Caterham Seven Manual de usuario descargar pdf (Pagina 79)

SECTION 9 - INSTALLATION OF ENGINE AND GEARBOX

Section 9

Page 2 Issue 1

PREPARATION

1 The engine is supplied with the engine

mounting brackets already fitted to the engine

block. Remove the brackets and retain the

fasteners. The special tools detailed in Table 1

will be required.

TABLE 1 SPECIAL TOOLS REQUIRED

Item Description

Engine hoist

and sling

SWL of 150 Kg (min)

2 Ensure that the clutch cable has been

fitted as detailed in Section 8.

3 The large diameter pre-formed 'J' hose

should be fitted onto the black thermostat

housing located on the RH side of the engine

block. Apply rubber lubricant to the short end of

the hose and push over the large outlet on the

thermostat housing, rotate until the hose sits as

high and as close to the engine block as

possible. Secure using a hose clip (fastener

pack ZCO07, Item (8)) ensuring the straight

section is facing forwards.

4 Apply rubber lubricant to the short end of

the smaller diameter pre-formed 'J' hose and fit to

the small outlet on the black thermostat housing

so that the straight section of the hose faces

horizontally rearwards. Secure using hose

clip (9).

5 Apply rubber lubricant to the plastic hose

connector (polythene bag marked 'coolant') and

fit to the straight end of the smaller diameter 'J'

hose. Secure with hose clip (9). Apply rubber

lubricant to the 5/8" heater hose and attach to the

plastic hose connector, secure with hose

clamp (9). This hose can be trimmed to length

once the engine has been fitted.

6 Connect the brown lead from the alternator

to the lower connector on the starter motor

solenoid. Also connected to this point is the large

red lead from the battery positive.

7 Remove the gearbox filler plug. This is not

essential, however access is restricted within the

confines of the transmission tunnel.

8 Protect the appearance of the engine bay

chassis tubes and pedal box sides and edges by

covering with card and/or masking tape.

9 Ensure that all wires and connector plugs

are secured and will not snag or catch the

engine/gearbox as it is lowered.

NOTE

Before fitting engine mounting rubber blocks

(polythene bag marked 'miscellaneous') ensure

that the large threaded (1/2" UNF) boss in the

centre is clear of rubber and that the bolt will

thread in cleanly.

10 Fit the engine mounting rubber to the LH

side of the engine bay. The two bolts (fastener

pack ZMS16, Item (3)), plain washer (18) are

passed downwards through the mounting,

through the chassis and secured with nyloc nuts

(10) and plain washers (18). Do not tighten.

11 Fit the engine mounting rubber to the RH

side of the engine bay, locate the engine earth

lead, a black lead approximately 300 mm long,

pass bolt (2), washer (18) downwards through

the lead, through the front hole of the engine

mounting, through the chassis and secure with

nyloc nut (10) and plain washer (18). Remove a

little paint from the chassis/mounting to ensure

that a good electrical contact is made. Pass bolt

(3), plain washer (18) downwards through the

chassis and secure with nyloc (10) and plain

washer (18). Do not tighten.

FITMENT OF ENGINE/GEARBOX INTO

CHASSIS

WARNINGS

(1) Never work alone underneath a car

without supporting it on axle stands or

equivalent. Do not rely on a jack alone.

(2) Use appropriate eye protection whilst

working under the car.

12 Remove the protective covers from the

propshaft (transmission tunnel) and the Plastic

Plug from the gearbox tailshaft housing.

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Caterham Seven Manual de usuario Pagina 79

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