1.6 (1991) to 1.8 (2009)?

[1991toyrolla]

Hello and Happy Holidays,

Does any one know if a stock 1.8 enginewith auto/overdrive can be dropped into a 1991 corolla sedan dx? If so, what else, besides the electronics, needs to be changed? Thanks.

[ayang951]

i think you will need custom engine and trans mounts... but i have never really done the information in swapping one in this car before, i used to have a 2001 corolla S so i understand the motor ok, but idk as to throw it in a older corolla though...

[rdyzz]

motor mounts are different, and you have to be aware of the exhasut manifold location and what it might run into, although i've looked into this swap (2zzge) it looks very much like it will clear, but you never know untill you put the engine in, thats when all doubts can be dispelled.

do you just want a larger engine? (7afe = aprox 1800cc) or just a newer engine?

[Donald]

I have read second-hand reports that it has been done in Jamaica and Trinniad, but those guys down there tend to be very secretive about their mods.
I have searched and have not been able to find any write-ups describing the modification involved.
I have seen a video on u-tube of a 2zz in an EE31 Tercel in Puerto Rico, so I am pretty sure it can be squeezed into an AE92.

You Tube

You Tube

You will definitely need the wiring and ECU.
The mounts will probably need to be fabricated or modified. particularly the right side (timing belt side).
I believe the axle splines at the hubs are different, so the axle shafts will probably not just go in.

I was seriously contemplating this swap when I had someone offer me a 4A-GZE for a price I couldn't refuse(Now in my FX-16).

[eage8]

There is a bunch of guys on twincam.org.au that have 2zz swaps done. I would start there.

but it would be much easier to just swap in a 7afe from a 93-97? corolla

I think you also run into fuel system issues with the 2zz. isn't it returnless?

[simple monkey]

1zz and 2zz have different engine mounts except for the passenger side mount. Although the zz engines have c series transmissions (c56) they are not replacement engines. The 7afe would be a much better swap, it produces more torque than the 4AGE and 4AC, and is very reliable. A lot of the under hood wiring is different, but it can be done. There is a guy who has swapped a 7afe into his ae92.
Here is the link: http://ae92corolla.com/?page_id=489
Hope this helps.
Cheers.

[Donald]

I have done the 7A-FE swap, and am about to do it again, (same engine into another car).
It is a straight drop in, but if you use the 7A ECU, then you will ne to do wiring mods.
I am told that you can run the 7A with the 4A-FE ECU and wiring, but you will need to use a distributor from a 4A-FE, or an early &A-FE from a Celica. But, with the 4A-FE ECU, you will loose the protection of the knock sensor.

The 7A produces the same horse power (115) as the big port 4A-GE, but delivers more torque (115 lb at 2500 as opposed to 105lb at 5500), starting at 2500RPM and holding that torqure steady up till just short of redline, about 5500RPM. The 4A-GE just starts pulling at 4500 RPM.

You will get the best performance from the 7A-FE if you use the matching gearbox. A 4A-FE gearbox can be used but you will run out of first gear very quickly as this engine does not rev vary high. The 7A gearbox has a taller first gear, but all the other ratios are the same as the 4A-FE.

The 4A-GE gearbox will be totally worthless with the 7A-FE, since it has a higher final drive ratio (4A-GE = 4.3:1 / 7A-FE = 3.7:1) and will cause the engine to turn 500 more RPM at 70 mph in 5th gear.

Swapping from a 4A-GE to 7A-FE in my '89 GTS, I felt that the car was much quicker with the 7A, launching much harder because of the fatter torque curve starting at a much lower RPM, and having the same top end performance. It does require that you short shift more than rev it high.

I used 4A-GE pistons in my 7A, with the intent of boosting the compression, which it did on a static compression test, but I am not sure how much it increased the compression ratio. I still hope to get it dynoed to see what I am actually getting for hp and tq.

Below, is a link to my swap. There isn't a lot of detail about the actual installation, because it is that simple and straight forward, a straight drop in. Any questions, just ask.

4A-GE pistons in a 7A-FE engine

[toyotaspeed90]

Originally Posted by Donald

I used 4A-GE pistons in my 7A, with the intent of boosting the compression, which it did on a static compression test, but I am not sure how much it increased the compression ratio. I still hope to get it dynoed to see what I am actually getting for hp and tq.

this is why you felt a difference. the FE heads have smaller combustion chambers than the 4age's.... the pistons are WAY more dished in a 4afe/7afe than a 4age.... and to make matters even better (for you) the 7a pistons are more dished than a 4afe. You can use 4afe pistons in a 7a block to increase compression without the possibility of there being an interference engine (think it raises somewherein the realm of .3-.5 of a compression point). Guessing using bigport pistons your 7afe is sitting around 10:1 or so.... if you used smallport pistons would yield it 11:1 or so... maybe higher.

[Donald]

You might be quite right.
I have strong doubts that the small port pistons would work.
They have more crown than the big port pistons, so you might not have any valve to crown clearance.
Of course we won't know for sure until somebody actually tries it.

I was thinking of installing the 7A (thinner) head gasket instead of the 4A-FE gasket (that is in there now, before puting this engine into the SR-5, but I chickened out. I would hate to rev the sucker up, and bend valves.
I know it clears with the 7A gasket when turning the engine by hand, but will make contact if the timing belt breaks. I don't know at what speed the valves might float, and am not adventurous enough to chance an engine failure on my DD.