Lauren's 1985 Kouki Trueno

[Lauren]

Since my last post I've managed to melt piston number four again. The car did a trackday at Anglesey but I wasn't happy with the handling so I only did a few laps over the course of the day.

Then I drove it all around northern Europe managing 3000kms in 10 days. On the way back it was really hot, so I had the car fully loaded, cruising at 130km/h and the aircon on full wack. I drove back from the middle of Germany to London in one go. Something like 800kms. I think that is what did it!

So I sourced another 4AGE with the intention of putting it in as a quick fix. But the new 4AGE was looking tired so we opted to do a rebuild to do it properly.

I employed the services of my good friend and current lodger! He's an engineer by trade and has spent the previous building overbored DB6 engines amonst other things. He's a fussy bugger and that is most definitely a good thing!

Okay Tom's pics:

My AE86 virtually buried, but still there! It will live again!



The block and ancillaries in the kitchen. This is everything back from the machine shop and a whole load of Toyota parts hiding in that box:



Block prior to de-burring:



De-burring the decked block:



The rather corroded side:



De-burred:



Engine stand spider attached to block ensuring that there is appropriate access for cleaning the oil gallery:



Block being prepped for painting:



Ready for final clean with cellulose prior to painting:



Painting:



Cleaning out all tapped holes:



Prepping the other side:



Final clean:



Ready for painting:



Painting:



Grimy oil pump with knackered seal:



Sump and baffle plate needs all the sealant removing:



Knife and brush used to remove all the sealant:



Finally all the sealant removed:



Oil pump with cover removed:



Remove plug for cleaning:



The components of the oil pump:



Oil pump assembled:



Tom had to use a heater on the parts washer to help it to work better:



Some of the clean parts building up:



The table of dirty components getting smaller, finally:



Curing the block paint:



Camshafts replaced by retainers to hold the tappets and buckets in place:



Cam covers are going to need a bit of work:



Cylinder head uncleaned. Spot the problem one!



Initially cleaned but I expect we'll do more with this:



An ever increasing pile of bits!



Random nuts and bolts cleaned:



Sorted and bagged:



Pistons, conrods and main bearing caps:



Main bearing caps dried immediately and protected from corrosion:



Everything you need to build a 4AGE!



Ready for re-assembly: