4age Blacktop Into Ae95 4wd Wagon

[rockcox]

Hi all, I've been searching out info on this swap for a while, It's been done before > http://forums.club4ag.com/zerothread?id=24643

 

but I found a lot of problems which weren't covered by that build or the 4agze that has also been done.

 

Here they are in no particular order

 

4AGE Alternator is on inlet side - need to relocate to exhaust side or remove diff-lock actuator on gearbox (same as blower issues on 4AGZE)

4AGE Air-Con pulley is 4rib and on the outer pulley - 4AFE is 3rib and on the inner pulley (no solution but to use 4AGE aircon)

 

Need to modify one intake support brace (uses same bolt on block as gearbox supports)

 

if you keep the alternator on the inlet side, need to modify the alt mounts to accommodate the gearbox supports

 

 

apart from these problems I need an engine/chassis mount (timing cover) and a flywheel and clutch. So my blacktop is up for sale. If it sells quickly, I will probably look into a 7AFE swap (after I check out the pulley and alternator configuration). If it doesn't sell, I will start getting the blacktop bits machined to fit the AE95. Once I start cutting the blacktop bits, it will only be good for a 4wd setup.

 

I can post some pics when I get my laptop online if anyone is interested.

[Sam_Q]

what mods would you have to do to the blacktop that would make it only suitable for a 4x4 install?

[rockcox]

what mods would you have to do to the blacktop that would make it only suitable for a 4x4 install?

 

oops, my mistake, I checked on the weekend and it's mods to the 4wd supports so that they bolt onto the outside of the alt brackets on the 4age. It looks like there is enough metal in the 4wd supports to grind them off without weakening them too much.

[Scoobzd]

instead of doing the conversion how about you just buy the car that already has the conversion done? I've had the car for nearly 2 years, joy to drive

[Instigator]

I put a ST 20v into my AE95. Dunno how different the blacktops are but I didn't have any of the problems you're describing.

 

Aircon came with the halfcut, just get a 4age compressor.

 

I run no difflock though have seen someone that was able to fit it.

 

[rockcox]

I put a ST 20v into my AE95. Dunno how different the blacktops are but I didn't have any of the problems you're describing.

 

Aircon came with the halfcut, just get a 4age compressor.

 

I run no difflock though have seen someone that was able to fit it.

 

 

Maybe the blacktop has a bit more re-enforcing around the alt brackets? There are two bolt holes on the block shared by both the alternator and the gearbox mounts. Is the alt on the inlet side of your slivertop?

 

I do have the aircon compressor from the 4age, but I was planning on using as many of the 4afe accessories as possible to reduce electrical hassles. oh well, electrical hassles it is.

[Instigator]

Tell me about it. My conversion took about a week for the mechanical side of things and another 3 for a mate and I to figure out the wiring :thumbsup:

[Trev]

http://forums.club4ag.com/zerothread?id=24643

 

That is actually a members old car:

 

http://www.rollaclub.com/board/index.php?showtopic=14705

http://www.rollaclub.com/board/index.php?showtopic=21841

[rockcox]

I've almost finished the wiring now, what a headache. And I haven't got the engine in yet, hopefully only fans and dash lights to go once the engine's in.

 

I am looking for a flywheel and an engine mount to finish the mechanical stuff...... here's some pics.

 

the modified inlet support (it was straight) to bolt outside the gearbox mount

 

the gearbox support needed a bit of grinding to fit the inlet support

 

inlet side. where the gearbox and alternator need to share bolt holes.

here you can see the inlet support (without bolt) where the gearbox support goes.

also the texta marks that show where the block needs to be ground back.

 

front of engine mount.....

Can anyone help me find a chassis mount to fit this? Is there a commonly available car which has a mount like this?

Well the answer is NO, I saw a ae11x in the wreckers and the mount is a different setup (bends at right angles) so I will need to use the 4afe mount and modify the timing cover.

 

.... old photo with the new wheels

Edited April 22, 2010 by rockcox

[rockcox]

The Blacktop is in and running well.

 

 

I used all of the old engine mounts, after grinding the gearbox mounts to size (to maintain proper thickness for alternator brackets etc.) everything lined up.

 

Exhaust needed to be modified behind the collector to go around the center diff and O2 sensor installed.

 

 

Wiring was the biggest headache. I used the whole 20v loom and fusebox, needed to run new wires for AM1, AM2, Heater Fan etc. Once the main relay was doing it's thing and making the fuel pump go the ecu told me that I didn't have power to the igniter. One more wire and she started first pop.

 

The blacktop is a very nice engine, drives like a normal car around town, but when you let it go over 5000rpm it's a different beast. The only problem is that the gearbox doesn't want to change gears at high revs; damn sloppy synchro wasn't a big problem with the 4afe.

[rockcox]

I'm preparing my car for summer use now, which means AC needs to work, Cooling fans need to work automatically. I would like the idle-up system to work as well.

 

I have used the complete AE111 loom, ecu and fuse box. Many of the wire colours are correct in the graft to the AE95 loom, but some I have guessed. Some I have traced back, and some I have just connected to earth or 12v to get the bugger running.

 

 

Without the full AE111 wiring diagram to work from, it seems that I have done something wrong in the wiring. While trying to get the fans to work with the temp switch I have found that when I flip my manual fan switch the engine starts cranking!

 

Is there a separate fan relay that I'm missing

 

 

I am trying to figure out where I went wrong. Do I have the starter switch wired into the back door of the fan circuit? My understanding of auto electrical is fairly basic and the circuits in these newer efi engines are anything but basic.

 

I think the fan circuits are connected to the starter circuit somehow (so that the fans do not run while cranking). Is this true?

 

I have the car booked into the auto elec on monday to do the AC hoses and gas, but am trying to straighten out the funny business first.

 

And before anybody asks, google gives me a bunch of results of people looking for the diagrams that I need. My ecu is fine, it's the main fusebox that's the problem.

 

Any general advice would be very helpful

[rockcox]

Rapidshare sucks! I just downloaded Toyota_Corolla_1992-1997_wyd_Haynes.rar

 

I think it's Polish! Like I wasn't confused enough :bash:

 

I found the one I needed Toyota_Corolla_E11_manual.pdf :laff:

 

Now I know I do need an extra relay block. I will have to use the ae95 one because I didn't get the blacktop one with my engine.

Edited September 19, 2010 by rockcox

[JedzWagn]

Nice thread dude - keep up the good work :y:

 

I'm currently building a 7agze to go into an AE95 got a long way to go...

[turtle20]

hey man i did the same thing early 2011 all your posts were really helpful

the only main probs i ran into was:

-grind out piece on back of engine block

-wiring(ugh lucky dads and auto sparky)

-alt,just used wiring parts out of original alt and left in same possy

-ait con plumbing needs to be modded, no biggy

-finding vac hose for 4wd diff lock

 

i used parts out of wrecked ae112 levin like the steering rack, brake booster inc. brakes, strut brace, coil pack, ac, alt ect to make the mod easier but ways around everything if you are keen on the mod

 

for me the bt isnt enough for my wagon so my next project is going to be putting a camry/aurion v6 1mz-fe or 3mz-fe vvti into my wagon will definately post and going to use the black top with 6 speed in a starlet and use that for a hack

 

as far as haters saying the bt is a stupid conversion for the wagon, it is 1000 times better than the 4a-fe, mine gets on the beach, drives well on the road and makes good acceleration so its a fun and easy mod for the car if you can do it cheap enough i say go for it :)