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 Rank: Elite        Groups: registriert, Registered Joined: 20/03/2011 Posts: 2,356 Points: 7,122 Location: UK
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Pack 17 Contains stages 58-60
Stage 58 contains:
A sprue of parts, Turbocharger L2, L3 & L5
Assembling the turbocharger (L)
Cut off the tab marked L on the turbocharger (L-3) with a cutter.
Test-fit this part to the underside of the turbocharger (L-2), so that the yellow-arrowed pin fits into the red-arrowed notch.
Separate the parts, and scrape away some of the paint from the indicated section of each one.
Also strip the paint from the central bar on the outer face of the turbocharger (L-3). Be especially careful with thin parts such as these – using the unsharpened edge of the cutter may help prevent any damage to the part.
Apply plastic adhesive to the stripped section of the turbocharger (L-2), then join this part to (L-3) as in the test fit and hold for 2-3 minutes.
Place the sprue of parts face down on a cutting mat, and carefully remove the indicated items.
Test-fit the turbocharger (L-1) into the central space in the turbocharger (L-2), so that the square-shaped sections fit neatly together.
Use a toothpick to push the part into place.
Dismantle the parts, use the toothpick to apply a small amount of instant adhesive to the central space of (L-2), then reinsert (L-1) and press it into place for about a minute.
Next, test-fit turbocharger (L-4) into the centre of turbocharger (L-3).
Very carefully scrape the paint from the central notch of the turbocharger (L-4).
Apply a little plastic adhesive to the stripped section of (L-3), then fit (L-4) into place and hold it there for 2-3 minutes.
Connecting the fuel pipes
You will need to remove all six fuel hoses from the sprue for this step, but as each part is very small, it is better to remove them one by one as you proceed with the assembly
Test-fit the first fuel hose (L) to the left-hand injector, as shown. The arrowed pin at the tip of the hose will fit into the circled hole.
When you are happy with the fit, remove the part, dab a little instant adhesive into the hole, then reinsert the hose and hold it in place for a minute.
Note the angle at which the hose should sit.
Repeat this for all the remaining left fuel hoses.
Now repeat for the three right-hand fuel hoses.
When the parts are fitted and the adhesive has dried, lower the fuel hose assembly onto the top of the engine block. The pins in the underside of each fuel hose should fit into the holes in the top of the fuel injectors. Begin with the left side.
The fuel hoses will fit around the injectors.
Lower the fuel hoses in from the back, using tweezers to help you guide them in.
Hold the parts in place, then dab a little instant adhesive into the circled hole, then press the first fuel hose socket into it and hold for a minute.
Repeat for the other two hoses.
When all the left-hand hoses are in place and the adhesive has dried, repeat this step to fit the hoses on the right of the assembly.
Once the hoses are fully dry and secure, you can turn the injectors so that the arrowed sections are angled.
Stage complete
This stage is now complete. The fuel hoses are attached to the injectors at the top of the engine block, and the left turbo is assembled.
Warthog attached the following image(s):
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Rank: Elite Groups: registriert, Registered Joined: 20/03/2011 Posts: 2,356 Points: 7,122 Location: UK
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Stage 59
Stage 59 Contains:
Exhaust base (L&R) Turbocharger R2, R3 & R5
Assembling the turbocharger (R)
Assemble the right turbo charger as you did with the left turbo charger.
Attaching the fuel pump and header tank hose to the engine block
Prepare the engine block assembly (Stage 58) and sprue of plastic parts (Stage 57).
With the sprue face down on your cutting mat, carefully use a cutter to remove the fuel pump and header tank hose.
Test-fit the fuel pump by pushing its yellow-arrowed pins into the yellow-circled holes, and inserting the end of the pipe into the hole on the 3-way union.
Remove the pump and dab a little instant adhesive onto the indicated area between the pins. Refit the pump and hold it in place for about a minute.
Dab the red-circled hole on the 3-way union with instant adhesive, then place the end of the fuel pump pipe into it, as in the test fit, and hold for a minute while the adhesive dries.
The 3-way union is not backed by a solid structure, so use your thumb to support it while you hold the parts together.
Now test-fit the header tank hose to the front of the engine block by fitting the pins into the corresponding holes beneath each of the water pumps, as indicated here by the arrows and circles.
For the test fit, do not push the pins in too hard, to prevent them becoming damaged during adjustment.
Remove the header tank hose, dab a little instant adhesive into each hole, then reinsert the hose’s pins and hold the part in place for a minute.
Stage complete
Your model’s right-hand turbo is assembled, and the engine block has its fuel pump and header tank hose fitted.
Warthog attached the following image(s):
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Rank: Elite Groups: registriert, Registered Joined: 20/03/2011 Posts: 2,356 Points: 7,122 Location: UK
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Stage 60
Stage 60 contains:
A Sprue containing the wastegate and turbocharger parts. An Alan key and screws.
Assembling the left and right wastegates
Place the sprue of parts on your cutting mat, and separate the indicated parts by cutting across the red lines carefully with a cutter.
Be careful not to damage the mounting pins (yellow arrows) of the wastegate fronts, as these are necessary parts of the components, and leave the blue-circled block intact on the end of the right wastegate pipe rear (see the Tip box on the previous page).
Test-fit the wastegate rear (L), the left cooling pipe rear and the wastegate front (L). The cooling pipe sits in the arrowed groove and should be able to rotate freely.
Scrape the paint away from the indicated surfaces of the wastegate front and rear parts.
Apply some plastic adhesive to the stripped section of the wastegate rear.
Fit the wastegate front and rear and the cooling pipe together again, and hold in them place for 2-3 minutes.
Make sure that the pipe is still able to rotate freely, then leave the parts aside for at least an hour while the glue dries.
Repeat this step to assemble the right wastegate, again ensuring that the pipe is able to rotate freely.
Remember to leave the end block on the cooling pipe of the right wastegate, to help you tell which is which.
Attaching the oil/water heat exchanger to the engine block
Test-fit the oil/water heat exchanger to the side of the engine block,
When fitted, the oil/water heat exchanger should sit flush with the bottom of the engine block.
Remove the heat exchanger, dab some instant adhesive to the indicated areas on the engine block’s side, then replace the part and hold it in place for about a minute.
Fitting the check valve and the water inlet pump pipe
Prepare the header tank (Stage 53) and the sprue of plastic parts (Stage 57).
With the sprue of parts face down on your work surface, remove the check valve and the water inlet pump pipe with a cutter.
Take care not to cut off the short pin on the water inlet pump pipe (yellow arrow), because this pin will locate the pipe in the header tank.
Use tweezers to test-fit the check valve into the circled hole in the top of the header tank, as shown.
Dab the yellow-arrowed pin on the check valve with instant adhesive, then reinsert it into the tank and hold it in place for about a minute.
Now test-fit the water inlet pump pipe into the yellow-circled hole on the upper edge of the header tank, as shown.
When you are happy with the orientation and fit of the water inlet pump pipe, remove it, dab it with instant adhesive, then replace it and hold it in place for about a minute.
Fitting the throttle sensors and oil filter joints to the plenum chamber
Place the sprue of parts saved from Stage 57 face down on your work surface, and carefully remove the left and right throttle sensors and the oil filter joints with a cutter.
Remove these tiny parts one at a time, as and when you need them, to avoid losing any of them.
Test-fit the right throttle sensor into the slot at the front right of the plenum chamber as shown.
Remove the throttle sensor, dab some adhesive onto the side of the slot marked below in red, then refit the sensor and hold it in place for about a minute.
Repeat the process to fit the left throttle sensor into its slot.
Your plenum chamber is now fitted with its two throttle sensors.
Test-fit the first oil filter joint by slotting it into the indicated hole on the engine’s lower front left side.
When you are happy with the fit, remove the part, dab a little instant adhesive onto the contact area, then refit it and hold it in place for about a minute.
Repeat for the right-hand oil filter joint.
Stage complete
At the end of this stage, your left and right wastegates are complete, and your engine, its plenum chamber and the oil/water heat exchanger are nearing completion.
Warthog attached the following image(s):
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Rank: Elite Groups: registriert, Registered Joined: 20/03/2011 Posts: 2,356 Points: 7,122 Location: UK
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Pack 18 contains Stages 61-64
Stage 61
Your parts with this stage: Exhaust pipe front (L) Exhaust pipe rear inside (L)Exhaust pipe rear outside (L)
Attaching the header tank to the engine block
Test-fit the header tank to the engine block. Note the positioning of the pins and holes as shown.
When you are happy with the fit, remove the header tank and apply a little instant adhesive to the indicated sections, using a toothpick. Replace the tank as in the test fit, and hold for one minute.
Next, test-fit the plenum chamber to the top of the engine block by joining the indicated sections.
Remove the plenum chamber, and dab only the indicated areas with instant adhesive.
Replace the plenum chamber and hold for one minute.
Use tweezers to hold the thin injection unit in place as you do this.
Fitting the removable nose box to the Monocoque
Prepare the monocoque assembly (Stage 56), the nose box assembly (Stage 1) and four screws J for this step.
Fit the nose box to the front of the monocoque as shown below.
Insert and tighten two screws J into the circled holes on the right side of the nose box, once fitted. The screws will fit into the lugs on the inside (shown by the blue arrows in the above photo).
Fitting the intercooler to engine pipes
Take the two intercooler to engine pipes (L and R) saved from Stage 56 and lay them out side by side, with the larger end of each at the bottom. The edges of the pipes’ upper ends, marked here with red lines, slope inwards towards the middle.
Remove the pipe and carefully scrape the paint away from the indicated area of its larger end.
Dab this area with instant adhesive, replace the pipe as in the test fit, then hold for one minute.
Repeat the process for the right-hand pipe.
Temporarily fitting the engine block
For this step, you will need the left and right engine mounting plates from Stages 53 and 55 respectively, plus two screws K, two screws L and two screws H
Lower the engine block onto the rear of the monocoque. The two circled ends of the intercooler to engine pipes, fitted in the previous step, should slot into the corresponding holes in the underside of the plenum chamber.
Now line up the left engine mounting plate to the left side of the assembly, using the colour-coded circles to locate the part correctly.
Remove the plate and insert a screw L and a screw K into the indicated holes, turning them just enough to hold them in position.
Replace the mounting plate and tighten the screws to secure it. Tighten them alternately, a little at a time, to avoid warping the plate.
Repeat the process for the right engine mounting plate.
Turn the assembly over, and check that the indicated screw holes are clear and ready to take their screws.
Insert and tighten a screw H into each hole.
Stage complete
This stage is complete and your MP4/4’s monocoque has the engine block attached at the rear, and the nose box fitted to the front.
Warthog attached the following image(s):
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Rank: Elite Groups: registriert, Registered Joined: 20/03/2011 Posts: 2,356 Points: 7,122 Location: UK
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Stage 62
Your parts with this stage: Exhaust pipe front (R) Exhaust pipe rear inside (R) Exhaust pipe rear outside (R) and assorted screws
Continuing the turbocharger assembly
Prepare the left and right exhaust bases (Stage 59), the turbochargers (L-5) and (R-5) from Stages 58 and 59, the sprue of remaining turbocharger parts (Stage 60) and the exhaust pipe front (L) from Stage 61.
Lay the sprue face-down on a cutting mat and carefully remove the turbochargers (L-7) and (R-7) with a cutter.
There are tabs marked L and R on the front of the sprue, so be sure to note which turbocharger is which when you separate them.
Test-fit the exhaust pipe front (L) to the exhaust base (L), matching the colour-coded sections.
Remove the exhaust base, dab some instant adhesive onto the indicated areas of the exhaust pipe front (L), and fit the base again. Hold for one minute.
Now remove the turbocharger (L-5) and dab some instant adhesive onto the exhaust pipe front, as shown. Re-attach the turbo and hold for a minute.
Repeat for the right-hand exhaust subassembly, using the turbocharger parts (R-5) and (R-7), and the right exhaust pipe front and base.
Joining the wastegates, inside exhaust pipes and tailpipes
Prepare the left and right wastegates (Stage 60), tailpipes inside (Stage 57) and the exhaust pipe rear inside (L) from Stage 61.
Test-fit the exhaust pipe rear inside to the left wastegate (the one without a block on its end), so that the indicated pin fits into the circled groove.
When you are happy with the fit, dab some instant adhesive to the indicated section, re-join the parts and hold for a minute.
Line up and test-fit the tip of the exhaust pipe rear inside to the first tailpipe inside. The ridge and groove should fit together.
Remove the tailpipe inside, apply some adhesive to the marked section, replace, and hold for a minute.
Repeat the process for the right-hand exhaust pipe rear inside, wastegate and tailpipe inside.
Adding the turbochargers (L-4) and (R-4) to the outside exhaust pipes
Prepare the sprue from Stage 58, the tailpipes outside (Stage 57), and the exhaust pipe rear outside (L) from Stage 61.
Carefully remove the turbochargers (L-2) and (R-2) from the sprue using the cutter.
Remove and fit the turbochargers one at a time to make sure you fit them to the correct pipes.
Test-fit the tip of the left pipe to a tailpipe outside. The ridge will fit into the groove.
When you are happy with the fit, remove the tailpipe outside, dab some instant adhesive to the indicated section of the exhaust pipe, and reattach, holding in place for one minute.
Now test-fit the turbocharger (L-4) to the other end of the exhaust pipe.
Separate the parts, apply some instant adhesive to the indicated section, then re-join them and hold for a minute.
Repeat the process for the right exhaust pipe, turbocharger (R-4) and remaining tailpipe outside.
Stage complete
This stage is now complete and the left and right inside and outside exhaust pipe subassemblies and the exhaust pipe front and base subassemblies, are all ready for the next phase of the build.
Warthog attached the following image(s):
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Rank: Elite Groups: registriert, Registered Joined: 20/03/2011 Posts: 2,356 Points: 7,122 Location: UK
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Stage 63
Your parts with this stage: Electrical system parts and wiring
Temporarily attach the underbody to the Monocoque
Hold the underbody middle panel with the silver surface facing you, then use a toothpick to push two holes into the circled areas to line up with the screw holes beneath.
Place the monocoque bottom plate rear onto the underside of the monocoque assembly, as shown, then add the underbody middle.
Holding the underbody in place, put a screw G into each of the circled holes, then tighten it with the size 0 screwdriver. Don’t tighten the screws too much.
Now do the same with the blue-circled holes, using the screws J and the size 00 screwdriver.
The underbody middle is now temporarily secured.
Adding the exhaust pipes to the turbochargers
Prepare the left and right turbochargers (Stages 58 and 59), and the exhaust pipe and base assemblies (Stage 62) for this step.
Test-fit the left exhaust pipe and base to the left side of the engine block. The pins fit into the holes.
Remove the exhaust base and dab it with instant adhesive, then replace it and hold it in place for a minute.
Test-fit the left turbocharger so that its yellow-arrowed tip fits into the central section of the exhaust pipe, and the pin sits in the groove.
Remove the turbocharger and dab some instant adhesive onto the marked ring on its tip (working all the way around), then replace it and hold in it position for a minute.
Apply adhesive only to the indicated section – the join with the intercooler to engine pipe does not need to be fastened at this stage.
Repeat the process for the right turbocharger.
Fitting the inside and outside exhaust pipes to the engine block
Prepare the underbody rear (Stage 49), the left and right inside and outside exhaust pipes (all Stage 62) and two screws J for this stage.
Identify the location of the two circled holes on the surface of the underbody rear, and push through these holes with the toothpick.
Lay the underbody down as shown, and insert the tailpipe end of the left inside exhaust pipe (the one without the sprue’s block still attached to tip of the wastegate) into the indicated hole.
Cut a 4cm strip of masking tape and place it over the entry point to hold the exhaust pipe in place.
Test-fit the underbody and tailpipe assembly to the rear of the monocoque. The circled surface of the wastegate will fit onto the arrowed ridge on the engine’s exhaust pipe front.
When you are happy with the fit, separate the parts and dab some instant adhesive onto the arrowed ridge on the exhaust front. Replace and remove the masking tape from the tailpipe end, fit the parts together again and hold for a minute.
When the adhesive has cured, gently remove the underbody rear from the assembly.
Next, use the cutter to remove the block from the end of the right wastegate cooling pipe, which was used to differentiate it from the left part.
The right wastegate and exhaust pipe will fit on the right side of the engine block, opposite the left one.
Fit the right pipe outside into the indicated hole in the underbody rear.
As before, hold the pipe in place with masking tape.
Test-fit the left outside exhaust pipe to the circled hole in the back of the turbocharger, by moving the underbody assembly back into place at the rear of the monocoque.
Separate the parts again, apply some instant adhesive to the marked section of the tailpipe’s end, re-join the parts and hold for a minute.
When the adhesive has cured, remove the underbody rear again, peeling away the masking tape before you do so. Your assembly should look like the one shown below.
Repeat this step in its entirety to fit the right inside and outside exhaust pipe subassemblies
Finally, replace the underbody rear as it was in the test fits, and secure it by tightening two screws J into the circled holes with the size 00 screwdriver.
Stage complete
This stage ins now complete. The monocoque has been fitted with two parts of the underbody, while the engine has its exhaust pipes securely in place.
Warthog attached the following image(s):
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Rank: Elite Groups: registriert, Registered Joined: 20/03/2011 Posts: 2,356 Points: 7,122 Location: UK
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Stage 64
Your Parts with this stage: Instrument panel rear, Instrument panel front and assorted switches and decals
Fitting the wastegate pipes front to the turbocharger air intakes
Prepare the left and right turbo air intakes (Stage 20), the wastegate cooling pipes front and the wastegate cooling pipes themselves (Stage 56).
Remove the masking tape from the left air intake, and test-fit the left wastegate cooling pipe front to it, using the arrows as a guide.
When you are happy with the fit, remove the cooling pipe front, dab some instant adhesive onto the indicated pins, then replace it and hold it in place for a minute.
Now test-fit one of the wastegate cooling pipes onto the end of the front part.
Separate the parts, apply a little instant adhesive to the base of the pipe front, then slide the pipe back over and into place. Hold for a minute.
Repeat the process for the right air intake and wastegate cooling pipe parts.
Temporarily fitting the turbo air intakes
Prepare the monocoque assembly from Stage 63.
Line up the left turbo air intake with the left-hand turbocharger and radiator housing.
Fit the round end of the air intake first.
Now fit the free end of the wastegate cooling pipe over the indicated tip of the exhaust pipe.
Repeat the process for the right-hand turbo air intake, again fitting the free tip of the wastegate cooling pipe onto the exhaust.
For now, detach both air intakes.
Lay each air intake on a tissue or other soft surface to prevent them getting scratched.
Removing the temporarily attached underbody rear
Remove the underbody middle and rear panels and the monocoque bottom plate rear from the monocoque, by removing the screws used to secure them (use a size 00 screwdriver for the four screws J and a size 0 driver for the two screws G in the underbody middle).
Now remove the screws L, K and H holding the engine mounting plates to the monocoque and engine block, using the appropriate driver for each.
Fitting the hose B
Prepare the wire A and hose B, used last in Stages 47 and 51
Cut two 40mm and two 35mm lengths of wire A, and two 50mm and two 45mm lengths of hose B.
Carefully slide the 40mm lengths of wire into the 50mm lengths of hose, and the 35mm wires into the 45mm hoses.
Dab some instant adhesive onto the arrowed pin on the right of the engine block, then use tweezers to feed the tip of one of the 50mm hoses onto it (with the 40mm wire still inside). Hold in place for a minute.
Dab the arrowed nozzle on the inside face of the turbocharger (shown separated from the exhaust pipe in the upper inset photo), and place the hose’s end over it. Hold in place for a minute.
Repeat this process for the left side of the engine block.
Now dab the nozzle on the left turbocharger with instant adhesive, and fit the end of one of the shorter, 45mm lengths of hose onto it (keeping the wire inside).
With the wire still inside it, bend the hose with tweezers so that it appears as below. It will fit onto the arrowed nozzle.
Dab this nozzle with instant adhesive and fit the hose tip onto it. Hold the hose in place for a minute.
Repeat the process for the right side of the engine block.
Stage complete
This stage is now complete, and the turbo air intakes and engine hoses are ready for the next assembly stagesWarthog attached the following image(s):
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