Project ST165-ST205 Swap

[zaluss]

Old build thread: viewtopic.php?f=44&t=48628

I forgot to post a build log here so here we go. I had to remove some of the pictures due to sizing and replaced them with links. Sorry


February 27th, 2015

Parts ordered for timing belt kit from PrimeMR2.com



3rd Gen 3SGTE from JspecAuto. $2295 shipped.

http://www.jspecauto.com/engine_details/1997/1994-1998_Toyota_TOYOTA_CELICA_3S-GTE_ALL_TRAC_ST-205_GT-4_TURBO_AWD_M/T_COMPLETE_SWAP!_CALDINA_ST215_3S_3SGTE_GT4



Video of compression test: https://www.youtube.com/watch?v=_lWE693jFws

March 11th, 2015
Picked up the car: The owner was an older gentlemen whose wife owned the car since new, purchased in Michael's Toyota in Bellevue. She passed away a few years ago and he just drove the car the weekends. The interior is absolutely immaculate. Seats were recently reupholstered. Everything works, including lumbar support and cruise control. The engine bay is clean but its leaking at the valve cover. Power delivery seems to be so so but the car has 200k+ miles. I'll get more pics later this evening.











March 13th, 2015
Motor is delivered. Everything is settled in. Missing the MAP sensor and plug too though.





April 17th, 2015

Timing belt. Looks like I need new cam seals and I stripped the philips screw on the water pump so that needed to be drilled out. Slight delay in finishing while I order those parts!

Ordered this to assist. Milwaukee Fuel 3/8" lithium impact. AMAZING. I never want to use air tools again it was so amazing.











May 1st, 2015

Timing belt all buttoned up.

Berk ST205 downpipe received in the mail.

Broke every god damn fuel injector clip. Ordered new ones.

Boat anchor cat/downpipe removed.

Oil cooler and HFH (Hoses from Hell) removed.

Waiting to go on. They weren't this mangled before I removed them but they don't call them the HFH for nothing.


May 3rd, 2015

Buttoned up the HFH install and downpipe. What a PITA that was...



This is pretty much all the space I had to remove the clip holding the clamp in place. Either that or remove the entire exhaust manifold :what:



Downpipe installed with this funny looking brace that took the OEM brace's place.




Pretty much just waiting on the axle seals and the fuel injector clips to drop the motor in. It'll be time to pull the existing motor, replace some bits while I'm in there, and drop the motor in. :thumbup:

May 8th, 2015

Started to take the original motor apart.

Leaky turbo.

No rusty battery tray!

This insane telescopic looking alternator cooling dust.



Also tested my new Milwaukee M18 Fuel 1/2" on the axle nut.
https://www.youtube.com/watch?v=EXL-wGfhhkU

May 9th, 2015

I was planning on dropping the motor today but I ran into a snag after dropping the subframe and axles. Looks like one of the bolts on the downpipe are stripped. I'm going to need to cut/drill that out.





May 13th, 2015

Engine is out. During the removal I forgot to drain the oil which resulted in 4 quarts of oil mixed with trans fluid and power steering fluid. Not fun.




Also noticed the fuel filter bracket is missing. That will make for a difficult removal of the filter. Hard to tell from.the picture but its just floating by the fuel line.



May 26th, 2015

Received my package from speed-source.net and proceeded to install the goodies inside.

New shifter bushings to replace the worn rubber.

The stainless clutch line seems to be a bit shorter than the original. I couldn't find any comparison pictures so I shot an email to speed source. Hopefully they will clarify.


May 30th, 2015

Motor is all buttoned up and ready to drop in so I started to work on the front suspension.

First things first...something has to break The control arm nut inside the unibody snapped off, letting the bolt float freely. I had to drill under the drivers side floor pan to get to it.





After that fiasco, I thought it would be best to just finish the drivers side and call it a day. Installed the powder coated knuckles with fresh bearings, new OEM ball joints, and then the coilovers...

The Ceika coilover sleeves I got were incorrect for the front. I swapped them with the rears and they bolted on fine. I shot an email to them to see if I could get the correct sleeves for the front. Its been a few months since I've ordered them so I might be SOL since I didn't check when I first got them.




May 31st, 2015

Installed the swaybar endlinks, stainless lines, and new rotors. The brake pads I got seem to be a little too thick and probably cheapies since they came free with the rotors. I think I'm going to look into either Toyota OEM pads or EBC greens.



This little thing won't fit inside the other thing...sigh :banghead: I'll make it work.






Also removed the FRAM fuel filter and replaced with OEM. The OEM one came with the proper bracket to mount to the chassis where the FRAM one was supported only by the fuel lines themselves :facepalm: I mean come on, really...

[Mr Alltrac]

Great work so far !
This is gonna be super clean when it's done !!

[GT4times2]

Great project, and very clean car. I have an ST165 (Model Year 1989, same color, no leather) just like that, and about to do the same. Going ST205 swap complete. Hopefully this summer. Keep it up. I'm loving it.

[zaluss]

Great project, and very clean car. I have an ST165 (Model Year 1989, same color, no leather) just like that, and about to do the same. Going ST205 swap complete. Hopefully this summer. Keep it up. I'm loving it.

Can't wait to see it!

June 7th, 2015

I forgot to take some more pictures but the engine is in. Motor mounts were a PITA to align but otherwise it went rather smoothly.

[RallyX-GT4]

Wow - that's coming together very nicely! What are you doing for engine management?

[zaluss]

Wow - that's coming together very nicely! What are you doing for engine management?

Stock ECU. I have no real plans for power mods beyond 300hp and from what I understand the stock ECU will handle that no sweat.

[zaluss]

June 15th, 2015

Some significant progress made.

After some unsuccessful attempts at getting the AC to work with the ST205, I ended up pulling the entire system. I had left the original AC compressor and lines untouched with plans on mounting the ST165 compressor to the new block but it turns out it didn't quite fit into the new bracket and the old bracket wouldn't work. I then tried to swap the ST205 compressor in but the lines didn't quite match and I didn't have the complete lines. Oh well, made room for other things.

Pile o' AC crap.



In the process of pulling the AC lines, I cracked one of the rubber molded power steering hoses. With the car being 27 years old, its of course no longer available.



With the AC gone, something will need to be done about the pulley that would be there.



I found this thread on 6gc.net http://www.6gc.net/forums/index.php?showtopic=36671 detailing an OEM solution. I prompted ordered the parts from Amayama Trading. I also got a package from them the other day with some brand new parts, straight from Japan. New intake boot and intercooler coolant bottle.





New heat exchanger with brackets that fit in factory mounting holes. I utilized the existing lines and pump for now.





Ceika got back to me regarding the incorrect brackets for the ST165 and prompted shipped me a full set via DHL Overnight from Taiwan.



Installed and looked great but I noticed that the brake line clip was completely different (and on the wrong side). At this point I'll live with it and make it work with some creative zip ties or something.



While I was there, I finished up installing the OEM pads and OEM tie rod ends.





I decided it would be a good time to check if the exhaust bolted to the MR2 downpipe. So far so good but the stock exhaust is in questionable shape.



Stainless clutch line installed.



Brass shifting bushings installed.



Bent accelerator cable. Need to replace this.



And I still need to source a transmission oil cooler. I would prefer to keep the factory lines but that is looking like less and less of an option.



Stay tuned for more!

[zaluss]

June 21st, 2015


Finished installing the front/rear motor mounts, crossmembers, and misc stuff underneath the car.





Test fitted new catch can and hoses. Trying to figure out where this vacuum line goes.





Installed the ST205 waterpipe from the intercooler but of course the lines extend way beyond the stock ST165 pump. I'm going to have to engineer this one.





Instead of going with a complete aftermarket solution for the transmission cooler, I'm thinking of utilizing the existing hosts with some new flared lines based on the ones that were cut from the car. If I can get new lines clamped with rubber hoses to your run of the mill 13 row JDM crap, that will do just fine. I'll run these to home depot to see what size they are and order the appropriate lines online.

[jl1524]

Good luck with the build, very interested to see it finished!

[zaluss]

June 27th, 2015

Few more bits sorted out. Fitted the ST205 stock airbox. It bolts with two of the factory ST165 bolt points which I'm just fine with.



Installed the AC delete pulley and belt.



Frozenboost oil cooler and AN lines from anplumbing.com installed.

[zaluss]

July 5th, 2015

The heat exchanger came with a Spal 12" so I went ahead and used that along with a new Flex-a-lite fan I ordered from summit. I wired both to individual 30amp relays triggered by the stock fan harness and they work beautifully. They are both set to pull air into the engine bay. Not sure why the last picture is poor quality but I got lazy and didn't extend the wiring when I should have as you can (kinda) see when I sleeved the wires.

[2RM]

Could you list the size of the AN trans cooler fitting and lines, please?

[zaluss]

http://www.frozenboost.com/water-to-air ... -1105.html

This has 1/2" NPT threads. I purchased 1/2" NPT to AN-6 90 degree adapters for the trans cooler.

http://www.anplumbing.com/Adapters/Metric-25.html

The transmission itself is M14x1.5. I purchased a M14x1.5 to AN-6 adapter. Make sure you get the one with the crush washer. #871406.

[zaluss]

July 11th, 2015

A few updates were missed but I finally got her started. I had everything hooked up yesterday, fluids filled, etc but she would crank and crank but not fire. Spark at the ignition coil, sparks at the plug. Fuel pump tested good. Timing was spot on. Fuel resistor had 12v. Nothing.

I pulled the plugs and they were dry as a bone so the injectors weren't firing. One of my buddies came by and we pulsed each injector per the EFI troubleshooting guide in the BGB. At first only 1 and 4 were going. We started her up and she ran like shit. We pulsed it again and then 1, 2, and 4 were going. We finally pulsed 3 again and now all of them were firing. No idea why but here she goes!

https://www.youtube.com/watch?v=IZOYUY8Z5qk

[freddie]

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