AE86 pt4: Install, break in, oil overheating issues and tune

It was finally time to fit the motor back into the car. I was so keen I worked extra hours the other days so I could take a half day off to do this.

I was so keen that I installed the clutch and flywheel without the sandwich plate on there... I was staring at it for a bit wondering what was missing then it hit me.

This was my first time installing an engine by myself. I was a little worried but it was actually pretty easy to do. I think it helped a lot having the gearbox off as I usually remove/refit engines with it on.

I rarely drink beer but I felt like this was a fitting moment for a cold one.

Wedged a hammer to stop the motor tilting back before the gearbox was installed to avoid stressing the mounts too much.

Accessories fitted and fluids filled we were almost ready to start.

I cranked over the engine with no spark plugs in to prime the oil system with no load on the bearings until I got pressure on the sensor.

I reinstalled the sparkplugs and did a final checkover.

It was time. I crossed my fingers and turned the key. It fired up and was idling smoothly and I was so relieved.
I did the startup procedure of varying rpm till fluids got up to temp, checked for any leaks, timing against the ecu and we were looking good.
I changed the oil and filter then took it for its maiden voyage.

All that was left to do was to complete the running in kms and repeated oil/filter changes. I took it for a few drives being mindful to vary load as it's bad to cruise at light load while running in an engine.

The oil temp always seemed to be pretty hot but it became evident that it was borderline problematic when I took it for a drive at mt donna and it was starting to push 130c.

I think the oil filter was copping heat from the headers and subsequently heating up the oil too.

The mt donna drive completed my running in kms so it worked out timing wise that I needed to change to fully synthetic oil.

Anyways to combat this I made up an oil cooler system consisting of the below:
- Trust Thermostatic Sandwich Plate
- Aeroflow oil cooler core
- EFI Solutions PTFE SS braided lines and fittings

I fabricated brackets to bolt to the bumper boltsand places it in the vent. Could possibly benefit from making ducting but that can be a later on thing.

Temps dropped substantially and the thermostat keeps it at an acceptable minimum temperature when street driving.

Some of you may recognise this petrol station.

And this carpark.

It was finally time for the tune.

Trent working his magic.

I must say it was quite nerve-racking to hear an engine that you built yourself making pulls to redline.

I had to leave before Trent finished but Cat sent me the dynograph when he was finished.

It's nothing crazy power wise but it's also nice to see that I made considerable power gains everywhere compared to the motor prior to the rebuild. It makes me feel a little better about spending so much on a NA 1.6L.

Red Line: Prior to death/rebuild as it was originally tuned here by Trent
Blue Line: Rebuild tuned
Green Line: Tuned with cam gear adjustments

I believe the dip is caused by reversion. It sort of reminds me of vtec in the hondas I used to own.

I left the car overnight for cold start to be tuned and picked it up the next day.

I made it home while smiling the whole way.

Final thoughts? I bought this car as a project and damn was it a fun one.

I learnt so much along the way (apologies to all the people I bugged with various questions) and importantly had a lot of fun.