ST202 to 3rd gen 3S-GTE swap, After months of waiting and working hard the swap is almost complete Options

[Paul_Celica_GT]

In this project topic I'll descripe the swap of my 3S-GE to 3rd gen 3S-GTE.

After driving 245.000 km with my 3S-GE, the clutch started slip badly, the timingbelt and the other belts were severly worn and, well, 175 horsepower just wasn't enough . So I decided to swap to a 3rd gen 3S-GTE. From a Japanese export company, Japan Partner I bought a Celica GT-Four, for the engine and other parts.

These are the photo's the export company send me:

















As you might see, it has (original) TRD sideskirts, TRD rear splitter, Eurou frontlip and a Blitz Spec Nur Exhaust. After months of waiting, I've ordered the car half of August, got it February 14th, it was finally time to pick it up in Amsterdam Harbour.

I rented a carambulance and went to the harbour to collect the car. In the harbour I found out that the Eurou frontlip hadn't made it, unfortunately. In all my excitement I forgot to take jumpcables with me, and of course the battery was dead. So we had to push the car









When I got home (50 km drive) I got the battery from my car and put it in the GT-Four, it fired up immediately. After driving it warm, I've put the pedal to the metal, damn it's fast! Huge power! Next day I started striping the ST205. But first, this is my setup:

3rd gen 3S-GTE
E56 gearbox with oilcooler (standard on my car)
OEM viscous LSD (standard on my car)
ATW intercooler
ST205 Superstrut suspension (I had ST202, which is identical , except for some minor points)
ST205 brakes
ST205 front bumper
ST205 hood
Airconditioning (standard on my car)
JDM folding mirrors

I've renewed the following parts:

Clutchkit (pressure group, frictionplate and bearing)
Timing belt
V-belt
Sparkplugs
Hoodlock (LHD ST205)
Accelerator link (LHD ST205, turns out to be the same as LHD ST202)
Gaskets

Here are the pics of my swap, be warned, it's gonna be a lot, over a hundred . I can't post all the pics in one post and I have to translated everything what I've typed from Dutch to English. This is gonna take some time, so be patient . Expect updates regularly. For those of you who can't wait, here is my site (in Dutch): Celica GT.nl. I'll try to comment all the pics.

Part 1, extracting the engine from the ST205:


The 3S-GTE in the ST205


Removed front bumper


Removed side fenders, lightning, undercovers and intercooler


All the fluids out and removed the radiators and airco condensor (or evaporator, always forget what's what)


Removed wiring harness


Unmounted front suspension, and removed driveshaft


Worn driveshaftboot, though I'm using my own driveshafts


Removed front steering knuckle and shockabsorber

After this I've removed the properlorshaft.


Continues on the next post.

[Paul_Celica_GT]

Time for an update!

PART 2: Maintaining the 3S-GTE engine

After I pulled the 3S-GTE engine from the GT-Four, it was time for some maintenance. I replaced the following parts:

• Timingbelt with rollers
• V-belt
• V-belt powersteeringpump
• Clutch, including pressureplate and bearing
• Spark plugs
• Fuel filter
• Engine Oil and Oilfilter
• Coolant
• Intercooler Coolant (Toyota Longlife Red)
• Gearbox oil
• Brakefluid (DOT 3 or better)
• Clutch fluid (is the same as brakefluid)

Beside these replacement parts you also need two things that aren't on the RHD GT-Four nor my LHD ST202:

• Hood lock, LHD, ST205, part nr. 53510-20510, EUR 63,48 inc taxes
• Accelerator cable *, LHD, ST205, part nr. 78180-2D310, EUR 155,90 inc taxes

*Note: the length of the Accelerator cable is the same for the ST202 and ST205, only the protection is at other places


Some of the replacement parts

Timingbelt


I removed the crankshaftpulley bolt using this special tool, though it's easier to loosen the bolt when the engine is still in the car


Upper cover removed


Engine mount removed, you kan see the green tensioner clearly now


Mounted new timingbelt, timing is exactly the same as before


Placed the covers back on and installed a (new) crankshaft pulley, the old one was damaged during removal unfortunately

Clutch

Before you can access the clutch the gearbox has to come off. Since I can't use the E154 gearbox, it needed to come off anyway. Be aware that the gearbox is heavy (40 - 50 kg). Don't drop it on your toe's like I did. Fortunately I weared workboots.


Removed the gearbox


Removed the pressureplate and the frictionplate. The flywheel was still ok


Cleaned the new pressureplate with brakecleaner


Mounted the pressureplate with the frictionplate in it on the flywheel. Used my eyes to center it


After the E56 transmission was removed, I changed the release bearing

Sparkplugs and valvecover

During replacement of the sparkplugs I found out that the valvecovergasket was leaking, because there was oil in the sparkplugshafts.


Removed the valvecover


Oil in the sparkplug shafts


Cleaned the oil out and replaced the sparkplugs


Installed valvecover with new gaskets

After all the maintenance was completed I pulled the 3S-GE engine from my ST202. See part three for that.