Lauren's 4AGE build by Tom (Icunonsove)

[pk_090]

What Sam said. This is a fantastic thread!

[elbon50]

What Sam said. This is a fantastic thread!

As previously said, the content of this thread ought to be in the knowledge base IMO

[synXero]

Makes me want to buy a set of pistons for room decoration.

What a job.

[Lauren]

Okay, about time I put it back together!

I've already got an inlet manifold gasket on order from Toyota. Will pick that up tomorrow and also order some injector seals as the ones on it look worn.

Today, I decided to make a start and try and work out where everything goes. After eighteen months it's a bit of a challenge finding all the right bolts which are thankfully bagged but not all marked up. Also had some fun working out how the ancillary brackets and block strengtheners go on. I got there eventually.

There is obviously a lot to do, but given the engine is built, it's really a matter of putting everything else back together so the engine and gearbox can go back in.

The engine as left by Mr Tom. He completed this last February.


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Tom has labelled some stuff, so I don't forget!

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Some of the bits laid out on the table. Just got to figure out where everything goes.

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The car in situ where it has sat since August 2012!

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Here I've put on the block strengthening bracket, engine bracket and alternator bracket on the inlet side.

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On the exhaust side, there is the strenthening brace, engine mount and AC and power steering bracket which is huge. There are other brackets that bolt to this!

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A trip down memory lane seeing these stickers of events of years gone by:

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Engine fan on and pulley. It's a bit cleaner than when it came off!

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[elbon50]

Well done

Keep at it

& do keep us up to date with progress

[Lauren]

Had a quick hour and a half at it today.

Got the engine ready for mating to the gearbox next weekend.

Torqueing the Inlet manifold:


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New injector seals on:

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Injectors in until I realised it would likely be easier to push them onto the fuel rail first. What a fiddly job on your own.


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Dizzy in:

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I might look at getting a new O ring. Couldn't find one amongst my new parts bag. Also can't find one of the bolts for the distributor so will order another from Toyota. Might be ordering a few lost bolts at this rate!

Alternator on. Was interesting that I found that when I bolted up the lower brace for the inlet manifold it didn't seem to fit right. If I did the bolt up to the block it would have been under tension. Turns out the AE86 has a different brace which is shorter and bolts off one of the lower block strengthening brackets.

Not that interesting, save for putting the fan/alternator/water pump belt on, it's pretty much ready for bolting the gearbox up.

Next weekend this can go on:


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Then hopefully we'll get it all back in.

[wilkie senior]

Looking forward to seeing it back on the road

[boondougal]

really good build thread.

When i was looking at the colour options for the cam covers i really wanted white but i got shot down a little so i changed it to a blue to match my car... which i think was the right touch but i do like the white... especially for your car!

this will look great back in the engine bay.

[Lauren]

Well progress seems to be slow. I seem to feel ill everytime I work on the car, it's just a bit too cold in the workshop at the moment.

We got the engine off the stand with the help of the engine crane. I put the clutch and pressure plate on, but then remembered, arrghh, MR2 crank, spigot bearing!

I'm glad I remembered as I wouldn't want to go through that again.

Here it is with the spigot bearing which the gearbox input shaft locates into:


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It does make it harder to get the gearbox on though.

Mark drills out the stripped thread on the bell housing:

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Then he taps it:

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Then helicoil in:

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Engine and gearbox reunited complete with new clutch.


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There are four bolts missing. Mark wasn't happy using whatever bolts were around so will have to order the right bolts from Toyota.

Next step is getting the engine and box in, not looking forward to that!

[gon]

excellent build
On my AE86 I have always put the engine and the box separated and then torqued them up once in place...
You have to lift the car off the ground a good bit to be able to put them in when they are stuck together ....

good one

[Lauren]

Well, the car is already in the air, so it's got to be easier. Last time I had the eninge apart I used an MR2 block and didn't realise about the spigot bearing. I then had to take the box off to put it in. Was a total nightmare, so didn't fancy all that fun and games by putting in the engine first!

[Lauren]

A bit more progress.

Mark insisted that I buy new bolts for the bellhousing to gearbox and block strengtheners. So off he went to Toyota:


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£25 for 8 bolts!

I'm glad we changed them though, the old ones were in terrible condition:


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Mark makes the first cut to the wiring loom in preparation for the new injector clips (we've changed to later injectors from an AW11):


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Meanwhile Si and I get the engine and box ready for lifting so we can get to those other bolts:


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Starter on and some shiny bolts too:


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Mark's soldering setup. I know crimping would be better but we don't have the gear. They will be well soldered, knowing Mark:


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Mark, hard at work:


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New injector plugs spliced into the old loom:


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Next the engine and box goes back in!

[PW@Woodsport]

Lauren i'm not sure you can do that, swap Mk1b injectors into an early 4a-ge setup.

The early square 4a-ge injectors are high impedance without a resistor pack, the Mk1b injectors are low impedance WITH a resistor pack..... i'm not even sure you can retro fit the resistor pack without also changing the ECU to a late type.

You need to be careful with that or risk ECU damage, i might be wrong or possibly the AE86 is different but it just raised an eyebrow when i saw Mk1b injectors going into an early setup.

[Lauren]

Okay, thanks for that Paul. Must admit, had no idea.

Edit, Mark said, all that's been checked it's not an issue.

[PW@Woodsport]

Ah ok, well if Mark's checked it out it must be fine as he knows his stuff, just never heard of anyone doing that with the 4a-ge, normally you have to swap the entire ECU/loom and fit a resistor pack, and i have seen various other makes of car having problems burning ECUs out trying to run the "wrong" injectors...

http://www.hondata.com/techlowohminjectors.html

Just thought it was worth a mention.

[Lauren]

No worries, cheers for that.

I would have no idea myself. We'll see what happens I guess.

[Lauren]

Just spoken to Mark. The both are low impedance resistors. The AE86 ECU and setup it not the same as the early AW11.

It runs low impedance without a resistor pack.

[PW@Woodsport]

That would make sense, but terribly confusing! Your AE86 ECU must be able to drive low imp injectors without a resistor pack, so pink Mk1b ones should then be fine.

What i don't like is Toyota making an early engined AE86 with the same colour and shape injectors as a Mk1a from the same era but changing the impedance, that's a bit naughty to say the least, i wonder how many people have bought some AE86 injectors and tried to use them in a Mk1a or vice versa?

I remember talking to Tom about this and now remember the two injector types resistance being somewhat the same.

That injector difference (but same colour/shape) would catch a lot of people out.

[Lauren]

I agree it's a total nightmare. Mark and Tom spent some time testing them and working out whether it was okay or not.

[Lauren]

Okay, we have the engine and box back in the car! It's been 20 odd months since it last sat in there!

Waiting for the rain to stop so we can open the shutter doors and get the engine and box in position:


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Shutter going up and time for the AE86 to meet the GT86.


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With three of us and me being underneath guiding the gearbox down, we had it all on the mounts within 15 minutes.


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Mocal sandwich plate for the oil cooler on and new Toyota filter added:


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Si gets busy with all the awkward bits:


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This pic doesn't show much, but it signifies the prop being back on the gearbox, so all is connected underneath:


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Exhaust manifold needs some more wrapping yet:


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Si still fiddling:


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A bi of a problem here. The inlet seems to have got broken somewhow where it's been stored out of the car. Not sure what to do, will see if Toyota still have new ones and price up, I think. Not sure I can do much with that.


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Still, a decent amount of progress has been made today.


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We need a few bits. Apart from the radiator, I need engine oil, gearbox oil and a few odds and sods. But, will hopefully have it running in a few weeks.