My DD Lovin K24

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SuperDougy
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My DD Lovin K24

Postby SuperDougy » Sat Jan 12, 2013 12:46 pm

February 1, 2011

I picked up my first Corolla to build a daily driver that I can also do some lite track days. I bought it off another member on club4ag. His post read, "I'm contemplating on selling my car after almost 3 years of ownership. Looking to get rid of everything I have with the car. Everything was purchased brand new and installed unless other wise stated." The price seemed steep up front but after I ran the numbers on the inventory list the Levin was basically free with the purchase of all the parts. It's an 85 Toyota Corolla GTS Hatchback converted to a Levin with 265,000 Miles. Even with all the miles the body was super straight, clean and rust free.

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So with my dad's help we loaded up the Levin and drove south.

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I took to my buddies shop to have it prepped for smog. It ended having an exhaust leak plus need a new cat and the timing set. After two attempts it passed.

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After three months of driving it around town the Corolla converted itself to steam powered. I had blown a head gasket plus had some major oil and power steering fluid leakage.

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Pure nastiness!


I had planed to drive the Corolla for a year with the stock 4ag before I did any kind of major engine work. Since this is my daily driver and will be used to transport my kids on rare occasions it needs to be reliable but performance oriented. So out with the old and in with the newer, bigger, better, shinier.

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Disconnecting everything for a clean drop.

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Renew, Reuse, Recycle. Sold the engine tranny with everything bolted on except the subframe to a local club member. He stripped it down and did a complete rebuild on the engine.

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The engine is out and the bay is covered in oil and power steering fluid. Time to roll up my sleeves and start pressure washing.

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People always say nice things come in small packages, then I retort "Really Bitchen things come in BIG packages!"

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I sourced out an f22c off of s2ki for the Corolla. It only has 6k miles on it and came with an Alaniz ported and polished head, Hondata intake gasket, Toda lightened flywheel, Clutchmasters stage 3 or 4 PP & disc, AEM serial data gauge and an oversized throttle body port matched to the manifold.

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Here kitty kitty kitty...


Ordered a swap kit from JSP. Notched out the subframe and oil pan.

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Relocated the clutch slave cylinder line to the other side of the engine bay.

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The first of many test fits.

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Quick Rondell Bar fitment. I was having a few issues with it fitting in the Levin bumper.

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The red mark is where the bumper is hitting. Might have to do a little bending.


The f22 came out to make way for some tunnel massaging. While it was out I went to work at cleaning up the under body and engine bay. I plan on painting the Corolla in the future once the swap is sorted and I've played with it a bit. So for now I'll just try to make it look decent.

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Still a little wet.

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"Wax on wax off, Wax on wax off, Good job Dougy-san."

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Back in and fitting very nicely.

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Still have a bit more waxing to do.

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Plenty of room for a fat little 3 inch thick Scirocco drag racing radiator and twin fan set up.


I'm not much for wiring so I decided to leave it up to the pros and pulled my dash and engine harnesses and sent them to Phoenix Tuning and have them build me a turn key harness.

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Here is the finished result. A Corolla and S2000 harness beautifully married together.

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I was having some fitment issues with the engine harness till I figured out two different bundles were swapped on their exit points from the main loom. So cut, tape and repeat.

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Since I had the entire dash out and was waiting for Phoenix Tuning to complete my harness I removed the sound deadening and replaced it with Dynomat SuperLite. Since this is my daily drive I want to retain a certain level of comfort and refinement. Plus with the f22 I just doubled my horse power so it's all good. I also cleaned all of my AC/heating system and ducts plus replaced all the foam gaskets and siliconed all the seams for maximum airflow.

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I also replaced all the dash light with LEDs. I found the 74-xHP3 worked the best for the push in bulb housing. It fit firmly in the socket with out cracking the housing. There are three bulbs, one pointing forward, left and right creating the maximum spread of even light distribution.

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For the twist in bulb housing I used NEO5x wedge dash light, 5mm.

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Once I got the harness back from Pionex Tuning I went about putting it back in and tiding up anything that was going back under the dash.

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The blower fan for the heating is back in nice and tight with it's new sills. No more dirt in the face when I need a little climate control.


Removed the immobilizer from the stock ECU. I'm not really sure where most people are mounting these so I cut off all the tabs except the one that takes a screw and put it in about where the stock one went. It was a really nice fit.

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Once the harness was in I began reinstalling all the creature comforts. The fan box and AC box are in and fitting nice and tight.

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The heater box is in along with dash and most of the ducting.


The custom straight shaft arrived.

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IT'S ALIVE!!! All the electrical works like OEM. Pure AWESOMENESS!!! Thanks Phoenix Tuning.


I've put most of the trim back. I also ran heavy gauge wire for speakers and an amp. I've got the gauges in but still need to sort out the mounting plate.

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Everything is in except for a few small pieces. I also installed a mount for my iPad and wired directly into the amp to be used as my head unit/GPS. I fallowed the DIY by Sound Man on how to wire up the iPad.

I purchased the mount from Ram Mount. I used parts: RAM-B-166-AP8U, RAM-114FMTU and RAP-B-354-75U. I had to lightly dremel the hole that the cigarette lighter socket fits in. I relocated the cigarette lighter socket behind the stereo din and plugged in a Scosche reVIVE II car charger so I can charge my phone at the same time I power the iPad.

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Now that the interior is mostly sorted I went to work under the hood.

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The engine bay is done. I took inspiration from Mr John trying to look OEM as possible. Even went with the same MINI Cooper S air filter box. Also relocated the battery to the passenger side. The 3 inch thick Scirocco drag racing radiator (AFC-80105N, FLX-365 http://www.summitracing.com) is installed and plumbed with the in and out on the driver side. There is plenty of clearance the intake elbow for the water hose. The Scirocco twin fan shroud is tightly fitted to the radiator for maximum air pull. I tucked some of the harness but will do more as I work on the Corolla in the future.


March 10, 2011

So as soon as we got the Levin back on the road we discovered a noise coming from the transmission. Dan pulled the motor/transmission and sent the tranny to a shop to be cracked open for inspection. It turned out to be a bad bearing that developed some rust on it from sitting dry for so long. All the gears are in great shape so I had the tranny shop drop a new bearing kit in. Also picked up a new Exady clutch and pressure plate and had the Toda flywheel resurfaced. While in the process of sorting the tranny my buddy Dan moved his shop, D&S Autoworks, to a new building to cope with his business growing. This postponed the Levin's reassembly. I figured since the Levin was in pieces I would post some detailed pictures of parts that were modified or sourced for the build.

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Mini Cooper air box. There was a small compartment on the side that was trimmed off to make it fit. I also opened up the outlet of the air box to make it match the f22 throttle body to reduce air flow restriction.

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Here is the new location for the fuel filter. Added a heat shield for the fuel lines to prevent vapor lock. You can also see the new hole in the firewall for the wire harness.

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The heater valve was pushing up against the valve cover so I disassembled it and rotated it counter clock wise 90 degrees.

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The battery shelf was removed and relocated to the passenger side. The clutch line was moved from the passenger side to the driver side of the tranny tunnel. You can see the S2000 slave cylinder still attached and sitting on the new manual rack. The Supra intermediate shaft is installed. I even copied Mr. John's Greddy oil catch can but I did not black it out for the full JSP stealth mode. Plus installed some new Cusco parts as well.

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The radiator is so small it fits in the core support opening with just a little trimming for the filler neck and cap to clear.

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The battery tray's new location.

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The Scirocco drag racing radiator and fans are very compact.

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The in and out pipes had to be angled to clear the alternator and AC pump.

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The top was angled 20 degrees and the bottom 45 degrees.

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Also had two post tacked to the bottom of the radiator to fit in the OEM mounting brackets.

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Needed to use a reducer to connect the radiator hose to the f22.

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Picked up a used set of Bride seats to freshen up the cabin plus increase rear accessibility once the car seats go in. ;-)

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Also put the carbon fiber center console in. Plus hung the door cards.


March 30, 2011

Finally got some time to put in my JDM cup holder and 400 gram shift knob.

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Here are a few detailed pictures under the hood. Was able to tuck the rest of the harness behind the firewall the last time the engine was out. It still needs to be wiped down but here you go.

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Also put in a Beatrush radiator cooling panel.

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Most of the suspension is sorted but I still need to dial it in. Currently it is set close to stock specifications.

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May 26,2011

My most recent mod is more for the daily driver side of my Corolla and less to do with performance.

I purchased Audi's LATCH retro kit to add a child seat LATCH system ("Lower Anchors and Tethers for Children") to the Corolla. We mounted mine in the center of the rear seat since I don't plan on taking two kids in the Corolla at on time. The center position is also the safest for a child in a side impact accident. Plus the center seat position gives my kids a direct view out the front window which should limit the amount of car sickness induced by the Corolla's suspension.

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Audi Latch bar. There are two different part numbers. The one with the wider mounting brackets is the one I used.

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Looks OEM baby!!!

Underneath the floorpan both holes clear everything. One of the holes comes out behind the heat shield which is no big deal. My buddy Dan helped me with the install and used some three inch washers to help distribute the force in the event of an accident.

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I mounted the top latch tether mount off to the side since the seats split 50/50 and the tether wants to slip between the seats. I may change this in the future but it works fine for now.

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This setup works so much better then the seat belts. I could not get the seat belt to tighten down enough to hold the car seat securely. Plus the LATCH system makes it a lot easier for me to swap car seats from car to car if need be. The end result came out very nice.

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July, 8th 2011

My Corolla is my daily driver. That also means driving the kids around town. At the moment I'm running tint free to keep the police less suspicious of my Levin but I had to find a way to keep the sun off the kids while sitting in the back seat. I tried a set of sun shades from BabiesRUs but that was a big fail. I ended up finding a sun shade for a 2006 VW Passat part# 3C0 064 036 that worked. The original price was $90 but now you can pick them up from any VW dealer for $13. The quality is very nice and looks very OEM and is pretty much fully extended. It was easy to install. Just two screws mounted into the rear speaker shelves. If your worried about the holes they are hidden under the rear speaker grills if you ever decide to remove the sun shade. Plus two hooks that slip behind the upper hatch roof molding. It took me five minutes to install. My cargo cover still has freedom of movement and can be removed. But the sun shade will come in contact with the average height adult passenger's head in the back seat due to the angle of the sun shade. So I would only recommend it for short passengers and car seats.

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Retracted.

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Extended

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Hook

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Part number

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July 13, 2011

Here is my Corolla/Corsa electric power steering column after it was finished. The first pic sucks since it was with a phone. The rest are the column installed. From the hub to the tilt is Corolla. From there to the spline is a Vaxhaull Corsa C electric power steering column. The upper part of the u-joint is Corsa and the lower part is Corolla which attaches to the manual rack with a Quaife QSR quick steering rack and pinion. Most of the two columns were disassembled and put together. It was crazy how close most of the tolerances were between the two different columns. Most of the inner shaft is Corsa except the the Corolla spline that was welded on so It would accept the Toyota steering wheel. It has a control module to adjust the weight of the steering from one finger parallel parking to pull out the big guns no assist track days.

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Finished Corolla/Corsa electric steering column.

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The electric motor makes for a tight fit. The vent housing under the column had to be modified with a hammer.

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The Corolla ignition, signal arm and trim all keep the interior looking OEM.

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The Corsa spline that slides into the Corsa u-joint

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Supra intermediate shaft leading up to the modified Corsa u-joint.

My Corolla/Corsa electric power steering column turned out really nice. I can use the OEM steering wheel, column cover and signal plus a Supra intermediate shaft on the opposite end. There's no draw on the engine and I can still run a manual quick rack. I have not track tested it to see how it holds up but a lot of guys use this Corsa column for rally. All in all it's the second best mod in my Corolla, f22 still takes first.
Last edited by SuperDougy on Sun Apr 07, 2013 9:18 am, edited 7 times in total.
85 Levin GTS K24
viewtopic.php?f=7&t=709

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86_LeViN
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Re: My DD Lovin!!!

Postby 86_LeViN » Mon Jan 14, 2013 6:31 pm

none but the first picture on your post works

goofesgts
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Re: My DD Lovin!!!

Postby goofesgts » Wed Jan 16, 2013 5:11 pm

cant see any pics besides first one!! how u loaded ythat thing in that box truck ?
how can i go to heaven? accepting jesus christ as youre savior!! thats youre ticket to heaven!

John H.
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Re: My DD Lovin!!!

Postby John H. » Thu Jan 17, 2013 11:38 am

Pictures aren't working!? Would love to see them!

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Re: My DD Lovin!!!

Postby ronny » Fri Jan 18, 2013 10:02 am

doug, thats alot of HTML.. haha
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SuperDougy
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Re: My DD Lovin!!!

Postby SuperDougy » Fri Feb 08, 2013 1:53 pm

ronny wrote:doug, thats alot of HTML.. haha


PICTURES UUUUUUUP!!!! :lol: Man I'm tired. :cry:
85 Levin GTS K24
viewtopic.php?f=7&t=709

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SuperDougy
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Re: My DD Lovin!!!!

Postby SuperDougy » Thu Apr 04, 2013 7:27 pm

Anyone have an SR5 engine harness for sale? If so PM me.
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lucky13evo
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Re: My DD Lovin!!!!

Postby lucky13evo » Sat Apr 06, 2013 11:39 pm

Whats up with the K swap. Want to see or hear about progress ;p car looks amazing>>

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SuperDougy
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Re: My DD Lovin!!!!

Postby SuperDougy » Sun Apr 07, 2013 5:56 am

Some time back I spun the bearing on the f22 and the Levin ended up back at D&S Autoworks waiting to be fixed. While it was there the body shop next door finally got there permit and opened their doors for business. So we pushed it over.

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85 Levin GTS K24
viewtopic.php?f=7&t=709

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SuperDougy
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My DD Lovin K24

Postby SuperDougy » Sun Apr 07, 2013 9:17 am

Here it is! Once the f22 was pulled from the Levin due to a spun bearing I decided to go K! To most it may seem crazy but to me it made sense. The f22 is an awesome engine but everything about it is expensive. The k is more economical and has more potential. Looking down the road the f-series will go up in price due to its increasing rarity while the k-series should stay reasonably priced due to mass production. I came across a great deal from Sportcar Motion on a built k20/24 with only 500 dyno miles on it.

Engine Specs: 
322HP 230 TQ on 100 Octane
K24 with K20 head
CP oversize pistons 12.5 X Forged
Crower rods
ACL race bearing
Balanced blue print bottom end
ARP head studs
K20a2 type s head port and polished by Portflow 
Skunk 2 valves, 
Skunk 2valve springs 
Skunk 2 retainers
Skunk 2 stage 3 cams

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I'm using the S2k tranny with a Ballad Sports K-series adapter plate and flywheel adapter.

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Chase Bays Mil Spec  K-Series Engine Harness.

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Hybrid Racing Universal Conversion Harness.

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2nrs Of Springfeild S2K24 manifold adapter plate.

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Plus:
Ktuned swivel neck 
Ktuned 90 degree water outlet 
Kpro
Custom engine mounts
Custom header
Ext...

Since I'm going from f-series to k-series my radiator, tranny and air intake are already set up. With all the adapters most of the stuff will bolt up. The first big hurdle will be the engine mounts. I plan on modifing my JSP mounts to work with the k24. The 2nd one is wiring. The Hybrid Racing Universal Harness should make it a bite easier to conect the K-Pro to the under dash harness. The Chase Bays harness will make the engine a stand alone unite requiring less integration in to the Levin's harness.
85 Levin GTS K24
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Billy_Andrea
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Re: My DD Lovin K24

Postby Billy_Andrea » Sun Apr 07, 2013 11:35 am

Wow!!!

That is all......

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SuperDougy
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Re: My DD Lovin K24

Postby SuperDougy » Sun Apr 07, 2013 5:26 pm

It sounds simple enough but it's not. The F22 just fits under the hood but the k24 is close to 3 inchese taller. This equates to the valve cover sticking out of the hood :? A bump on the hood :( or a new subframe design :o

The F-Series is pretty straight forward and it still requires fabrication work. But putting the K-Series in an 86 is much more difficult. For anyone who reads this form, it's a BUILD THREAD and NOT A DIY thread!! Even Mr John at JSP who was the first to drop a K24 in his drift car now has an F-Series back in it.
85 Levin GTS K24
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Re: My DD Lovin K24

Postby ronny » Mon Apr 08, 2013 4:34 pm

i love the powersteering setup!
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SuperDougy
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Re: My DD Lovin K24

Postby SuperDougy » Mon Apr 08, 2013 6:31 pm

It's really nice. The power steering makes the horse power more manageable and makes the Levin funner to drive on a daily basis.
85 Levin GTS K24
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typexd
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Re: My DD Lovin K24

Postby typexd » Wed Apr 10, 2013 3:46 pm

First off, I tip my hat to you sir! Awesome build. I have been looking into the powersteering setup you have and I am curious what year Vauxhall Corsa did your rack come out of? Just curious because I'm stationed in Germany now and access to Vauxhalls are insane. Also, which model Corsa since they go from A, B, C...etc?

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SuperDougy
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Re: My DD Lovin K24

Postby SuperDougy » Wed Apr 10, 2013 8:18 pm

typexd wrote:First off, I tip my hat to you sir! Awesome build. I have been looking into the powersteering setup you have and I am curious what year Vauxhall Corsa did your rack come out of? Just curious because I'm stationed in Germany now and access to Vauxhalls are insane. Also, which model Corsa since they go from A, B, C...etc?


Thanks! I believe It's the C. Here is the company that makes the control box for it. http://www.rallywiz.com/Shop/index.php? ... y&cat_id=2
Their site has some good info if you dig around. If you have more questions post them under my Corsa electric power steering thread so it may benefit others. :D
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Re: My DD Lovin K24

Postby typexd » Fri Apr 12, 2013 11:44 am

I have to admit, that is a genius mod. I have always thought about going to a manual steering conversion, but I hated the idea of parallel parking or having the girl drive my car with manual steering. Fortunately you have given me an even better reason to go forth with the mod. The only thing that concerns me is the frequent failure seen with these electrical assist. Have you run into any issues yet? The worst I have heard is that you just have to adjust the steering for the sensor.

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SuperDougy
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Re: My DD Lovin K24

Postby SuperDougy » Fri Apr 12, 2013 4:03 pm

I haven't had any problems but with all the work that's been done to my Levin it spends most of its time sitting in a shop. Someone did a similar mod with a Yaris electric power steering unit. This is more ideal for us in the States since it would be cheaper and more available. I was going to contact Rally Wiz and see if they could develop a control box for the Yaris electric power steering column. There are many other electric power steering columns in the US it's just a matter of trying to put it together.
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Re: My DD Lovin K24

Postby NikNes » Fri Apr 12, 2013 9:47 pm

Sooo clean and awesome.

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SuperDougy
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Re: My DD Lovin K24

Postby SuperDougy » Wed Apr 24, 2013 12:54 am

D&S Autoworks is working on my K24 swap while in Japan. 

Thy oil pan has been modified to clear the subframe. 
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The S2000 intake manifold is mounted to the K24 with the adapter plate. 
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85 Levin GTS K24
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Re: My DD Lovin K24

Postby dano » Wed Apr 24, 2013 11:31 pm

great buildup so far, I think I'm gona have to use your idea for the latch system on another car!
Build Thread!!!http://club4ag.com/forums/viewtopic.php?f=7&t=1459

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Re: My DD Lovin K24

Postby RuizXIII » Thu Apr 25, 2013 9:57 pm

Whoa! This is sweet. It started off cool and got really interesting.
I'm loving all the work you put in to this. I'm curious to see what that K24 does! I always thought those were neat.

How did you guys get the car in the back of the Uhaul? Big Ramp?
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SuperDougy
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Re: My DD Lovin K24

Postby SuperDougy » Fri Apr 26, 2013 9:36 am

We put it on a flatbed tow truck then drove the Levin in to the Penske truck. On the way down we drove trough rain and a little snow. It was nice driving the truck in bad weather rather than the Levin. Plus when we stopped for the night everything was locked up. We used about four heavy duty tow grade rachet straps to strap it down. My only concern was if the truck broke down what would we do. When we got to SoCal we backed the truck into my buddy's shop and drove the Levin on to a lift to get it out.
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goodknight
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Re: My DD Lovin K24

Postby goodknight » Wed May 08, 2013 6:13 am

Bump for updates pls.

Couldnt have come at a better time. I'm researching putting a k series into my ae, and this is one of the threads that popped up. Really, really appreciate you taking the time to document all of this, and I plan to do the same once my car is further along.

Pls do keep us informed, since I will likely follow your path very closely :)

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SuperDougy
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Re: My DD Lovin K24

Postby SuperDougy » Mon May 13, 2013 2:27 pm

The oil pan is painted and installed. You can see the f22 in the background with the JSP engine mounts cut off and templets on the k24 to make mounting plates for the brackets to be weld to. 
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Everything is on the engine and ready to test fit for any clearance issues. Even the Honda AC compressor is attached but will be replaced with a 4ag AC compressor so no need for expressive custom lines or trying to get the wiring figured out. 
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85 Levin GTS K24
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Re: My DD Lovin K24

Postby lucky13evo » Wed May 15, 2013 10:04 pm

Are you going to make this motor capable of running on 91? Do you have any pics of the k24 oil pan before you chopped it. Looks like it lost a lot of volume?? But i could be wrong. Keep up the awesome sork and keep us updated

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Re: My DD Lovin K24

Postby JDM20VAE101 » Fri May 31, 2013 4:41 pm

Awesome Build Sir!

Impressive!
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Re: My DD Lovin K24

Postby SR85DET » Sat Jul 06, 2013 11:09 am

well done! I'm thinking about making good use of the k20 in my garage but can't decide if its worth it to pull my sr20det yet...

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Re: My DD Lovin K24

Postby kitsune » Wed Aug 14, 2013 11:23 am

Looking good Doug!

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SuperDougy
Club4AG Enthusiast
Posts: 56
Joined: Sat Jan 12, 2013 8:46 am
Location: Bay Area

Re: My DD Lovin K24

Postby SuperDougy » Sun Nov 24, 2013 11:04 pm

It's been sometime since I posted an update so I decided to share the most current progress with my Ae86. The K24 mounts have been made and the engine is now bolted in the Levin's engine bay. Next is hooking everything back up and making small adjustments for fitment of hoses and lines. But it looks like most of it will be very straight forward since the F22 and K24 are very similar in size and layout. The tricky part will be the wiring but I'm hoping the Chase Bay wire kit will simplify the process. 

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The best part is the hood can close without having to cut a hole in it or add a bulge. John at JSP had a hole in his hood of his K24 swap to allow valve cover clearance but this was due to him not being able to use spacers on the subframe to meet drift competition regulations. Since I am building a daily driver I retained the spacers from my JSP F22 swap kit and it gave me just enough clearance to close the hood plus a little extra for engine movement. 

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85 Levin GTS K24
viewtopic.php?f=7&t=709

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