AE86 NA to GZE swap

[Paul Woods]

I thought this might interest a few of you, i talked about this car coming to see us a few months ago, well it's finally here and i might as well document its conversion from 4a-ge to 4a-gze here.
The car in question, this thing has a mint condition body, just stunning...

http://www.twobrutal.co.uk/forum/images/recovered/2012/05/51.jpg

This is the way it arrived off the boat, never been painted in the UK.

http://www.twobrutal.co.uk/forum/images/recovered/2012/05/52.jpg

http://www.twobrutal.co.uk/forum/images/recovered/2012/05/53.jpg

I'll be starting work on this in about a weeks time once i've got rid of the Ferrari 360 and Lamborghini Murcielago that currently grace our lifts :D

http://www.twobrutal.co.uk/forum/images/recovered/2012/05/54.jpg

[snowtigger]

Sweeet looking car, I fancy one a hatchback with 2gr or celica supra 2jze version.
Note to self stop looking at more toyotas.

[Adam W]

Wow, that thing is stunning. As much as I love the AW11, that must be the ultimate 80's Toyota for most people? Sounds like a great swap, keeping a period lump but increasing the power somewhat. What are the specs of the GZE that's going into it?

PS: Tell the owner to get some period bronze wheels on it, would look awesome against the black!

[adamh]

love it

[Tommytank]

Wow, that thing is stunning. As much as I love the AW11, that must be the ultimate 80's Toyota for most people?

Not tried a Supra? ;) These would be great cars if it wasn't for the overinflated premium they command.

So much goodness came from Toyota in the era of excess. Shame it's all changed.

This should be an interesting build!

[Adam W]

I had a Celica Supra with a V8 swap, and an MA70 which I got into the 10's at santa pod. I enjoyed them at the time, but since I've been introduced to the benefits of lightweight cars I wouldn't go back to either of them! I spent enough on my Supra over the years to buy a decent 911 or NSX, and then broke it for (relative) peanuts :(

[Paul Woods]

I was actually at Santa Pod watching one of your runs Adam, that car was pretty special.

[snowtigger]

That's the problem now all these are becoming classics and rare the prices go sky high then you have to pay out for all the improvements, bigger engines better brakes and suspension.

I've just had a quote of ohlins for a bespoke dfv coilovers £3000 on aw11 is it worth it probably not, the car probably is worth more as parts but to me it's priceless if it wasn't for the car I wouldn't have met such great friends and joined such a great club.

[Paul Woods]

The project swung into action today with the engine and gearbox removed, this is my first AE86 but i have to say it is ridiculously easy to work on, i removed that engine in under an hour.

http://www.twobrutal.co.uk/forum/images/recovered/2012/05/157.jpg

http://www.twobrutal.co.uk/forum/images/recovered/2012/05/158.jpg

http://www.twobrutal.co.uk/forum/images/recovered/2012/05/159.jpg

http://www.twobrutal.co.uk/forum/images/recovered/2012/05/160.jpg

There is a lot of work to do to the SC engine before installation, wiring to figure out and plumbing mods etc, but this looks relatively easy to be honest.

[Adam W]

I know it's heresy, but I'd love to stick a 1UZ into one of those. I'm sure I wouldn't be the first! The GZE swap is a great option though, more power with similar character to the original engine.

[Paul Woods]

You aren't alone there mate, nice big engine bay, screaming out for more cylinders to fill it up.

[hmmmmm]

Haha the no1 adress for mr2 swaps, there is a waiting line though, as they are currently working on a ferrari, a lambo, and a trueno :smile:

[hmmmmm]

What are the specs of the GZE that's going into it?


If its stock (which i presume it is, otherwise paul would not have the need for more cilinders):

4A-GZE

The 4A-GZE (produced in various forms from 1986 through 1995) was a supercharged (http://en.wikipedia.org/wiki/Supercharger) version of the 4A-GE. Based on the same block and cylinder head, the 4A-GZE engine was equipped with a Roots type supercharger (http://en.wikipedia.org/wiki/Roots_type_supercharger) producing 8 psi (0.6 bar) peak manifold pressure, and the compression ratio was lowered to 8:1 with the use of forged and dished pistons. Although fitted with upgraded pistons, they still had the same ports, valve timing, and head gasket as the naturally aspirated 4A-GE engine, although T-VIS (http://en.wikipedia.org/wiki/T-VIS) was omitted. It was used in the supercharged MR2 (http://en.wikipedia.org/wiki/Toyota_MR2) and in Japan-only FWD (http://en.wikipedia.org/wiki/Front-wheel_drive) Corollas, rated at 145 PS (107 kW; 143 bhp) at 6,400 rpm and 190 N·m (140 ft·lbf) at 4,400. In 1990 it was updated with the "smallport" cylinder head, 8.9:1 compression, and MAP D-Jetronic (http://en.wikipedia.org/wiki/Jetronic) load sensing and a smaller supercharger pulley producing 10 psi (0.7 bar). These updated 4A-GZE motors were rated at 165 PS (121 kW) and 210 N·m (155 ft·lbf) for the 1990/1991 AE92 Corolla (http://en.wikipedia.org/wiki/Toyota_Corolla) and 170 PS (125 kW) for the AE101.
The 4A-GZE is also popular for turbo conversions, as many parts do not need to be modified to support the extra boost.[16] (http://en.wikipedia.org/wiki/Toyota_A_engine#cite_note-15)

[snowtigger]

A 2jz would be awesome so would a v8 there was a wide arch one at japfest that would make a good recipient for a v8.

Mmm a 2gr would fit if we could fit a 6speed supra box.

[Paul Woods]

The 2gr-fse would be the one to use if we're talking 2gr, it has the correct bellhousing pattern and orientation for an inline mounted setup.

[adamh]

If its stock (which i presume it is, otherwise paul would not have the need for more cilinders):

4A-GZE

The 4A-GZE (produced in various forms from 1986 through 1995) was a supercharged (http://en.wikipedia.org/wiki/Supercharger) version of the 4A-GE. Based on the same block and cylinder head, the 4A-GZE engine was equipped with a Roots type supercharger (http://en.wikipedia.org/wiki/Roots_type_supercharger) producing 8 psi (0.6 bar) peak manifold pressure, and the compression ratio was lowered to 8:1 with the use of forged and dished pistons. Although fitted with upgraded pistons, they still had the same ports, valve timing, and head gasket as the naturally aspirated 4A-GE engine, although T-VIS (http://en.wikipedia.org/wiki/T-VIS) was omitted. It was used in the supercharged MR2 (http://en.wikipedia.org/wiki/Toyota_MR2) and in Japan-only FWD (http://en.wikipedia.org/wiki/Front-wheel_drive) Corollas, rated at 145 PS (107 kW; 143 bhp) at 6,400 rpm and 190 N·m (140 ft·lbf) at 4,400. In 1990 it was updated with the "smallport" cylinder head, 8.9:1 compression, and MAP D-Jetronic (http://en.wikipedia.org/wiki/Jetronic) load sensing and a smaller supercharger pulley producing 10 psi (0.7 bar). These updated 4A-GZE motors were rated at 165 PS (121 kW) and 210 N·m (155 ft·lbf) for the 1990/1991 AE92 Corolla (http://en.wikipedia.org/wiki/Toyota_Corolla) and 170 PS (125 kW) for the AE101.
The 4A-GZE is also popular for turbo conversions, as many parts do not need to be modified to support the extra boost.[16] (http://en.wikipedia.org/wiki/Toyota_A_engine#cite_note-15)

to add to that good info, the supercharged block was based on the later 4age block 87+ with 42mm big ends and 7 ribs, unlike the earlier mk1 block with 40mm big ends and less ribs.

[Paul Woods]

Ok, the engine is undergoing it's fabrication stage, so all of the little mods i need to do will be done now before the engine gets tore down and everything made pretty.
An immediate decision was made to ditch the AC. There is not enough room for both that and the alternator, not without compromising the job. The AE86 exhaust manifold wants to sit too close to the alternator if we try to keep both, so doing it this way gives us breathing space.

I made an alternator bracket, just rough mock up for now, it will be made pretty later. I'm going to run it on the SC belt which has its own tensioner, meaning we could just solidly mount the alternator and forget about it.

http://www.twobrutal.co.uk/forum/images/recovered/2012/05/186.jpg

http://www.twobrutal.co.uk/forum/images/recovered/2012/05/187.jpg

http://www.twobrutal.co.uk/forum/images/recovered/2012/05/188.jpg

Next job was to tackle that effing horrible Ford piece of plastic crap Fensport insist on supplying with big pulley kits, quite why i've no idea, we've seen loads of these disintegrate. A few years ago i discovered a nice upgrade using a Camry V6 cambelt idler pulley, absolutely bombproof....

http://www.twobrutal.co.uk/forum/images/recovered/2012/05/189.jpg

I mean what the hell is that meant to be? It's plastic... enough said.

http://www.twobrutal.co.uk/forum/images/recovered/2012/05/190.jpg

Next issue was the exhaust manifold, it sits right up against the "distributor".... circled yellow, the only thing i could do was cut the exhaust at the red line, orientate it away from the dizzy and weld it back up again....
http://www.twobrutal.co.uk/forum/images/recovered/2012/05/191.jpg

It now has a 10mm gap which i can slide a heatshield into and the manifold will be heat wrapped as well...

http://www.twobrutal.co.uk/forum/images/recovered/2012/05/192.jpg

I've noticed the OS engine mount wants to share a bolt hole on the supercharger bracket, so that will need attention, and the NS engine mount frontmost two holes want to share my alternator bracket, that is a much easier mod.

So it's all ready for stripping down now, that is all the modification i need to do at this stage.

[Paul Woods]

I stripped the SC engine today inspecting as i went. The bores on this engine are as perfect as i think i've ever seen on one, so i won't be touching those, all honing marks can be clearly seen, she's a good un.
The bottom end is also excellent but i found the usual block corossion around number 4 cylinder so i had to totally strip the block so it can be sent for decking, this area around number 4 will definitely blow in future if left like this. I will renew the big end shells while it's all apart.

http://www.twobrutal.co.uk/forum/images/recovered/2012/05/206.jpg

Bottom end...

http://www.twobrutal.co.uk/forum/images/recovered/2012/05/207.jpg

Block stripped, note the oil squirters.

http://www.twobrutal.co.uk/forum/images/recovered/2012/05/208.jpg

Alfie, aka Woodsport dog, is actually a golden lab, can't keep him out of the oil :D

http://www.twobrutal.co.uk/forum/images/recovered/2012/05/209.jpg

I will be busy over the next few weeks painting and reconditioning parts to go back on, for now that block needs to go to the machine shop.

[Paul Woods]

Finally got the block and head back from the machine shop, block all freshly decked i gave it a coat of rust inhibitor, it's heatproof as well...

http://www.twobrutal.co.uk/forum/images/recovered/2012/05/374.jpg

Then applied some silver top coat colour...

http://www.twobrutal.co.uk/forum/images/recovered/2012/05/375.jpg

The machined head...

http://www.twobrutal.co.uk/forum/images/recovered/2012/05/376.jpg

New bearings are on order from Toyota, so i'm stuck until they arrive on the 29th.

[adamh]

nice job. looking forward to hearing this supercharged number, running standard or more boost, whats the difference in pulley for more is it smaller? what happens to the tensiner does it cope , or do you slap a smaller belt on?

[Paul Woods]

The crank pulley goes bigger with an overdrive kit, the tensioner pulley is a crap ford plastic thing, which i found an upgrade for by using a Camry V6 idler, works a treat.

[Paul Woods]

I've partially stripped the engine bay for repainting, not everything needs to fully come off, i can mask what's left pretty easily. Now originally Andy and i discussed a quick tidy for the bay with some satin black rattle can, do the best i could was the brief, after all it's in for an engine swap, not a restoration. However i'd be letting the job down if i just used satin black, the car has a more grey coloured black than a full black, code 2X1, so i've ordered some of that and going to repaint the whole bay properly now, at no extra cost to the customer.

I just can't bring myself to do it quickly or half hearted, got to be right!

http://www.twobrutal.co.uk/forum/images/recovered/2012/05/429.jpg

http://www.twobrutal.co.uk/forum/images/recovered/2012/05/430.jpg

So, tomorrow this will be primed and painted, should look brand new.

[Paul Woods]

Didn't quite get around to painting today, but i did get the new bearings installed and the crank/pistons refitted...

http://www.twobrutal.co.uk/forum/images/recovered/2012/05/440.jpg

http://www.twobrutal.co.uk/forum/images/recovered/2012/05/441.jpg

Oil pump overhauled and new crank seal and gasket fitted...

http://www.twobrutal.co.uk/forum/images/recovered/2012/05/442.jpg

The engine as it is now...

http://www.twobrutal.co.uk/forum/images/recovered/2012/05/443.jpg

Stuck on this now until the gasket/studs arrive.

[Paul Woods]

I'm still waiting for parts to arrive but in the meantime the bay has been resprayed the same colour as the car, still got to detail various parts of the engine bay.

http://www.twobrutal.co.uk/forum/images/recovered/2012/06/171.jpg

http://www.twobrutal.co.uk/forum/images/recovered/2012/06/172.jpg

http://www.twobrutal.co.uk/forum/images/recovered/2012/06/173.jpg

[adamh]

looking good, i think customer will spend more time looking under hood than drive.

[Paul Woods]

I was able to make a bit more progress with this today, i had to tap out the block for the ARP studs as they were a little rusty, after that the ARP studs screwed all the way in...

http://www.twobrutal.co.uk/forum/images/recovered/2012/07/38.jpg

The MLS gasket was then fitted...

http://www.twobrutal.co.uk/forum/images/recovered/2012/07/39.jpg

Head refitted and torqued down, i use a 1/2" digital one for all my engine building which is super accurate...

http://www.twobrutal.co.uk/forum/images/recovered/2012/07/40.jpg

With the head torqued i fitted the supercharger cams (Andy your old cams in the NA engine were just stock Toyota, nothing fancy about them) , again i use a 1/4" digital torque wrench...

http://www.twobrutal.co.uk/forum/images/recovered/2012/07/41.jpg

HKS cam pulleys fitted...

http://www.twobrutal.co.uk/forum/images/recovered/2012/07/42.jpg

Water pump installed...

http://www.twobrutal.co.uk/forum/images/recovered/2012/07/43.jpg

It was at this stage when i looked at my notes that Andy and i had discussed and he wanted azure blue cam covers, so he doesn't know i've done this, but i mixed up a nice shade of purple to match the HKS pulleys, there's a clear Zaklee cambelt cover going on this engine so you're going to see the pulleys, i think blue is the wrong choice for the cam covers, but if Andy still wants blue i'll redo them for him... sometimes a little artistic licence is needed on these builds and i tend to have a good eye for the detailing stuff.

http://www.twobrutal.co.uk/forum/images/recovered/2012/07/44.jpg

http://www.twobrutal.co.uk/forum/images/recovered/2012/07/45.jpg

This purple changes shade depending on which angle you look at it.... polished stainless spark plug cover added too....

http://www.twobrutal.co.uk/forum/images/recovered/2012/07/46.jpg

So it's coming together nicely now.

[snowtigger]

Oooh liking this colour choice there mr woods that looks positively tasty.

[chief44]

This is a cracking thread. The attention to detail is inspiring as ever. Top work Paul.

[adamh]

1.6 goodness.

[Paul Woods]

Today saw the thermostat housing modified, i knew about this solution from someone elses build, but i always like to do things my way, so i gave it a few hours thought but just couldn't accomplish it any other way than the way it had been done previously, it appears to be the only solution to getting the thermostat/heater lines working on a 4a-gze mounted in an AE86.

Anyway, i had to make a new water pump pipe, with new block securing bracket, a 90* bend on the end and an 8mm take off for the throttle body pipes...

http://www.twobrutal.co.uk/forum/images/recovered/2012/07/119.jpg

Everything else mocked up in the fabrication stage, this works, clears everywhere it needs to and just needs cleaning/painting now...

http://www.twobrutal.co.uk/forum/images/recovered/2012/07/120.jpg

I got the injectors/rail fitted and the lower plenum painted/fitted.... so far brand new nuts and bolts have been used everywhere....

http://www.twobrutal.co.uk/forum/images/recovered/2012/07/121.jpg

[cdwood2010]

Very nice work there mr woods!

:)

[Paul Woods]

Thankyou oh round one.

[cdwood2010]

Thankyou oh round one.

No need for that. I will have you know I'm a comfy ride.

;)

[Paul Woods]

<shudders> poor Melony. :)

[Paul Woods]

More progress with this today, restoring this GZE is taking longer than i thought, but the Supercharger is now fitted along with all of the little brackets etc, again all new nuts and bolts used...

http://www.twobrutal.co.uk/forum/images/recovered/2012/07/343.jpg

Instead of blanking the ABV i've left it off altogether, this is because i need to make a new housing for the supercharger outlet so it seems pointless having the ABV there at all, after all if it's blanked off it's not needed....

http://www.twobrutal.co.uk/forum/images/recovered/2012/07/344.jpg

The engine overview as it looks now...

http://www.twobrutal.co.uk/forum/images/recovered/2012/07/345.jpg

[Plasticgeordie2007]

Thats a work of art that Paul

[Paul Woods]

Thankyou mate.

The engine is almost complete now, cambelt fitted, Zaklee timing cover, and oversized pulley fitted along with the Woodsport V6 idler pulley mod. Engine harness also fitted and coilpacks mounted, these may need relocating, i'll need to see how much space i have when the engine goes in...

http://www.twobrutal.co.uk/forum/images/recovered/2012/07/347.jpg

This build wasn't meant to be a nut and bolt job, but due to my OCD condition it's turned out that way, not exactly in the best interests of business turnover/profit but my main motivation for working on Toyotas has never been financial anyway!

http://www.twobrutal.co.uk/forum/images/recovered/2012/07/348.jpg

The wiring looks a bit of a nightmare, this was previously fitted to a front wheel drive Corolla, so it's an already modified engine loom, so i'll have to undo old conversion stuff, lots of fun.

[hmmmmm]

Piece of art! Just leave it there so everyone can have a look at it :wink: The clear cover i a great find, looked cool on the stock car you did, and the purple makes it look even better. To bad there isnt one for the V6, although you wont be able to see it as well.

[adamh]

ocd lol. good thing, the bolts they use are bleh. wonder if they changed anything on the newer cars

[Gon]

Hi Paul.

Good job being done there on the AE86 :) I also have one back at home and they are niceeee .:)

Quick question.
You have removed the pistons from the block and put the same ones back in.
Did you use new rings or the old ones ? did you hone the piston walls ?

I am thinking of removing the pistons from my engine and putting them back (just want to change the con rod bolts to ARP) but I am not sure if I will have good compression if I fit the same pistons rings without honing the block?? what's your opinion on that ?

Cheers. :)

[Paul Woods]

Hi Gon, if all you are doing is removing the pistons and putting them back in, as i did, there is no need to rehone the bores, you would be worse off doing that as your current rings are bedded into the bores as they are.

I haven't fitted new rings to this build, the bores were in mint condition, so all it needed was a quick clean up on assembly.

You will have the same compression that you did before taking the pistons out, obviously inspect the bores and if you see any wear only then do you need to consider new rings and a rehone, or if it's very worn 0.5mm oversized pistons and an overbore.

[Paul Woods]

Thanks folks, today the gearbox got cleaned and painted, i need to be careful how far i go here or it could very easily turn into a full resto, so i won't be painting the prop etc...

http://www.twobrutal.co.uk/forum/images/recovered/2012/07/364.jpg

Fitted the new spigot bearing into the crank...

http://www.twobrutal.co.uk/forum/images/recovered/2012/07/365.jpg

Once the flywheel and clutch were fitted i mounted the gearbox.

http://www.twobrutal.co.uk/forum/images/recovered/2012/07/366.jpg

Some extra detailing in the engine bay, new bolts on the brake pipe junctions and fuel filter, repainted brake master cylinder.

http://www.twobrutal.co.uk/forum/images/recovered/2012/07/367.jpg

Shortly after that it was fitted on its mounts...

http://www.twobrutal.co.uk/forum/images/recovered/2012/07/368.jpg

http://www.twobrutal.co.uk/forum/images/recovered/2012/07/369.jpg

http://www.twobrutal.co.uk/forum/images/recovered/2012/07/370.jpg

The day ended with the exhaust manifold wrapped and fitted...

http://www.twobrutal.co.uk/forum/images/recovered/2012/07/371.jpg

http://www.twobrutal.co.uk/forum/images/recovered/2012/07/372.jpg

I'll have my work cut out routing the IC pipework, it looks a real mission, and the wiring looks complicated, this GZE Corolla harness is not long enough to reach into the cabin, so i'll need to extend every ECU wire by the look of it, great.

[Gon]

Thank you for your reply Paul :) and once again , excellent work you do with these

[Tommytank]

That's a bit of a mission. As u say though, it's a reflection on your attention to detail, and from what I can see, a thorough job indeed!

[Goldy]

I have to say that engine looks bloody tiny in that mahusive bay.... it's crying out for more cylinders ;-)

[adamh]

first time i saw a bearing used on the crank!

[Paul Woods]

Quite common on older RWD cars mate, Sierras, Escorts and the like all had them.

[snowtigger]

Needs a v6 2gr-fse in that engine bay imho.

It does look rather sexy though as is.

[Paul Woods]

A project i had to stick on the back burner due to unexpected staff shortages and unforseen complications with the build, but recently i have been getting stuck into this one again with the aim of full completion very soon. One of the main stumbling blocks was the fact that the Supercharger engine harness was nowhere near long enough to reach into the cabin..... a major setback, so i have had to extend each ECU wire (some of them shielded signal wires) by 4 ft so the ECU canbe safely mounted dry in the cabin....

http://www.twobrutal.co.uk/forum/images/recovered/2013/06/441.jpg

I am almost there with this, then i can resume the project again as normal, hopefully there won't be anymore surprises and i can roll this one out soon.