UPDATE: 5.5agze 20v coming Spring 2015

[gaijin_rokurunner]

Oiling system:

I didn't opt for the dry sump setup for a few reason...its overkill for street cars that see track time, added weight for the oiling system and expensive. With that said I chose to keep the wet sump setup but upgrade it to meet my needs. Toda recently released a upgraded oil pump gear using a different type of high spec metal and CNC'd to closer tolerance then OEM. This ensures high speed reliability in the factory oil pump as well as safeguards against breaking at high rpm or sudden rpm spikes.

To go along with the gear the pump was ported to smooth out any sharp angles and an HKS oil pressure up kit was installed....this kit consist of a brass plug, a spring and spring seat. The brass plug is fitted into on of the oil passages in the block ....in the center it has a small hole to allow oil to pass at a restricted speed thus upping oil pressure...the spring is inserted into the center of the stock spring in the oil pump to add a stiffer motion and the spring seat ensures both springs are seated properly. The 4age is prone to low oil pressures at high RPM when the factory oil pump cant keep up...this setup will ensure I dont have that problem.

Moroso custom made the oil pan according to my design to withstand G force from acceleration, braking and cornering. I initially wanted a full aluminum pan but chose steel due to durability and longevity, also aluminum is prone to cracking over time. The design incorporates a stock pan with a custom tray welded on to it. Inside the tray is a trap door system that prevents oil from all building up on any side of the pan, keeping it in the center at the pickup where its needed. 3 drain plugs were added...on for oil, one for turbo train use if needed and one for crank case venting. Oil capacity was increased from 4 to 6.5 quarts for a few reasons. The 4age is an oil hungry engine, and the stock system just plain sucks. More oil capacity allows cooler oil to circulate through the engine by reducing how frequently the same oil is cycled and allowing more time to cool. this also helps reduce engine temps especially when u cement the block

[gaijin_rokurunner]

Windage tray:

All 4ages have windage trays but i took mines to the next level for performance and modified the tray and incorporated a teflon crank scraper to reduce drag...as the crank turns a windage cloud starts to form suspending oil within the energy made from the spinning crank. The modified tray allows oild to drain into the pan quicker, prevents the oil in the pan from sloshing back up into the spinning crank and shields the oil from the aerodynamic energy of the spinning crank which draws oil up into the windage cloud. The scraper on the other hand actively strips oil from the air(windage cloud) by interfering with the pressure build up at high rpm and physically scrapes oil off the rotating crank reducing parasitic drag which robs HP. A few other benefits of this type of windage tray and scrapper combo is reduction in oil foaming which can damage your engine, reduction in oil starvation by keeping the oil in the pan, and prevents the cylinder walls from being overloaded with oil. This is a stock tray modified, scraper is custom made

[gaijin_rokurunner]

DLC (Diamond like coating) treated piston pins and valve buckets compared to factory.....tests show using this type of coating on high wear parts can reduce friction by up to 50%. Also pictured are drive train comparison....stock spring, TODA spring and the spring I have engineered, along with the stock spring seat, retainer and retainer locks on the left also compared to what I had engineered. Spring weight reduction between stock and mines 3grams each, and retainers 1.5 grams each. If you notice the spring seat factory is like a washer and the ones i had made are an actual seat which prevents the springs from moving around and rubbing against the head and buckets causing hp robbing friction. Last pictures are the custom valves next to stock...Competition plus valve with re-engineered tulip design for better flow into the combustion chamber, back cuts on the valve head, swirl polished, and flatter faced to bump C/R by 0.2:1.

[gaijin_rokurunner]

Drivetrain:

To minimize crank to wheel power loss I had to go to the drawing table again and try to minimize loss best i could. What i came up with is some custom and top of the line drive train parts that I think will help me minimize power lose as much as possible....to begin I purchased a super light Ogura pro carbon racing clutch and flywheel package...I chose this for a few reasons....everything is fully rebuildable except for the flywheel. If my diaphragms go bad i can unbolt and purchase new ones, if the carbon disc wears out I can purchase a new disk and keep my center basket, if the tension plate goes bad I can purchase a new one without having to buy a whole pressure plate...the disc is 100% carbon fiber and are very light, very good friction co-effiecent, so you can use a fairly soft spring = light pedal, have a lot of internal damping so they engage as smoothly as an OEM organic clutch, contain solid lubricants as part of their makeup, making it pretty light on the flywheel facing, they can take so much heat then any metal clutch and cool a lot faster, the friction bond is more chemical than mechanical based, and lastly the wear rates are superior to metal and even OEM clutches and thats a plus especially at $700 a disc.

Tranny is a a custom made J160 6 speed from an Altezza made by Joe at LEEN. Mated with a 4.77 ring and pinion my car will be super quick on the road and track....top speed with my rim and tire setup is 162mph. I needed something a little more modern, stronger and reliable then the 28 year old T50 that came in my car so this was the best choice due to the ease of modifying to fit.

Drive shaft is a custom 2.75 inch carbon fiber one piece setup with steel yoke and rebuildable u joint....reasons I picked carbon fiber is its light, actually 15lbs lighter then the stock two piece shaft, able to absorb and eliminate high speed shock and vibration, vibration occurs at a higher RPM then steel or aluminum, my shaft actually has zero vibration up to 180mph and 11800 rpm where the same size shaft in steel or aluminum has vibration at 8000 rpm. Three times the torsional strength of steel, torsional spring allows for better traction grab, smoother shifting, better control out of corners and less shock load on the diff and tranny

Rear end is a fully built 6.7 toyota rear with TRD 1.5 way LSD mated with a 4.77 ring and pinion, slightly larger then OEM sway bar, fully adjustable 4 link and panhard rod and traction brackets....

Custom harmonic dampener courtousy of BHJ Dynamics...outstanding piece of machinery...should extend the life of my bearings greatly as well as reduce the rotating mass...for those using double row assesories they will be available in the future...dont kill your engine with those aluminum underdrive setups..the makers dont advertise the negative outcome of using them.

[gaijin_rokurunner]

Intake System/Blow by Breather
Im going to have two setups for the intake....one will consist of 100mm velocity stacks from SQ Engineering mated to their pipercross backplate and a pipercross filter...this will be the track setup....the other is my street setup using SQ 20mm velocity stacks(might move up to 40mm) a Mekaru Japan RWD 20v plenum and a Mekaru power chamber which will be feed air from the Hot Staff headlight intake I just got.


Not mines but exact same setup

[gaijin_rokurunner]

random pics from the shop during the build

[kaosboss]

Hey bro, nice build you have here. I have a question for you tho, have you ever thought about modifying your keyway to make it stronger. I have had my keyway break on my 4agte so i got the machine shop to extend the key on the crank.

[gaijin_rokurunner]

Im using one that my shop makes and puts on their formula atlantic engines...its a different type of hardened metal which requires them to heat the crank up and press it on...keyways shouldn't break, don't reuse them and your pulley should pressed on ensuring theres no play between it and the key.

[John H.]

This build is disturbingly awesome!
Keep up the amazing work sir!

-John

[Zenki85]

One of the most informative and great looking build I've ever seen!

[specialdjonez]

love the build up. keep it coming

[gaijin_rokurunner]

Thanks fellas...this is my last 4ag im building....wrapping up my 20 years of AE86/4ag experience with an all out engine...only thing I havent done to this engine is a dry sump setup...maybe in the future....next build im vnturing over to the 3sge Beams engines see what those things can do..

[Zenki85]

Thanks fellas...this is my last 4ag im building....wrapping up my 20 years of AE86/4ag experience with an all out engine...only thing I havent done to this engine is a dry sump setup...maybe in the future....next build im vnturing over to the 3sge Beams engines see what those things can do..

How many would you say you've built? Sir it's truly a art. And I'm pretty sure many on this site drools over the engine you are building up now!

I heard you can pull off from stock 350zs with the 3sge. But beams with itbs! A dream come true lol. 6speed what could go wrong? Besides getting parts seem to be hard lol. But seems like you won't have any problems. Magnificent build! Keep it upp.

*thumbsup*

[gaijin_rokurunner]

Probably about 15 + or - a few engines, ive had about 9 or so ae86's over the years...3 turbo setups, 4 gzes, 2 bluetops with carbs, 1 bluetop with gze kit, 1 5ag bluetop with fcon i got from a front cut, 2 stock bluetops with just bolt on mods, 2 redtops one with carbs and the other with modified intake for rwd this is my first,only and last 20v

[RuizXIII]

YES. Glad to see this thread back up. Amazing engine build for sure!

[gaijin_rokurunner]

installed the cold air chamber for the 20v plenum....looks good..need to figure out how Im going to plumb the fresh air in now also test fitting my fuel filter

[gaijin_rokurunner]

Back to the Dyno Thursday.....Adaptronic hooked me up with an individual cylinder tuning option for free so now I will have 4 individual maps, one per cylinder after 4000 rpm just like QRE tunes their formula atlantic engines...Had to send out my injectors again and they just got back.....one dead injector all the rest cleaned and rebuilt....RC Injector screwed me out of 175 dollars...they supposedly did the same thing but the injector place that re-did the process said no way these injectors have been cleaned in the past 10 years.....Ive heard stories about RC doing that to people...fabricating up flow charts and slapping new seals on your injectors without even doing the process......anyhow keep you all posted with the results next week and video!!!

[carbd7age]

What's the specs on that cardboard box under the hood? I know it's not stock...

[gaijin_rokurunner]

thats a 4CB-ge...specs are top secret

[ethergore2]

This build makes me feel inadequate.

[vovinamer]

Dope build.. Looking forward to seeing the numbers etc. question... How streetable do you think this engine will be? Idle etc... Especially with the aggressive cam setup..?

[ethergore2]

Dope build.. Looking forward to seeing the numbers etc. question... How streetable do you think this engine will be? Idle etc... Especially with the aggressive cam setup..?

I second that question.

[gaijin_rokurunner]

Should be very streetable...lots more low end torque to make up for the cams and lack of vvt...idle is actually very very stable and suprisingly smooth, im going to test the ICV to see if it gets any better but dont really need it....only reason for it not to be a daily driver is the fact that it only runs on 110 octane and as you know you cant just pull up to the pump to fill her up!

[The Robot Cow]

This build is just so damn cool!!!
To someone like me who just got started with the ae86 last year, this is a true inspiration!

[gaijin_rokurunner]

Well glad it can inspire you guys new to the world of the most expensive old school car and engine out there lol.....this is my 20 years of dealing with these cars going out with a bang build...engines back on the dyno...results monday (hopefully as long as nothing else goes wrong again)

[Autonerd]

Amazing build! What class will you race this car in?

[gaijin_rokurunner]

No class just open track days....racing is expensive and i work full time so just once in a while when i can get it in... Some local drift days to if i have time

[ronny]

this is my 20 years of dealing with these cars going out with a bang build...

amen brotha

[gaijin_rokurunner]

some fresh paint on 25 year old parts and new parts to complement.......almost ready for my new engine

[ajadorifter]

Bump