Installing Engine Attempt 2

Connected clutch line to the bellhousing conversion, it fitted well:

Fixed the torn off connector, still need to fit coil packs:

Found the first home for the ignition electronics (then noticed this would foul where the battery sits):

To solve the steering column/rack problem, I couldn't get the intermediate shaft out, so decided to cut and extend the column just after the first universal joint:

I got a new solid shaft welded in between the cut parts to increase the length to the required amount, I gave it a quick paint job to make it look nicer:

The front offside caliper was replaced with a new unit due to the torn bleed nipple:

KOYORAD radiator and Cusco Engine mounts arrive!

You can see a slight difference between the KOYORAD and standard radiator!

There is also difference between standard and Cusco engine mounts, the pin is at a different length down the mount which means the engine is sat lower, to lower the centre of gravity a bit. As well as being new rubber rather then very old rubber, it should help give the original more solid feel too,.You can see my original mount was splitting too.

Unfortunately and something not really documented is the KOYORAD isn't as well fitting as it makes out to be. Sure the pins at the bottom (still need original rubber mounts for) are aligned well. But the core being bigger needed the end cut off to fit through the AE86 front chassis.

I thought getting a replacement brake master cylinder would be easy, the first attempt at one showed it was for a left hand drive AE86 so I did not purchase it, the second one was below, a completely different style for a early AE86 (1983-1985) it turns out I have a later AE86, so this didn't fit (the later one is supposed to be superior but from what I've seen it leaks more)

For the third attempt I got a whole booster/servo and master cylinder combination so fitted it together rather then seperating it, gave the new one a clean up and installed, although it seemed to leak too :(

I fitted the coil packs in the original designed position, it just about fits but was quite tight to get in:

Belted up the alternator as the one which came with engine was designed to pull the power steering pump as well as the alternator:

 Fitted the wiring loom through the firewall:

2nd home for the ignition electronics (then realised it would foul anywhere to put the oil filter relocation kit:

I fitted the fuel in line on the fuel rail, but this still needed to be connected to the fuel filter, I also connected up the fuel out with a silicone tube:

Whilst working on the fuel filter I decided to undo it, and to my horror I completely twisted the metal fuel feed hose into it!

The oil cooler was next to go on, I made a quick bracket up to hold it in a decent position, it goes roughly where the old air conditioning radiator used to go (later realised this had to be moved as it is where the horn should be bolted too and my horns were where the headlamp needs to go!)

Next I decided to fit the radiator in. It wasn't as easy as a straight swap like KOYORAD implies, I needed to put extentions on the top rad holding mounts, which has made it difficult to now hold down the bonnet catch in place properly.

It was at this point I noticed the flaw with the horns/head light and oil cooler bracket too, the bonnet wasn't shutting properly and I realised I missed a bit! the front brace of the top crossbar (don't think that is correct terminology) where the radiator is mounted, so cleaned this up and installed:

Headlights and foglights were then cleaned up and put on to give the front some of its original character back :D

With the lights on I could install the oil cooler properly and see what holes I had available to bolt a bracket too. I ended up coming up with 2 seperate bits of metal, I later added an additional bracket to the lower part of the cooler too:

I got some flexible radiator hoses and cut to size to connect the water lines up to the engine, and did a couple of fluid fills on the engine:

Fitted a oil catch can to help clean up the intake from any oil from the head:

Finally I replace the fuel filter with a in line one and replaced the silicone hose from the return line with a proper fuel hose and fitted new fuel lines to the intake:

In theory with the ECU and battery plugged in, the engine could be started now with the fuel lines attached, so I gave it a go...