Write-up/How to: AE86 SR-5 to GT-S swap. ***No 56k***
06-11-2007, 06:04 AM
Post: #1
Write-up/How to: AE86 SR-5 to GT-S swap. ***No 56k***
Ok, for all you newbs out there. Or just anyone who is interested Smile

Here's a write-up/pictorial with partial details on how to do a SR-5 to GT-S swap. To either whet your appetite to do the swap, or maybe even scare you away from trying to do it yourself... Note: this is not write-up on a 'complete' SR-5 to GT-S swap which would include the interior, trim, badging and other pieces. But a mechanical write-up, basically what is considered the 'heart & soul' of what makes the gt-s, a GT-S. (OR the 'GT' in europe, or a 'hachi-roku' Trueno in japan)

I have no idea why it hasn't been done already considering there are quite a few people who have done this before. I say partially detailed only because I'm NOT going to detail every last nut/bolt/torque spec/etc that is required to do this right. I'm writing this with the assumption that anyone that IS going to do this swap has some basic mechanical ability and has atleast the ability to install a complete motor into a car. And has access to the Factory Service Manual, either by purchasing, borrowing or downloading one.

To begin with - Get your SR-5 chassis/shell. And GT-S donor car or parts necessary.

Partial List of parts needed:

1. Engine (complete, w/distributor, manifolds, injectors, alternator, smog equip, oil pressure sensor, coolant outlets/sensors, etc.)
2. Engine harness
3. Throttle cable from GT-S (or cruise system w/cruise cable for a gt-s)
4. MAF sensor
5. Ignitor/Coil
6. Starter (can use SR-5 but it does not have a necessary heat shield and will eventually die)
7. Flywheel & Clutch
8. GT-S bell housing (or whole GT-S trans)
9. Coolant reservoir (GT-S is different)
10. Washer reservoir (if you want it, GT-S is different)
11. Dash harness (w/associated electronics & ecu)
12. Instrument Cluster
13. Fuel pump (don't worry about the fuel level sender, its the same)
14. Fuel & Brake lines.
15. Front body harness (w/associated electronics - ie head light relay, fuse box, ect)
16. Clutch fluid hard line & slave cylinder
17. Catalytic Convertor
18. Cat-back exhaust (stock or not)
19. Rear body harness
20. GT-S E-brake cables. (Handle and center cable are the same, but rear cables are different.)

21. Complete GT-S rear differential. (including brakes & calipers)
22. Brake proportioning valve if using an SR-5 built before 10/85 (any built after have the same one as the GT-S)

+ Anything I missed.

Note: Some parts swapped over may need the brackets from the GT-S, IE: the coolant reservoir (has a small bracket that bolts the the pass side strut tower)

Or like on the ignitor/coil, my SR-5 didn't even seem to have the mounting holes for the bracket. So I had to make some out of aluminum stock bought at home depot.

1. A shell.

[Image: AEU86 AE86 - Write-up/How to: AE86 SR-5 ...*No 56k***]

[Image: AEU86 AE86 - Write-up/How to: AE86 SR-5 ...*No 56k***]

2. Strip the shell. You'll need to remove:
The engine/transmission.
All 4 interior wiring harnesses which will require almost complete dissassembly and removal of the interior with the exception of the hvac assemblies/case (Heater Ventilation & A/C - which is the evaporator, blower motor and heater core).
The brake & fuel lines from the passenger side frame rail where it meets the engine bay to the gas tank, which will also need to be removed (*custom fuel pump & lines can be done instead of using a GT-S gas tank & lines, but this post/write-up will NOT be outlining these options).
The driveline & rear differential.

[Image: AEU86 AE86 - Write-up/How to: AE86 SR-5 ...*No 56k***]

[Image: AEU86 AE86 - Write-up/How to: AE86 SR-5 ...*No 56k***]

[Image: AEU86 AE86 - Write-up/How to: AE86 SR-5 ...*No 56k***]

Also, you will need to remove a small bracket that is spot welded in 2 places on the right side front fenderwell area. It is what held the SR-5 washer bottle & coolant reservoir in place at the bottom. It will interfere and is not necessary for the GT-S airbox/filter, it also interferes with the K&N filter kit and possibly the INJEN one as well (but I have no first hand experience with the INJEN intake kits). In the picture below the mount is already removed and I sprayed the exposed spot welds with some black paint to prevent rust.

[Image: AEU86 AE86 - Write-up/How to: AE86 SR-5 ...*No 56k***]

NOTE: if your going to paint your car, interior or engine bay. Now would be the time, or you'll have to do a lot of it all over. Wink I did the interior & engine bay, exterior to come later. Here's a few pics for fun. But this is NOT part of the SR-5 to GT-S swap, and this is all the detail I'm giving here.

[Image: AEU86 AE86 - Write-up/How to: AE86 SR-5 ...*No 56k***]

[Image: AEU86 AE86 - Write-up/How to: AE86 SR-5 ...*No 56k***]

At this point the SR-5 chassis is almost literally just a shell and we can begin the process of swapping the GT-S components.
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Messages In This Thread
Write-up/How to: AE86 SR-5 to GT-S swap. ***No 56k*** - assassin10000 - 06-11-2007 06:04 AM
[] - assassin10000 - 06-11-2007, 06:04 AM
[] - assassin10000 - 06-11-2007, 06:05 AM
[] - assassin10000 - 06-11-2007, 06:05 AM
[] - assassin10000 - 06-11-2007, 06:06 AM
[] - evfan42 - 06-11-2007, 07:45 AM
[] - Mux213 - 06-11-2007, 09:03 AM
[] - oldskull - 06-11-2007, 01:21 PM
[] - assassin10000 - 06-11-2007, 05:31 PM
[] - Mux213 - 06-11-2007, 07:03 PM
[] - 86drift - 06-11-2007, 08:03 PM
[] - banpei - 06-12-2007, 09:10 AM
[] - banpei - 06-13-2007, 10:38 PM
[] - assassin10000 - 06-14-2007, 06:54 AM
sr5 to gts swap wirin harness - ae86 tn - 09-01-2009, 01:05 AM
[] - ae86 tn - 09-11-2009, 04:19 AM

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