Honda HPD L15A7, Assembly Manual

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Page 2: ...p End Page12 6 Wiring Harness Page 17 7 Induction Page 19 8 Oil Scavenge Pump Page 23 9 Oil Pan Page 30 10 Engine Accessories Page 37 11 Engine Coolant Plumbing Page 41 12 Quick Reference Torque Specification Sheet Page 42 13 Race Kit Accessories Page 44 14 HPD Engine Kit Installation Notes Page 45 15 Throttle Position Sensor Calibration Page 47 16 Engine Operation Parameters Page 48 17 Contact In...

Page 3: ...urself or others Proper service and maintenance is 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 Inc 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 warnings for ba...

Page 4: ...it service manual which is included in the HPD chassis electrical kit During disassembly the reuse of gaskets and O rings is specified This is because the L15A7 engine is delivered in new condition It has not been started and so the gaskets remain as new for their designed purpose It is recommended after running the engine that if any gasket or O ring is disturbed removed that it be replaced with ...

Page 5: ...HPD L15A7 Engine Kit Assembly Manual 4 8 2012 Remove the OE L15A7 Honda engine from the crate Remove the lid and cross bracing Attach lifting straps as shown Lift the engine from the crate ...

Page 6: ... engine from the crate cont d Once removed from the engine crate reference the Honda Fit Service Manual to remove the starter clutch and flywheel Then secure the engine onto an engine stand for the HPD engine kit installation NOTE Do not use oil pan as an attachment point ...

Page 7: ...tion Remove oil drain plug to remove engine oil Remove the A F Sensor Remove the heat shield Remove the catalytic converter Save the exhaust gasket and hardware for reuse in the HPD engine kit Remove the throttle body Save one of the four OE throttle body mounting bolts for mounting the HPD engine kit ACG ...

Page 8: ...shown Refer to Emissions section of the Fit manual Remove the engine mounting stud Use either a stud removal tool or double nut the stud to unscrew it from the engine Remove the intake manifold chamber Save the seals for reuse in the engine kit intake plenum Remove MAP sensor for reuse in the HPD engine kit Remove for use in race kit intake plenum ...

Page 9: ...er Save the intake runner and gasket for reuse in the HPD engine kit Remove the wiring harness and bracket Remove the water outlet Save the 4 x 16mm bolts for reuse in the HPD engine kit Remove the water temperature sensor and O ring from the water outlet housing Save them for reuse in the HPD engine kit Wiring Harness and Bracket ...

Page 10: ...not using an impact wrench use a crankshaft pulley holder Remove the oil pan The gasket sealant used during assembly is quite strong so oil pan removal will be challenging Alternate mallet strikes to sides of the oil pan near bottom front and rear until the tone changes then use prying tabs to lift pan from engine block surface NOTE Do not pry against the sealing surface Harmonic Balancer V TEC Pr...

Page 11: ...he locating dowels crank position sensor and threaded oil filter mounting boss from the standard pan for reuse in the HPD engine kit oil pan Also remove the oil drain bolt for reuse in the HPD engine kit Remove the locator dowels from the original oil pan Save them for reuse in the HPD engine kit Oil Filter Mounting Boss Crank Position Sensor Locator Dowels ...

Page 12: ...ate flange diameter reduction Use a grinder grinding wheel to remove only the amount of material bolt flange necessary Reinstall flange bolts and torque to 31 N m 23 lb ft At this point your L15A7 Honda engine is ready to accept the HPD engine kit parts Ensure all parts necessary for the build are included in your kit using the supplied bill of materials BOM Clean all sealing surfaces in preparati...

Page 13: ...ed to heat the area around the nipple to avoid damaging the thread in the cylinder head when removing it Remove the cam position sensor prior to heating to prevent damage to the sensor After cleaning the threads apply a liquid thread sealant to the water outlet block off plug Install the block off plug after thoroughly cleaning the thread locking agent from the threads Torque the plug to 40 N m 29...

Page 14: ...he metal gasket with the raised inner diameter facing out using the flange nuts from the EGR bypass pipe Torque the fasteners to 25 N m 18 lb ft Install the HPD engine kit water outlet manifold using the original hardware Apply liquid gasket per the 2009 2010 Honda Fit Service Manual or its equivalent ...

Page 15: ...Ensure the O ring is in place Torque the plug to 22 N m 16 lb ft Install the oil drain plug and sealing washer from the original oil pan in place of the PCV fitting Torque plug to 39 N m 29 lb ft NOTE Honda Performance Development recommends replacement of the washer every time the oil drain bolt is removed O Ring Oil Drain Bolt Washer ...

Page 16: ...ing it out from the back of the intake runner Be careful not to damage the bore Heat the intake runner to 120 C 248 F Install the PCV block off plug flush with the chamfered end down Install the EGR block off plate Use the standard gasket and fasteners Torque the fasteners to 24 N m 17 lb ft ...

Page 17: ...End cont d Insert the top hat spacer Use an adhesive media to hold it in place Install the bell housing adapter 12 x 28mm stud Use Hondalock 3 thread locking agent or equivalent NOTE The12x28mm stud is included in the chassis kit 12 x 28mm adapter stud ...

Page 18: ...HPD L15A7 Engine Kit Assembly Manual 17 8 2012 Engine Wiring Harness Install the HPD engine kit wiring harness Use anchor points that minimize harness exposure to heat and chafing cont d ...

Page 19: ...num supports 1 8 x 25mm flange bolt 2 8 x 20mm flange bolt 3 6 x 20mm flange bolt 4 Spacer A 5 x 8mm 5 Spacer B 5 x 6mm 6 Spacer C 7 x 8mm 7 Rear plenum support bracket 8 6 x 12mm 9 Heat shield NOTE The heat shield is included in the chassis kit and is needed for the Swift style exhaust system 9 6 7 1 8 3 2 4 5 ...

Page 20: ... 11 x 2 5mm O ring 4 Air temperature sensor w 15 x 2mm o ring 5 Intake plenum 6 Intake Plenum Support F 7 Intake Plenum Support R Lubricate the O ring with liquid silicone Install the OE MAP sensor and O ring Torque fastener to 40 kg cm 35 in lb Lubricate the O ring with liquid silicone Install the air temperature sensor and O ring Torque to 138 kg cm 10 lb ft 3 5 6 2 7 4 1 O Ring O Ring ...

Page 21: ...racket fasteners to 70 kg cm 5 lb ft NOTE The throttle body is fully prepared at HPD The following procedure details the preparation steps for future maintenance and repair Replace the original throttle body lever Use the following procedure Hold the throttle lever while removing the shaft nut The spring is under high tension and hand eye injury could result if you lose control ...

Page 22: ...le lever from the shaft Replace the OE throttle lever with the HPD engine kit throttle lever The throttle lever can only be installed one way Install it in the reverse order of disassembly Torque the throttle lever shaft nut to 90 kg cm 7 lb ft 1 Throttle body 2 6 x 55mm flange bolts 3 Restrictor 4 Gaskets 2 2 4 3 1 ...

Page 23: ...y Manual 22 8 2012 Induction cont d Install the throttle body with the restrictor and gaskets onto the intake plenum Match the orientation of the gaskets and restrictor to the throttle body Torque the fasteners to 12 N m 8 8 lb ft ...

Page 24: ...corners and edges of parts for sharpness Polish with 600 grit or finer emery paper as necessary During assembly apply a light coat of motor oil to parts Heat scavenge pump cover 20 minutes for bearing installation Do not exceed 120 C 248 F Install the bearings into the front cover Allow the front cover to cool to room temperature Install the circlips for bearing retention Install the 4 x 16mm dowe...

Page 25: ...ssembly Manual 24 8 2012 Oil Scavenge Pump cont d Install the oil seal and retaining circlip Insert the drive shaft from the front of the scavenge pump cover Install the retaining circlip Circlip 35mm Oil Seal Circlip 12 7mm ...

Page 26: ...nge Pump cont d Place the scavenge port B with cutouts facing up Locate the dowel cutout on the dowel pin Ensure the Woodruff key fits in the slot on the shaft Lapping of the key may be necessary Install the woodruff key Place the inner rotor onto the shaft ...

Page 27: ...tall the outer rotor Install the scavenge port A The ports are identical so the placement order is not critical Repeat steps for remaining rotor and port installation Align the rotors and ports so that the scavenge cartridge can be installed onto the scavenge pump cover Port A ...

Page 28: ...the 47 37 x 1 78mm O ring onto the cartridge Align the dowel pin cutout in the cartridge with the dowel pin on the scavenge pump cover Install the cartridge over the rotors and scavenge ports The first installation may be a tight fit over the dowel pin Dowel Pin Cutout Dowel Pin ...

Page 29: ...e cartridge on the scavenge pump cover Check for proper port and rotor clearance with a feeler gauge If the minimum thickness gauge does not go between the rotor and port face lapping of the face of the port will be necessary Clearance specification 0 080mm 0 180mm Lap the port as shown in the picture Use 600grit or finer emery paper and lubricate with WD 40 or equivalent Use a figure eight patter...

Page 30: ...HPD L15A7 Engine Kit Assembly Manual 29 8 2012 Oil Scavenge Pump cont d Install the 53 7 x 1 78mm O ring into the groove in the scavenge pump cover The scavenge pump is ready for installation O Ring ...

Page 31: ...ot included in the kit Install the oil pan mounting studs in the engine block above the oil scavenge pump housing The short thread end goes into the block Use a high strength thread locking agent Thread them in until the studs seat hand tight Long Studs are only used for the DB 1 DB 6 Formula F chassis Oil Pan Mounting Studs Long Studs DB 1 DB 6 only ...

Page 32: ...uid silicone then install them into the scavenge ports Inspect the O ring condition by looking in the oil scavenge pump cavity to ensure it has not been cut by the edge of the port during installation Increasing the radius of the edge of the port will be necessary if the O ring is cut Torque the strainer to 45 N m 33 lb ft 1 78 x 14 0mm 2 95 x 23 47mm ...

Page 33: ... AN 8 port plug Torque the plug to 34 N m 25 lb ft Lubricate the pre installed 24 x 2 5mm O ring with liquid silicone on the AN 10 male adapter oil inlet then install the fitting Torque the adapter to 40 N m 29 lb ft Lubricate the crankshaft position sensor O ring with liquid silicone then install the sensor Torque the fastener to 98 kg cm 7 lb ft ...

Page 34: ... sit freely on the mounting surface If it does not use a grinder to provide further relief space for the rear main bolts Check to make sure the rear surface of the oil pan is flush with the rear mounting face of the engine block If there is a difference in surface height use the supplied shims when mounting the full circle ring adaptor mount Check to make sure the oil pan has been notched at the f...

Page 35: ...ad fasteners in the left side holes Use Hondalock 2 thread locking agent or equivalent Torque the fasteners to 40 kg cm 35 in lb Install the oil pan skid plate Skid plate shown is a stock DB 1 style It is shown for demonstration purposes only and is not included Install the seal for the oil pump inlet passage from the race kit use grease to hold it in place Left Side Right Side ...

Page 36: ... retained during disassembly from the OE oil pan For the following items reference the Honda Fit Service Manual Install the oil pan gasket Install the oil pan Install the front chassis mounting studs with Hondalock 3 thread locking agent or equivalent Torque the studs to 12 N m 8 8 lbf ft Oil Pan gasket ...

Page 37: ...avenge pump bore Lubricate the O ring with liquid silicone Align the scavenge pump ports in the pan and the scavenge pump body then insert the scavenge pump Using a soft blow hammer tap on the scavenge pump cover to get O ring into the scavenge pump bore continue until the pump is lightly seated Put oil on the threads of the scavenge pump bolts Torque bolts to 12 N m 8 8 lb ft ...

Page 38: ... agent or equivalent to the threads of the bolt Install bolt with the washer Torque the bolt to 12 N m 8 8 lb ft If using the optional small alternator install the alternator using the following hardware 1 8 x 36mm knock bolt 2 OE throttle body bolt flange nut 3 OE exhaust manifold bolt 4 Alternator bracket If the original alternator is fitted use the original hardware and follow the 2009 2010 Hon...

Page 39: ...gine Accessories cont d Torque the alternator fasteners to 20 N m 15 lb ft Torque the pulley retaining nut to 40 N m 30 lb ft Install the harmonic balancer with spacer 14 x 53mm flange bolt and the pulley per Honda Fit service manual procedure Torque ...

Page 40: ...t d HPD special tool Excaliber Available for purchase Install the water pump and alternator drive belt then the scavenge pump toothed drive belt Install the flywheel per the 2009 2010 Honda Fit Service Manual Install the clutch per the 2009 2010 Honda Fit Service Manual ...

Page 41: ...s and thermostat per the 2009 2010 Honda Fit Service Manual Install the starter motor Torque the flange bolt to 64 N m 47 lb ft Install the O ring onto the breather restrictor and then install the restrictor into the crankcase breather pipe on the cam cover 1 Crankcase breather restrictor 2 O Ring 1 78mm x 7 66mm Coolant Connecting Pipe Thermostat Housing 1 2 ...

Page 42: ...riate to your chassis specifications It is recommended that the pipes be installed prior to installing the engine in the chassis The DB 1 DB 6 configuration is pictured 1 Upper front coolant pipe 2 Upper Rear coolant pipe 1 Lower Front coolant pipe not shown opposite right side 2 Lower Rear coolant pipe 1 2 2 ...

Page 43: ... 24 N m 18 lb ft Throttle Body Bolt 24 N m 18 lb ft Ignition Coil 9 8 N m 7 2 lb ft Fuel Rail 12 N m 8 8 lb ft O2 Sensor 44 N m 33 lb ft Engine Block Oil Pan 24 N m 18 lb ft 1 12 N m 8 8 lb ft 2 13 Rod Bearing Cap Bolt 9 8 N m 7 2 lb ft 90 Main Bearing Cap Bolt 25 N m 19 lb ft 40 Oil Pressure Pump Bolt 12 N m 8 8 lb ft Oil Pump Screen Bolt 12 N m 8 8 lb ft Crank Position Pulse Plate Bolt 19 N m 14...

Page 44: ...ick Reference Torque Specification Sheet cont d Cooling System Water Pump Pulley Bolt 14 N m 10 lb ft Water Pump Bolt 12 N m 8 8 lb ft Thermostat Cover Bolt 12 N m 8 8 lb ft Thermostat Housing Bolt 9 8 N m 7 2 lb ft Water Outlet Bolt 12 N m 8 8 lb ft ...

Page 45: ...HPD L15A7 Engine Kit Assembly Manual 44 8 2012 Optional Accessories Optional sensor kit assembly 1 Secondary harness 2 Fuel pressure sensor 3 Oil pressure sensor 4 Oil temperature sensor 3 4 2 1 ...

Page 46: ...to the modified housing when it arrives Throttle Position Sensor Initial adjustment of the throttle position sensor TPS is performed at HPD using the idle adjustment stop screw to ensure compatibility with supplied ignition fueling maps Do Not Adjust This Screw For Idle Speed Adjustment Idle Speed Adjustment The initial screw setting is turn out from fully seated Warm the engine to a minimum of 75...

Page 47: ...ttle lever With the throttle lever against the idle set screw adjust the cable to show visible slack Adjust the WOT set point on the pedal so that there remains a 0 40mm gap between the throttle lever and the throttle body This minimizes cable wear and stretching and limits the possible cause of cable breakage due to cable wear and fatigue ...

Page 48: ...alibration Across VCC and VOut Resistance is 670 k Ohms at WOT 4 470 k Ohms at idle and 4 6 k Ohms at 0 throttle Voltage is 4 7 V at WOT 0 5 V at idle and 0 5 V at 0 throttle NOTE 0 throttle is with the idle adjustment screw backed away from contacting the the throttle lever ...

Page 49: ...rs Water temperature minimum before going on the track 75 C 167 F Water temperature maximum 100 C 212 F Oil pressure minimum at idle operating temperature 340 kPA 49 psi Oil pressure minimum at 5000 rpm operating temperature 490kPA 71 psi Oil temperature maximum 140 C 284 F ...

Page 50: ...gine Kit Assembly Manual 49 8 2012 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 7310 ...