Project ST165-ST205 Swap

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Re: Project ST165-ST205 Swap

Postby zaluss » Mon Jul 13, 2015 10:49 am

freddie wrote:Nice read, and great photo. I think this will help me get my head around the order of procedure when I start installing my 205 engine into my 165.
I have heard getting the AC to work is a bit of a problem and there is a blog on it some where

If some one can help here....

I would appreciate it.

Fred


You would swap the suction valve from the ST165 to the ST205 pump. I didn't realize this until after I ripped the lines out of the car. The ST165 AC condenser will not fit entirely into the ST205 motor and the AC lines don't exactly match up. You just need to disassemble the condenser and swap the suction valves.

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Re: Project ST165-ST205 Swap

Postby Rick89GTS » Sun Jul 19, 2015 2:01 am

Great build, can't stop watching :smokes:
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Re: Project ST165-ST205 Swap

Postby zaluss » Fri Jul 31, 2015 1:10 pm

July 31st, 2015

Been a bit since the last update but more progress has been made. Everything has been essentially completed and I'm just waiting on a few bits to arrive:

- HKS T pipe from the UK to complete the intake.
- HKS replacement red 200mm filter.
- 5mm wheel spacers due to rubbing from the coilovers.
- More Toyota pink coolant to fill my WTA system.

I picked up a set of BFGoodrich 195/60R14 G Force Super Sport A/S mounted on the stock wheels. I couldn't decide on what wheels to get so I opted to use the stock ones for now. They fit nicely in my new 2015 Ford Edge :).

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Brake master cylinder replaced.

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New endlinks installed. I'll admit that I have no idea what I'm doing when it comes to the coilover installation. Since they were custom from Ceika, they came with no installation instructions. I did my best to install them using similiar BC coilovers from the ST185. I still don't quite understand the camber plate orientation or adjustments so I just left them alone. I'm not even entirely sure I have them on the correct side as they weren't marked. I installed the rear wheels and lowered the car just to eyeball the camber before I take it to the alignment shop. Since the closest performance shop that can align coilovers is quite a distance from me, I'll have to rely on a chain shop to do a basic alignment so I don't destroy my wheels.

Any suggestions regarding adjustment or orientation here would be appreciated! Below picture is of the drivers side rear.
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Re: Project ST165-ST205 Swap

Postby GT4times2 » Fri Jul 31, 2015 8:14 pm

Great work! Keep it up! Where did you order the connectors (injector clips) from? I have a few broken ones on my ST185/Caldina swap. Thanks.
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05 Toyota Avalon XLS
90 ST185 Gen4
88 ST165 Gen3-The works
89 ST165 Gen4-on the way
+ Many other projects, under covers....
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Re: Project ST165-ST205 Swap

Postby zaluss » Sun Aug 02, 2015 3:15 am

GT4times2 wrote:Great work! Keep it up! Where did you order the connectors (injector clips) from? I have a few broken ones on my ST185/Caldina swap. Thanks.

Ordered straight from the dealer. There is a part number listed on the injector clip.
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Re: Project ST165-ST205 Swap

Postby GT4times2 » Sun Aug 02, 2015 3:29 am

zaluss wrote:
GT4times2 wrote:Great work! Keep it up! Where did you order the connectors (injector clips) from? I have a few broken ones on my ST185/Caldina swap. Thanks.

Ordered straight from the dealer. There is a part number listed on the injector clip.



Very true. Totally overlooked that. Thank you.
Frantz
12 Toyota Sienna LE (The Daily Pacifier)
05 Toyota Avalon XLS
90 ST185 Gen4
88 ST165 Gen3-The works
89 ST165 Gen4-on the way
+ Many other projects, under covers....
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Re: Project ST165-ST205 Swap

Postby zaluss » Sun Aug 30, 2015 12:59 am

August 29th, 2015

Another long time since I've updated but I've finally got everything dialed in and running. My first test run out of the garage resulted in a low 500 rpm idle after a short 2 mile journey. I let the car sit overnight and the following day it would die immediately after applying any throttle. I took the throttle body apart and discovered the idle air control valve was clogged with carbon and the little door wasn't moving. Cleaned the IACV and tested the door which worked great. Put it all back together and did another test drive with the new Antera 109 trispokes I found on craigslist. I don't have the coilovers at the ride height I wanted yet because I wanted to leave room for some adjustments without taking the wheels off as I made my measurements. Just enough to get to an alignment shop at least.

Clogged with carbon.
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Stopped by an empty church parking lot to take some pictures.
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Re: Project ST165-ST205 Swap

Postby RallyX-GT4 » Sun Aug 30, 2015 4:23 pm

So... how does it run now??? You just can't leave it at that! :)
1988 - ST165 - RallyCross #3
1996 Mazda Miata - DD/Track Toy
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Re: Project ST165-ST205 Swap

Postby zaluss » Sun Sep 27, 2015 11:38 pm

RallyX-GT4 wrote:So... how does it run now??? You just can't leave it at that! :)


Ha! It runs...

September 27th, 2015

Few things have changed since the last update but not a whole lot. Long story short, I should of replaced the clutch while the engine was out because the clutch is slipping at WOT. No amount of pedal adjustment or bleeding seems to resolve it. That's what I get for being cheap! Now I have to pull the whole engine again (Why you ask? Because center diff). Before I discovered this little problem, I did do a few minor things to the car.

The factory boost gauge wouldn't work with the swap and I didn't want some gauge pod style boost gauge. I discovered an Omori boost gauge that the MR2 guys install in the factory location. Sounds like something I could do!

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Works great. Matches (kinda) the factory 80's style green without being obnoxious.

Also picked up a Twos R Us manual boost controller to compliment the boost gauge. Disabled the TVSV and set the boost to 12psi.

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Cleaned up the interior a bit as well.

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Re: Project ST165-ST205 Swap

Postby underscore » Mon Sep 28, 2015 4:20 am

Beautiful work! Finding a base in that kind of shape is rare, you're a lucky guy!
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Build thread http://www.alltrac.net/phpBB2/viewtopic.php?f=44&t=44216
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Re: Project ST165-ST205 Swap

Postby Mr Alltrac » Mon Sep 28, 2015 1:07 pm

12 psi? I thought the st205 came factory with 14 psi? Correct me if I'm wrong please, that number is just stuck in my head for some reason.

Car is looking great, really clean!
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Re: Project ST165-ST205 Swap

Postby zaluss » Mon Sep 28, 2015 3:02 pm

Mr Alltrac wrote:12 psi? I thought the st205 came factory with 14 psi? Correct me if I'm wrong please, that number is just stuck in my head for some reason.

Car is looking great, really clean!


Factory boost is 13.2 PSI max but I set it to 12 for testing since I disabled the TVSV.
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Re: Project ST165-ST205 Swap

Postby Mr Alltrac » Mon Sep 28, 2015 3:03 pm

Gotcha! Maybe I was thinking subaru world. I think my sti was 14.7 psi stock.
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Re: Project ST165-ST205 Swap

Postby zaluss » Sun Oct 04, 2015 1:18 pm

October 3rd, 2015

Preparing to drop the motor for the clutch replacement. Ordered a Clutchmasters Stage III FX300 clutch + ARP Flywheel bolts from Xiiimotorsports. Also ordered an OEM throwout bearing/rear main seal, and new pressure plate bolts. I damaged the pricey vacuum nipples for the power steering pump in the process of removal.

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Salvaging my fresh Redline trans oil. $17/quart ain't cheap.

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Engine dropped.

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Two hours wiggling that bastard off via the 'silo' method.

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Well that explains why the car was slipping under any power..

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Re: Project ST165-ST205 Swap

Postby zaluss » Sat Oct 10, 2015 9:38 pm

October 10th, 2015

Stuff has arrived and stuff needs to be replaced.

Removing the rear main seal.
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New OEM seal.
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Resurfaced OEM flywheel. Opted against using the Fidanza one.
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Sexy surface.
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ARP Flywheel bolts and Loctite 242.
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Installed and torqued to spec. What a PITA to hold the flywheel in place to do it.
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Clutchmaster FX300 fitted.
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New OEM pressure plate bolts.
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Installed and torqued to spec. Torque specs was rather low in the manual (17-20 ft lb iirc) so I added some loctite.
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Pricey moly paste and OEM throwout bearing.
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Lubing the slave contact.
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Lubing the bearing contact points.
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Lubing the pivot.
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Installed.
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Close up. You can see the nice thin layer of moly lube on the shaft. I put a very slight layer of antiseize on the spline as well.
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Back together. Probably throw it back in the car tomorrow or next weekend.
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