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AE86 N2 Components by TRD

Contribution by Richard White

 

Here's what you'll need to make your racing application engine with the 4A-GE by using TRD Technocraft Japan components.  Some of the parts are now available at Toysport America in Gardena, California.  Call (323)755-1177 for more information on these racing only components.  These are neither street legal anywhere nor very useable for street use, so don't even ask them if they are...  Fully equipped they make really nice racing engines, that were used for N2 class racing in Japan back in the late 80's.

Thanks Richard for the tireless efforts to make Club 4AG a better place!

---Moto-P

My purpose is to inform others that a 200HP naturally aspirated engine will take
lots of special pieces.  I have copied and summarized all of this information
from the "TRD Corolla, Levin, Sprinter, Trueno, Special Edition Bible", dated
1996.  Though I have tried to double check my entries, you should inform the
readers there could be mistakes and you (me too) are not responsible for damages
resulting from these errors.

--- Richard White

N2

The following outlines the JAF N2 sports parts for the Toyota Corolla and Toyota Sprinter 1600GT (AE86). All parts in this section completely conform to the JAF N2 standard and satisfy the regulations in Japan. However when making any modification to the sports parts, please refer to the regulations for the competition models. Reference, TRD Corolla, Levin, Sprinter, Trueno, Special Edition Bible, 1996.

Head Assembly

Part No.

Description

Qty.

Remarks

1101-AE801

Head Sub-Assembly, cylinder

1

Intake and exhaust ports have been enlarged and polished (intake:67.5mm x 31mm)(exhaust: 36~ 37mmØ ) Combustion chamber capacity » 35cc for 11.5 -to- 1 cr.

11115-AE801

Gasket, cylinder head

1

11121-AE801

Bushing, valve guide intake

8

Outside dia.: 11 +0.044 / + 0.037mm, interference fit: 0.010 ~ 0.044mm

11125-AE801

Bushing, valve guide exhaust

8

Outside dia.: 11 +0.044 / + 0.037mm, interference fit: 0.010 ~ 0.044mm

11131-AE801

Seat, intake valve

8

Outside dia.: 33.1 +0.042 /- 0.030mm, interference fit: 0.091 ~ 0.140mm, 3 angle valve job: 60° , 90° ± 30’, 120°

11135-AE801

Seat, exhaust valve

8

Outside dia.: 29.6 +0.042 / + 0.030mm, interference fit: 0.097 ~ 0.140mm, 3 angle valve job: 30° , 90° ± 30’, 120°

Short Block

Part No.

Description

Qty.

Remarks

13401-AE801

Crankshaft, Improved Heat Treat

1

Forged, pin dia 40 +0 / - 0.015mm, Pin Ø clearance: .040 ~ .060mm

Journal dia. 48 +0 / - 0.015mm

11701-AE801-01

Bearing Set, crankshaft

5

Thickness: 2.0 - 0.004 / - 0.008mm

11701-AE801-02

Bearing Set, crankshaft

5

Thickness: 2.0 +0.0 / - 0.004mm

11701-AE801-03

Bearing Set, crankshaft

5

STD #1, Thickness: 2.0 +0.004 / - 0.0mm

11701-AE801-04

Bearing Set, crankshaft

5

STD #2, Thickness: 2.0 +0.008 / + 0.004mm

13101-AE801

Piston, sub-assembly w/pin

4

Forged, Installed clearance: 0.12 +0.01 / - 0mm, @ 20° C

13101-AE811

Piston, sub-assembly w/pin

4

Cast, Installed clearance: 0.11 +0.01 / - 0mm, @ 20° C

13011-AE801

Ring Set, piston

4

Installed clearance, Comp.: 0.38 (0.28 ~ 0.41) 0.50; Oil: 0.40mm

13201-AE811

Rod, sub-assembly, connecting, (forged)

4

Use with 130101-AE801 piston

Assembly uses tension bolts. Inside dia. Of big end: 43 +0.024 / + 0.012mm

13201-AE821

Rod, sub-assembly, connecting, (forged)

4

Use with 130101-AE811 piston

Assembly uses tension bolts. Inside dia. Of big end: 43 +0.024 / + 0.012mm

13265-AE801

Bolt, connecting rod

8

Tensile type, Torque @ 620 +30/- 0 kg-cm, .14 ~ .19mm

13266-AE801

Nut, connecting rod

8

13281-AE801-01

Bearing, connecting rod

8

Thickness: 1.5 - 0.014 / - 0.018mm

13281-AE801-02

Bearing, connecting rod

8

#1, Thickness: 1.5 - 0.010 / - 0.014mm

13281-AE801-03

Bearing, connecting rod

8

#2, Thickness: 1.5 - 0.006 / - 0.010mm

13471-AE801

Pulley, crankshaft

1

Changed to accommodate the modified water pump, dry-sump oil pump and alternator pulley

15152-AE801

Pulley, oil pump drive

1

Number of teeth 17
Bolt, hexagon, socket head cap

4

M6x1.0 L=25

10508-AE801

Collar, oil pump drive pulley

1

90119-12168

Bolt, hex.

1

M12x1.25, L=55 "0"

11391-AE801

Pointer, timing

1

13451-AE851

Flywheel

1

STD type

13451-AE801

Flywheel

1

B&B type, Single plate with an adopter ring.

Not specified

Block

1

Id. Main bearing 52 +.050/+ .020mm, clearance: .050 ~ .065mm

 

 

Valve Train

Part No.

Description

Qty.

Remarks

13501-AE801

Camshaft, sub-assembly No. 1

1

Intake 304° , valve lift: 10.0mm, Clearance: 0.32mm, timing ATDC: 98° ± 2°

13502-AE801

Camshaft, sub-assembly No. 2

1

Exhaust 304° , valve lift: 10.0mm, Clearance: 0.35mm, timing BTDC: 102° ± 2°

13711-AE801

Valves, intake

8

Head dia.: 32.0mm, overall length: 99.6mm, stem length: 76mm, protrusion above spr. seat: 37.5mm

13715-AE801

Valves Exhaust

8

Head dia.: 27.5mm, overall length: 99.75mm, stem length: 76mm, protrusion above spr. seat: 37.5mm

90501-AE801

Spring, compression

16

Free height: 40mm, No. turns: 7.0, wire dia.:3.5mm, Installed load: 20kg., Installed height: 34.7mm

13741-AE801

Retainer, valve spring

16

13751-AE801

Lifter, valve

16

Under bucket type

10303-SP001

Pad, valve adjusting Under bucket type, t=1.2~ 3.2mm, selection, Intake clearance (cold): 0.32mm, Exhaust clearance (cold): 0.35mm

13523-AE801

Pulley, camshaft timing

2

Adjustable

Lubricating System

Part No.

Description

Qty.

Remarks

12111-AE801

Pan, oil

1

Dry sump

12127-AE801

Plate, oil pan

1

12121-AE801

Plate, oil pan baffle No. 1

1

12122-AE801

Plate, oil pan baffle No. 2

1

12123-AE801

Plate, oil pan baffle No. 3

1

Bolt, hex. Socket head cap

6

M6x1.0 L=38
Bolt, hex. Socket head cap

7

M6x1.0 L=10
Bolt, hex. Socket head cap

21

M6x1.0 L=22

26953-0996

Union (#12)

3

26981-09520

Ring, O

4

15100-AE801

Pump assembly, oil

4

Dry sump type; 56l/min (4000rpm), presure: 6~ 7 kg-cm2

15163-KP611

Pulley, oil pump

1

Number of teeth 27

10507-KP601

Union, (#12)

1

26982-09000

Union, (#10)

2

26983-09000

Ring, O

2

15195-AE801

Bracket, oil pump

1

91300-SP007

Bolt, hex.

1

10509-AE801

Collar

1

15196-AE801

Bar, oil pump belt adjusting

1

00250-SP024

Belt, oil pump

1

240L-050

15601-13011

Filter assembly, oil

1

15671-AE801

Bracket, oil filter

1

96732-31060

Ring, O

1

10505-AE801

Bolt Union

1

90201-19272

Washer

1

00001-ER425-12

Cooler assembly, oil

1

15750-AE801

Tank assembly, oil

1

15740-AE801

Tank assembly, oil breather

1

00001-E0400-12

Hose (oil pan to oil pump) #12, L= 350mm

00001-E0400-12

Hose (oil pump to oil cooler) #12, L= 1000mm

00001-E0400-12

Hose (oil cooler to oil tank) #12, L= 700mm

00001-E0400-12

Hose (oil tank to oil pump) #12, L= 1000mm

00001-E0400-12

Hose (oil pump to bracket) #12, L= 250mm

 

Cooling System

Part No.

Description

Qty.

Remarks

16400-15231

Radiator assembly

1

26.500kcal, heat dissipation capacity

16371-AE801

Pulley, water pump

1

00250-SP023

Belt, V

1

3-5M-750

Intake & Exhaust System

Part No.

Description

Qty.

Remarks

17111-AE801

Manifold, intake

1

91300-SP006

Bolt, stud

8

17177-AE801

Gasket, intake manifold to head

1

17104-AE801

Manifold sub-assembly, exhaust

1

4 into 1 headers

17401-AE801

Pipe sub-assembly, exhaust front

1

Tuned length

17405-AE801

Pipe sub-assembly, tail

1

Tuned length, exiting side of car

17173-AE801

Gasket, exhaust manifold to head

1

Ignition System

Part No.

Description

Qty.

Remarks

19100-AE801

Distributor assembly

1

CDI ignition system

19500-SP002

Coil assembly, ignition

1

19200-SP001

Amplifier assembly

1

Should be mounted inside car

90919-AE851

Cord set, coil & spark

1

10901-SP031-27

Plug, spark

4

#27

10901-SP031-29

Plug, spark

4

#29

10901-SP031-31

Plug, spark

4

#31

05637-00020

Mounting sub-assembly

2

82031-SP001

Harness kit, wiring

1

27411-AE801

Pulley, alternator

1

27060-16050

Alternator assembly

1

28100-15130

Starter assembly

1

Increased power output

Fuel System

Part No.

Description

Qty.

Remarks

21001-SP003

Carburetor set

1

2, twin side draft, Dellorto DHLA48, Throttle bore: 48mm, outer venturi tube dia.: 41mm, Inner venturi tube dia.: 8011.2, main jet: #210~ #230, Air jet: #220~ #240, emulsion tube: #8, slow jet: #65, slow air breather 7850-1, needle valve: #200, oil level: 14~ 18mm, accelerator pump jet: #33

21912-SP001

Insulator, carburetor heat

4

20102-SP001

O’ring

8

20103-SP001

Cushion

8

20104-SP001

Plate

16

94300-SP001

Nut

8

21112-SP003

Funnel

4

23100-SP001

Pump assembly, fuel

2

Electro magnet-type, fuel delivery: >90l//h, pressure. 0.36kg/cm2

00551-SP025

Union

4

05637-00020

Mounting sub-assembly

4

23300-26010

Filter assembly, fuel

1

00001-SP010

Tank assembly, fuel

1

Conforms to regulation, 56.8 liters

70701-SP001

Tank assembly, fuel collector

1

00001-E0400-06

Hose (fuel tank to fuel filter)

1

#6

00001-E0400-06

Hose (fuel filter to fuel pump)

1

#6

00001-E0400-06

Hose (fuel pump to surge tank)

1

#6

00001-E0400-06

Hose (surge tank to fuel pump)

1

#6

00001-E0400-06

Hose (fuel pump to joint T 1)

1

#6

00001-E0400-06

Hose (joint T 1 to carburetor)

1

#6

00001-E0400-06

Hose (joint T 1 to regulator)

1

#6

00001-E0400-06

Hose (regulator to joint T 2)

1

#6

00001-E0400-06

Hose (surge tank to joint T 2)

1

#6

00001-E0400-06

Hose (joint T 2 to fuel tank)

1

#6

00001-E0400-06

Hose (bleeder)

1

#6

00001-E8001-06

Fitting (6# 0° )

3

00001-E8045-06

Fitting (6# 45° )

12

00001-E8090-06

Fitting (6# 90° )

9

00001-E0824-06

T joint

3

00001-E0832-06

Union

1

00001-E0924-06

Nut

1

 

23280-SP001

Regulator, pressure

1

78022-AE801

Linkage set, accelerator

1

For Dellorto

78184-AE801

Bracket

1

Note – noticed unusual sign convention for tolerance on nominal dimensions