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 Rank: Super-Elite        Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 5,050 Points: 15,296 Location: ipswich
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STAGE 9A:
Engine block 5.
Pic 1: Locate the air conditioning compressor parts 9A, 9B and 9C.
Pic 2: Fit the parts together as shown.
Pic 3: Fit the assembly to the engine block 7A as shown and fix from behind with an IP screw.
Pic 4: Retrieve the engine block 6A and fit it to part 7A as shown.
Pic 5: Fix the parts together with 4 x BM screws.
Pic 6: Fit the intake manifold parts 9D and 9J together as shown and fix using 2 x AP screws.
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Rank: Super-Elite Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 5,050 Points: 15,296 Location: ipswich
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STAGE 9B:
Pic 7: Press the cover plate 9E in place.
Pic 8: Press-fit the 6 x injectors 9H into the injector rail 9G.
Note the direction of the angled ends on the injectors.
Pic 9: A different view of the assembly.
Pic 10: Fit the pressure regulator 9R to the rail and fix from behind with 1 x HP screw.
Pic 11: Fit the intake tank 9I to the manifold 9J as shown.
Pic 12: Fix with 2 x AP screws from behind.
Pic 13: Press-fit the injector rail 9G to the assembly as shown.
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Rank: Super-Elite Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 5,050 Points: 15,296 Location: ipswich
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STAGE 9C:
Pic 14: Fit the manifold plate 9F to the assembly.
It will only fit one way.
Pic 15: Retrieve the cylinder head 5A saved from stage 5 and fit the manifold assembly in place as shown.
Fix from inside with 2 x AP screws.
Pic 16: Press-fit the 3 x fittings 9N, 9P and 9Q into the relevant locations on the manifold.
Each part will only fit one way.
Pic 17: Press-fit the vacuum reservoir 9L into the end of the manifold, and the air intake tank 9K into the location on the top of the manifold.
The parts will only fit one way.
Pic 18: Fit the two hoses 9M and 9O to the circled locations as shown.
Hose 9M is the shorter of the two.
Pic 19: Save all 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: 5,050 Points: 15,296 Location: ipswich
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STAGE 10A:
Engine block 6.
Pic 1: Locate the parts of the throttle housing 10I and 10J and press-fit them together.
Pic 2: Press-fit the idle valve and throttle sensor 10L and 10M into the throttle housing.
Pic 3: Fit the vacuum reservoir 10O as shown.
It will only fit one way.
Pic 4: Fit the intake throttle 10K to the left of the throttle housing.
Pic 5: Fit the vacuum sensor 10N to the throttle housing as shown.
Pic 6: Retrieve the intake manifold assembly and fit the throttle housing 10J to the air intake tank 9I.
The hole in the end of 10J will fit over the pin on the right of 9I.
Pic 7: Fit the other half of the air intake tank 10A to the assembly and fix 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: 5,050 Points: 15,296 Location: ipswich
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STAGE 10B:
Pic 8: Fit the two intake sensor parts 10D and 10E together as shown.
Pic 9: Press-fit the assembly into the hole in the left of the air tank 10A.
The parts will only fit one way.
Pic 10: Fit the accelerator cable bracket 10G as shown and fix with 1 x KP screw.
Pic 11: Press-fit the sensor 10F to the air tank in the position shown.
Pic 12: Assemble the fuel filter parts 10B and 10C and fit the unit to the end of the air tank.
Pic 13: Fit the hose 10Q between the throttle control parts 10G and 10K as shown.
Pic 14: Retrieve the cylinder head assembly 7B.
It will attach to the intake assembly 5A.
Pic 15: Fit the parts together as shown and fix through the left end of 7B with 1 x FM screw.
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Rank: Super-Elite Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 5,050 Points: 15,296 Location: ipswich
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STAGE 10C:
Pic 16: Turn the assembly around and fix the other end with 1 x FM screw.
Pic 17: Retrieve the main engine block assembly.
Pic 18: Fit the engine block and cylinder head together as shown and fix with 2 x PM screws through the large holes indicated.
Pic 19: Retrieve the engine cover 5C and fit the small end of the hose 10H as shown.
Pic 20: Press-fit the engine cover in place on top of the engine assembly.
Pic 21: Fit the other end of the hose 10H in the hole in the air intake tank.
Pic 22: Fit the hose 10R to the locations on the engine as shown.
Pic 23: Fit the hose 10P to the locations on the engine as shown.
Store the assembly safely for now.
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Rank: Super-Elite Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 5,050 Points: 15,296 Location: ipswich
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STAGE 11:
Gearbox 1.
Pic 1: Press-fit the clutch cylinder 11B into the gearbox 11A.
The part will only fit one way.
Pic 2: Locate the clutch plates 11D and 11E.
Pic 3: Press-fit the parts together.
Pic 4: Locate the clutch plates 11C and 11F.
Pic 5: Press-fit the parts together.
Pic 6: Fit the clutch shaft 11G into the centre of the clutch plates 11C/F.
Pic 7: Fit the clutch assembly 11D/E as shown and fix from beneath with 1 x AP screw.
Pic 8: Carefully fit the Traction control sticker to the top front of the air box.
Pic 9: Store the engine and parts safely for now.
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Rank: Super-Elite Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 5,050 Points: 15,296 Location: ipswich
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STAGE 12:
Gearbox 2.
Pic 1: Press-fit the side cover 12B into the gearbox part 12A.
Pic 2: Fit the clutch assembly from the previous stage into the gearbox.
Pic 3: Fit the drain plug 12F into the slot in the gearbox.
Pic 4: Retrieve the other half of the gearbox 11A and fit it to 12A.
Fix the parts together with 2 x CM screws.
Pic 5: Fit the blanking plugs 12G and 12H into the screw holes.
They are shaped to fit neatly and smooth with the gearbox casing.
Pic 6: Retrieve the engine assembly and fit the gearbox as shown.
Secure with 2 x AM screws.
Pic 7: Fix the other side with two more AM screws.
Pic 8: Assemble the universal joint parts 12D and 12E as shown and fix with 2 x AP screws.
Pic 9: Store the assembly and parts safely for now.
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Rank: Super-Elite Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 5,050 Points: 15,296 Location: ipswich
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STAGE 13A:
Pulleys and mechanisms 1.
Pic 1: Fit the lower front casing 13B to the engine and fix with 2 x IM screws.
Pic 2: Assemble the water pump parts 13I and 13H as shown.
Pic 3: Fit the pump 13Q to the assembly.
Pic 4: Fit the water pump to the engine as shown.
Pic 5: Fix the pump in place using 2 x IM screws.
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Rank: Super-Elite Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 5,050 Points: 15,296 Location: ipswich
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STAGE 13B:
Pic 6: Assemble the alternator parts 13J, 13R, 13K and 13L as shown.
Pic 7: Fit the shaft assembly 13J and 13R into the alternator from the end with the narrow ridges on the casing.
Pic 8: Fit the support bracket 13M and fix with 1 x AP screw.
Pic 9: Fit the alternator to the engine just below the water pump and fix with 1 x IM screw, and 1 x AP screw.
Pic 10: Fit the two belt tensioner pivots 13D and 13C as shown and fix 13C with 1 x LP screw.
Pic 11: Press-fit the two top pulleys 13F into the top of the engine front.
Pic 12: Fit the belt 13E highlighted in yellow to the pulleys.
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Rank: Super-Elite Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 5,050 Points: 15,296 Location: ipswich
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STAGE 13C:
Pic 13: Fit the front cover in place and fix with 1 x IM screw at the top and 1 x AP screw at the bottom.
Pic 14: Press-fit the small pivot 13G in place as shown.
Pic 15: Assemble the compressor pulley parts 13N and 13O
Pic 16: Fit the mounting bracket 13P over the shaft on the assembly.
Pic 17: Fit the assembly to the compressor on the engine as shown and fix with 1 x AP screw.
Pic 18: Secure the other end of the assembly with 1 x GP screw.
Pic 19: Fit the self-adhesive decal 13S to the starter motor as shown.
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: 5,050 Points: 15,296 Location: ipswich
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STAGE 14A:
Pulleys and mechanisms 2.
Pic 1: Fit the pulleys 14B and 14C and fix with 1 x AP screw.
Pic 2: Fit the tensioner 14D as shown and fix with 1 x AP screw.
Pic 3: Fit the steering pump 14O to the front right of the engine and fix with 2 x AP screws.
Pic 4: Fit the pump connector 14P to the side of the steering pump 14O.
Pic 5: Fit the two pulley parts 14M and 14N to the pump shaft and fix with 1 x GP screw.
Pic 6: Fit the rear pulley 14L to the water pump shaft as shown.
Pic 7: Fit the front pulley part 14K in place.
Pic 8: Fit the drive belt 14A as shown in the diagram.
Pic 9: Fit the two tensioner parts 14H and 14J to the front of the engine.
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: 5,050 Points: 15,296 Location: ipswich
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STAGE 14B:
Pic 9: Fit the two tensioner parts 14H and 14J to the front of the engine.
Pic 10: Fit the tensioner 14I to the two pins on 14H and 14J.
The thicker end goes to the top.
Pic 11: Fit the pulley half 14G to the water pump spindle.
Pic 12: Fit the other half of the pulley 14F as shown.
Pic 13: Fit the fan 14E to the front of the water pump spindle and fix with 1 x BP screw.
Pic 14: Press-fit the hose connector 14Q into the hole on the side of the engine as shown.
It will only fit one way.
Pic 15: Fit the water hose 14R between the water pump and the engine.
Pic 16: Connect the end of the pipe 9M to the pin on the fuel filter as shown.
Pic 17: Fit the assembled universal joint saved from stage 12 into the hole in the end of the transmission case.
Store the engine safely for now. roymattblack attached the following image(s):
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