BEAMS Red Top Conversion Into ST184 Write-Up

[WFX]

BEAMS Red Top Into Celica ST184 Write-Up
By Wayne Siviour


Feb 16 2006
The time has finally come to get my new engine conversion underway and here is where I plan to write-up my progress with it all.

My lovely newer engine will be docking into the Port of Fremantle on the 24th of Feburary, 2006. I have already arranged a mate of mine to help me move the clip from the warehouse to the workshop (home) where we will be doing most of the work!

ST202 3SGE BEAMS Red Top Half Cut

Here is a list of what I shall be receiving:

Complete Motor:
-Block
-Complete Head
-Intake Manifold
-Throttle Body
-Power Steering pump
-Lower Engine/transmission harness
-Cam Angle Sensor
-Bell housing bolts
-Exhaust Manifold
-Alternator
-Starter
-Fuel Rail
-Injectors
-Canister
-Transmission Drive Shaft/Axle
-ECU(computer)
-5 Speed FWD Transmission
-With Clutch components assembled to the engine
-Engine Wiring Harness (UN-CUT)
-Misc Parts
-Guage Cluster

The old 5SFE (230,000 km) engine will be pulled out over the next week or so when time permits... man I'm going to have fun doing that! More pics throughout the progress and comments are welcome.

It has begun....


Mar 19 2006


UPDATE: Engine has been pulled out of clip!


Apr 5 2006
Got another a little update for you all!

- My old motor the 5SFE has been pulled from the car. Being that we were using a mates hoist we've pulled the motor out from the bottom, without a hoist this way would be almost impossible.



- Both motors now sit side by side as we exam them both in detail. The current outer shafts on the BEAMS motor were a little rusty and so we were going to use the outer shafts from my 5SFE but unfortuately they will not work together. The BEAMS motor has stronger ones anyway as we noticed when we took them apart. We are going to try and take the rusted hub piece off the end and use mine instead, hopefully we can work something out here.

The engine mounts on the BEAMS compared to my 5SFE are actually quite different as well. Front and rear mounts look like they take the torque of the motors so we will be taking the mounts from the BEAMS clip and using them on my original bar. The right side mount is exactly the same on both motors but the left side on the BEAMS has a fluid filled mount and based on its bolt pattern this will definately not fit in my 5th gen. So we will be trying to take the left side mounts and harness from the 5SFE and bolt it onto the BEAMS motor. If this works we're cooking with gas and will easily beable to mount it, if not.... well lets think about that at the time!

Mostly everything else looks like it will fit fine. Gear linkages we dont have to swap has mine are exact length and fitment. Most of the wiring looks very much the same as well and at this stage we are thinking of splicing it together rather then use the whole loom.




- I have ordered the following parts and we are waiting for there arrival before a first test install can be done:

JUN Light Weight Flywheel
TRD Clutch Cover
TRD Sports Facing Clutch Disc

Once we have these I shall bolt the tranny back on and we can attempt to make it fit!

- This weekend I will also be respraying the engine bay in Obsidian Black Pearl! Figured while the engine is out I might as well get rid of that grey looking colour and put some sparkle in there instead!

Thats it for now, will have heaps more photos after the weekend!!


Apr 6 2006
Ok... timing belt side engine mount definately will not fit, not a direct bolt in anyway. I'll have more detailed photos after the weekend but have a look at the image below:



As you can see the fitment of the fluid filled engine mount from the 3SGE BEAMS is different to my 5SFE one on the right. What we are going to try is taking the 5SFE engine mount and its bracket from the engine and bolt it directly onto the BEAMS motor.


Apr 11 2006
Ok so last weekend flew by and didnt leave us with much time to do anything so only a couple of updates this time round but definately progress in the right direction!

- My 5SFE engine mount and bracket does infact bolt straight onto the side of the BEAMS motor with no hassle what so ever... so that concludes one grey area!

- I used some industrial strength oil degreaser called 'TITAN' to clean my engine bay. Followed by taping up anything I didnt want to spray black and then finally I resprayed the entire bay in Obsidian Black Pearl. Pictures dont show much yet but get some sunlight in that thing and it will look very smchit!



Below is a few other pics I took on the day for your enjoyment and/or reference:



More updates to follow... were getting close to bolting her in now!


Apr 12 2006
Yet another update:

- Flywheel & Clutch parts have arrived at long last, now we can get some serious work done!



- We've inspected the timing belt and have agreed that the belt is in such good condition that at this stage we are going to leave it as is.

- We've also had a long look at the exhaust mainifold that comes with the BEAMS and we've decided to also run with this stock component. These babies are actually 4-2-1 tuned length ones and if the motor comes with something like that stock its gotta be good! Ive had a look at a few companies that make headers for the 3SGE and both look very nice but pricey. HKS one doesnt say it will fit the BEAMS and the Phoenix ones are very hard to find SO yeah gunna save some mooler & run with the stock ones. I shall just chrome plate the heat shield to dress it up a little.

- My new Whiteline Rear Strut Bar and Whiteline Front & Rear Sway Bars should be arriving any day now too! Hopefully that should help me a little when cornering with so much more power under the hood!

Hope everyone has a good long weekend and enjoys Easter, I'll be back next week with more updates and a belly full of choclolate!


Apr 17 2006
Ok after the looong weekend I have some updates.

We've fitted the engine into the car

BUT we have ran into a problem!

The timing cover fowls the brake master cylinder! See image below, I have circled the silver brake master cylinder and you can see the stock 5S-FE timing cover to the right. The BEAMS motor VVTi Cam comes out and hits that cylinder.



We removed the cover but the VVTi solenoid itself still fowls the brake master cylinder. The halfcut cylinder is different and will not fit. At the moment we are wondering if the entire brake booster unit will fit my car, thats what were gunna try next if it doesnt then were stuck!


Apr 25 2006
The Brake Booster Unit from the BEAMS halfcut fits my celica beautifully and will solve the problem, time to put it all back in now! Next issue we MAY run into is the driveshafts more on that later thou.

My Whiteline Front & Rear Swaybars have arrived and my new Whiteline Rear Strut Bar which will complement my exisiting Whiteline Front Strut Bar has also arrived!




May 1 2006
Another update after the weekend:

- 3SGE BEAMS engine is sitting comfortably in the car!! After swapping the Brake Booster Unit over everything just fitted into place!



- I have another issue however... 5SFE cross member does not clear BEAMS transmission and BEAMS crossmember does not fit my car nor do the two engine mounts on the member line up properly. Looks like we may need to custom fabricate something!




- The driveshafts are in the car also however they sit out a extra inch! Basically it means that once the weight is back on the ground that may/may not push the driveshafts into the box more. If it doesnt then we're sweet otherwise if it does then looks like we may have to custom fabricate something here too... hopefully were all good thou!

- We can see the wiring a little better now with it in the car. We've put the full wiring harness through the firewall and connected the ECU. However the plugs and wires that run from the ECU up to the Guage Cluster & AirCon are completely different which means weve got to sort out which wire goes where. On the fuse box side of things we need to work out which wires to connect onto my 5SFE fuse box.

- Matty (my sidekick and mechanic brains) had trouble getting the driveshafts out of the clip because the ends were rusted which meant it made it hard to unscrew the nut on the end. Next smallish challenge will be to get that nut back on pass the rusted bits if I need to cut the ends off so it leaves a good thread so be it.



Thats about it for now!!


May 4 2006
We shall be making more progress on the weekend and estimate the mechanical side of things is 2 weekends away. This weekend Matty goes to work on the cross member mutation and then the following weekend we will be fine tuning everything. Then its up to me to get the wiring sussed out.

Heres whats left of the half-cut:



Some more BEAMS pics:




Have a good weekend!!


May 10 2006
Semi final list of updates coming your way:

Crossmember and Engine Mounts - DONE!
Front Sway Bar - DONE!
CV Joints - DONE!

This is the last stretch before we turn the ignition!

My mate Matty who runs 'The Bling Garage' has been helping me out on this engine swap! I would like to honor is work on the BEAMS by showing him a little 'BLING' inside my engine bay. I present

The Bling Heat Shield



May 11 2006
Heres some photos from the custom crossmember and engine mount work we did!




Car was towed away from Matty's Bling Garage today, his work is done and the rest is up to me to finish! Thanks again Matt for your all your help, your hoist and your good welding skills! Its now back on home soil ready for the last leg... wiring!



And into the garage it goes... for now!




May 21 2006
Ill definately get some video up here as soon as the car is running but at the moment wiring is gunna be a slow progress till I start splicing wires together!

Heres a little outline of whats going to be happening:

To start with Ive been going over all the wiring diagrams I have and working out what goes where with the old 5SFE. Then because I have no BEAMS wiring diagrams Im comparing that to other diagrams such as Gen 3 3SGE and 1997 6th Gen 5SFE wiring diagrams. I do have a BEAMS ECU pinout which although in JAP does make a little sense. My BEAMS is of course a 4th Gen 3SGE, 1998 from a ST202 so you would think something has gotta be the same somewhere!



I need to connect wires that run from BEAMS ECU to ST184 Guage Cluster & A/C. As you can see from the image below the plug sizes are different and thats where I must sort out which wire is which and connect the BEAMS plugs to my old wiring loom that runs down from Gauge Cluster and AC.



I do have the BEAMS Guage Cluster which means before I even start this section I can simply use the loom from the BEAMS dash and plug in all the in-cabin bits so once engine bay wiring is sorted I can atleast start the car then work on getting my Guage Cluster to work.

I need to use my Guage Cluster for a few reasons one being that it will not fit where the ST184 one was due to its design. I will be however be giving my Guage Cluster an make over.



First off however I need to connect old fuse box to new fuse box (or vice versa dunno whats gong to be easier yet) and yeah get this mess sorted before I can even attempt to start it.



Yesterday after looking at wiring diagrams I decided to take a break (no I didnt have a Kit-Kat) and re-design my rear lights, it was the only thing that was letting the rear of the car down. Ive seen it done before so tried it myself and was quite impressed on how well it turned out. I also painted all the other bits black so it was all neat and tidy and looking like new!



Hope that made a little sense!!

[Roman]

Dang, that's great!

Good luck getting it up and running.

It makes my swap seem straight foward, compared it yours.

[WFX]

Thanks Roman!

Before I started this project I knew I would have a few things I would need to modify but not as many as it turned out to be! No going back now thou!

[PHOENIX]

god i am not looking forward to wiring. So you had a 5sfe.....i have a 5sfe in my deuce and am going to put a beams engine in it. Have you made any headway with the wiring. I have the full engine harness, i just dont have the beams harness that goes to the cab of the vehicle which is where its going to get tricky. Perhaps ill make a trip to toyota tomorrow and get a beams wiring book and maybe start translating.

If you could, keep a record of how you figured stuff out and what wires went where. This kind of thing is exactly what i would like to put up on the main site for other users to read and learn from, hopefully making future swaps easier.

[WFX]

June 18 2006
After weeks of sleepless nights, hissy fits and lots of swearing to try and understand the BEAMS wiring system I decided to make a start on the wiring and just start cutting wires! Just when you think you have it all sussed it goes and changes on you!

Using what wiring diagrams I have (which isnt much) and my trusty meter I slowly checked and double checked every wire, its location and its destination! I compared plugs and coloured wires from a range of different Toyota diagrams and spent countless hours writing down the details of every plug and wire

Its a official... I HATE WIRING!

I began cutting wires in the engine bay and then started to solder one by one as best I could where I thought that wire should be connected too! I decided to use my exisitng fuse box and its relays instead of using the ST202 one which looked alot more complicated. After most of the day I managed to get all power running around the car, lights, windows and all power related things were working from what I could see.



I do have a few wires left over from the BEAMS side of things that I do not know where they go! I know 2 of the wires go to a loop back plug which I have no idea about. As for the others hopefully one day soon I can grab a wiring diagram and work out what they do incase I need them! At this point I still have no crank and therfore will retire until next weekend!


June 24 2006
Started bright and early while my mind was fresh... I knew it wouldnt be fresh for long thou!

I began working out how I would get the car to crank! I discovered that one of the wires I originally thought was a earth was infact the crank wire!! I discovered this by accident when I unpluged the wires from the earth terminal and it bumped into the positive terminal and began to crank, thank you LORD!

From here I worked out where my original crank wires ran through the car on the 5SFE and discovered the plug in the top right hand corner near the diagnosis plug! I cut my exisiting loom and plug for this area and soldered my crank wires on! Now after turning the key to ON I get crank! But no spark!!

I have 2 wires left a big white wire and a orange one. The white wire didnt seem to do anything but the orange one looked like it was my original ignition wire as it ran to ECU, injectors and ignitor! For the life of me thou I couldnt work out where to connect this wire on to the BEAMS!



After more searching and testing I discovered yes I have crank, but no spark and no fuel!! I wasnt getting any power to my fuel pump!

Things Ive got to work out:
1) Where does the fuel pump power come from? Both on my old 5SFE and the BEAMS? Once I know this I can splice the 2 together and hope it works!
2) Which wires on the coil packs are the power wires and where do they get there power from? ECU? And is this power constant or provided from the ECU once it gets a signal from the motor!

Once I know this I should be a little closer to starting this beast!

I also need to sit down to try and work out what these plugs from the BEAMS ECU do exactly!



1) I suspect this plug is for the A/C, Ive also discovered the black wire here might also be for the Tacho!
2) I think this might plug into a relay as I cant seem to find a plug from the dash where this fits. Otherwise it does nothing!
3) This plug connects to another plug that feeds the lines up to the dash area!
4) This plug connects to another plug that feeds the lines up to the dash area!

I have my work cut out for me no doubt!

[WFX]

Yeah PHOENIX Ive written down everything Ive done and have tons more pictures for a proper write-up once Ive got it sussed!

If you can get atleast the wiring book with the diagrams I should beable to make out most of the stuff from just the wiring diagram and its coloured wires! From there we can cross check BEAMS wires with 5SFE wires and that should make it easier for future swaps!

[PHOENIX]

consider it done, im gonna go to toyota tomorrow and purchase the book, they should have it in stock since they are the regional parts distibutor for the tokyo area.

Tomorrow night, i will begin scanning it and ill send it to you when im done. Ill probably even pick up the engine manual also as i need that.

Then I'll begin translating. Translation will take me a few months though, but since i dont do anything at work, i will be able to work on it a little everyday.

[Roman]

Hey guys I've got a full beams loom from a celica sitting in my room, I could probably sort out a proper wiring diagram for the whole thing at some stage.

Pheonix, it's going to be a bit of a mish without the body harness half of the loom. Two of the four plugs that plug into the ECU, come from the body harness.

[PHOENIX]

WTF....are you serious........holy ****, i didnt know that.

Crap, looks like ill be ordering an expensive body harness from toyota......

Roman, do you have any pictures of the harnesses you have so i can check to see if i have one. i doubt i do though.......crap.

[Roman]

Yep for sure, I will grab some over the weekend.

I'm *sure* that they would have included the body loom however.
(Up to the kick panel by the passengers seat)
It doesnt make any sense not to.

If you've got all of that, it's almost plug and play.
If you've got the full MR2 loom, and you wire it up right, you've only got to hard wire the fuel pump to 12v, and the engine will fire up.
(Things like tacho etc wont work though)

[PHOENIX]

thats what i was figuring but im gonna double check tonight.......

He told me he gave me the full harness and ill only need to make a couple modifications to make it work, we will see.

[Roman]

Do you have the fusebox?

The fusebox is part of the body loom.

If you've got the fusebox, you've got the loom.

[PHOENIX]

i dont have the fusebox

I was actually considering purchasing one from toyota. When i get the manuals in, ill check with them and see what i need to complete my wiring. Or if i have enough atleast to wire everything together correctly.

[WFX]

I HAVE IGNITION!!!

This weekend I finally got the BEAMS to kick over and it purrs like a kittie! There were 2 wires I hadnt hooked up because I didnt know what they were for but now I know they were power wires for injectors and coils!

All the details coming soon!!

[PHOENIX]

outstanding!

cant wait for yo to finish up your write-up.

[Roman]

Congrats.

It's a pity we cant really have a beams owners meeting, as we're scattered on all four corners of the earth. haha.

Great to hear, I bet you cant wait to take it for a spin!

[PHOENIX]

yeah, in the states we might have 2 people show up at a beams only meeting

[WFX]

July 8 2006
Today was one of the greatest days in my BEAMS conversion as today I made it happen... engine was fired up for the 1st time!!

Here is a outine of how I made it happen! I took my trusty multimeter and I know only the basics of this tool but a mate of mine showed me a few niffy things you can do with one. So with extra knowledge in hand I entered the garage and began testing wires in the engine bay. I started with the 2 black wires I had left over which I originally traced to a loop back plug. I discovered that these 2 wires were in fact power wires for injectors and coils!

So I had my wires but I need somewhere to run them. Well I thought to myself why not run them to my orange wire I originally had on my 5SFE as that gets power once I turn the key to ignition... perfect! I was still missing power to my fuel pump however. I have no idea which wire on the BEAMS is used to run power to fuel pump so instead I decided to play GOD a little and run my own power wire from my orange ignition wire down through the firewall and directly to my blue power wire on the plug of the fuel pump. Turning the key to ignition now provides power to all three!

To secure this new custom designed ignition feed I decided to put a inline fuse in between the entire system. If theres no fuse then it automatically cuts power to injectors, coils and fuel pump! Match made in heaven!!

As you can see with the picture below Ive tidied up the engine bay wiring, battery has been moved to the boot to enable me more space in the engine bay, top right picture shows the inline fuse in my custom system (5SFE and BEAMS ignition systems working together) and bottom right picture shows newly attached wire to original fuel power wire!



Turned the key and all of a sudden BEAMS was ALIVE!! AGAIN!!! There was a few odd noises coming from within but after idling it for 10 -15 minutes it seemed to sort itself out and it sounded like magic! Topped up power steering as it too was still running itself through the system, poured in 10 litres of freshly bought 98 Octane fuel (its all we go here alright) and the sound simply echoed out of the garage and all over the neighborhood! Even managed to have the local V8 boys drive past in there V8 Charger to find out what all the noise was about! Beautiful mate!! Switched it off and all went quiet again.

July 9 2006
Today was a rather lazy day had a few things on and was still getting over that my BEAMS was actually working. I decided to re-paint my BEAMS Cover and Manifold. From what Ive researched in the past the original colour for the BEAMS Cover was Toyota Super Red (Code: 3L2) and the Manifold was the slightly brighter red, Toyota Red (Code: 391) but dont quote me on that being correct!

Instead I thought well BEAMS is special and my Celica is pretty unquie at the moment so why not a new, better red to match everything else. I decided to use Velocity Red and apply extra coats of Gold Flake Tint! I went to work, sanding, prepping and finally painting both pieces and after many coats of paint, tint & clear I thoughtI came up with quite a nice little improvment over the original.



Next week... THE TEST DRIVE!!!

As well as more wiring on the interior!



ENJOY!

[Roman]

Well done!

May I just make a suggestion regarding the fuel pump wiring....

The fuel pump is usually run via the circuit opening relay, in the fuse box.

If you have the fuel pump hard wired to the ignition, it can be dangerous in a crash, if your fuel lines split, and it keeps on pumping fuel out.

I've got mine wired up the same way as yours basically, but only as a temporary solution.

Apart from that, well done!

[Roman]

Loving the repainted manifold & rocker cover by the way, very nice.