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    Senior Member dtour's Avatar
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    Name
    Jon
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    Default RWD 20V Conversion AE86

    AE86 RWD 20V Conversion

    When researching the 20V conversion I came across a few headaches for one some people’s attitudes just sucked I know there is a search function! Every time I used it I got a thread with the answer use the search function. I have created this thread to make it a shit load less confusing to do this conversion, I have also included the places where I go the parts from because i know getting this stuff can be a pain in the ass.
    So here it is all in one place, bias free.
    This is not the cheapest way to perform this conversion but in my opinion it is the right way.

    *Will be uploading pics soon to make it even more clear*

    Parts Needed:
    - 20V 4age
    - RS-Chita Waterkit – RHDjapan.com
    - 16V RWD Waterpump, thermostat housing, bypass pipes for heater – imported from japan by Craig @ Just JDM
    - 16V altenator bracket – imported from japan by Craig @ Just JDM
    - 16V crank pully – imported from japan by Craig @ Just JDM
    - Distributor blanking cover/Crank angle sensor cover – Made by me
    - 2NZ Coilpacks off a Toyota echo – Pick N Payless
    - Ecu and loom – Kaizen Garage
    - MAP Sensor – Comes with ECU and loom
    - RWD extractors – Kaizen Garage
    - Clutch to suit a 212mm flywheel – Excedy
    - Fuel pumps: One low pressure lift pump, one high pressure efi pump and Surge tank – Rocket industries
    - KE70 Accelerator cable
    - Trumpets – Techno Toy Tuning
    - Thermo fans
    - Gearbox mount spacer - had it machined out of 10mm thick alloy plate



    Ditributor cover/CAS Cover

    - Remove the spark plug leads
    - Unscrew the three screws holding in the distributor and remove the cover
    - Measure 3cm from the opening to the back of the cover
    - Using a utensil of your choice to cut the excess part of the cover off
    - Make a ‘mould’ by taping the end that was cut off
    - Lay in a sheet of fibreglass and coat with resin once the resin is touch try remove the tape from the cover and coat with another layer of resin
    - Smooth to your satisfaction and paint the colour of your choice


    ^^^What you should be left with after removing the cap and rotor button^^^

    ^^^Showing the fiberglass on the inside^^^

    ^^^DONE^^^
    2NZ Coilpacks

    Perfect height for the 20V however the diameter of the shaft is greater than that of the motor. All that is needed to fit the coilpacks is to file down the shaft of the coilpack until it fits down the tube.
    Picked mine up from Pick N Payless for $80 for a set of four.




    RWD Exhaust

    20V Rwd extractors from kaizen garage, if you are using a ADM T50 where the clutch slave is on the passenger side of the transmission. You will require a 90° fitting for the connection also available from kaizen



    Intake

    You cannot use the standard airbox without modifying it to suit a RWD operation, if u wish to use it you have to seal the original opening and create an opening on the opposite end off the air box. That is a bit of effort so I decided to use velocity stacks/trumpets. When going down this path a MAP Sensor is required.



    ECU and Loom

    It is not possible to use the standard ECU due to the use of coilpacks and removal of the distributor.
    I used the Adaptronic ECU and loom custom made by Anthony at Kaizen

    Clutch

    If you are converting your AE86 from a 4AC your flywheel will not fit the 20V motor the 4AC has six bolt mounting and the 20V has 8 bolts so ensure that you get a manual 20V motor. Most transmission places will be able to match a clutch to your flywheel. So you will need a clutch and a spigot bearing. Spigot bearing number is 6001
    Thrust bearing is a NACHI Bearings product and it needs to be pressed onto the sleave that connects to the clutch fork. the part number for the bearing is BRG2155
    the clutch and pressure plate are just the regular 200 or 212mm setup for a 4AGE


    Thermo Fans and Radiator

    If you are converting your AE86 from a 4ac i recommend replacing the stock radiator, as a mininmum a JDM 4age radiator(Twin Core) often you can pick up a cheap aluminum twin core off ebay and upgrading to twin thermo fans is also a must, two 10 inch thermo fans work well.


    Gearbox Spacer

    After mounting the motor and gearbox there can still be issues in regards to clearance of the heater core hoses and the tumpets hitting the brake booster. to correct this i had a spacer made up to lift the gearbox and the rear of the motor to gain the extra clearance that you need. this is not always necesary it just depends on your setup.
    Last edited by dtour; 25th April 2010 at 01:17 PM.

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