feroza slow 4-age buildup

[rentonpeter]

although it may not sound like it at first yesterday was a very good day for me. i bought the wife a new car. Why would buying the wife a new car be good for me? well, she was so happy that she is getting a new car i can use the old motor from the other for an engine swap into the feroza! (i would have taken a photo but she took it to work today) The engine in question is a very tidy 4age bigport TVIS (TVIS gives more lowdown torque). i know there may not be too much tech in this article however here may be something new.

As toyota and daihatsu engines are similar the 4age is almost identical in size to the feroza motor and will be a relatively easy job. The other great thing about the 4age is it can handle more power (and i will be strapping a turbo to the side) and DOES bolt up to a hilux 4cyl gearbox with an off the shelf adaptor (which i have sitting in the shed, minus the bellhousing). so stay tuned for some updates along the way (will most likley be a longish journey as will be doing a rebuild (i have another one on the go at the moment too), making the turbo manifold, adding a megasquirt ecu and doing all the fab myself)

on other news got myself a free engine and box for my sierra yesterday too. 1.6 vitara motor (also getting rebuilt and turbo'd), a vitata box with gears.

i thought id give a quick few photos of my fez current condition and my sliders which were asked for some photo's of.







also a photo of the free engine! (the head is in a different box)

[Box Feroza]

This is great. If a 4ag fits easilly, you being the brave one to try it. A 4AGZE will also fit.

Hope all goes well for ya. Where can you get the bellhousing adaptor for the 4cyl hilux box? Can you tell I am getting a bit exited here.
Finally Feroza owners will have a decent and relativlly inexpensive motor and box combo.

Thanks for any info.

Cheers
Lukas

[chugga]

Good luck with it as the stock 1600 is way under powered for the Feroza.

[rentonpeter]

cheers guys. dellows do an adapter for the g5- series hilux boxes to the 4age engine (among others) and they are in NSW. there are also a couple of other companies in NZ that do it as well and another guy from Malaysia who i got told can get me one for $400. The bellhousing has the same bolt pattern and size as the w5- series boxes from some of the supra's so are a common box used by drifters who use the 4age which makes parts pretty readily available.

On another note. got myself a pair of hilux diffs (picking them up on the weekend) for $250 for the suzi and may look at trying to fit the hilux rear center into the feroza housing (with a bit of modifying of course) with some new axles. Will be on the hunt for a hilux IFS front diff as i am sick of the welded one thats in at the moment as i broke another cv on the weekend.

[MightyMouse]

You have though about the consequences of getting caught with this much work done to the vehicle haven't you ? Done without an engineers cert it will NEVER GET BACK ON THE ROAD... EVER.

I'd talk to an engineer first, and wouldn't get my hopes up. If your simply running 31" tyres its not going to be legal let alone all the other stuff......

It might not seem a big deal, but just think about it - the consequences are significant.

[rentonpeter]

all ready pre-approved by my engineer. (he was going to let me put a 3rz-fe with hilux box in before i changed my mind to this). everything im doing will be legal (as far as the body lift, engine, box and diffs) The engine capacity is staying the same and the increase in power is not enough to warrant any problems with the brakes (may be upgrading to disc rear anyways). the gearbox and differentials are not a problem in any way either. I am not lifting the vehicle any more than it is now (which is currently legal) and i just have to take the vehicle to QLD transport for them to run it over the pits to approve the body lift.


As far as tyres; be running road 30's around town and 32's off road. 30's are not technically legal but are small enough to look it and i still have a set of stock tyres if i need to switch back if i need to.

should all be under control and above board

[rentonpeter]

got a bit of work done on the weekend. removed the engine from the fez and put it in my mates g200 charade with the applause cam again. runs great. also ordered my gearbox adapter from dellow automotive (cost $500) and got a turbo (ct9) to strap to the 4age will be removing the 4age from the corolla this week too so can start striping it for the rebuild. i got a hold of some more funds so will be speeding up the process a bit. some pics of the removal and install will follow soon when i take them off my mates camera. also will post a list of parts from the fez that im selling (for cheap)

[rentonpeter]

ill update this list a bit more when i work out what i want to sell but here is a start.

- Lukey extractors (about 12 months old) -$120
- starter motor - $40
- Gearbox (has a rattle under load but i replaced all the bearings) -$180
- injected manifold (would suit someone converting from carby) $100 (inc. injectors and sensors)
- Alternator - $80
- ecu - $60

The loom may also be for sale too, just want to check to see if i need to splice from any of it

ALSO. Parts are located in BRISBANE. local pickup would be preferred, however can post if you ask nicely and pay for it

[wacky]

I'll take the extractors, PM me asap

[rentonpeter]

some pics

charade engine coming out


Feroza engine out



We had to swap all the accessories and manifolds


The clutch is also different from a feroza or applause to a charade (the charade one is about 10mm smaller diameter)


ready to go back in



just about ready to go and needing a final clean


my shed is so full of junk and car parts at the moment


more photos of the 4age removal will be coming soon and the rebuild. plenty of parts are still available from the old motor (including sump) so if you need something just ask.

[Tzi]

Did you put the feroza engine in a charade?

... maybe I missed that bit...

[rentonpeter]

yes. well actually it was an applause motor to start with so it worked well. I have a 4age for mine with a ct9 turbo for it. hopefully i will get some work done for it tomorrow and take some photo's

[rentonpeter]

unfortunately i have been held up, yet again, in the project. Some guy who was supposed to be buying one of my other cars to help fund the project turned out to be a scamming bastard who was trying to steal the car and rob me. Fortunately i didn't loose any money but i also didn't gain any or sell my other car.

this however only slows the process down a little (as does study which is a pita at the moment). Some news on the car is that i managed to pick up a IFS hilux diff and cv shafts for $150 today and it is now sitting on my shed floor with all the other parts. i levitated it under the car and worked out the mounting which seems to be pretty straight forward. The only downside to this is the diff has to be mounted approximately 10 mm lower than it is now to clear the steering linkage, but the gains of an airlocker and more solid diff to turn 32 inch tyres will help to make up for the small clearance loss. Hilux inner cv's will be retained and new shafts will be manufactured to match the feroza outer cv at the right width. Even though higher stress levels will be put through the outer cv through turning larger tyres it will still cause less stress than the welded diff did previously as it was under load constantly. As can be expected i will be manufacturing a pretty solid bash plate to cover the diff to avoid unwanted rock contact. So the project is moving.... just slowly......

Here is a pic of the new diff


Here is the 4age sitting on the floor, waiting for me to do something with it. The manifold required a cut and shut job to switch throttle body orientation. Although this may not look as pretty as a stock RWD manifold it is significantly cheaper. the current sump will also require modification for RWD orientation and to clear the new diff location.

the waiting engine :(


I will give another progress update when i have done something constructive worth noting.

[rentonpeter]

hi guys, this isn't really huge progress but at least i had the time to do something. Got the engine onto the stand and started to strip it down. I actually got a pleasant surprise when i pulled it apart. The motor has done nearly half a million km's in the corolla. I knew it had a freshen up at some point but its still in great nick. there is no lip on the bores, valves still seem in good nick, no gunk in the motor at all. the bearings also still looked great as did the crank and cams.



i didn't take any photos of taking the accessories off because im sure nobody really cares about that stuff. not that they probably care about seeing this too much either


the head still looks pretty good. going to get seats done on valves and stem seals done but the guides seem to be ok.


the bottom end looked pretty good as well




there is a bit of reflection from the camera and they need a hone but seem ok apart from that.



the pic of the bearings didn't really turn out but you can see the condition of the pistons anyways and I'm pretty happy with it.


Even though its in pretty good shape i'm still going to be putting a complete rebuild kit through it just to make sure its reliable. I don't want to be pulling it out again any time soon.

I also dropped the block into the engine bay with the sump attached. It will clear the hilux diff location even though the sump bulge is at the front. I will have to relocate the drain plug as it is currently on the left side and will move it to the back so i wont be dropping the oil on the diff.

The engine mounts will need to be relocated about 150mm further back and the cross member for the gearbox another 300 mm further back. Because the distributor is on the side of the engine instead of the back the motor will be sitting about 100mm further back in the engine bay, leaving me more space for a better radiator and space to mount good thermo fan. One problem i found is the gearstick location is about 70mm too far forward so i need to work out some sort of shift linkage. if anyone has any idea's or knows someone else who has done this please let me know. cheers guys

[rentonpeter]

i know it has been a while since i have posted... however today i got a small job done that i wasn't keen on doing. I converted the cable clutch to a hydraulic setup. as many of you keen readers would know, i am installing a hilux gearbox, which runs a hydraulic setup which is superior to a cable setup.

The bell housing i am using uses a corolla slave cylinder as well as corolla clutch fork. As this was the case i used a .... you guessed it.... corolla master cylinder as well. The clutch pedal on the corolla (ae82) is mounted separately and can be removed easily; only being held on by the master cylinder bolts and one 8mm bolt. The feroza clutch pedal is part of the brake pedal box and the lower dash section as well as the instrument cluster ( to remove the speedo drive cable) and the steering column require removal. the easiest way to remove the column is to unbolt the two 8mm bolts near the steering wheel on the shaft underside and the four 6mm bolts holding the cover to the firewall and slip the shaft off the slide joint near the steering box.

Once both were removed i was left with this:
(note that the clutch pedal had already been removed from the pedal box from the feroza)

Once removed the toyota pedal assembly was trial fitted to the feroza and its required position marked. I chose to use one of the existing mounts for the old pedal box as it gave me an easy mounting point and a fairly clear position in the engine bay to mount the master cylinder body. The old clutch pedal mounts were removed and the top left section of the pedal box trimmed away so the corolla pedal assembly could be added.



The corolla pedal assembly was then tack welded to test its position and once checked was welded and reinforced to restore strength to the original bracket.

This meant the pedal was in the incorrect position for the car so both pedals were cut:

and grafted in the appropriate area to allow for correct pedal travel as well to restore its original position



A mig welder with argon shield gas was used to ensure a strong permanent weld.


The finished product back in the car.

it was starting to rain by this point so i didn't get to take any photo's of the firewall side but will next time i am doing some more work on the car (which will be fairly soon).

Not a huge job but one that needed doing on the way to finishing the project.

[F300tazmanian]

Nice project!

I'm also thinking of that

[rentonpeter]

thanks for the interest in the build.

I haven't had a huge amount of free time at the moment and when i have its been raining so not a huge amount of progress has been made unfortunately. I did get the cylinder head reconditioned and get the parts i needed for the rebuild. I also stripped, cleaned and painted the block. It was also then honed, deck face cleaned and all threads cleaned and retapped out. As everyone knows photo's are so much more entertaining than words so i took some of what got done.

Here are a couple of the engine bay side from the hydraulic clutch setup.


I still need to clean up some of the panel work but fortunately the original brake lines still fit around the master cylinder.




The block after painting


Honed and cleaned


the cylinder head after its reconditioning. The guides were replaced, valves cut and new seats, refaced, crack tested and cleaned.


Looks nice and clean now, unfortunately (and fortunately) it will be covered in dirt soon


My new parts for the rebuild


Hopefully i will have some more done by next weekend (hopefully the engine will be together) and i will have some more progress to report.

[tufferoza]

mmmmm... 4age goodness.

[BORN2RUN]

hows the build process coming along brother?

[rentonpeter]

hey mate. cheers for following along with the build. unfortunately i have had a bit of a slow time with the car in the past week or so. have been busy between uni and work and everything else. I will definitely have a update in the next week. The project is definitely still progressing but i don't have anything new to show you guys yet.

[BORN2RUN]

its cool cuz. have fun n yeah hope to hear the next update.

[tufferoza]

i hope this project is still moving?

any updates?