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 Rank: Super-Elite        Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 4,511 Points: 13,693 Location: ipswich
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STAGE 42:
The parts in this stage are for assembling and fitting the crankcase cover and ignition belt.
Locate the crankcase cover and timing shaft, parts 42A and 42C.
Press the parts together as shown.
Locate the oil hose fitting, part 42D and fit this to the crankcase cover.
It will only fit one way.
Secure from behind using 1 x DP screw.
Retrieve the engine assembly and locate the other timing shaft, part 42B.
Press the part in place on the front pin on the left oil pump housing.
Fit the crankcase cover to the front of the engine.
It will only fit one way.
Secure using 2 x DM screws.
Locate the vent pipe, part 42E and fit the square end into the locating slot on the left throttle mount, part 36A.
You may need to do this using narrow tweezers or thin long nose pliers.
Locate the turbo oil pipe, part 42F and fit the two rectangular pins into the locations on the top of the crankcase cover, part 42C and the distributor mount, part 35A.
The oil pipe will only fit one way.
Locate the ignition distributor belt, part 42I and fit it over the two pulleys at the top right of the left bank cylinder head.
Locate the toothed pulley, part 42G and fit this to the pivot on the ignition distributor mount, part 35A which will also locate in the teeth of the belt.
Fix the part using 1 x WP screw.
Locate the other toothed pulley, part 42H and fit this to the pivot on the end of the left cylinder head, also locating it with the teeth on the belt.
Secure the part using 1 x WP screw.
Store the assembly safely for now.roymattblack attached the following image(s):
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Rank: Super-Elite Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 4,511 Points: 13,693 Location: ipswich
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STAGE 43:
The parts in this stage are for assembling and fitting the right camshaft pulleys and timing belt.
NOTE: The following instructions differ from the printed ones as fitting the rubber belt as the instructions suggest is almost impossible due to the belt being made of a fairly firm material and it would not stay in place.
It would not be possible to fit the belt fully in position at an early stage as suggested.
Locate the two camshaft pulleys, parts 2 x 43A.
Fit these to the top two pivots on the right cylinder head and fix with 2 x WP screws.
Locate the two washers, parts 2 x 43C and fit them over the two pivots on the right cylinder head and the top of the right crankcase cover.
Position the timing belt, part 43G over the top two pulleys and lift it up underneath the left pulley.
Fit the idler belt pulley, part 43B to the pivot underneath the left top pulley, trapping the belt in place.
Fix using 1 x WP screw.
Fit the other idler belt pulley, part 43D over the lower pivot where the washer was previously fitted.
Fix using 1 x QM screw.
Wrap the right side of the timing belt under and around the pulley, part 43D and hold it in place as you fit the next pulley, 43F in place on the pivot next to 43D.
The timing belt should go over the top of this pulley.
Fix using 1 x QM screw.
Fit the final pulley, part 43H on the lower pivot on the crankcase cover, with the timing belt going around it.
Fit the pulley bracket, part 43E in place over the pulley and fix using 1 x BM screw.
Study the picture showing the belt position to make sure everything is in order.
Store the assembly safely for now.roymattblack attached the following image(s):
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Rank: Super-Elite Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 4,511 Points: 13,693 Location: ipswich
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STAGE 44:
The parts in this stage are for assembling and fitting the left camshaft pulleys and timing belt.
NOTE: The following instructions differ from the printed ones as fitting the rubber belt as the instructions suggest is almost impossible due to the belt being made of a fairly firm material and it would not stay in place.
It would not be possible to fit the belt fully in position at an early stage as suggested.
Locate the two camshaft pulleys, parts 2 x 44A.
Fit these to the top two pivots on the left cylinder head and fix with 2 x WP screws.
Locate the two washers, parts 2 x 44C and fit them over the two pivots on the left cylinder head and the top of the left crankcase cover.
Position the timing belt, part 44G over the top two pulleys and lift it up underneath the right pulley.
Fit the idler belt pulley, part 44B to the pivot underneath the left top pulley, trapping the belt in place.
Fix using 1 x WP screw.
Fit the other idler belt pulley, part 44D over the lower pivot where the washer was previously fitted.
Fix using 1 x QM screw.
Wrap the left side of the timing belt under and around the pulley, part 44D and hold it in place as you fit the next pulley, 44F in place on the pivot next to 44D.
The timing belt should go over the top of this pulley.
Fix using 1 x QM screw.
Fit the final pulley, part 44H on the lower pivot on the crankcase cover, with the timing belt going around it.
Fit the pulley bracket, part 44E in place over the pulley and fix using 1 x BM screw.
Store the assembly safely for now.
roymattblack attached the following image(s):
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Rank: Super-Elite Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 4,511 Points: 13,693 Location: ipswich
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STAGE 45:
The parts in this stage are for fitting the oil pipe connection.
Locate the oil pipe, part 45A and fit it in place on the engine with the blue end locating in the hole in the crankcase top and the yellow end fitting on the left pin of the oil pipe connector, part 42D.
Locate the long chrome oil pipe, part 45B and fit this to the oil pipe connector, part 42D, with the curved part of the pipe fitting inside the timing belt and the long straight part running along the lower side of the engine.
Locate the grey oil hose and fit this to the pins on the oil hose fitting, part 40F, and the right cylinder head oil pump, part 41C.
Locate the black oil hose, part 45D and fit one end to the lower pin on the oil pipe connector, part 40F.
Connect the other end to the pin on the white pressure regulator, part 40A.
Store the assembly safely for now.
roymattblack attached the following image(s):
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Rank: Super-Elite Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 4,511 Points: 13,693 Location: ipswich
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STAGE 46:
The parts in this stage are for fitting fuel and oil pipes.
Locate the fuel line, part 46A and fit this in place on the engine with the blue end attaching to the left fuel rail, part 26B and the yellow end connecting to the left pin on the pressure regulator fitting, part 34I.
Locate the right fuel line, part 46B and fit this in the same way, connecting the blue end to the right fuel rail, part 30B and the yellow end to the right pin on the pressure regulator fitting, part 34I.
Locate the clear oil hose, part 46C and fit one end to the pin on the ignition distributor mount, part 35A.
Leave the other end loose for now.
Locate the shorter black sensor cable, part 46D and connect one end to the left air intake sensor, part 27E.
Leave the other end loose for now.
Locate the longer black sensor cable, part 46E and connect one end to the right air intake sensor, part 31E.
Leave the other end loose for now.
Locate the left turbo hose, part 46F and connect the black end to the pin on the bottom right of the crankcase, as you are looking at it.
Store the assembly safely for now.roymattblack attached the following image(s):
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