Safety note: The engine and gearbox assembly weighs 350 kg. Ensure that any lifting equipment is
adequately rated for this weight. This includes all strops, chains and shackles.
5.1.3 Fitting engine
Rig the engine and gearbox assembly to an engine crane using the two lifting eyes attached to the front &
rear cylinder head studs and install the unit to the chassis engaging the studs from the three rubber engine
mounts with the 2 front chassis brackets and the hole in the gearbox mounting plate. Secure with the
mudguard washers and nyloc nuts. The engine will need to be tipped back a little to allow it to drop under
the chassis hoop. Remember to remove the gear-stick if fitted before fitting the engine.
5.1.4 Clutch slave cylinder
If not already fitted install the clutch slave cylinder to the bell-housing using the studs fitted, insert the push
rod and eye into the slave cylinder and push piston in until it stops, adjust the pushrod until 2mm of free play
can be felt before locking up the lock nut. Fit the spring to the eye on one of the mount studs and connect the
other end to the pushrod eye mount pin.
5.1.5 Connect and bleed clutch
Connect the clutch hydraulic hose to the clutch slave cylinder. Fill the hydraulic reservoir with hydraulic
fluid and bleed the system. Check the clutch operation.
5.1.6 Servo vacuum hose
Using the 3/8” ID rubber vacuum hose and hose clips connect the servo vacuum connection to the inlet
manifold connection via the non-return valve, this may be from the donor or part of the servo elbow. If from
the donor take care to fit it the correct way round, i.e. allowing flow from the servo to the engine and not the
reverse.
5.1.7 Prop-shaft
Check that the rear prop-shaft flange mates correctly with the differential input shaft flange. If not correct to
fit. Connect the gearbox output flange to the differential flange with the modified prop-shaft using the 8
3/8”UNF special shouldered bolts & nyloc nuts. Tighten to 25ft-lbs. Note that the prop-shaft is fitted with
expanding splines closest to the engine.
5.1.8 Fuel and breather pipes
The fuel pipes can now be connected to the carburetors, from the front end of the metal fuel pipe join a short
length of fuel hose and run into a fuel filter, from here use another short length of fuel hose from the fuel
filter to a ‘T’ piece (some carburetors have a through feed for second carburetor and don’t need a ‘T’ piece).
If you have two ¼ inch pipes the upper is input and the lower is for overflow, fit another length of pipe to the
overflow and run this down to the bottom of the sump to vent safely. Refer to figure 6. The larger pipe if
fitted is a breather and needs to be connected to the engine front cover breather, pipes are available for this.
5.2 Exhaust system
You will need the following parts for this operation:
• 6 part stainless steel exhaust system comprising:
o Front downpipes incorporating flexible sections (2)
o Silencer boxes (2)
o Rear pipe (L/H)
o Rear pipe (R/H)
o Manifold to downpipe sealing rings (2)
• 21/8” exhaust pipe “U” bolt type clamps (4)
• Crossmember mounting rubbers (2)
• Rear mounting rubbers (flat type) - (2)
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