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 Rank: Super-Elite        Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 4,919 Points: 14,903 Location: ipswich
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STAGE 27A:
Injection pump and turbocharger.
Pic 1: Locate the injection pump parts 27A, 27C and 27D.
Pic 2: Press-fit the parts together as shown, securing 27C from underneath with 1 x AP screw.
Fit the 4 x pump fittings 27G as circled, aiming downwards.
Pic 3: Fit the intake pipe half 27F as shown and fix with 1 x AP screw.
The parts have a small ‘keyway’ fitting so will only fit one way.
Pic 4: Fit the turbo part 27H as shown fixing it with 1 x AP screw.
The parts have a small ‘keyway’ fitting so will only fit one way.
Pic 5: Press-fit the other pipe half 27E as shown.
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: 4,919 Points: 14,903 Location: ipswich
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STAGE 27B:
Pic 6: Fit the assembly 27A onto the base part 27B as shown and fix from underneath with 1 x AP screw.
Pic 7: Fit the turbo cover 27I in place as shown and fix with 2 x AP screws.
Pic 8: Fit the turbo hub and bracket 27K and 27J together as shown.
Note the small nut detail on 27J should be at the hub end.
Fix with 1 x AP screw.
Fit the assembly over the shaft on 27I.
The parts have a small ‘keyway’ fitting so will only fit one way.
Pic 9: Fit the turbo manifold 27L and fix with 1 x AP screw.
The parts have a small ‘keyway’ fitting so will only fit one way.
Pic 10: Cut 4 lengths of pipe from 27M to the sizes shown.
Pic 11: Fit the pipes to the injector fittings as shown with the 2 x 150mm pipes at the top and the 2 x 120mm pipes at the bottom.
Store the assembly safely.
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: 4,919 Points: 14,903 Location: ipswich
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STAGE 28A:
Intercooler.
Pic 1: Fit the intercooler part 28C and bracket 28K together making sure the ‘square’ ends of the bracket locate on the posts inside the intercooler.
Fix with 2 x AP screws.
Pic 2: Fit the pipe half 28R as shown.
Pic 3: Fit the cap 28D and fix with 1 x AP screw.
Pic 4: Fit the other bracket 28K to the intercooler part 28G in the same way as step 1 and fix with 2 x AP screws.
Pic 5: Fit the bottom bracket 28I into the hole in the top of 28G and fix from inside with 1 x CM screw.
Pic 6: Fit the cap part 28H as shown and fix with 1 x AP screw.
Pic 7: Fit the assembly into the main intercooler 28A as shown.
Fix the bracket 28K using 2 x AP screws.
Pic 8: Fit the other end of the intercooler 28G as shown and fix through bracket 28K with 2 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: 4,919 Points: 14,903 Location: ipswich
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STAGE 28B:
Pic 9: Fit the back panel 28B in place and fix with 2 x AP screws.
Pic 10: Fit the two support legs 28E to the intercooler as shown and fix from the outside using 2 x BM screws.
Pic 11: Fit the two end brackets 28F as shown and fix from the outside with 2 x LM screws.
Pic 12: Fit the three hose connectors 28M, 28N and 28O in place as shown.
Pic 13: Cut a 150mm piece of hose from 28P and fit it to the end of the connector 28N.
Pic 14: Fit the black hose 28Q to the connector 28M.
Pic 15: Retrieve the turbo assembly from the previous stage and fit it to the intercooler assembly as shown.
The tab on the end of 28G will fit inside the slot on the end of the turbo 27H.
Fix using 1 x AP screw.
Pic 16: Fit the rear bracket 28J in place as shown.
Pic 17: Fit the connector 28L to the intercooler and fit a 150mm piece of hose 28P as shown.
Pic 18: OPTIONAL DETAIL – You can add some contrast to the intercooler by colouring the grille slots using a fine black marker pen.
This is at the builder’s discretion.
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: 4,919 Points: 14,903 Location: ipswich
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STAGE 29A:
Intake manifold.
NOTE: The printed instructions are missing some important steps.
These are detailed further on.
Pic 1: Locate the manifold part 29D and the 4 x brackets 29E.
Pic 2: From the inside, insert the brackets through the slots as shown.
Pic 3: Shows the brackets fitted.
Pic 4: Fit the manifold cylinder and flange unit 29H and 29G together as shown and fix from the inside of 29G with 1 x AP screw.
DO NOT fully tighten the screw. The flange may need adjusting later.
Pic 5: Assemble the other three sets of parts in the same way but note that 29F has a pin on one end that the other three do not have.
Make sure none of the screws are fully tightened.
Pic 6: Fit the manifold tube assemblies to the previously assembled manifold half as shown.
Note that 29F is at the right end of the assembly.
Fix the parts with 4 x AP screws.
Pic 7: Press-fit the outer manifold tube parts 29B in place as shown.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: 4,919 Points: 14,903 Location: ipswich
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STAGE 29B:
Pic 8: Retrieve the turbo intake assembly from the previous stage and fit the top two hoses from the group of 4 on the intake to the end two flanges on the manifold assembly as shown.
Pic 9: Shows a close up of the two hoses to use.
Pic 10: Shows a close up of where the hoses connect.
Pic 11: Fit the lower two hoses from the group of 4 on the intake to the other two flanges on the manifold assembly as shown.
Pic 12: Shows a close up of the two hoses to use.
Pic 13: Shows a close up of where the hoses connect.
Pic 14: Retrieve the engine assembly and position it as shown.
Pic 15: Check that the manifold flanges are all angled as shown.
You should still NOT tighten the fixing screws in the centre.
Pic 16: Fit the manifold to the engine as shown.
It now becomes clear why the manifold screws were not fully tightened as it will be easy to adjust each one into the correct position.
Fix the manifolds to the engine using 8 x QM 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: 4,919 Points: 14,903 Location: ipswich
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STAGE 29C:
Pic 17: From the other side, fix the manifold bracket at the right that is furthest away, to the post on the top of the engine using 1 x QM screw.
IMPORTANT:
THE NEXT FOUR STEPS HAVE BEEN OMITTED FROM THE PRINTED INSTRUCTIONS.
You MUST follow these steps to continue with the build.
Pic 18: Press-fit part 29I onto 29R as shown.
Pic 19: Fit the turbo and intake assembly into place on the engine as shown.
Pic 20: This shows where the turbo unit will fix to the exhaust manifold.
Make sure the manifold flange is sitting horizontally.
The parts will press together.
Pic 21: This shows where the end of the intake pipe will fit into the manifold on the engine.
The parts just clip together.
The build now continues in the same way as the printed instructions.
Pic 22: Fit the two brackets 29J and 29K as shown.
Pic 23: Cut the hose 29M into 2 x 100mm lengths.
Pic 24: Fit the hoses onto the two unions 29L and then fit them both to the top of the manifold as shown.
Pic 25: Store the assembly safely for now.roymattblack attached the following image(s):
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