good work so far man...good luck with that wireing!!..keep us updated i wanna see the finial result

Well guys, another update for you. Last night we built some brackets for the intercooler and got that hung, as well as fabricating all of the intercooler piping that we could without the engine actually installed. Also got the boost gauge installed so that's ready to go.

The intercooler brackets





Bolting it up







Boost gauge



There's going to be a lot of this involved this weekend



Intercooler piping











So yeah, the engine swap is officially starting TONIGHT at 6pm. We're going to have a camera and laptop on-site and will be updating as often as possible. Our goal is to be completely done with the swap no later than Sunday. I am going to go and continue to work on the wiring harness.....I need to finish it in 4 hours hoping for a miracle...

Alright good news...........



the harness is done.....got started working on the celica about 8:30-9:00. My friend and I are still working away on it but I figured an update would be nice.
Right now it is about 3:00 AM......redbull ftw

Harness plugged into the engine:


Taking the car apart:






Dropping the engine:




The 5s is out:






Here is a picture of my friend, who happens to be my boss, and I after we dropped the engine.




This post has been edited by Prodigy515: Oct 25, 2008 - 2:04 AM

So we were slacking on the updates because of being so busy actually doing the swap, finally got some time now. Basically here's how it all went down:

Most of the week after work prodigy worked on the wiring harness using another Celica engine harness.
Thursday after work, 9pm to 3am, installed and tig-welded intercooler and about half of the piping.
Friday after work, started work at about 8:30pm and worked all through the night until about Saturday at 9am. We got the 5SFE out, tranny swapped over, and 3SGTE bolted into place. Then we went and crashed at my place for a few hours.
Saturday 1pm to 11pm got all rest of the intercooler piping tig'd up, as well as the cold air intake, and all the other million little things to do.
Sunday slept in a little bit, got started around 12. Finished up the exhaust work and installed the belts and then primed it and fired up on the first try... as usual Took it for a nice test-drive and called it a night. The complete swap was done from taking the car into the shop at 9pm on Friday to Sunday at around 6pm, about 22 work-hours.

Enjoy the pics...





Kirk mount inserts...











True cold air intake





Caldina BOV installed...





Check out how I routed the intercooler piping. I think it came out awesome...













This post has been edited by Dr_Tweak: Oct 27, 2008 - 12:20 AM

Looks great! Nice job!

I ENVY YOU PRODIGY. thats what its all about man, getting in there and gettin it done!


...... that looks like my alternator belt!!! LOL WE will meet on the highway when i get down there! lol.

you are the man prodigy!! wish somebody would have told me!!! i knew doc was going to be at the garage, but i didnt know THAT was going on!! lol a 4 hour drive is starting to look even better!!



This post has been edited by easternpiro1: Oct 27, 2008 - 12:48 AM

Thanks guys We spent quite a long time planning out this thread, we thought it would be funny to add in a few practical jokes, like the first post and waiting until the very end to reveal who the "friend" behind the swap was.

This was by far the fastest 3S swap that I've ever done. (This is prodigy's only car so it HAD to be done by Sunday night). First, we did a lot of planning to make sure that we had everything ready to go, and we did everything possible that could be done before actually starting the swap, such as the Walbro fuel pump, the boost gauge, hanging the intercooler and doing as much of the piping as we could, plus doing the timing belt/seals/gaskets etc on the engine.

Then we brought everything over to the shop and got to work. We ran short on a couple of small things, like a few clamps and one coupler. Thankfully we had some extra around from other swaps that we were able to pull from, that saved us a potential problem. Of course I sent prodigy off to the parts store a bunch of times to pick up little odds and ends.

Once we got everything put together and warmed up we took it out on the street to make sure all was well. Of course it wasn't long before we opened it up We did a little bit of V8 hunting and then went back to the shop and spent a couple hours cleaning up. After that we parted ways and I went to get my wife some flowers for being gone all weekend

About 10 minutes after I get home, my phone rings and I'm like, uh-oh. I look and sure enough it's him. I answer and he's like, "Hey, the Celica started making a racket and I pulled over, now my battery light is on". Right away I though, alternator belt, and sure enough, he checked and it was all shredded. By pure coincidence he happened to be less than a block away from the shop. So I said, "take the alternator belt off and head over to the shop on battery power, I'll be there in a few minutes". Turns out that the parts store gave him a 6-rib belt instead of a 5-rib belt, I didn't notice when I put it on. So we stole the belt off easternpiro's car and got that installed, then it was all set. Now I need to buy a new belt for piro's car

And yeah, it pulls nice

-Doc

Awesome job guys! Three days... wow!

good job guys!

loving the OEM COP setup, one of the things that i realllllly like about the 4th gen 3s. well, that and the pimp OEM side feed manifold. lol

tweek, do you have a solid source for 4th gen parts?
just curious.

Hell yeah - badass guys.
Prodigy - now you just need my Caldina Floor Mats to get all you can from that beast

>

Yeah, the manifold is teh hotness.

As a matter of fact, I do

-Doc

sorry to hijack the thread :

Manny,

I'm selling some gen4 engine parts. Look at this thread :

http://www.alltrac.net/phpBB2/viewtopic.php?t=29319

Thanks

Sam

>

i think i want to cry... sorry to hijack the hijacker.

are you guys going to dyno tune?

pitcelica, I'm interested in that downpipe!!!

Matt, first order of business is going to be to build a full 3" mandrel-bent stainless steel tig-welded exhaust system. Then, we'll pick up a boost controller, and run it on the dyno to tune the cam gearS. Then I forsee us picking up an AEM FI/C and seeing what we can do with that

-Doc

Sorry I haven't had time to post up....but wow the car feels great. When we finished the swap on sunday my 30 minute drive home turned into aout a 3.5 hour long drive all around the surronding area. First and second gear do not have traction as of now I am looking forward to seeing what the lsd will do for it. Also need to do some brake and suspension work on the car to help it handle the power.

All in all the car is amazing, it is nice to be able to tell people that I have a swapped car and that there is NO check engine light on, I have cruise control, a/c, and power steering. oh and it is pretty fast too.

Vids anyone?

I don't know how to make these smaller for downloading, sorry...

Engine running:

http://phoenixtuning.com/bennett/PA280003.MOV

1-2 shift in the parking lot:

http://phoenixtuning.com/bennett/PA280004.MOV

2nd gear pass and shift to third from in the car:

http://phoenixtuning.com/bennett/PA280006.MOV

-Doc

This post has been edited by Dr_Tweak: Oct 28, 2008 - 7:40 PM

NICE!!! IMMA CALLIN YOU OUT PARTNER!!!

>
Oh hell yeah - I DEMAND vids of that!

>
ahh thats good to hear, i had heard the 4th gen parts are a bunch harder to come by than the 3rd gen,...do you find that to be true?
pittcelica, im not looking for any parts, like i said to tweek, i was just curious.

Uh, not really, no... and a lot of parts are shared between the 3rd and 4th gen engines anyway

-Doc

>


awesome, good to know.

Tweak... make a list of parts between the 3rd and 4th. Please.....

Well, timing belt for one

Is there something specific you guys are concerned about replacing?

-Doc

DR. Tweak...im very proud of your flawless works and someday...ill just ship you my car...i plan to do a restoration someday and i can't think of anyone else to do the job other than you...and PROD...i ENVY YOU and EAST for putting in the ST215, but once I save up, i'll join you two in on the club of the st215; Prod how much was estimated cost for whole project? (and doc...really just three days huh?) ,

This post has been edited by chacha: Oct 29, 2008 - 9:20 PM

>

this is a list that pitcelica made, as you can see in prodigy's pics the 3rd gen cams fit (with some modification?)


So, as I can seen, a lot of people want to know what are the aftermarket parts are available for the ST215 3SGTE engine. Here's are some parts that are bolt on :

-Adjustable cam gear (AEM, Fidanza, HKS, OBX, ATS). Any cam gear kit for 3SGTE will fit.

-XS Power SSAC ST205 manifold/downpipe used with a ST205 turbo will convert the one-piece ST215 manifold/turbo to a nicely upgradeable ST205 Ct20b turbo kit. You can add to this a t3/t4 adaptor and you will be able to use a t3/t4 turbo (like I did on my ST215 swap)

-Pistons, rods, crankshaft are all the same for ST205 and ST215

-The injectors are the same as the ST205 one, so, if there is a 3rd gen fuel system available, it will fit the ST215 too.

-The exhaust camshaft is the same as the ST205 one. So an HKS 264/272 exhaust camshaft will bolt on. For the intake, I don't know if the HKS one would fit. Next year, when money will allow it, I'll buy a HKS264/264 camshaft kit and I'll know if the intake camshaft fit or not.

-You can remove the top ATA intercooler and add a FMIC as easy as any other 3SGTE.

The things that need heavy custom work is the ECU/wiring harness, ignition component (because of coil-on-plug). In my case, I used a Megasquirt II ECU with Ford EDIS wastespark ignition system and everything works nicely.

The other aftermarket parts like BOV, wastegate, air intake, boost controller etc, can be fitted easily like on any other 3SGTE engine.

So plz, stop saying that the ST215 engine isn't easily modifiable, there are plenty of parts that can be used to give a lil more hp to this unknown beast.

>

I wasn't asking about mods... I was talking more about oem parts.

>

it was a whole post copied. i forgot to take that out. it was a discussion on another thread. not a comment directed to anyone. :

hi, here are some oem parts that are interchangeable :

-pistons
-connecting rods
-crankshaft
-exhaust camshaft
-cam gears
-timing belt
-water pump
-Intake manifold (bolt pattern are the same)
-fuel rail and injectors from ST215 are 540cc and top feed, so they have the same output rating as gen3, but they are top feed instead of side-feed(gen3)
-exhaust manifold (same bolt pattern)(but the 4th gen exhaust manifold is casted with the turbine housing)
-MAT sensor (manifold air temp)
-MAP sensor
-crank pulley
-oil pans
-oil pickup system
-knock sensor
-ac compressor
-alternator (I need to verify this)

I need to look at valves and springs to see if they are interchangeable or not. I'll look in my Toyota EPC later.

Hope to help!

sam

The alternator can be replaced with one from any 5SFE or 3SGTE, along with the a/c compressor and the p/s pump (though the 4th gen p/s pump uses an electronic sending unit for the idle-up).

Bear in mind that the 4th gen injectors are also high-impedance, and no resistor pack is used.

-Doc

also, the starter is interchangeable. and VERY easy to install.