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

[slide86]

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)

[slide86]

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

1. cylinder head
2. cylinder block (not shown)
3. crankshaft
4. valves
5. spring seat
6. valve spring
7. valve retainer
8. collets
9. bucket/lifter
10. cam gear
11. camshaft
12. piston
13. conrod
14. lower compression ring
15. upper compression ring
16. oil scraper rings
17. bearing

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

[slide86]

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

1. throttle body vacumn
2. -
3. oil pressure switch
4. -
5. starter solenoid trigger wire
6. oxygen sensor plug
7. coil and igniter plug
8. resistor plug
9. here is the coil location and associated plugs
10. coolant sender for dash cluster
11. TVIS plug (located under intake manifold)
12. TPS plug
13. cold start injector (plug in hand)
14. intake air temp sensor plug (in hand)
15. pcv hose
16. 4 injector plugs
17. here you can see what most injecotr plugs look like after some hard work
18. MAP sensor plug. MAP sensor just seen on firewall
19. here you can see down the back of the head to the water outlet
20. here are the 2 coolant temp sensors. one is for the ECU and the other for cold start injector
21. here you can see the plugs being removed
22. and both plugs off
23. this plug is important, it basically has alot of wires that are used for the dash cluster. important for a conversion
24. MAP sensor location and earth wire
25. Coolant hoses too the throttle body for cold start
26. alternator harness that contains sense wire, charge light wire and B+ wire
27. throttle body cable and adjuster
28. cable removed from throttle body
29. brake booster vacumn hose
30. vacumn source for fuel pressure reg. pressure reg also shown
31. this is the fuel cap, if you dont know this one.....your stuck on the side of the road somewhere
32. Removing the FUEL DAMPER. dont get this confused with the regulator
33. removing the fuel line from the damper
34. this is the regulator on the other end of the fuel rail
35. fuel line removed from the regulator
36. removing the banjo bolt from the cold start injector
37. the cold start injector with removed line
38. unbolting fuel rail bolts
39. spacer to correctly position rail
40. removing the fuel rail
41. injectors and orings
    

[slide86]

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.



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]

excellent idea, those books are awesome .. i thought about doing the same thing

[NIZLAH]

champion.......................................... .

[focus_7]

sticky pls.

[hitoriko]

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]

Thankyou so much, just what I was looking for wiring everything up, thankyou so much

Travis

[Kid Karola]

Huw have you got Vol. 21 yet? My life feels so incomplete until I can get a copy