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