AE86 Restoration and 4A-GE Component Parts Reproduction Project
The AE86 Levin/Trueno: From boom to culture
While family-oriented models such as the Corolla and Sprinter adopted front-wheel drive starting with the fifth generation, sports-oriented models continued to use rear-wheel drive to allow drivers to enjoy the sporty handling unique to rear-wheel drive vehicles. With this complete redesign, the names “Levin” and “Trueno,” which had previously been reserved for models with DOHC engines, were adopted for all coupe models, while models with DOHC engines were given the “GT” badge.
There were two body styles available, a two-door notchback coupe and a three-door hatchback coupe, powered by either a 1.5-liter (3A-U) engine or a newly developed 1.6-liter DOHC 16-valve (4A-GEU) engine. The GT series initially featured a five-speed manual transmission, but an electronically controlled 4-speed automatic transmission (ECT-S) was added in May 1985. The suspension features a combination of struts and a four-link system with lateral rods. This generation of the Corolla Levin was beloved by fans who preferred the driving characteristics of rear-wheel drive vehicles, and it has become particularly popular since production ended under the name “hachi-roku (AE86).”
29 parts have been reproduced with the commitment to providing complete support for car enthusiasts
We began working on reproducing AE86 parts in parallel with the development of the GR86, the second-generation GR model. AE86 GR Heritage Parts went on sale in November 2021, alongside the launch of the GR86, following repeated consultations with suppliers while listening to the concerns and requests of customers and third-party partners who have supported us over the years.
The first items launched were the rear brake calipers and steering knuckle arms, followed by rear driveshafts. Since then, we have continued to closely communicate with owners by soliciting requests via our website and at events, and as of February 2026, we have reproduced 29 GR Heritage Parts. We work tirelessly with our suppliers every day to continue supplying parts to customers who want to keep driving their AE86s long into the future, rather than just supplying them temporarily, using modern technology, manufacturing methods, and materials and adapting production to our current facilities. Following the announcement, we received comments on social media such as “Car enthusiasts couldn’t be happier,” “This is such a wonderful project,” and “I want to praise the suppliers,” which reaffirmed the immense level of anticipation surrounding this project.
We began selling rear brake calipers and steering knuckle arms in November 2021, followed by rear driveshafts in December. As of February 2026, we have reproduced 29 GR Heritage Parts.
Restoring an entire AE86, including the engine, using Heritage Parts
The second part of our restoration project using GR Heritage Parts and carried out at GR Garage, a dealership under the GR umbrella, is the AE86 Restoration Project. This project was launched to showcase the activities of the GR Heritage Parts Project undertaken by GAZOO Racing and to highlight the maintenance expertise of GR Garage. We restored a 1986 AE86 (Sprinter Trueno GTV) that had been sitting unused in a corner of a warehouse from scratch, with the engine (4A-GE) handled by Toyota and the body restoration carried out by GR Garage Mito Keyakidai, operated by Ibaraki Toyota.
The 1986 AE86 and 4A-GE that had been sitting in a corner of the warehouse
“When I first saw the AE86, it was covered in rust. It was so bad that I wondered if it could even be fixed.“ (Hironori Tanaka, Manager of GR Garage Mito Keyakidai)
The restored vehicle is a 1986 Sprinter Trueno GTV. It was a non-running car that had been sitting in a warehouse for five years. It was severely rusted throughout, with holes in parts of the floor, and movable parts such as the rear door and moonroof had been removed. Fortunately, when we reassembled the parts that had been stored separately, there were no missing exterior parts. The removed seats, though very dirty, were in good condition with no tears. We replaced the aftermarket wheels, steering wheel, and exhaust manifold with used genuine parts during the restoration.
Removed rear door and moonroof
The vehicle restoration work was carried out by three engineers from GR Garage Mito Keyakidai and two master craftsmen from Ibaraki Toyota TH Center. The process spanned a wide range of tasks, including assessing the current condition, disassembly, sourcing necessary parts, painting the exterior, and reassembling the suspension and engine, all of which were carried out with great care.
Removing and inspecting vehicle parts
We removed the front and rear bumpers, lights, engine, transmission, differential, suspension, interior, and windows to strip the body down to its bare frame, then inspected every nook and cranny. We repaired any areas affected by corrosion. The inner fenders had been damaged by corrosion, so we modeled and built new ones using parts salvaged from a Hiace. In areas without existing parts, such as the lower edges of the door panels and the B-pillars, the team overcame challenges through skilled craftsmanship, such as shaping and welding sheet metal. The interior was thoroughly cleaned using Toyota’s high-quality Marumaru Clean car wash service, restoring it to a pristine condition. During the painting process, we began by painting the lower half of the body black and the upper half white. We thoroughly removed rust from the suspension and brake component parts, and replaced all available genuine parts, including GR Heritage Parts, with new ones.
“We had ordered the necessary Heritage Parts in advance. For those restoring cars, the time spent scouring part lists to find parts is also fun.” (Takeshi Tomiyasu, Ibaraki Toyota TH Center)
Using cylinder heads and cylinder blocks reproduced with new added value
The engine (4A-GE) installed in the vehicle was overhauled in-house at Toyota. It used prototypes of the cylinder head sub-assembly and cylinder block sub-assembly, for which orders began in February 2026. These parts are the result of a painstaking effort to modernize the engine, retaining its original design and specifications while incorporating the latest simulation technologies, manufacturing methods, and materials.
“When we exhibited at the Tokyo Auto Salon and spoke with customers, we received various comments such as, ‘This part breaks.’ Seeing that many customers were struggling with this issue, we began to explore the possibility of reproducing the 4A-GE.” (Tomoya Oshima, Project Manager, ICE Development Division)
The original engineers had since retired, and only the blueprints remained. Therefore, Toyota engineers, led by the ICE Development Division, used 3D scanning to precisely measure the original parts. They then created digital CAD drawings based on the AE92 model, which had been the most frequently requested by customers during conversations at events. In addition to refinements such as reducing the unevenness of the intake ports, honing the cylinders, and adding knock pins to the cam caps, as many customer requests as possible were incorporated into the cylinder head and block, including intentionally increasing the wall thickness of parts of the intake and exhaust ports to leave room for tuning.
“Customers clearly have a deep passion for these parts, so we wanted to create something even better while adding modern value. Since the only thing left were hand-drawn blueprints from 40 years ago, we created 3D CAD models based on them. It was a real challenge because CAD relies entirely on calculations, and sometimes dimensions wouldn't match up, or numbers wouldn't add up correctly. We created these parts while constantly puzzling over how to solve such issues. I hope customers can enjoy driving their AE86 for 10 or 20 years to come.” (Tomoya Oshima, Project Manager, ICE Development Division)
Applause erupting the moment the engine started Applause erupting
We identified parts that could be reused within Toyota, and, while paying tribute to the ideas and ingenuity of our predecessors, worked as a single team to carry out everything from parts cleaning and assembly to testing. We also modernized various parts, including piston rings with improved sealing and friction performance, crankshaft bearings with resin coating for improved friction performance, and head gaskets with modified materials and structures for improved sealing performance and reduced indentation. The project was infused with a passion from Toyota that rivaled that of enthusiasts; when the engine fired up, applause erupted in the control room.
We brought the 4A-GE, assembled using the new cylinder head and block, to GR Garage Mito Keyakidai, installed it into the AE86 restored by the engineers, and started the engine. The sparkling new muffler produced the dry exhaust sound unique to the 4A-GE, exactly like the original AE86 of that era.
“Watching an old car get restored makes me appreciate sports cars and cars in general. I was truly moved!” (Yu Tamura, GR Consultant, GR Garage Mito Keyakidai)
This AE86 made its debut at the FUJI 86/BRZ STYLE 2025 with Initial D event held in September 2025. It showcased the future of the AE86, following in the footsteps of hydrogen and BEV models, and attracted significant attention both in Japan and internationally. GAZOO Racing will continue to focus on reproducing Heritage Parts using the latest technology to ensure that all car enthusiasts can enjoy driving their beloved cars without worry and with a smile on their faces.
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