4A-GZE into FX16 swap

[Donald]

After much debating and analysis paralysis, I have finally decided on an autocross car.

The car: 1987 Corolla FX-16.




It was a tight fit backing that car in on the tow dolly!!




After some good washing, I found a little red car under all that mould.







The engine: 4A-GZE (MAP)






The car has a dead engine and has been sitting for about 4 years.

The engine is from an AE101, and comes with a limited slip gearbox, axles, ecu, and a cut wire harness.

The wire harness was cut at the gearbox and evrything to the gearbox side is missing.

So far I have removed the remnants of the harness from the engine and the harness from the car. Those are to be packaged and sent to Dr. Tweak.

The engine has been disassembled down to the block and crank.
I have measured the bores, crank shaft end play, and checked the block deck for warpage. All check good.

The #2 and #3 piston rings are gummed up in the grooves and I can see that #2 had serious blow-by.

The supercharger has oil in the impeller chamber....... Not good I think. I suspect I need to replace the seals.

The axle shafts need rubber boots.

[Kiwi-Corolla]

Nice! Looks like a great project. Appears to have come up quite nicely after the wash. There are still a few of these floating around over here. My mate has one that's been sitting in his backyard untouched for the last 7-years. Looking forward to seeing your progress

[ariel_86]

Looks like quite the find and very cool project. Do you plan on running in SMF then? I hope you kick some civic-butt!

[RobMilkshakes]

Looks good, Donald. I've always wanted an fx16. Sadly though the only one I've ever found in my area was a standard fx and had significant front end damage :/

I'm looking forward to your progress

[eage8]

looking good Donald

I notice that that engine doesn't have a power steering pump... are you going to use it?

[xxyang2000]

Rob
Do you still need it. I have one (1987 corolla fx16) at Atlanta Ga. If it too far?
David

Originally Posted by RobMilkshakes

Looks good, Donald. I've always wanted an fx16. Sadly though the only one I've ever found in my area was a standard fx and had significant front end damage :/

I'm looking forward to your progress

[REN69]

fk'yeah! I approve of this thread.

[Donald]

Originally Posted by ariel_86

Looks like quite the find and very cool project. Do you plan on running in SMF then? I hope you kick some civic-butt!

Yes, SMF.
Civics are the primary prey.

There is a particular red one that keeps beating me, but he doesn't know what I have in store for him for next year.

I have been eyeing these FXs for a few years now. There is a red GT-S there also that I had wanted originally, but they dont have the title for it.
I tried locateing the previous owner but he apparently doesn't live in the area anymore.
I could have gone the rout of getting a mechanic's lean, and a title that way, but I really wanted to get this project started now, so I took this car instead.

The GZE engine came with no power steering pump, but I have one from the original engine that was in my '89 GTS, and the one on the FX also.
If you need a pump, I can probably let you have one, but it will have to be after I get the car running, to make sure that I have a good pump.


I plan on using my AE92 K-Sport coil-overs but had doubt about them fitting this car because of the difference in the bolt patterns for the strut top mounts.
I had tried making templates from cardboard to see if they would work, but it didn't look like it would.
Anyway, I have finally actually matched up the K-Sport top mount to the body, and I think I have enough space to drill holes for them to work.

What I have found out is that the AW11 MR2 has a similar bolt pattern to the AE82.
I am not sure it is an exact fit, but a dam sight closer than the AE92.
If the AE92 top mounts can't be made to work, I will get some MR2 top mounts
($145 each )

Depending on what wheels I use I might go with AE101 front brakes. (larger disk and larger caliper piston)
Right now I am using 15 X 6" wheels with 205/50/15 Nitto NT-01 tires on my GT-S for auto-x, they are great, but I am thinking of getting 13 X 9 Miata wheels and some 45 or 50 profile Hoosier A6 tires, these are supposed to be even better.
If I go with the 13x9 wheels I will have to keep the stock brakes. But with that smaller outer wheel diameter I won't need more powerfull brakes anyway,
If I keep the 15s I'll install the AE101 brakes.

Today, I ordered piston rings, main and connecting rod bearings (Toyota OEM $200)

[eage8]

For tires you really have 2 competitive choices. 255/40/13 up front and 225/45/13 in the rear or 275/35/15 front and 225/45/15 rear.

[Donald]

Originally Posted by eage8

For tires you really have 2 competitive choices. 255/40/13 up front and 225/45/13 in the rear or 275/35/15 front and 225/45/15 rear.

Well a lot hinges on if I can get a set of 13" wheels for a good price. I already have the 15s so to change will require a very good deal.

I have $1300 into the engine already, original purchase price, bearings, rings and gasket set.
Wiring is going to run me close to $800 because the engine harness I got is butchered.
I am guessing about another $400+ for a complete exhaust system.
So I'll have to see what is left for tires and wheels. I'll probably run what I have for another season since they still have some good meat on them.

[Donald]

Today I try fitted the front K-Sports.
They fit, Just barely. The stud holes are right up against the cutout. I would never do this on someone elses car, and I am going to try and modify some fender washers to add clamping area around those two holes I drilled.





Tomorrow, I will try on the rears.

[trucke]

Originally Posted by Donald

There is a red GT-S there also that I had wanted originally, but they dont have the title for it.

Depending on what wheels I use I might go with AE101 front brakes. (larger disk and larger caliper piston)
Right now I am using 15 X 6" wheels with 205/50/15 Nitto NT-01 tires on my GT-S for auto-x, they are great, but I am thinking of getting 13 X 9 Miata wheels and some 45 or 50 profile Hoosier A6 tires, these are supposed to be even better.
If I go with the 13x9 wheels I will have to keep the stock brakes. But with that smaller outer wheel diameter I won't need more powerfull brakes anyway,
If I keep the 15s I'll install the AE101 brakes.

A note on the larger brakes. A previous owner added larger brakes to my white FX16. The rotors are 1.5 pounds heavier that stock which adds unsprung weight. Not a good trade-off for very little braking improvement. For autocross, stick to stock. Go bigger for track events.

I might be interested in that other FX16 for parts. We can talk about that at a later time.

Those Notto NT-01's are very fast tires. There are a couple of M3's that added those here and one has jumped to top five in PAX at our autocrosses. The Hoosier are a little quicker but cannot be street driven. With a 13" wheel, the Hoosier are a much better choice. The Hoosiers are very light too! = less unpsrung weight.

[Donald]

Originally Posted by trucke

A note on the larger brakes. A previous owner added larger brakes to my white FX16. The rotors are 1.5 pounds heavier that stock which adds unsprung weight. Not a good trade-off for very little braking improvement. For autocross, stick to stock. Go bigger for track events.

I might be interested in that other FX16 for parts. We can talk about that at a later time.

Those Notto NT-01's are very fast tires. There are a couple of M3's that added those here and one has jumped to top five in PAX at our autocrosses. The Hoosier are a little quicker but cannot be street driven. With a 13" wheel, the Hoosier are a much better choice. The Hoosiers are very light too! = less unpsrung weight.

Although autocross is the primary and immediate plan for this car, track days are a consideration. I also think the K-Sports will handle the extra mass.
I have AE101 front brakes on my '89 GT-S, and I am satisfied that the improvement in feel and force, is significant enough to warrant the unsprung weight increase.
Still, smaller track wheels ar my ideal plan, but I appreciate the observation, and will keep your opinion in mind.

I have a separate set of wheels and tires for street and track. I use Nitto NT-01s for track only and Nitto Neo Gens for the street.
I am very pleased with the NT-01s but the cars that keep beating me are usually running Hoosier A-6s.

The final choice in wheels and tires will come down to how much money I have left over after I get the FX running.

[eage8]

Originally Posted by trucke

A note on the larger brakes. A previous owner added larger brakes to my white FX16. The rotors are 1.5 pounds heavier that stock which adds unsprung weight. Not a good trade-off for very little braking improvement. For autocross, stick to stock. Go bigger for track events.

I'm going to agree. I've seen CSP miata guys drill a billion holes in the rotors to lighten them up. not only are they unspring weight, but they're also rotational mass, so it's like adding 3 lbs to your flywheel too.

I would just install a nice set of pads and maybe a new set of brembo rotors and call it a day.

[Donald]

Yesterday I cleaned the mating surfaces and checked the head for warpage.......Checked good.

I started changing valve guide seals and lapping the valve faces. One valve has what looks like a casting flaw in the mating surface. It is not a crack or chip, it just looks like an air space was there in the casting.

You can just see the black mark running down accross the mating surface



Today I started pulling the head off the engine in the FX, hopeing to salvage a valve from that.