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Re: DIY: swapping an AE92 4AGZE into a zenki AE86 GT-S
Posted: Mon Apr 11, 2011 1:29 pm
by 4agshoob
Re: DIY: swapping an AE92 4AGZE into a zenki AE86 GT-S
Posted: Mon Apr 11, 2011 1:31 pm
by 4agshoob
Re: DIY: swapping an AE92 4AGZE into a zenki AE86 GT-S
Posted: Mon Apr 11, 2011 1:38 pm
by 4agshoob
now , if your car isnt at stuper stance like mine , you wanna spring for either of the following , to mount your alternator....
1st gen 4afe
4agze aw11
4ac
Re: DIY: swapping an AE92 4AGZE into a zenki AE86 GT-S
Posted: Mon Apr 11, 2011 1:39 pm
by 4agshoob
now that the most confusing part of this swap is over. all i can do is try and answer questions. i know your thinking "what the hell , i thought this was a DIY". but when it comes to aftermarket front mount intercoolers, and piping , or choice in aftermarket radiator and mounting, it pretty much is a DIY. replacing a fuel pump with a higher volume unit , is pretty basic knowledge. if you didnt use anything aftermarket, and followed this guide: after you swap fuel pumps, hold your breath and turn the key.
with that ill post a few pics, i personally only have a few things left:
swapping fuel pump
after market oil cooler
changing the oil
filling with coolant
fuel return line (but im using an aftermarket ADJ. FPR)
bolt shifter into tranny
get new exhaust put on
and a few vacuum lines.
as i go thru and attemp to start the car , and see anything i miss , ill go back and edit it in in the appropriate sections of this DIY.
Re: DIY: swapping an AE92 4AGZE into a zenki AE86 GT-S
Posted: Mon Apr 11, 2011 7:27 pm
by 86boy
CRAZY MAD PROPS!!!
HOLY SHIT!!!!! <--- not sure if it's ok to swear but I am because it deserves it!!!!!
This is one of the most in depth swap guides I've seen! step by step with wiring even! I sir bow down to you for pure RESPECT!
yes I'm excited to see this, because I was starting to get a little worried.... I've never swapped a different engine (not there originally) into a car. I've done my fair share of swapping the same thing. I was thinking there was a LOT more to this swap. You just gave me all sorts of encouragement...
Re: DIY: swapping an AE92 4AGZE into a zenki AE86 GT-S
Posted: Tue Apr 12, 2011 12:55 am
by 4agshoob
well , you still gotta change out the fuel pump to larger to stock to compensate for the larger demand of fuel........change radiators..(im using a civic shorty aluminum , with dual core , and 12" electric fan.) you dont have to do a front mount , but it helps keep the engine bay temp down.running an oil cooler is a good idea, and i dont mean the stock one , but im sure it would suffice but ill be using after market. in that case you either swap the oil pan for the 16v one with the oil inlet already there , or drill and tap the gze oil pan , and fit a NPT fitting to it , and use the OEM sandwitch plate from the 16v.
and i myself have encountered a bit of a problem....everything comes on , everything is getting juice , and the motor turns over , im getting spark....but for some reason my fuel pump isnt kicking on. i know its probably as simple as 2-3 wires, and i know where the confusion is...the ae92 4agze has its own seperate fuel pump relay on the engine harness , as well as a COR. but....the ae86 controls the fuel pump from the COR on the ae86 chassis.....so , i think i need to run the blue , and blue/black wires from the somewhere to somewhere else....if i cant figure it out , ill just put my fuel pump on a switch...
Re: DIY: swapping an AE92 4AGZE into a zenki AE86 GT-S
Posted: Tue Apr 12, 2011 9:29 am
by 86boy
Yes sir!
I knew about the few other things (fuel pump, radiator, oil cooler, etc). there's always one or two things I miss or run into similar to the problem you have encountered! Which I was going to "upgrade"/swap out before I started to tear it down.
When I did my bluetop 4age swap into my car. It would start and run, but only for a few seconds then die. Stupid ground wire for the air sensor was broken in the harness. Fixed that and then ran like a champ.
oh btw what oil cooler are you planning on running?
Re: DIY: swapping an AE92 4AGZE into a zenki AE86 GT-S
Posted: Tue Apr 12, 2011 1:03 pm
by 4agshoob
a 14-row unit from a USPS mail truck, steel braided line, etc. it actually was a transcooler........i get them them second hand with their lines all the time. when the trucks reach 60k miles for their first major service interval, the trans is flushed , and new cooler fitted, so ive always got about 4-5 of these things all the time, they are one of the items i regularly sell.
Re: DIY: swapping an AE92 4AGZE into a zenki AE86 GT-S
Posted: Tue Apr 12, 2011 5:43 pm
by 4agshoob
ok , i got the fuel pump problem figured out. i turn the ignition on , and ground my multi meter , then go to touch the green/red wire on the COR and then the COR clicks on and my fuel pump comes online. and its only getting 4 volts......strange really. so i jumpered the green/red with a chassis ground to help it ground.
Re: DIY: swapping an AE92 4AGZE into a zenki AE86 GT-S
Posted: Tue Apr 12, 2011 6:24 pm
by 4agshoob
Re: DIY: swapping an AE92 4AGZE into a zenki AE86 GT-S
Posted: Wed Apr 13, 2011 6:00 pm
by 4agshoob
first start vid......
http://www.youtube.com/watch?v=jkvi6LMoyxI" onclick="window.open(this.href);return false;
Re: DIY: swapping an AE92 4AGZE into a zenki AE86 GT-S
Posted: Wed Apr 13, 2011 8:12 pm
by 86boy
werd! Take it for a test drive yet? or is the interior still all tore apart?! lol
Re: DIY: swapping an AE92 4AGZE into a zenki AE86 GT-S
Posted: Wed Apr 13, 2011 8:16 pm
by 4agshoob
yeah , i dont wanna tie up anything or reassemble anything till i know its gonna run absolutely right. havent test drove yet, the registration is expired, no insurance , and exhaust isnt back on yet.
Re: DIY: swapping an AE92 4AGZE into a zenki AE86 GT-S
Posted: Wed Apr 13, 2011 8:23 pm
by 86boy
fair enough. At least it runs! That's always a plus. Where did you get the piping for the intercooler?
Re: DIY: swapping an AE92 4AGZE into a zenki AE86 GT-S
Posted: Wed Apr 13, 2011 9:58 pm
by 4agshoob
ebay....cxracing
2" piping...the 4agze is finnicky with manifold pressure irregularity's. i think the intercooler is too big , but its the only one i could immediatly purchase, that would remotely fit without butchering the car up, plus by having it mounted the way it is , it keeps piping to a minimum........so i have 2 plans of action:
1. i have a 27"x6"x2.5" intercooler with enlogated end caps and 2.5" openings. im gonna have the welding shop cut the opening flanges off, and cap them , the weld me 2 2" pieces of pipe onto the back side of the end caps , pointing towards the engine bay. kinda like an srt4 intercooler. if i do that , it will fit perfectly between the headlights, and also give my radiator more cool air.
2. the intercooler thats in it now is 18"x12"x3", if you look at the pics above youll notice i have it at a 45 degree angle to allow air to pass thru the radiator a little more than if it were flush mounted against the radiator. im basically gonna have both end caps cut in half across the center, then cut off. then basically im gonna take the non outlet side of the end cap, flip it to the other non outlet side , and weld it back on like an end tank. then on the other side weld a block-off plate against the outlet where its cut , and then weld the other outlet on , on the other side of the block of plate. so that way it will be a single side entry and exit intercooler, and really reduce my piping.
the only other thing i think im gonna change , is the manifold entry pipe that bolts to the intake manifold , basically weld on a different elbow, then i have a 90* 2.5"to 2" boot leaving the s/cgoing forward. ill probably end up making this hard pipe as well.