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View Full Version : 4AGE MASTER BOOK a guide to all things 4AGE *cooling system update 18/8/2009*



slide86
8th August 2009, 08:10 PM
Here is something new......

I am getting together as much info as i can to make it easier or people to work on their 4ages.

Not all of us are as blessed as i am to have all the Levin & trueno magazines and the 4AGE MASTER BOOK, the AE86 OWNERS BIBLE, 4AG tuning and the CARBOY 4AGE

so id thought id scan useful pics from these so people are able to do teh basics to their cars.

ill start of with things like
- identifying sensors and plugs on a 4age.
- how to set timing, both cam timing and dizzy
- cooling system components

be aware, this takes a fair bit of effort and time. i wont really appreciate any shit in this thread as im going out of my way and spending ALOT of time to upload all this info.

(i know this probably breaches copyright......but hey...its the internet)


http://www.ae86drivingclub.com.au/dcimages/5/20268.jpg

slide86
8th August 2009, 08:11 PM
http://www.ae86drivingclub.com.au/dcimages/5/547365.jpg

alot of people know the internals of an engine.....but some havent ever seen inside one. so here are the internals laid out...


cylinder head
cylinder block (not shown)
crankshaft
valves
spring seat
valve spring
valve retainer
collets
bucket/lifter
cam gear
camshaft
piston
conrod
lower compression ring
upper compression ring
oil scraper rings
bearing


the picture is an exploded view of how all the components go together.

slide86
8th August 2009, 08:11 PM
Here is a view of all the sensors on a 4age engine. This will be VERY USEFUL when trying to diagnose a fault with your car.
If some one says "check the coolant temp sensor" now you will have an idea of what it looks like, the connector and where its located :)

http://www.ae86drivingclub.com.au/dcimages/5/20275.jpg
http://www.ae86drivingclub.com.au/dcimages/5/20276.jpg
http://www.ae86drivingclub.com.au/dcimages/5/20277.jpg


throttle body vacumn
-
oil pressure switch
-
starter solenoid trigger wire
oxygen sensor plug
coil and igniter plug
resistor plug
here is the coil location and associated plugs
coolant sender for dash cluster
TVIS plug (located under intake manifold)
TPS plug
cold start injector (plug in hand)
intake air temp sensor plug (in hand)
pcv hose
4 injector plugs
here you can see what most injecotr plugs look like after some hard work
MAP sensor plug. MAP sensor just seen on firewall
here you can see down the back of the head to the water outlet
here are the 2 coolant temp sensors. one is for the ECU and the other for cold start injector
here you can see the plugs being removed
and both plugs off
this plug is important, it basically has alot of wires that are used for the dash cluster. important for a conversion
MAP sensor location and earth wire
Coolant hoses too the throttle body for cold start
alternator harness that contains sense wire, charge light wire and B+ wire
throttle body cable and adjuster
cable removed from throttle body
brake booster vacumn hose
vacumn source for fuel pressure reg. pressure reg also shown
this is the fuel cap, if you dont know this one.....your stuck on the side of the road somewhere
Removing the FUEL DAMPER. dont get this confused with the regulator
removing the fuel line from the damper
this is the regulator on the other end of the fuel rail
fuel line removed from the regulator
removing the banjo bolt from the cold start injector
the cold start injector with removed line
unbolting fuel rail bolts
spacer to correctly position rail
removing the fuel rail
injectors and orings

slide86
8th August 2009, 08:13 PM
here is a quick lesson on CAM TIMING.

lots of people seem a bit miffed when it comes to this sorta thing, so here is a pic to get an idea of where your cams and crank should be to get the timing correct.

http://www.ae86drivingclub.com.au/dcimages/5/20278.jpg

the big photo is the one to concerntrate on, this is how your cams should align when the engine is on top dead centre CYL 1. if they are not in this postition then you have a CAM TIMING issue.

you can see in picture 3 the postion of the crank in relation to the cams. you can clearly see the notch in the crank gear, it should align with the dimple in the oil pump surface.

it is essential that you have cylinder 1 on top dead centre (TDC) compression when checking these.

70XIN
8th August 2009, 08:44 PM
excellent idea, those books are awesome .. i thought about doing the same thing :)

NIZLAH
8th August 2009, 09:04 PM
champion.......................................... .

focus_7
9th August 2009, 12:28 AM
sticky pls.

hitoriko
9th August 2009, 09:20 AM
i Have a toyota engine repair manual repair manual for the 4age and a few ae86 mags - i need a scanner though - the repair manual covers the 4ac and the 4age and i think i have a 4k one aswell

Trav_555
9th August 2009, 11:08 AM
Thankyou so much, just what I was looking for wiring everything up, thankyou so much

Travis

Kid Karola
14th August 2009, 09:55 AM
Huw have you got Vol. 21 yet? My life feels so incomplete until I can get a copy :yeah:

blacky86
15th August 2009, 06:25 PM
Hey guys, ive edited the original pages for the sensors and chucked in the English translation to make life a bit easier.

http://www.ae86drivingclub.com.au/dcimages/8/7/8/20731.jpg

http://www.ae86drivingclub.com.au/dcimages/8/7/8/20732.jpg

http://www.ae86drivingclub.com.au/dcimages/8/7/8/20733.jpg

Frak
15th August 2009, 07:12 PM
blacky86, good work :thumbup:

blacky86
15th August 2009, 07:24 PM
If anyone else wants to translate the other pages ill be happy to edit the ones there with english.

Also, if anyone knows which plugs #2 and #4 are ill chuck them in.

70XIN
15th August 2009, 09:22 PM
#2 is dizzy

racking my brain to work out what #4 is, a ground maybe? there can't be that many more things left on the exhaust side! :D

FAST EDDIE
16th August 2009, 10:41 AM
4 is air con compressor id say

blacky86
16th August 2009, 06:58 PM
Page 1 is now updated

Golberg
17th August 2009, 12:42 AM
#2 is dizzy

racking my brain to work out what #4 is, a ground maybe? there can't be that many more things left on the exhaust side! :D

70XIN is on the money, its not got anything to do with aircon, that's another plug, a round one.

Its an earth that typically connects to the main 'block to rail' strap.

marvis
17th August 2009, 02:32 PM
This is awesome. Nice work guys.

blacky86
18th August 2009, 10:15 PM
Page 1 is fixed (again)

slide86
18th August 2009, 11:26 PM
cooling system.

here are some of the cooling system components of a RWD 4age setup.

good if you are converting to rwd and need to see what parts are missing/what goes where.

http://www.ae86drivingclub.com.au/dcimages/5/20998.jpg

http://www.ae86drivingclub.com.au/dcimages/5/20999.jpg

pretty self explanatory really.

basically it shows the water pump and thermostat housing, the bypass hose and the rear outlet.

second pic shows the details of the TVIS system and vacumn lines. inlet manifold is also shown being fitted.

Low Style
28th August 2009, 11:34 AM
the whole book in english would be awesome LOL!

can i have all pages?

DearmanKE
26th July 2011, 10:44 PM
Hey guys, ive edited the original pages for the sensors and chucked in the English translation to make life a bit easier.



http://www.ae86drivingclub.com.au/dcimages/8/7/8/20732.jpg



Number 20 the 2 coolant sensors, can anyone tell me which is the one for the ecu and which is the one for the cold start as only one of mine is plugged in, one is green one is brown..

cheers!

Golberg
26th July 2011, 11:30 PM
Brown is cold start
Green is ECU temp

DearmanKE
30th July 2011, 09:03 PM
ok thanks looks like il leave it unplugged( mines got the ecu one plugged in) and continue my search for why my bigport is slow

Golden Circle
5th February 2012, 07:06 PM
can someone clear the air for me please? what is going on on the back of the water pump? and what is that tube that gets stuck into it??

Golberg
5th February 2012, 07:45 PM
That tube goes between the back of the pump and the top outlet.

Its purpose to criculate water through the engine when the thermostat is closed.

The pipe which goes off the back of the pump to the rear of the block is the heater bypass.

Golden Circle
7th February 2012, 10:01 AM
thanks heaps goldberg. can you buy the tube anywhere? you're a proper sick ####, I'm just reading your 16v cooling guide now on rollaclub.

Golden Circle
7th February 2012, 10:09 AM
just reading it now, Golberg if I'm running carbs on my 7a can I even take advantage of the throttle body cooling? and could just get away with using my 4AC rear water pipe?

Golberg
7th February 2012, 10:19 PM
Indeed, use the 4AC pipe.

Depending on if you have a knock sensor you may be able to just bolt it straight on.

High-Rolla
25th March 2013, 09:18 PM
is the book downloadable (english) or buy? and if so where ! :)

Dskew3
29th April 2013, 07:28 PM
its on ebay for about 100 ish last time i looked .

Dskew3
28th August 2013, 04:18 PM
hay slide86 just wondering on how you translated it into english i just bought the book.