4age swap / conversion into ADM sprinter. What do I need?

[Riverside]

Hey guys,

I have spent the last hour trying to use the search function but either I am blind or it isn't doing what I had hoped.

I have the opportunity to purchase a good engine (16V), Loom and ECU. It comes with alternator etc.

What I need to know is EXACTLY what other items I need to purchase or modify to suit my ADM sprinter.

What are my options with fuel system?

Of course exhaust needs to be done.

Are there any other items I am not aware of? Really need to figure out everything before I buy an engine.

Thanks for your help :)

[Sam-Q]

ok I will give you a head start where you didnt look, go to rollaclub and click on the FAQ, read in particular on fuel systems. Otherwise go to my website which is linked in my signiture and look on 20V rwd conversions it covers some stuff which is applicable to both engines.

The short answer is:

Fuel: Either one pump (VL) that sucks out of the tank- the pump isnt designed to do this but it works with a little noise and you will get fuel surge under quarter of a tank or you run 2 fuel pumps with a surge tank. Either way change all your lines to high pressure EFI lines with proper EFI clamps.

You also a spigot and a 4age compatiable RWD clutch line, I can supply you both of these.

[Riverside]

I bisited your site..... Very helpful, Thanks.

Could you expand on the need for clutch line? My vehicle is already fitted with a RWD T50 gearbox. I was under the impression everything backwards of the engine could be left the same. eg: using my 4ac flywheel and clutch etc. The engine I am looking at is out of a AW11 if that makes any difference.

[Sam-Q]

read this:

http://www.ae86drivingclub.com.au/forums/showthread.php/20686-jdm-bellhousing

[Riverside]

Awesome, now I understand why. :)

Is there any other items I could be missing? The last thing I want is to have the conversion take me alot longer because I had not taken come costs into account.

Thanks heaps Sam

[70XIN]

Nico, you can use your 4AC clutch/gearbox etc, but the flywheel pattern on a 4AC is 6-bolt, 4AG is 8-bolt .. otherwise, both are the same dimensions.

You CAN also use your stock '4AC' clutch line, but most brands of 4AGE extractors come far too close to it where it bolts to the slave, cooking the clutch fluid and generally making things difficult. The banjo-bolt ended braided clutch line that Sam-Q posted up alleviates that problem.

[Sam-Q]

the modification of the loom to suit a RWD engine? how about the obvious chopping and rewelding of the intake manifold

[Riverside]

Intake manifold has already been cut and shut.

I was told that the loom still needed the "mods" done to it.

TOXIN..... Are you saying that I need to ensure the engine comes with a flywheel? If so, what size does that flywheel need to be in order to use my existing clutch?

Again, thanks heaps guys.

[70XIN]

Yes you need a flywheel, although finding a standard one shouldn't be hard or costly. You want a "200mm" flywheel.

You'll also need to do something with the water/radiator lines if it's still in a FWD setup.

[biggo]

You will need a shorter rear water outlet as the aw11 have super long ones. Also a remote thermostat holder.

[Riverside]

All good info. :)

Does anyone know if i can reating my current air-con setup? eg: will the compressor and brackets just bolt up to the twin cam 4A? Thats really important to me :)

I am told the alternator on the 16V is on the other side to my 4AC. The engine comes with the alternator mainly because it is a multi-rib belt as opposed to my current V belt. Could this pose an issues?

[Anthony]

Hey Nico, I replied to your PM. As for the aircon, it all bolts up, but the 4AC compressor uses a V Belt, whereas the 4AGE is 5 rib. So you can change compressors (and regas obviously), but unless you find a RWD 4AGE compressor you will need to change brackets and perhaps lines as well.

[Nikkojoe]

You can change the pulley on the compressor as the compressors on their own are the same, but you will still need brackets to mount it inline with the crank pulley.

You COULD change your 4age to use the 4ac pulley setup, you will just need to get your alternator pulley converted to a V belt and whether it will line up is a question itself (you can remove the crank and water pump pulley and fit it to your 4age). That way all your a/c stuff will bolt up.