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

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    Veteran slide86's Avatar
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    Default 4AGE MASTER BOOK a guide to all things 4AGE *cooling system update 18/8/2009*


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    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)

    Last edited by slide86; 8th August 2009 at 09:47 PM.

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    Veteran slide86's Avatar
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    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.
    Last edited by slide86; 8th August 2009 at 10:13 PM.

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    Veteran slide86's Avatar
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    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
    Last edited by slide86; 8th August 2009 at 10:54 PM.

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    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.
    Last edited by slide86; 8th August 2009 at 11:12 PM.

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

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    champion.......................................... .
    ------------------>>>Need something welded locally??? Hit me up, I may just be able to help<<<------------------

    BENT MECHANIX - Garage 20:

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    sticky pls.

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    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
    . h i t o r i k o .

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

    Travis

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