Project Corona - 1990 ST185 Gen4 Swap

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Project Corona - 1990 ST185 Gen4 Swap

Postby daveryan » Sun Aug 09, 2020 10:45 pm

So I've owned my Alltrac for 20 years now, but it has been sitting in the garage for the last 7 with a head gasket or some other terminal issue. Anyway, since I'll be working from home for the foreseeable future, I decided to get it running with a gen4. I'll be cleaning and freshening as I go, and deleting the ABS an A/C as well. Wiregap is doing the harness.

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Tired old engine gen2 out!

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No, this isn't black paint

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After 10 cleanings. Only 10 more to go!

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First coat of etching primer. I went back and forth on painting this, but after all that cleaning I wanted to try and preserve my efforts.

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Sprayed the gearbox with 4 coats of VHT cast aluminum paint, or was it 6? Two whole cans at least. Will do clear after this cures.

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Unloading the gen4

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ABS delete and other parts from a GT-S. $32 total at the pick-a-part

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Stripping engine bay for cleaning and paint

Once the gearbox paint has cured I can get the gen4 on the stand and start freshening that.
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1990 ST185
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Re: Project Corona - 1990 ST185 Gen4 Swap

Postby grip-addict » Mon Aug 10, 2020 4:22 am

that is the cleanest 3s transmission i've ever seen. that looks like a ton of work... but so nice.
Good luck with the swap! keep the build thread going as you do stuff :)
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Re: Project Corona - 1990 ST185 Gen4 Swap

Postby GT4times2 » Mon Aug 10, 2020 8:52 am

Looking very good. Great job on the gearbox. Super clean. And good move on the Gen 4. They're getting harder to find these days.
Frantz
12 Toyota Sienna LE
12 Toyota Camry SE
90 ST185 (MRP) Gen4 swap
90 ST185 (Gray)
88 ST165 Gen3-The works
89 ST165 Gen4-on the way
88 St165 (white)- 2020 Project
+ Many other projects, under covers....
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Re: Project Corona - 1990 ST185 Gen4 Swap

Postby transneptunian » Thu Aug 13, 2020 12:41 am

Looking good. I see you had an ample amount of Toyota’s patent rust proof coating.
1993 JDM ST-185 - The project
1999 Dodge Ram 1500 - The tank
2017 Dodge Caravan - The grocery getter
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1993 Toyota Celica

Re: Project Corona - 1990 ST185 Gen4 Swap

Postby daveryan » Fri Aug 28, 2020 5:34 pm

After a grueling few weeks of prepping and painting virtually everything in front of the firewall, I've got a break while I await the harness and powder coating.

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Engine bay painted and then 2K cleared

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Non-ABS brake lines and new steering rack installed. Body electrical harness re-wrapped with Tesa. New headlight plugs as the old ones were disintegrating.

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Obligatory parts haul pic

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First peek inside the Gen4

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Gen4 timing belt, seals, water pump, and idler pulleys replaced


I really need to decide on what clutch to use. Leaning towards the CM FX300
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Re: Project Corona - 1990 ST185 Gen4 Swap

Postby simple » Fri Aug 28, 2020 6:03 pm

I was going to ask how you got the crankshaft pulley off but then I saw the impact gun.
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Re: Project Corona - 1990 ST185 Gen4 Swap

Postby daveryan » Fri Sep 25, 2020 7:16 pm

Small update since I'm still waiting on a clutch disc before I can put it all all back together. Finished my clocking bracket, powder coating is done. I did find a stripped exhaust stud, so I had to remove the turbo and helicoil that :shoots:

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More info on the bracket
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Re: Project Corona - 1990 ST185 Gen4 Swap

Postby daveryan » Sun May 02, 2021 11:41 pm

After hibernating all winter, here is what I've done so far this spring:

FMIC and rad fan is done. Working on a trans cooler setup now. Originally I wasn't going to run one, but then I remembered how old the transmission is, and I have room for it. I daily drove with this battery setup for years, so I'm just keeping it as-is
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FMIC. 2.25" hot side, 2.5" cold side. All done with off-the-shelf parts. Two tubing pieces needed to be cut shorter, so I might get those welded later.
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Intercooler has rubber mounts top and bottom
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This large Spal fan should be plenty, but the bracket can accommodate a second one - if the wiring can handle it. I was warned that mounting it to the rad with those plastic threaded rods can cause radiator leaks over time, so this is mounted to the frame. I only drilled one M6 hole for all of this. The rest is riv-nuts in existing holes.
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Headlight restoration. Four headlight assemblies were used to make two good ones. Prepped and painted, new stainless hardware where possible, especially the M5s
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Old #5. This was all working fine, but since I'm putting in a Supra pump for the gen4, some restoration can (and must) be done. Thanks to Tippo for posting his experience with this.
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The fuel send pipe gave up when I tried to disconnect it, so it was only a matter or time...
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Not shown: ECU and tach adapter is installed, and I gutted the interior to make that easier. (was going to get gutted and restored eventually)
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Re: Project Corona - 1990 ST185 Gen4 Swap

Postby daveryan » Mon May 03, 2021 12:30 am

Wow, I didn't realize in my prior post, the engine was still on the stand. Continuity error :P

Obligatory engine install pics, and bonus pics:

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I sleeved most of the Wiregap harness. The alternator main was a bit long so I shortened it and re-terminated
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My "classic" battery mount
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Re: Project Corona - 1990 ST185 Gen4 Swap

Postby abeans » Mon May 03, 2021 1:41 am

Looks great.

Does that guy making the harnesses use all new connectors? Looks like no.
1990 St185 Celica
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Re: Project Corona - 1990 ST185 Gen4 Swap

Postby simple » Mon May 03, 2021 2:11 am

Nice update. The intake tubes look great! Yeah wiregap uses the connections supplied with the harnesses. Nothing new. Would cost a lot more if they did.
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Re: Project Corona - 1990 ST185 Gen4 Swap

Postby lalojamesliz1 » Mon May 03, 2021 2:57 pm

Great work so far!
Thanks for the picture of the abs delete kit.... I've been wanting to do that but never really knew what to look for.
Now I also want to clean up and paint my trans ha ha ha
91 Celica all-trac gen3 swap (small-med $$$ sponge)
69 mustang 408w (large $$$ sponge)
08 sequoia 5.7L
14 avalon
02 taco dbl cab V6 turd
and a 2 car garage :shoots:
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Re: Project Corona - 1990 ST185 Gen4 Swap

Postby Tippo » Tue May 04, 2021 12:40 pm

Amazing job! Definitely doing something similar when my gen2 grenades.
1992 SW20 MR2 Turbo 4th Gen 3SGTE Swap. Aquamarine Pearl. Project "Prissy"
1992 ST185 Celica All-Trac Turbo. Teal Metallic. Project "Lazarus"
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Re: Project Corona - 1990 ST185 Gen4 Swap

Postby daveryan » Mon May 10, 2021 7:00 pm

abeans wrote:Looks great.

Does that guy making the harnesses use all new connectors? Looks like no.


Generally no, but he might have converted/replaced one or two. You do get and new OBD port of course. I myself replaced some connectors - the ones I damaged when sleeving it:)
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