AndyTTR
01-04-2006, 12:16 AM
This swap is pretty straight forward as far as conversions go, but I thought I'd post up a bit of info about it so that anyone interested can get an idea of what's involved.
Engine:
- You will require the ST202 throttle cable (fits ST162 accelerator pedal with no dramas).
- Gen 3 thermostat housing needs to have the ST162 thermo-switch for the thermofans welded into it.
- The ST202 exhaust manifold will foul on the driver's side thermofan. The best solution is to go down to the wreckers and grab the front mounted thermo fan from the base model 3SFE powered ST Celica. It's a straight bolt in job. While you're there, grab the A/C piping that runs across the front of the A/C condenser and under the thermofan.
- Despite having the same bolt hole spacing, the gen 1 A/C compressor wont fit the gen 3engine as the top fittings foul on the beefier alternator support bracket. Use the gen 3 compressor and get a new set of fittings made up by an A/C shop.
- The sump has a triangular support for the flywheel cast into it, this will foul on the N-S crossmember and will have to be removed with a grinder / dremel or whatever you've got handy. When you can see the flywheel though the hole you've made you've just about taken off enough material to clear the crossmember. :)
Gearbox:
- The original S53 gearbox from the ST162 wont bolt up to the gen 3 as it runs a larger flywheel and the starter motor is mounted on the outboard side of the flywheel. Doing a dodgy and redrilling the flywheel bolt holes in order to run the original S53 g.box is not recommended - i've been told the 3SGE runs an off centre flywheel for balance, redrilling the flywheel will put this off centre and the results can only be bad.
- The ST202 E153 gearbox wont go straight in. It will require the fabrication of a new top g.box mount and a pair of sleeves on the gear selector cables to stop them from sliding out. The speedo drive is also on the back of the diff rather than the top like an S5X box. You can get around this by using the mechanical drive from a AE101 g.box which has a 90 deg. bend built into it. It drops straight in, but whether it will show the correct speed is anyone's guess. Using this gearbox will also require a mix and match driveshaft setup. I've been told that the ST202 inner CV's, ST165 front driveshafts and ST162 outer CV's are the way to go?
- Plan B is to use the S54 gearbox that is sometimes found in ST202 halfcuts. Everything bolts straight up using the original ST162 mounting hardware and driveshafts. As a bonus the gear ratios are similar to the original S53 - no long boring camry ratios here!
Wiring loom (main points):
- Wiring for a/c and thermofans needs to be removed from the original loom and added to the new loom.
- Reversing lights and accessory 12v is connected on the chassis side of the st162 loom, the st202 has it on the engine side of the loom. To avoid a short circuit use the original reverse light switch wiring.
- ST202 charging lamp fuse is on the chassis side of the loom, ST162 has it on the engine side. Probably in your best interest to wire that up to the existing fuse in the st162 fusebox.
- Gen 3 ECU manages the a/c idle up rather than the a/c amp as per the st162. I've found it works best with the A/C signal still connected to the ECU but have the new idle up VSV (which is much larger than the ST162 valve) to the original A/C amp.
I'll post a few pictures later on, but for the moment here's a website that i put together to help people out.
http://members.optushome.com.au/an-d/gen3/gen3conversion.htm
It's been a few months since i did this, i'm sure the guys that have done it more recently will have a few more points to add which i've forgotten. :)
Engine:
- You will require the ST202 throttle cable (fits ST162 accelerator pedal with no dramas).
- Gen 3 thermostat housing needs to have the ST162 thermo-switch for the thermofans welded into it.
- The ST202 exhaust manifold will foul on the driver's side thermofan. The best solution is to go down to the wreckers and grab the front mounted thermo fan from the base model 3SFE powered ST Celica. It's a straight bolt in job. While you're there, grab the A/C piping that runs across the front of the A/C condenser and under the thermofan.
- Despite having the same bolt hole spacing, the gen 1 A/C compressor wont fit the gen 3engine as the top fittings foul on the beefier alternator support bracket. Use the gen 3 compressor and get a new set of fittings made up by an A/C shop.
- The sump has a triangular support for the flywheel cast into it, this will foul on the N-S crossmember and will have to be removed with a grinder / dremel or whatever you've got handy. When you can see the flywheel though the hole you've made you've just about taken off enough material to clear the crossmember. :)
Gearbox:
- The original S53 gearbox from the ST162 wont bolt up to the gen 3 as it runs a larger flywheel and the starter motor is mounted on the outboard side of the flywheel. Doing a dodgy and redrilling the flywheel bolt holes in order to run the original S53 g.box is not recommended - i've been told the 3SGE runs an off centre flywheel for balance, redrilling the flywheel will put this off centre and the results can only be bad.
- The ST202 E153 gearbox wont go straight in. It will require the fabrication of a new top g.box mount and a pair of sleeves on the gear selector cables to stop them from sliding out. The speedo drive is also on the back of the diff rather than the top like an S5X box. You can get around this by using the mechanical drive from a AE101 g.box which has a 90 deg. bend built into it. It drops straight in, but whether it will show the correct speed is anyone's guess. Using this gearbox will also require a mix and match driveshaft setup. I've been told that the ST202 inner CV's, ST165 front driveshafts and ST162 outer CV's are the way to go?
- Plan B is to use the S54 gearbox that is sometimes found in ST202 halfcuts. Everything bolts straight up using the original ST162 mounting hardware and driveshafts. As a bonus the gear ratios are similar to the original S53 - no long boring camry ratios here!
Wiring loom (main points):
- Wiring for a/c and thermofans needs to be removed from the original loom and added to the new loom.
- Reversing lights and accessory 12v is connected on the chassis side of the st162 loom, the st202 has it on the engine side of the loom. To avoid a short circuit use the original reverse light switch wiring.
- ST202 charging lamp fuse is on the chassis side of the loom, ST162 has it on the engine side. Probably in your best interest to wire that up to the existing fuse in the st162 fusebox.
- Gen 3 ECU manages the a/c idle up rather than the a/c amp as per the st162. I've found it works best with the A/C signal still connected to the ECU but have the new idle up VSV (which is much larger than the ST162 valve) to the original A/C amp.
I'll post a few pictures later on, but for the moment here's a website that i put together to help people out.
http://members.optushome.com.au/an-d/gen3/gen3conversion.htm
It's been a few months since i did this, i'm sure the guys that have done it more recently will have a few more points to add which i've forgotten. :)