• 3/8”UNF brass manifold nuts & spring washers (8)
• M8 x 25mm stainless bolts and stainless nyloc nuts (4)
• M8 x 20mm stainless bolt, stainless spring washer and stainless plain nut
• 1/4”UNF x 3/4” bolts & spring washers (4)
5.2.1 Down pipes or stainless manifold extension pipes
The exhaust system fits together as per Fig 3, assemble the exhaust down pipes/extension pipes on to the
manifolds and hang in place on the exhaust hangers with the supplied rubber mounts, check the hanger
mounts can’t touch and knock before locating and fitting the M8 x 20mm stainless tie bolt between the pipes
just after the flexi pipes. Once in place tighten the manifold to down pipe clamps/flanges.
5.2.2 Silencers
Install the silencers with the pipe entering the centre of the exhaust and exiting on the inside, then fit the rear
pipe sections in place and hang on the rear rubber mounts, mount the rear rubbers behind both the exhaust
and chassis using the inner of the two lugs supplied. Lift the exhaust to maximum height without it touching
on the chassis before tightening these mounts and fitting clamps at both ends of the exhaust silencers.
5.2.3 Rear tie bracket
Once happy with the position of the rear silencers make a bracket to span the gap between the two rear pipe
mounting lugs to tie the rear pipes together, if preferred you can use these lugs independently and mount
with rubber bushes into the rear diff plate.
5.2.4 Testing exhaust mounts
Shake both sections vigorously to simulate the vibration imparted by the engine in operation and if there are
any points of contact with the chassis, adjust the assembly to eradicate. Adjustment is easier using a lever
between the chassis and the mid mounting point.
5.3 Cooling system
You will need the following parts for this operation:
• Radiator core
• Radiator mounting bushes and clips (2)
• Radiator top & bottom hoses and hose clips
• It is assumed that the by pass hose between the water pump and the inlet manifold has been fitted as
part of the engine rebuild. If not, one is needed with hose clips.
• Radiator hoop (from the chassis kit)
• Radiator pressure cap (15 psi)
• Electric cooling fan and control unit
• 5/16”UNF x 1” bolts & nyloc nuts (2)
• 5/16”UNF x 3/4” bolts & nyloc nuts (2)
• 5/16” plain washers as required
• 3/8”UNF x 2” bolts & spring washers (2)
5.3.1 Painting radiator and fitting cooling fan
First paint the radiator matt black (a spray can will give a good finish), then fit the electric cooling fan to the
radiator using the manufacturers instructions. The fan should be fitted on the front of the radiator
horizontally centered with the radiator core and fitted as high on the core as practical. If your fan is already
mounted remove it before painting then refit afterwards, We suggest painting the radiator as it can be seen
from behind the radiator shell grille and the cooling fan is less noticable.
5.3.2 Radiator hoop
Fit the radiator hoop to the chassis with the 5/16” x 1” bolts & nyloc nuts, use a measuring tape to ensure the
centre of the hoop is central to the chassis. The larger tabs point forward and are for mounting the radiator.
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