how to upgrade 165 turbo/ic to 2 gen turbo/205ic ** UPDATED*

Write ups and tutorials for maintenance and modifications.

Postby killer_siller » Sun Aug 14, 2005 11:06 am

so around $400?

what about the 205ic and all that jazz?

i know those are REALLY hard to come by.

what about the 205 heat exchanger? did you have any problems fitting that? where did you get yours?
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Postby saved_1992 » Sun Aug 14, 2005 11:53 am

the 205 ic is expensive, anywhere from 400-600 i have seen being sold, i do not have a 205 heat exchanger, i used an ac condensor that is 12x27x1 that was for an older toyota truck 81-86. the condensor i got for free.
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Postby acylon » Fri Aug 19, 2005 8:30 pm

So, if you use the 1/2" spacer on the exh manifold you wouldn't have to moddify the 185 turbo?

Where do you get that spacer?
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Postby saved_1992 » Fri Aug 19, 2005 9:01 pm

from my measurements 3/8 should work also, the ones in the pics i bought on ebay, the skinner of the 2 was 35.00 and thicker one was 65.00 but is was much better in quality. just sold the flanges to 91alltrac.

yes no mods needed

ps i will try to track down the place i bought them from

sorry no luck but now i do remember (read old posts) the 3/8 came from ebay the 1/2 inch came from a link on this site (i think Gary posted it up).
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1988 a driver (RED) sold
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Postby saved_1992 » Sun Oct 23, 2005 1:55 am

i sold the car with this set up, the 165 rubber coupler was working perfect

maybe the new owner will update
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1992 the keeper (RED)
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Postby 91 alltrac » Fri Dec 16, 2005 6:59 pm

several issues

if you use the manifold spacer then you will need a 1" spacer to mate the dp to midpipe. not a big problem, I just used 2 3/8" collector flanges (from muffler shop) and 3 gaskets to make a sandwich.

I was able to use the top hole of the return pipe and secure it to ones of it orignal mounting holes, maybe this is due to the spacer. I did not need to cut it off.

I had to cut a 1" section of the oil feed line brace/bracket so that I could bend the line to fit.

I had to cut the water line from the water neck since it would not clear the gearbox. not a big issue, flared the end and ran new water hose.

I had to use an st185 return rubber hose since its 1/2" longer and wanted the extra rubber for my own peace of mind.

your no longer able to use the turbo stay/brace. I would like some extra support. maybe later on make a brace.

I am currently using the stock wta but have a 205 in the shed.

not too bad, fairly straight forward. hardest part was getting the right parts to make it work and taking care in bending the oil lines.
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Postby saved_1992 » Fri Dec 16, 2005 8:28 pm

cool thanks for the input :D hope the write up helped

which spacer did you use? how much room did it give you to clear the actuator and oil filter bolt?

do you have any pics?

did you use the stock 185 downpipe?
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1988 work in progresss (205 assem w/tdo6/haltech)sold
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Postby 91 alltrac » Sat Dec 17, 2005 12:08 am

yea the write up gave me a good general idea of whats needed but you never know until you actually tackle the prob.

it clears the oil bolt by a few mm's, I used the thicker flange.

yea I am using the st185 dp.

will try to post some pics this weekend.
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Postby 88st165 » Sat Dec 17, 2005 5:03 pm

where did you locate the spacers? i looked on ebay and found nothing...
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Postby saved_1992 » Sat Dec 17, 2005 7:55 pm

88st165 wrote:where did you locate the spacers? i looked on ebay and found nothing...


http://www.jgstools.com/turbo/index2.html

for the manifold spacer, it is in the write up (flange)
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1988 work in progresss (205 assem w/tdo6/haltech)sold
1988 a driver (RED) sold
1992 the keeper (RED)
1993 sold to 2of81 (RED)
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Postby saved_1992 » Thu Dec 22, 2005 6:51 pm

91 alltrac wrote:yea the write up gave me a good general idea of whats needed but you never know until you actually tackle the prob.

it clears the oil bolt by a few mm's, I used the thicker flange.

yea I am using the st185 dp.

will try to post some pics this weekend.


forgot to ask what did you use for the longer studs?
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omaha,ne
1988 work in progresss (205 assem w/tdo6/haltech)sold
1988 a driver (RED) sold
1992 the keeper (RED)
1993 sold to 2of81 (RED)
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Postby 91 alltrac » Sat Dec 24, 2005 2:58 am

I just measured the depth of the exhaust holes, added the extra thickness of the 2 gaskets, flange and washers. Then went to a specialty hardware store and bought new grade 8 bolts and extra washers since they were a little longer then I wanted.
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Postby d1alltrac » Sat Jan 07, 2006 3:06 am

i just did this too....pretty straight forward when you use the spacer, i had a hell of a time trying to line up the oil feed line though.
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Postby saved_1992 » Sat Jan 07, 2006 1:11 pm

d1alltrac wrote:i just did this too....pretty straight forward when you use the spacer, i had a hell of a time trying to line up the oil feed line though.


were you able to find longer studs? or did you just use longer bolts?

also you have an aftermarket exhaust did it bolt right up or did you have to use a spacer at the down pipe flange? pics?
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omaha,ne
1988 work in progresss (205 assem w/tdo6/haltech)sold
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1992 the keeper (RED)
1993 sold to 2of81 (RED)
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Postby d1alltrac » Sat Jan 07, 2006 1:58 pm

i havent put the exhaust back on yet so im not sure if im gonna need spacers, ill get it all finished up next week sometime and get some pics, i need to pick up a thinner fan too

and yeah i just used bolts, i looked for studs but couldnt find any so i figured this will do at least for a while

oh yeah btw, the write-up helped...it would have been a serious PITA if i didnt have that spacer
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