Build the legendary PORSCHE RS 2.7. Pack 3

Build the legendary PORSCHE RS 2.7 Pack 3

Build the legendary P O R S C H E RS 2.7 Contents PAGE STAGE 13 The rear engine cover 55 14 The left intake manifolds and throttle bodies 59 15 The right intake manifolds and throttle bodies 63 16 The intake manifolds and throttle bodies (1) 67 17 The intake manifolds and throttle bodies (2) 71 18 The oil filter and engine compartment 75 19 The underbody (1) 79 20 The underbody (2) 83 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.

Step by Step Stage 13: The rear engine cover In this stage, you will assemble the engine s rear cover, which is made up of three parts. When you have assembled the cover, you will fit it to the engine. YOUR PARTS 13B 13A 13C 13D BM DIAGRAM 13A Engine compartment panel 13B Rear engine cover 1 13C Rear engine cover 2 13D Rear engine cover 3 3 BM 2 4mm screws 6 1.7 4mm screws 55

PORSCHE 911 CARRERA 13D 13C STEP 13-1 Place the rear engine cover 2 (13C) on a flat surface so that the four central screw holes are visible. Place the rear engine cover 3 (13D) onto the central section of cover 2, and secure the assembly with four screws. 13C 13B STEP 13-2 Insert the posts at the ends of rear engine cover 2 (13C) into the holes in rear engine cover 1 (13B). Make sure the parts are oriented correctly. 56

Step by Step BM BM 13B 8A STEP 13-3 Place the rear engine cover assembly onto the underside of the engine, placing the holes onto the three pins and securing the two assemblies together with two BM screws. 13A STEP 13-4 Keep the engine compartment panel (13A) in a safe place for later use. 57

PORSCHE 911 CARRERA THE FAMOUS ENGINE OF THE PORSCHE 911 The Porsche 911 is characterised by its air-cooled flat-six engine. The choice to use this engine goes back to the inception of the 911 in 1963. The flat engine, placed low at the rear, gave the car a low centre of gravity giving it more stability at higher speeds. A total of 1,580 units were launched to comply with the regulations that would allow it to participate in the FIA GT World Championship. With a cylinder bore increased to 90mm and a stroke maintained at 70.4mm, the cylinder capacity increased from 2.4 litres on the previous model to 2.7 litres (2,687cc). The compression ratio was increased to 8.5: 1 and a power of 210bhp was reached at 6,300rpm with a maximum torque of 255Nm at 5,100rpm. 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. 58

Step by Step Stage 14: The left intake manifolds and throttle bodies In this stage, you will assemble the left intake manifolds and throttle bodies, which will then be ready to be fitted to the engine in the next stage. YOUR PARTS 14B 14D 14N 14G 14H 14I 14O 14E 14C 14L 14M 14F 14A 14J 14K BP FP DIAGRAM 14A Left intake manifolds and throttle bodies 14B Throttle control rod 1 (2) 14C Throttle control lever 1 14D Throttle control lever 2 14E Throttle control rod 2 14F Throttle control rod 3 14G Throttle control bracket 14H MFI (mechanical fuel injection) microswitch 14I Throttle control lever 3 14J Guides (4) 14K Right intake manifolds and throttle bodies 14L Throttle control lever 4 (2) 14M Throttle control rod 4 14N Throttle control rod 5 14O Throttle control lever 5 9 BP 1.2 3mm screws 7 FP 1.5 4mm screws 59

PORSCHE 911 CARRERA 14A STEP 14-1 Place the intake manifolds and left throttle bodies (14A) so that the engraved L is visible. Position two of the guides (14J) over the holes in the left throttle bodies (14A). Secure with two FP screws from the opposite side. FP FP 14J STEP 14-2 14A Align the hole of the shorter wing of throttle control lever 1 (14C) with the indicated hole in the left throttle bodies (14A). Secure the part with a BP screw. 14C BP 14F 14F 14D 14G BP BP STEP 14-3 STEP 14-4 Secure throttle control rod 3 (14F) to the side of the throttle control bracket (14G), using a BP screw through the indicated hole. Secure throttle control lever 2 (14D) to the other end of throttle control rod 3 (14F) with a BP screw, as shown. Do not overtighten the screw, as the lever must be able to move. 60

Step by Step 14E 14D 14B STEP 14-5 Insert the straight end of the throttle control rod 2 (14E) into the free hole in throttle lever 2 (14D), and then into a throttle control rod 1 (14B), as shown. STEP 14-6 Insert the ends of throttle control rod 2 (14E) and throttle control rod 1 (14B) into the two indicated holes in the left throttle bodies (14A ) and the throttle control lever 1 (14C). 14A 14E 14C 14B 14D 14A STEP 14-7 Insert the post of the MFI microswitch (14H) into the hole in the left throttle bodies (14A). The other post should be pointing up. 14H 14I STEP 14-8 14H Place the hole at the end of throttle control lever 3 (14I) onto the post on top of the MFI microswitch (14H). 61

PORSCHE 911 CARRERA 14G STEP 14-9 Insert the free end of throttle control rod 2 (14E) into outer hole of throttle control lever 3 (14I). Then lower throttle control rod 3, so that the throttle control bracket (14G) is positioned on the other side of the lever (14I), and insert control rod 2 into it. 14I 14E STEP 14-10 14I FP Tighten an FP screw through throttle control lever 3 (14I) and into the throttle control bracket (14G) to secure them. 14G 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. 62

Step by Step Stage 15: The right intake manifolds and throttle bodies In this stage, you will assemble the right intake manifolds and throttle bodies, supplied in the previous stage, as well as the air filter housing. YOUR PARTS 15A 15C 15D 15B 15A Air filter housing 15B Air filter housing cover 15C Mounting base R 15D Mounting base L 15E Wing screws (2) 15F MFI connector 15G Left Injector hoses (3) 15H Right injector hoses (3) 15F 15E 15G 15H 6 1.7 4mm screws DIAGRAM 63

PORSCHE 911 CARRERA STEP 15-1 BP Take throttle control rod 4 (14M) and the two throttle control levers 4 (14L). Place the levers onto the ends of the rod and secure them with two BP screws. BP 14L 14L 14M 14B STEP 15-2 14L Insert the straight end of throttle control rod 5 (14N) into one of the free holes in throttle levers 4 (14L), and then into throttle control rod 1 (14B), as shown. 14N 14K 14K FP 14O BP 14J 14J STEP 15-3 STEP 15-4 Place the right intake manifolds and throttle bodies (14K) so that the engraved R is visible. Position the two guides (14J) over the holes in the throttle bodies (14K). Secure with two FP screws from the opposite side. Align the hole of the shorter wing of throttle control lever 5 (14O) with the indicated hole in the right throttle bodies (14K). Secure the part with a BP screw. 64

Step by Step 14K STEP 15-5 Align the hole in the shorter wing of the throttle control lever 1 (14C) with the hole in the right intake manifolds and throttle bodies (14K). Secure the two parts together using a BP screw. 14C BP STEP 15-7 There are letters R and L engraved on the inside of the air filter housing (15A). Place the mounting base R (15C) on the right side (R) and mounting base L (15D) on the left side, and secure both with two screws each. STEP 15-6 Retrieve the assembly from Step 2, and insert the three posts into the three corresponding holes (indicated) in the control levers and throttle bodies. 14K 15C 15D 14O 14N 14B 15A 15E 15E STEP 15-8 Insert the two wing screws (15E) into the holes at the side of the air filter housing (15B). 65 15B

PORSCHE 911 CARRERA 14K STEP 15-9 14J Insert the three right injector hoses (15H) into the holes in the guides (14J), as indicated in the image. 15H 14A STEP 15-10 Now place the three left injector hoses (15G) into the guides in the left throttle bodies, as shown. 15G 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. 66

Step by Step Stage 16: The intake manifolds and throttle bodies (1) In this stage, you will fit the left inake manifolds and throttle bodies to the engine. YOUR PARTS 16A 16B 16C 16D 16E 16F 16G 16H DP DIAGRAMS 16A Spark plug leads left (3) 16B Spark plug leads right (3) 16C Air intake hose 1 16D Air intake regulator housing 16E Air intake hose 2 16F Hot air hose 16G Ignition coil lead 16H Oil hose 12 1.7 4mm screws 2 DP 1.5 3mm screws 67

PORSCHE 911 CARRERA DP 16D 16E 16D 16C STEP 16-1 STEP 16-2 Place the tab of the air inlet regulator housing (16D) into the notch in air intake hose 2 (16E). Secure the two parts with a DP screw. Place air intake hose 1 (16C) at the other end of the air intake regulator housing (16D). Secure with an screw. STEP 16-3 Place the air filter housing (15B) on the free end of the air intake hose 1 (16C). They can fit together only one way round. Secure with an screw. 15B 16C STEP 16-4 Secure the assembly to the the air filter housing from the previous stage with an screw. 15B 15A 68

Step by Step STEP 16-5 9E Retrieve the engine top assembly. Locate the projections in the centre of the ignition coil and the distributor. Place one end of the ignition coil lead (16G) onto the distributor and the other end onto the ignition coil. 16G 9G 8A 14A STEP 16-6 Insert the three left spark plug leads (16A) into the guides on the left intake manifolds and throttle bodies (14A). 14J 16A 14A STEP 16-7 Place the left intake manifolds and throttle bodies (14A) on top of the engine, as shown. Secure from below with three screws. 8A 69

PORSCHE 911 CARRERA 10F 15G 16A 11D 9F 11C STEP 16-8 First connect the three left injector hoses (15G), shown here in three shades of red. Place one end onto the injectors (11D) and the other end onto the left injector outlets (10F). Then connect the left spark plug leads (16A), shown here in orange, blue and green, to the spark plug connectors (11C) and the distributor. You can turn the spark plug connectors (11C) if necessary. 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. 70

Step by Step Stage 17: The intake manifolds and throttle bodies (2) In this stage, you will use the parts provided in the previous stage to complete the assembly of the intake system. YOUR PARTS 17A 17G 17H 17I 17J 17B 17K 17C 17D 17E 17F 17L 17A Engine compartment 17B Engine compartment reinforcements (2) 17C Oil filter holder 17D Oil filler cap 17E Oil filler tube 17F Engine oil filter 17G Fuse box and rear relay 17H Wing screw 17I CDI control unit (capacitor discharge ignition) 17J MFI fuel filter 17K MFI fuel filter bracket 17L Cold start enrichment solenoid valve 16 1.7 4mm screws DIAGRAMS 71

PORSCHE 911 CARRERA 14k STEP 17-1 Take the three right spark plug leads (16B) from the previous stage, and insert them into the guides on the right throttle bodies, as shown. 16B 14K STEP 17-2 Insert the short end of the MFI connector (15F) through the free hole of throttle control lever 4 (14L) and into the right manifolds. 14L 15F STEP 17-3 Place the free end of the MFI connector (15F) into the hole in the left inlet manifolds (14A). Lower the right manifolds (14K) into place on top of the engine, and secure them from underneath with three screws. 15F 14K 14A 8A 72

Step by Step 10F 15H STEP 17-4 11D 16B 11C Connect the three right injector hoses (15H), shown in three shades of red, to the injectors (11D) and the injector pumps (10F). Connect the right spark plug leads (16B), orange, blue and green, to the spark plug connectors (11C) and to the distributor. 9F 16H STEP 17-5 Connect the oil hose (16H) to the indicated pin on top of the engine. 8A 15A STEP 17-6 16E Lower the air filter housing assembly onto the pins on the top of the left and right inlets. Fit the free end of air intake hose 2 (16E) into the recess in the rear engine cover 1 (13B). 14K 13B 73

PORSCHE 911 CARRERA 10E 16F STEP 17-7 Finally, insert one end of the hot air hose (16F) into the hole in the engine cover and fit the other end onto the thermostat. 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. 74

Step by Step Stage 18: The oil filter and engine compartment In this stage, you begin to assemble the engine compartment using parts supplied with the previous stage. The parts supplied with this stage are fragile, so make sure you store them safely until they are needed. YOUR PARTS 18A 18A Circuit board 18B Tab 18C Speaker 18B 18C DIAGRAM 17K STEP 18-1 Insert the MFI fuel filter bracket (17K) into the top of the MFI fuel filter (17J). Make sure that the projections on the sides of the two parts are aligned. 75 17J

PORSCHE 911 CARRERA 17L 17A 17K 17J STEP 18-2 Locate the three vertically aligned holes in the side of the engine compartment (17A). Place the two projections from the fuel filter and bracket into the top and bottom holes, then tighten an screw through the central hole to secure them. STEP 18-3 Insert the long thin end of the cold start enrichment solenoid valve (17L) into the hole in the top of the MFI fuel filter bracket (17K). STEP 18-4 The CDI control unit (17I) has a rectangular projection at the bottom that engages with a corresponding hole in the engine compartment. Place the CDI control unit into position and secure with an screw. 17I 17A 17I STEP 18-5 Insert the wing screw (17H) into the small hole in the fuse box and rear relay (17G). Place the fuse box and rear relay onto the engine compartment, next to the CDI control unit. Secure it there with an screw. 17H 17A 76 17G

Step by Step 17B 17B STEP 18-6 Insert the two posts of the engine compartment reinforcements (17B) into the holes in the outer corners of the engine compartment (17A), and fix them with screws from below. 17A 17C 17C 17E 17F STEP 18-7 STEP 18-8 Insert the post of the oil filler tube (17E) into the oil filter holder (17C). Secure with an screw. Insert the engine oil filter (17F) into the other hole in the oil filter holder (17C). Secure it with an screw on the other side. 17A STEP 18-9 Insert the engine oil filter and oil filler tube through the large hole in the side of the engine compartment (17A). Push it in until the holder is pressed against the compartment. Secure with an screw on each side. 17E 17C 77

PORSCHE 911 CARRERA 17D STEP 18-10 Place the oil filler cap (17D) onto the end of the oil filler tube. 17E 17A STEP 18-11 13A Place the engine compartment onto the engine compartment base (13A), aligning the posts and holes. Fix the base in position 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. 78

Step by Step Stage 19: The underbody (1) In this stage, you will fit the circuit board and the speaker, provided in the previous stage, to the underbody. YOUR PARTS AM 19A Underbody 3 AM 1.7 3mm screws 6 BM 2 4mm screws 4 HM 2 x 6mm screws BM 19A HM 79 DIAGRAM

PORSCHE 911 CARRERA 18C STEP 19-1 Place the underbody (19A) on a flat surface, with the inside facing up. Locate the three holes near the front of the underbody. Then place the speaker (18C) in the raised circular area. 19A HM HM HM STEP 19-2 Secure the speaker (18C) with three HM screws. 18C 80

Step by Step 18A STEP 19-3 Take the circuit board (18A) and place it next to the speaker, with the large hole fitting over the indicated post. Align the holes in the corners with the corresponding posts. When handling the circuit board, be careful not to touch the metal parts, and to take care, because the board is fragile. 18C 19A BM BM BM BM STEP 19-4 Tighten a BM screw into the holes in each corner of the circuit board (18A). Be careful not to overtighten them, to avoid damaging the board. 18A 81

PORSCHE 911 CARRERA AM 18B 18C 18A STEP 19-5 Pass the wires from the circuit board (18A) between the two posts next to it. Place the tab (18B) onto the posts, and secure it with two AM screws, as shown. 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. 82

Step by Step Stage 20: The underbody (2) In this stage, you will fit the various parts of the underbody together. YOUR PARTS 20A Central underbody panel 20B Steering rack panel 20C Steering column bracket 8 BM 2 4mm screws 6 CM 2.3 5mm screws 11 IM 2 5mm screws 20A DIAGRAM 20B 20C CM BM IM 83

PORSCHE 911 CARRERA IM IM IM IM 19A STEP 20-1 Lay the central underbody panel (20A) beneath the underbody, aligning it with the large hole in the centre. Secure the panel to the underbody with four IM screws, inserted from above. 20A CM CM CM CM 4A STEP 20-2 Retrieve the chassis front (4A), and locate the four tabs on the rear. Place them onto the four posts at the front of the underbody, and secure the parts with four CM screws. 19A BM 20C STEP 20-3 Place the steering column bracket (20C) onto the indicated area of the chassis front, positioned so its higher side is rearmost. Align the holes and tighten a BM screw into each. 84 BM 4A

Step by Step BM BM BM BM 20B STEP 20-4 19A Turn the assembly over, and position the steering rack panel (20B) onto the two posts on the underbody. Check that the four holes in the panel are aligned with those in the underbody and the steering rack. Tighten a BM screw into each of these holes. 6B STEP 20-5 Connect the wire from the battery box to the matching wire from the circuit board. The connectors can only fit together one way. 18A STEP 20-6 18A Connect together the yellow wires from the circuit board and the speaker. 18C 85

PORSCHE 911 CARRERA 19A STEP 20-7 8A IM IM IM IM 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. 86 Retrieve the engine, and place it into the space at the rear of the underbody. Align the holes in the tabs with the corresponding holes in the underframe. Fix the engine in place with four IM screws, inserted from below.