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Suzuki Engine in


700newtons

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We lowered the engine in today.

 

See a short time lapse film here

 (sorry about the door blocking the view - you weren't expecting BBC production values were you?)

I was a bit concerned that the gearbox made contact with the heat proof insulation on the driver's footwell, and it doesn't seem straight as it goes into the transmission tunnel. However, the bolts for the engine mounts slot in (after a bit of leverage) and an email from Caterham confirmed that this is correct.

We had a good engine hoist - it made it fairly straightforward. I hung it using two climbing slings; one from the engine lifting ring and another with a 'larks foot' around the opposite engine mount bracket and then carefully threaded through the engine to avoid damage.

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The 160 instructions specify one long and one stubby bolt for the LH and RH engine mounts. I think that this must be for older models - both brackets need 2.5 inch bolts.

After getting the engine in, I made more progress front suspension and got the uprights in (my missing bolts came in the post this morning).  I used a trolley jack to compress the suspension and slot the top wishbone bolts in (with the engine acting as a counterweight)

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One problem I had today is dealing with fiddly bolts on the gearbox mount. I'm having trouble getting spanner to hold the top nut as I torque it from below. I'll try again tomorrow. I'll also finish the front suspension and start doing the engine connections.

 

(edit 22/12/2014. NB I think that the August 2014 instructions for the gearbox mount bolts maybe wrong. It might be better to use the 20mm bolts rather than the 25mm M8 bolts. The longer bolts look as if they protrude too much and they are also required for the handbrake assembly.  I also found that an M8 washer under the bolt head helped a great deal, it elevated the bolt head so that I could hold it with a spanner while using the torque wrench underneath.) 

 


 

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Not feeling 100% today (cold) so had a day off.

However, I figured out how to do the tricky gearbox mounting nut up. (It was right up against the rubber and I couldn't get a spanner in to hold it while I torqued it up to 20Nm). Today I just wedged a screwdriver in between the rubber and the nut and got it to 20Nm - I'll take that.

Also have have realised my Earth connections are not quite right. I think that the long lead goes to the top nut on he starter motor. The shorter lead circles back to an obvious Earth point on the chassis, by the battery. (I previously connected the long Earth lead to the engine mount brackets. However, this is going to come too close to he exhaust pipe.)

 

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Hi Simon - great blog and good to see the build going so well. Many notes being taken this end for when I start mine next week. Oh, and can I please have the number of 'Helpful Derek at Caterham'! 

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  • Leadership Team

Peter enjoy the day it comes (and please blog!)

When the car comes they give you a card with Derek's contact details.

Cheers, Simon

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