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 Rank: Super-Elite        Groups: Registered
Joined: 30/01/2013 Posts: 4,604 Points: 13,607 Location: Monmouthshire UK
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Pack 2 contains Stages 14-25
Stage 14 – Fuel hose and heater hose
Contains parts –
Fuel hose
Radiator cap and hose
Heater hose
Radiator
Remove the distributor from the engine block (Stage 13). Be careful with the cables when handling it, now remove the fuel rail and the V belt from the block.
Using a screwdriver, push up on the post in the large hole in the underside of the engine to lift the valve covers and the cylinder head cover clear of the block. Remove the valve covers and cylinder head cover from the engine block.
Align the projections on the fuel hose with the holes in the tops of the carburettors and push into place. Lift the valve covers away from the cylinder head cover, and also remove spark plug lead 6 from its hole. Hold the heater hose and insert the end through the gap in the bridge between the sides of the valve covers then push the two pins on the underside of the hose into the holes in the cylinder head cover.
Now replace the valve cover and cylinder head cover then refit the distributor.
Spark plug lead 6, the fuel rail and the V- belt can all be re-installed.
Hold the radiator cap alongside the radiator. You will see that the radiator has a D-shaped hole that matches the pin on the cap, push the radiator cap into this hole.
Stage Complete
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Rank: Super-Elite Groups: Registered
Joined: 30/01/2013 Posts: 4,604 Points: 13,607 Location: Monmouthshire UK
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Stage 15 – The Oil Pan
Contains parts –
Oil pan A
Oil pan cover
Oil pan C
Oil pan B
Place the oil pan cover and oil pan C next to each other. There is only one way the cover can be fitted to pan C, because the pins on the cover are of different sizes, and they match correspondingly sized holes in pan C.
Align the diagonal edges of oil pan C and oil pan B and push the parts together then align the pins on oil pans B and C with the corresponding holes in the recessed area of oil pan A and push parts B and C into place.
Align the pins on the oil pan cover with the holes in oil pan C, and push the cover into place.
Turn the engine block over, and align the two posts on the topside of the oil pan assembly with the holes in the underside of the block and push the posts into the holes.
Stage complete
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Rank: Super-Elite Groups: Registered
Joined: 30/01/2013 Posts: 4,604 Points: 13,607 Location: Monmouthshire UK
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Stage 16 – The battery and the screenwash tank.
Contains Parts –
Battery cables × 2
Air filter
Brake master cylinder
Clutch master cylinder
Battery
Screenwash hose
Screenwash tank
Fit both of the battery cables into the D shaped holes on the top of the battery.
Align the end of the screenwash hose with the hole in the screenwash tank and push the end of the hose into the tank, keeping it straight as it goes in.
If the screenwash hose is difficult to insert into the tank, make it thinner by scraping away some of the end with a knife, remove a small amount, then test-fit. Repeat this until the fit is easier but still secure.
Stage Complete
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Rank: Super-Elite Groups: Registered
Joined: 30/01/2013 Posts: 4,604 Points: 13,607 Location: Monmouthshire UK
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Stage 17 – The Exhaust Pipes
Contains parts -
Exhaust pipe A
Exhaust pipe B
Type K screws × 3
Type F screws × 2
Type G screws × 4
Line up the flattened end of exhaust pipe A with the open end of the primary silencer (Stage 12).
Place the hole in the end of exhaust pipe A over the screw hole in the primary silencer, also, align the pin on the underside of the pipe with the corresponding hole in the silencer.
Next, place the flattened end of exhaust pipe B into the end of the primary silencer, align with the screw hole then push into place.
Finally, secure both exhaust pipes with a type K screw and tighten.
Stage complete, save any unused parts
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Rank: Super-Elite Groups: Registered
Joined: 30/01/2013 Posts: 4,604 Points: 13,607 Location: Monmouthshire UK
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Stage 18 – Left Rear Wheel
Contains parts –
Left rear wheel
Left rear hub nut
Half round needle file
The parts supplied with this stage are the left rear wheel and its hub nut, plus a half round needle file.
The left rear wheel and hub nut will be used in Stage 19. If you are not ready to work on that stage at the moment, store the wheel and nut safely until you need them.
Place the wheel and its hub nut back into the bag that they came in, and label it with the stage number (18).
Stage complete, save any unused parts.
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Rank: Super-Elite Groups: Registered
Joined: 30/01/2013 Posts: 4,604 Points: 13,607 Location: Monmouthshire UK
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Stage 19 – Left Steering Knuckle
Contains parts –
Rear tyre
Brake caliper
Left steering knuckle
Front axle shaft
Nut
Brake disc
Take the left rear wheel supplied with Stage 18, and insert it into the rear tyre, working around the edge, pull the sidewall over the wheel then turn the wheel around, and pull the other sidewall over it.
Align the pins on the brake caliper with the holes in the steering knuckle then insert the pins of the caliper into holes of the steering knuckle.
If the caliper is a loose fit, secure it with some adhesive.
Identify the two sides of the brake disc. Hold the brake disc with the outer side facing up, and insert it between the steering knuckle and the caliper then adjust the brake disc’s position so that the low circular projection on the inner side fits into the recess in the knuckle.
Take the left front wheel and align the hole in the centre of the
brake disc and steering knuckle assembly with the spindle in the centre of the wheel.
Push the disc and steering knuckle onto the spindle then turn the assembly until the hexagonal-centred hole in the brake disc fits over the hexagonal section of the spindle.
Insert the front axle shaft into the hole in the centre of the knuckle and push in as far as it will go.
Place the nut into the largest hole in the cross wrench then tighten the nut onto the axle, hold the steering knuckle and check that the wheel turns freely. If it doesn’t, loosen the nut slightly to free it.
Prepare the left front hub nut. To tell the hub nuts apart, those for the left wheels are marked ‘left side’ and those for the right wheels are marked ‘right side’.
There is a magnet inside the hub nut to hold it in place. Make sure the magnet is clean and unobstructed before fitting the nut to the wheel.
Stage complete.
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Rank: Super-Elite Groups: Registered
Joined: 30/01/2013 Posts: 4,604 Points: 13,607 Location: Monmouthshire UK
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Stage 20 – Right rear wheel.
Contains parts –
Right rear wheel
Right rear hub nut
The right rear wheel and hub nut will be used in Stage 21. If you are not ready to work on that stage at the moment, store the wheel and nut safely until you need them.
Place the wheel and its hub nut back into the bag that they came in, and label it with the stage number (20).
Stage complete.
stevie_o attached the following image(s):
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Rank: Super-Elite Groups: Registered
Joined: 30/01/2013 Posts: 4,604 Points: 13,607 Location: Monmouthshire UK
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Stage 21 – Right steering knuckle
Contains parts –
Rear tyre
Brake caliper
Right steering knuckle
Front axle shaft
Nut
Brake disc
Take the right rear wheel supplied with Stage 20, and insert it into the rear tyre, working around the edge, pull the sidewall over the wheel then turn the wheel around, and pull the other sidewall over it.
Align the pins on the brake caliper with the holes in the steering knuckle then insert the pins of the caliper into holes of the steering knuckle.
If the caliper is a loose fit, secure it with some adhesive.
Identify the two sides of the brake disc. Hold the brake disc with the outer side facing up, and insert it between the steering knuckle and the caliper then adjust the brake disc’s position so that the low circular projection on the inner side fits into the recess in the knuckle.
Take the right front wheel from stage 7 and align the hole in the centre of the brake disc and steering knuckle assembly with the spindle in the centre of the wheel.
Push the disc and steering knuckle onto the spindle then turn the assembly until the hexagonal-centred hole in the brake disc fits over the hexagonal section of the spindle.
Insert the front axle shaft into the hole in the centre of the knuckle and push in as far as it will go.
Place the nut into the largest hole in the cross wrench then tighten the nut onto the axle, hold the steering knuckle and check that the wheel turns freely. If it doesn’t, loosen the nut slightly to free it.
Prepare the right front hub nut. To tell the hub nuts apart, those for the left wheels are marked ‘left side’ and those for the right wheels are marked ‘right side’.
There is a magnet inside the hub nut to hold it in place. Make sure the magnet is clean and unobstructed before fitting the nut to the wheel.
Stage complete.
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Rank: Super-Elite Groups: Registered
Joined: 30/01/2013 Posts: 4,604 Points: 13,607 Location: Monmouthshire UK
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Stage 22 – The transmission case
Contains parts –
Right transmission case
Left transmission case
Clutch case cover
Type H screws × 2
Type I screws × 2
Hold the clutch case cover and align the two tabs with the notches in
the right transmission case, then push the two tabs on the clutch case cover into the notches in the transmission case.
Align the posts on the insides of the left and right transmission cases, when the posts are aligned, push the two halves together.
Wrap masking tape around the transmission case assembly to hold the two sides together. Then store the assembly in a labelled plastic bag, unless you are going to work on the next stage straight away.
Stage Completestevie_o attached the following image(s):
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Rank: Super-Elite Groups: Registered
Joined: 30/01/2013 Posts: 4,604 Points: 13,607 Location: Monmouthshire UK
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Stage 23 – The Engine
Contains parts –
Firewall
Hood lock
Water outlet housing
Starter
Right engine mount
Left engine mount
Oil temperature sensor
Flexible hose
Left mirror
Remove the oil pan from the engine (if it’s still attached to it), along with the two manifolds.
Locate the two holes in the side of the cylinder block and the one in the water pump and insert the end of the water outlet housing into the hole in the water pump, while inserting the two projections on its side into the two holes in the cylinder block, then push firmly into place.
Refit the two manifolds into the holes in the side of the cylinder head.
Dismantle the oil pan and insert the end of the oil temperature sensor into the hole in oil pan B then Put oil pan B back into its place on oil pan A. Tighten a type G screw (Stage 17) into each of the two holes in the oil pan.
Next, Fit oil pan C onto oil pan B and secure with a type G screw.
Insert the posts on the inside of the oil pan into the corresponding holes in the bottom of the engine block and secure with a type F screw in the oil pan, then push the oil pan cover back into position on oil pan C.
Align the pins of the right engine mount with the indicated holes in the engine block and the oil pan and insert the pair of pins into the two holes in the engine block. Next, push the right engine mount’s third pin into the hole in the oil pan.
Apply some adhesive to the end of the crankcase vent and glue it back into position. Fit the left engine mount in a similar way to the left side of the engine.
Align the pins on the flexible hose with the holes in the engine block and the oil pan and push into place. Handle the hose very carefully, because it is easily damaged.
Align the D-shaped hole in the starter with the matching post on the front of the transmission case (Stage 22). Secure with adhesive if necessary.
Hold the transmission case at the rear of the engine block and insert the oil pan into the corresponding area at the bottom of the case, then lower the front of the case into place.
Tighten a type I screw into the hole in the underside of the oil pan to secure the transmission case to the engine block.
Stage completestevie_o attached the following image(s):
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Rank: Super-Elite Groups: Registered
Joined: 30/01/2013 Posts: 4,604 Points: 13,607 Location: Monmouthshire UK
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Stage 24 – The engine compartment.
Contains Parts –
Engine compartment
Place the firewall from Stage 23 into the engine compartment and push into place on both sides. Insert the hood lock (Stage 23) into the hole in the rear of the engine compartment.
Place the radiator (Stage 14) between the firewall and the front of the engine compartment and align the hole at the bottom edge of the radiator with the hole in the engine compartment – secure with a type H screw.
Identify the brake master cylinder and the clutch master cylinder from Stage 16. Insert the brake master cylinder into the correct hole in the engine compartment and push fully into place, then push the clutch master cylinder fully into the hole next to the brake master cylinder.
Stage Complete.stevie_o attached the following image(s):
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Rank: Super-Elite Groups: Registered
Joined: 30/01/2013 Posts: 4,604 Points: 13,607 Location: Monmouthshire UK
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Stage 25 – Glove box cover
Contains parts -
Instrument panel
Glove box cover
Insert the glove box cover into the area of the instrument panel then insert the pin at the end of the glove box cover into the hole in the side of the instrument panel.
Keep the pin in the hole and lever the other side of the cover towards the other side of the glove box section then push the cover into the glove box section until the pin enters the hole.
The top edge of the glove box cover should be aligned with the back of the panel.
Open and close the glove box cover to check that the movement is smooth and unobstructed.
Brush any dust from the instrument panel and store the assembly in a plastic bag.
Stage complete.
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