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 Rank: Super-Elite        Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 4,791 Points: 14,519 Location: ipswich
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STAGE 9A:
Gear shift assembly.
Pic 1: Retrieve the transmission case cover 8E from the previous stage and fit the two shift levers 9A and 9B as shown, fixing them from behind with 2 x AP screws.
Pic 2: Press-fit the cover in place on the transmission.
Pic 3: Fit the gear shift pivot 9I as shown and fix with 3 x AAM screws.
Pic 4: Fit part 9G into place on part 9I and fix from behind with 3 x AP screws.
Pic 5: Press-fit part 9H to the front of the assembly.
Pic 6: Fit lever 9E to the lower hole in the bracket as shown.
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Rank: Super-Elite Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 4,791 Points: 14,519 Location: ipswich
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STAGE 9B:
Pic 7: Fit lever 9D to the upper hole in the bracket and the other end to the pin inside lever 9B.
Pic 8: Fit lever 9C as show to the centre hole in the bracket and the other end to lever 9A.
Pic 9: Fit the small universal joint 9J in place as shown and fix from each side with 2 x AP screws.
Pic 10: Press the end cap 9M onto the end of the starter motor 9K.
Pic 11: Fit the solenoid 9L to the side of the starter motor and fix with 1 x AP screw as shown.
Pic 12: Fit the starter motor to the side of the engine and fix with 1 x AP screw on the inside edge.
This is quite fiddly so take your time.
Pic 13: Fit the small bracket 9F in place on the gear shift rod assembly.
Store the engine 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: 4,791 Points: 14,519 Location: ipswich
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STAGE 10A:
Ignition distributor.
Pic 1: Press-fit the distributor cap 10A as shown.
Pic 2: Locate the sprue of wiring caps 10B.
Pic 3: Cut the caps from the sprue and fit them to the distributor cap. Take care here not to break any of the pins they fit to on the cap.
Pay attention to the numbering on this pic for adding the wires.
Pic 4: Fit the two connectors 10E to the end of the engine.
Pic 5: Fit the large connector 10F as shown.
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Rank: Super-Elite Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 4,791 Points: 14,519 Location: ipswich
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STAGE 10B:
Pic 6: Cut 2 x 140mm wires from 10H and fit them to the engine.
Cap ‘1’ connects to plug 3 on the left side of the engine.
Cap ‘2’ connects to plug 4 on the left side of the engine.
Pic 7: Cut 2 x 110mm wires from 10H and fit them to the engine.
Cap ‘3’ connects to plug 2 on the left side of the engine.
Cap ‘4’ connects to plug 1 on the left side of the engine.
Pic 8: Turn the engine around.
Cut 1 x 110mm wire from 10H.
Cap ‘5’ connects to plug 4 on the right side of the engine.
Cut 1 x 140mm wire from 10H.
Cap ‘6’ connects to plug 1 on the right side of the engine.
Pic 9: Cut 1 x 110mm wire from 10H.
Cap ‘7’ connects to plug 3 on the right side of the engine.
Cut 1 x 140mm wire from 10H.
Cap ‘8’ connects to plug 4 on the right side of the engine.
Pic 10: Cut 2 x 70mm and 1 x 40mm wires from 10H and fit them to the connector 10G as shown.
Pic 11: Connect the 40mm wire to plug cap ‘9’.
Fit the other two 70mm wires to the pins on parts 10E.
Pic 12: Locate the sprue of wire combs 10C.
Pic 13: Cut two of the combs from the sprue and fit them to the wires as shown.
Pic 14: Cut two of the combs from the sprue and fit them to the wires on the other side as shown.
Store the engine 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: 4,791 Points: 14,519 Location: ipswich
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STAGE 11A:
Air filter and carburettor.
Pic 1: Locate the manifold parts 11E, 11F and 11G.
Note the parts are marked ‘L’ and ‘R’.
Pic 2: Assemble the parts as shown and fix with 4 x EP screws.
The parts will only fit one way.
Pic 3: Locate the fuel pump parts 11K, 11L and 2 x 11N.
Press-fit the parts together as shown.
Pic 4: Fit the base 11M to each pump and fix with 1 x EP screw.
Pic 5: Locate the flange 11O and fit the two assembled pumps as shown and fix them using 2 x FP screws.
Pic 6: Fit the carburettor body 11J as shown between the two pumps and fix it to the flange 11O using 1 x EP screw from the other side.
Pic 7: Fit the carburettor to the manifold assembly as shown and fix using 4 x AP screws.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: 4,791 Points: 14,519 Location: ipswich
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STAGE 11B:
Pic 8: Turn the assembly over and fit the manifold flange 11M to the manifold 11F. Fix in place with 2 x EP screws.
Pic 9: Shows a different view of the assembly.
Pic 10: Fit the manifold flange 11I to the manifold 11G. Fix in place with 2 x EP screws.
Pic 11: Press-fit the 3 x air filter parts 11B, 11C and 11D together.
Pic 12: Press-fit the filter assembly into the air filter housing 11A.
Pic 13: Fit the fuel supply pipe 11P to the carburettor assembly by fitting the pins on the blue unions into the holes in parts 11K and 11L.
Pic 14: Press-fit the carburettor and manifold assembly onto the top of the engine as shown.
The angled flanges on the manifold legs with click-fit into the recesses on the cylinder head.
Pic 15: Fit the air filter assembly as shown and secure it with 1 x EP screw.
Store the engine safely for now.
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Rank: Super-Elite Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 4,791 Points: 14,519 Location: ipswich
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STAGE 12A:
Engine mount and alternator.
Pic 1: Fit the alternator and bracket 12F and 12J together as shown and fix from behind with 2 x AAM screws.
Pic 2: Fit the housing cover 12G to the assembly and fix from behind with 1 x AP screw.
Pic 3: Press-fit the alternator bracket to the rear of the assembly as shown.
Pic 4: Fit the alternator assembly to the two upper holes on the left of the engine mount 12A.
Fix from the other side with 2 x AAM screws.
Pic 5: Shows the rear of the assembly.
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Rank: Super-Elite Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 4,791 Points: 14,519 Location: ipswich
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STAGE 12B:
Pic 6: Fit the alternator sprocket 12J over the spindle on the alternator.
Pic 7: Fit the flat alternator pulley 12D as shown.
Pic 8: Fit the front of the pulley 12E and secure with 1 x BP screw.
Pic 9: Fit the crankshaft pulley and vibration damper 12C and 12B together as shown.
Pic 10: Fit the assembly 12B to the two holes at the bottom of the engine mount frame and fix from behind with 2 x AP screws.
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: 4,791 Points: 14,519 Location: ipswich
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STAGE 13A:
Power steering and oil pumps.
Pic 1: Fit the oil pump and bracket 123A and 13D together. Fix them using 2 x AP screws.
Pic 2: Fit the two pump pulley parts 13B and 13C together.
Pic 3: Fit the pulley to the pump as shown with the pulley part 13B outwards.
Fix with 1 x BP screw.
Pic 4: Fit the pump shaft and cover 13J and 13K together as shown.
The parts will only fit one way.
Pic 5: Fit the oil pump housing 13L to the assembly. It will only fit one way.
Pic 6: Fit the assembly to the right upper side of the frame 12A and fix from behind with 2 x AP screws.
Pic 7: Fit the power steering pump 13L over the shaft on part 13J.
Pic 8: Fit the pump spigot 13H to the pin on the steering pump 13L.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: 4,791 Points: 14,519 Location: ipswich
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STAGE 13B:
Pic 9: Press-fit the two pulley parts 13F and 13G together. The parts will only fit one way.
Pic 10: Fit the pulley to the end of the oil pump as shown with part 13G uppermost. Fix with 1 x BP screw.
Pic 11: Attach the sump oil pump 13A to the side of the engine using 2 x CM screws.
Pic 12: Attach the straight end of the oil line 13E to the top pin on the bracket at the rear of the engine.
Pic 13: Fit the other curved end of 13E to the outer hole on the sump pump as shown.
Pic 14: Fit the other three oil lines 7E, 7F and 7G in order to the other three holes in the pump.
HINT – You may find it easier to remove the pump from the engine to fit the oil pipes and then re-fit it afterwards.
Pic 15: Store the parts 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: 4,791 Points: 14,519 Location: ipswich
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STAGE 14A:
Water pump and fan.
Pic 1: Locate the water pump fitting 14E and fit the attachment 14F in place.
NOTE – This part may already be fitted as supplied but if it is a loose fit, a dot of adhesive might be advised.
This is entirely at the builder’s discretion.
Pic 2: Attach the pump inflow 14D to the rear of 14E and fix with 1 x AP screw.
Pic 3: Retrieve the mounting bracket 12A and fit the pump assembly to the two top fixing points as shown and secure with 2 x AM screws.
Pic 4: Press-fit the two halves of the pulley 14A and 14B together.
Pic 5: Press fit the outer section 14I onto the two pins on 14B.
Pic 6: Press-fit the outer ring 14C in place on 14I.
Pic 7: Fit the assembly over the shaft on part 14E.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: 4,791 Points: 14,519 Location: ipswich
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STAGE 14B:
Pic 8: Fit the pump pulley hub 14H over the shaft on 14E.
Pic 9: According to the printed instructions - Fit the fan 14G to the end of the shaft 14E, locking the key-way slots together.
Fix with 1 x BP screw.
NOTE: You are advised not to fit the fan at this point as the next stages will be rendered almost impossible.
Pic 10: Attach the frame assembly to the front of the engine using 2 x AM screws.
Pic 11: Turn the engine upside down and fit one of the belts 14J between the inner pulley on 12C and the pulley 12B.
Pic 12: With the engine the right way up fit a belt 14J between the inner pulley on 12E and the pulley 14L.
Pic 13: With the engine the right way up fit a belt 14J between the inner pulley on 14C and the pulley 13F.
Pic 14: With the engine the right way up fit a belt 14J between the inner pulley on 13B and the pulley 12C.
Pic 15: Now the fan can be fitted.
Fit the hose 14L to the pin on the end of the pump 14E and pass it through the hole on the side of the frame 12A.
Pic 16: Fit the oil hose 14K to the pin on the end of the pump 13L, locating the other end in the hole on the engine block.
Save the assembly safely for now.
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