Assembly manual, Sample pages
Contents
1. Blair spotweld cutter to cut the pin from the plate drilling from the back side at the punch mark The pin will be removed together with a small piece of the plate SI SECTION C CHASSIS PREPARATION Body pre mounted on chassis option Most of the time consuming items listed in this section are already done although it couldn t hurt to check critical fasteners You can skip all the Section C items except removing the windshield bumpers lights and fuel filler cap in preparation for paint BODY REMOVAL The body must be removed to paint the chassis but is not necessary to remove the body from the chassis to paint the body All E R A turn key cars are painted with the body already bonded to the chassis but without mechanicals installed This requires careful masking to minimize overspray but guarantees good body panel fit Installation of all the mechanical components is easy with the body on the chassis Itis in fact much harder to install the body over the mechanical components When doing any disassembly note any adjusting shims and their location Mark each for reassembly DOORS HOOD AND TRUNK LID Note the location of the hinges and the number of shims for all pieces Remove the door hinge covers Remove the doors hood and trunk lid from their hinges Note that the basice kit is shipped with short pieces of half round rubber taped to the door openings This is put there to prevent rattles and w2. Remove the retaining clip and the clevis pin TYH SISSVHO Loosen the jam nut at the clevis Turn the threaded rod to change the length as necessary When finished tighten the arm set screw For balance bar parts installation see page 142 Clutch height adjustment is covered on page 104 BRAKE PEDAL HEIGHT ey Master cylinder installation is described on page 61 ANIA A DN VIEW FROM BOTTOM For people of average height set the distance from the rear of the pedal face to the forward part of the foot box to To change the brake pedal height turn both threaded about 7 If you are much taller or shorter you may move rods equally in or out ay le Peta SEO RON aE Oe DICA A enmcc ee Check the tightness of the brake lines and switch fittings 103 SECTION G BODY INTERIOR CARPETS INTERIOR REAR PANEL een gt rd si After masking the body spray or brush contact cement on the panel areas and the back sides of the vinyl and carpet Install the vinyl on the central aluminum side panels Trim even with the vertical edges and leave a short amount at along the floor 115 Install the side carpets starting by lining up the corner s as shown vy dx TES e se i pae n e da di e J Carefully form the carpet over the wheelhouse bulge and push into the side and top areas Trim off the excess material SECTION G BODY INTERIOR Attach the tunnel carpet 17 with ab
3. TKO 500 600 Install the spacer between the mount and the mounting boss The offset standard length input shaft goes toward the rear esi i Fork installed in TKO 600 TRANSMISSION TREMEC The Tremec TKO series has a boss on the right side that must be trimmed back flush in order to clear the chassis X brace Note that the TKO 600 is metric threaded 10 x 1 5 on the inner holes 2 13 on the outer holes Trim flush with rib TKO 3550 TKO II 34 SECTION B PARTS PREPARATION HOSE TRIMMING INSTRUCTIONS FOR 4BBL MANIFOLD ALUMINUM CONNECTOR The two lower radiator hoses must be modified to fit gt ai After checking fit cut and trim the hoses as shown a nica i Tit Sao oaae ong out CUT HERE GATES 21178 The long leg of the aluminum connecting tube goes toward the radiator Lower Hose Ford small block FOR LEFT EXIT Ford FE water pump WATER PUMP Con tube radiator to aluminum tube fr A m GOODYEAR 62107 DISCARD Hose Gates 20390 Connecting hose for aluminum water pump This substitutes for the 21047 shown above DISCARD FOR RIGHT EXIT SMALL BLOCK FORD WATERPUMP Con tube radiator Use the center portion from the radiator to the lower End piece from end section of connecting tube You must tell us that you re using a upper hose may fit better small block when you order 429 460 FORD Lower hoses are the same as the FE Ford You must use an in line filler cap 1
4. e Moroso or an expansion tank If you are using an in line filler only you must use an overflow system that replenishes the system automatically Pad the X member if the upper hose touches it Upper hose 39 SECTION B PARTS PREPARATION CONNECTING TUBES If you are sure that the wiper motor functions correctly and don t want to disassemble the wiper motor itself skip steps _ Wheelbox qonman 4 through 8 F a L h a Take out the 4 screws holding the cover to the gearbox ee and remove the cover Connecting ar rod Remove the circlip and washer from the connecting rod big end and remove the connecting rod Note the bottom washer Remove the circlip and washer from the back side of the crankshaft and push out the crankshaft from the housing Retain all the parts Note the thrust washer on the inside of the crankpin Mark the relative position of the round motor housing to the aluminum gear reduction housing Remove the two ewe long screws holding the motor housing to the frame Undo the large nut and remove the cable tube wheelbox Separate the two with gentle soft hammer taps if assembly from the motor necessary Do not lose the felt washer and thrust washer Remove the wheelbox backing plates and remove the in the bearing cup at the bottom of the housing tubes from the wheelboxes Inspect the brushes for wear or sticking the commutator Using a tubing cutter or hacksaw cut off approximately 2 for excess
5. for 600 bhp Overheating at speed is almost S i always the result of incorrect engine settings usually gt retarded ignition timing Check your dynamic timing at Connecting tube idle and 3000 3500rpm or as recommended by your engine From 20620 with thermo switch builder Sometimes an extremely tight new engine can cause overheating With upper connecting tube 144
6. its original shape pulling away from the corners Trim the ends of the weather stripping as shown REAR EDGE Glue upper OF DOOR end of door seal toward n ff _ Trim off inside n Ne SF igs end of seal GY as shown FRONT EDGE s OF DOOR E DOORGASK SIDE CURTAIN FERRULES Side curtain ferrule inserted in door angle to match S inner panel Retaining n D FERRULE Slip the ferrules into the holes on the top of the doors and note the length that each extends past the inner panel SECTION E BODY PREPARATION Mark each ferrule so there are no more than 2 or 3 threads i i All components are pre installed on every Kit showing between the mark and the door surface on its shortest side Cut off the excess at the mark and slightly round off the ie O edges with a file or sander support Hold the ferrules in place with the retaining rings provided Seat the retaining rings against the door surface tightly DOOR PULL STRAP OPTIONAL Drill a hole 30 bit Just to the rear of the side curtain ferrule Loop the strap over the latch ball and use the screw and countersunk washer at the front a re Onto intake manifol F m DOOR INSTALLATION The doors can be installed now but to make other e throtink operations easier it s best to wait until near the end See Fit the rod end C through the footbox using a large page 123 for installation details washer on either s
7. lock washer is necessary Raise the rear suspension assembly into position with a floor jack guiding the forward ends of both trailing arms into the brackets on the sides of the frame Don t install the bolts yet Move to the trailing arm on the other side of the car Sight 3 through the hole in the chassis and determine whether the Note Jag suspension in top hole f oe length of the trailing arm will have to be adjusted Screw ERA suspension in bottom hole do the trailing arm in or out on the rod end as necessary If the assembly does not line up perfectly pry or pull on the hub carrier to shift things around while installing the spacer and bolt If the holes do not exactly line up grinding a taper on the bolt may make it easier to get the threads to start Torque the bolts on both sides to 45 Ib ft Tighten the upper pivot bolts to 90 Ib ft Connect the brake flex line to the bracket on the chassis XKE HANDBRAKE LEVER AND CABLE You can use then entire XKE handbrake cable linkage as shown below Note angle TOP VIEW OF TRAILING ARM Atralarm 99 SECTION F SUSPENSION ASSEMBLY If even more adjustment is required a bore Tilton BRAKE AND CLUTCH PEDAL cylinder can be substituted for the BMW clutch master cylinder A new clutch hose is also required Special Order Only ADJUSTMENT Adjust pedal face angle here MACHINED FLAT TOWARD THE HOUSING d braklink Because the front brake wheel cylinde
8. of the radiator Fill the system with the cooling mixture Once water flows bubble free from the radiator bleeder shut the valve Actually we usually fill the system with water first and pressure test for leaks then drain half the water out We can also tell the condition of the cleanliness of the cooling system by the drain water To water pump e With the expansion tank full loosen the water temperature fitting on the intake manifold Air will From 21047 be expelled When nothing comes out but fluid or 62107 tighten the fitting If you have a heater it may be necessary to bleed air from the system by disconnecting a hose at the heater nipple r Connecting tube e Repeat the bleeding process after the car is run From 20620 with thermo switch More air will usually come out Standard one piece upper hose e Check the hoses and retighten all the hose clamps OVERHEATING From straight hose 1 75 id x 4 5 L Gates 21236 Use a 165 F 180 F thermostat for street use Leaving the thermostat out will cause overheating The boiling point of a water anti freeze mixture with a 15 psi cap is over 230 FF It is not harmful and normal for the water temperature to rise to 210 F 220 F with the car not moving at Upper connecting tube We do NOT recommend using an underdrive waterpump pulley on the street To water pump ie i AT SPEED From 21047 The E R A 427SC uses an oversized radiator made by or 62107 Griffin rated
9. the tunnel Attach the plate and cover to the tunnel VELCRO Bunch up fabric The door should latch on the second catch without being under retaining plate ay VELCRO Te NED slammed If it doesn t shut all the way with a solid chunk check for latch striker misalignment or an interference fit between the two parts To check for misalignment hold the latch lever in the open position and shut the door without putting any pressure on it up or down The door latch should seat into the striker without resistance or sharp contact sounds Re align vertically if necessary Open and shut the door several times then check the striker receptacle of the latch for shiny spots File these Ce He ATTACHING PLATE spots being careful to hold the file flat Recheck fit and ATTACH HERE FIRST repeat the process if necessary dii Install the dead pedal over the carpet Re bolt the hand brake lever in place Fold the outer flap of the cover over the lever and attach to the inner flap with the Velcro and snap 121 SECTIONH_ FINAL OPERATIONS Attach a small hose to the slave cylinder bleeder nipple CLUTCH HYDRAULICS emersing the other end of the hose in a small cup of fluid Loosen the nipple about turn with a 2 or 7 mm wrench PRESSURE HOSE INSTALLATION Work the arm on the clutch pedal shaft instead of pushing ia pedal itself until only clear fluid comes out of Close the bleeder nipple and pump the clutch pedal several tim
10. ASSEMBLY AND SERVICE MANUAL FOR THE Era Replica Automobiles 427 ROADSTER Chassis 758 on Revision 10b 6 08 Copyright 2008 Era Replica Automobiles SECTION A PARTS NEEDED ENGINE Remember All piston engines have a limited torque spread If you decide to build a fire breathing monster expect to suffer at the lower RPMs Because the E R A 427SC is light every hiccup is felt Very high octane gasoline is becoming scarce and octane boosters can be a pain to deal with If you re going to do a lot of street driving use a conservative compression ratio E R A turnkey cars are usually built with 9 5 1 or 10 1 maximum COOLING Always use a thermostat in your system for street use If the engine fails to reach normal operating temperature it may affect driveability and lubrication In warm climates a 165 F to 180 F thermostat works the best Use a restrictor plate for racing conditions only The thermostat should be modified as shown on page 38 EMISSIONS Requirements vary from state to state Most states require that your car meet the specifications of the year of your engine Check with your local authorities Side pipes with catalytic converters are available but we have no experience with them Bore Stroke BHP Torque net net lb ft 4 05 378 320up 427 4 23 3 78 410 up 480 4 13 3 98 325 475 The original Cobra used the 427 CID Side Oiler engine in the first cars intended for comp
11. d the Jag trailing arms but you do need everything else e Limited Slip Differential Many XJ differentials were open A new limited slip may be retrofitted for about 700 e Brakes Try to get serviceable hydraulic and emergency brakes There were no major changes in XKE rear brake until 1968 when both the calipers and rotors were updated The later units are cheaper and easier to rebuild than the early units e Gear ratio There should be a tag on one of the rear cover bolts for example 43 13 on the tag 3 31 ratio If there is no tag mark the input shaft flange and the half shaft or brake disc for reference and rotate the axles by turning the input shaft For every time the axles and brake disc turns over once the input flange should rotate approximately 3 turns 3 31 1 ratio or 3 times 3 54 1 ratio See the chart on page 12 for the best ratio for your engine transmission combination Custom ERA Rear Suspension e Dampers coil over shocks All E R A rear suspensions require 4 dampers and coil springs coil over shock absorbers Specifications are the same as for stock Series II Jaguar XKE XJ dampers cannot be used See page 23 for part numbers and page 53 for length specifications Dampers with adjustable spring seats and externally adjustable damping are available from E R A USING THE E R A JAG SUBFRAME The stock Jaguar XJ control arms and half shafts will be exchanged for shortened pieces when you b
12. ear when the car is shipped You may discard the rubber etc Lengths of new gasket are included in the parts boxes shipped with the kit Remove the door hinges and metal closing panels behind door hinges Remove the hood and trunk hinges noting their location L and R are stamped into the hood hinges The trunk hinges are the same from left to right and are stamped with T BUMPERS BUMPER BRACKETS Front If you have the optional nudge bar s detach them from the overriders Remove both fresh air inlet ducts and screen from the front body Remove each bumper tube assembly from its mounting point The upper nut is accessible from inside the nose The lower nut is accessed through a hole in the inner splash panel Rear Unbolt the bumpers from their mounting brackets upper bolt and chassis lower bolt The nuts on lower bolt are reached through the access holes on the bottom of the rear chassis cross member If nudge bar is fitted remove as a unit WO n s s Jackpad Threaded rog Body grommet REAR Bumper bracket Spacer used only with nudge bar 0D ROLL BAR Remove the center access panel from the rear bulkhead See page 83 Remove the bolts from roll bar brace one at each leg and at the top and bottom end of the rear brace Remove the shim washers from the lower end of the brace and slide the brace down to disengage the upper slip joint Pull the roll bar hoop up and o
13. es If there is more than 1 travel at the pedal before resistance is felt repeat the bleeding procedure ADJUSTMENT The slave cylinder has an internal spring that keeps a small amount of pressure to extend the piston at all times Most throw out bearings will operate with the small constant ii pressure involved Those that cannotmust use a return ro spring and be adjusted periodically EERENS oral REI tate Pat OS 7 tate tata If you wish you can use this preload to automatically keep the clutch adjustment at zero clearance This will however reduce the life of the throwout bearing Since clutch wear will be most seen when the driven disc is being broken in you may want to keep the automatic mode during the first couple hundred miles and then install a return spring See page 104 for clutch pedal height adjustment WITHOUT RETURN SPRING Increase the length of the throw rod by unscrewing the ball end forcing the piston in the cylinder to just bottom out Note that the cylinder is spring loaded to the fully extended osition With BMW Master Cylinder Decrease the length of the adusting rod so that there is about movement when you push the transmission arm toward the front of the car With Tilton Master Cylinder Check the tightness of all fittings before bleeding BLEEDING The car must be level or with the front end slightly higher for this operation Aclichadj Fill the brake clutch
14. etition The remaining cars were equipped with a mix of 427s and 428 Police Interceptor engines Both engines are logical for use in an authentic car TheE R A was designed around these engines The Ford FE series is not especially heavy with the all iron version weighing only slightly more than 600 lbs We have seen complete engines with aluminum heads intake manifold w 2 x 4bbl carbs and water pump scale at 522 lbs Simply adding an aluminum intake will bring the weight on a stock 428 to 585 Ibs The best engine depends on your driving style and your budget If you are not experienced in the FE series engine be wary of building your own exotic engine The FE series 1s a bit quirky and you may make some very expensive mistakes Before you buy anything get a good Ford engine building book available from Autobooks etc Ford production of major 427 and 428 parts ceased in the 1980s Fortunately most FE engine parts are being reproduced You can still find original 428 cores that were used in many full sized Fords Using a vintage engine may have an advantage when registering your car When you buy parts keep the receipts See Inspection page 152 In general the 428 is much cheaper and easier to find than the 427 The later vintage 428 Cobra Jet CJ or 428 Super Cobra Jet SCJ engine is fine for all around street use offering from 325HP to 425HP with very good low RPM response and tractability Most 428 cores can have the
15. f tape With a temporary marker trace the profile of the lower edge of the attaching plate onto the pocket Also mark where both ends of the plate fall eint doorpnl3 Remove the door pocket from the door and trim the edge of the door pocket approximately 1 outside the marked line Cut wedges out of the edge of the material almost up to the marked line TRIM OFF EXCESS MATERIAL tet TRIM AROUND FASTENERS AS NECESSARY ein DOORPANLI Re install the pocket onto the door Apply contact cement to the edge and backside only of the attachment plate and the back side of the pocket material Let dry to a tack free condition 85 Carefully stretch the material over and partially around the attachment plate Remove the attaching plate from the door Tape or clamp the upper edge to a flat surface and finish gluing the edge Before attaching the pocket to the door glue the rug items 7 and 15 in the rug installation diagram on page Error Bookmark not defined to the inside of the door with contact cement Install the door pocket and the latch onto each door DOOR WEATHERSEALS Lay the doors outer surfaces down on a soft surface Clean the door edge and rubber with a mild solvent Glue the door weatherseal start with about 60 trim the ends later provided onto door lip about from the door edge using contact cement or weather strip adhesive Don t stretch the weather stripping It will eventually shrink to
16. for Ford engines are listed on page 153 4 Front gt BASIC PREPARATION ON Remove cooling fan from engine water pump pulley Install the fitting for the water temperature gage in the RIGHT SIDE intake manifold adjacent to the distributor Note that some manifolds must be tapped NPT If your manifold is tapped NPT you may be able to adapt with a Weatherhead fitting 3200 x 8 x 6 available at your local Ford FE Engine b engmt jobber Note If you have excessive engine motion or a very high torque engine go to Install the mounts onto the Ford small block as shown below www erareplicas com 427man engine mountmod for mount modification details Front of engine Mote Both the left and right studs are offset on the pad toward the front of the engine Ford Small Block b sbengmt The FE mounts look similar but they cannot be exchanged from side to side Note that the stud surface is angled slightly from the engine side Install the engine mounts onto the FE block as shown below 32 SECTION B PARTS PREPARATION CLUTCH Install the clutch pilot bearing driven disk and pressure plate CLUTCH THROW OUT FORK Forks for small and large spline transmissions are available from E R A The standard Ford small spline fork see page 25 for part number can be left stock or bored through for easier adjustment Drill remember that the part is hardened the indentation to id
17. ide of the hole Install the pedal assembly A with the linkage bracket B ACCELERATOR PEDAL AND LINKAGE onto the foot box At the back secure to the fiberglass with bolts through the brace bracket and spacers At the front secure with the front steering flange bearing bolts Loosely bolt the bracket D onto the engine using the rear most intake manifold bolt The final object is to have the cross shaft as parallel to the firewall as possible so the orientation of the bracket may be changed so that the vertical and rod end support are toward the firewall Adjust the placement of the rod end in the bracket so that the cross shaft is roughly horizontal Fit the left end of the transverse link F to the rod end on bracket B Secure with a cotter pin Slide a rod end E onto the transverse link and bolt to the bracket D Note This linkage can be adapted to most engines If yours requires something different please call us The FE dual quad setup requires an additional linkage assembly 86 SECTION E BODY PREPARATION COOLER WITH REMOTE FILTER FUEL TANK Mount the remote filter on the water pump with the E R A adapter bracket Some modifications to the pump might be The 19 gallon aluminum fuel tank is baffled with one way necessary doors separating the volume into four sections capturing the fuel toward the front center of the tank during cornering and acceleration A drain plug is at the right front of the tank bo
18. ir performance updated by the addition of new heads from Edelbrock and Shelby at reasonable cost With an appropriate intake manifold and carburetor a 428 will put out over 400 streetable bhp SECTION A PARTS NEEDED REAR DRIVE SUSPENSION ASSEMBLY Jaguar based Suspension The E R A 427SC is designed to use either the Jaguar rear suspension in an E R A subframe or a custom E R A suspension unit with outboard brakes The E R A unit is available as a kit with with all our conversion parts ready for your differential and brake parts or as a complete assembly See page 43 for details JAG PARTS SELECTION See page 23 for application list The Jaguar differential is the same Salisbury unit that was used in the original Cobra with only some casting changes It is adequate for 500 BHP and can be made even stronger by using stub axle parts from Concours West Gears wear is not normally a problem even in well used assemblies but always replace seals The vintage of the Jaguar differential is punched in the casting at the lower right corner of the cover The top number is the year the bottom number is a special code Translation we don t know what it s used for A simple way to determine whether a post 1980 unit will work is the presents of inboard brakes The later inappropriate assemblies have brakes mounted on the hub carriers When selecting and buying a used rear end look for e Completeness You don t nee
19. ket to the main body as shown on page 78 for bodywork alignment prior to painting Bolt the trunk hinges they are marked with a T on the lid side loosely onto the body with any shims found earlier Loosely bolt the trunk lid with factory shims onto the hinges Carefully close the lid not letting the front edge contact the body Center the lid in the opening Slowly lift the lid just enough to get your arm and a wrench inside and snug the bolts on the lid part of the hinges Remember to check the front edge while lifting lid The lid can be adjusted further by moving the lid and hinges in unit at the connection on the inner panel Tighten bolts and recheck fit TRUNK STAY Pre installed Attach the trunk stay to the trunk lid as shown using the sheet metal screws at the bottom stainless steel dome head screws at the top 68 SECTION E BODY PREPARATION Stretch the door pocket into place with its forward edge even or slightly past the front edge of the door frame and of the way up from the hinge bottom mounting holes Hold the top of the pocket in place with masking tape Attach the hinge loosely with the two upper bolts Mark and punch holes for the two lower bolts through the door pocket Attach the bottom of the hinge and snug the bolts Gently and evenly pull the bottom edge of the door pocket down over the bottom edge of the door Stretch only enough to eliminate any wrinkles Hold in place with several pieces o
20. out 1 extending past the front edge allowing the carpet to be folded over to the backside and glued Cut out for the shifter ashtray and hand brake lever Screw the tunnel into place To make cleaning easier the two piece floor carpets are held in place with snaps and Velcro Fit the carpets in place and mark the floor where the snaps are to go Drill 1 4 holes and screw the snap bases into place Remove carpets to fit seats FRESH AIR CABLES Lubricate the rubber grommet located midway up the front of the driver s footbox on the left hand side with silicone spray or petroleum jelly Push the cable through the grommet and install the cable loop on the fresh air control valve as shown on page 63 Attach the cable to the side of the footbox with a cable Replace the door strikers as described on page 123 The clamp added thickness of the carpet should make the rear edge of the door flush with the body If not add or subtract shims Also see the illustration on page Error Bookmark not defined HAND BRAKE LEVER COVER Using the figure below as a guide open up the hand brake lever cover and align the cut out section on the inside flap around the hole in the transmission tunnel behind the lever bunching it up as necessary in the center Attach the front edge of the boot by drilling holes through the fabric into the tunnel eint doorrug 1 Hold the attaching plate against the cover and tunnel Drill four holes into
21. r the fuel tank neck and secure with the screws See the filler cap illustration oilclr7 92 SECTION E BODY PREPARATION FUEL FILLER CAP Remove excess RTV and clear the drain hole with a wire etc Install the vent and drain hoses to the lower flange as The cap and outside flange are indexed with punch marks shown Run the drain hose through the hole in the bottom or a common number on the outside edge of the upper corner of the well at the side of the trunk mounting flange This corresponds to where the latch of Pass the vent hose through the seal plate and connect to the filler cap falls when the cap is fully screwed onto the the aluminum tube that comes through the hole in the flange tank s mounting flange Note the odd hole falling just outside the upper flange on the body and lower flange A water drain for the filler well is integrated into the bottom flange of the filler cap The tube in the lower mounting flange channels water out of the well through a hole in the trunk FLANGE Put a generous amount of RTV silicone gasket sealer on the top surface of the flange Line up the drain hole on the flange and the body Hold the lower mounting flange in place on the underside of the fender INSTALLATION Tank vent hose Fuel tank extension Seal plate ebod fuelfill Place the gasket and upper flange on top of the fender with the flange markings toward the right side at 3 O clock as viewed from abo
22. reservoir with DOT 3 or DOT 4 fluid Silicone fluid is not recommended 137 SECTION H FINAL OPERATIONS COOLING SYSTEM SETUP The optimal operating temperature for most FE engines is WATER HOSE LAYOUT FE about 185F 85C This will keep water condensation in the oil to a minimum and allow adequate oil flow We do not recommend using a restrictor plate in place of a thermostat unless the car is used exclusively for track use Install the radiator hoses and optional top tube connector and lower hose connector The hose part numbers and instructions for modifying the front lower hose are covered on page 39 See page 150 for your best mix of water and anti freeze The radiator cooling fan thermostatic switch is in the lower With a 15p n ressure cap the boiling point will be raised hose connector Connect the harness wires as shown on to about 240 F page 81 and detailed in the wiring instructions There is Fill the system through the expansion tank leaving about also an over ride switch on the dashboard 142 of expansion space above the coolant level See the diagrams below for the cooling system circuits With some engines especially the FE Ford air tends to be trapped in the intake manifold and cylinder heads To Do NOT remove the spring from inside the long lower remove he trapped air hose It prevents the hose from collapsing at speed e Drill the thermostat as shown on page 38 e Open the bleeder at the upper right
23. ront mounted battery is bolted in place onto the front of the right foot box and to the top of the front outrigger It s pre installed on every chassis so the holes are already in place d voltreg d battery_mount BATTERY REMOVE AND REPLACE The engine compartment mounted battery is accessed by removing an access panel at the rear of the right front wheel e Remove the hose from the fresh air valve e Note that the top panel screw and the three lower screws are removed from the engine compartment side and the lower screws from inside the wheel well The bottom edge is secured to the chassis outrigger with sheet metal screws 64 SECTION D BODY CHASSIS ASSEMBLY From inside the grille opening or engine compartment lift the hinges assemblies into place Align and bolt to the body and hood with the shims used earlier Tighten all bolts Carefully lift the hood checking the front edge clearance Adjust and or change shims if needed AI Adjust the hood strikers on the firewall so that the hood is Automatic latch lt A N flush with the body The hood seal will be compressed a SM es Carnate Tats Bracket on under side ae HOOD PROP of bodylip ATE TE N Pre installed LO TT The upper and lower stay brackets are factory attached as ebod trnkstay shown Screws or blind rivets Retaining clip HOODPROP Note the orientation of the keyhole slot and the bend in the rod TRUNK LID Tape the gas
24. rs require more fluid than the rears the balance bar is always set up with the outside push rod longer than the inside one There are VIEW FROM UNDER CAR flats machined on the one side of each connecting rod end Nbrpedal Install the rod ends on the balance bar with the flats toward the balance bar housing See above and page 143 INSTALLATION If necessary clean and grease the needle bearings in the chassis and in the brake pedal NOTE ON THE BRAKE BALANCE ADJUSTMENT The rod length has no effect on the front rear brake bias which brakes lock first If necessary the bias can be Slide the pivot shaft through the chassis bearings with the adjusted as described on page 142 splined end toward the inside If the engine is installed the shaft must be installed from the outside of the chassis For a preliminary setting adjust the outer rod so that there are of threads showing on the outer master cylinder rod on the inner rod with the jam nuts against the rod Install the thrust washer s brake pedal and clutch pedal onto the shaft Secure the clutch pedal with the shoulder screw end Install the clutch throw out arm onto the splined end of the FRONT shaft Orient the throw out arm approximately opposite BRAKE the pedal See the illustration on page 137 To adjust the orientation of the clutch arm change the length of the connecting rod between the clutch pedal throw out arm and the clutch master cylinder
25. ttom The fuel sender is in the center front section of the tank and installed at E R A If you find it necessary to remove the sender use a fuel resistant sealant like Versachem Gasket Sealant 3 Aviation A jumper wire is taped to the top of the tank that mates with the connection to the rear harness Remove material from the lower boss shaded area INSTALLATION Place the tank under the car and connect the sending unit wire s Assemble the other components as shown The water pump may require modifications to the bottom mounting boss instructions included with cooler kit Raise the tank between the frame rails guiding the filler neck through the body hole Hold in place with one 16 USS bolt per side Install the rest of the bolts and WITH REMOTE FILTER se washers 69 5 LONG ors E FUELFILTER Sa J n te 1 W i de ha x n N j n Fi San f f r lt Pa j i Sa A tay 7 gt Tay r F fd gt if da fer fe mae t n d J fan ebod oilclr5 WITH IN LINE THERMOSTAT Ebod Fueltank WITH REMOTE FILTER AND CANTON THERMOSTAT SA PS i Connect the fuel outlet on the center rear of the tank to the ee t i steel line on the chassis both OD with a length of rubber fuel line An in line fuel filter can be conveniently installed within this section of line Use clamps on all connections Slide the seal plate ove
26. ut from the chassis Remove the rubber grommets from the body Doors etc Remove the filler panel below the door opening Remove latching hardware from the main body including the hood firewall latches Remove the aluminum interior panels that are below the door openings and the aluminum firewall RADIATOR AND SHROUDING Remove the optional oil cooler and shrouding See page 90 Remove the optional front fan assembly See page 89 Remove the rear fan on its bracket See page 88 Remove the side and lower shrouding 3 pcs from inside the grill opening Remove the upper radiator mounting tab and gently lay the radiator back against the chassis Soft paddling will help insure that nothing is damaged Remove the top radiator shroud See page 88 SECTION D BODY CHASSIS ASSEMBLY VOLTAGE REGULATOR The regulator part number on page 26 installs with 10 sheet metal screws bolts on top of the left foot box into captive speed nuts More chassis and body ID numbers The chassis is stamped with the ID number in three places The left front X member inside the top shock mount Ground from harness N On the transverse tube behind the engine usually covered by the aluminum firewall panel On the outside of the frame just inside the right rear tire The body is marked inside the hood opening on the left return lip about a foot from the front of the opening BATTERY TRAY Pre installed The standard f
27. uy the subframe from us Series II XKE parts will not have to be modified although Series III parts will All XKE lower control arm mounting brackets that bolt to the sides of the differential must be exchanged for XJ units All mounting bushings and hardware are included with the E R A subframe Do NOT replace the control arm roller and needle bearings with aftermarket urethane bushings The net result will be wheel hop and generally sloppy handling The E R A subframe requires XKE style coil over dampers While not necessary special height and damping adjustable units are available from E R A Springs can be changed to 16 ones of higher rate See page 53 STEERING GEAR Starting with chassis 759 the car requires a Flaming River gear FR1502 3x3 with modified tie rod adapters This is similar to a Mustang II unit but shortened by 3 Modifications are shown on page and complete units are available from ERA FRONT ROTORS AND CALIPERS WITH BOLT ON WHEELS Most mid sized GM cars from 1970 1978 used the correct pieces with 2 piston calipers Station wagons may use different parts Chevrolet lists the same rotor and calipers for all sedans SECTION B PARTS PREPARATION ENGINE COMPONENTS We cannot give complete rebuilding instructions here What follows are the E R A specific requirements for your engine General torque specifications for typical bolts are found on page 151 Good reference books
28. ve Hold everything together with the stainless steel screws provided 93 SECTION F SUSPENSION ASSEMBLY 7 Lubricate the insides of the upper chassis brackets with REAR SUSPENSION JAGUAR BASED lithium grease so that the sides of the rubber bushing will slide into them Guide the suspension assembly into the XJ COMPONENTS IN E R A SUBFRAME chassis brackets Using a little light oil on the threads Thread the trailing arms onto the rod ends with jam nuts install the 5 5 bolts with flat washers but don t tighten yet already installed on the lower control arms Thread on until one or two threads show Leave the jam nuts loose LUBE INSIDES BRAKE LINE BRACKET d eracage Note that the trailing arm bushing is angled slightly relative to the trailing arm tube See the bottom of the illustration on page 99 On one side of the car Rotate the trailing arm so that the bushing angle matches the chassis bracket Hold the bushing against the inside of the chassis bracket and sight through from the outside hole Use a large screwdriver to move the assembly so that the sight is straight into the threaded portion of the chassis bracket Slip the aluminum spacer between the outside of the trailing arm bushing and the chassis bracket See the f rearsusp illustration above Slide the x 3 bolt through the flat washer upper hole in the bracket spacer and trailing arm bush engaging the locking threads in the chassis No
29. wear and arcing and the lower bearing Clean from one end of the original tube between the right the parts with a solvent if necessary Work the brushes in wheelbox and the motor Save the nut and the piece of and out to insure free motion tubing Use the short tube for the guide at the end of the Install the armature carefully into the gear housing until it second wheelbox contacts the sides of the brushes Using a hook shaped Slide the nut onto tube shorter tube supplied the one with wire or other appropriate tool retract each brush in turn so just one end flared that the commutator can slide past the edges of both brushes and continue into the gear case Flare the end of the tube with the nut Slide the drive cable through the tube If the cable is tight at the new Put 1 or 2 drops of oil in the lower bearing of the armature flare use a drill bit to clean the inside of the tube housing Excess oil will contaminate the brushes later on Install the armature housing aligning the marks on the MOTORTREPARATON housing and the frame Reinstall the long retaining Screws STROKE CHANGES Remove the plastic gear from the crankshaft by supporting the edge of the gear and tapping the shaft with a soft hammer Be careful not to damage the circlip groove The position of the crankpin must be changed in order to increase the stroke of the cable Punch the underside of the crank plate exactly opposite the center of the crankpin Use a
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