Honda HPD L15A7, Installation Manual

Page 1: ...Eng D gine B 1 a HPD Insta and D D L15 allati DB 6 5A7 on M 6 Cha Manu assis 8 al s 2010 ...

Page 2: ...paration Page 4 4 Install Slave Cylinder Page 6 5 Modify Shifter Rod Page 8 6 Bell Housing Oil Tank Preparation Page 9 7 Install Fuel System Page 10 8 Engine Installation Page 17 9 Oil System Page 20 10 Install Modified Shifter Rod Page 22 11 Miscellaneous Page 24 12 Completed Install Page 25 13 Engine Side Cover Blister Installation Page 27 14 Contact Information Page 30 ...

Page 3: ... or injury to yourself or others Proper service and maintenance are essential to the racer s safety and the reliability of the race car If you need to replace any parts always use the correct parts supplied by Honda Performance Development or American Honda Motor Co Inc Do not use inferior quality or unapproved parts Because this manual is intended for professional technicians we do not provide wa...

Page 4: ...engine with the HPD engine kit into a Swift DB 1 DB 6 chassis The converted L15A7 engine is designed to be installed utilizing the existing mounting points of your chassis without modification For the purpose of this manual all photos are of a DB 1 chassis Specific parts and procedures unique to the DB 6 are explained when necessary ...

Page 5: ...2x 5 Dowel 14 x 20mm 2x 6 Spherical Bearing DB 1 7 Circlip Internal 1 06 DB 1 8 Flange Bolt 10 x 25mm 9 Flange Bolt 10 x 40mm 10 Flange Bolt 12 x 60mm 2x 11 Flange Bolt 12 x 65mm 12 12 x 28mm stud Polish the circlip groove to remove the sharp edge Heat the adapter plate Install the spherical bearing A light to moderate press is normal Install the internal circlip 3 3 9 2 2 8 11 10 10 6 7 1 12 Circ...

Page 6: ... dowels Mock up the adapter plate to the engine Note the area where the shifter rod passes through This area will need to be tapered towards the bearing Mark the area of the engine block for material removal Remove only enough material to allow the rod to move freely leaving enough material to maintain a mating surface Dowels ...

Page 7: ...e used for the Swift slave cylinder NOTE Use new seals and backing rings Install a new release bearing onto the slave cylinder Install the HPD chassis kit input shaft using the same procedure as the Swift unit Refer to the appropriate manual for your type of gearbox for proper installation It is suggested that the input shaft seals be upgraded replaced at this time ...

Page 8: ...gine block to the end of the clutch fingers This is dimension A 2 Place a straight edge across the front of the bell housing and measure from the straight edge to to the mounting surface of the slave cylinder This is dimension B 3 With the slave cylinder compressed into the bore measure the installed height of the slave cylinder Add 4 0mm to this dimension for freeplay This will be dimension C 4 U...

Page 9: ...e middle shifter rod Weld one joint onto the new rear rod gearbox side Lay your and HPD s rod next to each other and measure the difference in length approximately 4 inches This will be the amount to remove from the middle rod Cut the middle rod Weld the second Apex joint onto the middle rod Drill the bolt hole being careful to line up the linkage properly NOTE It is suggested to wait until the en...

Page 10: ...ual 9 8 2010 Bell Housing Oil Tank Preparation DB 1 DB 6 Using Hondalock 2 or its equivalent install the AN 10 plug in the upper left oil return port This is now an engine mounting point Install oil tank cover using existing bolts and an RTV type sealant ...

Page 11: ...ection systems The HPD kitted fuel system runs at 50 60 PSI The feed hose needs to be rated at a minimum of 150 psi Remove the regulator from the kit Discard the ring the small O ring and the small clip Modify the fuel cell cover by using the drawing provided to add a third outlet This will become the fuel out The AN 6 center hole previously the fuel out will be for fuel pump harness The right sid...

Page 12: ...or square as it will be easy to cut the O rings It will take some force by hand to install the regulator Install the clip in the housing Position the housing so the return fuel port faces toward the bottom of the fuel cell Using a pipe thread sealant install the AN 4 to 1 8 NPT adaptor into the housing on the cover top side This will connect to the AN 4 bulkhead feed fitting Regulator Housing Pres...

Page 13: ...fuel cell bottom side This will connect to the fuel pump NOTE Be sure the regulator is sending excess fuel back into the tank down and not into the cover up Install the fuel pump harness into the AN 6 hole Ensure the O ring is in place Snug down the connector Loosely install both 90 AN 4 bulkhead fittings in to their respective positions Use the AN 4 crush washers between the flange and the jam nu...

Page 14: ...the cell is not collapsed you may have to lift up on the retainer ring for an accurate measurement Calculate the length of the connector hose Install the pressure regulator housing assembly onto the bulkhead fitting in the cover Snug the fitting Measure from the bottom of the cover to the bottom of the hose nipple on the housing record this number Measure the length of the fuel pump from the botto...

Page 15: ...g correctly on the top of the fuel cell cover so access to the retainer bolts is possible and supply and vent hoses are not overly twisted Connect the fuel pump harness to the pump Pigtail the harness around the hose being careful that the harness does not chafe on the regulator housing You will need to cut out some of the fuel cell foam from the left side piece Only remove enough to be able to in...

Page 16: ...s connect the fuel test port to the out side of the fuel filter Mount this assembly using the cushion clamps about 4 5 inches from the mid bulkhead this is only a suggested location Install the 45 push loc fittings onto the supplied hose Install the fuel feed line onto the fuel cell cover and route the same as the original This will connect to the fuel filter with another 45 degree push loc Cut th...

Page 17: ...0 Install Fuel System DB 1 DB 6 cont d Install the third 45 push loc onto the supplied hose Connect this to the vent fitting on the fuel cell cover route it the same as the fuel feed line NOTE You will need to supply your own vent check valve Route the hose as normal ...

Page 18: ...gine race kit manual Install the gearbox adaptor with the supplied dowels and socket head bolts to the bell housing The spacers in the chassis for the lower front mounting studs need to be a minimum length of 30mm to prevent the flange nut from bottoming on the shank of the stud 1 18 Four 3mm thick washers are included in the kit to help adjust this dimension If needed they are to be placed betwee...

Page 19: ...the head from the bottom From Engine Kit Installation Manual Pg 17 Slide the engine into position thread the nuts onto the front studs Loosely install the upper mount bolts into the head Apply a small amount of anti seize to the splines of the input shaft Ensure the lower rear mount studs are in position and not binding Introduce the bell housing assembly onto the engine ...

Page 20: ...g up the bell housing Where the bell housing and the adaptor meet on the underside it may be necessary to install shims before tightening the bottom studs Shims are included in the kit 0 01mm and 0 02mm thickness Install the main chassis bolts into the bell housing Install the 10mm flange nut onto the engine stud Check the shim dimension on the bottom of the engine adaptor plate Install the k nuts...

Page 21: ...with the proper procedures If not done correctly you could cause damage or harm to yourself or others The oil feed for both chassis is on the lower right side of the oil pan This is an AN 10 fitting There is an in line filter included in the kit This should be incorporated into the oil feed line Be sure it is installed in the correct direction The oil return line is a AN 12 at the bottom of the sc...

Page 22: ...ve cover 2 That the valve cover breather is not interfering with the operation of the rear anti roll bar 3 That the DB 1 kit has AN 8 hose end fittings and adaptor fittings for the breather lines 4 That the DB 6 kit has push loc fittings for all breather lines DB 6 owners may need to grind the indicated area on the bell housing adapter to prevent chafing of the oil feed line Area to be clearanced ...

Page 23: ...l Modified Shifter Rod Install the HPD supplied rear shifter rod Install the bolt to the shaft and selector fork at the gearbox Line up the shifter lever in the cockpit and mark through the middle Apex joint to place the new bolt hole Remove the shaft and drill new bolt hole ...

Page 24: ...lation Manual 23 8 2010 Install Modified Shifter Rod cont d Install the middle shifter rod tighten all bolts securing the shifter rod and check that you can select all the gears Make fine adjustments at the lever end in the cockpit if necessary ...

Page 25: ...tle pedal stop is strong enough to withstand the force of your foot The pedal should not be able to rock side to side on its pivot point as this will lead to premature cable wear and inconsistent full throttle applications Install the exhaust system Depending on your previous system you will need to adjust the height of the tail pipe support Install the Lambda sensor per the Honda Fit service manu...

Page 26: ...Swift Chassis DB 1 DB 6 L15A7 Engine Installation Manual 25 8 2010 Completed Install Left Side View Right Side View ...

Page 27: ...the same as your previous engine We recommend you prime the oil and fuel systems before starting your L15A7 engine for the first time See Operating Parameters section of your L15A7 Engine Kit Assembly Manual NOTE HPD recommends installing a 19 20psi radiator cap Follow the Honda Fit Service manual guidelines for all fluid recommendations Connect the brake and clutch lines Bleed the systems as norm...

Page 28: ...pirator and eye protection This set of instructions presumes the reader is familiar with basic composites work Read and understand all steps of this procedure before starting it If you doubt that you can correctly complete the task do not hesitate to have an experienced composites shop complete it for you Warning Improper service or repairs can create an unsafe condition that can cause your custom...

Page 29: ...ove too much material When the hole is roughly cut out inside the line a pneumatic die grinder with a porting stone or flap wheel works well for final trimming Or use sand paper held in the hand Do not use a disc as it can easily remove too much material Once satisfied that trimming is complete and that there is a close fit between the side cover and the blister set the blister aside and invert th...

Page 30: ... dry while mixing the resin and hardener thoroughly When the acetone is evaporated and the resin and hardener are thoroughly mixed brush a light layer of resin over the sanded and cleaned surfaces allowing the resin to fill the gap between the side cover and the blister Place the widest patching layer carefully in place distributing it evenly inside and outside the outline of the blister Using the...

Page 31: ...6 L15A7 Engine Installation Manual 30 8 2010 Contact Information Honda Performance Development Inc 25145 Anza Drive Santa Clarita CA 91355 661 294 7300 Honda Racing Line grmsadmin hra com Phone 661 702 7777 Fax 661 294 7367 ...