Parrot's Sprinter & Levin shed

Posted: Tue Sep 04, 2007 8:08 am Post subject: Parrot's Sprinter & Levin shed

This is my ADM car (essentially like a USDM SR5) which I converted to 4AGE power about 15 years ago with an English engine loom spliced into the ADM loom. Disc brake rear end etc etc.

AE86 : Projects > Parrots Sprinter amp Levin shed

AE86 : Projects > Parrots Sprinter amp Levin shed

Anyway, after the first child was born it started playing up after 10 years of faultless running. So taken off the road and stuck in the shed to be replaced with a Peugeot 307 family runabout.

AE86 : Projects > Parrots Sprinter amp Levin shed

Eventually worked out the problem, a dodgy connection at EFI relay 2 due to a massive soldered connection to the injectors.

AE86 : Projects > Parrots Sprinter amp Levin shed

So decided to rebuild it properly this time. In these days of Ebay and the net, sourcing parts is easy so this is now essentially in GT apex spec, or will be when all the bits are bolted back on. Have a habit of fixing or installing something then deciding to pull it off again to "improve" something.

AE86 : Projects > Parrots Sprinter amp Levin shed

Have made a few improvements along the way however.
Don't get much of a chance to work on it so it is taking a while......

Posted: Tue Sep 04, 2007 9:20 am Post subject:

damn nice car is it resprayed or ? It looks so clean

Posted: Tue Sep 04, 2007 12:37 pm Post subject:

No not resprayed, engine bay got a thorough scrub and the inside I sprayed with a can after removing the sound deadener.

Fortunate with rust, only a little at the bottom of the B pillars. The original owner fish oiled it thoroughly and whilst stripped out, have repeated the exercise.

Posted: Tue Sep 04, 2007 10:00 pm Post subject:

Nice!

But I thought the Aussies got the 3A engines, not the 4A, or was that New Zealand? Blonde question

Posted: Wed Sep 05, 2007 5:33 am Post subject:

We got 4AC's only in AE86's.

I believe NZ got 4AC AE85's and AE86's as well as 4AGE's

Wataru Joined: 12 Dec 2006 Posts: 76 Location: New Zealand

Posted: Wed Sep 05, 2007 10:03 am Post subject:

Posted: Fri Sep 07, 2007 2:00 pm Post subject:

Car
1985 ADM Red with sunroof

Engine
7 rib block, bottom end never touched (replaced a 3 rib block installed initially)
TRD 0.8mm head gasket
Wade 268 degree cams, vernier cam pulleys.
2 1/4" mandrel exhaust (was meant to be 2" mandrel but they stuffed up) with cat
All rear drive ancillaries, water outlets, alt brackets etc
standard Jap ECU with 185cc injectors but will be replaced with 225cc 1GGTE injectors and HKS F-Con piggyback after engineering
standard exhaust manifold
standard AE86 EFI fuel pump and bracket plus fuel line
Camry V6 twin core radiator with factory electric fan
ARC 'induction box' (standard Jap air cleaner for engineering)
Mocal remote oil filter setup to setrab 13 row cooler
UK engine loom
Jap engine ancillary loom (lights, charging, idle up etc)

Drivetrain
ADM T-50 with JDM bellhousing
Some heavy duty clutch, can't remember
Stock LSD 4.3 cwp

Suspension
Front:
AJPS 6kg springs on conventional strut
KYB 4 way shocks
T3 Camber tops
T3 RCA's
power steer arms
urethane bushed steering rack
Noltec urethane bushes throughout
adjustable whiteline front swaybar

Rear:
4.5kg AJPS springs
koni red dampers
Noltec urethane bushes
adjustable whiteline rear swaybar
T3 traction brackets
will get a adjustable panhard rod soon

Brakes:
Jap standard vented brakes
Jap standard rear discs
Mintex m1144 pads all around
cusco brake master cylinder brace
Jap brake booster and Jap rear disc proportioning valve
new RDA slotted rotors

Interior
Standard maroon
Jap velour seats, standard ADM rear seats (coming out)
Nardi classic wheel with 115mm personal/nardi boss (AE82 twincam wheel for engineering)
will get some sort of race seat down the track
Ditched the aircon
removed interior sound deadening, no radio being put back
Jap under dash loom
UK market dash cluster (240kmh)

Other bits and bobs:
Standard GT Front lip/ rear spoiler
Hayashi racing 14 x 6 wheels plus have a set of standard 14 x 6 intra alloys
old school strut brace
Headlights, indicators Jap GT levin lights with eyelids, levin tail lights
levin postbox grille with factory foglights
late folding electric mirrors

Posted: Mon Sep 24, 2007 2:40 pm Post subject:

I have updated this with new photo's and info after some recent interest.

Was trawling at pick and payless and came across a July 1988 VZV21 Camry auto V6 (2VZ-FE), with a twin core radiator for $55. Radiator inlet and outlet is on the same side as an AE86. Same basic design with plastic top and bottom tanks. You could look at it insitu and not even notice that it wasn't standard. Subsequently have noticed that the later V6 camry APPEARS to have the exact same radiator.

AE86 : Projects > Parrots Sprinter amp Levin shed

Compared to a standard AE86 radiator, overall height from top of radiator cap to bottom of tank is identical, 470mm. Width of camry is 710mm whereas AE86 is 592mm. Thus there is about 59mm of radiator either side with out airflow. Now fitted, and it goes in nicely clearing the chassis rail on the drivers side and the battery tray on the passenger side Now that I have it actually sitting properly, the wiring loom still fits in its original location contrary to my original post.

AE86 : Projects > Parrots Sprinter amp Levin shed

You need to relocate some lower locating brackets as the lugs are in a different position, although the lugs on the bottom of the camry rad are the same size as the AE86. I have taken the lower radiator mounting brackets from a ST162 and AE82 (drivers side bracket on these is a bolt on so easy to take off the donor) but make sure you get the rubbers too as these brackets have a bigger hole for the insulator to sit in. You do need to cut these brackets down to fit neatly to the AE86. You can still leave the AE86 brackets insitu as the camry lugs are a little inside so could refit the AE86 radiator if required. The top brackets do need to be relocated. Make sure you get the camry V6 jobbies as they have a D shaped moulding to suit the V6 rad, rather than a half moon shape found on everything else. I then extended these out by welding on a section of another bracket. Looking at this photo, the two inner bottom mounts are the new ones for the camry, the two outers are the original AE86 mounts.

AE86 : Projects > Parrots Sprinter amp Levin shed

The inlets and outlets are placed about 30mm further over towards the drivers side once you centre the radiator. The standard bottom hose fits easily without modification. However the top hose would need to be altered essentially as the radiator outlet diameter on the top only is 34mm across compared to 31mm on the AE86. No big deal. I ended up using a top hose of a SA61 I think which was new and soft and fitted over the radiator easily. Just cut off the bit I needed. The camry radiator has a transmission cooler incorporated in the bottom tank as evidenced by two olived couplings which I have removed and plugged.

Of course this radiator has twin thermos fitted so simplifies that too. Have double checked it fits with the hood down as I have taken off a guard and could see through.

No smart comments re my (lack of) welding prowess thanks

Posted: Fri Oct 12, 2007 4:52 pm Post subject:

Finally got my oil cooler with remote filter finished tonight. Had to wait to get two 45 degree fittings from Think Automotive in the UK. Amazingly difficult to get here in Australia and then when I did locate them, would have cost more than double what I eventually got them for, and that includes postage, plus saved a drive to Dandenong. Now waiting to hear back from Think Automotive to check I have configured it properly. Edit: heard back overnight it is setup correctly.

AE86 : Projects > Parrots Sprinter amp Levin shed

Have now put the dust shields back on all four discs, what a pain in the arse....

Now wiring up the thermo fan as per The Witzl, once I decide where to put my auxillary fuse box and relays.

Then to rebuild all the calipers.

Getting there slowly....zzzzzzzzzzzz

Posted: Fri Oct 12, 2007 8:37 pm Post subject:

How come you put the dust covers back on? Ive just taken mine off cos they were so bent up but i threw them away thinking they were no good. They were no good though! Unsalvagable.

Posted: Sat Oct 13, 2007 2:38 am Post subject:

Required over here as part of our engineering process. As AE86's never came out in Australia with 4AGE's (only 4AC's) Legally you need to have the car examined by an authorised engineer prior to registration as a conversion. Dust shields are a requirement along with assorted other bits and bobs.

Posted: Sun Dec 16, 2007 3:42 pm Post subject:

No change in pace but we are getting there. All the interior is back in except for front seats. Have finally finished wiring in the foglights, thermo fan, and horn. Doing my best to keep things looking as factory as possible. Have turned my oil cooler the right way up i.e. not upside down (thanks Thanh for giving me the push). Replaced the fusible link block at the battery positive terminal with one out of an AE93, as mine was all cracked and the lid missing. Has the same rated fusible links in the same place. Nice and neat. Today I finally rebuilt the front calipers, and now need to get on to the rears, though they look a bit more complicated.

Have now complicated things for myself however as I now have another project to put all my spare AE86/4AGE bits in! This one (KE25) will be a dedicated club racing car as I don't think I could bring myself to thrash the AE86 on the track now. A lot lighter too.

Posted: Sat Dec 22, 2007 2:35 pm Post subject:

My T3 RCA's and traction brackets arrived this week. Those traction brackets are serious bits of steel, unlike the cheapo ones often on ebay.

Picked up my other project today, but doubt I will do anything with it for a good long while.

AE86 : Projects > Parrots Sprinter amp Levin shed

Will give me plenty of time to decide whether to put my AE86 stuff in or if I should locate a 2TG instead.

Posted: Sat Dec 22, 2007 9:50 pm Post subject:

Did you have to wait long for the T3 traction brackets? I paid for mine, then 3-4 weeks later I contacted them only to be told they hadn't even made them? One day I will maybe have rear suspension.
Im pretty impatient anyway when it comes to waitng on car parts in the mail, but this is driving me nuts! Stupid

Posted: Sun Dec 23, 2007 2:18 am Post subject:

No they arrived after about 2 1/2 weeks. And they come via registered post by the way. I specifically asked for mine to come in steel rather than painted red and I will be painting them black, otherwise they stand out like dogs balls.

Posted: Sun Dec 23, 2007 2:25 am Post subject:

oooh, nice a KE25! Very Happy

KE2*'s rock! It's about time im starting on mine Smile

Posted: Tue Jun 16, 2009 3:34 am Post subject:

Home with the dreaded swine flu (at least it seems like it) so good chance to sit on the web all day. So what has been happening? Not much actual work.

As for my KE25 shell

AE86 : Projects > Parrots Sprinter amp Levin shed

Shot with DSC-W35 at 2009-06-15

Currently looks like this! Was to be my next project and I have been sourcing all the various bits to turn it into a 3TG TE27, again with everything factory. Have virtually everything I need now, such as engine / gearbox crossmembers, transmission tunnel console, dash cluster, gauge clusters, master cylinder setups, pedal box, engines and gearboxes, badges and exterior trim. Main task recently has been roofing over the storage area. We never got TE2x's in Australia, so everything has to sourced from overseas.

However everything has been tossed up in the air as I recently acquired this, which will become my first priority once the AE86 gets out of the garage.:

AE86 : Projects > Parrots Sprinter amp Levin shed

Was a great surprise when this became available, and I have always wanted one after helping a mate who used to race one with a 4AGE. After extending my roof over it, plans for it include some fairly minor rust repair (mainly surface rust) and an engine rebuild. Had been laid up for a few years before it resurfaced. This car is well documented in this http://www.rollaclub.com/board/?showtopic=29498 thread.

One other slight possibility is that I have located another one owner KE25 2 speed auto nearby owned by an elderly lady that has always been garaged etc and is immaculate. She doesn't want to sell it yet, but by the time I am ready to do the TE27, it may have fallen into my clutches! Anyway, time will tell.

Why my love affair with Corolla's? This is me, many years ago.

Posted: Tue Jun 16, 2009 9:55 am Post subject:

luv those pics Thumbsup

Posted: Tue Jun 16, 2009 11:05 am Post subject:

Haha pure class man! Thumbsup

Posted: Thu Jul 30, 2009 12:53 pm Post subject:

Finally got my TE27 arms from the US. Latest pickup, a complete wiring loom from a 2TG TE27 in Japan, plus some KYB 8 ways for the rear. It has to be 'period' mods if you ask me.

Have got a lot of parts for the 27 now. The gauge cluster and instrument cluster, centre console with original clock & radio, accel pedal, tailshaft, gearbox and engine crossmembers, pedal box, correct brake booster and master, induction box and filter housing, 8 way rear KYB's, new levin guard badges, seals and so on.

I've got a couple of RA28 rear ends which I'll get cut down and converted to leaf spring. With the steering arms, I can put AE86 struts in the front, plus I've got AE86 discs for the rear

Now just looking for the levin script badge for the TE27, plus a drivers side tail light for the KE15. Also picking up various suspension components and hopefully a K-B airfilter from somewhere. Bit worried they will all disappear as almost everything is obsolete, especially for the KE15. Thinking seriously of stockpiling a laminated windscreen for each car.

Haven't actually worked on anything though :0

However, thinking about some short stroke options for the shocks which might get the AE86 off axle stands and allow me to get the KE15 in the shed.

Posted: Sat Oct 03, 2009 4:05 pm Post subject:

Been quietly working away behind the scenes locating various parts, mainly for the KE15 at the moment. New brake stuff, suspension components and so on. Still looking for some correct carb kits, and planning an engine pulldown for a suspected cracked piston.

One thing I was super pleased about was my KE15 seats. Was unimpressed by the old style seats without headrests. So measured up the distance between the holes for what were presumably optional headrests (7 inches) and headed for pickapart. Found some black Mark 1 VW Golf seats with separate headrests and they are perfect. You can even adjust the angle they sit at, and most importantly they have plain vinyl on them and look the part.

Have finally finished sorting out the shed, sorting out parts for each car, and tidying up. Now need to get on with finishing the caliper rebuilds on the AE86, putting the drivers door and seats back in, front guards back on (one needs painting) and tightening everything up.

The I will start on the KE15. Today I actually attacked it and removed the towbar which required removing the rear bumper. Can't get over how good the boot is on this car, like new.

Posted: Mon Oct 12, 2009 1:43 pm Post subject:

Well have finally got my stock AE86 rear calipers apart. With the kids and everything, I sort of get 10 mins here, 30 mins there to do stuff. I was a bit worried as there is all this talk that you need special tools to strip them down, and the reference about some special tool in the factory manual is rather vague.

Yes you need a tool to turn the piston, but they are readily available at any autopart shop. Seem to need some tool once you unscrew the piston, but in reality, they all come apart easily enough, and you just need some reasonably long internal circlip pliers to get at the circlip in the bottom.

The first one came out with a bit of a struggle since the only circlip pliers I had that were long and narrow enough to just reach were fairly buggered. The second caliper one I couldn't get at due to the orientation of the circlip lug holes.

So next day down to Repco where they had them on special at $12! Had the other circlip out in 10 secs. If you have the right tool for the job, goes so easy. The piston spindle is a bit of a prick to get out due to the O ring at the other end making it difficult to pull out. So just screw the piston back onto the spindle a bit and you have something to actually grip and pull. This didn't work for the second caliper, but by very gently levering under the lip either side of the piston with two flat drive screw drivers, it popped out easily.

Inside, the caliper was filthy, with barely any crappy dried out grease. I can't believe they were actually functioning. So now I need to get on with reassembling them! Then once this set is done, I will get on and rebuild a second set I have to go on the TE27.