I didn't put 2 and 2 together and just realised I saw this on EJ9.co.uk :D
Very tidy specimen, Lauren :)

Well, the car drove for the first time in over two years, albeit round the yard to the contained where it's going to live to see out the winter.

It started easily enough, everything working okay. I admit, I did a couple of doughnuts in the yard, only to be requested to do a few more by the guys over other side of the yard who service trucks. So I did a few more. 8)

To be fair they did give me a hand to get it into the container, though I turned down the offer of using a forklift! Thankfully we found some bits of plate steel lying around and used them as ramps to get it in. Was actually quite easy.

Outside the workshop for the first time since August 2012:
[img]https://scontent-a-lhr.xx.fbcdn.net/hphotos-xpa1/v/t1.0-9/10436347_10152422220116467_2575626812542864770_n.jpg?oh=aff9868e9fe32e9e24c412890a0cc69a&oe=550A772B[/img]

The evidence for testing an AE86 does what it's supposed to do:
[img]https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-xpa1/v/t1.0-9/10857876_10152422261226467_6297794961300445917_n.jpg?oh=6b9e185e64ea467db777468142c54b65&oe=553AC755&__gda__=1430761795_1ba4d109a2fce73264c07c39db6c0b6d[/img]

And finally in the container:
[img]https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-xpf1/v/t1.0-9/1891107_10152422264421467_5618563265278237795_n.jpg?oh=3ea61f363a566b032a20265f40653a3c&oe=553DDAC0&__gda__=1425764095_9cc855dd503dc0e65fb7bb89e4e761ca[/img]

Got the water pump, now just need to find some to fit it!

[img]https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-prn1/t1.0-9/10273798_10151993434096467_1388271263975440468_n.jpg[/img]

That's way too much work, Kev and I'm not sure I've kept all the receipts!

Basically I've replaced everything from valve stem oil seals to rings, bearings and all that stuff. I've also replaced any bolts needed too. I've only used Toyota parts for the lot.

Really it's simply a head gasket set, rings, all bearings. The actual part numbers you will need for some of these will vary depending upon bearing size for example, so it wouldn't be that useful and a head gasket set is fairly easy to spec, you just buy the lot.

All you need to do is give you VIN plate to your Toyota parts guy and they do the rest.

You should document a list of all the Toyota engine part codes you've fitted and put it in the technical section for reference Lauren!

Yep, total pain! Water pump is ordered from Toyota, will have it by Wednesday. Won't have an opportunity to work on it though for another three weeks. :(

Have Sprint next weekend, then BHP at Lydden Hill for the May bank holiday.

Oh man that sounds like such a pain! Old cars can be such a nightmare sometimes. You need it running to realise why the struggle is all worth it though, hopefully that happens soon

Balls, had a thought, changing the water pump is a bit of a PITA. All the belts, crank pulley, timing covers and cam belt need to come off to get at the pump.

could take a punt on changing the front, but that can be just as much trouble trying to clean the mating surface of old gasket.

Fun job eh? Put it all back together only to take it apart again!

Exhaust manifold wrap finished finally.

[img]https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-prn1/t1.0-9/10294225_10151966017951467_2608772392334259892_n.jpg[/img]

Mark had an idea to fit all studs to the head for the exhaust manifold rather than two studs and three bolts:

[img]https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-prn1/t1.0-9/1959243_10151966018091467_6597037896927077406_n.jpg[/img]

Trouble was we couldn't get the manifold on. So in the end we reverted back to stock. All new Toyota bolts of course.

Managed to get a downpipe to cat gasket for free from Kwik Fit. Still leaks though. :( So will need a thicker gasket.

I went to put on the undertray which meant the car was close to being lowered onto it's wheels once more for a celabratory drive around the yard, only to find a drip of coolant. Yep, water pump gone. FFS. That won't be cheap and whilst not quite the hardest job in the world to change is a bit of a PITA. So, not much in the way of progress today.

Yep, just a few more jobs to do, then it's ready.

In terms of getting it started I had forgotten a connector which powers the ECU from the loom. Once I'd figured that out we then had fuel and ignition, but as when it fired it slowed the turnover of the engine down. We re-set it to TDC and I took the dizzy off and made a good guess at getting the rotor arm pointing at number one.

Then the moment I turned the key it ran straightaway. The idle was going up and down, but this was quickly traced to a vaccuum hose on the idle up that hadn't been connected. Once we did that, it ran so smooth. :)

It is a real relief it's up and running again and there really isn't much to do get it through the MOT. We've decided that Mark will be the custodian of the AE86 and he is going to use it through the summer.

A big thanks must go to Si for all his bearding help and Tom for doing the build so meticulously well. Though when he repained the crank pulley he covered the timing marks!