Chapter 11. Engine & Associated Systems Contents INTRODUCTION. Tools Required

Transcription

1 Chapter 11 Engine & Associated Systems Contents INTRODUCTION...1 Tools Required...1 Parts Required...2 FITTING OF ENGINE AND SYSTEMS Fitting Chassis Mount Fitting Radiator Brackets Preparing Engine Fitting Engine...3 INTRODUCTION 5 Fitting Cooling System Fitting Header Tank Fitting Sender Wires Fitting ECU & Relays Fitting Oil Catch Tank Fitting Fuel Hose... 8 A 2000cc Zetec engine is supplied with the Aero Race Car along with throttle bodies, ECU and a type 9 gear box. The engine is supplied complete and ready to fit. This chapter also covers fitting of the cooling system, engine wiring harness/ecu and exhaust system. Tools Required A. Engine Hoist B. Socket Set C. Spanner Set D. Rivet Gun E. Torque Rench

2 Engine & Associated Systems 11 2 Parts Required A. Engine Mounting Plate A B B. Radiator Bracket C. Radiator D. Compleat Engine & Gearbox E. Webcon Wiring Harness F. ECU G. ECU Brackets H. Oil Catch Tank C D I. Expansion Tank J. Kinked Water Hose K. 90 Water Hose L. Alluminium Water Pipe (long) M. Alluminium Water Pipe (short) N. Large P Clips x2 O. Jubalie Clips x8 F E G P. Exhaust Manifold Q. Silencer R. Silencer Bracket H I J I K L N N O M O P Q

3 Engine & Associated Systems 11 3 FITTING OF ENGINE AND SYSTEMS 1 Fitting Chassis Mount 9 Secure with six 4.1mm rivets. (Fig2.2) 1 Locate the nearside chassis engine mount from your parts. 2 Position the bracket on the flat plate welded to the chassis 3 Secure using M8x25mm bolts with plain washers on both sides and nyloc nuts. (Fig1.1) Fitting Radiator Brackets 4 Locate from your parts the two aluminium radiator brackets, along with two M6x16 cap head screws. 5 Fit the aluminium panels to the radiator with one M6x16 cap head screw for each bracket along with a spring washer on each. (Fig2.1) 3 Preparing Engine 2.2 Your engine will be supplied to you ready to fit with a gear box throttle bodies and senders fitted. Be careful when lifting the engine into the car, take your time and use proper lifting equipment Do not position yourself under a suspended engine or torque any bolts Connect the engine securely to your hoist; it is preferable to have an engine stabilizer rather than using rope. 4 Two people are required to fit the engine safely. 4 Fitting Engine 1 Lift the engine up high enough so as the gearbox shaft will clear the chassis with the engine at an angle. (Fig4.1) 1 To fit the engine the gear stick needs to be removed to clear the tunnel. (Fig3.1) Push the engine in towards the chassis with one person manning the hoist and one on the end of the gearbox, pushing it down to clear the top of the tunnel. (Fig4.2) 2.1 The alluminium brackets need to be fitted to the radiator before they are riveted to the car. 6 Attach the radiator to the lower mounting brackets welded to the chassis. Fix using M6x16 cap head screw one spring washer and one plain washer. 7 Position the radiator so that is sitting level to the chassis. 8 Using the aluminium brackets as a template drill six 4.1mm holes in the chassis cross member Remove the three bolts securing the gearstick. Note how the stick fits the detent in the box for refitting. (Fig3.2) The engine is a tight fit in a race car chassis and will require a bit of maneuvering to get it into position. 4 Attach the gearbox mount first then lower the engine down onto its engine mounts. (Fig4.3)

4 Engine & Associated Systems 11 4 The mounts come with the nyloc nuts fitted to them, so they need removing before lowering the engine on to its mounts Push the end with the bend into the flexible hose connected to the thermostat housing. Position the jubilee clip over the aluminium pipe and tighten to secure the two together. 6 Cut a 170mm length of flexible water hose and connect it to the aluminium pipe just fitted. 7 Place two jubilee clips on to the hose and tighten one down securing the hose and the aluminium pipe together. (Fig5.2) Fit the nyloc nuts on to the engine mounts with a plain washer and tighten to 47Nm (35ft/lbs). 5 Fitting Cooling System 1 Locate the hoses and aluminium pipes from your parts ready to hand. 2 Cut a 100mm length of flexible water hose. Push the hose on to the thermostat housing (A) at the back of the engine. (Fig5.1) Push the remaining end of the hose onto the upper hose of the radiator secure with the remaining jubilee clip. 9 Locate the flexible hose with 90 bend, push it on to the water pump located at the front nearside of the engine. 10 Place two 40mm jubilee clips on to the hose. Tighten one jubilee clip to the water pump outlet securing the hose to the pump. (Fig5.3) Push the end of the kinked pipe on to the lower radiator outlet. Secure with the remaining jubilee clip. 15 The two aluminium pipes require securing to the chassis, this is done with large P clips. 16 Position a P clip over the upper hose near to the nose end of the nose cone. (Fig5.6) A Place two 40mm jubilee clips over the hose. Position one of the clips over the thermostat housing and tighten 4 Locate the long section of aluminium water pipe, it has a large curve bent into one end Locate the small straight section of aluminium pipe with a tee piece on it. Push it on to the 90 hose and secure it to the hose with the remaining jubilee clip. (Fig5.4) 12 Locate the kinked hose and push it on to the end of the section of pipe just fitted 13 Place two 40mm jubilee clips onto the hose. Tighten one of the clips securing the hose to the aluminium pipe. (Fig5.5) Line the hole in the P clip up with the center of the cross member and drill a hole into the chassis. 5.7

5 Engine & Associated Systems Tap into the chassis with an M5 tap and secure the clip down with an M5 dome headed screw and spacer. (Fig5.7) 19 Position another P clip over the lower aluminium pipe. (Fig5.8) 15mm 300mm Line it up with the center of the chassis down tube that can be seen behind the front nearside wheel. 21 Drill a 4.1mm hole and tap an M5 thread in to the chassis. 22 Secure the pipe with a M5 dome headed screw. 6 Fitting Expansion Tank 23 Locate the expansion tank, small bore aluminium pipe, reducer hose and small bore kinked hose from your parts Drill the other two holes using the bracket as a guide and rivet in position 27 Secure the expansion tank to the bracket with an M5x16mm cap screw and nyloc nut. Place a washer either side of the cap screw. 28 Position the tank so that it is level. Drill a hole for the other mounting through the scuttle using the tank as a guide. 29 Secure with an M5 cap screw and nyloc nut. Fit a washer either side of the cap screw. (Fig6.2) Fit the small bore kinked hose to the end of the small bore aluminium pipe and secure with 25mm jubilee. 33 Place a jubilee clip on to the hose. Secure the hose to the main water pipe T piece. Secure with the remaining jubilee clip. 34 Secure the small bore aluminium pipe to the large upper main pipe with cable ties. 35 Locate the small silicon bung from your parts. 36 Fit the bung to the spare union on the thermostat housing. Secure with a 25mm jubaliee clip. (Fig6.5) NOTE The expansion tank is mounted to the offside of the scuttle. It is secured to the scuttle in two places. One mount is straight through the left hand mounting tab. The right hand mounts to an aluminium bracket which is riveted to the scuttle Fit the reducing hose to the lower outlet on the expansion tank and secure with 30mm jubilee clip. (Fig6.3) 7 Fitting Sender Wires Locate the coil plug on the wiring loom it should be exiting the offside of the tunnel and is marked coil. (Fig7.1) 24 Mount the aluminium bracket to the scuttle. Position the lower two holes 15mm from the bottom of the scuttle and 300mm from the bottom left of the scuttle. (Fig6.1) 25 Drill the lower two holes to the diagram. Secure with rivets Locate the aluminium pipe from your parts. Fit to the reducing hose and secure with a 25mm jubilee clip. It then runs down to the T in the main lower aluminium water pipe. (Fig6.4) Plug the connector in to the coil which is located at the rear of the engine rocker cover. (Fig7.2)

6 Engine & Associated Systems The plug has a wire spring clip that needs to be removed before fitting the plug and then needs to be repositioned to lock the plug in place. Most sender plugs are mounted in a similar way with a spring retaining clip. 4 Locate the crank position connector on the wiring loom, it should run down the nearside bulkhead with the starter motor wires. 5 Plug the connector in to the sender which is found at the lower near side of the engine block just before the gearbox. (Fig7.3) Locate the fuel injection wires, which exit the offside of the tunnel and are not secured at the moment. They are labeled, INJ1, INJ2, INJ3, INJ4, AirTemp and one with a RED label on it. (Fig7.6) Connect the RED labeled plug to the throttle position sensor (green wire) that can be found near to the alternator. (Fig7.9) Locate the oil pressure wires (White with black sheath) from the loom which should be routed along with the alternator wires. 16 Connect the eyelet to the oil pressure sender mounted on the nearside of the engine by unscrewing the plastic nut. (Fig7.10) Fit the retaining spring clip as done for the coil connector. 7 Locate the water temperature wires (green and black) the black wire has an eyelet crimped to it, and the green wire has a spade connector. They should exit the tunnel on the nearside 8 The sender is located on the thermostat housing next to the engine water outlet. (Fig7.4) 9 Remove the temp sender from the engine (comes with gauges if you don t have a complete kit) Refit the sender, trapping the eyelet (black wire) behind it. (Fig7.5) 10 Secure the green wire to the end of the sender Connect the 4 injector pugs (INJ1 etc) into the injectors on the throttle bodies. (Fig7.7) Connect the AirTemp plug to the air temp sender which is mounted to the air filter back plate. (Fig7.8) Locate the water temp connector for the ECU (Blue and Black). It should be run along the offside of the chassis with the alternator wires. 18 Connect the plug to the water temp sender plug mounted to the head under the inlet manifold. near the alternator (Fig7.11)

7 Engine & Associated Systems Secure any loose wires on this side of the engine and ensure that all connection are correct. 20 Locate the alternator wires (Brown and Brown/Yellow) they should run along the offside of the chassis. 21 Connect the large brown wires (two wires into one eyelet) to the left connection on the back of the alternator should be marked (B) (Fig7.12) 8 Fitting ECU & Relays 1 Locate from your parts the ECU and its mounting brackets. The ECU is to be mounted in the passenger foot well weather the car is right hand drive left. 2 Secure the aluminium brackets to the ECU. It is secured with two M5 cap head screws on each side with nyloc nuts fitted on the bottom. (Fig8.1) 7 Find a suitable location under the scuttle on the tunnel top panel where the wires are not stretched 8 Mark the position of one of the pre drilled holes in the bracket onto the tunnel top. 9 Drill a 4.1mm hole in the tunnel top and secure the plastic bracket to the tunnel top with a rivet. 10 Fit the relays to the bracket and secure any loose wiring with cable ties and saddle clamps. (Fig8.3) Ensure that all the cables and wires are secured properly, with adequate clips and saddles Connect the brown/yellow wire to the smaller terminal next to the large brown wires. The alternator shown in the picture is a bosh. This may be a different make. The connection though is the same. 23 Locate the Lambda sender from the wiring loom it should be routed across the top of the nearside bulkhead and then down to the bottom of the car. Note its location as it will be fitted to the exhaust manifold after the body work has been fitted. (Fig7.13) Plug the ECU into the engine harness and position in the desired location. Ensuring that the wires are not over stretched. 4 Mark the positions of the brackets on the tunnel of the passenger footwell. 5 Drill the four 4.1mm holes and secure with rivets. (Fig8.2) 9 Fitting Oil Catch Tank 1 Locate the aluminium catch tank from your parts. The catch tank is mounted to the right offside of the engine. The clearance between the tank, master cylinders and steering shaft is limited. Don t fit the tank until the master cylinders and steering shaft are in place. 2 The tank sits on two pieces of aluminium that bridge the two main chassis rails. (Fig9.1) Locate the plastic relay mounting bracket on the engine harness (it is pre attached to the relays)

8 Engine & Associated Systems Position the tank in place and check the clearance to the parts surrounding it. When a suitable position has been decided mark where the tags on the tank line up with the chassis rails. 4 Cut two pieces of scrap aluminium and rivet them onto the chassis. 5 Drill a hole in each of the two tabs on the catch tank. (Fig9.2) 11 Place a jubilee clip over the hose before attaching it to the breather pipe. 12 Locate the 20mm O/D fuel hose, push the hose on to one of the smaller pipes exiting the catch tank. Fit a jubilee clip over the pipe and tighten. 13 Route the hose round the coil to the other side of the engine and connect the hose to the crank case emishion control valve located at the rear near side of the engine. Cut to length as required. (Fig9.5) Reposition the tank on the straps and drill through the aluminium plate previously fitted to the chassis. 7 Secure the catch tank with M5 cap head screws and nyloc nuts fit repair washers to each side. (Fig9.3) Push the remainder of the 20mm O/D fuel hose on to the remaining pipe exiting the catch tank. Fit a jubilee clip and tighten. 15 Route the hose to the vacuum union on the air filter back plate. (Fig9.6) Secure the hose with a jubilee clip. 6 Locate the feed hose on the throttle body, route it over to the hard feed line. (Fig10.3) Locate a length of 25mm O/D flexible fuel hose and a length of 20mm O/D flexible fuel hose. 9 Push the 25mm O/D fuel hose onto the larger tube on top of the catch tank fit a jubilee clip over the hose and tighten. 10 Run the hose over to the breather pipe on the rocker cover cutting to the required length (Fig9.4) 10 Fitting Fuel Hose The Webcon throttle bodies come complete with fuel hose attached already. The hoses need to be attached to the hard lines exiting the tunnel. 2 Note which hard line is the feed and which one is the return. 3 Locate the hose that is attached to the fuel regulator, route it neatly under the throttle bodies to the hard lines. (Fig10.1) 4 Offer the hose up to the return line and cut to length. (Fig10.2) Offer the hose up to the feed hard line and cut to length. Secure with a jubilee clip. 11 Fitting- Exhaust The Exhaust should not be fitted until the body has been fitted as it needs to exit through the side panel 8 Place the manifold on to the exhaust ports by feeding it through the body work on the nearside of the car. 9 Bolt the manifold in place with the bolt supplied with the engine (Fig11.1) 9.4

9 Engine & Associated Systems Locate the silencer bracket from your part and bolt it through the hole drilled when the body was fitted into the M10 stud welded to the chassis using M10x50 bolt. 11 Apply some silicone exhaust paste to the end of the manifold (about 25mm), feed the silencer pipe on to the manifold with the exhaust clamp fitted first. (Fig11.2) Secure the silencer to the rubber mount with the nut fitted to it. Be careful not to twist the rubber mount when tightening. (Fig11.3) 11.3