4A-GZE into AE92

[ThaChemist]

Hi everyone,

I'm new to conversions - I've got an '88 Corolla GT-S (AE92) and I've been doing the conversion from the 4A-GE to the 4A-GZE. This forum has been very helpful!

The transfer from JDM to North American parts (I'm in Vancouver) went just fine: I switched the oil pans to keep the oil cooler going, flipped the flywheel and transmission and all the rest, and only had to build a custom alternator mount. Mounting the engine and doing the electrical work doesn't look too bad, thanks to diagrams and all that in this forum and other places online.

I've run into a few questions, though, which I'm sure some of you masters could help me with:

(1) I paid for the computer, but they delivered a 4A-GE computer, which I've already got. I know it will run, but don't I actually need the GZE computer for the right fuel mix, emission controls and all that? The switch is legal, but we do have emissions inspections over here (a terrible thing), and I'm having a bit of a tough time figuring out the JDM emissions system as it is.

(2) This is my first supercharged engine, so I'm a bit lost on the intercooler. I've heard the stock intercooler isn't terrific, plus it's a bit hard to find around here. Any recommendations on a good one or a good type? There are lots of wreckers around here, as well. I've got a decent aftermarket high-flow intake and exhaust system, if that makes a difference. The engine is a pretty tight fit, so if the intercooler doesn't fit up front by the oil cooler, I don't mind doing the hood-scoop thing. Also, is it better and/or cheaper to get a piping kit or get some muffler people to bend it for you? I've got access to a full shop and can do welding and all that.

(3) What kind of clutch would be decent to put on it? I'm not looking to chirp third on a regular basis, just something that can handle the added power and a bit of fun. It is a 40+ hp increase, but I'm not likely to be adding more boost in the near future.
I was looking at these online:
"ACT Toyota Corolla Xtreme Pressure Plate w/ Toyota Corolla Street Disc Clutch Kit 277 ft-lb"
or "ACT Toyota Corolla Heavy Duty Pressure Plate w/ Toyota Corolla Street Disc Clutch Kit"

(4) Anything mean surprises in the electrical or other areas I should be aware of?

Cheers!

[ThaChemist]

No one? I can't go wrong with the clutch and I'm still tracking down the computer...

But I do need an opinion on the intercooler (or decent intercoolers in general), anyway. There's space up in front of the rad, by the oil cooler, so I could put a new one there, or, if I want to track down the original cooler, it's not so difficult to do a hood-scoop.

I know custom pipe-work can be done at muffler-shops and that - I was just wondering the expense of it vs. the original and if it's worth it.

[sbyder]

1) use a 4AGZE ECU. Toyota have a reason they made different ECU's for different engines. Otherwise they would have made a "4AG Series" ECU.

2) Just get an ebay cheapy intercooler. A front mount intercooler will always perform better than a top mount so no matter what you get, its still an upgrade. The Justjap coolpro intercoolers are a good unit and cheap. Buy some lengths of stainless or alloy piping and some random bends, tape them all together in the right formation and take them to a welder to weld them up, or buy lots of silicon joiner hose OR buy just buy straight lengths and buy lots of silicon bends. Again, ebay is your friend.

3) & 4) NFI.