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View Full Version : 3SGTE into my ST162 - "FWD Fury"



RyanD
03-09-2010, 05:41 AM
Since I purchased my GTS in the spring of 2007, I had always entertained the thought of doing a swap to give my car the power it deserves. But the final straw came at last year's Ogopogo meet, when the others were leaving me in the dust; no amount of drafting, sling-shot passing, and the cranking of "Radar Love" to 11 could help me achieve the speed I wanted.

But the pieces finally fell into place this winter when the organ donor appeared and presented a good opportunity for both my brother (ChrisD) and I:

http://www.celicatech.com/forums/showthread.php?t=45139

He parted it out to make some extra dough, and I got the engine - and, more importantly, his expertise - at a severely discounted rate. Here's the donor at its worst, prior to it being in our possession:

http://i33.photobucket.com/albums/d99/oilerfan05/GoodwinShelby_Image_2.jpg
http://i33.photobucket.com/albums/d99/oilerfan05/GoodwinShelby_Image_7.jpg

Anyway, here's my 162 and the eventual home of the 3SGTE:

http://farm4.static.flickr.com/3613/3421676133_7f37f6c84e.jpg
http://farm4.static.flickr.com/3432/3809085995_8bfab34f5a.jpg

The transmission from the donor is royally screwed and we'll be using mine from the 162 (which is actually a JDM 5th gen anyway).

This past weekend we were able to start working away at the engine. Over the course of the past few days we were able to remove the engine completely. Removing the exhaust and the damaged axle proved to be a bit of a challenge, but we were able to accomplish our goal for the weekend:

Ready to begin:

http://i33.photobucket.com/albums/d99/oilerfan05/IMG_2225.jpg

The project actually began late on Friday night when we installed some shelving in Chris' garage. Running a pseudo chop shop takes up a lot of space!

http://i33.photobucket.com/albums/d99/oilerfan05/IMG_2336.jpg

Removing everything:

http://i33.photobucket.com/albums/d99/oilerfan05/IMG_2328.jpg
http://i33.photobucket.com/albums/d99/oilerfan05/IMG_2343.jpg
http://i33.photobucket.com/albums/d99/oilerfan05/IMG_2331.jpg

Chris had an overflow problem with a used oil container, so I decided to take a picture rather than to actually help:

http://i33.photobucket.com/albums/d99/oilerfan05/IMG_2350.jpg

Ready to remove the engine. After trying to lift it up unsuccessfully, we dropped it instead:

http://i33.photobucket.com/albums/d99/oilerfan05/IMG_2354.jpg

Woo! She's out. Big step completed:

http://i33.photobucket.com/albums/d99/oilerfan05/IMG_2356.jpg

So what's next? The project will go on hold for a week or two while we finish up the part-out. The final pieces will be removed and then we get to chop it out with the sawzall. Once that's done, my GTS will makes its way into the garage and engine pull number two will commence.

Plans are ongoing, but Chris will be taking care of the wiring conversion and we'll be looking at installing a front-mounted intercooler such as this one from Treadstone:

http://www.treadstoneperformance.com/product.phtml?p=29&cat_key=63&prodname=TR8+Intercooler

Chris' 165 will be getting one in the near future too!

The project just kicked off, so I'll have more to come in the next few weeks with some more progress pics. :D

I say it lots, but I need to say it here as well. HUGE thanks to my brother for helping me with this project. Without him, it simply wouldn't be possible.

CriScO
03-09-2010, 06:09 AM
Damn I love your GT-S. Cleanest hatchback I've ever seen. Good luck with the swap!

Shadowlife25
03-09-2010, 11:35 AM
I am SO glad you finally got a project thread started! :)
I have bugged your brother about it for a while now.

I wish you guys would have PM'd or called me, I could have told you by phone how to pull that motor complete in absolutely no time.

You are in good and capable hands there either way Ryan.
Your brother Chris is an intelligent and resourceful fellow, you will both fare well in your projects.

Best wishes and looking forward,

- Mario

ChrisD
03-09-2010, 05:07 PM
I'm most thankful we had some warm weather to work in! This is definitely the missing piece to your car.

Thanks Mario - the process didn't take a tonne of time, we ran into a couple issues with seized bolts that slowed us down. Even air tools weren't helping! Dropping it actually made more sense anyway, minimizes the use of garage space in there.

It will be exciting once we get to work on Ryan's car. Can't wait.

sodap0p
03-09-2010, 07:47 PM
good luck guys! I will come help(drink the booze while you guys do the work(aka: supervise)), let me know if you need me to bring some tools.

RyanD
03-10-2010, 12:24 AM
Thanks for the encouragement and the compliments, guys. This is a pretty exciting project. :)

rev_head
03-10-2010, 02:21 PM
was wondering when this would start cant wait for updates. couldnt be a more deserving 162 for the gte convertion

RyanD
03-15-2010, 03:37 AM
I should really re-name this thread, as it certainly entails more than just an engine swap. Chris and I didn't get a whole lot done last week for various reasons, mostly because of scheduling and whatnot, but we certainly made up for lost time today.

We got together on Thursday night and intended to remove the glass and cut off the roof of the donor car, but we didn't have the right tools to remove the windshield and side windows. As you know from the previous update, we dropped the engine so what we did finish on Thursday night was cutting off some of the bracing of the front clip to slide the engine out so that we could access and work on it easier.

Today we made a quick stop at Princess Auto and got the right tools to remove the glass.

We did our absolute best to keep the windshield in its perfect condition, but we quickly learned that working with auto glass isn't the simplest of jobs. We got the windshield out, but it suffered cracks all over the place when we were finished. Oh well, life goes on. But we were able to successfully remove the two side windows and keep them intact, despite the ridiculous amounts of epoxy that were holding them in and the failure of our removal tool near the end (the blade that goes underneath the glass to cut the glue snapped off while in use).

Once that was complete, we busted out the sawzall and made short work of the roof. The 185 was converted into a sporty convertible!

Of course, we did more than just the cutting of sheet metal. In addition to that, we were able to remove various interior accessories (e-brake, seat belts, etc), the remaining door and window, brake lines, as well as the gas tank. That was a plus in itself, as it gave me with a full tank of fuel for my truck!

Chris also tackled some work on the engine. He removed the intercooler, downpipe, and noticed that the spark plug wires were originals ('92 stamped).

All told, it was an extremely productive day. Only a few things left to remove from the rear of the car (rear differential, exhaust) and then we can cut this thing all apart and make several trips to the dump/metal scrapper. Here are a couple pictures to show just how bare this thing is looking. Soon my 162 will makes its way into the garage and the swap will truly get to an exciting level.

http://i33.photobucket.com/albums/d99/oilerfan05/IMG_2364.jpg
http://i33.photobucket.com/albums/d99/oilerfan05/IMG_2372.jpg
http://i33.photobucket.com/albums/d99/oilerfan05/IMG_2369.jpg

RyanD
03-17-2010, 04:52 AM
Another productive evening in the chop-shop and we're starting to see the end of the part-out.

Here's what we accomplished in a couple hours tonight:

- Removed miscellaneous parts from the engine bay (power steering reservoir, AC hose, etc) to just have metal left.
- Removed the right-rear suspension
- Removed the heater components from the dash area
- Removed part of the exhaust to make room for our upcoming cutting sequence
- Spent too long trying to switch blades from the sawzall (obvious design flaw that's a problem we have to accept and deal with, lol)

But once we got the blade switched out we cut off the front clip!

http://i33.photobucket.com/albums/d99/oilerfan05/IMG_2374.jpg

http://i33.photobucket.com/albums/d99/oilerfan05/IMG_2380.jpg

http://i33.photobucket.com/albums/d99/oilerfan05/IMG_2376.jpg

I just noticed that you can see how big the puddle is underneath the car. We needed to cut through some of the brake lines, haha. No big deal for the sawzall:

http://i33.photobucket.com/albums/d99/oilerfan05/IMG_2375.jpg

http://i33.photobucket.com/albums/d99/oilerfan05/IMG_2379.jpg

On Saturday, all this and what you don't see (the side of Chris' garage is full of random crap) will be loaded into my small Ford Ranger. It will require several loads to the metal scrapper/dump, but it will be quite satisfying!

187flatliner
03-17-2010, 05:05 AM
i feel sorry for the car you just cut up....but hey life goes on.

RyanD
03-17-2010, 03:05 PM
Haha, we felt a little bad before we started too. But the car was completely messed up and we figured this would also be a good way to help keep other Celicas on the road or to help them get back there. That's the great thing about organ donors! Nothing's going to waste. :)

ChrisD
03-17-2010, 03:52 PM
Haha, yeah the car was long gone before we got to it. Would be too cost prohibitive to try to fix.

I'm excited to get this thing out of my garage! Things will definitely start to move quickly once Ryan's car is in there.

Also, I wouldn't mind parking my own cars in there sometime in the foreseeable future. :laugh:

sodap0p
03-18-2010, 02:53 AM
Yeah very sad, but I've fixed two cars using parts from that beast :)

Cheers! to the organ donor, RIPieces

RyanD
03-19-2010, 05:22 AM
^ Damn right man!

Tonight we got some more done. We cut the firewall in half to make the pieces more manageable for the dump trips. It went fairly smooth, but it got a little difficult with that 90 degree turn, as that also happened to be where the greatest layering of metal was. Only two more cuts to make and I predict they'll go pretty smooth.

Here are a few pictures. It's looking less like a car skeleton and more like a heap of metal now - and that's what we want!

http://i33.photobucket.com/albums/d99/oilerfan05/IMG_2381.jpg

http://i33.photobucket.com/albums/d99/oilerfan05/IMG_2387.jpg

http://i33.photobucket.com/albums/d99/oilerfan05/IMG_2388.jpg

http://i33.photobucket.com/albums/d99/oilerfan05/IMG_2385.jpg

When liquid wrench doesn't do the trick, you need to bust out the heavy artillery on these exhaust bolts:

http://i33.photobucket.com/albums/d99/oilerfan05/IMG_2390.jpg

Tomorrow we need to remove the sub-frame and then make the final cuts. After that, we'll disassemble a few things (transmission for the dump and the rear diff for selling) and we can make our series of dump trips on Saturday. Our goal remains the same...have Chris' garage full with two running vehicles by Saturday night. We should be able to get it done.

Shadowlife25
03-19-2010, 05:36 AM
Ryan, :)
I would also recommend if it is still possible, cutting out the rear pan and putting together a "AWD Conversion" kit.

You have all that is necessary and if packaged as such, you could make some decent $.

Great work so far.

Also, that last photo with he sparks flying is made of WIN!

ChrisD
03-19-2010, 04:58 PM
I think the trouble we'd run into is shipping. The size of the pan would require freight shipping, which I am not keen on doing. We can think about it I suppose. With that said, the diff, drive shaft, rear axles are sold and much of the right hand side suspension items are fuked.

LOL, wicked shot there as I made (kinda) short work of that bolt. to get at the 2nd exhaust bolt we decided to just pull the subframe first. Might be the first person in history to remove the subframe just to remove the exhaust! :hehe:

RyanD
03-19-2010, 05:16 PM
You made short work of the tip of your finger too, but I didn't get that shot. :hehe:

sodap0p
03-19-2010, 05:35 PM
http://i33.photobucket.com/albums/d99/oilerfan05/IMG_2385.jpg

.

Chris looks psycho here, Calgary Chainsaw Massacre....hehe

ChrisD
03-20-2010, 11:14 PM
LOL!

The car, is now gone!

Pics to come...

DudeMan
03-20-2010, 11:42 PM
Never noticed this thread until now, great work guys.

It's too bad we live 3 hours away or I'd offer a hand.

Just out of curiosity, what condition were the inner and outer rocker panels in?

sodap0p
03-21-2010, 12:45 AM
Never noticed this thread until now, great work guys.

It's too bad we live 3 hours away or I'd offer a hand.

Just out of curiosity, what condition were the inner and outer rocker panels in?

Left hand side were good(no rust anywhere on this car), Right hand side, well look at the very first photo of this thread, and that should tell you :)


LOL!

The car, is now gone!

Pics to come...

Sweet! great work! I cant wait to see Ryan's FWD Fury in action.

RyanD
03-21-2010, 01:14 AM
It was a very rewarding past couple of days. Chris and I stayed up relatively late last night finishing up the removal and cutting of a few pieces. We were probably the first people in the world to do this series of events:

- Remove the sub-frame so we could remove the exhaust
- Then lift the entire rear shell away to reveal the sub-frame (and so we could cut it up easier...you'll see in the pictures, lol)

The pictures aren't great because of the sunlight that was lighting up half the garage, but you get the idea of how it looked this morning before we carted things away.

Three truckloads took care of everything - two to the metal scrapper which gave us a cool profit of $30, and one to the dump which set us back $26. We netted $4 bucks out of it! As long as we didn't have to pay anything, we were happy. :)

http://i33.photobucket.com/albums/d99/oilerfan05/IMG_2398.jpg

http://i33.photobucket.com/albums/d99/oilerfan05/IMG_2401.jpg

http://i33.photobucket.com/albums/d99/oilerfan05/IMG_2406.jpg

The side of Chris' garage also served as storage space for random parts and cut up steel:

http://i33.photobucket.com/albums/d99/oilerfan05/IMG_2403.jpg

http://i33.photobucket.com/albums/d99/oilerfan05/IMG_2404.jpg

The engine neatly tucked away for the time-being:

http://i33.photobucket.com/albums/d99/oilerfan05/IMG_2422.jpg

http://i33.photobucket.com/albums/d99/oilerfan05/IMG_2423.jpg

So what's next? I think we're going to take a few days off and start the swap officially next week. We'll park my GTS in the garage so we can remove the harness and Chris can get working on the wiring job while I clean up the engine. Very exciting day!

Shadowlife25
03-21-2010, 01:30 AM
Great progress you two! :)

I am excited for you to finish and tell us how awesome it is.

ChrisD
03-21-2010, 04:54 AM
I love the last pic of the empty garage...first phase complete! Seriously got a lot done over the last couple weeks.

Really looking forward to getting the 162 in the garage, finishing up the wiring and moving on to the "fun" stuff. :D

ChrisD
03-21-2010, 04:58 AM
Never noticed this thread until now, great work guys.

It's too bad we live 3 hours away or I'd offer a hand.

Just out of curiosity, what condition were the inner and outer rocker panels in?

Hehe no worries. We'll get to meet up at least next weekend while we are in town. Diff is off and ready to go for ya. :)

Well, the rocker panels on the left hand side were technically fine, the right hand side was damaged due to the accident. Unfortunately, it's all at the metal recyclers now. :( Hey - do you have any use for the subframe? This one is fairly clean if yours is rusted bad.

ChrisD
04-04-2010, 09:38 PM
So, work has now begun on the 162. Ryan will get pics up soon I'm sure.

Initial thoughts, discovered a few things:

-Trans is a 16x S53, not a 18x version like we had thought. (previous owner had swapped tranny's, we thought to the newer version but wasn't) The big issue is that the starter on the 16x runs under the exhaust manifold instead of on the other side. Our plan right now is to drill out the trans and tap for the mounts. Fingers crossed it works out. I remember Jeremy doing this back in the day, not sure if others have done it recently...

-The '89 has the ABS control unit in the engine bay like the 5th gens. This causes the cruise to be relocated elsewhere in the engine bay that will be in the way for our intake and FMIC piping. I think I've convinced Ryan that he doesn't need cruise anyway... :hehe:

Also pulled the trans and harness off the 185 engine, and got most of the way getting the harness off the gts. I think tomorrow we'll push to get the harness off and maybe pull the 162 tranny so that we can begin to mod it and clean it up before we pull the engine. Also will make pulling the engine out a breeze.

I think we'll shoot for a 1 month timeline to completion, we'll see. Somewhat depends on some parts coming in.

RyanD
04-05-2010, 04:54 AM
Before we commit to drilling and tapping for the mounts on the transmission, we'll check to see if the donor can be salvaged (ie. removing some of the casing that contains the mount). This is probably unlikely, but we'll check it out. You'll see in the pictures below that the markings are already made for a mount, so that task shouldn't be too difficult. We'll see how it goes. Here are a few pictures:

http://i33.photobucket.com/albums/d99/oilerfan05/IMG_0012.jpg

http://i33.photobucket.com/albums/d99/oilerfan05/IMG_0014.jpg

http://i33.photobucket.com/albums/d99/oilerfan05/IMG_0016.jpg

Here's where we'll need to mount the starter. As you can see, there are markings already there - and there are some on the inside as well, for the large hole:

http://i33.photobucket.com/albums/d99/oilerfan05/IMG_0019.jpg

http://i33.photobucket.com/albums/d99/oilerfan05/IMG_0023.jpg

http://i33.photobucket.com/albums/d99/oilerfan05/IMG_0021.jpg

Tomorrow's plan is to remove the rest of the wiring harness, remove the exhaust (HKS/Magnaflow, which I'll be selling complete with a year-old, beautiful, Magnaflow muffler - stay tuned for that), and remove the transmission from my old engine so we can begin working on the modifications.

ChrisD
04-05-2010, 08:57 PM
So from a bit of searching looks like we can do either.

A) Drill and tap holes in the bellhousing to mount the starter on the other side
or
B) Swap the bell housing from the GT4 trans onto the S53

Either work in theory I guess. Anyone know how much effort is involved in swapping bell housings? Probably will have to do a little how-to on this issue once we are done...

RedRkt01
04-05-2010, 09:17 PM
Ha, my 162 should be done in the next month as well!

Shadowlife25
04-05-2010, 11:56 PM
ChrisD: Swapping the housings shouldn't be horrible...

That being said, I suppose we shall see, eh? :)

RyanD
04-06-2010, 06:25 AM
ChrisD: Swapping the housings shouldn't be horrible...

That being said, I suppose we shall see, eh? :)
I like that. Anything not horrible is something we're looking for. :biggthumpup:

Update: A little over three hours work put in tonight netted us a rather productive result. I removed the exhaust and disassembled it (no pics yet, as I want to clean it up and post it for sale first), and Chris finished up the removal of the wiring harness, radiator and intake manifold - plus a lot of other stuff in the engine bay. Next up is removing the transmission and we're ready to pull the engine, which should be pie considering all that will be left in the engine bay is the block.

http://i33.photobucket.com/albums/d99/oilerfan05/IMG_0035.jpg


Ha, my 162 should be done in the next month as well!
Beauty! This is turning out to be a great year for the 162, 'round these parts.

RedRkt01
04-06-2010, 03:01 PM
Beauty! This is turning out to be a great year for the 162, 'round these parts.

Yes, Sir! Five years of storage has the itch in me to complete it. My 3rd Gen 3SGE is all ready to go. All I have left to do is wait for the new mounts to arrive so I can drop her in. In the meantime I am dropping the fuel tank to clean the 16 gallons of varnish out. after all that is done she's going straight to paint shop.

GT4RC
04-08-2010, 08:18 PM
Good work guys! I can't wait to see it in person!

ChrisD
04-09-2010, 05:31 PM
Well dammit, I think I might have lost my axle socket. This was somewhat of an inconvenience last night, haha. And I used the damn socket a few weeks ago on the parts car. Bah, apparently it has legs.

So instead of pulling the tranny, we tried to pull apart the 185 trans and eventually gave up due to it being more work than we wanted to do. We'll leave using the casing as plan B, and modify the S53 to work as plan A.

I think this weekend Ryan will focus on a lot of cleaning work, I'll probably get going on the harness conversion.

sodap0p
04-09-2010, 05:35 PM
I'll pop by and show off a MR2 if I get one this weekend. What size socket is the axle socket? do you need me to bring something?

RyanD
04-09-2010, 05:38 PM
MR2, eh? Yeah you'll definitely have to show that off!

I think it's 29mm...not positive, though. I'll check around my place to see if we have one too.

It sure would have been nice to do some parts cleaning in the sunshine and warmth, but nooooo. Screw you, Calgary weather.

4thgenceli
04-09-2010, 05:39 PM
MR2, eh? Yeah you'll definitely have to show that off!

I think it's 29mm...not positive, though. I'll check around my place to see if we have one too.

It sure would have been nice to do some parts cleaning in the sunshine and warmth, but nooooo. Screw you, Calgary weather.
If it's off the st162, it's a 32mm socket.

RyanD
04-09-2010, 05:44 PM
Oh okay, thanks! Wouldn't want to bring the wrong one. :D

sodap0p
04-09-2010, 06:17 PM
I should have one, in a 3/4" though, probably not in my 1/2" set.

Yeah Ryan, the weather sucks! I just missed getting hit by it on my way home yesterday. My power was going on an off for about 3 hours last night. My wife was going crazy cause the PVR couldnt tape her survivor and Gray's show, but I'll download them for her when I get home tonight.

ChrisD
04-09-2010, 06:20 PM
LOL @ PVR'ing...

Do you have a 1/2 to 3/4 adapter? Biggest drive I have are 1/2".

sodap0p
04-09-2010, 06:27 PM
I should have a reducer, if not Ill bring my 3/4 ratchet

RedRkt01
04-09-2010, 07:57 PM
I'm doning the axles tonight. I'll check the socket for you guys and post up in about 3 three on what size it is.

BTW guys, I dunno if GTE + S53 is the smartest idea. Its not a bad idea, but isn't it the very last tranny any of us would want to use on an S series engine? At least try to source an S54.....just saying! Maybe I'm wrong. I just thought I'd sugges keeping your eyes peeled for another tranny.

ChrisD
04-09-2010, 08:33 PM
I'm thinking it will be ok, a lot depends on driving style...plenty have run the s53 for years without hassle. If something were to happen, we will look, but I'm willing to bet we'll be more than fine.

:)

RyanD
04-09-2010, 10:01 PM
After reading the 162 forums a little bit, it seems that many would recommend the stock transmission but the starter being on the other side almost forces people to upgrade. But we'll hopefully be taking care of that!

RedRkt01
04-09-2010, 10:04 PM
Yeah, that whole starter deal is stupid.....what a bad place for that!

sodap0p
04-10-2010, 02:44 AM
your a big boy, you could just push start it :)

sodap0p
04-10-2010, 04:31 AM
I'll head over after I pickup the MR2, I found a 1/2drive 32mm impact, I'll call first and make sure you guys are home.

Cheers,

ChrisD
04-10-2010, 05:29 AM
Sweet! Talk to ya tomorrow. Good choice btw. ;)

Berg
04-10-2010, 05:18 PM
I should have checked this thread more often. If you have an air compressor I have an impact wrench you could borrow.

Cheers,
Berg

RyanD
04-11-2010, 01:38 AM
We actually have a couple of impact wrenches too. We tried to use them when working on the parts car but didn't have much success with some exhaust bolts. You're right that we should be using it more often, though. lol

Update. Today we changed the pace a little bit and tackled some different things. Chris began to go to town on the wiring harness while my goal was to clean a few parts. I ended up only cleaning/de-greasing the intake manifold, but much of the time was spent working on polishing it up.

I tried different kinds of sand paper to get the surface smooth, but it was far too slow a process and it was difficult to work in the smaller, more detailed areas. I ended up busting out the Dremel and grinding the surface down. It came out well, but took about 4.5 hours to get to this point. From here I want to sand it down with various grit sand papers and then polish it up. I'm pleased with the results so far and it should end up looking good.

We thought about doing the runners as well, but they won't be seen so it seems like some wasted effort to be polishing them. As long as it's clean, I'm happy.

We also saw sodap0p's new MR2 today. Lookin' good, man. :)

http://i33.photobucket.com/albums/d99/oilerfan05/IMG_0043.jpg

http://i33.photobucket.com/albums/d99/oilerfan05/IMG_0054.jpg

http://i33.photobucket.com/albums/d99/oilerfan05/IMG_0053.jpg

sodap0p
04-11-2010, 02:02 AM
Wow it came out nice!! I only saw it part way :)

That looks painful Chris...Im glad I didnt stay long...hehe

Thanks Ryan, I did enjoy driving her today. I took your advise and went and washed the engine bay. Ill make another thread and add the before and after photo's and such, probably here under the projects section.

Cheers Guys!!

ChrisD
04-11-2010, 02:49 AM
Haha, it's not so bad. I guess I'm used to it by now. I probably made it 30% through the harness so far.

Found one interesting item, the cold start injector wire at the ECU was not present. All of the other wiring was there to the injector and time switch, but not to the ECU. Double checked my diagrams, and opened up the ECU just to make sure. Wasn't there. So I added it and wired it up like OEM and all should be good. The harness didn't look like it had ever been touched, so I'd bet the CSI has never been fired.

Other than that, hoping to have the harness complete within the week. :)

Oh yeah, BTW 32mm is not the right size! Doh!

sodap0p
04-11-2010, 02:54 AM
Oh yeah, BTW 32mm is not the right size! Doh!

bigger or smaller? I can probably burn down tomorrow

ChrisD
04-11-2010, 03:00 AM
Smaller than 32. Bigger than 27. :)

sodap0p
04-11-2010, 03:25 AM
I have a 30mm impact, then 27. Im sure I have other sizes, Ill bring what I got

DudeMan
04-11-2010, 03:53 PM
http://i33.photobucket.com/albums/d99/oilerfan05/IMG_0053.jpg


I'm with Soda, if I saw that mess of wiring I'd run.:eek4dance:

Projects coming along well, good job!

Lonestag
04-11-2010, 06:01 PM
Cool project guys.
And yeah, I would spend months trying to figure out that wireing.

skidMarkNZ
04-11-2010, 10:27 PM
Cool project guys.
And yeah, I would spend months trying to figure out that wireing.

yeah like the nightmare im having.:thumbsdown:

ChrisD
04-12-2010, 12:58 AM
yeah like the nightmare im having.:thumbsdown:

Ouch, months...eek. I've now got about 10 hours in, probably have 5-7 more hours and I'll be done. I'm doing everything to perfection too. Of course it helps that this is like the 6th harness conversion that I've done! The first one took, well, quite a bit longer...lol.

10 hours of wiring in 2 days is tiring tho! I need a nap.

skidMarkNZ
04-12-2010, 05:15 AM
Ouch, months...eek. I've now got about 10 hours in, probably have 5-7 more hours and I'll be done. I'm doing everything to perfection too. Of course it helps that this is like the 6th harness conversion that I've done! The first one took, well, quite a bit longer...lol.

10 hours of wiring in 2 days is tiring tho! I need a nap.

Yeah i hear ya, well...

try wiring a 4th gen 3sgte from a caldina gtt... into a 2nd gen 3sfe dash loom....

*facepalm*

ChrisD
04-12-2010, 04:17 PM
LOL, never done a Caldina, but done 3sfe to MR2 3sgte, 6th gen GT to 185, 165 to 185, and 184 to 205, and others....if you have the engine diagrams, pinouts it's all about following a very logical process.

Have you seen my write up on how to wire a swap? It's a decent read, but if you follow it step by step there is little room for any issues. And it will work with any conversion.

http://www.celicatech.com/forums/showthread.php?p=30010153#post30010153

RyanD
04-13-2010, 07:05 AM
Not a whole lot to report tonight, but another 3.5 hours in the books. Chris continued with the wiring and I traded the Dremel for 80-grit sandpaper to continue working on the intake manifold. Progress was good on both.

Of course, we needed to take a little product shot of our stack of new parts. Lots of good stuff! The intercooler on the left belongs to Chris and mine is on the right.

http://i33.photobucket.com/albums/d99/oilerfan05/IMG_0061.jpg

4thgenceli
04-13-2010, 02:41 PM
What kind of radiator is that?

ChrisD
04-13-2010, 03:10 PM
Happy Birthday Ryan!!!

Interestingly, this is the ASI rad that was in the group buy, Ryan purchased, got a call the next day from a guy here in Calgary that has a 'warehouse' in town with them in stock. Looks like this company "Autopwr" has rebranded the ASI rads. And this was purchased on ebay from the ASI rep David Wang too. So Autopwr = ASI, at least for the ST16x rads.

Wiring went ok last night, I think I'm down to only 6 ECU wires left, and I have to add a couple other minor things like the injector resistor pack, water neck plug, alternator plug for the 185 alt, and the rad fan switch. And maybe eliminate a few things if I can.

Also I'm integrating the starter relay mod that was done by the previous owner, and adding a common ground and a common +12V switched power source in a relay box that can be tapped into whenever needed. I didn't tell Ryan about that yet, haha.

4thgenceli
04-13-2010, 03:25 PM
Happy Birthday Ryan!!!

Interestingly, this is the ASI rad that was in the group buy, Ryan purchased, got a call the next day from a guy here in Calgary that has a 'warehouse' in town with them in stock. Looks like this company "Autopwr" has rebranded the ASI rads. And this was purchased on ebay from the ASI rep David Wang too. So Autopwr = ASI, at least for the ST16x rads.

Wiring went ok last night, I think I'm down to only 6 ECU wires left, and I have to add a couple other minor things like the injector resistor pack, water neck plug, alternator plug for the 185 alt, and the rad fan switch. And maybe eliminate a few things if I can.

Also I'm integrating the starter relay mod that was done by the previous owner, and adding a common ground and a common +12V switched power source in a relay box that can be tapped into whenever needed. I didn't tell Ryan about that yet, haha.
Awesome.


Happy birftday ChrisD's bro!

Looks like I"ll be picking one of those radiators up then. There's a guy in WA selling em on egay.

sodap0p
04-13-2010, 03:48 PM
HAHA!!

Happy Birthday Ryan!

RyanD
04-13-2010, 08:57 PM
Haha, thanks gents! :D

RedRkt01
04-14-2010, 03:09 PM
Awesome.


Happy birftday ChrisD's bro!

Looks like I"ll be picking one of those radiators up then. There's a guy in WA selling em on egay.

Lets see if we can get a deal on a pair.

4thgenceli
04-14-2010, 03:29 PM
Lets see if we can get a deal on a pair.
PM/or email me por favor.

rev_head
04-15-2010, 05:07 AM
good to see the updtes flowing :)
what cams did you go with? interesting dump pipe iv never seen one with a flex join.
gonna be one of the coolest gt2s ever!

ChrisD
04-15-2010, 04:25 PM
Hehe, cams are for me. We just tossed all of our parts in for a photo op. They are HKS 256's tho.

DP is Berk Technology. Awesome design. http://www.tcsmotorsports.com/ has them for good prices.

Wiring now 90% done. All that is left is the ISC, MAP sensor, Alternator plug for the 185 alt, rad fan switch. Last night I wired in the injector resistor pack, water neck plug, ignitor, and a couple other misc things. 3 wires on the 185 ECU left, the 162 ECU plugs have now been fully removed. :)

Ryan kept going with the polishing of the manifold, in the wet sanding stage now and about ready to move to actual polishing.

He might post some pics, today is a busy day tho as we are headed to Vegas to celebrate his 21st! With that said, we are taking the weekend off.

ChrisD
04-15-2010, 04:28 PM
Oh yeah, we got a schwack of Toyota parts in yesterday, and the first of two boxes of IC piping. :D

Berg
04-15-2010, 05:22 PM
As someone who has spent time polishing engine parts I know how much work it is. I also know how rewarding the results are. I'm looking forward to seeing your results.

What are you going to do with the valve cover? Polish the whole thing (eek! lotsa work)? Or polish just the "TOYOTA" and paint the rest?

My first Celica had the 2S-E engine (I know I know). The top of the intake manifold was flat with a lowered part around the letters "EFI". I used a sanding block and wetsanded the letters and the flat part like you are up to 2000 wet. I then polished it with a wheel. I used a wrinkle finish paint on the manifold and used a rag with paint thinner to wipe the paint off the polished parts. It looked really sharp. Sadly I lost the pictures of it. Just something to consider.

Cheers,
Berg

RyanD
04-15-2010, 05:43 PM
We've tossed a few ideas about what to do with the valve cover, but I think we're still undecided. After doing the manifold I definitely know how much work it is, so that's something to consider. lol.

The manifold is coming out good, I think. Getting in and around the tight spots is a real pain in the ass, but the minor scratches that I'm unable to get out should go away (or at least be hidden) once we polish it up.

During the wet sand:
http://i33.photobucket.com/albums/d99/oilerfan05/IMG_0067.jpg

After the wet sand...ready for polishing:
http://i33.photobucket.com/albums/d99/oilerfan05/IMG_0081.jpg

Chris' wiring centre:
http://i33.photobucket.com/albums/d99/oilerfan05/IMG_0070.jpg

Our shipment from Toyota:
http://i33.photobucket.com/albums/d99/oilerfan05/IMG_0072.jpg

ChrisD
04-15-2010, 06:03 PM
Hmm, wrinkle black would probably look pretty good. Then again, over time still might look crappy if it gets scratched / banged up?

Berg
04-15-2010, 07:08 PM
I liked the way it looked. That and I thought that it was much easier than polising the runners. The paint itself was pretty tough. And with a front mount intercooler I don't see much danger in scratching the valve cover. Mind you a plain painted or polished valve cover would be just as succeptible to scratches. I've never tried "touching up" wrinkle paint. The non flat surface might make it easier to fix spots that have been damaged. Whatever you decide to do I'm sure it will look great!

Cheers,
Berg

sodap0p
04-15-2010, 10:19 PM
Our shipment from Toyota:
http://i33.photobucket.com/albums/d99/oilerfan05/IMG_0072.jpg

Im comin to steal those wires!! :)

RyanD
04-22-2010, 06:40 AM
After taking a few days off to relax and drink in Vegas, we were back to work tonight. Not many details to share, but Chris completing the wiring tonight - all that's left is to wrap it - and I began the polishing stages of the manifold.

Polishing is a three-stage process (or, perhaps, two depending on how things go) using a solid bar compound that doesn't create much of a mess...just some polish dust here and there.

A few passes with the polishing compound combined with the drill attachment pads and we knew it was going to be a success. That red reflection is my car:

http://i33.photobucket.com/albums/d99/oilerfan05/IMG_0200.jpg

And after about 2.5 hours of polishing:

http://i33.photobucket.com/albums/d99/oilerfan05/IMG_0214.jpg

There were times when I wanted to throw the manifold into the alley because I couldn't see the light, but nights like tonight are really quite rewarding. I'm pretty jacked about seeing this in my engine bay! Probably about two hours left and I'll be done.

We'll be back at it again tomorrow!

rev_head
04-22-2010, 01:30 PM
well worth the effort! that looks shit hot mate, should be very proud

ChrisD
04-22-2010, 05:10 PM
I agree, it really does look awesome! And that is after only the first of the 3 stages of polish. The 3rd is supposed to be the one that brings out the "colour". This one is the "abrasive" stuff. Not so bad for the first step for sure.

Yes, finished the wiring of the harness. Just have to re-wrap it all up and make it look pretty. No major problems to report. A few things that I changed up, such as the water temp gauge sensor, moved the sensor into an unused blank on the st185 water neck (@the head). Also, pulled the rad fan switch sensor from the 162 water neck (@the thermostat) and it threads directly into the new radiator. But really, minor stuff. All in all the harness conversion went well. I'll get some pics of it all wrapped up tonight.

Plan for tonight:

-wrap harness (Chris)
-pull axles (Chris)
-pull transmission (Chris and Ryan)
-finish polishing manifold (Ryan)

Need that trans out so that we can convert it this weekend. Also got to install some gaskets and stuff, HFH, etc this weekend. Want to have everything ready so that next weekend, we can drop the 3sge and pop in the GTE.

wOOt.

RedRkt01
04-22-2010, 06:10 PM
Chris, how do you guys do that? I'm thinking of doing something similar on the Intake Mani/ACIS Runners when I have the head work done. BTW, you're spelling 'colo(u)r' all wrong ;).

Berg
04-22-2010, 06:36 PM
I see no error in his spelling of "colour" :haha:

RedRkt01
04-22-2010, 06:44 PM
Lol. Berg, your smiley kind of reminds me of a moose which kind of reminds me of the land of canandadia which kind of reminds me of those crazy people that live up there in the cold and spell things weird........haha

Berg
04-22-2010, 08:01 PM
Lol. Berg, your smiley kind of reminds me of a moose which kind of reminds me of the land of canandadia which kind of reminds me of those crazy people that live up there in the cold and spell things weird........haha

:canada:
Land of the mighty and majestic moose.
And proper spelling.
And really good beer.

That manifold is looking really good. Unfortunately polished bits never look as good in pictures as they do in person. I know that you said you arenít going to be polishing the runners, are you planning on just leaving them or are you going to paint them? I only ask because painting them would make them easier to keep clean.

Cheers,
Berg

RyanD
04-23-2010, 06:35 AM
We didn't get as much done tonight as we had hoped, but that's life. Chris is nearly finished wrapping the harness and I finished the manifold tonight. We attempted to remove the axles but ran into a ridiculously seized nut. Still, progress was made and we can't complain about that.

A couple pictures of the final polish job:

http://i33.photobucket.com/albums/d99/oilerfan05/IMG_0220.jpg

http://i33.photobucket.com/albums/d99/oilerfan05/IMG_0227.jpg

All done:

http://i33.photobucket.com/albums/d99/oilerfan05/IMG_0240.jpg


Chris, how do you guys do that? I'm thinking of doing something similar on the Intake Mani/ACIS Runners when I have the head work done. BTW, you're spelling 'colo(u)r' all wrong ;).

It's actually a very easy process. Just takes time and patience - a lot of both. I'll give you some details tomorrow morning...I just need some sleep right now!

sodap0p
04-23-2010, 02:13 PM
We attempted to remove the axles but ran into a ridiculously seized nut.


Got heat? need a torch, even propane would help, but acetylene would get way hotter.

nice work, that mirror finish looks amazing!

RyanD
04-23-2010, 07:43 PM
Here's a little EDU on polishing the intake manifold - I'll repeat a couple pictures just to show the process and to make it easier to follow:

Depending on the smoothness of the surface when you start, we may be able to skip the first step. The manifold I was working on was a lot like sandpaper, in that it was very rough and gritty, so an extra step was required to get the surface smooth.

Before we started:

http://i33.photobucket.com/albums/d99/oilerfan05/IMG_0012.jpg

I used a Dremel and some rounded stone attachments to go over the entire surface to remove the heavy pits and to quickly remove the dirty and ugly aluminum surface. I initially started with a heavy grit sandpaper, but progress was ridiculously slow. The Dremel was a good choice.

Once that was finished, I then had a reasonably flat surface - albeit very rough, after the Dremel job. From here it was time to pick up some 80 grit sandpaper and work over the entire manifold.

http://i33.photobucket.com/albums/d99/oilerfan05/IMG_0043.jpg

http://i33.photobucket.com/albums/d99/oilerfan05/IMG_0054.jpg

After that, a used a little bit of 120 grit to smooth it out a little more prior to wetsanding.

At this point the surface should be pretty smooth. Use 400 grit sandpaper and a bucket of water and start wetsanding. The surface will get really smooth during this process and even start showing a bit of a shine. Once you're satisfied with the smoothness of the surface, it's time to start polishing.

http://i33.photobucket.com/albums/d99/oilerfan05/IMG_0067.jpg

These are the tools we used for the polishing. We picked up a variety of wheels and drill attachments because the corners and tight spaces posed a problem throughout the process.

(Not our picture)

http://www.princessauto.com/components/com_virtuemart/shop_image/product/8263014.jpg

Some of the ones we got were bigger, which made it much easier. The cloth wheels were great to get into the tight spaces because it would flex and bend much easier. The small attachments didn't work as well in those areas, surprisingly.

So now that you have the tools, you'll need some good polish. Pictured above, there are three colored bars - we used something similar. You can see some of them here:

http://www.princessauto.com/view-all-products-in-shop?keyword=polishing+compound&orderby=product_name

"4oz Polishing Compound"

To use those, you just start spinning your buffing wheel on the drill and rub it against the bar. It collects enough and then you go to town! For our purposes, we used the black, brown, and white colors. Of the entire series, black is the most abrasive and clearly did most of the polishing in this three-stage process. The brown is next in line in the process, but I didn't find it to do too much. The final color is white, which is the finest of the three and gives a final polish to the aluminum and supposedly brings out the color a little more. I'll buy it, as reflections were more pronounced after that stage.

Just as I started polishing. You can see the dull wetstanded surface too:

http://i33.photobucket.com/albums/d99/oilerfan05/IMG_0200.jpg

http://i33.photobucket.com/albums/d99/oilerfan05/IMG_0220.jpg

http://i33.photobucket.com/albums/d99/oilerfan05/IMG_0240.jpg

It's important to note that between stages, I would wash and degrease the piece you're working on. The metal collects a lot of dust and film during each stage, so I think it was a good idea to remove all the crud before you proceed. Plus, you get a better idea of what it looks like.

And that's all! When all was said and done, this manifold took me about 15-17 hours to complete. I'll probably do a few polish touch-ups once it gets in the engine bay, just as a final cleaning.



Got heat? need a torch, even propane would help, but acetylene would get way hotter.

nice work, that mirror finish looks amazing!

We actually may have a torch...surprised we didn't think about that before. And thanks!

Shadowlife25
04-23-2010, 11:59 PM
Great work Ryan!

Remind me later to copy this over to a How-To: Polish Aluminum.

Or have your brother do it! :p

sodap0p
04-24-2010, 01:36 AM
princessauto rocks!! I go bi-monthly...hehe

ChrisD
04-29-2010, 04:47 PM
Weather was shit yesterday, but we got back at it a bit.

No new pictures, but last night Ryan pulled the flywheel and replaced the rear main seal and rear end cap gasket, I pulled the turbo off and replaced the HFHOE. We'll do the HFH on Saturday along with the timing belt, cam seals, and some other stuff. Valve cover is removed, Ryan's cleaning that up and doing something special with it over the next week. I'm sure it will look good, he's got an eye for those sorts of things.

We tried again to get the axle bolt off again, with a torch, still no luck. Will have it soak in Liquid Wrench until Saturday and hopefully we'll have more luck. Still dumbfounded by this one, we had the damn bolt off last year, and this is a summer only car!

Oh yeah, we did get the clutch and the IC piping in but didn't take any product shots.

Siyx
04-29-2010, 05:00 PM
Amazing shine, hmmm i still have $50.00 left on a Princess Auto gift card :facesjump:

ChrisD
05-02-2010, 04:19 PM
So, Ryan told me to write up the summary of yesterday's events, so here it goes.

The day started off with a nice find of a 6 foot pipe, and a steel rod that I had laying around. This would prove to be crucial in getting the axle nut off. Now prepared with the proper 30mm axle nut socket, about 1L of Liquid Wrench sprayed on it over the last week, we were determined to get it off.

Crack! It finally came loose! We figure it took a solid 700 ft-lbs to remove it. Craziness, especially considering that we just had the brakes off last year, and this car is not driven in the winter.

So after that, Ryan went to work cleaning the block, and I went and pulled the axles out. Mission accomplished.

http://www.celicatech.com/gallery/files/4/dsc01063_sm.jpg

http://www.celicatech.com/gallery/files/4/dsc01052_sm.jpg

Here's a shot of the GT4 front shaft compared to the '89 ST162's.

http://www.celicatech.com/gallery/files/4/dsc01054_sm.jpg

I also did the HFH. That is a pain even with the engine out.

Next, I pulled the transmission. Spent about an hour cleaning it, damn thing was disgusting.

http://www.celicatech.com/gallery/files/4/dsc01056_sm.jpg

http://www.celicatech.com/gallery/files/4/dsc01058_sm.jpg

Then it was time for the starter relocation. First, drilling it out with a hole saw, then getting the hole just big enough with a dremel and a file.

http://www.celicatech.com/gallery/files/4/dsc01068_sm.jpg

http://www.celicatech.com/gallery/files/4/dsc01070_sm.jpg

http://www.celicatech.com/gallery/files/4/dsc01072_sm.jpg

Then drilling and tapping for bolts.

http://www.celicatech.com/gallery/files/4/dsc01074_sm.jpg

http://www.celicatech.com/gallery/files/4/dsc01075_sm.jpg

Meanwhile, Ryan dremelled in a notch for the IAC valve. Forgot to get a picture of this, but all it is is a notch in the inlet just like the ST185 manifold has. The 3sge does not use this.

From here, I did the timing belt and cam seals.

http://www.celicatech.com/gallery/files/4/dsc01077_sm.jpg

All going well until I try to reinstall the tensioner. God do I hate the tensioner. The bolts would not thread in straight at all. I suspect the previous job had cross threaded them, b/c I couldn't get them in nice even just trying to thread them in by hand with out the tensioner in place. Giving it one shot to thread them in, it started to go, then got stiff....and snap! FFFFFUUUUUU!!!!! Snapped one of the tensioner bolts off in the head. Looks like we'll be heli-coiling it or doing something similar. FUCK ME.

http://www.celicatech.com/gallery/files/4/dsc01082_sm.jpg

After that, we discovered the rear main seal had a little issue requiring us to reinstall it. Part of the lip was folded over on itself...wierd. Pulled the cap off, reinstalled. Then snapped one of those bolts...and we were using a torque wrench!!!!! Bah. Stupid weak bolts. Pulled one off of Ryan's 3SGE. After that, buttoned up, and installed the resurfaced flywheel and new clutch from Southbend / DXD.

http://www.celicatech.com/gallery/files/4/dsc01062_sm.jpg

http://www.celicatech.com/gallery/files/4/dsc01079_sm.jpg

sodap0p
05-02-2010, 04:51 PM
Cant you just leave the bolt in there? chop of its head and use as a stud instead? throw on a nut with a lockwasher and you're golden! :)

Dude, you should put that motor on a stand, I noticed yesterday Princessauto has one for $50 on sale. I got a Princessauto hat (has checker plate on it) yesterday (spend $100 or more, Saturday only though)

AWESOME work on the starter, too bad about the tensioner.

ChrisD
05-02-2010, 05:20 PM
Bolt is too short, haha. I'll probably pick up a heli coil set. Might head down to auto value this AM.

No stand, almost done at this point and I'm too cheap for that. :hehe:

sodap0p
05-02-2010, 05:28 PM
I have Heli Coils, but they are all SAE :(

If you want to use a SAE bolt, you could use my set

ChrisD
05-02-2010, 05:32 PM
Thx Steve :) I think I'll try to get the right metric one if they have them. If not I'll give you a shout. :) I have a twosrus.com tensioner stud kit I'd like to use instead of bolts anyway...makes so much more sense than bolts.

sodap0p
05-04-2010, 10:06 PM
any updates?

4thgenceli
05-04-2010, 10:39 PM
Refresh my mind, starter relocation was because it doesn't clear the turbo correct?

celica9303
05-05-2010, 05:16 AM
looks good guys!

ChrisD
05-05-2010, 05:01 PM
Refresh my mind, starter relocation was because it doesn't clear the turbo correct?

yep. :)

As for updates, not a whole bunch.

Ryan has been busy working on the valve cover, cleaning it up, and he also picked up an M8x1.25 Helicoil kit.

Back at it tonight. Between tonight and tomorrow we have to helicoil the tensioner, finish the t-belt install, install the valve cover, install the new clutch release bearing, install the transmission, swap intake manifolds, install the wiring harness.

Steve, still good for the engine hoist? We will be ready to use it Saturday, should only need it for the weekend as long as everything goes to plan!
:)

Berg
05-05-2010, 05:07 PM
Hey Chris.

I realized last night that I still had my makeshift 14mm wrench you were going to borrow in my tool box. Did you still want to borrow it?

Cheers,
Berg

ChrisD
05-05-2010, 06:20 PM
Oh ya, crap! Hm. You going to make it to Race City on Friday? (if weather improves)

One more thing, must remove PS Pump from the 3SGE engine. :D

RedRkt01
05-05-2010, 07:00 PM
One more thing, must remove PS Pump from the 3SGE engine. :D

Doesn't that suck. I have damn near brand new units off of the ST202 and ST215 that I can use for my projects, but no. Toyota had to design a funky system for the 4th Gen that won't accept the newer interchangable pumps.

RyanD
05-05-2010, 09:40 PM
This valve cover has been a huge pain in the ass. I wanted a good black paint and polish combination but wasn't thrilled with my polish job in some areas. In the tight spaces, it just looked dirty. So I decided to paint a portion of the area I intended to polish to clean it up. Assuming it all works out, it should look badass. Hopefully it works...

Also, screw this weather. It's a lot less fun working in a garage when the temperature is below zero.

sodap0p
05-05-2010, 09:57 PM
This valve cover has been a huge pain in the ass. I wanted a good black paint and polish combination but wasn't thrilled with my polish job in some areas. In the tight spaces, it just looked dirty. So I decided to paint a portion of the area I intended to polish to clean it up. Assuming it all works out, it should look badass. Hopefully it works...

Also, screw this weather. It's a lot less fun working in a garage when the temperature is below zero.

I hope it comes out how you like it, I hate polishing...hehe

This weather so sucks, I havent been able to drive my 2 since the weekend :(

Berg
05-05-2010, 10:03 PM
Oh ya, crap! Hm. You going to make it to Race City on Friday? (if weather improves)

One more thing, must remove PS Pump from the 3SGE engine. :D

Have to see what the weather does. Either way I already told my girlfriend that I was planning on making an apearance, so I should have the free time to get it to you. If the weather doesn't improve how about beers instead?

Cheers,
Berg

sodap0p
05-06-2010, 04:31 PM
Have to see what the weather does. Either way I already told my girlfriend that I was planning on making an apearance, so I should have the free time to get it to you. If the weather doesn't improve how about beers instead?

Cheers,
Berg

I'm down for beers too! count me in! :)

ChrisD
05-06-2010, 04:58 PM
So last night we got a few things done. Ryan conveniently forgot to bring back my dremel and my tensioner stud kit, so we couldn't really touch the timing belt. I guess he was forgetful b/c the plan he had for the valve cover didn't work out.

So we installed the clutch release bearing, then the transmission. Then moved on to swapping intake manifolds. Vac routing is a bit different between the 3sge/3sgte, so I had to improvise a bit. Decided to delete the Turbo-VSV, and the coolant lines feeding the throttle body. Then we swapped in a new ignition cap & rotor and called it a day.

Tonight we have to finish the timing belt and install the wiring harness. I doubt the valve cover will be ready, so we'll probably pop that on Saturday before we install the motor.

ChrisD
05-07-2010, 05:43 PM
Another evening at it.

Started off with a trip to the post office to pick up a new goodie. Megan 3" N1 style muffler with silencer.

http://www.celicatech.com/gallery/files/4/dsc01092_sm.jpg

After cracking that open, Ryan went to once again try to remove the power steering pump with my only 14mm wrench, which happens to be rather inconveniently sized. :hehe: He was not successful. Kevin (Berg) has a tool which might do the trick for us though, fingers crossed.

After that, we had the task of Helicoiling the tensioner bolt holes. Fun!

http://www.celicatech.com/gallery/files/4/dsc01082_sm.jpg

After hacking off the end of it, I went to town with my drill. I sacrificed a half dozen bits to the cause. eek.

http://www.celicatech.com/gallery/files/4/dsc01083_sm.jpg

Here is what was left of the bolt:

http://www.celicatech.com/gallery/files/4/dsc01088_sm.jpg

And done! With twosrus stud kit installed. First off, I got to say that stud kit ROCKS. I will never use bolts in there again. Soooooooooo much easier to just pop the tensioner on and adjust it's position from there.

http://www.celicatech.com/gallery/files/4/dsc01090_sm.jpg

Tonight, we'll take a break and maybe get my 165 on the 1/4 mile if weather holds. We'll see.

Berg
05-07-2010, 06:24 PM
Hey Chris,

What time were you thinking of heading to the track? I was just thinking that if you want I could come by and see if we can get that power steering pump off before heading over. Let me know.

Cheers,
Berg

RyanD
05-09-2010, 01:41 AM
w00t! Engine is in! Hopefully we'll get some pics of it soon, but we'll see because the camera was crapping out on us.

Kevin, thanks for much for the tool. It worked great to crack the last bolt. And Steve, thanks for the procuring the hoist. It worked beautifully!

ChrisD
05-09-2010, 02:37 AM
+1, big thanks to Kevin and Steve for tool and hoist!

Not a very difficult day to be honest, but in terms of progress a big step. :)

So after pulling the PS pump, which was made much easier thanks to Berg's fabricated tool, Ryan and our Dad went to work pulling the 3SGE. In the mean time I installed the harness on the GTE. This went pretty quickly, no major snags.

http://www.celicatech.com/gallery/files/4/dsc01098_sm.jpg

Next up, time to pop in the GTE. Went in through the top. Took a bit of wiggling, adjusting, raising, and lowering, and raising again, but we got it in place and secured to the left and right motor mounts. Again, not too bad at all.

http://www.celicatech.com/gallery/files/4/dsc01108_sm.jpg

What's that in there?

http://www.celicatech.com/gallery/files/4/dsc01109_sm.jpg

First real view of the polished manifold installed...

http://www.celicatech.com/gallery/files/4/dsc01113_sm.jpg

And where she now sits.

http://www.celicatech.com/gallery/files/4/dsc01114_sm.jpg

RyanD
05-09-2010, 03:20 AM
Sweet, it was taking pictures! lol. Good stuff.

As Chris said, it wasn't exactly a taxing day work-wise. But it was probably the most satisfying to see the engine finally drop into my 162. I'm getting really excited now!

Berg
05-09-2010, 03:40 AM
Glad to see things worked well. Sorry I couldn't come by and give you a hand. Are you going to take a vid of the first startup?

Cheers,
Berg

RyanD
05-09-2010, 03:54 AM
Glad to see things worked well. Sorry I couldn't come by and give you a hand. Are you going to take a vid of the first startup?

Cheers,
Berg
Oh no problem. With our dad there, we had plenty of hands and eyes to make sure we were covered.

And yes, I definitely plan on taking some video. HD too! lol

sodap0p
05-09-2010, 02:33 PM
That looks awesome guys! great work!

Yeah Kevin, I offered to help them too, they told me to pound it, but they did take the engine lift (kidding :) )

ChrisD
05-10-2010, 01:17 AM
Some progress today. Returned the hoist to Steve first, came home and put in a couple hours on the car. Ryan installed the power steering pump, did some more painting on the valve cover, threw in the new igniter, while I started to button up a few things in the enigne bay. Heater hoses, fuel lines, clutch line, shifter cables, speedo cable, and some other stuff in that area.

Overall got a fair bit done given that we were taking our time and not expecting to work today anyway. Hoping to be inside of two weeks till startup. Still a fair bit to do yet.

:)

http://www.celicatech.com/gallery/files/4/dsc01122_sm.jpg

celica9303
05-10-2010, 04:51 AM
Just cuz Im curious. Whats the yellow bar thing on the hoist for? balancer of some sort? ive never seen one, if its usefull I may have to get one for my hoist (when i get it) an why does it seem that everyone take the motors out the bottom and back in through the top? I've done lots of honda swaps and weve always gone in and out through the top???

RyanD
05-10-2010, 05:34 AM
Yeah, the yellow bar is definitely a helpful tool when lifting an engine. Not only does it have four chains on it, but you're right on when you guessed that it was a balancing device too. It was especially useful when we needed more weight on one side of the engine to balance it differently...it was essentially once we were trying to get the engine on its second mount.

Are you renting or buying the hoist? We rented one a few months ago and the same device came with the rental. This one was borrowed from a friend but we ended up buying the leveler bar. I would imagine any place that sells hoists ought to carry it as well.

And I can't answer your last question, but I would guess it has to do with space. When we pulled the GTE from the donor car, we ended up dropping it because we were unable to pull it up - that transmission was huge! But since the sizes worked better the second time around, we were able to pull the GE and drop the GTE through the top this past weekend. :)

celica9303
05-10-2010, 05:53 AM
Yeah, the yellow bar is definitely a helpful tool when lifting an engine. Not only does it have four chains on it, but you're right on when you guessed that it was a balancing device too. It was especially useful when we needed more weight on one side of the engine to balance it differently...it was essentially once we were trying to get the engine on its second mount.

Are you renting or buying the hoist? We rented one a few months ago and the same device came with the rental. This one was borrowed from a friend but we ended up buying the leveler bar. I would imagine any place that sells hoists ought to carry it as well.

And I can't answer your last question, but I would guess it has to do with space. When we pulled the GTE from the donor car, we ended up dropping it because we were unable to pull it up - that transmission was huge! But since the sizes worked better the second time around, we were able to pull the GE and drop the GTE through the top this past weekend. :)

Ill be buying a hoist and engine stand.....im a tool whore i have about 4000k in just hand tools in my garage that doesnt include handmedowns from dad, grandpa, uncles....ect. or my airtools and my boxes(3 TOTAL).
I really need to pay off my matco guy so i can hopeduly buy more...

looks good ryan and chris ! this makes me itch for my swap even more but i is poor folk...lol

ChrisD
05-14-2010, 04:41 PM
Done last night:

# Install axles, brakes, suspension
# Poly fill engine mounts
# Cold start injector - may require 3sge hard line
# Throttle body & throttle cable

To do:

# Install valve cover
# Install cross members & engine mounts
# Swap fuel pump
# Check vac lines for leaks
# Fab EGR block-off plate
# Finish wrap of harness & connect loose ends
# Install ECU
# Install 3SGE alternator belt pulley
# Install alternator & belt)
# Install starter
# Swap coil, install strut bar
# Install fuel injector resistor pack
# Build battery mount & install
# Air box/shield
# Install intake & AFM
# Clock turbo
# Install turbo & downpipe, re-install all studs
# Mount FMIC
# Build FMIC piping & install
# Install radiator, new fan, coolant hoses
# Install new spark plugs (NGK BKR7EIX) & wires
# Fluids: oil (Mobile1 10w30), oil filter (Toyota), coolant (Toyota Red), trans fluid (Redline MT90)

Fire it up!

# Check timing
# Install hood
# Complete exhaust work
# Wheel Alignment

sodap0p
05-14-2010, 07:16 PM
wow! I love the to do list! that's awesome. It looks like you guys will have it on the road in no time.

RyanD
05-14-2010, 07:58 PM
That's the plan! Next weekend, if we stay on course. We're putting in some work tomorrow night and on Sunday, so we should get quite a bit done before the weekend is out. We got more done that we'd originally estimated yesterday, so we're rolling along. The biggest thing on that list is mounting the IC and its piping, but I think we should be okay.

ChrisD
05-16-2010, 06:20 PM
Late freakin night. Apparently, the 162 fuel pump is a bitch of a job. I say apparently, because I did very little helping. :hehe: I remember it taking about an hour on the 165 and 185.

Encountered one hickup, we missed the centre gasket for the valve cover when making our Toyota order. Got the big main one, but missed the centre one. Kind of important! It's ok tho, should have it by next weekend without much trouble. It just makes the progress pics look less nice without being able to show off the freshly wrinkle-painted paint job.

With that said, I present you with the to do list.

Done last night:

# Swap fuel pump
# Fab EGR block-off plate
# Finish wrap of harness & connect loose ends
# Install ECU
# Install 3SGE alternator belt pulley
# Install alternator & belt
# Install starter

To do:

# Install valve cover
# Install cross members & engine mounts
# Check vac lines for leaks
# Swap coil, install strut bar
# Install fuel injector resistor pack
# Build battery mount & install
# Air box/shield
# Install intake & AFM
# Clock turbo
# Install turbo & downpipe, re-install all studs
# Mount FMIC
# Build FMIC piping & install
# Install radiator, new fan, coolant hoses
# Install new spark plugs (NGK BKR7EIX) & wires
# Fluids: oil (Mobile1 10w30), oil filter (Toyota), coolant (Toyota Red), trans fluid (Redline MT90)

Fire it up!

# Check timing
# Install hood
# Complete exhaust work
# Wheel Alignment

Pic of the engine mounts, now curing. Interesting note, the Front and Rear mounts are identical in bolt pattern with Ryan's '89 GTS to the '93 GT4.

http://www.celicatech.com/gallery/files/4/img_0290.jpg

ChrisD
05-17-2010, 05:30 AM
Done today:

# Clock turbo
# Mount FMIC
# Install turbo
# Wrap DP

To do:

# Install valve cover
# Install cross members & engine mounts
# Check vac lines for leaks
# Swap coil, install strut bar
# Install fuel injector resistor pack
# Build battery mount & install
# Air box/shield
# Install intake & AFM
# Install downpipe
# Build FMIC piping & install
# Install radiator, new fan, coolant hoses
# Install new spark plugs (NGK BKR7EIX) & wires
# Fluids: oil (Mobile1 10w30), oil filter (Toyota), coolant (Toyota Red), trans fluid (Redline MT90)

Fire it up!

# Check timing
# Install hood
# Complete exhaust work
# Wheel Alignment

So Ryan wrapped the upper half of his Berk downpipe to keep heat away from the rad and the engine in general. It's nice having the flex, very little worry of cracking with it.

http://www.celicatech.com/gallery/files/4/dsc01133.jpg

Meanwhile I clocked the turbo. Took off the c-clip with an angled needlenose pliers, popped it off. Couldn't find the pin at first, but once I moved the housing around a bit it was there, and I pulled it. Compressory housing pops right off.

http://www.celicatech.com/gallery/files/4/dsc01127.jpg

Ryan then fabbed up a plate for the wastegate actuator. We did a quick test with a bike pump and it still moves a tad before opening the wastegate. So we're making up a 2nd plate that will utilize the starter bolt. Although it's probably fine where it is, he would see higher boost without making sure it is securely held on.

http://www.celicatech.com/gallery/files/4/dsc01134.jpg

Then we tag teamed installing the FMIC. We had some right angle brackets previously used for his fogs that were very solid, so we used them. The treadstone IC had threaded mounting points already on it, making that part easy. Lots of measuring, cutting, drilling and we came up with this pretty simple setup.

http://www.celicatech.com/gallery/files/4/dsc01137.jpg

http://www.celicatech.com/gallery/files/4/dsc01139.jpg

And some shots, installed. Looks AWESOME!

http://www.celicatech.com/gallery/files/4/dsc01145.jpg

RyanD inadvertantly posing:

http://www.celicatech.com/gallery/files/4/dsc01147.jpg

http://www.celicatech.com/gallery/files/4/dsc01148.jpg

And the engine as it sits pretty much.

http://www.celicatech.com/gallery/files/4/dsc01149.jpg

A solid weekend, got a lot done!

RyanD
05-17-2010, 05:39 AM
EDIT: Bottom of the page FTL.


Done today:

# Clock turbo
# Mount FMIC
# Install turbo
# Wrap DP

To do:

# Install valve cover
# Install cross members & engine mounts
# Check vac lines for leaks
# Swap coil, install strut bar
# Install fuel injector resistor pack
# Build battery mount & install
# Air box/shield
# Install intake & AFM
# Install downpipe
# Build FMIC piping & install
# Install radiator, new fan, coolant hoses
# Install new spark plugs (NGK BKR7EIX) & wires
# Fluids: oil (Mobile1 10w30), oil filter (Toyota), coolant (Toyota Red), trans fluid (Redline MT90)

Fire it up!

# Check timing
# Install hood
# Complete exhaust work
# Wheel Alignment

So Ryan wrapped the upper half of his Berk downpipe to keep heat away from the rad and the engine in general. It's nice having the flex, very little worry of cracking with it.

http://www.celicatech.com/gallery/files/4/dsc01133.jpg

Meanwhile I clocked the turbo. Took off the c-clip with an angled needlenose pliers, popped it off. Couldn't find the pin at first, but once I moved the housing around a bit it was there, and I pulled it. Compressory housing pops right off.

http://www.celicatech.com/gallery/files/4/dsc01127.jpg

Ryan then fabbed up a plate for the wastegate actuator. We did a quick test with a bike pump and it still moves a tad before opening the wastegate. So we're making up a 2nd plate that will utilize the starter bolt. Although it's probably fine where it is, he would see higher boost without making sure it is securely held on.

http://www.celicatech.com/gallery/files/4/dsc01134.jpg

Then we tag teamed installing the FMIC. We had some right angle brackets previously used for his fogs that were very solid, so we used them. The treadstone IC had threaded mounting points already on it, making that part easy. Lots of measuring, cutting, drilling and we came up with this pretty simple setup.

http://www.celicatech.com/gallery/files/4/dsc01137.jpg

http://www.celicatech.com/gallery/files/4/dsc01139.jpg

And some shots, installed. Looks AWESOME!

http://www.celicatech.com/gallery/files/4/dsc01145.jpg

RyanD inadvertantly posing:

http://www.celicatech.com/gallery/files/4/dsc01147.jpg

http://www.celicatech.com/gallery/files/4/dsc01148.jpg

And the engine as it sits pretty much.

http://www.celicatech.com/gallery/files/4/dsc01149.jpg

A solid weekend, got a lot done!


w00t. Thanks for posting the pics and telling the story Chris! The IC looks great in the photos (and in person too, obviously).

WALKER
05-17-2010, 05:43 PM
It's starting to look great guys, can't wait to go for a ride in it!

celicaturbo700
05-17-2010, 05:55 PM
wow this beast is coming right along. great work!

rev_head
05-20-2010, 07:50 AM
hurry up and finish! hahaha. good progress as alwys :)

RyanD
05-20-2010, 08:09 AM
hurry up and finish! hahaha. good progress as alwys :)

We're close...really close now! We worked tonight and built all the FMIC piping. It turned out fantastic - of course, it helped to have the right tool (bandsaw). Since I'm on vacation, my task is to polish up the pipes tomorrow and Friday in preparation for our final few days of work. Our goal is to work on Saturday, and possibly Sunday if we need to. We may anyway because we want to build an airbox and proper battery mount. After that, we're firing it up! This weekend is the time we've been waiting for. :)

I bought some mandrel bent exhaust pipes today, so once we start it up we can drop it off at the exhaust place to get that tied up.

Chris will post the latest pictures tomorrow morning, I'm sure.

4thgenceli
05-20-2010, 08:44 AM
Shit that IC looks awesome! Can't wait to buy & install mine now!

ChrisD
05-20-2010, 03:27 PM
We're close...really close now! We worked tonight and built all the FMIC piping. It turned out fantastic - of course, it helped to have the right tool (bandsaw). Since I'm on vacation, my task is to polish up the pipes tomorrow and Friday in preparation for our final few days of work. Our goal is to work on Saturday, and possibly Sunday if we need to. We may anyway because we want to build an airbox and proper battery mount. After that, we're firing it up! This weekend is the time we've been waiting for. :)

I bought some mandrel bent exhaust pipes today, so once we start it up we can drop it off at the exhaust place to get that tied up.

Chris will post the latest pictures tomorrow morning, I'm sure.

werd.

So my camera started sucking ass. 1 pic turned out...colours are funky, but you get the point. We will get good pics this weekend, most definitely. Maybe Ryan will 'bust out' the big boy?

On a side note, we decided that routing FMIC piping is easy.

Next step, is to make a custom ghetto beading tool, with credit to the DSM folks: http://www.dsmtuners.com/forums/custom-fabrication/324132-homemade-intercooler-pipe-bead-tool.html

http://www.celicatech.com/gallery/files/4/dsc01151.jpg

ChrisD
05-20-2010, 04:53 PM
Here's our pipe cutting tool: portable metal cutting bandsaw. At $80, it was a hell of a deal. (especially when you go halfsies!)

http://www.celicatech.com/gallery/files/4/img_0297.jpg

sodap0p
05-20-2010, 04:55 PM
Princess Auto ROCKS!

RyanD
05-21-2010, 04:45 AM
Yes it does!

Made the ghetto beading tool tonight:

http://i33.photobucket.com/albums/d99/oilerfan05/DSC_0313.jpg

http://i33.photobucket.com/albums/d99/oilerfan05/DSC_0318.jpg

ChrisD
05-21-2010, 01:51 PM
Nice! That will work well. Any pics of the tool?

black_celicagti16
05-21-2010, 01:55 PM
Lookin good ;)

RyanD
05-21-2010, 11:30 PM
Ah yes, a picture of the tool. Well, two or more years since I last broke out the welder and it went well. It's dirty, but it's strong as hell:

http://i33.photobucket.com/albums/d99/oilerfan05/DSC_0325.jpg

Not sure why my hand looks screwy, but yeah...

http://i33.photobucket.com/albums/d99/oilerfan05/DSC_0326.jpg

http://i33.photobucket.com/albums/d99/oilerfan05/DSC_0327.jpg

As for something that does look pretty - I polished up all the IC piping today. They look awesome!

http://i33.photobucket.com/albums/d99/oilerfan05/DSC_0321.jpg

http://i33.photobucket.com/albums/d99/oilerfan05/DSC_0323.jpg

Buying unpolished pipes has to be the best financial move we made throughout this project. IIRC, the unpolished pipes were half the cost. But after only a few hours work, they look just as good.

Shadowlife25
05-21-2010, 11:53 PM
Very nicely done Ryan!

From looking at the tool, I am a bit confused about how it actually works to make the bead, but the welds do look strong.

The piping turned out looking really great! About how long would you estimate it took to get to that point from an unpolished state?

RyanD
05-22-2010, 12:17 AM
Very nicely done Ryan!

From looking at the tool, I am a bit confused about how it actually works to make the bead, but the welds do look strong.

The piping turned out looking really great! About how long would you estimate it took to get to that point from an unpolished state?
Thanks!

I should have taken a picture with the tool inside of a pipe - but basically, the cradle sits on the outside of the pipe while the washer part goes on the inside. Then you just clamp it down and it makes the nice bead.

Polishing the piping was surprisingly easy. It's nice to be working with good aluminum, too. I started at around 1:30pm today and finished just before 4:30. That included giving each piece a quick wetsand and my cleanup time. I did a two-stage process for the polishing. First, I used the block compound with the drill (the same stuff I used on the intake manifold, a few pages back), and then finished with Mothers Mag and Aluminum Polish. It's a liquid paste, so I figured it would work well as a final buff by hand with microfiber towels. Worked great!

ChrisD
05-22-2010, 04:45 AM
So....I guess I need a new pair of vice grips! :laugh:

The pipes look wicked! That bead shot is basically what the pipes looked before polishing. I am still impressed with how big of an impact you can make with the right products when doing polishing.

Mario, check this pic...not ours, but from the DSM guys, same design of tool:

http://www.dsmtuners.com/forums/attachments/custom-fabrication/91688d1233872185-homemade-intercooler-pipe-bead-tool-beadslikebutta.jpg

For anyone that wants to run their FMIC like we did, the pipes above are what you need laid out there nicely for you. 7x90, 1x45, 1 straight pipe.

ChrisD
05-22-2010, 04:48 AM
Buying unpolished pipes has to be the best financial move we made throughout this project. IIRC, the unpolished pipes were half the cost. But after only a few hours work, they look just as good.

Half the cost from ebay pipes too. And we have high quality aluminum, not thin crap with coatings from China that you can weld. Going to give props to Global Tech & Engineering (http://www.globaltecheng.com/) again on those.

RyanD
05-22-2010, 07:12 AM
Oh, we might be able to salvage the vice grips - but I wouldn't use them for any kind of precision work after we're finished with them.

Yeah, maybe another pair would make more sense...lol.

4thgenceli
05-22-2010, 07:33 AM
Interesting. I have like 3 pairs of vice grips, I may just have to create that tool.

Now when using it, did you have to close it to make the flare, then unlock, reposition, and do it again?

I'm just thinking it may be easier to somehow fabricate the same idea of a tool, but with a rolling washer.

ChrisD
05-22-2010, 02:23 PM
They do produce larger tools with the 'rolling' type idea, but they are like $200. So this option, at $10 was a better expense. To do the bead, you basically just crimp it down, move the pipe a bit, crimp, repeat, repeat, until you've done the pipe.

And no, I'd like to keep it as a bead roller! I'll buy new vice grips, thats no prob.

ChrisD
05-22-2010, 02:23 PM
They do produce larger tools with the 'rolling' type idea, but they are like $200. So this option, at $10 was a better expense. To do the bead, you basically just crimp it down, move the pipe a bit, crimp, repeat, repeat, until you've done the pipe.

And no, I'd like to keep it as a bead roller! I'll buy new vice grips, thats no prob.

3s_woob
05-22-2010, 07:41 PM
Great job Chris and Ryan! Good luck on starting it today!!! =)

RyanD
05-24-2010, 05:59 AM
Great job Chris and Ryan! Good luck on starting it today!!! =)

Thanks! We needed a bit, lol.

We worked real hard this weekend but just fell short. Chances are we would have started it tonight if LOST wasn't on. :D

All that's left is to wire up the starter relay and radiator fan. While Chris is doing that, I'll put the wheels back on and clean his garage...then it's time to fire it! We'll be doing that early tomorrow morning.

So far we know the fuel pump works perfectly! We had to put it to use today so we could drain the fuel. Pics to come...I'm very pleased with how it looks. The airbox isn't yet complete, but that can be installed once the car is out of Chris' garage. I'll be finishing it up this week sometime.

Tomorrow will be a very exciting day.

ChrisD
05-24-2010, 02:31 PM
Thanks Ryan! Well lucky for us it is a long weekend which gives us an extra day. Hopefully, it will be an easier one for us. It is very, very close!

Berg
05-24-2010, 03:39 PM
So we're going to get to see the vid of it starting tonight? lol.

I'd love to come and see it, but I'm heading to Drumheller for the day. Once it's all back together we'll have to do the beer thing again.

Cheers,
Berg

RyanD
05-24-2010, 11:14 PM
So we're going to get to see the vid of it starting tonight? lol.

I'd love to come and see it, but I'm heading to Drumheller for the day. Once it's all back together we'll have to do the beer thing again.

Cheers,
Berg

That sounds great! And yes, you will see the video. It's currently uploading on YouTube.

So yeah, we got it started today! It started and ran (runs) beautifully. The only thing that we had to fix up after the start was an air leak off the turbo - a hose and a few minutes later, that was fixed. As well, my power steering wasn't working because the belt wasn't tight enough. Again, a pretty easy fix - we tightened it up and it worked great.

I couldn't be happier with how well things went. Not having any issues from the first startup is a big thing.

Tomorrow morning, Chris and I will drop it off at the exhaust shop and then I'll actually be able to drive it!

http://i33.photobucket.com/albums/d99/oilerfan05/DSC_0331.jpg

http://i33.photobucket.com/albums/d99/oilerfan05/DSC_0334.jpg

http://i33.photobucket.com/albums/d99/oilerfan05/DSC_0336.jpg

I'll get some better pictures up tomorrow.

The video will be up shortly.

EDIT: Here it is:

6mpUDEkjd30

Shadowlife25
05-25-2010, 12:00 AM
I am so happy for you guys! :D

Feels great to have all your hard work pay off right?!

4thgenceli
05-25-2010, 12:10 AM
Awesome work guys!

Mine's coming.. I promise.

ChrisD
05-25-2010, 03:54 AM
Yep, great day! :woot: Definitely rewarding. First rolled in the donor car back in January, but once that was parted things really moved along well. As with any project, lots of roadblocks, things you didn't expect or anticipate, but we managed through them and are really happy with the result.

Also, I fricken love Ryan's engine bay. IC piping route, Odyssey battery, mix of polished parts with black accents, valve cover looks sweet, anyway....it all fits perfectly with the car.

celica9303
05-25-2010, 04:32 AM
awesome work guys! cant wait to get me a motor..... will we see some vid of it on the street?

WALKER
05-25-2010, 04:46 AM
Congrats guys. That engine bay does look sweet! Great work, can't wait to go for a ride!

rev_head
05-25-2010, 05:08 AM
awesome work, glad to see it running :). that bay is pure sex!

RyanD
05-25-2010, 05:31 AM
Thanks for the compliments guys! And Dave, I think we can arrange a ride in the near future. :)

I have to give a public thanks to my brother. Without him, this project wouldn't have even been thought of. Not only that, but he dedicated many, MANY hours of his own time and garage space to help me out. Rep incoming. :D

GT4RC
05-25-2010, 11:06 AM
Congratulations you guys, looks fantastic. Very clean install as expected. I really like how you mounted the odyssey in there. plan on building an airbox next? seems like you have that battery out of the way quite nicely there :)

By the way You're going to have such a blast whenever your right foot gets heavy :P

Berg
05-25-2010, 02:14 PM
Way to go! I can't wait to see it in person! I really like how the engine bay turned out. A very good example of how things turn out when you take your time and do them right!

Cheers,
Berg

sodap0p
05-25-2010, 02:38 PM
nice work! I cant wait to go for a boot!

Mafix
05-25-2010, 02:48 PM
looks good ryan.

RedRkt01
05-25-2010, 02:59 PM
Congrats fellas! I'm glad it worked on the first try.

DudeMan
05-26-2010, 03:40 AM
Good job boys, should be a whole new car.

RyanD
05-26-2010, 03:48 AM
Oh, it's a whole new car alright. We got to drive it today after we finished up at the exhaust shop. It's really, really fun to drive! I couldn't be happier right now. :)

klapa
05-26-2010, 04:38 AM
GREAT looking engine and bay - very fine detail and sounds great!

Great work and congrats that your hard work has paid off - now it's time for hard fun!

Shadowlife25
05-26-2010, 05:22 AM
Oh, it's a whole new car alright. We got to drive it today after we finished up at the exhaust shop. It's really, really fun to drive! I couldn't be happier right now. :)

In car video or it didn't happen! :haha:

No really though, have your brother film and gives a play by play of your driving impressions compared to the original setup! :)

RyanD
05-26-2010, 05:51 AM
In car video or it didn't happen! :haha:

No really though, have your brother film and gives a play by play of your driving impressions compared to the original setup! :)
That could probably be arranged...I'll be taking my brother and sister and law out tomorrow night, so we could possibly include the camcorder. :D

ChrisD
05-26-2010, 02:52 PM
Damn lightweight FWD cars...that car is fricken quick! :hehe:

Really happy with how it turned out. lol....not sure how Lisa would feel about testing "driving impressions"...haha. But I'm sure we could get a vid.

Berg
05-26-2010, 04:31 PM
So are you and Ryan going to go head to head at race city? (This Friday doesn't look good weather wise though)

Any chance we could see some pictures detailing the intercooler piping (from turbo to throttle body)?

Cheers,
Berg

ChrisD
05-26-2010, 04:55 PM
Next few weeks I can't. I won't be racing for a while, probably not until all my major changes are done. Not sure about Ryan, don't really want to push the trans/axles that hard with launches and such.

IC piping shots will come, we have one change we're going to make since it runs a little too close to the DP and rad for our liking. Don't think it is a major task though.

Berg
05-26-2010, 07:12 PM
Cool. I understand about the not wanting to push the trans, but I'm sure I'm not the only one who wants to see these cars go head to head. :duel:

Looks great! I look forward to seeing the "major changes" and their results!

Cheers,
Berg

RyanD
06-01-2010, 04:21 AM
Just a small update. After finally getting the right size clamps for the BOV hose, I was able to install it correctly:

http://i33.photobucket.com/albums/d99/oilerfan05/DSC_0373-1.jpg

http://i33.photobucket.com/albums/d99/oilerfan05/DSC_0381.jpg

It actually started late last week when I got a 1" pipe welded to the IC pipe to connect the BOV. It works great!

I also had to order a new axle seal as I've been experiencing a small transmission fluid leak. It will be here tomorrow, so hopefully we can get that fixed up tomorrow. Shouldn't be too hard to replace.

ChrisD
06-01-2010, 07:01 PM
Nice, I take it Princess Auto had the T-bolts you needed. Might have to paint the outlet on that bov now to match your otherwise spotless engine bay. :D

RyanD
06-01-2010, 07:34 PM
Yeah, I was thinking that too. I'm still considering the filter as well, but as you said, it could just end up being a waste of money.

sodap0p
06-01-2010, 09:01 PM
put a 'real' BOV in her, By-pass valves suck ;)

from the picture it looks like your just venting anyway

ChrisD
06-01-2010, 09:22 PM
LOL, the MR2 BOV/BPV is one of the best designs out there and has been proven not to leak under even extreme boost levels due to it's design.

BTW, the only difference between a BPV and a BOV is that the discharge is recirculated - making this a BOV as it is vented to atmosphere. :P

Funkycheeze
06-01-2010, 11:17 PM
I wouldn't be too worried about the transaxle and halfshafts as long as you don't use drag slicks, and don't clutch dump. Alot of the older Toyotas are quite overbuilt in that department - I'm still on a stock diff other than the upgraded LSD, and stock halfshafts/stub shafts etc. in the rear end.

As a side note, looks really nice! I might be slightly partial to red cars that have black/chrome accents in the engine bay. I even painted my block red when I was doing the engine build.

sodap0p
06-01-2010, 11:41 PM
LOL, the MR2 BOV/BPV is one of the best designs out there and has been proven not to leak under even extreme boost levels due to it's design.

BTW, the only difference between a BPV and a BOV is that the discharge is recirculated - making this a BOV as it is vented to atmosphere. :P

I learn something new everyday...

its still FUGLY....hehe :)

rev_head
06-02-2010, 08:12 AM
if anything while still running an afm you should be running a re-circulted BOV anywayz

still very jealous

zen
06-02-2010, 11:12 AM
LOL, the MR2 BOV/BPV is one of the best designs out there and has been proven not to leak under even extreme boost levels due to it's design.

BTW, the only difference between a BPV and a BOV is that the discharge is recirculated - making this a BOV as it is vented to atmosphere. :P

i agree with this. ive bought two bovs (hks sequential bov, greddy type s bov) and i like neither one of them. i bought them to eliminate turbo flutter and seems like they are not that responsive. it takes a split second for the valve to release the pressure. now on the other hand, the stock bov for the st215 motor works supurb. just relocated it as close as i can to the turbo and it works much better than any other bov. it just doesn't give the kool woooosh sound.

RyanD
06-03-2010, 05:15 AM
if anything while still running an afm you should be running a re-circulted BOV anywayz

still very jealous
Our thought was to install it this way and then see how the car responded before committing to recirculation. So far so good. It runs and drives flawlessly.

Thanks again for the compliments guys! And Ryan, I totally agree with your thoughts on the color combination in the engine bay. Hard to beat IMO!

lindsley
06-09-2010, 07:04 PM
Read entire thread, great work.

DudeMan
07-08-2010, 05:33 PM
For anyone that wants to run their FMIC like we did, the pipes above are what you need laid out there nicely for you. 7x90, 1x45, 1 straight pipe.

I actually plan on routing my intercoolers piping the exact same way and I have a few general questions.

1. Some of your 90s look like they are different sizes, did you guys order them like that or cut them down yourselves?

2.Where did your order the couplers and bands?

3. It looks like ryan has Treadstones TR8 model intercooler and I'm considering the same one for my project. However, I noticed on Treadstones website that they offer this same model except the inlet is on top instead of the side. Now maybe I've missed something but wouldn't that make routing the hot pipe easier? I mean instead of wrapping all the way around the intercooler to the side, like most have it set up, it would just come down off the turbo almost directly into the top of the intercooler.

Hopefully that made sense. If not ill add a picture of the intercooler I'm talking about.

4. I can't see very well, did you mount the IC to the stock crash bar?

5. How long did it take to receive your downpipe from TCS Motorsports?

6. How long was the single piece of straight pipe you ordered?

If you'd like I can make a new thread so Ryans isn't cluttered.

DudeMan
07-08-2010, 11:09 PM
These are the two different intercoolers I'm referring to.

http://www.treadstoneperformance.com/~treadstone/prod_imgs/img-484-0-large.jpg

http://www.treadstoneperformance.com/~treadstone/prod_imgs/img-29-0-large.jpg

4thgenceli
07-08-2010, 11:13 PM
The TR6 is the one they ordered. TR8 is the one with the top inlet.

They ordered the bends, and then cut the pipes (as their 90* bends came with like 3 or 4" of straight)

DudeMan
07-08-2010, 11:21 PM
^ Actually the TR6 and TR8 both come with a side inlet but either can be purchased with a top inlet instead.

Thanks, I had a feeling they cut the pipes down with that Princess Auto bandsaw but I wanted to be sure.

4thgenceli
07-08-2010, 11:22 PM
Interesting. I've only seen the TR6 as the side feeds.

RyanD
07-09-2010, 03:30 PM
- Yep, I have the TR8 model:

http://www.treadstoneperformance.com/product.phtml?p=29&cat_key=63&prodname=TR8+Intercooler

- Yes, we just ordered a bunch of 90* bends and cut them down with our bandsaw. It worked quite well.

- The couplers and bands (in addition to the pipes) were purchased from siliconintakes.com:

http://siliconeintakes.com/

- I'm curious to see how routing it with the top inlet would work. There's a chance you could run into space issues, but I suppose that's unlikely. Would it be easier? Hard to say, because the way we did it was super easy. Full mock-up on that side took us under an hour.

- Yes, the IC is mounted to the crash bar. It's a very simple setup - we had some steel brackets that were originally used to mount my fog lights, so we drilled some holes and bolted it in. It's very stable and strong:

http://www.celicatech.com/gallery/files/4/dsc01137.jpg

- The downpipe came in about two weeks IIRC.

- I think we ordered a piece that was 5' long. Chris is doing his IC piping too, so we ordered extra pipe and the longer piece made sense. You could order one that's 2' long (from siliconintakes.com) and that would be plenty.

Hopefully that helped!

Also, a bit of an update. We installed the new polished heat shield the other day. I think it looks pretty badass:

http://i33.photobucket.com/albums/d99/oilerfan05/DSC_0407.jpg

ChrisD
07-09-2010, 05:47 PM
Heat shield's looking good! :cool: Will have to see some pics out in the daylight, the shield looks like it's sporting a "bike tire" paint job. :hehe:

A top inlet would not be easy to setup. The radiator is in the way! :)

Ryan's got a TR8, I have a TR10. :eek:

BTW, to clarify the piping is all from Global Tech Engineering. For that straight piece, one length from them is plenty.

RyanD
07-09-2010, 07:41 PM
A top inlet would not be easy to setup. The radiator is in the way! :)
LOL, oh yeah!



BTW, to clarify the piping is all from Global Tech Engineering. For that straight piece, one length from them is plenty.

Damn...I knew I forgot. Chris was more qualified to answer the question anyway since he placed the order. :hehe:

sodap0p
07-09-2010, 07:52 PM
I need to put on my sunglasses to look at your engine...man thats shiney :)

DudeMan
07-09-2010, 11:09 PM
Thanks guys, I've wanted to do the side feed intake manifold/clocked turbo/front mount setup for a while now and I just wasn't sure about the details.

Feel a lot more confident tackling this in the next few months.

Engine bay is immaculate, I really like the black valve cover and red wires. I remember reading somewhere that Celica wires are black and MR2 wires are red, is that what you have?

Heat shield is very well done, I have to ask, is it a cooking pot?

Oh yeah, the radiator. I knew I was forgetting something, lol that's actually kinda funny now that I think about it. Its been so long since I've had a radiator or even an engine in my car I guess I'm starting to forget.

ChrisD
07-14-2010, 05:21 PM
Yep those are OEM MR2 wires.

No cooking pot, SS heat shield from Kelsport: http://cgi.ebay.com/Celica-GT4-3SGTE-Turbo-Heat-Shield-Polished-ST185-SW20-/220635519042?cmd=ViewItem&pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item335ee6d842

lol, yep the rad is just one of those non-optional parts. :lmao: