Approaching an engine swap comes with a lot of uncertainty. Especially when the engine swap you want to perform, is a rare one, not performed on many vehicles. There is often a lack of information and support available for times when you aren’t sure what the next step is. It can also be costly if you have to do iterative testing and develop strategies to coax something to work correctly.
The following is a set of instructions that should allow anyone with at least a journeyman level knowledge in basic mechanics and tool usage, to swap a 5th generation, 3SGE BEAMS engine into a "1977 Toyota Celica Liftback." A full list of parts and where to purchase them is included. The 5th generation 3SGE BEAMS engine came in Toyota's "Altezza" model in Japan, however was not offered for the US market. The engine is an ideal choice as it is lightweight, inexpensive, incredibly durable, and capable of substantial power increases.
- 5th Gen. 3sge BEAMS engine W/ transmission, harness, ecu
- Transmission Speedometer Adapter
- Fuel Pump
- Fuel Pressure Regulator
- Fuel Pressure Regulator Gauge
- KoyoRad Radiator
- Frame Spacers
- Aw11 Manual Steering Rack
- Upper Radiator Hose Part # 71751 E
- Lower Radiator Hose Part # 72039 D
- Electric Fan
- Fan Shroud
- Throttle Lock
- Engine Cross-member
- Transmission Cross-member
- Transmission Sealing Plate
- Shifter Mount
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Step 1: Part One: Steering
- Obtain a manual steering rack from an aw11 (chassis code) Toyota Mr2. Alternatively, you may use an AE71 Toyota Corolla manual rack. Each of these steering racks is rare and difficult to locate. To improve your chances of finding one, visit Car-Part.com. They inventory a vast network of auto parts recycling centers and remain a top choice when considering ease and availability.
- Remove the steering column and have the Steering Rack Adapter installed at a welding shop or performance shop.
- Install your modified column and new steering rack.
Step 2: Part Two: Mounting the Engine in the Chassis
- Obtain and install a crossmember from an AE86 Toyota Corolla. Pictured above is a model made by Xcessive Manufacturing. You can use the factory Toyota model, but you will need to drill your own mounting holes and that can cause alignment issues. Ultimately, the best option is to buy one from Xcessive Manufacturing if you’re not comfortable drilling your own holes. You will also need to buy the 1” subframe spacers (needed to clear the pinch-weld on the Celica). You can make these yourselves with some 1” steel from your local hardware store, if you want to save some money.
- In order for the engine to clear the steering rack, the oil pan on the bottom of the engine will need to be modified slightly. The aluminum bracing will need to be machined off as shown. This can be done at your local machine shop.
- Machining the oil pan leaves the transmission bell-housing open to the elements. To solve this problem, the Transmission Sealing Plate should be installed between the transmission and the engine.
- Using the Engine Mounts, install the engine into the chassis.
Step 3: Part Three: Mounting the Transmission
Step 4: Part Four: Fuel System
- Install a Walbro 255 in-tank Fuel Pump into the factory fuel pump location.
- Custom fittings will need to be made to use the fuel pressure regulator. This can be done many ways but one easy way is to have custom banjo bolt fittings made at any hydraulic hose supplier.
- Install the Fuel Pressure Regulator with Gauge as shown. Connect the return line of the fuel rail to the bottom of the fuel pressure regulator and return to the fuel tank to the side.
- Fuel Pressure should be set to approximately 60 psi.
Step 5: Part Five: Cooling
Step 6: Part Six: Wiring the Engine to Run
- Locate the E-Connector on the ECU side of the harness
- Connect the shown wires from the E-connector as shown
- Behind the front, passenger kick-panel, locate the black/white wire seen above
- Verify this is the starter signal wire by probing it and turning the key to the starting (cranking) position. The wire should only show voltage while cranking.
- Tap into this wire and run a wire from it to your black starter signal connector located on top of the starter.
- Connect your starter to Battery positive via the post on top near the starter signal connector.
- Wire the Electric Fan as shown in the relay diagram.
Step 7: Part Seven: Conclusion
There may be additional steps to get your BEAMS-swapped Celica on the road such as exhaust, rear differential, drive-line, clutch, etc. These vary greatly depending on one's unique situation, however. At the least, after following this step-by-step instruction guide, your BEAMS engine should now be running successfully in your car.