HPD L15A7 Engine Installation Manual Van Diemen Chassis 100823
Contents
1. The left side water lines are routed as follows Use the blue 135 hoses and water pipes provided Refer to the photos below and illustration From the stock Van Diemen crossover pipe to the top front left radiator inlet also run a 10 hose from the crossover pipe up to the header tank From the rear left radiator outlet to the engine water inlet thermostat housing The right side water lines are routed as follows From the stock Van Diemen crossover pipe to the rear right radiator inlet From the front right radiator outlet using the stock Van Diemen tube to the water outlet on the cylinder head Install a bleed line from the top of the right radiator to the header tank 7 2010 Honda facing Van Diemen Chassis L15A7 Engine Installation Manual Cooling System cont d VAN DIEMEN COOLING SYSTEM LEFT Fi L AIR BLEED SS BRAIDED HOSE lt P RADIATOR CATCH TANK RADIATOR MAIN FILL STOCK CROSSOVER HPD PIPE BLUE 135 DEGREE HOSE We BYPASS HOSE THERMOSTAT HOUSING Water Out muli Water In a MT gt gt 2 S iP EEEEEiiE x X MLcLLZNMM MIOMlM9ME IM H r lt z__ _ 25 7 2010 Van Diemen Chassis L15A7 Engine Installation Manual Miscellaneous Install the throttle cable Use the method described in the Race Engine Assembly manual pg 48 to set full throttle Performance Tip Be sure your throttle pedal stop is strong enough to2. back into the tank down and not into the cover up 7 2010 Honda facing Van Diemen Chassis L15A7 Engine Installation Manual Install Fuel System cont d Install the fuel pump harness into the AN 6 hole Ensure the O ring is in place on the bottom side of the plate Snug down the connector Install the AN 4 45 bulkhead fitting onto the plate Looking from the rear of the car rotate fitting to the 10 o clock position Cut the top internal fuel hose to 140 3mm then install it onto the barb fitting on the regulator Install clamp Position the fuel pressure regulator assembly in middle cutout of fuel fill tube Install the AN 4 female hose fitting into the fuel hose Secure with clamp Install onto bulkhead fitting Secure regulator housing with the supplied Ty raps 7 2010 Honda facing Van Diemen Chassis L15A7 Engine Installation Manual Install Fuel System cont d Install sock filter onto the pump Use a 1 4 socket to push the filter locking ring onto the pump Installing the filter in this manner will require cutting the filter from the pump to remove it in the future Alternatively the post can be cut off of the pump to cut a 3mm thread with a tap Use a 3 x 4mm bolt to attach the fuel filter to facilitate ease of removal and installation for maintenance and replacement Position the fuel pump in the fuel fill tube and secure with hose clamp Check its position in the fuel cell wi
3. 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 Attach the oxygen Lambda sensor on the PON primary pipe as illustrated below Lu al MR Consider the use of heat insulating a tape and materials in sensitive areas EC IN such as the oil inlet line 0 Install the oxygen Lambda sensor per the Honda Fit service manual Plug into the engine harness Depending on your previous exhaust system you may have to modify the rear exhaust hanger or fabricate a new one 7 2010 Honda facing Van Diemen Chassis L15A7 Engine Installation Manual Miscellaneous cont d Install the middle shift rod tighten all bolts and check that you can select all gears a eee 27 7 2010 Van Diemen Chassis HPD 37g L15A7 Engine Installation Manual Completed Installation E r Left Side View SEI T b e gii Sa AM Tite e EAE LIT e I 7 2010 Van Diemen Chassis L15A7 Engine Installation Manual Completed Installation cont d E Installing fluids The oil system will hold the same volume as your previous engine did We recommend that 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 Ass
4. This should be incorporated into the oil feed line Be sure it is installed in the correct direction The oil return line is an AN 12 located at the bottom of the scavenge pump If you run an oil cooler run the line from the scavenge outlet to the front cooler inlet then run a second 12 line from the cooler exit to the return pipe located at the top of the oil tank as illustrated above If you run without an oil cooler run the return line from the scavenge outlet directly to the return pipe located at the top of the oil tank 7 2010 Honda facing Van Diemen Chassis L15A7 Engine Installation Manual Oil System cont d 1 Install the two breather lines one from f the cam cover to the return tank and the other from the rear of the tank filler neck to the rear reservoir Be sure the 2mm breather restrictor is installed in the cam cover where the breather hose connects _ PY e _ e rwsuiarov gt vX 5 35 TWwotgouqpMmm WUW WNhmu ui ii WF EEEE HW xwx WwW W W lt cN iGg amp 5 5 5 5 5 5 5Z xee MMA oo e ee 22 7 2010 Honda facing Van Diemen Chassis L15A7 Engine Installation Manual Cooling System Install rubber grommets with steel top hat bushings into mounting points of coolant overflow tank Install coolant overflow tank onto upper front engine mount Ss 23 7 2010 Van Diemen Chassis O HPD 3ra L15A7 Engine Installation Manual
5. ance from the back of the engine block to the end of the clutch fingers This is dimension A Place a straight edge across the front of the bell housing and measure from the straight edge to the mounting surface of the slave cylinder This is dimension B 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 Use the following equation to determine the proper slave cylinder spacer length B C A XX spacer length 7 2010 Honda facing Van Diemen Chassis L15A7 Engine Installation Manual Install Slave Cylinder cont d Install the HPD Van Diemen input shaft supplied with the chassis kit Follow the procedure as outlined in the Hewland LD200 transmission and Van Diemen chassis manuals Refer to the appropriate manual for your type of gearbox for proper installation 7 2010 ME j ISIL Van Diemen Chassis L15A7 Engine Installation Manual Install Fuel System The Fit Fuel system consists of the fuel pump fuel filter regulator assorted fittings and hoses If you are using your own hose supply ensure that it is rated for high pressure fuel injection 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 In preparation for installation of t
6. d measure out the resin and hardener The tail section is made with epoxy resin but satisfactory patches can be had with vinylester or polyester resins as well Resin dye may be added to match the color of the patch to the color of the side cover resin Resin dyes suitable for all resin types may be purchased at Tap Plastics http www tapplastics com shop product php pid 50 amp e Once again clean the sanded inner surfaces of the side cover and blister with acetone on a paper towel and let it 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 brush gently wet it out with resin and work out any air bubbles or creases in the fabric so it lies flat to the surface When the widest layer is wetted out carefully place the next smaller layer on top of it and wet that layer out Alternatively you may start with the narrowest layer it is not critical Repeat until all layers are in place and wetted out Allow to fully cure before proceeding e Once theresin is fully cured appropriately 24 hours for epoxy or 12 hours for vinylester or polyester carefully remove the masking tape Using a small sanding bl
7. embly 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 normal _ rr rrr r P P rrrrr idJel wrF i W wWMWMNMWW M kkWWk 5 Z2 AA4y yZAJ AAA AJ5Z gt lt o rrront H 29 7 2010 Honda facing Van Diemen Chassis IHP L15A7 Engine Installation Manual Bleeding The Cooling System If the water system is completely dry it is best to refill the system from the inlet thermostat cover and the water pipe coming from the outlet back of the head Fill with distilled water This will push the air up into the header tank When water is seen E at the end of the tubes reconnect Water ao them in their proper position ZA Outlet Loosen the 1 8 plug on the upper rear water pipe This will let air escape during the burping process As an option you can install a 3 hose back to the header tank as a permanent running bleeder Pret Fitting 7 2010 Honda facing Van Diemen Chassis n D L15A7 Engine Installation Manual Bleeding The Cooling System cont d B Fill the header tank and run the engine up to 175 Fahrenheit This will allow the thermostat to open At this point you should see air bubbles in the header tank NOTE Be cautious when looking in the header tank hot water can discharge from the filler nec
8. es of HPD L15A7 Engine Installation Manual Van Diemen Chassis 7 2010 Honda facing Van Diemen Chassis O eet lH4P PD L15A7 Engine Installation Manual Table of Contents 1 Safety Consideration and Warnings Page 2 ZEIT qe Page 3 3 Bell Housing Adapter Preparation Page 4 IRN Page 6 5 Slave Cylinder Installation Page 7 FA SEN Page 10 7 ENGINE INSTANATION critica Page 16 FS EEE Page 21 JE Serio Page 23 Lege raem Page 26 RS otipleted L Es AN OU ici Page 28 12 Bleeding The Cooling System e Page 30 13 Engine Cover Installation eese Page 32 T4 CONSCHIRIOMIA 10 0 eee ae E E E E Page 36 7 2010 Honda facing Van Diemen Chassis EEE HM o eet lH4P PD L15A7 Engine Installation Manual Safety Precautions The service information in this manual is intended for use by qualified professional technicians Attempting service or repairs without the proper training tools and equipment could cause injury or death to you and others It could also cause damage to the engine vehicle or create an unsafe condition This manual describes the proper methods and procedures for the race kit installation related to your chassis in addition to service and repair procedures described in the Honda Fit service manual Some procedures require the use of specifically designed tools and dedicated equipment An
9. he L15A7 Honda engine an inspection of the engine bay frame rails and the cz fuel cell is recommended Fuel cell foam should be inspected for age and degradation while the bladder also should be carefully examined for wear punctures tears or signs of leaks lt A LK 7 The fuel cell container also should be inspected and any sharp edges screw rivet heads etc either removed or covered by a protective material Thoroughly clean the cell before assembly oo 10 7 2010 Honda Racin Van Diemen Chassis a eel L15A7 Engine Installation Manual Install Fuel System cont d HPD s Van Diemen Fuel System Components Install the regulator into the housing using a light oil or silicone lubricant on the O rings Make sure to insert the regulator square as it will be easy to cut the O rings It will take some force by hand to install the regulator Install the retainer clip into the housing Pressure Regulator as 11 7 2010 Van Diemen Chassis L15A7 Engine Installation Manual Install Fuel System cont d Using the pipe thread sealant install the 1 8 NPT to 5 16 barb into the housing on the fuel cell bottom side This will connect to the fuel pump Using pipe thread sealant install the 1 8 to 5 16 barb into the housing on the cover top side Position the housing so the return fuel port faces toward the bottom of the fuel cell NOTE Be sure the regulator is sending excess fuel
10. ing Adapter Preparation cont d Install the 12 x 28mm stud in the upper left threaded hole Bottom fit the stud using a thread retaining compound 7 2010 Honda facing Van Diemen Chassis IHPD L15A7 Engine Installation Manual _ uM Oil Tank Preparation Optionally the oil tank cover can be modified like the one in the picture to reduce oil splash and foaming Install oil tank cover using existing hardware and an RTV type sealant Install the standard Van Diemen pickup tube filter assembly in the lower right side of the oil tank Alternatively fit the HPD supplied 90 degree AN fitting as illustrated here 7 2010 Van Diemen Chassis HD L15A7 Engine Installation Manual Install Slave Cylinder HPD adapter and mounting bolts with washers Remove the existing clutch release bearing slave cylinder and input shaft It is suggested that the input shaft seals be upgraded replaced at this time Prior to installing the slave cylinder adapter place the supplied O ring on the existing slave cylinder mount Installed O ring 7 2010 Honda facing Van Diemen Chassis L15A7 Engine Installation Manual Install Slave Cylinder cont d On gearbox side of adapter apply a thin film of sealant around the mounting holes prior to installation Install the slave cylinder connect the hydraulic lines and install the input shaft Clutch Slave Cylinder Placement Measure the dist
11. ing material from the standard Zetec tail test fit the HPD air intake and make your initial outlines for removing material from the top sides of the tail section Be careful not to remove too much material It is better to make an initial smaller than required opening and then trim to fit Go slowly and trim just a bit of material each time to prevent over trimming The air intake also may be slightly trimmed to provide the best possible fit Once trimming of the Zetec cover is complete test fit it to your chassis with the HPD L15A7 engine installed Ensure there is the necessary clearance for the intake manifold throttle linkake air filter etc Trace a line around the opening approximately 2 outside the trimmed edge of the hole Scrub the area with acetone to remove all traces of dirt grease and oil It is critical to a successful installation that all traces of dirt oil and grease be removed from this area or the new resin will not properly adhere Next using a sanding block with medium grit paper or a die grinder and flap wheel abrade the surface inside the 2 line down to raw resin and or glass Remove just enough material to get clean resin glass Don t grind through to the surface Once the sanding is complete vacuum the area to remove the dust Lightly abrade the inner face of the blister to ensure a fresh bonding surface Ss 34 7 2010 Honda Racin Van Diemen Chassis EEE E iS eel L15A7 Engine Installation Manual Engine Cove
12. k Rev up the engine to burp out any remaining air Shut off engine and fill header tank with distilled water Secure the cap and close the plug at the upper rear water pipe If you still see air and the engine temp is climbing above 200 Fahrenheit shut the engine off and let it cool down Then proceed to start up and bring engine temp up to 175 Fahrenheit and burp the system again erre r cl S G2PB gt _ N 9uUZ53 M MAH IEEE Mm n M M 31 7 2010 Honda Racin Van Diemen Chassis BEEN eel L15A7 Engine Installation Manual Engine Cover Installation By Stan Clayton Dauntless Racing Cars February 2010 Safety Precautions Personnel undertaking this procedure should read and understand all relevant MSDS documents before using resins hardeners catalysts and solvents as they can be hazardous to one s health Use appropriate safety equipment at all times while working with these materials with a minimum of long sleeves protective gloves respirator 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 A WARNING AMECO E Improper service or repairs can create an Failure to properly follow instructions a
13. led Carefully follow the procedures and Carefully follow the procedures and precautions in this manual precautions in this manual and other service material 7 2010 Honda facing Van Diemen Chassis MM eet HPD L15A7 Engine Installation Manual This manual details the steps necessary to install the Honda L15A7 engine with the HPD engine kit into a circa 1999 2008 Van Diemen chassis The converted L15A7 engine is designed to be installed utilizing the existing mounting points of your chassis without modification 7 2010 Van Diemen Chassis L15A7 Engine Installation Manual Bell Housing Adapter Preparation Adapter Plate 12 x 55mm stud Bell housing dowel 2x 12 x 28mm stud 12mm Flange Nut 2x 14 x 20mm dowel pin 12 x 60mm flange bolt 2x 10 x 25mm flange bolt 10 x 40mm flange bolt 3 8 16 x 3 socket bolt 10x 1 5 x 50mm socket bolt 3x m een dc Install the locating dowels Using the three 10 x 1 5 x 50mm IEEE Socket Bolts m socket bolts attach the adapter plate Ni N to the bell housing NO Kn On the engine side install the 12 x 55mm stud in the lower starter mount Install it so that 27mm of the stud protrudes from the block surface Use thread retaining compound to hold it in place Do not bottom the stud Doing so will prevent the flange nut from achieving full engagement on the stud 7 2010 Honda facing Van Diemen Chassis IHPD L15A7 Engine Installation Manual Bell Hous
14. nd unsafe condition that can cause your precautions can cause you to be seriously customer or others to be seriously hurt or hurt or killed killed Follow the procedures and precautions in Follow the procedures and precautions in this manual carefully this manual and other service materials carefully ls 32 7 2010 Van Diemen Chassis L15A7 Engine Installation Manual Engine Cover Installation cont d Modifying an existing Kent or Pinto tail The simplest modification is to simply create clearance openings for the Honda intake manifold and throttle assembly Install a cover plate made from sheet stock aluminum fiberglass etc over the air intake used in the previous Kent Pinto application rrrr Prr aamy a yo r c smMS gt gt m M M gt M Mm m p N M MSM Ml Mq8 pPo0 _ _Tt_RRz xhchvwvwvyvvv nnn n M M M 33 7 2010 Honda facing Van Diemen Chassis L15A7 Engine Installation Manual Engine Cover Installation cont d Installing the HPD intake on a Zetec tail section A more complete solution is to install the air intake supplied with the HPD Chassis Kit to a Zetec style tail section The Zetec tail is preferred as it presents a slimmer cross section without the side bulge required for the carburetor intake manifold clearance required by the Kent or Pinto F2000 tails Follow these steps to make the installation e Before remov
15. ock and medium grit paper or a dremel or die grinder with a small stone carefully sand down any resin bubbles that are standing proud of the outer surface of the side cover e fthere are any unsightly transitions between the outer surface of the side cover and the blister sand the outer surfaces of the blister and side cover with medium grit paper and apply a thin layer of body filler to smooth the transitions Shape and sand the body filler to a smooth line Repeat thin layers of body filler as needed to get the desired smooth transition line then sand and prep for painting e Prime and paint as desired Ss 35 7 2010 Honda Racin Van Diemen Chassis aa eel L15A7 Engine Installation Manual Contact Information Honda Performance Development Inc 25145 Anza Drive oanta Clarita CA 91355 661 294 7300 Honda Racing Line grmsadmin hra com Phone 661 702 7777 Fax 661 294 7367 lt mnmMXatlM2ms1M ll_r1_ m 1 _ T X1 _ S l_ k4e ml vB D PWu _rkzczceo cr crcrr _rrr 36 7 2010
16. r Installation cont d e Place the trimmed air intake on the fiberglass cloth you will use to make the bonding patch Trace a line approximately 1 5 outside the air intake s outline and cut the fabric to match the line then cut out a matching outline approximately 1 5 inside the outline of the air intake You will now have a shaped piece of fiberglass cloth approximately 3 wide Repeat the process to produce two more pieces approximately 2 wide and 1 5 wide All three layers can be the full width but narrower strips will save a little weight Three layers should do the job but you may add additional layers if you wish so long as they do not conflict with the engine installation e tis now time to fit the air intake to the tail section and tape the outside with 2 masking tape Ensure the entire outside outline of the opening is covered with masking tape or resin may leak out onto the outer surface of the side cover You may also wish to tape the air intake in place with additional pieces of tape running fore and aft and up and down on the outside of the tail e With the air intake securely taped in place tape ONLY on the OUTSIDE surface place the tail section upside down on a soft mount that will support the tail without distorting it You are now ready to bond the air intake in place e Ensure the resin and hardener catalyst and tail section are at or above the minimum working temperature of the resin Wear all appropriate safety gear an
17. rails to the oil tank transaxle assembly Secure the front lower engine bolts If necessary use hardened washers as shims installed between the motor mount and the frame rail Follow the Van Diemen instructions for shimming and squaring the chassis 7 2010 Honda Racing Van Diemen Chassis IHP L15A7 Engine Installation Manual Engine Installation cont d You also may need to shim the upper front mount with washers six hardened 2 5mm thick washers are included in the chassis kit Note The mounting bracket and or washers may need to be modified to a specific chassis Use caution in making any modifications as the coolant header tank sits on this bracket _T F rt th pV FYyTYyYyT_ gt lt lt lt gg e 4 xX6XKK X FNWrW biibeYtrW b bbmWmtiiiziil o me z_r z r 20 7 2010 Van Diemen Chassis PDD 235 mg L15A7 Engine Installation Manual Oil System Layout all the hose and fittings before assembly to understand how the hoses are to be placed NOTE If you are cutting the braided hose to length and installing the fittings yourself be sure you are familiar with the proper procedures If not done correctly you could cause damage or harm to yourself or others The oil feed is on the lower right side of the chassis running from the tank to the right front corner of the sump These are both AN 10 fittings There is an in line filter included in the Chassis Kit
18. s L15A7 Engine Installation Manual Engine Installation X W iis The water inlet at the thermostat housing needs to use an alternate thermostat cover The cover clocks the water line at 90 from standard parallel to the ground The thermostat housing will require some material removal to facilitate the water hose clamp Be careful not to remove too much material A 3 8 NPT bung is supplied in the Van Diemen chassis kit This will be welded to the stock cross over tube to allow running of an air bleed line to the supplied header tank 7 2010 Van Diemen Chassis LPD 295 d L15A7 Engine Installation Manual Engine Installation cont d Measure 2 3 4 from the outside of the main chassis down tube be sure you will have access to tighten the fitting and hose NOTE Before cutting the AN 10 bleed hose to length it is recommended to mock up the header tank to confirm the length is correct Mocked up This will account for any deviations in position the placement of the bung rim i Thread the 3 8 x 10 fitting into the bung using pipe sealant Cut the 10 hose to the length determined in the previous step then install the straight and 45 fittings 7 2010 Honda facing Van Diemen Chassis L15A7 Engine Installation Manual Engine Installation cont d ad od j This engine will install in the same manner as your previous engine pg oo Be sure the water line
19. s are installed b A on the engine per the engine race kit manual Install the lower front engine mount to the oil pan Washers are included in the kit to help with any shimming that may be required If needed they are to be placed between the mount and the frame member Note The frame mount holes are 7 16 diameter rather than the stock Van Diemen 10mm This is to facilitate installation into a variety of chassis You may need to install reducing sleeves in the bores Note This engine mount also comes with oversize 7 16 bores This is to facilitate installation in all chassis You may need to install reducing sleeves to achieve the stock 10mm sizing of the Van Diemen Have the upper mount loosely in place until the frame rails bell housing and front lower mount are all in place then shim the upper mount at the chassis attachment points as necessary 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 7 2010 Van Diemen Chassis O HPD 3r L15A7 Engine Installation Manual Engine Installation cont d Align the input shaft splines with the clutch and mate the bell housing to the engine When you have the dowels engaged you can thread in all fasteners and snug up the bell housing Once the engine transaxle assembly is in position secure the engine bay frame
20. th the sock filter in place A 5mm standoff from the bottom of the fuel cell to the filter is desirable Tighten hose clamp around fuel tube and fuel pump After the fuel pump position is set measure for the second lower internal fuel hose and cut to needed length for the distance between the regulator and fuel pump Use supplied clamps to secure hose ends onto fittings Install fuel fill tube assembly into fuel cell install the fuel filter sock onto the fuel pump NOTE Do not run the fuel system without the filter sock installed 7 2010 Honda facing Van Diemen Chassis IHP L15A7 Engine Installation Manual Fuel filter mounting Pictured is a proposed fuel filter location and mounting method NOTE The optional fuel pressure sensor will fit between the 1 amp 2 intake runners 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 the hose to length and install 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 _mmmy y h tf lt lt v v Rcte e ea rrk r r NnRNnNhhNDNYt Y o1_ o_ wo ym_ouyd4a U Vd T rr 15 7 2010 Van Diemen Chassi
21. y person who intends to use a replacement part a service procedure or a tool that is not recommended by Honda or the race sanctioning body must determine the risk to their personal safety and the safe operation of the vehicle Any error or oversight while performing this conversion or service can result in faulty operation damage to the vehicle 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 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 basic shop safety practices for example hot parts wear gloves If you have not received shop safety training or do not feel confident about your knowledge about safe servicing practices we recommend that you do not attempt the procedures described in this manual We cannot warn you of every conceivable hazard that can arise in doing service and repair procedures Only you can decide whether or not you should do a given task AN WARNING Failure to properly follow instructions and precautions can cause you to be seriously hurt or killed AN WARNING Improper service or repairs can create an unsafe condition that can cause your customer or others to be seriously hurt or kil
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