ST162 3SGE Swap (Photo Diary)

[matt86sx]

matt86sx, thanks for your quality post. Your 3rd gen swap was some nice work =) Seemed like everything went pretty smoothly. I'm going to use my 1st gen exhaust manifold as my 2nd gen 3S didn't come with its naitive one. I haven't planned a solution for the throttle cable yet, but I'm on top of most other parts of the MR -> FWD process.

I know my steering rack isn't in great condition, but I'm not sure the budget will allow a replacement yet. Once the engine is out I'll look further into it to see how good/bad it is.

You're quite welcome! I only did my swap in October so most of it is still quite fresh in my head. Yeah everything did go pretty smoothly, so if I can pull it off I'm sure you will be able to as well! Hence my comment that it's not as daunting as it may first appear.

Using the 1st gen exhaust manifold will work out well - it will bolt right up and will help with the budget since you're using what you already have. (Both the exhaust and the fan)

Hope you've managed to get the driveshafts out OK. Those bolts that hold the RH axle carrier to the block are indeed a hassle to get to, using a fairly long extender on your socket helps. Also when actually lifting the engine out, lifting it only by the hook near the alternator will cause the engine/box to hang at an angle that makes it much easier to get out. Discovered this the hard way when lifting the engine out, but did it this way when installing the new engine and it worked very well.

If your steering rack is looking a bit tired and you plan on keeping the car for a while then I would still strongly consider changing it over, even if you have to scrape the funds together for it. If it needs doing say in the next 12 months you'll be kicking yourself because the labour costs you'll need to pay someone to do it will be pretty savage. With the engine out however, you'll easily be able to do it yourself and save a lot of money in the long run. Still, wait and see what kind of condition that yours is in first I guess.

Looking forward to seeing your progress, keep us up to date.

Matt

[urantia]

Ah so you just unbolted that carrier from the block? spose that's another way of doing it instead of removing the circlip.

I am going to try installing a fwd beams engine in the st162 soon, but if not, definetly the gen3!

Rob! your coming to tas soon! well well let me see i do need some celica parts! i'll PM you. (it's dingaling here btw)

[RobST162]

hey urantia/dingaling, yeah I am short on time but for sure if it's something I have here, no worries!

I wish SOMEONE would hurry up and actually do a beams.. lol

annyway back to the thread

[buck naked]

Thanks for all the help on those drive shafts boys, I didn't realise I had to pry it off. I was scratching my head looking for some bolts to undo =) Those two bolts connecting the drive shaft bracket to the engine block that are giving me grief are soaking in some WD40. I'll have another crack at them shortly. It looks like my next chance to work on the car will be Sunday afternoon, unfortunately.

The car is up on jackstands about half a meter up. I've got space to move and use the crane in front and along side the car, so I'm hoping I won't need to move it. I'm thinking of raising the car another 10-20cm to get at these bolts though.

Andy, the Haynes directions said to remove the suspension cross member, I also wanted to remove it to get at some of the connections between the firewall and the engine from underneath.

Rob, the plugs I have belong to the ECU I'm fitting, so everything should be sweet. One thing I am missing is the plug for the instrument pannel. I'll look into that shortly. I do have an auto electrician friend coming to help me out with all the wiring, so hopefully that part will be in safe hands.

Matt, nice tip on just using that hook - I'll look into that. I was planning on lifting it out on an angle like that, but that hook would simplify things =) As for the steering rack, I'm only planning on having the car for another 3 months, and I just don't think the budget can stretch for it. If I was planning on keeping the car, it would definitely be a priority!

urantia, ST202 SS-III Beams -> ST162 - make it happen =)

[buck naked]

Day Two



Following your tips, I got the drive shafts out no worries. Thanks a lot! Positive rep going out =)



With everything disconnected, it was time to wheel the hoist in position and get under way. I used Matt's single-lifting-point technique and it was going well. I decided to wheel the floor jack in under the car and jack it up under the gearbox to support it as I started to lift the whole lot out. Unfortunately, I mistakenly lifted the gearbox too high up and I jammed the gearbox side engine mount against the chasis mount point. I mean seriously jammed, I tried to pull past it and I lifted the whole front of the car without budging. Tried beating it out with a screwdriver and mallet and tried everything I could think of but had no success.



So looking at how the gearbox is connected to the mount via a bracket, I started trying to take the bracket apart. The bolts were stuck incredibly tightly and they started stripping them before they were budging. I stopped before I made things worse and with a sigh, I packed it up for the night. Tonight I'm dropping by my father-in-law's and I'm going to ask him about it. I'm not sure if I'll have to cut them out, drill them out or what.

[AndyTTR]

Ouch, that's tough man! You kinda needed to shoehorn it out, lifting straight up doesn't work (trust me, i learned the hard way too - three engine mounts later...). You could try lowering it back down so that the weight of the engine is on the stuck mount and malleting it? I wouldn't resort to cutting things just yet, lots of penetrating spray and some brute force should unstick it.

I reckon you might need more space to move sideways too.

[buck naked]

It was a dumb-assed impulsive move. I thought it would be a good idea to do it while I undid the engine mounts, except I did it AFTER I'd already done the engine mounts I don't know what I was thinking.

The whole engine was hanging off it as I was malleting it... honestly, this thing is so stuck, it's ridiculous! I've got the bolts soaking in several doses of WD40, I'll have another crack at it tomorrow night.

[Aust162]

Are you doing this part by yourself? i found that u really need two people for this.makes it soo much easier.

with one of the chains, hook the alternator bracket one closer up the chain links, and give plenty of slack onto the dissy bracket chain. this gives you an angle to lift with. then lower the engine down 1st. i then jumped under the car and pushed the gearbox down (from the top of it)and pushed it over to the drivers side. i kept constant pressure on it while my brother slowly jacked it up with the crane.

It's a really tight fit, but you get there in the end.

Note: our crane was setup on the drivers side, not front-on like your though..

Good luck with it

[CLG]

What are you up too James - need a hand? I need my engine crane back for a bit - cast iron V8's are bloody hard to move without one. Give me a call and let me know?

[buck naked]

Day Three

Day three was a huge success. I got those two troublesome bolts removed and released the gearbox from the jammed mount with the help of Clint's meter long breaker bar. No further dramas lifting the engine out, everything was disconnected and it lifted out easily from the single hook on the west side of the engine. The two engine blocks are now sitting on my garage floor and day four will be dedicated to preparing the new donk. I hope to have finished up the prep work and have the new 3S lifted in by Friday! Wish me luck...

[buck naked]

Day Four

Work began unbolting the ancileries connected to my ST162 3S-GE and then connecting them up onto the new block. This included the alternator, the power steering pump and the airconditioner. It was interesting to see the brackets the different FWD/MR configurations use to connect the ancilleries. The blocks have the same bolt holes and patterns, and so moving the bits and peices over was an easy job.



From left to right: 1st gen 3S-GE with the ancilleries off, 2nd gen 3S-GE awaiting the ancilleries, and finally, 2nd gen 3S-GE with the ancilleries on.



Connecting up the power steering lines

I'm going to need to purchase some replacement belts for the pulleys and I have a question.



The first picture is the main pulley on the old 3S, the second is from the new 2nd gen 3S. You can see a smaller inner line on the inside of the old 3S pulley which the power steering used to attach to. On the 2nd gen, both the inner and outer runs are the same diamater, and the inner one is thicker than the run for the power steering (4 ridges instead of 3).

My question is, can a 3 ridge belt be run on a 4 ridge pulley? Should I swap over the different pulleys, or can I make do with what I've currently got setup.

Lastly, will I have any significant difficulties if I attempt to complete the work on these pulleys after the new block is in the car as time constrants are forcing me to cut a few edges.

Thanks for all the help!

[CLG]

Yep, no real problems there. I can bring my pulley remover, and we can swap the pulley's over too if you're worried about the pump speed in the new setup - let me know?

[matt86sx]

Looks like it's all coming along very nicely! I'd definitely swap the pulleys over, best to keep everything consistent. Is the diameter of the outer pulley (that runs the alternator etc) on each of them the same?

Keep the updates coming mate.

[buck naked]

Day Five
Reaching the limits of my skills, knowledge and tools, I enlisted the services backyard mechanic extrodinare Clint and his supervisior, Mechanic Puppeh!



Using the trusty "screwdriver between the bolts" trick to provide leverage for the flywheel nuts, the fandangled pulley puller, and aplying liberal elbow grease when facing the flywheel, Clint and Chubs can make any job look easy.

[buck naked]

It's been a few weeks since I've even stepped into the garage! I recently got a promotion at work, and between the extra responsibilities and training someone for my old position, work on the Celica hit a standstill. It's time to get the ball rolling again, I've set a goal of the 11th of March to be finished with the swap - ready for the 'Old Skool Toyota's dyno day!

Current to do list:

• Find workshop to modify S54 gearbox
• Obtain ECU to dash plug (22 pin)
• Find old "to do" list and add items to this list