I was contacted during mid summer by this client. I had just begun OST-070, and he wanted OST-071 for his AE71.




As you can see, it currently has a clean 4AC engine in it......




But he wants a bit more.........





More to come......

So... the first order of business is to acquire a 4AGE - not so easy anymore, this one took about 2 months for my client to find.



It is an early 1989 (10/1988 built) 4AGE (vin number tag on engine traced using toyodiy) that was originally delivered to Canada.



I got the engine on a stand.....









and began dismantling the engine..... As more of my clients are wanting complete engines, this tool is quite handy, jaws are a good fit





Head gets pulled..... damn.... not good news

EVERY ONE of the cams journals is seriously damaged......







How bad...????




While this can be repaired - the time and effort is more then finding, and paying for another head.

Another head is found, and it is in very nice condition.




and un-machined.......




more to come......

clean car

the gear is often too close to oil pump case, for most tools to fit between
If the gear is really stuck on there, I've seem pieces broken from the edge of the gear... or the tool
Half of em I drill & tap/use a heavy duty puller on stubborn crank gear
One CA18 pulley made a loud bang when it released. I was taking a break.... then Bammm!! Scared the crap outta me

strange looking flywheel. Some aftermarket perf upgrade ?.
Then there's that stupid looking distributor cap(came on 1 of my 4AGEs too). Toyota engineer had to be on drugs. Fugly

Flywheel is from a FWD or MR2. Will need a new one for a RWD, the water plumping will also have to be changed or modified. Same here on the distributor cap, I've never seen one like that?
Davew7

jinx wrote:clean car

the gear is often too close to oil pump case, for most tools to fit between
If the gear is really stuck on there, I've seem pieces broken from the edge of the gear... or the tool
Half of em I drill & tap/use a heavy duty puller on stubborn crank gear
One CA18 pulley made a loud bang when it released. I was taking a break.... then Bammm!! Scared the crap outta me

strange looking flywheel. Some aftermarket perf upgrade ?.
Then there's that stupid looking distributor cap(came on 1 of my 4AGEs too). Toyota engineer had to be on drugs. Fugly

davew7 wrote:Flywheel is from a FWD or MR2. Will need a new one for a RWD, the water plumping will also have to be changed or modified. Same here on the distributor cap, I've never seen one like that?
Davew7

Dist cap is fwd for use in the AE92.


Flywheel is from a Blacktop, and it does work in rwd, I have the same flywheel in Surreptitious - it is around 13#s, so 2-3#s lighter then any other stock flywheel. I think its a score....


I'm hoping ( ) that I will not have that bad of an encounter (broken tool, or pulley)



So first things first.... get it all cleaned.


The head.......





and the block.... note already bored, and honed....






getting the block taped up...





as with a number of builds.... this one also gets the metal blackening epoxy coating





By the way..... did you see the repair?





more to come.......

oldeskewltoy wrote:
By the way..... did you see the repair?

upper water pump mounting point - you can see the heat applied, and the repair inside.





So while the block cures... Head work commences... beginning with a deburr




And a bit closer.....



this piece broke off with very little pressure, it could have ended up swallowed.......




more to come.....

Port work begins....





One down....






further progress.... 3 down





and 3 down on the intake side....





Makin' chunks....... a bit closer view of working an exhaust bowl....




more to come.......

After finishing the porting, the head goes back to the shop for a fresh 3 angle, and of course back cut on the intake valves.




A unique opportunity... 2 heads, side by side, OST-073 on top before work begins, and OST-071 on the bottom showing all the port work and its fresh 3 angle





With the valve job complete, it is time to measure chamber volumes. Head is propped up allowing me to get an accurate measure




and the results.........




more to come.......

Both the head, and the block are back in my hands.

The head has been machined .009" to get chamber volumes back to 36cc, and now it is ready for re-assembly.




Cam clearance were checked and all now set to .008"




I also got the short block back......



....and buttoned up the bottom end. (Nice cross-hatch in that hone job!)



If I hadn't mentioned, I am again using the Flos.ie 4AGE engine bolt kit....




you can easily tell by all the shiny bolts. Note the empty bins on the bottom right: sump, rear seal, and oil pump





Now we wait another month for the correct Cometic gasket to arrive.

more to come....

It has been over a month.... and I've been busy finishing a few other client's heads.... OST-074, and OST-076 are water cooled 8V Porsche heads - one turbo, one n/a, and OST-072, and OST-073, lets just say... "more to come".............

but for now back to finishing up 071.

Had to share this image.........



The correct head gasket came in 5 weeks after order, installation went smoothly



I now do 6 passes on the head bolts, 2 @25, 2@36, and 2@48 (metal head gasket) Why do I now do 6 passes? I've found that after each pass, the center bolts are no longer the same torque they were, and as you go along the 2nd pass, they even up. With this method, on the 6th pass, you will likely only add turns to the center 2 bolts only.


with the head and block now as one, and the new Cat cams installed.





add in a newly powder coated inner timing cover, and a set of vintage HKS timing pulleys...




set cam timing ever so carefully....







All that is left is final assembly..... (this pic just before)





a bit more to come.......

Wrapped up... waiting for client to pick it up