Toyota 4AGE build

[windymiller]

Hi guys,

I'm new on here and currently building a 16ver using a Toyota 4AGE from a MK1 MR2. Work done so far is:

Subframe complete and engine fitted
Driveshafts made
Selectors fitted and connected
Exhaust manifold made
Clutch done

Here's a couple of pics to wet your whistle:

http://i438.photobucket.com/albums/qq107/angleseymr2/DSC00483.jpg
http://i438.photobucket.com/albums/qq107/angleseymr2/DSC00585.jpg
http://i438.photobucket.com/albums/qq107/angleseymr2/P1236_14-12-09.jpg
http://i438.photobucket.com/albums/qq107/angleseymr2/DSC00663.jpg

Things to do:

Make an inlet manifold
Cooling system plumbing
Wiring
Fuel plumbing
Maybe change the gearbox for one with the starter and selectors at the back.

Cheers,

Warren

ps I'll take some better pics when I get a chance!

[Dazzler]

Its looking good...

If you wanna keep the tie bars in the same place you will need to cut the corner off the sump

There are some pics on my build of an inlet, its easy, just time consuming porting it all

Great to see another 4age

[spNOam]

See Daz, he managed to keep some support under the engine/box :D

[Dazzler]

See Daz, he managed to keep some support under the engine/box :D

lol.... i did in the end... just wanted to try something different

[windymiller]

Cheers Daz. I had a good look at your build before I started to get an idea of whats involved. Very helpful. Sump is already cut out and the tie rods fit nice. I've taken the engine out tonight and started fitting a Carina gearbox with the starter and selectors at the back, to leave move room for the rad and fan (hopefully!). Job halted as I need a flame thrower to sweat the carina ring gear onto the MR2 flywheel.

Here's some more pics:

http://i438.photobucket.com/albums/qq107/angleseymr2/P2041_31-01-10.jpg

http://i438.photobucket.com/albums/qq107/angleseymr2/P2228_07-01-10.jpg

http://i438.photobucket.com/albums/qq107/angleseymr2/P1537_04-12-09.jpg

http://i438.photobucket.com/albums/qq107/angleseymr2/DSC00669.jpg

http://i438.photobucket.com/albums/qq107/angleseymr2/P1516_03-12-09.jpg


I was having a look tonight, and I think I may have the engine too far over to the drivers side. Oops. I'll know for sure when the engine is back in and I get some wheels on it.

[spNOam]

Awesome pictures Warren, well done, keep up the good work, nearly ready to start up, thats a real milestone.

[Dazzler]

Well

you can use a later MR2 box with the "ears" i have a few kicking about for mounting starter at the back (straight swap) or use the corolla box with the ears to move the shifter to the back (i have one of those spare too)

On my build i had the engine so far back there was no chance of running a box with the shifters at the back

If you have the full engine loom the wiring is easy easy!

Be running next week?

[Dazzler]

oh just read your comment and looked at your frame.... i think your right about it being too far to the drivers side, i fond there is only maybe an inch or so to spare with its left right position without the wheels catching

[windymiller]

Oh sh1t! If I shift the engine over I don't think I'lll be able to use the rear shifters either, unless I cut into the subby around the suspension donut. I do have some wheel spacers that are 1-1/8" thick I think, but I don't really want to use them. Think I'll chuck the gearbox back on without the flywheel and see how it all looks.

On the starter front, the MK1 MR2 box has the 'ears' but the starter isn't a straight swap so I had a trawl around the scrappy to see what would fit. Then I found the Carina box with the starter and shifters at the back. I'll be a bit miffed if I can't use it....!

[windymiller]

Daz, what was the offset of your wheels (mounting face to inner rim distance, not center line to mounting face)?

[Dazzler]

erm... now your asking.... i built it on the Huddersfield 5.5x12's then fitted 6x12's later on, these were the standard mini ofset type

[windymiller]

Ta. I'll bung my 12" minilights on and get it central, then worry about what'll fit and what won't.

[pantera2075]

Carina starter fits on the other side of the C52 box - I had to do this with mine to give space for the exhaust.

And those pics above remind me a helluva lot of my conversion - apart from you welding is better than mine.

[windymiller]

Lol! It helps having a whopping big welder! Starter being moved for the same reason. I've had to fit a remote oil filter too. Did the Carina starter work ok with the 4AGE flywheel? Mine looks very slightly different and I didn't want to risk it all jamming up on the first crank of the engine!! Hopefully your welding is better than my measuring! Having a night off the project tonight - 9" grinder coming out of retirement tomorrow... :grin:

[pantera2075]

My starter is off a '93 Carina E - bolted straight on and worked. Only bit of a bodge is the trigger wire connection which ain't great.
And for oil filter, both me and Daz just removed the whole cast ally housing and screwed the filter straight to the block - easy.

[windymiller]

I tried that too, but there's no chance of fitting it behind my manifold! Did you guys have your engine tilted forward a bit?

I've done a bit on it today - I've swapped the selectors for the Carina ones so they're now out the back:

http://i438.photobucket.com/albums/qq107/angleseymr2/Mini/P1022_05-03-10.jpg

Also, here's the pics of the wheel clearance at full lock:

http://i438.photobucket.com/albums/qq107/angleseymr2/DSC00942.jpg

http://i438.photobucket.com/albums/qq107/angleseymr2/DSC00943.jpg

I'm thinking of slicing the smaller pulley off and leaving the engine where it is.

[Dazzler]

My conversion the engine was dead level and more over to the right (as you look from the front)

Where the gear box selector output is on yours would have hit the towers on mine.

Also i would say my engine was lower and further back

[pantera2075]

Bearing in mind mine is a GTM, so other factors apply:
My engine is horizontal too.
Left/right position isn't so important for me, but it's definitely further across, and further back - my waterpump pulley fouls the suspension tower under heavy accel.
Mine also looks to be lower in the subby. As a guide, the top of my dipstick tube is about 10mm above the top of the subby tower - and is tight up against it.

A decent amount of cornering force and that tyre will hit the bottom pulley by the looks of it..

[Dazzler]

http://i438.photobucket.com/albums/qq107/angleseymr2/DSC00942.jpg




Just took a look at this, this isnt going to work, you corner on any sort of lock and the suspension is going to compress and the tyre is going to hit the engine mount and subframe.

You need to be coming out right that the very top of the subframe, come in tight to the engine and "Hang" the mount over it to stand any chance of turning the wheel and the suspension compressing and not hitting the frame

[windymiller]

Thats pretty much the conclusion I reached when I put the wheels back on!! I'm thinking of not moving the engine, instead, I'm going to remove the smaller pulley. Also, the inner rim of the wheels I plan to use will be 20mm (ish) further out giving me even more clarance. I feel like a right numpty now.....

[windymiller]

Well, I've managed a few hours in the shed, althought the blinking gas has run out on the welder. I've started modding the o/s frame to go up and over the mounting:

http://i438.photobucket.com/albums/qq107/angleseymr2/P0827_07-02-10.jpg

Also, I've roughed up the bracket for the selectors:

http://i438.photobucket.com/albums/qq107/angleseymr2/P195601_06-02-10.jpg

I've got a few tweeks to make when I get some gas to get the selectors clearing each other, then I'll make the bracket for the cable.

I've also got the Corsa radiator in rough position:

http://i438.photobucket.com/albums/qq107/angleseymr2/P0828_07-02-10.jpg

I took one of the plastic ends off the rad and turned it upside down so that the hose spigot is at the bottom and will miss the dizzy.

I'm a bit stuffed now without gas so I may have a fiddle with the wiring and work out how to mount an alternator.

[pantera2075]

You can't "remove" that outer bit of the crank pulley - you need to grind it off.
Also, for alternator, I mounted mine exhaust side on 2 custom brackets picking up a couple of random tapped holes in the block. It just clears the oil pressure sender, and there ain't a lot of movement available.
Engine will be coming back out in a couple of weeks - i'll get pics.

[Dazzler]

I put my alternator on top of the engine mount with the belt running either side of the mount.

all my pics are here http://www.16vminiclub.com/gallery/thumbnails.php?album=759

http://www.16vminiclub.com/gallery/albums/userpics/P060509_21.44%5B01%5D.jpg
http://www.16vminiclub.com/gallery/albums/userpics/P120509_16.17%5B01%5D.jpg

to get the belts to line up i had to sit the pully side of the alternator inside here
http://www.16vminiclub.com/gallery/albums/userpics/P200509_19.44.jpg

[windymiller]

Daz, it looks to me like you'v got the alternator mounted on the subby, is this the case? if so, have you had any issues with the belt coming off?

[Dazzler]

Yeah it was mounted on the subby and i had no issues

[MattG]

i would really try and mount the alternator off the engine if you can.for long term use it will be the only way to go.

Matt

[windymiller]

Progress has been made! I'll try and get some pics up soon.

[Dazzler]

.......

[waits for pics with arms crossed] lol

[windymiller]

For those of you with cramp in your arms, here's some more pics of the progress:

I've managed to modify the original alternator bracket, and squeeze it in the front. I've also modded the frame to improve clearence. I'll have that pulley off soon and have it removed in a lathe to keep the heat down so the rubber damper isn't affected.

http://i438.photobucket.com/albums/qq107/angleseymr2/P1800_20-02-10.jpg

http://i438.photobucket.com/albums/qq107/angleseymr2/P1801_20-02-10.jpg

http://i438.photobucket.com/albums/qq107/angleseymr2/P195201_20-02-10.jpg

http://i438.photobucket.com/albums/qq107/angleseymr2/P1952_20-02-10.jpg

Since taking these, I've also mounted the rad and fan. I've now got the inlet manifold cut too so I can crack on with that. Selectors are also sorted with a bracket made for the cables. I'll take some more pics soon when the engine is back in.

[windymiller]

Hey guys, after a break of over a year, the project has been re-started (and so has my marriage!!) Here's a pic of the new gear cable brackets and linkage at the back of the engine:

http://i438.photobucket.com/albums/qq107/angleseymr2/Mini/P1022_05-03-10.jpg



Here's a poor photo of the selectors. Pretty easy to mount, just weld 4 bolts to the tunnel and plonk the selectors on top. A small amount had to be taken off the selector hole for clearance:

http://i438.photobucket.com/albums/qq107/angleseymr2/Mini/P1238_19-09-10.jpg



Here's a shot of the inlet manifold I've made. I still need to add connection points for two vacuum hoses:

http://i438.photobucket.com/albums/qq107/angleseymr2/Mini/P1726_26-09-10.jpg

I've started on the wiring and I'm hoping to fire it up for the first time in the next week or so :D

[mearcat]

windymiller - Can you please advise where you got (or brand) the oil filter adapter that's on the block. It looks like a really neat item. Cheers.

[windymiller]

Hi mate, I bought a remote filter kit off ebay for a Toyota MR2 MK1. You can also get them here: http://www.speedflowshop.co.uk/take-off-plate-side-feed-with-various-thread-versions-570-top01-1024-p.asp

I had to cut the square piece off mine to get it to fit behind the manifold, so it needs to be tightened up with a filter strap instead of a spanner but thats no big deal 8)

Hope this helps.

Warren

[windymiller]

Forgot to add - the brand is Mocal.

[spNOam]

Any pictures of developments?

[windymiller]

Hi mate, hows things? I'll try and take some tonight. I'm going out there in a bit to see if I can get it to fire :D:D:D:D:D:D

There's lots of wires tied together and no cooling system, but I'm hoping to get it to flash up. We're not far off getting it fully 'turnin and burnin' :cool:

[tiny2403]

if ya want a hand with wiring gis a shout:D

[spNOam]

if ya want a hand with wiring gis a shout:D

I need to wire full throttle shift cut into DTA....:-D

[spNOam]

Hi mate, hows things? I'll try and take some tonight. I'm going out there in a bit to see if I can get it to fire :D:D:D:D:D:D

There's lots of wires tied together and no cooling system, but I'm hoping to get it to flash up. We're not far off getting it fully 'turnin and burnin' :cool:

Huge milestone if you get it to run....expecting videos now :D all the best.

[windymiller]

Here's a couple of photo's showing the progress:

http://i438.photobucket.com/albums/qq107/angleseymr2/Mini/P1215_07-10-10.jpg

http://i438.photobucket.com/albums/qq107/angleseymr2/Mini/P1214_07-10-10.jpg

http://i438.photobucket.com/albums/qq107/angleseymr2/Mini/P121302_07-10-10.jpg

http://i438.photobucket.com/albums/qq107/angleseymr2/Mini/P121301_07-10-10.jpg


I was hoping to have it fired up last week, but it turns out the injection fuel tank I have is full of rust, so I'm modifying the standard tank for now:

http://i438.photobucket.com/albums/qq107/angleseymr2/Mini/P1212_07-10-10.jpg

I've got sparks so with the fuel system sorted we should have smoke too :D


tiny2403 if ya want a hand with wiring gis a shout

I might take you up on the offer Chris when it comes to doing the wiring properly ;)

[windymiller]

Well, after a couple of wiring issues and a tweak of the dizzy it finally started!! :D:D:D:D:D:D

I've still got a long way to go, but at least I've got a stupid grin on my face :D I've got a vid which I'll upload tomorrow, meanwhile I'm having a smug beer or two :beer::beer::beer::beer:

[spNOam]

Stupid grin.....I know it well.....

[windymiller]

Here's the motivation to finish the job:

http://i438.photobucket.com/albums/qq107/angleseymr2/th_FirstRun.jpg (http://s438.photobucket.com/albums/qq107/angleseymr2/?action=view&current=FirstRun.mp4)

[spNOam]

Well done! Great to have another 16valver in the area :D:D:D

[tiny2403]

good on ya we will have to pop over some time for a look :p

[windymiller]

No worries Chris, I should be in most evenings this week.

[windymiller]

Here's an update on the build.

New dash made and in place:

http://i438.photobucket.com/albums/qq107/angleseymr2/November2010014.jpg

I now need to mount a few switches and the ecu and tidy up all the wiring.

I've chaned the MGF radiator to a micra one and plumbed in the cooling system. I still need to mount a radiator fan switch in the pipework somewhere though.

Still got plenty of small jobs to do, and the big job of painting. I might even have a tidy up soon :(

[windymiller]

Well, I've managed to find a bit of time to have a play in the garage. Engine bay is starting to come together now:

http://i438.photobucket.com/albums/qq107/angleseymr2/DSC01663.jpg

http://i438.photobucket.com/albums/qq107/angleseymr2/DSC01665.jpg

I'm going to try and get the front bumper mounted tonight and a bit more wiring done. New headlamps are on order so hope to get the front end finished this week :D

[windymiller]

I thought I'd better update my diary as I'm getting near to completion :D

Here's a shot of the interior:

http://i438.photobucket.com/albums/qq107/angleseymr2/DSC01802.jpg

And a shot of the dash:

http://i438.photobucket.com/albums/qq107/angleseymr2/DSC02272.jpg

http://i438.photobucket.com/albums/qq107/angleseymr2/DSC01805.jpg

http://i438.photobucket.com/albums/qq107/angleseymr2/DSC02274.jpg

http://i438.photobucket.com/albums/qq107/angleseymr2/DSC02270.jpg

http://i438.photobucket.com/albums/qq107/angleseymr2/DSC02271.jpg

The front end has been fitted properly since taking these shots, along with the front arches and a few other bits. I'll be booking an MOT on Saturday, so I need to sort a fog light and a few wiring issues on Friday when I get home, then its finger crossed :D

[windymiller]

Well, its been on the road now for a couple of months and been through an autotest in a dis-used quarry, so I thought it was time for a strip down to check it over:

http://i438.photobucket.com/albums/qq107/angleseymr2/Mini/20111119_160527.jpg

http://i438.photobucket.com/albums/qq107/angleseymr2/Mini/20111119_191018.jpg

http://i438.photobucket.com/albums/qq107/angleseymr2/Mini/20111119_211108.jpg


I've found a couple of small areas on the subframe where bits have been rubbing so I'll need to adjust things. I still need to sort out the cooling fan so that it comes on automatically. And there's a small crack in the original subframe to weld up, but apart from that, its not too bad :D

I'm also looking into fitting a 6 speed Toyota Celica gearbox if funds allow...

[Beavis]

ive finally got around to looking at your build most impressed

[jimmorris3]

Nice build, ull gain a few bhp getting the air filter away from the rad tho , Jim

[windymiller]

Good idea Jim, I'm just struggling for space for the filter. I need to replace the corrugated aluminium inlet pipe with a silicone one and I'll try and re mount so it gets some cooler air.