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Location:
northern beaches
Registered:
August 2002
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Sprinter/4age help
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Fri, 30 August 2002 08:18
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hey guys
some time in the not to distant future i plan to convert my ae86 sprinter 4ac to a 4age, this is my first engine conversion so id like to make sure i know wat im up for before i start. ive read the article on this conversion but i wish to clear a couple of things up.
oh yea i plan to use a rwd 4age
i can use the orginal gearbox?
what sort of clutch kit do i need?
will the original radiator be good enough? if not what should i replace with?
what accelerator cable should i use?
does this modification need egineer certification?
will it affect my insurance?
how hard is the wiring? i have limited auto electrical experience, should i just get someone to do it for me?
finaly the fuel system, from what i understand a vl fuel pump with bigger feed lines, without a surge tank will be adequate so long as i keep the tank above 1/4 full, is this correct?
anything i have missed?
is this coversion do able for a first timer?
sorry about the length of the post, but im keen to get my hands dirty!
thanks
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Location:
Canberra
Registered:
May 2002
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Re: Sprinter/4age help
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Fri, 30 August 2002 10:41
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i can use the orginal gearbox?
YES. If the motor you buy doesnt have the gearbox stays for the lower gearbox bolts, transfer them over from your 4AC. You should use the original engine mounts from the 4AC also for a straight bolt in.
what sort of clutch kit do i need?
the motor you buy *should* have a 200mm clutch. Daikin sell a heavy duty full faced clutch kit for approx $325. part number R1127HD I think.
will the original radiator be good enough? if not what should i replace with?
I would expect that with a near standard 4AGE this should be fine.
what accelerator cable should i use?
I shortened the standard one, but mines in a TE72, not a sprinter.
does this modification need egineer certification?
not here in the ACT, dunno about your state. will you use the factory computer?
will it affect my insurance?
i'd say so! any modification seems to set those mongrels money hungry.
how hard is the wiring? i have limited auto electrical experience, should i just get someone to do it for me?
If you dont have much experience, then yes, get someone who knows about it to do wire it up. Auto electricians can be expensive though.
finaly the fuel system, from what i understand a vl fuel pump with bigger feed lines, without a surge tank will be adequate so long as i keep the tank above 1/4 full, is this correct?
A VL pump will supply more than enough fuel. Its up to you if you want to risk not running a surge tank.
anything i have missed?
is this coversion do able for a first timer?
for sure! Just ask many questions of the people who have already done it on these forums as you go. Theres a wealth of information from several members here with 4AGE sprinters i'm sure.
Cheers
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Location:
northern beaches
Registered:
August 2002
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Re: Sprinter/4age help
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Fri, 30 August 2002 11:02
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yes i do plan to use the standard computer
thanks heaps for that info TE72_Turbo
these forums are great!
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Club Member
Location:
sydney
Registered:
May 2002
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Re: Sprinter/4age help
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Sat, 31 August 2002 00:28
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let me make some ammendment to TE72's comments which may make it cheaper easier, whatever I havent answered differently you can take as being the most accepted prefered method as hes written it.
| cri_ag wrote on Fri, 30 August 2002 2:18 AM |
hey guys
some time in the not to distant future i plan to convert my ae86 sprinter 4ac to a 4age, this is my first engine conversion so id like to make sure i know wat im up for before i start. ive read the article on this conversion but i wish to clear a couple of things up.
oh yea i plan to use a rwd 4age
i can use the orginal gearbox?
what sort of clutch kit do i need?
>>>>St marys brake and clutch do a full kit with 600-800 rated pressure plate and a good clutch with a new thrust bearing for about $170
will the original radiator be good enough? if not what should i replace with?
what accelerator cable should i use?
>>>>KE30 is perfect if you wrap it once around the brake master, it has the same bolt pattern as a sprinter on the firewall and is only $30 from P&PL, but make sure you get a good one!
does this modification need egineer certification?
will it affect my insurance?
>>>>shannons cost me about $700 a year for full comprehensive and I have a shit record!
how hard is the wiring? i have limited auto electrical experience, should i just get someone to do it for me?
>>>>Its pretty simple really but if you want someone to do it for you it will be cheaper thru the club so get in touch with me when youre ready and ill put you on to the right bloke 
finaly the fuel system, from what i understand a vl fuel pump with bigger feed lines, without a surge tank will be adequate so long as i keep the tank above 1/4 full, is this correct?
>>>>>something Ive recently been told is that an AW11 mrr intank pump and housing is exactly the same as the AE86 factory item (I havent confirmed this yet but it sounds feasable) otherwise you can get a AE82 bracket and lengthen it slightly using the intank pump...I personally dont recommend external fitted pumps due to the danger if something hits it but in the end its your choice
anything i have missed?
is this coversion do able for a first timer?
>>>>make sure you have the fuel pump relay with the computer and go to a thermo fan instead of the clutch fan. 2" exhaust is big enough for any road application. dont forget if you are using a FWD engine to put the spigot bearing in the end of the crank. you may also prefer to get a clutch line made up so that you clear any exhaust system you use and make up a heat shield out of tin for the clutch slave and you wont have any problems with fade. Dont forget to change over the temp sensor from the 4A-C to the new engine, and for known result you should also use the same oil pressure sender that way it will be a better comparison when you look at your gauges with the new engine.
sorry about the length of the post, but im keen to get my hands dirty!
thanks
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Location:
Melbourne
Registered:
August 2002
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Re: Sprinter/4age help
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Sat, 31 August 2002 04:21
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IRA11Y
so you meant the EFI AE82's fuel tank, intank fuel pump, and bracket will fit in AE86 with a bit of mods? ( or I just need to fit the AE82's intank fuel pump into the AE86 fuel tank? )
that's a good news to me...as I don't want to use external fuel pump either. But do you think the pump is enough for 20V 4AGE?
Thanks.
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Location:
Brisbane
Registered:
July 2002
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Re: Sprinter/4age help
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Sat, 31 August 2002 04:25
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Hah hah ... I'm also in the same boat. Have already acquired both engine & all other parts so am just waiting for my mechanic to get around to the conversion. Was hoping it'd be today but unfortunately he's still busy with his prior projects such as his twin turbo'ed WRX ... oh well ... 
Still, if you're doing a Blue top conversion like I am, you'll definitely find this article useful ...
http://www.geocities.com/project_post/
It details a blue top conversion for a US AE86 however it appears they swap the EFI baffle petrol tank with the old 4ac tank. You'd be lucky to find one over here so you'd probably have to upgrade your fuel system with a surge tank etc rather than just a simple fuel pump upgrade.
As for insurance, no one would touch me apart from Just Cars. Quoted me $1,900 comprehensive so I was like f#%@ that.  I'll still probably end up with their 3rd party property policy at around $255 a year.
I'll also just save up $$$ each year to afford another AE86 as a back-up in 2 years time. Now I just need to look for space ... 
Good luck & Cheers!
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Club Member
Location:
sydney
Registered:
May 2002
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Re: Sprinter/4age help
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Sat, 31 August 2002 10:56
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use the AE82 fuel pump and bracket (modified) and put it in the AE86 tank
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Location:
Melbourne
Registered:
August 2002
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Re: Sprinter/4age help
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Sat, 31 August 2002 11:11
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Good, so do I put the fuel pump in where the original fuel pump's position, or other position?
And will this provide sufficient fuel for 20V 4AGE?
Thanks.
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I supported Toymods
Location:
Northern Beaches
Registered:
May 2002
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Re: Sprinter/4age help
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Sun, 01 September 2002 13:22
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cri_ag im also in the norther beaches area, whats your sprinter look like? I might of seen it around.
U might of seen mine around, its a blue one, with black rims and newly lowered
I did my 4age conversion at the beginning of the year and its fairly straight forward. Mine did come out of a sprinter though so didn't have wiring issues
Im using an external fuel pump and it works fine, don't know what its off though. I can run my rank to pretty much empty and thrash around with no surging don't know why though as others have more problems, maybe something to do with using an external pump? U don't need to upgrade the fuel lines, they are fine.
As for the ke30 throttle cable, I went to auto one at manly and got one NEW!! for like $30 
U don't need to get it engineered, just take it down to a blue slipper, there is a guy in brookvale who did mine and it just costs like $25 to get the engine numbers changed over.
Insurance well for the price of the car is it worth having full? Im 19 and have third party with Shanons for like $600 a year
[Updated on: Sun, 01 September 2002 13:24]
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Location:
northern beaches
Registered:
August 2002
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Re: Sprinter/4age help
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Thu, 05 September 2002 10:54
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g-day Ribbo
my conversion has hit a bit of a snag, i was suposed to be purchasing the sprinter off a mate, but he has decided he wants to hang on to it a bit longer! doh!
anyway dosent mean im not going to do the conversion. i just have to wait till he is ready to sell it to me, or find another one to buy
i think i have seen your car around looks kewl!
have you gone up against any cars from the area? im trying to get an idea of what sort of performace i could expect.
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Location:
Montrose, VIC
Registered:
May 2002
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Re: Sprinter/4age help
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Thu, 05 September 2002 11:13
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As for performance, I think it depends a bit on diff gears. I find ae82/ae92's with 4age's in them (factory) to be pretty dull and lifeless, but the couple of RWD 4age's I've driven that people have put into cars seem to pull pretty damned well, just a great drivable small engine. I think the trick is to stuff some 4.3 gears in there!
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I supported Toymods
Location:
Northern Beaches
Registered:
May 2002
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Re: Sprinter/4age help
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Thu, 05 September 2002 22:59
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I don't seem to really get too many races in it unfortunatly 
I think people either have no idea of the car so don't bother, or think there is something crazy in there cos its a sprinter hehe
I can keep up with most cars through first and most of the way through second. But I lose out all the time if I have to hit third cos of as has been said the ratio of diff, its not a 4.3
In the area I have run a mates white vl turbo, pretty even till about half way through second, mates silver vti-r civic was pretty even but he is pretty shit with manual hehe
basically to about 60 its pretty damn quick for a 1.6
but lacks after that
pulls 0-100 in about 8.7 so its respectable, and it pulls heaps harder than my old ae82 twin cam.
U got icq? best way to see if its what u want, we could meet up and ill take u for a run in it
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Location:
northern beaches
Registered:
August 2002
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Re: Sprinter/4age help
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Fri, 06 September 2002 09:07
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cool, i used to have icq but my computer stuffed itself and i never bothered re installing it, ill download it again and try to remeber my name and password, when i do ill give my icq number
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Location:
northern beaches
Registered:
August 2002
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Location:
Sydney- Sutho Shire &...
Registered:
June 2002
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Re: Sprinter/4age help
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Fri, 06 September 2002 11:19
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After we converted my ae82 from 4ac to ge (import motor), and then did my brothers ae86, it was only natural to find a nice straight 400m somewhere. 
Mine ran the 4ac gearbox, sprinter used ge box with disc rear end. Both cars had extractors but otherwise stock.
The ae82 launched better slightly- easier to control slip, but from then on nobody gained on the other. The sprinter always felt quicker though.
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I supported Toymods
Location:
Northern Beaches
Registered:
May 2002
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Re: Sprinter/4age help
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Sat, 07 September 2002 07:13
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well mine came out of a sprinter so we just pretty much striped everything required out of that car and put it in mine, so all the wireing came with it and its an aftermarket computer anyway.
So the two looms just needed to be joined. A friends dad did that for me
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