Build the legendary PORSCHE RS 2.7 Pack 5
Build the legendary P O R S C H E RS 2.7 Contents PAGE STAGE 29 Rear disc brake 120 30 Rear wheel 123 31 Rear disc brake 126 32 Rear wheel 129 33 The crankcase (1) 133 34 The crankcase (2) 136 35 The left exhaust heat exchanger 140 36 The right exhaust heat exchanger 144 Editorial and design by Continuo Creative, 39-41 North Road, London N7 9DP. Published in the UK by De Agostini UK Ltd, Battersea Studios 2, 82 Silverthorne Road, London SW8 3HE. Published in the USA by De Agostini Publishing USA, Inc.,121 E. Calhoun Street, Woodstock, IL 60098. All rights reserved 2017 Warning: Not suitable for children under the age of 14. This product is not a toy and is not designed or intended for use in play. Items may vary from those shown.
PORSCHE 911 CARRERA Stage 29: Rear disc brake In this stage, you will assemble the first rear disc brake. YOUR PARTS 29A 29B 29C 29D 29E 29A Rear brake disc cover 29D Rear brake caliper B 29B Rear brake disc 29E 29C Rear brake caliper A 6 1.7 4mm screws DIAGRAM 120 Brake hose connector
Step by Step 29A STEP 29-1 Align the holes in rear brake caliper A (29C) with those in the rear brake disc cover (29A). Fix the parts together with two screws. 29C 29A 29B STEP 29-2 Turn the assembly over and push the rear brake disc (29B) into the centre of the rear brake disc cover (29A). STEP 29-3 Align the holes in rear brake caliper B (29D) with those in the rear brake caliper A (29C). 29B 29C 29D 121
PORSCHE 911 CARRERA STEP 29-4 Fix the parts together with two screws. 29C 29D STEP 29-5 Insert the larger end of the brake hose connector (29E) into the hole in rear brake caliper A. 29C 29E STAGE COMPLETE Here is how your assembly should look at the end of this stage. Keep any unused parts, assemblies and tools to one side until they are needed. 122
Step by Step Stage 30: Rear wheel In this stage, you will assemble the first of the two rear wheels. YOUR PARTS 30A 30C 30B 30D 30E DIAGRAM 30A Tyre 30B Rim 30C Wheel 30D Hub cover 30E Washer 4 2 4mm screws 123
PORSCHE 911 CARRERA 30B STEP 30-1 Place the rim (30B) into the tyre (30A). 30A 30C STEP 30-2 Turn the assembly over and insert the wheel (30C) into the tyre, aligning the holes of both. 30B 30A 124
Step by Step 30C 30B 30A STEP 30-3 Tighten three screws into the three holes in the wheel. STAGE COMPLETE Here is how your assembly should look at the end of this stage. Keep any unused parts, assemblies and tools to one side until they are needed. 125
PORSCHE 911 CARRERA Stage 31: Rear disc brake In this stage, you will assemble the second rear disc brake. YOUR PARTS 31A 31B 31C 31D 31E 31A Rear brake disc cover 31D Rear brake caliper B 31B Rear brake disc 31E Brake hose connector 31C Rear brake caliper A 6 1.7 4mm screws DIAGRAM 126
Step by Step 31A STEP 31-1 Align the holes in rear brake caliper A (31C) with those in the rear brake disc cover (31A). Secure the parts with two screws. 31C 31A 31B STEP 31-2 Turn the assembly around and place the rear brake disc (31B) into the centre of the rear brake disc cover (31A). 31B 31D 31C 127 STEP 31-3 Align the holes in rear brake caliper B (31D) with those in the rear brake caliper A (31C).
PORSCHE 911 CARRERA STEP 31-4 Make sure the holes in the brake calipers are aligned, then tighten two screws into them to secure. 31C 31D STEP 31-5 Insert the larger end of the brake hose connector (31E) into the hole in rear brake caliper A (31C). 31E 31C STAGE COMPLETE Here is how your assembly should look at the end of this stage. Keep any unused parts, assemblies and tools to one side until they are needed. 128
Step by Step Stage 32: Rear wheel In this stage, you will assemble the second rear wheel and fit the disc brakes onto the chassis assembly. YOUR PARTS 32A 32B 32A Tyre 32B Rim 32C Wheel 32D Hub cover 32E CM Washer 4 2 4mm screws 3 CM 2.3 5mm screws 32C 32D 32E DIAGRAM 129
PORSCHE 911 CARRERA 32B 32C 32B 32A 32A STEP 32-1 STEP 32-2 Insert the rim (32B) into the tyre (32A). Turn the assembly over and insert the wheel (32C) into the tyre. Make sure that the screw holes of the wheel and rim are aligned. STEP 32-3 32C Tighten three screws into the holes in the wheel. 32B 32A 31A 24C STEP 32-4 Place the main body assembly upside down on a flat surface. Place one of the rear brake assemblies onto the swingarm of the right rear suspension, with the brake caliper facing forward. 130
Step by Step STEP 32-5 27B Locate the free ends of the rear brake hose and handbrake cable (27B). Pass them between the swingarm and the underbody, and connect them to the protruding parts of the brake hose connector (31E). 19A 24C 31A 31E 24C STEP 32-6 31B Mount the right rear wheel onto the rear disc brake. Make sure the post on the inside of the rim engages with the disc. Then place a washer (32E) into the centre of the rim and secure the wheel with a CM screw. 32E 32B CM 27B 23C 23C 29C 29E STEP 32-7 Take the remaining rear disc brake and set it onto the swingarm of the left rear suspension. Follow the previous steps to mount the left rear wheel. Position the disc so that the calipers are facing forward. STEP 32-8 Locate the free ends of the rear brake hose and handbrake cable (27B). Pass them between the left rear suspension swingarm and the underbody, and connect them to the protruding parts of the brake hose connector. 131
PORSCHE 911 CARRERA STEP 32-9 Fit the post on the inside of the rear wheel into the space in the centre of the brake disc. Place the washer (30E) into the rim and secure the wheel with a CM screw. 23C 29B 30E CM 30B 32D 30D 30B STEP 32-10 Insert the hub covers (30D and 32D) into the centres of the rims. STAGE COMPLETE Here is how your assembly should look at the end of this stage. Keep any unused parts, assemblies and tools to one side until they are needed. 132
Step by Step Stage 33: The crankcase (1) In this stage, you will assemble the first parts of the crankcase. YOUR PARTS 33A 33B 33D DIAGRAM 33A Crankcase 33B Right cylinder block 33C Left cylinder block 33D Oil pipe 33C 7 2 4mm screws 133
PORSCHE 911 CARRERA 33B STEP 33-1 Insert the posts on the inside of the right cylinder block (33B), marked R, into the holes in the tabs at the side of the crankcase (33A). 33A STEP 33-2 Secure the block to the crankcase with two screws inserted through the crankcase tabs (33A). 33A 33C 33A STEP 33-3 Insert the posts of the left cylinder block (33C) into the holes in the tabs on the other side of the crankcase (33A). 134
Step by Step 33C 33A STEP 33-4 Secure the left cylinder block (33C) to the crankcase with two screws. 33D STEP 33-5 33B Align the hole in the oil pipe (33D) with the hole in the right cylinder block, as shown. Secure it with a screw. STAGE COMPLETE Here is how your assembly should look at the end of this stage. Keep any unused parts, assemblies and tools to one side until they are needed. 135
PORSCHE 911 CARRERA Stage 34: The crankcase (2) In this stage, you will continue the assembly of the crankcase and then fit it to the engine. YOUR PARTS 34A Right cylinder head cover 34A 34B 34C 34B Right cover 34C Left cylinder head cover 34D Left cover 34D 34E 34F 34E Crankshaft pulley 1 34F Crankshaft pulley 2 34G Fan belt 12 2 4mm screws 3 CP 1.7 3 5mm screws 34G CP DIAGRAM 136
Step by Step 34A STEP 34-1 Place the right cylinder head cover (34A), marked R, on the right cylinder block, inserting the three projections into the corresponding holes. Secure the parts together with a CP screw. 33B CP STEP 34-2 Place the left cylinder head cover (34C), marked L, on the left cylinder block (33C). Secure it there with a CP screw inserted from the inside. 34C 33C CP 34B 33B STEP 34-3 Insert the pins on the right cover (34B) into the holes in the right cylinder block, as shown. Secure the parts with two screws. 137
PORSCHE 911 CARRERA STEP 34-4 Insert the pins of the left cover (34D) into the holes in the left cylinder block (33C). Use two screws to secure the cover. 33C 34D STEP 34-5 Place crankshaft pulley 1 (34E) onto the post on the rear of the crankcase, with the smooth side facing forward. Next, fit crankshaft pulley 2 (34F) onto the post so that the small circular depressions are facing the back. Use a screw to secure the parts. 33A 34E 34F 34G 8F STEP 34-6 8E 19A 138 Locate the fan pulley (8F) on the engine. Place the fan belt (34G) in the space between the pulley and the fan, passing the belt down, as shown in the inset.
Step by Step 33A 34E 34F 21A 19A 8A 34G 33A STEP 34-7 Turn the main body assembly over. Pull the fan belt down and place it over the crankshaft pulleys. Insert the semicircular tab on the crankcase (33A) into the transmission case. Make sure that the posts of the engine fit into the corresponding holes in the crankcase. 8A STEP 34-8 Fix the crankcase to the engine top with four screws. STAGE COMPLETE Here is how your assembly should look at the end of this stage. Keep any unused parts, assemblies and tools to one side until they are needed. 139
PORSCHE 911 CARRERA Stage 35: The left exhaust heat exchanger In this stage, you will assemble the left exhaust heat exchanger. YOUR PARTS 35A Left exhaust heat exchanger 1 35A 35B 35C 35D 35E 35G 35F 35H 35I 35J DIAGRAM 140 35B Left exhaust heat exchanger 2 35C Left exhaust heat exchanger 3 35D Left exhaust heat exchanger 4 35E Left exhaust heat exchanger 5 35F Left exhaust heat exchanger 6 35G Left exhaust heat exchanger 7 35H Left exhaust heat exchanger 8 35I Left exhaust heat exchanger 9 35J Left exhaust heat exchanger 10 20 1.7 4mm screws
Step by Step 35H 35G 35F 35F STEP 35-1 STEP 35-2 Place left exhaust heat exchanger 7 (35G) into the left exhaust heat exchanger 6 (35F), and secure it with two screws. Place left exhaust heat exchanger 8 (35H) into the rectangular socket at the end of left exhaust heat exchanger 6 (35F), as shown. Secure with an screw. 35F 35F 35E 35E STEP 35-3 Engage the left exhaust heat exchanger 5 (35E) with the left exhaust heat exchanger 6 (35F), aligning the indicated holes of both parts. STEP 35-4 Tighten an screw into each of the two indicated holes to fix the parts together. 141
PORSCHE 911 CARRERA 35C 35D 35B 35B STEP 35-5 Align the hole in the tab on left exhaust heat exchanger 4 (35D) with the hole in the end of left exhaust heat exchanger 2 (35B), as shown. Use an screw to secure it. STEP 35-6 Insert the pins on the inside of left exhaust heat exchanger 3 (35C) into the holes in left exhaust heat exchanger 2 (35B). Secure the parts with an screw, inserted through the hole in the centre of left exhaust heat exchanger 3 (35C). 35A 35A 35E STEP 35-8 STEP 35-7 Place this assembly onto the parts from Step 35-4, aligning the pins and holes. Secure the two assemblies together with two screws. Insert the pins of the assembly into the holes in left exhaust heat exchanger 1 (35A). Secure the parts together from below with four screws. 142
Step by Step 35I STEP 35-9 Place left exhaust heat exchanger 9 (35I) onto the end of left exhaust heat exchanger 1 (35A), positioned so that the free end is pointing upwards. 35A 35J 19A STEP 35-10 Insert the end of left exhaust heat exchanger 10 (35J) into the bottom end of the hot air pipe (16F). Secure it there with two screws inserted through the chassis, as shown. 34C 16F 12A STAGE COMPLETE Here is how your assembly should look at the end of this stage. Keep any unused parts, assemblies and tools to one side until they are needed. 143
PORSCHE 911 CARRERA Stage 36: The right exhaust heat exchanger In this stage, you will assemble the right exhaust heat exchanger. YOUR PARTS 36A 36B 36D 36C 36E 36F 36G DIAGRAM 36A Right exhaust heat exchanger 1 36B Right exhaust heat exchanger 2 36C Right exhaust heat exchanger 3 36D Right exhaust heat exchanger 4 36E Right exhaust heat exchanger 5 36F Right exhaust heat exchanger 6 36G Right exhaust heat exchanger 7 13 1.7 4mm screws 144
Step by Step STEP 36-1 36D Align the tab on right exhaust heat exchanger 4 (36D) with the hole in the end of right exhaust heat exchanger 2 (36B), as shown. Use an screw to secure them. 36B STEP 36-2 36C Insert the pins of right exhaust heat exchanger 3 (36C) into the holes in right exhaust heat exchanger 2 (36B). Secure the parts with an screw. 36B 36B STEP 36-3 36C Insert the pins on the assembly into the holes in right exhaust heat exchanger 1 (36A). Fix them together with four screws, inserted from below. 36A 145
PORSCHE 911 CARRERA 36E STEP 36-4 Combine right exhaust heat exchanger 5 (36E) with right exhaust heat exchanger 6 (36F), aligning the parts as shown. 36F STEP 36-5 36E Fix the two parts together with two screws. 36F 146
Step by Step 36A STEP 36-6 Place the two assemblies together, as shown, and secure with two screws. 36F 36G STEP 36-7 36A Place right exhaust heat exchanger 7 (36G) onto right exhaust heat exchanger 1 (36A). Position the part so that the end is pointing upwards. STAGE COMPLETE Here is how your assembly should look at the end of this stage. Keep any unused parts, assemblies and tools to one side until they are needed. 147