notnilc20's 1986 ae86 Hatch build/restoration

notnilc20
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notnilc20's 1986 ae86 Hatch build/restoration

Postby notnilc20 » Fri Feb 12, 2016 11:11 am

hello fellow members. i finally made the leap and got myself a 1986 corolla sr5 that was in the middle of a gts conversion..............i need help. i have so many parts i'm getting dizzy. my problem is i don't know what parts are for the gts conversion or the old sr5 engine parts. i have from i can tell, the 4age bluetop engine installed and the transmission installed. the diff and rear end not sure it it's gts or sr5. the drive shaft is not installed but i have one. not sure if it's from sr5 either.

another thing is the car has been sitting for awhile and the guy i bought it from had it for 5 years and didn't do much to it so he couldn't help me out much with info as to what has been done so far and what still needs to be done. here are some pics so i'm hoping the eight-six gurus on here can tell me what i have and don't have. on a side note, why is it such a pain to post pics on this forum? using photobucket is a pain.
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Last edited by notnilc20 on Thu Jun 02, 2016 9:15 pm, edited 1 time in total.

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notnilc20
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Re: notnilc20's 1986 ae86 Hatch build clean-up

Postby notnilc20 » Fri Feb 12, 2016 11:13 am

day 1
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notnilc20
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Re: notnilc20's 1986 ae86 Hatch build clean-up

Postby notnilc20 » Fri Feb 12, 2016 10:59 pm

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notnilc20
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Re: notnilc20's 1986 ae86 Hatch build clean-up

Postby notnilc20 » Fri Feb 12, 2016 11:08 pm

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Pogipoints619
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Re: notnilc20's 1986 ae86 Hatch build clean-up

Postby Pogipoints619 » Fri Feb 12, 2016 11:17 pm

Sr5 drum brakes 8 bolt rear 6.3"

GtS disc brakes 10 bolt rear 6.7"
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notnilc20
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Re: notnilc20's 1986 ae86 Hatch build clean-up

Postby notnilc20 » Fri Feb 12, 2016 11:21 pm

Image

notnilc20
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Re: notnilc20's 1986 ae86 Hatch build clean-up

Postby notnilc20 » Fri Feb 12, 2016 11:23 pm

Pogipoints619 wrote:Sr5 drum brakes 8 bolt rear 6.3"

GtS disc brakes 10 bolt rear 6.7"


thanks for this info.

notnilc20
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Re: notnilc20's 1986 ae86 Hatch build clean-up

Postby notnilc20 » Fri Feb 12, 2016 11:33 pm

i noticed that the steering rack has been looped off with a hose too and there is no power steering reservior or pump in the bay. is this a common thing to do to the 86? i hear sime people do a manual steering conversion and eliminate power steering but is this a safe way to do it?

notnilc20
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Re: notnilc20's 1986 ae86 Hatch build clean-up

Postby notnilc20 » Fri Feb 12, 2016 11:35 pm

i also notice the emissions system seems to have been deleted? can anyone confirm by looking at these pics? you can see in this pic on the exhaust manifold that tube has been clamped shut also same thing for the tube coming off the intake side. next pic


Image

Deuce Cam
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Re: notnilc20's 1986 ae86 Hatch build clean-up

Postby Deuce Cam » Sat Feb 13, 2016 1:53 pm

Lots of people loop the steering lines. Not sure if it's really a safety issue, but I wouldn't do it, however I'm picky.

Regarding the emissions/egr system... I don't see a pic of the intake side. The exhaust tube is definitely cut. It looks like some of the vacuum components of the system are still there (located near the back of the valve cover behind the fuel rail).

I'm not sure how to tell the difference between sr5/gts driveshaft.

I'm sure others will chime in to help. Give it time.

notnilc20
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Re: notnilc20's 1986 ae86 Hatch build clean-up

Postby notnilc20 » Sat Feb 13, 2016 10:42 pm

Deuce Cam wrote:Lots of people loop the steering lines. Not sure if it's really a safety issue, but I wouldn't do it, however I'm picky.

Regarding the emissions/egr system... I don't see a pic of the intake side. The exhaust tube is definitely cut. It looks like some of the vacuum components of the system are still there (located near the back of the valve cover behind the fuel rail).

I'm not sure how to tell the difference between sr5/gts driveshaft.

I'm sure others will chime in to help. Give it time.

ok thanks deuce cam. here is a pic of the intake side. is this egr system necessary for the engine to run right?
Image

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Re: notnilc20's 1986 ae86 Hatch build clean-up

Postby davew7 » Sun Feb 14, 2016 5:38 am

If you do not have an inspection requirement then the engine will run OK without the EGR and most of the other emission controls. Your will need the O2 sensor, it's missing on the exhaust manifold. You will need a replacement or a resistor in the circuit to send the correct voltage to the ECU. You also need the vaccum line hooked up on the fuel pressure regulator on the fuel rail. Two down and only 100 more items needed to fix. Yup a lot of us have been there!!! Dave W

notnilc20
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Re: notnilc20's 1986 ae86 Hatch build clean-up

Postby notnilc20 » Sun Feb 14, 2016 7:56 am

davew7 wrote:If you do not have an inspection requirement then the engine will run OK without the EGR and most of the other emission controls. Your will need the O2 sensor, it's missing on the exhaust manifold. You will need a replacement or a resistor in the circuit to send the correct voltage to the ECU. You also need the vaccum line hooked up on the fuel pressure regulator on the fuel rail. Two down and only 100 more items needed to fix. Yup a lot of us have been there!!! Dave W


thank you so much for the reply Dave. what is the main purpose or reason that someone would delete the egr system?

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Re: notnilc20's 1986 ae86 Hatch build clean-up

Postby Deuce Cam » Sun Feb 14, 2016 9:15 am

When deleted, usually the entire system is removed for aesthetics because it gets rid of clutter. However yours still has the vacuum system, and instead of putting a block off plate on the intake and a bolt on the exhaust, the tube was just cut and crimped on each end. Maybe someone thought it wasn't functioning correctly and decided to block of the tubes? It's very odd to be honest.

notnilc20
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Re: notnilc20's 1986 ae86 Hatch build clean-up

Postby notnilc20 » Sun Feb 14, 2016 12:03 pm

Deuce Cam wrote:When deleted, usually the entire system is removed for aesthetics because it gets rid of clutter. However yours still has the vacuum system, and instead of putting a block off plate on the intake and a bolt on the exhaust, the tube was just cut and crimped on each end. Maybe someone thought it wasn't functioning correctly and decided to block of the tubes? It's very odd to be honest.


ok. what do you suggest i do? should i just remove it all together? i dont have emissions testing in my state. thanks again deuce.

maybe the previous owner thought it would help with performance. i'm thinking maybe that's why he chose to loop the power steering to take a little load off the engine but what do i know?

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Re: notnilc20's 1986 ae86 Hatch build clean-up

Postby Deuce Cam » Sun Feb 14, 2016 12:27 pm

Perhaps, but iirc the system can be 'turned off' by plugging one of the soft vacuum lines coming off the diaphragm. Also there's no performance benefit for removing it. It's anyone's guess why it was done. The person obviously didn't know what they were doing. You can leave it that way or do I what I mentioned in my last post to de-clutter.

FYI if you end up needing a gts driveshaft I have a spare fs.

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Re: notnilc20's 1986 ae86 Hatch build clean-up

Postby notnilc20 » Sun Feb 14, 2016 9:09 pm

i was able to turn the crank after some cussing and elbow grease. i decided to dig a bit deeper today and removed the intake manifold and exhaust manifold and this water plug fell off the block. i found a lot of rust inside the water passage. can this be cleaned out?
Image

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Re: notnilc20's 1986 ae86 Hatch build clean-up

Postby Deuce Cam » Sun Feb 14, 2016 9:38 pm

Holy cow it looks like solid rust in the pic!

Hopefully some knowledgeable folks will chime in for you. I have no experience in that area.

notnilc20
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Re: notnilc20's 1986 ae86 Hatch build clean-up

Postby notnilc20 » Sun Feb 14, 2016 11:06 pm

Deuce Cam wrote:Holy cow it looks like solid rust in the pic!

Hopefully some knowledgeable folks will chime in for you. I have no experience in that area.

yeah it's just the angle of the picture. but it's pretty rediculous. i don't know why people let their stuff sit for years and years on end. frustrating. saw some youtube vids of people running garden hose at the thermostat opening and just letting it go full blast until clear water iscoming out. i'll probably yank the motor out and have a machine shop clean it real good for me. a lot of trouble though for some rust. but the last thing i need is a big chunk of rust clogging up my radiator.

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Re: notnilc20's 1986 ae86 Hatch build clean-up

Postby notnilc20 » Mon Feb 15, 2016 9:53 pm

ok, so today i got the head off and decided im going to remove the block and take it to a machine shop to have them clean it and pressure test it along with the head. wonder if me and a friend can lift the block out of the car without using a hoist. probably not. i also drained the oil and for the first 10 seconds it was water that poured out...clear as your bathroom tap water.....wtf? then old oil started to come out. wow. i hope i can salvage this block.

also reading the lsd tech page on hachiroku.net and pogipoints info here i foundd out the diff that came with the car that isn't installed is a lsd. it has 10 bolts and the blue paint on the end. however, it looks like it's been sitting for ages as well. i'll take it to the machine shop too and see what they can do for me as far as rust cleanup. i may need new clutch plates for it and that'll be fun too.

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Re: notnilc20's 1986 ae86 Hatch build clean-up

Postby Pogipoints619 » Wed Feb 17, 2016 9:03 am

Some options & advice for you...seeing you have Arkansas plates and don't have to worry about emissions. Keep some of the stock peripheral items, ditch the 16v, & do a 20v blacktop swap it will save you the headache of sourcing different bits and pieces to get your 16 valve running correctly.
Even when your *stock* rebuild is complete, I can guarantee you wont be satisfied with the power output after being nickel & dime'd on all the machine work/head refresh and it wont be long before the bug hits you and your looking for more performance out of the engine.
20 valve engines are easily available nowadays for relatively cheap & with the ease of plug in play harnesses now you could easily spend one weekend and have your car up and running.

As for cheap rear end upgrades, Search ebay, local craigslist or browse dwarf/sprint legend race car classified forums. A majority of that community commonly run modified toyota 10 & eight bolt differential/spools with a variety ratios and they dont have inflated initialdtaxjdmdudebro prices like the majority of greedy phukers in this forum.

BTW, you can ditch that pinched off egr line on your exhaust manifold and plug it with a differential or transmission drainplug, they have the same thread/pitch.
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Re: notnilc20's 1986 ae86 Hatch build clean-up

Postby aaronlee133 » Wed Feb 17, 2016 10:18 am

Notnilc20,

Looks like you're going straight into it - good for you. I've had parts taking up 4 shelves on a rack so i totally can relate to the dizzying sense of it all. Stay organized, tag everything, take pictures, and take notes on a notepad. I had to do all that just to stay sane!

As far as the egr goes - best to remove it completely since its already crimped off. I purchased the following block off kit from ksd but as others mentioned above you can make your own: http://www.ksdengineering.com/KSDEngineering-EGR-Blockoff-Plate-w-Gasket-_p_59.html

More importantly however, the thing that really concerns me is 2 fold: 1) You said the crank was really hard to turn (which should not be the case. If anything, if you have a 1/2 inch ratchet you should be able to turn using 1 hand and it should be smooth in between stroke. 2) If you said water came out with oil then that def points to a blown head gasket. Thus allowing the water and oil to mix, which also prolly means water got into areas of the block it obviously shouldn't have. I'm interested to see what the cylinders and pistons look like once you remove the head.

Instead of spending more monies as someone rightfully noted above, I think it would be best to ditch it and grab a 20v or another 16v that you know is properly working. I'm all for keeping the 16v even with limited power but the 2 things you described above leads me to believe that there's more internal issues not worth trying to resolve. I wouldn't want for you to waste all this money when you can simply pick up a functioning engine for same price.

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Re: notnilc20's 1986 ae86 Hatch build clean-up

Postby aaronlee133 » Wed Feb 17, 2016 10:25 am

as a follow-up - here is the image someone already posted elsewhere on club4ag about egr delete:Image

Deuce Cam
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Re: notnilc20's 1986 ae86 Hatch build clean-up

Postby Deuce Cam » Wed Feb 17, 2016 1:58 pm

These guys make some great points about a different engine in running condition. If yours has just been sitting for god knows how long + having water in the sump = not a good sign.

The diff 3rd member/pumpkin is also concerning considering the rust. If there's any pitting on the r&p (and bearing surfaces) it's basically toast.

It's a shame the previous owner didn't put more thought into storing vital components correctly.

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Re: notnilc20's 1986 ae86 Hatch build clean-up

Postby notnilc20 » Wed Feb 17, 2016 11:28 pm

hey guys thnks for the great advice. yeah i originally wanted to do a 20v and the car i bought came with a 20v head and ecu. but i think it would be easier to just get a 20v motor already put together. anyway, then i got to thinking i wiuld like to turbocharge this car. i did a turbo on my 86 mercedes 190e 16v when i was in my early 20s and i love the feel of a turbo car. so since the 16v bluetop has a lower compression it might be decent to turbo it. plus i love the idea of fixing up this poor engine. but i'm always up for suggestions. especially since i'm still new to the eightsix community. anyway, here are some more pics. i yanked the block out and put it on the engine stand. it looks bad but i think it will clean up alright. also the crank does turn easy now. just when i first tried to turn it it was tough because it hd sat for so long. what do you think? ;am i crazy?
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Last edited by notnilc20 on Wed Feb 17, 2016 11:42 pm, edited 1 time in total.

notnilc20
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Re: notnilc20's 1986 ae86 Hatch build clean-up

Postby notnilc20 » Wed Feb 17, 2016 11:33 pm

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Re: notnilc20's 1986 ae86 Hatch build clean-up

Postby notnilc20 » Wed Feb 17, 2016 11:37 pm

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Re: notnilc20's 1986 ae86 Hatch build clean-up

Postby notnilc20 » Thu Feb 18, 2016 8:48 am

harbor freight loves me and to be honest, i love them too... :)
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notnilc20
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Re: notnilc20's 1986 ae86 Hatch build clean-up

Postby notnilc20 » Thu Feb 18, 2016 8:51 am

guess now would be the time to paint the engine bay and clean up some if the surface rusty on some of the parts.
Image

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Re: notnilc20's 1986 ae86 Hatch build clean-up

Postby aaronlee133 » Thu Feb 18, 2016 9:24 am

Haha, I have the same hoist and stand from harbor freight - i know the feeling!

The pistons appears to have more than just carbon build-up; looks more like oil... prolly from the headgasket and perhaps oil seeping into the cylinders from the top?

The rust on the passage ways def isn't 'normal'. If you have a machine shop or engine shop in mind I would send them those pics to get their thoughts on whether they can restore or save.

Either way, with the block out now, you might as well do everything else! Just get yourself a proper AW11 manual rack + T3 bushing + MK3 intermediate shaft, new fuel filter, clean up that booster or delete it all together... perhaps some new subframe bolts? - can't tell if that's surface rust but looks to be in pretty needy shape esp if you think about the load those bolts are under. I picked up some new ones from the Toyota dealer just last year so I know they're still avail.

Other than rusty bolts and brackets; frame and firewall seem to be in good shape!

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