminum bushings made up to fit them. The upper rad support was strenghened with angle steel to support the weight of the engine. WIth all of the mounts bolted down the engine is very secure in the bay. There is no movement which will translate into more power to the wheels.
Here are some pics of the subframe...
Here are some pics of the lower engine mount...
Here is a pic of the stock tranny mount...
The wiring harness was made by splicing my old 2.4 harness into the new 3.8 harness. We got a little bit of a break here because we had the PCM sent to the US to be reprogramed. They removed all of the automatic settings, some of the emissions and the ABS so these were all able to be eliminated from the harness. It still took about 25 hours to get the new harness ready to go in the car. We started by cutting what we didn't need off the 3.8l harness, and labled everything that we would need. We then did the same with the old 2.4l harness and wired the two together. With the help of the wiring diagrams from both engines this went pretty smothly. Below is Nathan (The mechanic who did this swap) playing with the harness. The PCM was also able to be located in the stock location.
The rest of the install was pretty easy. For fuel we used a complete sending unit from a grand prix GTP. The whole unit fit into the stock location in the fuel tank. The power steering lines and throtle cables had to be re-routed and some other minor things like that. As for time it was about 70-80 hours to get it done.
Here are some other pics that I took...
The power steering lines were actually pretty easy. We were able to use the stock lines, we just had to rebend them to fit our project.
Here is a shot of the rear exhaust manifold. There is not much room there and we may still have a problem with the heater hoses that go into the firewall for the heater core but I plan on getting some headers made up so that should fix that. And even still, who needs heat in the summer
Here is a shot of the new battery in the trunk. I rewired all the main power and grounds for the car with 4 gauge wire. I really didn't have to relocate the battery as there was enough room under the hood but I plan on running a small stereo in the car and I thought this would be the best place for it.
We were hoping to have the car out for a test drive yesterday (Friday) but unfortunatly GM sent us the wrong belt for the accessories. They sent us one for an engine that has air conditioning...and of course I got rid of my air
So we will have to wait till monday to get a new belt and take my baby out for a rip. I will post up some pics of the test drive and hopefully a little smoke show too.
If anyone has any questions on how the swap was done or wants to see a picture of something that I haven't posted already please feel free to ask away. I will do my best to answer any questions that you may have.
One last thing to add, if anyone wants to have this swap done and doesn't have the facilities, equipment, or skills Double Z Automotive can do it for you. If you are going to try this swap yourself and you just need a little help (like having a harness made up for you) then Double Z Automotive can help you out as well.
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Quoth the Raven 'Nevermore
raven@accesswave.ca
Raven Autosports
55 McQuade Lake Cres,
Halifax, Nova Scotia, Canada
(902) 850-3330
10.82@132
Brad's cam takes video to I think so I will get some video of it and post it up.
thanks <br> 
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