Sunday 9 March 2014

Build Day Fifteen - Engine Hoist, Washer Bottle, Engine Mounts and Gearbox Assembly

As the build had been taking it's toll on me I decided it best to take a quick break for a couple of weeks to get my head back in order and to get my motivation back together.  So Charlotte and I popped over to Lily Beach in the Maldives for a bit of scuba and sun (well it was actually booked a year ago, but I thought my version of the event sounded better).  Anyway... We got back very early this morning - 2am in fact, but I was chomping at the bit to get the engine and box in before I go back to work tomorrow, so a few hours kip and I was ready to go.  However, I'm feeling quite jet lagged as I'm typing away now, so bare with me on today's post...!

Whilst on holiday I ordered an engine hoist, as this would be delivered by the time I got back and easier for me to have ready for today - so the first task was to put that together.  Derek (not CC Derek) came over to give me a hand, so we got to work...

Engine hoist prior to assembly.
Engine hoist prior to assembly. 
I went with a foldable version which means the legs can be moved a vertical position for easy storage when not in use.
I went with a foldable version which means the legs can be moved a vertical position for easy storage when not in use.
Middle support in place.
Middle support in place.
Engine Crane built - only took half an hour or so.
Engine Crane built - only took half an hour or so. 
We then put it in place to see if we needed the 900kg or 300kg reach, and went with the 300kg reach.
We then put it in place to see if we needed the 900kg or 300kg reach, and went with the 300kg reach.
As the engine was in it's post delivery location, we moved it out using the crane to make accessing and working on it prior to installation easier.
The engine then got moved out to make access easy for fitting the gearbox, or so we thought!
The engine then got moved out to make access easy for fitting the gearbox, or so we thought!
Other side of the engine.
Other side of the engine.
2.0 Litre Ford Duratec
2.0 Litre Ford Duratec
Next stage was to fit the washer bottle, connecting the washer motor and tubing - pretty easy and didn't take too long... It's well worth softening the tubing with some warm water prior to pushing it place, as otherwise I don't think it would've gone on..
Washer bottle and motor in place.
Washer bottle and motor in place.
Washer bottle tubing in tunnel and tie-wrapped into place.
Washer bottle tubing in tunnel and tie-wrapped into place.
Next job was to put the engine mounts in.  Got the bolts, washers and nyloc nuts ready, sized everything up, and the body skin under the chassis hadn't been drilled out properly, so it was out with the Dremel to open the holes to allow the bolts all the way through.

Using the Dremel to open up the body skin to allow the bolts that hold the engine mounts to the chassis through.
Using the Dremel to open up the body skin to allow the bolts that hold the engine mounts to the chassis through.
The instructions mentioned a 300mm black cable which goes into the front hole of the left engine mount, but this (pic below) is the only wiring that would fit, and had the right connectors - so I'll be checking this is ok with Derek at CC in the morning.  But, other than that the engine mounts are ready and waiting for the engine.
Engine mounts ready and waiting for the engine.
Engine mounts ready and waiting for the engine.
Next step - remove the alternator and starter motor, as the engine won't go in unless these are removed first.
Alternator ready for removal.
Alternator ready for removal.
Starter motor unit awaiting removal.
Starter motor unit awaiting removal.
Engine now minus alternator and starter motor unit.
Engine now minus alternator and starter motor unit.
Jet lag aside, the day WAS progressing well.  Next part in the instructions says to lower the engine and gearbox assembly into the engine bay... Hang on... Where's the bit where you fit the gearbox to the engine?  Ahhh I see - about 50 pages back in the manual on page 72, with about 8 different (all unclear) variations on what to do.  Take the bell housing off, and attach the gearbox from the inside of the bell housing out, then the very next paragraph tells you NOT to remove the bell housing and mount the gearbox to the engine from the outside of the bell housing.  There was also an O-ring supplied in the gearbox box saying it had to be fitted, and the instructions mentioned this needs to be siliconed to the selector shaft...?!?  

Selector Shaft O-Ring must be fitted between transmission and bell housing - and siliconed into place..?
Selector Shaft O-Ring must be fitted between transmission and bell housing - and siliconed into place..?  
Doesn't sound right to me, so a lot of head scratching went on, and we decided to call it a day, as I didn't have any gasket silicone anyway. 

Selector Shaft O-Ring - is this the right place to put it?!?
Selector Shaft O-Ring - is this the right place to put it?!?
As I don't have a labelled gearbox parts bag, I think these are the right cap head bolts to attach the gearbox to the bell housing - or is it the bell housing that's attached to the gearbox!  Only time will tell!
As I don't have a labelled gearbox parts bag, I think these are the right cap head bolts to attach the gearbox to the bell housing - or is it the bell housing that's attached to the gearbox!  Only time will tell!
This is the sorry state of affairs of today's 'engine and box' install - but looking on the positive side, all the groundwork is done for a (hopefully) pain free install tomorrow night.
This is the sorry state of affairs of today's 'engine and box' install - but looking on the positive side, all the groundwork is done for a (hopefully) pain free install tomorrow night.
I will be emailing quite a few bits to check with Derek at CC after I publish this post, and provided he confirms what we've assumed today then we'll apply a silicone gasket seal to the bell housing and gearbox, then the box will be attached from the outside to the bell housing.  Not too sure what the outcome on the o-ring will be though.  And all being well the engine will be in tomorrow night!

8 comments:

  1. Daniel,

    The two wires you have connected to the engine mount need to be connected to the starter motor solenoid. i.e. Where the other brown wire is connected. There should in a pack somewhere be a 10mm thick black sheathed cable. That is the one to connect to the engine mount and engine bracket.

    Be careful as to which way you bolt the gearbox to the bell housing as it is different for different set ups. I had to remove the bellhousing as I had the 2.0 Duratec with the 5 speed type 9 box. It may be different for yours.

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    1. cheers buddy - I didn't think the two brown wires were right... I'll change that tonight, and I think it's gearbox to bell housing on the 6 speed box, but have emailed Derek at CC to confirm. The instructions are really vague and contradictory too, which isn't the most helpful in these situations!

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  2. Daniel,
    Welcome back, I had suspected that you had bailed from that lovely UK weather at this time of the year!

    I see from the pictures that you have the 6-speed box, so here is what you need to know:
    1) The O ring goes on the selector shaft, which is the shaft that sticks out above the main drive input shaft. Your's looks "flush" to the front plate right now, but if you had a gear lever in place and tried to select a different gear, you would see it move and for some gears the shaft would stick out more. So the O ring goes around this and seats in the indentation around it, put some silicon sealer on it when you put it in. (I hope you have not stretched it putting it on the input drive shaft)
    2) The box does attach to the bell housing using 4 bolts (M10 I believe and spring washers, but I remember it was pretty obvious which bolts! since they need to be long enough and thread into the bell housing cleanly). Per the manual, no gasket is used between the gearbox and the bell housing, just a bead of silicon around the edge. torque 47NM
    3) From your pictures, it looks like the engine mounts are fitted already on the engine. You will need to take them off to get the engine in the bay (it is tight). Get the engine roughly in place, then put the mounts on and leave them "loose" until all the bolts are in, including the ones into the rubber mounts on the chassis. Only when all bolts are threaded in loosely, including the gearbox mounts, should you go around and tighten them up.

    Finally, you have the wrong cable attached to the engine mount on the chassis. You should have a 300mm long thick black cable, like a battery cable. This is the main earth between chassis and engine and goes from the front of the engine mount to a bolt on the engine side of the same mount. I have picture on this post http://csr175.wordpress.com/2013/10/06/moving-the-alternator/, you can see the cable in question is the black one with the yellow tag in the middle. It is connected to the top front bolt on the engine side of the engine mount and the front bolt on the chassis side of the rubber engine mount.

    Good luck putting the lump in.

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    1. Cheers Mark - literally just emailed Derek at CC, then replied to Andrew Bissell's comment, and then yours came through too. I had wondered about the engine mounts - thanks for the info and that's about all I need to know... for now! :-)

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  3. Daniel,

    Very Jealous about your holiday, I bet it was brilliant. This is a link to the Earth Cable you need, http://www.caterhamparts.co.uk/product.php?id_product=902. Mine didn't come with one either, seems to be a part they miss!

    For your records I have attached it to the top of the black engine mount as the only other reference to an earth cable says attach it to the outer most bellhousing bolt - Which isn't physically possible! It is the Battery Earth that needs attaching to that. Had me and others scratching our heads for a while one weekend!

    Caterham had attached one to my bell housing already and supplied a spare O-Ring for me which didn't go down well when I came across it after installing the engine and returned the hoist! It was a horrible feeling discovering that, but members on Blatchat put my mind at rest! Phew. Started mine for the first time last night! :-)

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  4. Cheers for the info - I bet starting it was a great feeling... Looking forward to that day for sure :-)

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  5. Hi Daniel,

    Great post, love that you document all the building process with images.
    I wanted to know the model of the engine hoist you are using?

    Thanks.

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    1. Hi Billy,
      Thanks for your comment and question. I hope the blog is of use to you.... I can't actually remember what engine hoist I used, as I bought it on eBay (new) and have since sold it...

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