Rav4 3sfe to 5sfe engine swap Options

[ricochet1490]

So, I bought my first Rav4 about a month or 2 ago. I've been in the celica world for a long time and I wanted a winter beater. As it turns out, the 3s decided that it was going to start Rod knocking like a beast. Needless to say, car needed work.

I had an old 5s just sitting on a pallet in the garage collecting dust. it came from a 94 celica, and it ran when it was pulled.

Now that I've got everything out of the Rav, and from what i'm told, the 5s block will need ground on the back to make space for the transfer case, but otherwise it should be pretty straight forward I think.

I haven't had time to research everything... but to be honest there isn't much out there on this particular swap because there aren't that many gains to be had. For me the gains are purely $$$.

if you guys see anything glaring, PM me and let me know if you would....

The Plan
1) swap wiring harness from 3sfe to 5sfe
2) "depending on how the ecu works out", swap over exhaust manifold because of OBD1/OBD2 differences in the model years
3) hook tranny and T-case to 5sfe ( grind block as needed, additionally brace as needed for missing mounting points)
4) repair subframe rust, mount engine and tranny to subframe - reinstall in car
5)hook everything back up including 3sfe ecu to run engine. ** Pray ecu can deal with extra stroke/air and change fuel delivery to accomodate**
6) ** pray that i don't need to swap injectors to do this to get engine to running** - Does anyone know if there is much in the way of difference between the injectors? basically I'm looking to run the 5sfe like a stroked 3sfe. Should work I'd think.

[ricochet1490]

So I've got everything sorted I think. As you can see here, the crank position sensor runs off the timing sprocket with the sensor integrated into the oil pump. Everything else had already swapped over and plugged up.


So, tonight with any luck I'll have the obd1 5s oil pump removed, the one from the 3sfe swapped in, and the oil pan back on. After that I'll swap over the AC and begin trying to mount the 5s to the awd gear box, grinding the block where I need to to make it fit. Then a swap of exhaust manifold somewhere there to make sure I get that oxygen sensor... I think it'll work.

The only thing that'll stop me now is if the 3sfe ecu doesn't have enough fuel map to run the 5s because of the extra stroke. But I'd sure hope it would. We'll see what happens I guess.