Serendipity's comprehensive AE86 J160 swap

[Serendipity]

Nice write up! Are you going to have to fab a custom exhaust header to over come clearance issues?
davew

Hi Dave. Thanks a lot. Which clearance issues? Any AE86 header fits.

[davew]

I thought with a larger trans you would have to off-set the exhaust system?
Davew

[Serendipity]

I thought with a larger trans you would have to off-set the exhaust system?
Davew

The exhaust routes outside the steering column. We haven’t modified the location of the steering column, therefore, we should have no problems using an exhaust designed for a LHD AE86.

You’re likely mixing up fitment issues between LHD and RHD exhaust manifolds. I know from my communication with TODA that their RHD manifold will NOT fit LHD. Moreover, OBX LHD knockoffs are notoriously poorly fabricated and need to be modified to fit properly. A DK member who bought two of the told me that they both fit differently and had interference problems. Lol

[Serendipity]

Step 6: Wiring

The new ECU harness is set up for a GTS, but as my baby was born an SR5, we had to move a couple pins to match.


We had also piggy backed a new pin and plug for the alternator with my SQ order. Time to refresh it.


Double checking the SPAL electric fan wiring. All good in the hood.


There were a few more wires to hook up for the ECU.


There’s also a plug for a CAN BUS, should we decide to add/use a data logger.


Double checked the 12V positive line all the way back to the fuel pump. A-OK.

Picked up a Toyota harness plug with pins for the reverse lights from Tweaked.

AEM Wideband setup.


Grounds Grounds Grounds

An often overlooked part of a refresh or new ECU setup is replacing the grounds. We don’t want to waste any dyno time chasing after things we should have done beforehand.


Battery Ground: 1 gauge with Pico adhesive heat shrink, sealing the soldered union from corrosion. Replaced the OEM M6 bolt with a plated M8.


Engine Ground: 2 gauge with plated M8 bolt into the frame rail.


Intake and trans grounds: 10 gauge with plated M8 bolts.


We're almost ready to crank her over.

[Serendipity]

Step 7: Clutch hydraulics

Not that interesting of a step, but a necessary one.

Rebuilding the slave master.


New clutch soft line.

[Serendipity]

Step 8: Intake filtration

Can't run an engine without a proper air filter.

[Serendipity]

CHAPTER 5: FINAL STEPS

Step 1: Shifter
Step 2: Driveshaft
Step 3: It lives!
Step 4: Tuning

[Serendipity]

Step 1: Shifter

C’s short shifter in place


See how they run…see how they run..

[Serendipity]

Step 2: Driveshaft

Warren has an impressive collection of crusty old shafts. Which one of these princesses will fit the glass shoe?


Our Cinderella is an auto 3TC ('80-'83) propeller shaft/front shaft. It fit perfectly with the GTS rear end and rear shaft! Well well well…


Now to send it to Island Torque Converter to have the propeller shaft built with the new slip and weld yokes.


Back from Island Torque Converter with a Spicer serviceable u-joint and both halves balanced together. The intermedate shaft was already rebuilt a short time ago. The painted yellow marks tell us how to properly phase the driveshaft.


Now to replace the hanger bearing with the one from my T50 setup. Goodbye hammer...


Now to paint it so it looks the part. Black goes with everything.


Installed and ready to rock. Nevermind the ugly catalytic convertor.

[Serendipity]

Step 3: It lives!

-Battery connected and charged: Check!

-Grounds secured: Check!

-Harness connected to all plugs and sensors: Check!

-ECU connected: Check!

Let’s fire her up!


****. Won't start... After all that effort replacing the grounds, it seems the starter isn’t grounding through all the adapter plates and their finishes (starter to starter adapter; anodyzed, starter adapter to mounting adapter; painted, mounting adapter to bellhousing). Haha…

All we need is one more ground...This time from the starter to the engine block.


Started up like a champ. Listen to her purr…