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Blitz FIA-18 Specifications

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1. Leading Belgian driver Bernard Munster produced some startling results across Europe in hi 5 Corsa GSi EJ GEARBOX AND DIFFERENTIAL ASSEMBLY A close ratio dog type gearbox kit has been specially developed for this model This gearbox utilises the casing and intermediate housing or sandwich plate from the standard car s F13 speed gearbox but the component parts of the close ratio kit must be assembled along with a revised end cover and gearshift cover assembly As this is a heavy duty gearbox unit many of the component parts are larger that the corre sponding standard item To accommodate these some detailed internal modifications must be carried out on the casing BEFORE commencing assembly operations CASING MODIFICATIONS The following operations are required within the area normally containing the DIFFERENTIAL UNIT Remove the speedometer drive gear assembly and blank off the hole with the blanking plug supplied The speedometer drive gear support lug can now be removed by grinding away the excess material Also chamfer the region adjacent to this blanking plug and remove excess material by creating a flattened profile to the area immediately above the centreline of the differential bearing housings This will give the additional clearance required for easy installation of the differential a
2. PS 4 t t tS F2 4 t2 F3 DEEN SXT03AW039 SXT03AWO52 SXTO3AW060 5 04 012 FRONT SUSPENSION PARTS LIST CIRCLIP STRUT SEAL RETAINER LOCK TAB BUMP RUBBER 26011925 11011778 5 812 0 018 5 509 2 90299503 5 509 17 5 509 5XS09 13 WASHER 5 509 ACOO6 UNION 5XS09 ACO12 BOLT 5 509 007 SEAL Ta 5 509 ACO16 93 lt 2 gt 2 way 5 809 5 SS AG 24 4 NL T CAD RYO 5XT09 035 90299071 1 Hy 4 5 509 01 LHD ASSY Ta 5 809 11 RHD ASSY 5 509 UNION c 5 809 ACOO9 SEAL gt 900084412 11042712 90008441 1 90233191 Ars 90193771 sxso9 AC025 RHD 5 509 AC010 LHD 4 90334773 5 509 04 PAS PIPE KIT RHD 5 509 26 PAS PIPE KIT LHD 5 509 14 NOVA CORSA POWER STEERING ASSEMBLY 5 509 24 RHD 5XS09 05 LHD tack mountings Universal joints A power assisted high ratio steering rack system has been designed and developed as a complete package for the Group A car This includes the steering rack steering pump external power ram oil reservoir mounting brackets all oil pipes and fittings The power assistance characteristics closel
3. EN E M 075 M 0 75 0 75 gt un cS m 0 75 3 5 But 0 75 5 9 210 2 3 4 amp 220 2 3 amp amp 4230 7 3 5 amp 92401 1 6 92501 2 1 5 5 7 92501 23 457 32701 2 3 45 67 280 23 45 6 7 8 92901 21143 476497 SUE FER EDEL SOR USK FLER MUR FUER OMA ACD ENGER LUNE TWSTRUMENTE LIG PWPUCOUER HE nO MORE GEN FOR GREAT si Our DEL ORCH BREMSE INSTRUMENTS tn Cow RECEIVER BER MENT ING FOR BRITAIN MMOSOU sem PRESSURE BRINE Cow CLOVE wv EN MM te HOT 31 ELECTRICAL WIRING DIAGRAM 21 ces ELS vi ws viw gt Tali O OA ON s ws 30 2 3 5 0 30734 5676 9320 2 2 63676 9330 1345 47 4 920113 q 3 6 6 9359 2 24 7 8 930 1 47 8 9301 2 gt 2 9390 3 4 3 2 9380 9 479 eras emu ES Pr s 24 pa pr 4 5 5 0 8 wa 1 5 ER 15 5 5 2 55 ss 3
4. BRAKES PARTS LIST SXTOSAW076 5 05 077 HANDBRAKE MASTER CYL 0 625 H BRAKE MASTER CYL ADAPTOR GM The Group A engine specification has been fully developed in the International rallying arena during 1989 and has shown to be powerful and very reliable The special components required to build a replica power unit form the basis of the Group A engine parts kit Heavy duty engine mounting rubbers are included and fit as a direct replacement for the standard components Competition engine preparation is really a very specialised operation and requires equipment and skills beyond the scope of a skilled vehicle mechanic In spite of this to assemble the Nova Corsa 1600 engine and Group A parts kit would be a relatively easy task for most competent vehicle mechanics The basic engine design the machined cast and die cast finishes are to such a high standard on the production unit that the need for excessive individual component preparation is minimal By following the guidelines of this chapter using the special components supplied correctly assembled would produce a fairly powerful and reliable power unit The basic cylinder head is very efficient in it s standard form and the procedures outlined in this chapter do not extend to further modification of the standard component Obviously there is scope for optimisation of power output by subtle modifications to both the cylinder head manifolds and valve insta
5. COMPETITION BUILD MANUAL gt gt lt SAB ue IDE 2 Se Mc NOVA CORSA EUROSPORT COMPETITION BUILD MANUAL NOVA CORSA COMPILED AND DEVISED BY Andrew Duerden WITH Gordon Birtwistle EuRg SPORT ISBN 0 9516102 0 1 GM EURO SPORT 1991 2nd Edition All rights reserved No part of this book may be reproduced or transmitted in any form or by any means electronic or mechanical including photocopying recording or by any information storage or retrieval system without permission in writing from the copyright holder Front cover Graham Turner Produced by Martin Meadows Marketing Printed by J T McLaughlin Ltd Euxton Chorley Published by Euro Sport Publications Hadley House Great Glen Leicestershire LES OGN England FOREWORD Ever since the basic Nova appeared on the competition scene back in 1985 clubmen have been recording success after success In its first year of rallying the potent GM Dealer Sport Nova GTE in the hands of Dave Metcalfe showed a fantastic turn of speed emphasising its competitiveness and serving notice of its potential for honours That initial Nova GTE was put together by Engineer Brian Ashwood and his team Their background work prepared the foundation for the new Nova Corsa project the Motor Sport Development engineers David Gray in particular developing and aquiring the many and varied parts
6. NOTE This engine has been developed to run on FOUR STAR PREMIUM LEADED FUEL Before setting the idle speed and C O levels check the dynamic ignition timing This should be set with the engine running without load on part throttle at 2000 RPM and should be 32 FUEL degrees BTDC The idle speed adjusting screw is located on the inlet manifold throttle butterfly housing To increase idle speed turn screw outwards The C O levels are controlled by a potentiometer in the ECU housing and adjusted by a screw concealed by a tamperproof plug Idle on this engine may be slightly erratic but should be set to between 1300 to 1500 RPM and with 1 1 2 to 226 C O level If the engine can be run on a dynamometer or the complete vehicle on a rolling road the ignition can be further adjusted on full load at 5000 RPM and should be set to 20 degrees BTDC BOLT TORQUES Cylinder Head Ist stage 3 5 Kg m 2516 ft 2nd stage 6 0 Kg m 45 Ib ft 3rd stage 9 0 Kg m 65 Ib ft Main Bearing Cap 8 0 Kg m 58 Ib ft Con Rod Cap 4 0 Kg m 30 Ib ft Camshaft Pulley 5 5 Kg m 40 lb ft Crankshaft Pulley 6 0 Kg m 45 lb ft Flywheel 6 0 Kg m 43 16 ft FUEL SYSTEM The standard 42 litre 9 2 gallons steel petrol tank is retained The standard high pressure delivery pump is also retained but must be repositioned to the area between the fuel tank and spare wheel well The existing mounting bracket can be modified for use
7. INCL STRUT SEAL RETAINER SXTO3AWO052 2 CASTOR BRACKET 5 503 001 2 BOLT 10 76 11086131 4 REAR SUSPENSION BUILD LIST 5 504 NUT M10 11085941 4 BOLT 10 22 11086032 2 DESCRIPTION PART NUMBER CAR QTY NOT INCL TIE ROD 5XS03AC002 2 ROD END BEARING 5 503 003 90223659 1 BUSH 5 503 004 REAR BEAM BUSHES 5 504 003 2 LOCKNUT FOR ROD END 5 503 005 2 BOLT 10 84 11086161 2 BOLT ROD END TO BRKT 5 503 006 2 NUT M10 11062003 2 LOWER CONTROL ARM L H 5XS03AC007 l REAR SPRING GRAVEL 5 504 004 2 LOWER CONTROL ARM R H 5 503 040 1 REAR SPRING TARMAC 5 504 005 2 BOLT LCA TO CHASSIS 5 503 010 2 TOP SPRING RUBBER 90223644 2 BUSH INNER LCA 5 503 011 4 BOT SPRING RUBBER 90168139 2 2 BUSH BOTTOM POST 5 503 012 2 SHOCK ABSORBER GRAVEL 5 504 001 2 MOUNTING POST LCA 5 503 013 2 SHOCK ABSORBER TARMAC 5 504 002 2 POST RETAINER 5 503 014 2 SHOCKER RUBBER 90147599 2 STEERING KNUCKLE L H 5 503 015 1 BOTTOM SHOCKER RUBBER 8982738 2 STEERING KNUCKLE R H 5 503 016 1 CUP WASHER SXT04AWO015 2 FRONT HUB FLANGE 5 503 017 2 FLAT WASHER SXTO4AW016 2 5 FRONT HUB BEARING 5 503 018 2 TOP DAMPER NUT 11041034 4 FRONT HUB CIRCLIPS 5 503 019 4 BEARING INNER 11070311 2 WHEEL STUD 19 8 BEARING OUTER 11054489 2 WHEEL NUT 01 6 OIL SEAL 90217059 2 DAMPER HOUSING L H 5 503 020 1 DUST 6696899 2 DAMPER HOUSING R H
8. Gravel and Off Road Events Minibloc Reference Number 5XS04A0004 All Tarmac Events Minibloc Reference Number 5 504 0005 NOTE An additional spacer may be required under the springs to achieve the correct rear ride height and appearance when using the European tarmac front spring REAR SUSPENSION GEOMETRY All conditions of use CAMBER From 0 degrees 40 mins negative to I degree 35 mins negative Maximum deviation Left to Right 30 mins TRACKING From 0 5mm Smins Toe Out to 4 Omm 40 mins Toe In These parameters cannot be adjusted and if they fall outside of the above limits it would suggest that the rear beam has become distorted WHEET S AND TYRES Wheels have been specially produced for this car by O Z These are available in 15 inch diameter with a 6 inch rim width Experience has shown that this gives the best possible wheel tyre configurations from a performance point of view for both tarmac and loose surface use They also give compatibility with a wide range of tyres and sizes permitted within this engine capacity class from most major tyre manufacturers PERFORMANCE DATA Fifth gear 7600 RPM Final Drive Racing Tyres Gravel Tyres Ratio 18 56 14 14 60 14 KPH MPH KPH MPH 4 53 1 166 5 102 7 175 6 108 3 4 86 1 155 3 95 8 163 9 101 1 TYRE PRESSURES FRONT REAR Racing tyres 2 0 Bar 1 6 Bar Gravel Tyres 1 8 Bar 1 6 Bar 11041034 T 5X04 5 90147599 8982738 25 S
9. 400 2 3 4 5 6 7 8 94101 2 3 4 amp 7 94201 2 q 567 94301 2 3 5678 3440 2 3 4 5 6 94501 L oam 15 15 110 O O TESEL 1 2 ELECTRICAL WIRING DIAGRAM 31455477 8 94601 2345 8 9 94701 2 1 4 5 6 7 8 94801 2 4 5 6 7 8 3490 1 4545 57 9 9 E ELECTRICAL WIRING DIAGRAM 10 Gl G2 H7 L1 L3 M4 R2 R12 51 56 529 15 17 23 17 H20 20 P23 p24 50 60 544 14 18 23 Y24 FUSE IN FUSE BOX BATTERY ALTERNATOR CHARGING INDICATOR LIGHT IGNITION COIL IGNITION COIL HEI INDUCTIVE SENSOR SYSTEM STARTER MOTOR BLOWER RADIATOR RESISTOR CABLE CARBURETTOR PREHEATING AUTOMATIC CHOKE SWITCH STARTER IGNITION DISTRIBUTOR SWITCH TEMPERATURE COOLING AGENT INDUCTIVE SENSOR WITH IGNITION MODULE SOLENOID VALVE IDLE CUT OFF IGNITION DISTRIBUTOR HEI INDUCTIVE SENSOR SYST CONNECTOR INSTRUMENT FUSE IN FUSE BOX TELLTALE CHOKE IGNITION MODUL IGNITION COIL RELA Y DASHPOT RELAY MIXTURE PREHEATING TIMING CONTROL EST RELAY COASTING FUEL CUT OFF RELAY IDLING CONTROLI IGNITION COIL HEL INDUCTIVE SENSOR SYSTEM VACUUM SENSOR INTAKE MANIFOLD SENSOR OIL TEMPERATURE EST MIXTURE PREHEATING SWITCH BOWDEN CABLE CHOKE SWITCH CLUTCH PEDAL SWITCH THROTTLE VALVE SWITCH TEMPERATURE MIXTURE PREHEATING INDUCTIVE SENSOR EST SOLENOID VALVE DASHPOT IGNITION DISTRIBUTOR
10. 5 812 Exchange unit 021 Group N Exchange unit 5 506 09 5 806 026 Oil pipe amp sandwich plate kit 5 506 18 5 506 19 5 506 23 5 506 20 tre Tail pipe 5 508 4 Complete Exhaust 5 508 6 Bracket kit 5XS08 ACOO7 90299071 LN 3 5 512 018 Primary 5XS08 ACOO1 Centre 5 508 2 O6AC002 90299070 5XS06 5 506 ACO28 Ring set 90299503 5 506 002 5 506 003 5 506 004 5 506 005 5 506 006 5 506 007 5 506 008 5 506 009 5 506 017 5 506 023 5 506 024 5 506 025 5 506 026 5 506 027 5 506 028 2877481 8960970 9292730 11041182 11048672 11082881 25055364 90009241 90076083 90076329 90080026 90087290 9008980 90095603 90096765 90118441 90128184 90136269 90136928 90136950 90144386 9014442 90144686 90144687 90144696 90147917 90156374 90156315 90156344 90156361 90156883 90166406 90233169 90234259 SUB GROUP 06 ENGINE CYL HEAD GASKET 1 2MM PISTON C W RINGS CON ROD BOLTS CYLINDER HEAD BOLTS ENGINE MOUNTING L H ENGINE MOUNTING R H ENGINE MOUNTING REAR COMPETITION AIR FILTER OIL PICK UP PROTECTOR OIL COOLER SUMP BAFFLE PLATE CAMSHAFT KIT OIL PIPE KIT LASH PAD PISTON RING SET SUB GROUP 08 FUEL AND EXHAUST PEDAL COVER CLAMP HOSE SCREW SCREW CLAMP FUEL FILTER HOSE 10 METRE GASKET C
11. 8936749 9282535 9285234 11052432 11054062 11072461 11072641 11079311 90043251 90052801 90119338 90119868 90119869 90124865 90126931 90126932 90149859 90306547 90320486 90320483 STRUT BRACE BRACKET LH STRUT BRACE BRACKET RH BODY STRENGTHENING KIT COMPLETE FUEL TANK GUARD OIL COOLER MOUNTING BRACKET HANDBRAKE BRACKET ROLL CAGE MAIN HOOP REAR ROLL CAGE SIDE RAIL L H ROLL CAGE SIDE RAIL R H ROLL CAGE SCREEN RAIL ROLL CAGE BAR TO STRUT TOP ROLL CAGE FOOTWELL BAR ASSEMBLY ROLL CAGE DOOR BAR PLATE KIT ADDITIONAL BODY STRENGTHENING BOLT KIT WINDSCREEN FRONT HEATED SUB GROUP 11 BODY PANELS HOOD ASSEMBLY WASHER SPRING CONNECTION BOLT SPRING BEARING NUT WASHER NUT SCREW RIVET BUMPER SPRING CABLE ASSEMBLY FENDER ASSEMBLY FENDER ASSEMBLY BRACKET SHANK L H SHANK R H HOUSING HOOK SUPT BONT BONNET od o oo ON BODYSHELL PARTS LIST SUB GROUP 14 EQUIPMENT 8943550 8971279 90116970 90162259 90162808 90166622 90166624 90172597 90204465 90204466 90283671 90283672 90302206 90302010 90302256 90309921 90320013 BASE ARM BRACKET SUN VISOR MIRROR ASSEMBLY KIT KIT SUN VISOR PANEL ASSEMBLY PANEL ASSEMBLY PANEL GREY PANEL GREY GRILLE ASSEMBLY BUMPER ASSEMBLY BUMPER ASSEMBLY REST GREY L
12. 90344306 VALVE PRESSINGS WASHER WASHER NUT SCREW NUT M10 SCREW SCREW SCREW GASKET GASKET FAN SCREW BUMPER BUSHING SCREW RETAINER CLAMP FUNNEL BUMPER BRACKET TANK RADIATOR HOSE 10M RING BUSH ASSEMBLY CARRIER ASSEMBLY HOSE BRACKET R H BRACKET L H RADIATOR HOSE HOSE SPOILER PIPE ELBOW HOSE HOSE HOSE CLAMP SPRING BRACKET rS tS NOOR ONA IS tS tS SUB GROUP 18 HEATER 3023773 3033435 3048824 3050567 3050577 3050579 3050581 3050583 3050584 3050588 3050602 3051159 3052061 3052207 3053289 3053291 3058407 8974979 11038826 11063471 11068521 11072641 11074201 11075092 11076991 11505830 52450241 52450254 52450259 90034826 90038150 90038348 90053836 90120333 90120363 90120378 90126694 90139062 90158239 90196859 90208107 902 19865 902 19866 90221198 90221467 90227051 90320270 SEAL CLIP SCREW ASSEMBLY LEVER LEVER CLAMP ROD LINK VALVE GEAR SHAFT RADIATOR VALVE HOUSING ASSEMBLY CLIP WASHER LEVER CLAMP GROMMET SCREW NUT SCREW SCREW NUT SCREW ASSEMBLY NUT SCREW CHAMBER CHAMBER LEVER HOUSING GASKET CLAMP GASKET HOUSING FLAP CONTACT ASSEMBLY GASKET HOUSING RETAINER HOUSING COVER INSERT ASSEMBLY INSERT ASSEMBLY CLIP CLIP BLOWER ASSEMBLY CABLE w Nu OOOO N mi
13. 031 5 507 032 5 507 033 5 507 034 5 507 035 5 507 036 5 507 037 5 507 038 5 507 039 5 507 040 CIRCLIP SHIM CIRCLIP 5TH GEAR INPUT SHAFT PLATE STOP SPRING CABLE HEATER SPRING SHAFT CLUTCH PEDAL PEDAL CLU PEDAL ASSEMBLY PEDAL ASSEMBLY CAP ACCELERATOR BRACE PEDAL CABLE HEATER CLUTCH COVER 190MM CLUTCH COVER CLUTCH DRIVEN PLATE 5 8 x 20 SPLINE CLUTCH RELEASE BEARING CLUTCH RELEASE HOUSING END COVER INPUT SHAFT CLUSTER STH GEAR INPUT SHAFT SPACER COLLAR 5TH GEAR SELECTOR FORK 1 SELECTOR FORK 2 SELECTOR FORK 3 SELECTOR ROD 1 SELECTOR ROD 2 SELECTOR ROD 3 SELECTOR ROD 4 SPLINED SLEEVE DRIVE DISC BEARING SLEEVE SPLINED SLEEVE DISC DRIVE BEARING SLEEVE SPLINED SLEEVE DRIVE DISC DRIVE DISC DRIVE DISC DRIVE DISC BEARING TRACK 5TH GEAR STH GEAR OUTPUT 4TH GEAR OUTPUT 3RD GEAR OUTPUT 2ND GEAR OUTPUT IST GEAR OUTPUT STOP RING REV IDLER BEARING END COVER BEARING NEEDLE CAGE BEARING NEEDLE CAGE BEARING NEEDLE CAGE SELLOCK PIN SELLOCK PIN GEAR LEVER 5 507 041 5 507 042 5 507 043 5 507 045 5 507 046 5 507 047 5 507 048 5 507 049 5 507 050 5 507 051 5 507 052 5 5
14. OFF ROAD TRACKING 2mm toe out CASTOR 4 degrees ve CAMBER 11 2 degrees ve FRONT ROADSPRING DATA Gravel and Off Road Events Superprogressive Reference Number 5 503 031 European Tarmac Events Superprogressive Reference Number 5 503 032 Smooth Tarmac Spain or similar Superprogressive Reference Number 5XS03AC033 NOTES The springs have been designed to give optimum performance and correct vehicle ride height when the lower spring guide ring or platform is set at 140mm This is when measured from the top edge of the spring platform to the knuckle attachment lugs GENERAL COMMENTS When setting the suspension in the first instance it is suggested that the top mountings he positioned such as to give maximum positive castor That is with the top of the strut as far as possible towards the rear of the suspension turret aperture Further adjustment can then be carried out at the knuckle and the spherically jointed end of the lower arm as required EURO TARMAC LOW TARMAC 2mm toe out 4 degrees ve 2 degrees ve NOTE For predominantly radiused road surface as found in Ireland for example reduce front wheel camber to 1 2 degrees ve NOVA CORSA 5 089 FRONT SUSPENSION ASSEMBLY 5 501 5 LH 5 501 6 5 803 25 5 803 24 5 503 27 GRAVEL ae 5 503 28 TARMAC 6 503 0231
15. RH 5 1 5 503 ACO31 GRAVEL 5 503 ACO32 EUROTAR 5 503 SPANISH TAR 5 503 041 SHORT SPANISH N 5 018 5 503 6026 5 503 22 N 5 503 5 5 503 ACO15 LH ACO16 RH 5 507 ACOB7 LH ASSY 11041034 5 505 9 1 5XTO3AWO31 5 503 DES pa a fa 5 803 17 5XS03 4 are 5 507 ACO86 lt _ 5 3 a SA XSO5ACOO3 LH 5 505 04 RH 5 503 ACO11 5 5 503 71 5 503 5 5 505 5 5 503 5 AW039 803 Z 5 505 59 BOLT 5XT05 AW049 NUT 5 503 13 5 5 AW050 WASHER 1 4 gt 9 10 AW001 2 5 AW019 5 503 ACO3 T AW031 5XS03 sx103 9 6 503 04 E Blue Carbon Metallic 5XS05 024 5 503 ACO12 0511 5 505 6 5XS03 ACOO1 5 503 AC007 LH 5 505 AC002 RH 5 503 ACO10 5 505 001 1 2459 5 505 7 3466 5 505 11011191 11041034 11071988 11085941 11086131 11086032 90129661 90157191 90157192 5 503 001 5 503 002 5 503 003 5 503 004 5 503 005 5 50 06 5 503 007 5 503 008 5 503 009 5 503 010 5 503 011 5 503 012 5 503 013 5 503 014 5 503 015 5 503
16. a 90 ampere alternator and additional individual wiring harnesses appropriately relayed and fused The 1600 model is fitted with a 44 ampere hour capacity maintenance free battery This is completely satisfactory for all competition applications When refitting the wiring loom following a major vehicle rebuild such as this certain precautions must be taken to ensure satisfactory performance of all electrical components Wherever possible secure the wiring to the bodyshell using proprietary clips and always use grommets where the wiring passes through metal panels Additional care when making cable runs will pay dividends neat tidy and secure means safe and reliable Ensure all plug in connectors are clean and completely engaged when assembled Special attention must be given to all the earthing points around the vehicle as some of these may have become insulated during the painting process Thoroughly scrape away excess paint from these positions to ensure a good connection Certain additional electrical items are obligatory under FIA Appendix J regulations concerning safety A general circuit breaker must be fitted to cut out all electrical circuits and must now be wired in such a way that it also stops a running engine A foot switch to operate the horn from the co driver s side of the car must also be fitted To fit these and other important items the following procedures should be adopted CIRCUIT BREAKER Master Switch An
17. and components to produce the Clubmans Kit The kit together with this manual now ensures that anyone can faithfully reproduce the factory specification relying on the techniques and experience gathered from many years of successful competition and hopefully gain the results that have now been shown to be within the Nova Corsa s capability This manual sets new standards in providing an exact and detailed guide to the preparation of a vehicle for motorsport use Andrew Duerden together with Gordon Birtwistle has tapped that vast reservoir of specialist knowledge held by the Motor Sport Developments engineering staff to produce a unique reference book The mystique behind building a top flight competition car has now been removed now its down to the driver Good Luck Melvyn Hodgson Chairman and Managing Director Motor Sport Developments DISCLAIMER Every effort has been made to ensure that the contents of this publication were accurate and up to date at the time of going to press No liability can be accepted by the authors or publishers for loss damage or injury caused by errors in or omission from the information given Motor sport can be hazardous and the in clusion of any information does not necessarily make it safe to use in any form of competition or testing The modifications described in this publica tion are in some cases of an extensive nature but have all been specifically designed to give
18. ideal position for mounting this is the centre console just above the gearlever linkage see photo Using the existing wiring loom take the thickest battery ve lead 16mm and re run it through the bulkhead to the switch terminal Connect the other switch terminal directly to the starter motor using similar 16mm cable Replace the link lead from the starter motor to the alternator with 16mm cable This will now be suitable for use with a larger output alternator if required Now take the remaining smaller diameter 10mm battery ve lead re route and attach it directly to the alternator To ensure that the engine is also cut when the master switch is moved to the off position the coil ve terminal must be connected to one of the two small W contacts on the master switch The second W contact must be connected to chassis ground A coil ve terminal can easily be found on the rear face of the instrument cluster as this lead is also the tachometer pulse supply lead light green Run an additional wire from this connection point to the appropriate W terminal on the master switch following the path of and taped to the existing harness where possible for support NOTE Certain event regulations require that this switch can also be actuated from outside the vehicle In this case a choke or bonnet release cable assembly can be adapted to operate the switch from a cable pull mounted on the bulkhead FOOT SWITCH This switch
19. made out of plastic but if Blanking plug in cylinder head Priming the lifters LE INJECTION 2 The new external breather connector 1s a The finished head Oil pump packed with grease Oil cooler in position ENGINE made from a non translucent material must include a transparent window for compliance with Appendix J Group A See photograph showing additional elbow in place LUBRICATION SYSTEM The standard oil pump is retained and is capable of giving adequate flow and pressure for this engine specification However in view of the modifications to the oil feed in the cylinder head casting the oil pressure relief valve must be adjusted to compensate This entails the fitting of a 3mm shim behind the pressure relief valve spring to increase its pre load The oil cooler connects to the engine by a sandwich plate that attaches to the block between the oil filter unit The high pressure pipes are made to the correct length for connection to the oil cooler radiator when fitted to the left hand side of the front panel viewed from the front of the car A special attachment bracket is supplied Before assembly fill oil radiator and pipes with chosen engine oil Difficulty can be experienced in generating oil pressure on initial start up after a major engine rebuild This is due to problems in getting the oil pump and system primed To overcome this it is suggested that the oil pump
20. matched dampers have been developed to cover tarmac and gravel applications These springs are constructed from tapered wire and offer a wheel travel capability coupled with increased spring rate unattainable from conventionally constructed constant wire diameter springs ASSEMBLY PROCEDURE Ensure that all components are thoroughly cleaned and bushes lightly lubricated prior to assembly Assemble under clean conditions at all times The spherical joints are located both in the lower control arm and strut top mounting plate by circlips Attach lower control arm to chassis pick up point using the larger 12mm bolt supplied This hole should have been enlarged to suit this bolt during the bodyshell preparation Prior to assembly fit the front wheel bearing to its housing in the knuckle and retain with the two circlips At this stage press the drive flange into the wheel bearing and fit the wheel studs to this assembly Fit the threaded insert into the mounting post clamp from the TOP face secure by clamping with standard pinch bolt The knuckle assembly can now be attached to the lower control arm by a cap headed bolt and washer inserted through the underside of the outer spherical joint into this threaded insert The lower suspension arm is attached to the lower control arm at one end by a bolt but the spherical joint at the opposite end locates with a bracket attached to the front crossmember This has been profiled to fit the
21. of a Nova Corsa model to FIA International Group A level to the specification within the Clubmans Kit Other parts and assemblies can be used in preparation of a group A Nova Corsa but they are not included in this manual and do not form part of the GM Euro Sport package The manual has been laid out with easy to read pages within well defined sections The preparation chapter has been sub divided into various sections referring to vehicle sections bodyshell running gear etc this has then been subdivided into the separate divisions relating to specific components At the end of each section you will find a parts diagram together with a list of parts and assemblies referred to within that section The actual pricing list is in a separate booklet supplied with this manual Now you have received the manual it is of paramount importance that the registration card at the front is completed and returned This card is the only method by which to ensure further updates for the 12 month period following registration will be sent to you As new equipment is developed or a component is evoluted bulletins to update the manual will automatically be sent to those who have registered on the cards provided This manual is designed to provide you with the fullest information on the preparation of a Nova Corsa model for international rallying We are always interested to know your comments in writing on any aspect that you feel could be improve
22. rotor be packed with light assembly grease before the oil pump is fitted To do this the backplate will have to be removed from the pump casing to expose the rotor assembly Refit backplate correctly after packing with grease CRANKSHAFT PULLEY The standard single vee belt pulley must be replaced by the poly vee belt pulley provided This belt specification is essential as it drives both the alternator and the power steering pump The power steering pump is attached by bolting to the block face below the camshaft driven gear FLYWHEEL The standard item is retained However it is advisable to check the weight of the unit prior to assembly as there is a minimum homologated weight requirement for the flywheel and starter ring gear assembly INLET AND EXHAUST MANIFOLD Discard the E G R valve assembly situated between the injectors for cylinders 2 and 3 Fit blanking plate to the exposed hole making sure that the blanking plate is completely sealed to the face of the manifold The standard injectors are inadequate for this degree of engine performance Injectors with a much higher discharge capacity are supplied in the engine build kit These are taken from the GSi 2000 16 valve engine unit The standard cast exhaust manifold must be retained under Group A regulations but a modified system from the manifold is permitted and has been developed for this engine specification ENGINE MANAGEMENT SYSTEM The Nova Corsa 16001e
23. specialists associated with Nova Corsa engine building have been developing their own alternative engine management systems These are all Group A legal and in most cases the ultimate power is slightly increased but with significantly improved mid range performance and drivability Whilst there is a cost penalty for the improved system it is worthwhile consideration even if your donor car already has Bosch L3 1 Jetronic set up simply because of the increased performance readily available This becoming a more obvious decision should your donor car be to one of the completely non compatible specifications If the engine is equipped with the full Bosch L3 1 Jetronic system both ignition and fuel requirements are controlled individually The major changes to the camshaft characteristics and compression ratio in full Group A tune dictate different fuel and ignition requirements The ignition system is electronically programmed by a unit mounted to the underbonnet bulkhead This is replaced in the kit by a similar component matched to the requirements of this engine specification and is plugged in as a direct replacement The electronic control unit ECU for the injection system is integrated with the air flow sensor and mounted in a cast alloy housing on top of the air flow sensor A reprogrammed unit is supplied and can be fitted as a direct replacement Remove the standard ECU by slackening the four attachment screws around the housing
24. the door aperture Position these drill the two holes and bolt into position The door rails and the front roof rail should be loosely bolted in position at this stage There are two forward facing brackets on each of the side rails which are to carry the arms that attach to the front suspension turret area The upper bracket on each side should ideally be close to or in contact with the actual door pillar at that point However because of tolerances in both the bodyshell and rollcage a spacing washer may be required to bridge the prior to tightening the attachment bolt to the door pillar Using this bracket as a guide with extreme caution pass a 10mm drill through the bracket and drill outwards through the shell until the point of the drill JUST starts to SHOW on the outside of the shell then STOP drilling Using a hole saw the drill bit acting as centre open out this hole to 25mm from the OUTSIDE of the car through only TWO of the panel thicknesses LEAVING the pilot hole in the INNER skin at 10mm diameter The front suspension turret front tower arms can now be fitted A template is supplied to assist in marking out the holes required through the bulkhead area and into the windscreen wiper motor well for these front support arms The template is for the RIGHT side of the car looking forwards the position for the other side can then be judged having completed the operation on this right hand side unit Take extra care w
25. the inside of the bodyshell The tube can now be inserted through the plate and sill before finally welding into place Centre tunnel prior to modification The blanking plate in position Gear linkage bearing bracket Front valence bracket mounting r Washer added to suspension mount i 1 sill unforced lowe The completed inner wing note stitch welding Jacking point in the sill lower arm mounting 1 Please note that both front wings MUST be removed for this operation Thoroughly check items supplied against the component parts list to make sure that there are no shortages It is advisable with a complex multi point cage such as this to loosely assemble the cage prior to making any attempts to actually fit the structure to the car Reference to the roll cage assembly drawing will give a clear indication of the intended final construction You will then be more familiar with the individual components and where they will eventually be secured Once this has been established the cage can be split into sections ready for assembly into the bodyshell Position the rear frame alongside the body shell and tilt it forward such that the mounting points for the rear suspension turrets are upper most Maintaining this position pass the frame through the door aperture into the bodyshell and locate the foot mountings onto the sill The frame still tilted forwa
26. washer supplied should be fitted to the plain side These bolts must be tightened by a torque wrench immediately after the geometry has been set to the required figures This is a very critical area on the suspension and as a precaution the torque figure should be checked as a service operation during vehicle use TIGHTENING TORQUES Top Bolt 14mm to 18kg m 130 Ib ft Bottom Bolt 12mm to 12kg m 90lb ft FRONT SUSPENSION DATA As a direct result of National and International rallying experience with this model the GM Eurosport development engineers in conjunction with their team drivers have optimised the suspension settings for different types of event and surfaces It is suggested that these are adhered to particularly for the first competitive outing after which some drivers may prefer to make their own subtle changes to these settings to give slightly different handling characteristics The package has been developed for optimum performance without a front anti roll bar When setting the castor and camber angles it is vitally important that both sides of the car measure similarly The tracking figures should also be regularly checked sudden discrepancies in the measured data could indicate that some component has been damaged In Group A specification this is a very responsive vehicle and to maintain driver friendliness attention to the geometry settings is a priority FRONT GEOMETRY DATA DESCRIPTION GRAVEL and
27. 0037242 90038440 90045820 90053508 90059582 90069100 90069102 90069132 90069864 90087070 90087621 90091989 90114142 90119046 90119074 90119143 90119222 90119222 90119429 90119429 WASHER CONNECTION RELAY CONNECTION PLATE PLATE HOUSING ASSEMBLY HOLDER HOLDER GASKET GASKET FLASHER SOCKET SCREW NUT SCREW NUT NUT SCREW FUSEBOX BATTERY LINK ASSEMBLY MOTOR STEM GAUGE FUEL GAUGE TEMP VOLTMETER GAUGE OIL TACHOMETER SPEEDOMETER SOCKET CAP NUT ELECTRIC FUEL PUMP BLADE ASSEMBLY SWITCH SWITCH ASSEMBLY SWITCH ASSEMBLY FASTENER RELAY ASSEMBLY HORN ASSEMBLY NOZZLE ASSEMBLY BUMPER HOSE 10M HOUSING PLATE ASSEMBLY TANK ASSEMBLY SPACER ARM ASSEMBLY SWITCH ASSEMBLY SWITCH ASSEMBLY O Ue m t O tS n N M ELECTRICAL PARTS LIST 90126713 90128703 90138193 90155309 90158391 90166684 90166992 90166993 90187653 90187654 90191677 90207947 90209022 90225422 90225427 90225483 90225811 90241775 90257160 90274345 90274651 90278814 90297763 90314309 90320505 90320537 90320551 90322064 90344306 SWITCH FUNNEL STRAP COVER CLAMP HORN ASSEMBLY LAMP LAMP HEADLAMP HEADLAMP SWITCH PLATE SWITCH PLATE ASSEMBLY LAMP ASSEMBLY LAMP RR COWL ASSEMBLY RELAY A
28. 016 5 503 17 5 503 018 5 503 019 5 503 020 5 503 021 5 503 022 5 503 023 5 503 024 5 503 025 5 503 026 5 503 027 5 503 028 5 503 029 5 503 030 5 503 031 5 503 032 5 503 033 5 503 034 5 503 035 5 503 038 5 503 040 5 503 041 SXTO3AWO18 19 SXTO3AW020 SXT03AWO031 SUB GROUP 03 FRONT SUSPENSION WASHER DAMPER NUT NUT NUT M10 BOLT M10 x 76 BOLT MIO x 22 BOLT M12 x 55 STEERING KNUCKLE L H STD STEERING KNUCKLE R H STD FRONT CASTOR BRACKET TIE ROD ROD END BEARING BUSH LOCKNUT FOR ROD END BOLT ROD END TO BRACKET LOWER CONTROL ARM LEFT BOLT LCA TO CHASSIS NUT METAL LOCK BOLT LCA TO KNUCKLE BUSH INNER LOWER CONTROL ARM BUSH BOTTOM POST MOUNTING POST LOWER CONTROL ARM POST RETAINER STEERING KNUCKLE L H MOD STEERING KNUCKLE R H MOD FRONT HUB DRIVE FLANGE FRONT HUB BEARING FRONT HUB CIRCLIP DAMPER HOUSING ECCENTRIC ADJUSTER BOLT NUT M14 TOP STRUT MOUNTING BUSH NUT DAMPER TOP LOWER SPRING SEAT SHOCK ABSORBER GRAVEL SHOCK ABSORBER TARMAC UPPER SPRING SEAT SPRING SEAT LOCK RING ROAD SPRING ROAD SPRING ROAD SPRING DAMPER HOUSING R H WASHER STRUT TO KNUCKLE BOLT SEAL FRONT STRUT LOWER CONTROL ARM RIGHT ROAD SPRING LOW OR SHORT SPANISH TAR DAMPER STEM NUT WHEEL STUD O Z WHEEL STUD REVOLUTION SPHERICAL BEARING t gt r gt gt
29. 05 005 5 505 007 5 505 009 5 505 010 5 505 011 5 505 012 5 505 017 5 505 019 5 505 020 5 505 022 5 05 024 5 05 025 5 05 026 5 05 7027 5 05 077 5 505 028 5 505 029 5 505 030 5 505 031 5 505 034 5 505 032 5 505 033 5 15 5 05 021 5 05 014 5 05 018 SXTOSAWO11 SXTOSAWO10 SXTOSAWO19 PART NUMBER 5 506 002 5 506 003 5 506 004 5 505 CAR QTY d NNSINSNNNN m 5 506 1 8 NOT INCL INCL CLUBMANS KIT BUILD LIST CYLINDER HEAD BOLTS ENGINE MTG L H ENGINE MTG R H ENGINE MTG REAR AIR FILTER REPLACEMENT CAMSHAFT KIT VALVESPRINGS VALVESPRING TOP CAP LASH PAD UNDERLAY WASHER INLET UNDERLAY WASHER EXHAUST VALVELIFTER OIL PICK UP PIPE PROTECTOR OIL SANDWICH PLATE SANDWICH PLATE ADAPTOR SANDWICH PLATE O RING PIPE S PLATE TO COOLER PIPE COOLER TO S PLATE OIL COOLER SUMP BAFFLE PLATE EXHAUST SYSTEM BUILD LIST DESCRIPTION INJECTORS PRIMARY PIPE SECONDARY PIPE TAIL PIPE PIPE KIT POWER STEERING BUILD LIST DESCRIPTION POWER STEERING RACK NUT RACK TO BULKHEAD TRACK CONTROL ROD NUT TRACK ROD TO KNUCKLE GAITER RACK TO B HEAD POWER STEERING RESERVOIR RESER
30. 07 053 5 507 054 5 507 055 5 507 056 5 507 057 5 507 058 5 507 059 5 507 060 5 507 061 5 507 062 5 507 063 5 507 064 5 507 065 5 507 066 5 507 068 5 507 069 5 507 070 5 507 071 5 507 072 5 507 073 5 507 074 5 507 075 5 507 076 5 507 077 5 507 078 5 507 080 5 507 082 5 507 084 5 507 085 5 507 086 5 507 087 5 507 088 5 507 089 5 507 090 5 507 091 5 507 093 5 507 094 5 507 095 5 507 096 5 507 097 5 507 100 5 507 101 GEAR LEVER KNOB GEARCHANGE SPINDLE CRANK BLOCK REV INTERLOCK REMOTE MOUNTING COVER PLATE GEAR LEVER SPACER SPRING SEATING BALL JOINT SPRING RING INTERNAL CIRCLIP EXTERNAL SPRING SCREW 15 1 SCREW M6 x 25 x 1 SCREW 2BA 1 2 SCREW M6 x 12x 1 SPRING WASHER SPRING WASHER SPRING PIN GAITER TURRET HOUSING GUIDE BOLT SPINDLE INNER STOP RING GUIDE BOLT SCREW MS8 x 20 x 1 5 SPRING WASHER M10 SPRING WASHER M8 BUSH OIL SEAL ROLL PIN OPERATING BALL CIRCLIP GUIDE BOLT INTERMEDIATE LEVER OUTER SPRING INTER LEVER INNER SPRING INTER LEVER OPERATING BALL L H NUT OUTPUT SHAFT THRUST WASHER STEEL BALL OUTPUT SHAFT 4 53 1 151 DIFF GEAR 4 53 1 68T DRIVESHAFT L H DRIVESHAFT R H GEAR LINKAGE ROD ANGLED GEAR LINKAGE ROD STRAIGHT THRUST WASHER SCREW CSK M6 x 8 DIFF CASING CROSSPIN SI
31. 09 015 1 UPPER UNIVERSAL JOINT 5 509 016 1 5 5 509 017 1 ENGINE MANAGEMENT SYSTEM BUILD LIST 5 512 DESCRIPTION PART NUMBER CAR QTY NOT INCL IGNITION CONTROL UNIT STD 90241189 1 Bs IGNITION MODIFIED SXS12UK004 1 EXCHANGE IGNITION COIL AMPLIFIER 90241775 1 FUEL CONTROL UNIT STD 90322064 1 FUEL CONTROL UNIT MOD 5 5120 005 1 EXCHANGE ENGINE WIRING HARNESS 90225910 1 MAIN IGNITION RELAY 90225811 1 FUEL INJECTOR STD 16 0280150774 4
32. 1 BODYSHELL 3458232 3466306 3466675 3466674 7978459 8944952 8970517 8975570 9287242 11010091 11037971 11038552 11052752 11054132 11063471 11072042 11078822 11080401 11081011 11085301 11086102 11092501 90008419 90008420 90035052 90037240 90039884 90043397 90046285 90055545 90119275 90119317 90119793 90119794 90119795 90119796 90119811 90119819 90120003 90120004 90120010 90120011 90120012 90120021 90120022 90120025 90120026 90120033 90120034 PLUG BUFFER SPACER SPACER STRIKER CLIP WASHER BALL PIVOT BOLT WASHER CLIP SCREW SPRING PIN SCREW ASSEMBLY NUT CIRCLIP SCREW ASSEMBLY SCREW RIVET SCREW RIVET COUNTERSUNK SCREW DOOR ASSEMBLY DOOR ASSEMBLY SUPPORT BOLT CLIP CLIP BOLT ROLLER BRACKET STRIP ASSEMBLY ROD ROD ROD ROD ROD ROD STRIP STRIP CHANNEL GLASS ASSEMBLY GLASS GLASS GLASS GLASS GLASS WEATHERSTRIP WEATHERSTRIP Car Qty lt U any Cy N one om e BODYSHELL PARTS LIST 90120039 RAIL ASSEMBLY 1 90120040 RAIL ASSEMBLY 1 90120049 RAIL ASSEMBLY 1 90120050 RAIL ASSEMBLY 90120387 CLIP 4 90120519 GLASS ASSEMBLY 1 90120522 WEATHERSTRIP 90120512 WINDSHIELD 90120524 STRIP 90126615 WEATHERSTRIP 1 90126616 WEATHERSTRIP 90126619 WEATHERSTRIP 1 90126620 WEATHERSTRIP 1 90126623 CLAMP 12 90126697 SCREW 20 90127137 SPRING ASSEMBLY 90127601 CHECK
33. 1 5 505 059 5 010 SXTOSAWO11 5 05 014 SXTOSAWO1S SXTOSAWO18 5 05 019 5 05 021 5 05 022 5 05 036 5 05 049 5 00 5 05 074 SXTOSAWO75 COVER LEVER ASSEMBLY BRACE ASSEMBLY BRACE ASSEMBLY PULL ROD FRONT CALLIPER L H FRONT CALLIPER R H FRONT DISC L H FRONT DISC R H DISC MOUNTING BELL PAD 1511 PAD 2459 PAD 3466 FRONT CALLIPER MOUNTING BOLT REAR CALLIPER DISC REAR REAR CALLIPER MOUNTING BRACKET PAD 0511 PAD 2459 PAD 3466 REAR CALLIPER MOUNTING BOLT M10 x 30 BRAKE PEDAL BOX LHD BRAKE PEDAL BOX RHD BALANCE BAR ADJUSTER BALANCE BAR ADJUSTER PAD FRONT BLUE PIPE INNER WING TO CALLIPER PIPE L H INNER WING TO MASTER CYLINDER PIPE R H INNER WING TO MASTER CYLINDER PIPE RR MASTER CYL TO B HEAD PIPE H BRAKE MASTER CYL TO FLOOR PIPE H BRAKE M CYL TO FLOOR PIPE FLOOR TO REAR CALLIPER PIPE BULKHEAD TO BRAKE PIPE KIT PUSH ROD YOKE HANDBRAKE CAPSCREW DISC TO BELL 3 STRAIGHT UNION 90 UNION SINGLE BANJO TWIN OUTLET BANJO 90B HEAD UNION NUT OUTLET BANJO BOLT INLET BANJO BRAKE FLUID RESEVOIR NUT DISC TO BELL WASHER DISC TO BELL REAR MASTER CYL 0 75 FRONT MASTER CYL 0 7 SUB GROUP 05 BRAKES gt gt tS SHEEN 20 n tS t t t
34. 5 4 4 i _____ 8804 ACOOB IN ee _ 8 104 12 d gt C 5 504 1 GRAVEL 5 504 2 TARMAC S d Q 2 5 804 004 GRAVEL Ya 523242 5 504 5 TARMAC 225 5 504 009 TAR SHORT N gt EN 1 5 505 12 5 504 07 O 5 504 N 5 504 ACOO6 5 04 AWO19 NOVA CORSA REAR SUSPENSION ASSEMBLY 5 505 015 0511 5 505 017 2459 5XS05 ACO18 3466 5 305 010 5 505 19 5 505 011 6696899 8967950 8982738 9028814 11029779 11041034 11054489 11062003 11062003 11062003 11070311 11082434 11086161 11086161 11086682 90121753 90129572 90129572 90142944 90147599 90157548 90168139 90217059 90223659 90223644 90278814 90288688 90288688 90304054 5 504 001 5 504 002 5 504 003 5 504 004 5 504 005 5 504 006 5 504 007 5 504 008 5 504 009 5 04 012 5 04 014 SXTO4AWO015 S5XTO4AWO019 SXTO4A W020 5 510 002 SXTIOAWOOL REAR SUSPENSION PARTS LIST SUB GROUP 04 REAR SUSPENSION REAR HUB DUST CAP NUT DAMPER BOTTOM RUBBER BOLT STUB AXLE TO BEAM WASHER TOP DAMPER NUT HUB BEARING OUTER NUT NUT METAL LOCK 10 NUT M10 HUB BEARIN INNER SCREW SCREW HEX HEAD BOLT 10 84 SHOCK ABSORBER BOLT 10 63 WASHER BOLT ASSEMBLY STUB AXL
35. 5 503 034 1 NUT 8967950 2 e ECCENTRIC BOLT 5 503 021 2 WASHER 90121753 2 NUT M14 5 503 022 2 LOCKTAB 5 4 033 2 WASHER 11011191 2 SHOCK ABSORBER 11086682 2 i NUT 11071988 2 STUB AXLE 5 504 007 2 SHOCK ABSORBER GRAVEL 5 503 027 2 BOLT STUB AXLE 90278814 8 SHOCK ABSORBER TARMAC 5 503 028 2 ANTI ROLL BAR 13MM 90142944 1 T BUMP RUBBER SXT04AW012 2 DAMPER STEM NUT SXTO3AWO18 2 ANTI ROLL BAR 16 5MM ANTI ROLL BAR 18 0MM SCREW M10 x 35 NUT M10 WHEEL STUD BRAKE SYSTEM BUILD LIST DESCRIPTION FRONT CALIPER L H FRONT CALIPER R H FRONT DISC L H FRONT DISC R H DISC MTG BELL PAD 2459 FR CALIPER MTG BOLT REAR CALIPER REAR DISC CALIPER MTG BRKT REAR PAD 2459 Rr CALIPER MTG BOLT PEDAL BOX BALANCE BAR ADJUSTER BRAKE FLUID RESERVOIR FRONT MASTER CYL 0 7 REAR MASTER CYL 0 75 HANDBRAKE MASTER CYL 0 625 HANDBRAKE CYL ADAPTER PIPE INNER WING TO CALIPER L H INNER WING M CYL R H INNER WING TO M CYL Rr M CYL TO BULKHEAD BULKHEAD TO H BRAKE M CYL H BRAKE M CYL TO FLOOR FLOOR TO REAR CALIPER TWIN OUTLET BANJO BANJO BOLT SINGLE OUTLET BANJO 90 DEG B HEAD UNION 90 DEG UNION STRAIGHT UNION B HEAD UNION NUT ENGINE BUILD LIST DESCRIPTION CYLINDER HEAD GASKET 1 2MM PISTON ASSY COMPLETE CON ROD BOLTS 90157548 90288688 11082434 11062003 5 4 019 PART NUMBER 5 505 001 5 505 002 5 505 003 5 505 004 5 5
36. AP LOCKING PLATE RIVET CAP COVER GASKET BUSHING SLEEVE BUFFER VALVE PUMP FUEL NECK ASSEMBLY CLAMP ASSEMBLY STRAP ASSEMBLY STRAP ASSEMBLY GASKET WEATHERSTRIP GROMMET SPRING CLAMP ASSEMBLY ELBOW VALVE HOSE 10 METRE HOSE HOUSING kA p o m m m m ANH ph ENGINE PARTS LIST 90234260 90234261 90234613 90264020 90281492 90284248 90297337 90298933 90298947 90299441 90299839 90322066 90322926 5 508 001 5 508 002 5 508 004 5 508 006 5 508 007 5 508 008 5 508 009 FILTER AIR HOUSING CLAMP ASSEMBLY NUT SUPPORT CLIP TANK ASSEMBLY SOCKET HOSE ASSEMBLY HOSE BRACKET ASSEMBLY TUBE AIR BRACKET ASSEMBLY EXHAUST PRIMARY PIPE EXHAUST SECONDARY PIPE EXHAUST TAIL PIPE COMPLETE EXHAUST SYSTEM KIT BRACKETS KIT FUEL PIPES SET OF INJECTORS hd SUB GROUP 13 COOLING 5508521 8977239 8977239 11013122 11061401 11067237 11081411 11081921 11082101 16501079 16501080 22061380 90065239 9009 1989 90106190 90112004 90119426 90126547 90128703 90128168 90128625 90128691 90136753 90166406 90169058 90190757 90223659 90226607 90278895 90279158 90298318 90298963 90298964 90302205 90323360 90324040 90324041 90324057 90343325
37. ASSEMBLY 2 90127901 LOCK ASSEMBLY 90138963 SHIM 90139737 LOCK SET 1 90151294 BUSH BLACK 10 90151890 GUSSET ASSEMBLY 1 90151892 GUSSET ASSEMBLY 90151902 STRIP ASSEMBLY 2 90158326 WASHER 2 90191511 BUMPER 2 90191855 REGULATOR 2 90191912 GUDGEON 90197144 BEARING PLATE 2 90198717 FASTENER 20 90203106 BUTTON 2 90203883 CONTACT ASSEMBLY 1 90203903 CONTACT ASSEMBLY 90203903 ESCUTCHEON 2 90207043 HANDLE 2 90208004 PANEL 1 90221455 HANDLE ASSEMBLY 1 90221456 HANDLE ASSEMBLY 90226139 TAILGATE 90226099 CLAMP NUT 4 90226113 SCREW ASSEMBLY 4 90226495 PULL ROD 90270224 GASKET 2 90296063 MIRROR ASSEMBLY 90296097 MIRROR ASSEMBLY 90320209 FRAME 90320210 FRAME 1 5 501 001 ROLL CAGE ASSEMBLY 1 5 501 002 SUMPGUARD 6MM THICK 5 501 003 SUMPGUARD 10MM THICK 1 5 501 004 STRUT BRACE TUBE 1 5XSACO17 N 5 20 N 5 15 5 5 016 5 5 21 5 5 5XS 1 7 mf SS Era 1 5 5 20 of 5XS 21 NOVA CORSA ROLL CAGE Tia Cage Complete Part 5 501 1 5 501 005 5 501 006 5 501 007 5 501 008 5 501 009 5 501 010 5 501 013 5 501 014 5 501 015 5 501 016 5 501 017 5 501 020 5 501 021 5 501 022 5 501 023 5 501 024 2878335 2890670 2899421 3466309
38. CTION UNIT FUEL IGNITION MODUL IGNITION COIL EZ 11 TIMING CONTROL EZ 11 RELAY INJECTION UNIT FUEL IGNITION COIL HEI HALL SENSOR SYSTEM EZ 11 PUMP FUEL SENSOR TEMPERATURE COOLING AGENT SWITCH THROTTLE VALVE SWITCH ENGINE HOUSING SWITCH TEMPERATURE ENGINE OIL SLIDE VALVE AUXILIARY AIR SOLENOID VALVES FUEL INJECTION HALL SENSOR IGNITION DISTRIBUTOR EST CONNECTOR WIRING HARNESS ETRONIC 7 PINS 425 427 409 427 430 405 406 409 410 420 433 434 433 434 431 414 423 411 413 419 422 406 431 463 451 460 437 440 440 449 463 466 438 439 463 458 455 456 444 444 461 450 457 441 443 445 437 438 463 466 LOMBARD MOTOR FRANCE SSS Waar imes GROUP N GUIDELINES A Group N car is fundamentally a standard production car fitted with obligatory additional safety items such as a roll cage safety harnesses and plumbed in fire extinguishers to comply with specific FIA Regulations for Touring Cars Group N In addition you will have to carry out some further permitted modifications to make the car more competitive Starting with the engine not a great deal can be done to a normally aspirated engine under Group N regulations apart from blueprinting which is not cost effective The basic engine design and component finish is to such a high standard that the need for excessive individual component preparation is minimal However t
39. DE GEAR RAMP F13 GEAR ASSEMBLY DIFF ASSEMBLY 5 507 102 5 507 103 5 507 104 5 507 105 5 507 106 5 507 107 5 507 108 5 507 109 5 507 110 5 507 111 5 507 112 5 507 113 5 507 114 5 507 115 5 507 118 5 507 119 5 507 139 5 507 140 5 07 027 SXTO7AW028 19 SXTO7AW030 SXTO7AWO031 02 SXT07AWO033 SXTO7AW034 DIFF BEVEL GEAR DIFF MOLY PLATE FRICTION PLATE 1 9 FRICTION PLATE 2 0 FRICTION PLATE 2 1 BELLVILLE WASHER BELLVILLE WASHER SMALL SEAL BEARING SLIDE AP CLUTCH AP CLUTCH PLATE OUTPUT SHAFT 4 36 1 AP RELEASE BEARING GUIDE AP RELEASE BEARING CARRIER AP RELEASE BEARING PLUG SPEEDO BLANK CAPSCREW AP CLUTCH COVER OUTPUT SHAFT 4 64 1 RING GEAR 4 64 1 APEX JOINT MOD BOLT FOR APEX JOINT 6 45 SADDLE WASHER ADJUSTER ASSEMBLY FRONT ADJUSTER CLAMP BULKHEAD BEARING HOUSING SPHERICAL JOINT CIRCLIP FOR B HEAD BRG HSG m QN ON QU GN N GEARBOX amp FINAL DRIVE DATA The Homologated ratios for the heavy duty gearbox are as follows It is important to remember that these are internal and not the overal
40. E STUB AXLE ANTI ROLL BAR 13MM DAMPER TOP RUBBER ANTI ROLL 16 5MM BOTTOM SPRING RUBBER HUB OIL SEAL REAR BEAM TOP SPRING RUBBER SCREW SHAFT ANTI ROLL BAR 18MM DAMPER SHOCK ABSORBER GRAVEL SHOCK ABSORBER TARMAC REAR BEAM BUSH REAR SPRING GRAVEL REAR SPRING TARMAC ALLUMINIUM REAR HUB STUB AXLE DRILLED FOR TRIP CABLE SPACER REAR DAMPER TOP REAR SPRING TARMAC SHORT BUMP RUBBER 52MM FLAT WASHER CUP WASHER WHEEL STUD WHEEL STUD REVOLUTION SUB GROUP 10 WHEELS WHEEL 6 x 15 WHEEL NUT 0 ROS 1 ta Z gt 36 44141 1 141 1 1 1 14 1 245 414 EJ THE BRAKING SYSTEM A dual circuit hydraulic system with in car brake balance control actuates Automotive Products four pot calipers at the front fitted to 267mm diameter by 25 4mm thick ventilated discs Solid rear discs 251mm diameter by 9 6mm thick are supplied complete with appropriate caliper mounting brackets and alloy hubs An hydraulic handbrake conversion kit is supplied and includes the modified bracket spacer and hydraulic cylinder Aircraft specification stainless steel Aeroquip type brake pipes have been developed and come as a package complete with all the necessary elbows and bulkhead fittings The designated brake pipe layout is shown in the accompanying diagram and the in
41. ETTER GTE FRONT SUSPENSION The basic concept of the standard road car s suspension layout has been retained but extensive modifications have been made to the way that the components have been constructed A revised front suspension assembly has been designed fabricated and homologated specifically for use in Group A motorsport and MUST be used as a complete package There is no compatibility between individual components and those found on the standard car This new assembly consists of a modified knuckle assembly fabricated lower control arm incorporating spherical joints an adjustable tubular lower suspension arm castor control link complete with spherical bearing and reinforced front attachment bracket The heavy duty front strut body with adjustable spring platform position is fitted with a De Carbon monotube gas filled shockabsorber insert This attaches to the knuckle assembly and incorporates a wheel camber adjustment facility in the top securing bolt The alloy top mounting uses a spherical joint housed eccentrically to allow further castor and camber adjustment The knuckle assembly supplied in the kit is derived from the normal production component but has been further machined within the wheel bearing housing to accept the larger diameter wheel bearing and the top mounting bolt hole enlarged to 14mm To complement this package a selection of superprogressive road springs and suitably
42. FUSE IN FUSE BOX 1 161 153 163 164 150 151 156 160 162 163 196 184 178 193 195 196 172 173 196 188 191 177 178 187 189 185 193 190 192 198 199 169 172 175 179 181 184 196 199 183 186 187 201 202 212 210 211 205 217 218 220 221 206 229 207 205 205 203 210 ELECTRICAL WIRING DIAGRAM E H8 TELLTALE HIGH BEAM 219 K1 RELAY BACK WINDOW HEATED 293 294 9 BUZZER HEADLAMPS ON WARNING 214 215 M3 MOTOR BLOWER HEATED 297 299 S2 SWITCH ASM LIGHT P1 FUEL INDICATOR 271 2 1 SWITCH LIGHT 209 210 2 TEMPERATURE INDICATOR COOLING AGENT 273 55 TURN SIGNAL SWITCH ASM P3 CLOCK 285 55 2 SWITCH LOW BEAM 219 220 4 SENSOR FUEL 271 22 SWITCH FOG LAMP REAR 228 229 PS SENSOR TEMPERATURE COOLING AGENT 273 47 CONTACT SWITCH DOOR AND HEADLAMPS ON WARNING 214 215 P7 TACHOMETER 276 P8 GAUGE OIL PRESSURE 278 XI SOCKET TRAILER 203 209 9 VOLTMETER 277 X2 CONNECTOR AUXILIARY USERS 214 215 P10 SENSOR OIL PRESSURE 278 X17 1 5 205 207 219 R3 CIGARETTE LIGHTER 289 F6 F7 F15 FUSE IN FUSE BOX 237 253 250 2 SWITCH ASM LIGHT 52 2 SWITCH LIGHT PASSENGER COMPARTMENT 281 H3 TELLTALE TURN SIGNAL LAMP 261 3 SWITCH BLOWER HEATER AND BACK WINDOW HEATED 295 299 H6 TELLTALE HAZARD WARNING SYSTEM 257 57 SWITCH BACK UP LAMP 291 H9 STOP LAMP LEFT 252 11 CONTROL SWITCH BRAKE FLUID 268 H10 STOP LAMP RIGHT 253 513 SWITCH PARKING BRAKE 267 TURN SIGNAL LAMP FRONT
43. HEI INDUCTIVE SENSOR SYST IGNITION DISTRIBUTOR EST 109 101 116 112 113 121 122 105 107 109 112 127 126 106 107 112 114 109 120 121 128 124 137 156 162 164 140 141 136 137 144 151 159 161 153 154 147 148 146 148 149 137 156 140 153 159 136 145 147 140 167 150 160 161 Y39 SOLENOID VALVE COASTING FUEL CUT OFF Y41 SOLENOID VALVE IDLING CONTROL Y42 INDUCTIVE SENSOR HEI X10 ADJUSTMENT CONNECTOR INSTRUMENT X18 CONNECTOR WIRING HARNESS HEL3 PINS Fl FUSE IN FUSE BOX H30 TELLTALE ENGINE TBI 57 CONTROL UNIT TBI KS8 RELAY PUMP FUEL L3 IGNITION COIL HEL INDUCTIVE SENSOR SYSTEM M21 PUMP FUEL M33 POWER UNIT IDLING P14 SENSOR DISTANCE P23 VACUUM SENSOR INTAKE MANIFOLD P30 TEMPERATURE SENSOR COOLING AGENT P33 LAMBOA SENSOR P34 SENSOR THROTTLE VALVE POSITION S91 SWITCH OIL PRESSURE TBI 14 INDUCTIVE SENSOR EST 24 IGNITION DISTRIBUTOR EST 2 INJECTION VALVE TBI XII CONNECTOR WIRING HARNESS TBLS PINS X13 TEST CONNECTOR El PARKING LAMP LEFT E2 TAIL LAMP LEFT E3 LAMP LICENCE PLATE E4 PARKING LAMP RIGHT ES TAIL LAMP RIGHT E6 LAMP ENGINE COMPARTMENT E7 HIGH BEAM LEFT E8 HIGH BEAM RECHTS E9 LOW BEAM LEFT 10 LOW BEAM RIGHT Ell LIGHTS INSTRUMENT 24 FOG LAMP REAR 26 LAMP SWITCH LIGHT LAMP SYMBOL INSERT SWITCH E34 LAMP HEATER CONTROL 3 4 5 FUSE IN FUSE BOX FI4
44. LEFT 259 14 SWITCH OIL PRESSURE 269 H12 TURN SIGNAL LAMP REAR LEFT 260 15 SWITCH LAMP TRUNK COMPARTMENT 280 H13 TURN SIGNAL LAMP FRONT RIGHT 263 S16 CONTACT SWITCH DOOR DRIVER 282 Hi4 TURN SIGNAL LAMP REAR RIGHT 263 17 CONTACT SWITCH DOOR CO DRIVER 283 H17 TELLTALE TURN SIGNAL LAMP TRAILER 255 S18 SWITCH LAMP GLOVE BOX 290 H33 AUXILIARY TURN SIGNAL LAMP LEFT 258 2 CONNECTOR AUXILIARY USERS 284 288 H34 AUXILIARY TURN SIGNAL LAMP RIGHT 262 X17 CONNECTOR INSTRUMENT 267 269 270 273 276 K2 FLASHER UNIT 256 F17 FUSE IN FUSE BOX 302 K10 FLASHER UNIT TRAILER 255 256 F21 FUSE WASHER UNIT HEADLAMPS 318 K59 RELAY RUNNING LIGHT 236 242 K62 CONTROL UNIT DIM DIP LIGHT 244 248 H2 SIGNAL HORN 333 55 TURN SIGNAL SWITCH ASM K8 RELAY INTERVAL WIPER WINDSHIELD 310 313 55 3 SWITCH TURN SIGNAL 262 263 K9 RELAY TIME DELAY WASHER UNIT HEADLAMPS 316 318 58 SWITCH STOP LAMP 253 K30 RELAY INTERVAL WIPER BACK WINDOW 326 328 52 SWITCH HAZARD WARNING 256 260 M2 MOTOR WIPER WINDSHIELD 302 305 308 311 SOCKET TRAILER 250 251 261 265 M8 MOTOR WIPER BACK WINDOW 323 325 7 CONNECTOR INSTRUMENT 261 M24 PUMP WASHER HEADLAMPS 318 MSS PUMP WASHER WINDSHIELD AND BACK WINDOW 329 E13 LAMP TRUNK COMPARTMENT 280 E14 LAMP PASSENGER COMPARTMENT 281 59 SWITCH ASM WIPER UNIT E15 LAMP GLOVE BOX 290 9 1 SWITCH WIPER WINDSHIELD 302 306 E16 LAMP CIGARETTE LIGHTER 288 59 2 SWITCH WIPER WINDSHIELD INTERVAL 308 311 E17 BACK U
45. P LAMP LEFT 291 59 5 SWITCH WIPER BACK WINDOW AND WASHER UNIT 327 329 E19 BACK WINDOW HEATED 293 564 SWITCH SIGNAL HORN 333 E32 LAMP CLOCK 286 E33 LAMP ASHTRAY 287 E25 HEATING MAT FRONT SEAT LEFT 363 E30 HEATING MAT FRONT SEAT RIGHT 367 F8 9 16 18 FUSE IN FUSE BOX 293 298 280 270 284 11 FUSE IN FUSE BOX 347 H4 TELLTALE OIL PRESSURE 269 HS TELLTALE CLUTCH BRAKE FLUID AND PARKING BRAKE 267 K37 RELAY CENTRAL LOCKING DOOR 337 343 ELECTRICAL WIRING DIAGRAM M14 M15 M19 M20 M29 M32 30 37 S41 546 568 578 2 17 21 K8 K9 K30 H7 H16 K76 K77 K78 K79 K80 M4 M12 P14 MOTOR WINDOW LIFTER FRONT LEFT MOTOR WINDOW LIFTER FRONT RIGHT MOTOR CENTRAL LOCKING DOOR REAR LEFT MOTOR CENTRAL LOCKING DOOR REAR RIGHT OUTSIDE MIRROR ADJUSTMENT RIGHT MOTOR CENTRAL LOCKING CO DRIVER DOOR SWITCH HEATING MAT FRONT SEAT LEFT SWITCH WINDOW LIFTER FRONT LEFT SWITCH CENTRAL LOCKING DRIVER DOOR SWITCH HEATING MATS FRONT SEATS SWITCH OUTSIDE MIRROR ADJUSTMENT SWITCH WINDOW LIFTER FRONT RIGHT CONNECTOR AUXILIARY USERS FUSE IN FUSE BOX FUSE WASHER UNIT HEADLAMPS RELAY INTERVAL WIPER WINDSHIELD RELAY TIME DELAY WASHER UNIT HEADLAMPS RELAY INTERVAL WIPER BACK WINDOW MOTOR WIPER WINDSHIELD PUMP WASHER WINDSHIELD MOTOR WIPER BACK WINDOW PUMP WASHER BACK WINDO
46. SSEMBLY COIL LAMP ASSEMBLY WASHER TRANSFORMER SCREW GASKET COVER SWITCH HARNESS GAUGE CONTROL UNIT BRACKET t t N N 00 ELECTRICAL WIRING DIAGRAM we 0 75 R12 529 5 1 M fJ i Alef Lj 1001 2 3 45 7 9110 13458847 8 91201211 458547 8 13 4 5 6 7 91401 2 2 4 5 67 91501 2 2 5 amp 7 91601 2 5 7491001 2 4 6 8 9801 2 3 5 amp 8 1901 2 14598799 191 081 1 51 CATTERY 01 CONTACT ATOATOA SENSON POTOR EMD IME 512 Ww 15 1 2 1 0 SENSOR MOTOR ENGINE oi toi c SCHMEDENISCHME 11 MOTOR ANG INE CHE FUER LEI TADEN 6 1 U TREKT ION 191 bis 47002 LS 11 2 12 11 2 511 COLOR ARE IAT ION FOR 85 H ove IED 1 2 11 11 2 VERGASER 019 0007 ron CROSS SECTION ELECTRICAL WIRING DIAGRAM an 1 Q 05 5 sut 0 78
47. VOIR CAP RESERVOIR CAP SEAL RESERVOIR BRACKET PIPE RESERVOIR TO PUMP POWER STEERING PUMP PUMP POLY V PULLEY BOLT PULLEY TO PUMP POLY BELT CRANKSHAFT PULLEY ALTERNATOR PULLEY PIPE PUMP TO RACK PUMP OUTLET UNION 5 506 005 5 506 006 5 506 007 5 506 008 5 506 009 5 506 025 5 506 011 5 506 012 5 506 013 5 506 014 5 506 015 5 506 016 5 506 017 5 506 018 5 506 019 5 506 020 5 506 021 5 506 022 5 506 023 5 506 024 PART NUMBER 5 508 009 5 508 001 5 508 002 5 508 004 5 508 006 PART NUMBER 5 509 001 5 509 002 07840453 90170401 5 509 003 90193771 90008411 90008412 90334773 5 509 004 90233191 90299071 11042712 90299503 90299070 90296436 5 509 005 5 509 018 m OG b OG 00 OG 5 508 CAR QTY 5X509 CAR QTY e MO M en mae w NOT INCL NOT INCL ZI CLUBMANS KIT BUILD LIST UNION SEAL 5 509 019 1 RACK INLET UNION 5 509 006 1 RACK INLET UNION SEAL 5 509 007 1 RACK OUTLET UNION 5 509 008 1 RACK OUTLET UNION SEAL 5 509 09 1 BANJO BOLT 5 509 012 1 PIPE RACK TO RESERVOIR 5 509 010 1 LOWER UNIVERSAL JOINT 5 509 014 1 JOINING SHAFT 5 5
48. W PUMP WASHER HEADLAMPS SWITCH ASM WIPER UNIT SWITCH WIPER WINDSHIELD SWITCH WIPER WINDSHIELD INTERVAL SWITCH WIPER BACK WINDOW INTERVAL FUSE IN FUSE BOX FUSE FILTER HEATING BATTERY DIESEL GENERATOR DIESEL SENSOR ENGINE REVOLUTION CHARGING INDICATOR LIGHT TELLTALE PREHEATING TIME CONTROL UNIT PREHEATING TIME RELAY SENSING RESISTOR RELAY PRE RESISTOR RELAY CHARGING INDICATOR RELAY FILTER HEATING MOTOR BLOWER RADIATOR STARTER DIESEL SENSOR DISTANCE 351 353 355 357 339 342 339 342 346 348 339 342 362 363 351 354 337 338 365 367 345 348 355 358 338 347 373 389 381 384 387 389 395 397 373 376 372 378 392 394 398 389 372 375 378 382 396 397 409 434 401 411 413 423 414 423 418 424 426 427 429 430 413 416 433 434 409 405 406 417 418 363 79 382 RS R19 R21 R22 51 588 5114 2 U12 1 012 2 17 Y24 X19 GLOW PLUGS PRERESISTOR BLOWER RADIATOR SENSING RESISTOR PRERESISTOR GLOW PLUGS SWITCH STARTER SWITCH TEMPERATURE COOLING AGENT RADIATOR SWITCH TEMPERATURE COOLING AGENT ENGINE FILTERHEATING ASM SWITCH TEMPERATURE HEATING RESIST SOLENOID VALVE FUEL CONNECTOR INSTRUMENT PLUG CONNECTION ALTERNATOR 3 PINS PLUG CONNECTION 3 PINS PLUG CONNECTION 2 POLIG FUSE IN FUSE BOX TIMING CONTROL INJE
49. Y POLY V BELT CRANKSHAFT PULLEY BEARING PULLEY PUMP POWER STEERING RACK NUT STEERING RACK TO B HEAD GAITER RACK TO B HEAD PIPE RESEVOIR TO PUMP PIPE PUMP TO RACK RACK INLET UNION RACK INLET DOWTY SEAL RACK OUTLET UNION RACK OUTLET ALLY CRUSH WASHER PIPE RACK TO RESEVOIR PIPE VALVE BODY TO RAM BANJO BOLT COPPER WASHER LOWER UNIVERSAL JOINT JOINING SHAFT U JOINT UPPER SHAFT KIT PIPES RHD UPPER UNIVERSAL JOINT 55 ek Soy bai pcd pan ya i e gn NB eR eB eB he s Neh ear suspension from underside ear springs OZ Wheel REAR SUSPENSION The standard rear axle beam is retained for the Group A specification and does not require additional strengthening Special competition bushes are supplied in the kit and should be fitted to the body mounting pivot point of the rear axle De carbon gas filled shockabsorbers have been developed in conjunction with superprogressive minibloc rear springs for gravel and tarmac events These must be used in conjunction with the corresponding front springs and shockabsorbers as they are part of a fully integrated package The 18mm diameter anti roll bar standard fitment on the GTE GSi models must be fitted for tarmac surface applications However certain drivers may also prefer the loose surface handling characteristics resulting from running with a rear anti roll bar fitted REAR ROADSPRING DATA
50. a wide range of competition type seating for both driver and co driver Also carefully remove both the gearlever gaiter support bracket and the centre support shelf from the centre tunnel section in readiness for the installation of the revised gearshift and linkage at a later stage Once the carpet centre support has been removed an elongated hole approximately 80mm by 25mm must be formed in the centre section of the floor panel along its centreline starting 80mm rearward of the tunnel to bulkhead bodyseam This is to give access to the engine bay for the revised gear linkage The area of centre tunnel and exposed hole immediately below the gearlever gaiter support bracket can be closed off and strengthened using the shaped blanking plate supplied This should be welded into place The gear linkage forward support bearing housing bracket should be welded into position at the forward end of the centre tunnel BODYSHELL Access for this operation is from the underbonnet and underside of the bodyshell However before welding this bracket into place the bearing housing itself should be modified to fit the bracket correctly This will entail cutting away a portion of the bearing housing flange just below two of the attachment holes Three holes should then be drilled through the housing and bracket using the housing as a template Three nuts should then be tack welded to the rear face of the bracket This will enable easy attachment o
51. ackets for this exhaust system have not been attached Experience has shown that it is easier to mark the exact position for the mounting brackets with the system in place This allows for some variation between vehicles and exhaust systems to be catered for The chassis mounted rear bracket should first be removed from the car Replace with and weld into place the modified bracket supplied The front bracket should be welded on to the rear gearbox mounting centre bracket The position can be determined by attaching the front downpipe to the exhaust manifold The other part of this bracket can then be tack welded to the front pipe to line up with it Now remove the front pipe and complete the welding operation on the bracket Refit front pipe and fully secure to gearbox mounting point The centre pipe section and rear silencer box should now be offered into place By twisting each section relative to each other the optimum position can be determined giving satisfactory clearance over the rear axle beam spare wheel well etc Mark position for the rear mounting bracket and tack weld in place if possible Remove from car for final welding operation It is suggested that short lengths of small diameter tubing are welded to the pipes on either side of the sleeve joints to create a facility for lockwiring the pipes together rather than using exhaust clamps This gives a quick release attachment invaluable for on event servicing or replacement
52. ad is attached by heavy duty cylinder head bolts and must be fitted along with the heavy duty competition gasket supplied Make sure that the head face is thoroughly clean and dry fit with dry gasket No grease or sealants to be used Make sure that the head is properly located on the locating dowels before any attempt is made to secure Ensure that the mating faces of the camshaft housing and cylinder head are also thoroughly clean then apply recognised sealant to both faces prior to final assembly Lightly lubricate the thread area of the bolts to minimise thread friction during the tightening procedure The bolts should be tightened in three stages adopting a spiral pattern sequence from the centre of the cylinder head Ist stage 3 5 kg m 25 Ib ft 2nd stage 6 0 kg m 45 Ib ft Finalstage 9 0 kg m 65 Ib ft The three tightening stages should be carried out operating the torque wrench in a CON TINUOUS angular movement until the required torque figure has been reached This will almost eliminate the errors introduced by the friction in the threads and under the bolt head The gasket thickness when fully clamped is 1 2mm 0 047in which is equivalent to a volume of 6 1 cc As the standard engine breather system has been deleted an external breather must be pro vided Connected to the camshaft top cover this pipe should then lead into an auxiliary catch tank with a minimum capacity of 2 litres This container could be
53. affected area before assembly The amount of material to be removed can easily be confirmed by offering up the mainshaft complete with the gear All the above mentioned points are highlighted in the illustrations for this chapter GEARBOX ASSEMBLY PROCEDURE Itis very important that all the parts required are thoroughly cleaned prior to commencing reassembly of the gearbox and a clean swarf free area is reserved for the build Carefully remove all gears from the mainshaft since they have only been fitted loosely to the shaft for packaging purposes It may be prudent to note the sequence of this assembly and confirm with the diagrams provided The final drivegear pinion is integral with the mainshaft but prior to further assembly carefully fit the spacing washer behind the gear making sure that the small locating ball is correctly located in the small hole provided in the shaft and spacer thus preventing the spacer from revolving Now lightly lubricate the roller bearings and slide over the mainshaft along with the gear wheels and selector hubs in the order and position shown by the exploded diagrams and photographs NOTE If the donor gearbox has already cov ered a significant distance renew the mainshaft The F13 casing Looking into gear compartment Chamfer completed Casing detail 27 Sandunch plate detail GEARBOX AND DIFFERENTIAL ASSEMBLY and 1st motion shaft bearings as a precaution Now at
54. an the component with petrol or other suitable solvent Blow out the oil passages with compressed air prior to reassemble The main bearing shells and bolts are as production PISTONS AND CONRODS To give the correct increase in the compression ratio and increased durability Cosworth full skirt forged pistons are supplied These have a lighter gudgeon pin which is a pressed fit into the small end bearing as in the normal production condition The Cosworth pistons are sized to be compatible ONLY with the standard production bore dimensions These are in fact graded but the increased operating clearances with the Cosworth piston easily accommodates any slight variance in bore size The Cosworth piston is a direct replacement for the standard unit which can be discarded Circlip grooves are evident around the gudgeon pin housing on the Cosworth piston these must be completely disregarded as circlips are not required for this application As a precaution the conrods should be crack detected after the standard pistons have been removed and prior to assembly with the replacement pistons However both the removal and fitting of the pistons to the conrods is a specialised operation and must be carried out by appropriately qualified and equipped personnel Heavy duty conrod bearing cap retaining bolts are supplied which also give more positive bearing cap alignment The pistons have a designed deck height to give a compression ratio of
55. and the sandwich plate The reverse gear thrust washer must not be fitted as it would prevent full engagement of the gear in this gearbox Carefully insert this shaft assembly into the hole in the sandwich plate making sure that the small LOCATING BALL is aligned with the machined groove in the sandwich plate Using a copper faced hammer drift the shaft fully into the hole The long interlocking pin can now be inserted into position through the reverse gear detent hole Fit reverse gear selector fork to shaft fit into sandwich plate and secure fork to shaft with roll pin The FOUR detent pins and springs can now be inserted and retained using the force fit plugs The gearbox cluster assembly is now com plete and can be checked for correct operation before final installation into the gearbox casing NOTE This unit must be fitted to the gearbox casing BEFORE the special end cover is attached To re check clearance of 4th gear to casing refer to previous instructions regarding casing modifications Cluster and plates before assembly Introducing the shafts onto the sandwich plate The gearbox cluster assembled Gear selector fork installed Diff and crown wheel Gear shift cover GEARSHIFT COVER AND DIFFERENTIAL ASSEMBLY In conjunction with this gearbox a revised gearshift mechanism has been developed ensuring precision gearchange characteristics and better durability The standard gears
56. approximately 11 4 1 and when installed should protrude above the block face at top dead centre by 0 4mm plus or minus 0 10mm 0 016ins plus or minus 0 004ins This dimension should be checked in case of block discrepancies ENGINE BLOCK The bore size must be standard to remain within the 1600cc maximum capacity limits and should therefore conform to the following dimensions 79 025mm 3 1112ins An oversize competition piston has not been developed Prior to assembly deglaze bores to a micro finish and 45 degree hatch pattern The take off hole for the standard engine breather tower assembly situated on the inlet side of the block must be blanked off with the plate supplied See photograph for the detail Assemble in accordance with normal build procedures CYLINDER HEAD ASSEMBLY Carefully dismantle the cylinder head placing each component in numbered removal order so that the parts required can be reassembled in their original positions Prior to further cylinder head preparations a modification to give increased oil supply to the hydraulic lifters thus ensuring adequate oil pressure under high oil temperature and sustained high engine speed operating conditions MUST be carried out The oil pressure feed hole in the cylinder head casting situated at the exhaust side of the cylinder head face should be increased in diameter This operation requires extra care and entails drilling out the existing angled 2mm hole
57. are now left These are for additional attachment of the sides of the rear frame Drill 10mm holes through the INNER SHELL ONLY at the four rear frame side mounting points Pass the upper fixing block upwards inside the shell position a heavy gauge washer between the shell and the frame then retain by inserting the bolt Repeat for the lower fixing points Check that all bolts and component parts are in place and that you are content with the general fit Now go round ALL attachment points and thoroughly tighten all bolts The strengthening and preparation is now complete but it is suggested that the roll cage is removed whilst the bodyshell is painted FRONT SUSPENSION BRACE This is the last item under the general description of body strengthening and must be fitted to the car by attaching to the front suspension top mounting bolts This can be left until all the other operations have been carried out Spacers may be required to give adequate clearance between the brace and the manifold on certain vehicles SUMP AND TANK SHIELDS An undershielding kit has been developed for the Group A car This front shield protects the engine sump and transmission assembly and attaches by four bolts to the front mounting points for the forward facing lower suspension arms The rear of the shield is attached by two bolts adjacent to the inner pivot points for the lower wishbones A threaded insert is already incorporated in the strengthening pla
58. ched to the left hand suspension turret using the bracket supplied All the pipes are made to the correct length and have the appropriate end fittings such that they can only be fitted in the correct way The power steering pump is attached to the engine by two bolts and driven from the crankshaft pulley by a common poly vee drive belt that also drives the alternator Two universal joints and two mini shafts are provided to connect the steering column to the power steering rack assembly One shaft fits between the two U J s the other fits into the end of the steering column having first removed and discarded the original lower column shaft NOTE On certain vehicles the replacement lower column shaft may require further machining before it can be correctly fitted into the existing lower column support bush In this case refer to the diagram showing the revised machined condition The steering column can now be connected to the power steering rack by attaching the two 0 75 Tighten all clamping bolts thoroughly Initially the system will require bleeding to remove any air pockets Top up the pump reservoir with new fluid Dexron 90 020 172 to the edge of the filler neck Start engine and immediately switch off repeating this procedure until the fluid level is at the MIN mark with the engine stationary To bleed the system start engine and allow to idle whilst the steering wheel is turned from lock to lock Finally check the
59. crossmember AFTER the strengthening plate for this point has been attached and has been designed to fit in this original position using the three original mounting bolts This bracket is also designed to be used as the front attachment for the sumpguard The shockabsorber insert should be fitted to the strut body to be secured by a single nut but lightly lubricate the bearing surfaces and make sure that the bump stop rubber is in place on the shockabsorber rod before assembly The lower spring guide ring chosen road spring spring clamp required for this operation top spring plate followed by the top mounting assembly can then be secured by a single nut There is provision for a grease nipple to be fitted to the top part of the strut body just above the threaded section Access to this nipple can be made between the lower coils of the road spring for occasional lubrication with a proprietary graphited grease The completed shockabsorber and spring assembly is attached to the knuckle using the special bolt supplied This 14mm top bolt is handed since it has an eccentric head to enable wheel camber adjustment The offset head of this bolt fits between the two small angled plates on the strut body the lock nut and special Front suspension installed Camber adjustment bolt Front attachment bracket Range of front springs gv Access to grease mpple EEE L 1 Platform set herght hardened
60. d or modified We will also be happy to receive any details of ommisions or items that you would like to see in the manual Only by feedback can we continue to improve on what is hoped will be a helpful and informative book MODEL AVAILABILITY When preparing a vehicle to the clubmans specification contained in this manual it is intended that the base vehicle used will be an existing Nova GTE or Corsa GSi These models are identical save for badging and very small differences in trim Additionally some slight variations on standard specification occurs territory to territory For instance most Nova GTE models sold in the U K come equipped with central locking and sunroofs Corsa GSi models sold in right hand drive form in the Republic of Ireland do not have these two items fitted as standard However apart from these minor differences the main mechanical characteristics remain the same The motive unit is a Family One nominal 1600 cc overhead camshaft fuel injected type which is designated 1600 SE and currently is not fitted to any other vehicle The Family One group of engines which includes the 1200 cc and 1300 cc version with different bore stroke configurations also includes a carburettored 1600 cc unit known as 1600 SV type which has a different cylinder head and distributor to the SE motor but in most other respects remains the same The transmission is known as the F13 type and the basic production unit i
61. dividual pipe lengths have been optimised for installation in accordance with that scheme INSTALLATION AND ASSEMBLY Care must be taken whilst handling ALL brake system components and before connecting individual pipes and fittings together it is suggested that they are blown out with an airline to ensure they are free from dirt etc Lay the flexible pipes roughly in place inside the shell to get the general idea as to where they will be finally sited Reference to the general schematic diagram will indicate the position in more detail Because the pipe lengths are fixed it is advisable to partially secure the pipe run to the bodyshell before marking out the positions where the pipes pass through bulkhead panels Holes can then be made for the appropriate bulkhead fittings and once the pipes are connected up in their correct positions they can be finally secured neatly to the panels using proprietary clips The twin master cylinder pedal box assembly attaches to the original brake servo mounting studs The 0 7 cylinder is for the FRONT brake system the 0 75 cylinder is for the REAR brake system A flexible drive cable fitted with a hand control that can be mounted on an auxiliary bracket or on the centre console connects to one end of the brake balance adjustment beam This operates the brake balance adjustment beam from within the car Special brackets are supplied to convert the handbrake to hydraulic actuation The mas
62. f the bearing housing to the bracket after it has been welded into position This bracket is shaped to fit the exact position required and when measured should be 65mm rearwards from the face of the steering rack mounting plate This should then exactly locate the bracket in its correct position which when measured should be 65mm rearwards from the face of the steering rack mounting plate NOTE This is a delicate operation as the positioning of this support bracket is crucial for satisfactory gear linkage operation The aperture in the steering rack mounting bracket where it meets the lower chassis region must also be increased in size along the lower edge by removing 10mm from this flange Seam weld the section after removing this metal NOTE This MUST be carried out at this stage to give adequate clearance for the revised gearchange mechanism Refer to the diagrams for guidance The bodyshell now free from all unwanted items can be cleaned off in readiness for the seam welding and strengthening operation All exposed body seams throughout the bodyshell that are actually spotwelded in the production process require further stitching preferably with a MIG type welder This entails making an additional 25mm run of weld every 35mm along EACH visible body seam throughout the bodyshell and applies equally to the underside underbonnet and bulkhead areas However the lower flanges of the front chassis rails where they join the inner
63. fluid level in the system when the system is cold and the engine not running The level should then reach the MIN mark At normal operating temperature the level should not be above the MAX mark If the fluid level drops particularly low check the system for leaks Under no circumstances allow the pump to be driven with insufficient or no fluid in the system NOTE Do not use the vehicle with the power assistance disconnected this could lead to damage within the valve assembly 70mm gt 3451666 3460213 6665033 7837496 7838084 7838204 7840453 7847036 11011778 11042712 26011925 90008411 90008412 90052498 90052550 90105246 90125328 90157076 90157258 90167063 90170401 90191415 90193771 90233191 90250338 90296436 90299503 90299070 90334860 94115831 5 509 001 5 509 002 5 509 003 5 509 004 5 509 005 5 509 006 5 509 007 5 509 008 5 509 009 5 509 010 5 509 011 5 509 012 5 509 013 5 509 014 5 509 015 5 509 016 5 509 017 5 509 026 SXT09AWO035 SUB GROUP 09 STEERING PLATE BEARING WASHER RING RING SHAFT ASSEMBLY TRACK CONTROL ROD COLUMN ASSEMBLY NUT BOLTS PULLEY TO PUMP TRACK ROD END RESEVOIR CAP RESEVOIR CAP SEAL SWITCH ASSEMBLY BOLT SPRING BOLT SEAL CLAMP COVER ASSEMBLY NUT TRACK ROD TO KNUCKLE HOUSING POWER STEERING FLUID RES POWER STEERING PUMP RESEVOIR BRACKET ALTERNATOR PULLE
64. front pads may be a consideration However since there is the possibility that the DS11 material may not always be running within its optimum temperature range the brake balance could become inconsistent and very REAR biased even to the extent of continuous rear wheel locking Should these circumstances prevail the choice of DS 11 has not been the correct decision Revert to the recommended Ferodo 2459 720 5XS05 5 505 22 LHD 5XS05 23 RHD 5 505 AC034 5XS05 5XS05 ACO31 5 505 2 LHD 5 505 21 RHD 5 5 077 5 501 10 5 505 051 5 5 36 5 05 AWO15 MASTER CYLINDER SIZE 5 05 076 5 05 075 5 05 014 5 05 018 5 05 4 Brake pipe kit 5 505 5 5 505 29 5 AWO19 CORSA FRONT REAR BRAKE ASSEMBLY 5 505 2 8952997 90125799 90142222 90142226 90157720 5 505 001 5 505 002 5 505 003 5 505 004 5 505 005 5 505 006 5 505 007 5 505 008 5 505 009 5 505 010 5 505 011 5 505 012 5 505 015 5 505 017 SXSOSACO18 5 505 019 5 505 020 5 505 021 5 505 022 5 505 023 5 505 024 5 505 028 5 505 029 5 505 030 5 505 031 5 505 032 5 505 032 5 505 033 5 505 034 5 505 035 5 505 036 5 505 05
65. hen cutting out these holes it is better to make them too small initially and progressively increase them to give a close fitting This then leaves less of a gap to be filled after final completion of the roll cage installation and maintains compliance with the fireproofing requirements Now feed this support arm into position from the front of the car and bolt to the side rail top mounting Mark out Foot mounting welded in position Upright close to door position Holes in bulkhead BODYSHELL PROTECTION Opening of the hole from the outside of the car Marking the rear shield attachment point the two holes alongside the suspension turret and drill out to 10mm A third 10mm hole has to be drilled at the point where the diagonal support meets the front tower arm but opened out to 25mm on the outer skin of the chassis member to enable the fixing bolt to be inserted and tightened Bodyshell and rollcage tolerances again may require spacing washers to be fitted to bridge the gap between the tower arm and the body panel prior to tightening the attachment bolt Again use the 10mm hole as the pilot hole for the hole saw The diagonal support arm can now be passed down through the wiper motor well area to the lower attachment point the front tower arm can then be positioned and the assembly fully secured Repeat this procedure for the other side of the car Four heavy gauge washers and fixing blocks
66. here is some scope for a power increase as a result of re programming the ignition and fuel electronic control units and these modified components are now generally available on the aftermarket Suspension modifications are permitted in that the springs and shock absorbers may be replaced with uprated units but their working principle and attachment points must remain unchanged The ride height of the vehicle must conform to the homologated dimensions Flexible bushes at the suspension pivot points may be changed for mechanically similar bushes but made from a harder compound The dimensions of the brakes must remain as normal production specification for the model but the pad lining material can be changed The handbrake may be converted to fly off action and aviation type brake lines are permitted but no form of brake balance adjustment is allowed The exhaust system can be modified from the first silencer box to the exit provided that the pipe size does not exceed that forward of the first silencer box BODYSHELL The reinforcement procedures and the body strengthening components featured in the Group A Kit outlined earlier in this manual for the Group A car can be followed as seam welding and strengthening of the suspended part is allowed under Group N regulations Please note that the carpet and gearlever gaiter supports referred to in that section CANNOT be removed The seat mounting system can be modified to accept sea
67. hift cover assembly is replaced by a modified assembly supplied as a complete unit This is a heavy duty construction and is compatible with the redesigned gearchange linkage DIFFERENTIAL ASSEMBLY PROCEDURE Alternative final drive ratios in heavy duty form and a six pack limited slip differential assembly have been fully developed for use in conjunction with this gearbox unit The increased size of this crown wheel does not allow sufficient space to retain the speedometer drive gear The limited slip differential is supplied fully assembled and is pre set to give approximately 75 lock up This figure has been determined by extensive rallying experience with the model and gives good traction characteristics yet remaining easy to drive There is scope within the limited slip unit for this figure to be altered by alternative shim configuration but would suggest that the 75 figure will more that satisfy the needs of the majority of drivers Assembly of this differential unit to the crown wheel follows the normal service procedure for the Nova Corsa model Don t forget the general rule that if the donor transmission has already covered a considerable distance rebuild with new bearings If in doubt fit new IMPORTANT PLEASE NOTE This heavy duty differential assembly CANNOT be FITTED to REMOVED from the differential housing until the gearbox assembly is withdrawn from its casing by a minimum of 5mm DRIVESHAFTS To trans
68. if damaged The system can then be attached using the standard exhaust mounting rubbers CLUTCH ASSEMBLY A sachs 190mm diameter solid disc centreplate competition clutch with heavy duty diaphragm cover has been developed This unit is supplied in the Clubmans Kit and fits the standard flywheel without any modifications However it does require a special release bearing which is supplied complete with a special bearing carrier This carrier requires detailed modification for it to fit the existing gearbox casing as follows One of the three locating flanges must be reduced in thickness to give clearance against the gearbox casing at one point This can be achieved by carefully grinding away the excess material thus thinning the selected flange around its outside diameter The three attachment holes around the carrier must then be slotted and elongated to adapt to the smaller pitch circle radius of the threaded holes in the casing Assemble by first fitting the O ring seal followed by the thin spacer ring Secure in position by attaching the bearing carrier to the gearbox casing with the three bolts Clutch cable adjustment procedure follows that for the standard car 5XS12 ACOO7 Exchange unit 020 Group N Exchange unit NY 3 J Fuel pipe 5 508 8 Injectors set 5 508 AC009 Bx Oy ve V 5XS06 ACO25 Hydraulic cam kit JOUW NOVA CORSA COMPETITION ENGINE COMPONENTS
69. in this revised location The fuel filter supplied should be mounted on the special bracket and attached to the bulkhead as shown in the photograph Armoured fuel lines Aeroquip type are supplied to the correct length for running through the inside of the vehicle and for connection to the injection system These can be fitted by following the guidelines in the chapter for the installation of brakepipes NOTE Under certain extreme conditions of vehicle use for example tortuous Alpine ascents on dry tarmac intermittent fuel surge may occur particularly when running with a low fuel content Keeping the fuel level ABOVE half full will prevent this condition Fuel filter position Downpipe installed Rear section installed Clutch parts Paddle clutch may be subject to change THE EXHAUST SYSTEM CLUTCH A revised front downpipe centre pipe and tail silencer have been developed in conjunction with the engine development programme The dimensions selected for the front downpipe and centre pipe enhance the torque characteristics of the Group A engine and the engine management system has been optimised for this system Whilst the total system is considered effective as a silencing device and meets current U K Traffic Regulations it is the responsibility of the competitor to ensure conformity with the traffic regulations of the countries through which the event is run FITTING GUIDE Mounting br
70. ings large diameter lower spring platforms valve washers modi fied top retainers valve spring cups and thrust pads are provided and must be assembled in the following sequence INLET VALVE Place large diameter lower spring platform over valve guide boss Fit appropriate valve through guide and press valve stem oil seal into place Fit valve spring followed by the modified top retainer and secure with split collets valve stem keys EXHAUST VALVE Place standard rotator platform over valve guide boss Finish off assembly as for inlet valve CAMSHAFT The design data for the camshaft supplied is as a direct result of extensive dynamometer testing and competition experience with this power unit Camshaft lubricant is provided and must be applied liberally to the lobes prior to assembly During the fitting of this camshaft to the housing camshaft case take care not to damage the oil seal with the lobes of the camshaft The standard timing marks should be used for final assembly and experience has shown that in the majority of cases they represent almost optimum ti ming for this cam Again there is scope for optimising the valve timing as tolerances in the engine block dimensions do have an effect on the actual timing The correct timing for this camshaft is confirmed by measurement of the INLET valve lift at top dead centre and this should be 4 4mm 0 1732ins when measured with zero valve clearance The cylinder he
71. l electronic instrumentation to establish the position The big end caps whilst they are each matched to their conrod during machining are NOT marked when fitted to the standard production engine Before removal mark the big end cap to conrod position to ensure rebuild 18 in correctly matched order SUMP PAN The standard sump pan is retained but requires an additional baffle plate and pick up pipe protector to prevent oil surge during braking and hard cornering manoeuvres This specially profiled baffle plate and the protector should be attached by brazing to the sump pan in the positions shown in the diagram It is important not to exceed the maximum oil level marks on the dipstick prior to subsequent competition use The oil surface could easily be picked up by the rotating crankshaft significantly increasing the drag with a subsequent detrimental effect on power output CRANKSHAFT If there is any doubt as to the type of use that the engine may have already had measure the crankshaft for wear and crack detect as a precaution Production balance levels are Engine ready for installation Baffled sump pan Cosworth piston The block with blanking plate position Cam housing with blanking plug installed ENGINE already very good and no further balancing is required If the crankshaft is not as new lightly polish the journals with a suitable grade of crankshaft finishing tape Thoroughly cle
72. l extent of the available free movement This will give better access to install and secure the interlock pin assembly to the sandwich plate with two cap headed bolts Once this is fitted the mainshaft can be returned to its correct position up against the bearing and the 1st 2nd gear selector rod returned to the NEUTRAL position The 3rd 4th gear selector rod can now be inserted through the axis of the 5th gear selector assembly into the 3rd 4th gear selector fork and secured with care by roll pins The 5th gear pawl assembly should now be attached to the sandwich plate using two cap headed bolts making sure that the slot in the 3rd 4th gear selector rod located the end of the pawl The 5th gear complete with its hub and selector fork can now be fitted to the end of the mainshaft The selector fork locates on the end of the 5th gear selector rod assembly Secure the gear to the shaft with the 33mm nut NOTE LEFT HAND THREAD and tighten to a torque of 14kg m 1001b ft THEN indent the locking collar Insert the small blanking plug into the hole in the end of the 5th gear selector shaft assembly Please ensure that the small holes in the shaft blanking plug and selector fork ALL align with each other BEFORE securing with two roll pins The other 5th gear can be fitted with the spacer ring to the end of the 1st motion shaft and secured by a circlip Fit the reverse gear to its shaft with the thick spacer positioned between the gear
73. l ratios RATIO NUMBER OF TEETH Ist 2 541 33 13 2nd 1 76 1 30 17 3rd 1 42 1 27 19 4th 1 19 1 25 21 5th 1 04 1 24 23 Rev 3 31 1 29 13 X 43 29 Several optional final drive ratios have been homologated but the crown wheel and pinion sets that equate to the ratios are not necessarily readily available The following ratios are currently being used successfully Gravel 4 64 1 Tarmac 4 36 1 PERFORMANCE DATA Fifth gear 7500 RPM Final Drive Ratio Racing Tyres Gravel Tyres 18 56 14 14 60 14 KPH MPH KPH MPH 4 64 1 161 10 100 05 4 36 1 171 433 106 48 BI NI Av r SPEEDS IN GEARS 7500 rpm 4 36 1 Final Drive 18 56 14 Michelin Racing Tyres Interior shot ELECTRICAL SYSTEM GM The standard wiring loom and 55 ampere alternator are completely satisfactory and need only be modified when several extra electrical components are to be fitted Under certain event conditions four additional driving lamps a short wave radio and additional navigational instruments may be required Under these circumstances we would advocate the fitment of
74. llation although ALL dimensions must conform to those homologated The nature of the possible modifications is such that they should ONLY be carried out by a competition engine preparation specialist Cylinder head and manifold modification to realise a worthwhile gain in power requires knowhow combined with careful and laborious attention to detail Yet to throw power away by an incorrect approach to the modifications is all too easy Please remember that a good competition engine can only be developed from a good standard production unit If at all possible always use a new or very lightly used engine unit as the basis for conversion to Group A specification Cleanliness and careful assembly is the keynote to successful engine assembly Y ENGINE AND MANAGEMENT SYSTEM A correctly prepared and assembled unit should produce between 140 and 150 BHP with maximum power developed at between 6800 and 7000 RPM ENGINE PREPARATION PROCEDURE NOTE IMPORTANT DETAILS Before commencin the stripdown of the standard engine unit and whilst the engine is in running order ensure that the ignition timing is correctly adjusted This should be 10 degrees BTDC at idling speed Then mark the distributor to cylinder head position so that this correctly timed position is not lost when the distributor is removed Failure to do this will prevent correct repositioning of the distributor after the rebuild and it would then require access to specia
75. ls from other sources can be used although they may differ in several basic respects The main differences being confined to the front suspension turrets and the inner and outer chassis rails They have already been additionally strengthened in the 1600 models From experience these bodyshells GM do not present any problems under motorsport conditions and are equally as good as the 1600 shell when fully prepared with the body strengthening kit Obviously some additional plating and welding could be required particularly in these areas on bodyshells from an alternative source Before Commencing any bodyshell preparation operations both front wings doors and tailgate must be removed from the bodyshell All sound deadening material and general sealants around all body seams can then be removed to provide more favourable welding conditions The application of heat to the required area will enable any surplus material to be scraped off more readily finishing off the operation with a wire brush It s a fairly laborious task but very important and if thoroughly carried out will pay dividends at the welding and later stages of preparation Any surplus brackets unused supports such as brakepipe petrol pipe clip attachment points can be removed and to enable a revised seat mounting system to be fitted the standard seat adjustment mounting brackets should also be removed with care This will enable a much more satisfactory installation of
76. mit the extra power developed by the engine in Group A trim it has been necessary to design and develop special heavy duty driveshafts These are fitted with much larger constant velocity joints and special drive flanges running in larger diameter wheel bearings These shafts are capable of handling the torque from the 2 litre engine so the competition life in this application is considerably improved The driveshafts must be fitted in accordance with workshop procedures for the standard car GEARCHANGE MECHANISM Three joints shaped connecting rod long straight shaft short hollow shaft shaft support bearing and housing gearchange lever assembly and joining block are supplied This is a complete assembly and can only be used as such ASSEMBLY PROCEDURE This can only be fitted in the first instance AFTER the engine and gearbox have been installed Attach the shaft support bearing and housing to the forward mounted bracket previously welded into place during the bodyshell preparations Fit one Apex joint between the short shaft from gearshift cover and one end of shaped connecting rod The long straight shaft should be lightly lubricated and positioned through the hole in the centre tunnel through the forward positioned spherical bearing and finally connected to the shaped connecting rod using another Apex joint The gearchange lever assembly can now be joined to this straight shaft using the remaining Apex join
77. ngine was introduced in early 1988 and featured the Bosch L3 1 Jetronic fuel injection system Since then certain evolutionary changes have been made to the engine management system during the production process as alternative suppliers have been introduced to supply similarly functioning components The advent of the exhaust catalyst to meet certain market legislation has also lead to a completely different management system just for the catalysed engine specification The Group A parts kit was initially fully developed around the original Bosch L3 1 Jetronic system This incorporates a Bosch ignition ECU Bosch ignition distributor and Bosch air flow sensor ECU Donor vehicles fitted with the Siemens ignition ECU and Lucas ignition distributor must be converted to the Bosch specification as the other units cannot be modified to match the Group engine requirements Donor vehicles running with a catalyst are fitted with the Bosch Motronic system While this is far superior to the Bosch L3 1 Jetronic system it has not been further developed as a part of the Clubman Group A engine parts kit In this case the whole system would have to be replaced by the Bosch L3 1 Jetronic components Ed ENGINE There is an alternative solution for donor vehicles that do not comply and for those requiring a better management system than the Bosch L3 1 Jetronic anyway Since the introduction of the Group A engine parts kit several engine preparation
78. ppendix J for Touring cars Group A permit a limited amount of bodyshell reinforcement but it is important to adhere strictly to the definitions of the particular Article No 5 7 1 Lightening and Reinforcements modifications outlined within this chapter are in compliance with these guidelines General Motors Europe have extensive motorsport experience with the Nova Corsa model and have developed a body strengthening kit specifically for use in conjunction with the 1600cc model range This kit includes all the additional reinforcement plates required for the suspension pick up points engine mounting points roll cage pick up points and a side jacking point etc When fitted in conjunction with the requisite additional welding as described will give an adequate degree of increased strength and durability demanded by a motorsport environment A specially designed roll cage has been developed and homologated for this model This cage also incorporates the rear mounting points for the safety harnesses Due to the nature of the modifications they can only be effectively carried out on a bare bodyshell so if your starting point is either a new 1600 Nova GTE or Opel Corsa GSi then all mechanical trim and electrical components must be completely removed from the vehicle before embarking on any aspects of bodyshell preparation Whilst this section applies primarily to bodyshells with Part Number 90297213 LHD or 90297215 RHD bodyshel
79. rd at the top can now be moved towards the rear of the bodyshell then turned to an upright position and further rearward until the rear suspension turret mountings can be located centrally onto the rear suspension turret tops Now drill a 10mm hole on each rear turret mounting and insert a bolt The rear part of the roll cage is now located in its correct position Position the foot mounting brackets Sill Mounts making sure that they are seated correctly on the sills and accurately mark out the six attachment bolt holes Detach the rear turret mountings and move the frame forwards so that the six holes marked out can now be made to 25mm diameter Attach the foot mountings to the rear frame and bolt up fully before returning the frame to its fitted position Drill out the remaining rear turret mounting bolt holes and fully attach with the 10mm bolts The foot mountings can now be welded in position to the sills It is important to clean this area thoroughly to ensure good welding conditions for this operation Now the two rails can be positioned and attached to the rear frame with bolts Fit the front roof rail to prevent the side rails from falling inwards whilst the front frame foot mountings are positioned on the sill Mark out and attach these to the sill in the same manner as at the rear Two mounting blocks are provided with tabs to give additional attachment for the side rails These attach to the roof stiffening rail above
80. requires a lead from the ve side of the horn brown white and a return to chassis ground We would suggest making the connection with the ve side of the horn in the region of the horn push where the lead emerges at the top of the steering column and connects to a contact ring rather than breaking into the harness at the lower end of the steering column Again follow the path of and tape to the existing harness for support ELECTRICAL SYSTEM NAVIGATIONAL EQUIPMENT AND RADIO Take two feeds one from each main terminal on the master switch and connect into a fuse box This then gives the option of a permanent live feed for radio or switched feed for instruments AUXILIARY LIGHTING The main supply should be taken directly from the master switch and connected to the power input supply of the relay s To comply with technical vehicle regulations additional driving lights should be switched off when the headlights are on dipped beam Control switching of the relay s must therefore be taken from the main beam circuit and we would suggest taking this supply from the input side of fuse number three The wire will require soldering to this terminal By using double throw switches with on off on sequence they can be fitted such that in the UP position the additional lights are switched on and off by the main beam i e legal and in the DOWN position they would be on at all times regardless Refer to the line diagram showing a t
81. s fitted in five speed form to all GM 1600 cc Family One engined Vauxhall and Opel cars The 1600cc injected Nova and Corsa GTE GSi models were first introduced in the spring of 1988 and received no major revisions to the standard specification until late 1990 when a facelifted version was introduced This model incorporated revised bumpers grille front wings and headlamps coupled with a new interior styling package and was referred to as a GSi in both Nova and Corsa livery Although this manual concentrates on the preparation of vehicle using a Nova Corsa GTE GSi as a base the section concerning bodyshell preparation does include details on the minor differences in bodyshells if preparing a car from another hatchback bodyshell from the range of various cubic capacity Nova Corsa models Vauxhall Nova GSi am E 5 Rm pes The Vauxhall Dealer Sport Nova in Scrutineering E HOMOLOGATION The use of production series cars in international motorsport is governed by a set of rules and regulations laid down in the annual Year Book of Automobile Sport issued by the FIA the governing body and specific vehicles require documents to verify their approval for use and these are issued by the International Motor Sport Federation FISA as the Sporting Ministry of the FIA and are contained in Homologation Papers The 1 6 injected Nova and Corsa models are contained in one document covering bo
82. ssembly Clean off all internal rough edges due to variances in castings to give clearance for the crown wheel The following operations are required within the area normally containing the GEARBOX ASSEMBLIES The reverse gear shaft support housing is already machined to convex profile this must be further modified by grinding to a rounded profile To ensure COMPLETE engagement of the dog teeth in 4th gear the 1st 2nd and 3rd 4th gear selector shaft support housing must be spot faced removing 1 5mm from the entire face of the casting at this point The casting must also be relieved by further radiuses in the corner of this area to give additional clearance between the casing and the selector fork enabling it to butt against this machined face The amount to be removed can easily be determined by inserting the selector fork and shaft into position in the casing as a guide Since the 4th gear wheel is larger than the standard item a considerable amount of material must be removed from the casing at the point where the gear cluster encroaches into the differential housing Approximately 2mm clearance is called for when assembled and this clearance can be viewed through the aperture in differential case when the gearbox cluster is fitted into the casing Modifications to INTERMEDIATE HOUS ING or SANDWICH PLATE The mainshaft bearing housing will foul on the 1st gear wheel unless the casting marks are removed by rounding off the
83. t and the short hollow shaft which slides over the end of it This forms a sliding joint for gearchange adjustment purposes and can be firmly fixed in the desired position using the clamping block BEFORE MARKING OUT where the gearchange assembly is to be attached to the centre tunnel the gearbox should be placed in NEUTRAL gear position the gearchange in NEUTRAL position and the sliding joint provisionally clamped in mid position With the gearchange assembly firmly attached check the availability of the six gears Any final adjustments to the linkage can be made by first slackening the four bolts on the sliding joint clamping block this will then allow the lever to be repositioned 90112325 1 58507 AGORS 438 1 140 4643 54507 DIFFERENTIAL ASSEMBLY 5 507 ACTON TRANSMISSION PARTS LIST SUB GROUP 07 TRANSMISSION 11031269 11075391 90086806 90092175 90105504 90120399 90121287 90121529 90121286 90135901 90135918 90136166 90136230 90278159 0320269 5 507 001 5 507 002 5 507 003 5 507 005 5 507 006 5 507 008 5 507 009 5 507 010 5 507 011 5 507 012 5 507 013 5 507 014 5 507 015 5 507 016 5 507 017 5 507 018 5 507 019 5 507 020 5 507 021 5 507 022 5 507 023 5 507 024 5 507 025 5 507 026 5 507 027 5 507 028 5 507 029 5 507 030 5 507
84. te supplied for this area and should have been fitted during the bodyshell preparations The rear attachment points are not pre drilled in the sumpguard These must be marked out to suit the individual vehicle with the front of the sumpguard correctly attached The holes must then be drilled out to size 12 to 12 5mm for positive location of the sumpguard since this then becomes an integral part of the chassis NOTE The hole positions can easily be marked on to the shield by the following method Remove the head from a 12mm bolt screw this remaining threaded portion into the rear attachment point leaving approximately 5mm of thread above the surface Fit the shield to front attachments and apply pressure to the rear of the shield at each attachment point the threaded section should then clearly mark the shield accurately where the holes should be drilled The lighter gauge rear shield is profiled to fit around the fuel tank area The rear part of the shield attaches to the rear tank mounting points Three holes must be drilled on either side of the shield for bolting through the floor 3M 5 501 NOVA CORSA BODY STRENGTHENING KIT BODY STRENGTHENING Part 5 501 07 11 DESCRIPTION Additional plate kit Heated Bolt kit 5 501 2 N 6mm 5 501 N 10mm Part number Description SUB GROUP 0
85. ter cylinder support bracket should be welded to the centre tunnel behind the handbrake lever Refer to the photograph for exact position The 5 8 master cylinder attaches to this bracket complete with the spacer block The pushrod is then attached to the handbrake lever using the adaptor brackets supplied and they should be welded to the handbrake lever They should be positioned such that when the handbrake lever is in the position the pushrod is FULLY extended from the master cylinder Remember this handbrake is NOT fly off action and should this be required is left to the discretion of the vehicle builder The front brake disc is first attached to an alloy adaptor plate which is then placed over the drive flange The brake caliper can then be fitted over the disc assembly and attached to the knuckle using the high tensile cap headed set screws The front discs are handed and to maximise the brake cooling advantages must be fitted such that air is drawn through the disc from the inside of the disc by the webs in the casting during forward motion of the vehicle The front brake pipes must be connected as shown in the diagrams and photographs However check the installation to ensure that they have sufficient articulation throughout the available suspension travel and wheel lock angles A special alloy bracket is provided to attach the rear brake calipers to the rear suspension beam These brackets fit between the stub a
86. th badged variants The relevant document has been issued with the FISA Number A 5375 and is obtainable from the ASN or National Sporting Authority of the country ir which you are based At all events in which a car is entered within the group A classification the vehicle must have the FISA Homologation Papers The responsibility of obtaining these papers from the ASN is that of the entrant and or driver As a guide a set of specimen homologation papers for the Nova GTE Corsa GSi are included in this manual These papers CANNOT be used as homologation documents at event scrutineering From the specimen set you will see that the first 16 pages refer to the basic specification of the production vehicle The following pages then refer to specific items used in motorsport and unless the item is included within these pages it cannot be used on a vehicle prepared for group A classification You will find that the extension papers i e those pages after the first 16 basic sheets refer to a number of the same items but to different specification or dimensions For the purpose of the Clubmans Kit all items are homologated and are recommended fitment even if there are other similar items homologated It is the case that although say a number of brake disc caliper combinations have been homologated and tried on the Nova Corsa models the actual unit used in the clubmans kit and referred to in the text has been found to the best alternati
87. the ultimate performance These may adversely affect the normal life of standard parts and may thus affect the New Vehicle Warranty This does not mean that the performance car will be unreliable in fact it may be assumed that it will be at least as reliable as other cars of comparable performance Any inclusion of performance parts in the Clubmans Kit or parts described in this booklet does not necessarily mean that the parts comply with the relevant homologation regulations or National Type Approval requirements It is the competitors responsibility to ensure that his vehicle complies with regulations and is eligible for the specific homologation category for which the vehicle is entered CONTENTS GM Introduction Model Availability n Homologation k Preparation Bodyshell Front suspension Power Steering 22 Rear suspension 25 The Braking system 25 Engine 52 Transmission 42 Electrical 39 Group N guidelines Appendix Clubmans Kit contents Homologation papers Philips Car Stere Z 01111 m7 e YPRES Mobi obil i i 4 gt Nova GSi Super Challenge competitors on the Ypres rally INTRODUCTION This manual has been specifically produced in conjunction with the GM Euro Sport package of parts assemblies and components produced by Motor Sport Developments and known as the Clubmans Kits Consequently the text refers exclusively to the preparation
88. this stage the mainshaft bearing can be fitted into its housing in the sandwich plate and secured with the correct circlip For ease of assembly press the other bearing on to the lst motion shaft and loosely position its large retaining circlip behind the bearing in readiness for final assembly This circlip CANNOT be fitted AFTER this shaft and bearing have been pressed into the sandwich plate The sandwich plate must now be supported in a vice with the gearbox side facing towards you Take hold of the two assemblies mainshaft and lst motion shaft and whilst holding the two in mesh simultaneously introduce the shafts to their respective positions through the sandwich plate That is the mainshaft into its bearing the lst motion shaft and bearing into its housing securing the 1st motion shaft with the large circlip behind the bearing Now reposition this assembly in the vice turning it through 180 degrees such that the gear clusters are behind the sandwich plate and facing away from you Place the 181 214 gear selector fork around its hub and press the selector shaft through this fork and into the sandwich plate Ensure that the detent grooves are uppermost and then carefully secure the fork to the shaft with two roll pins The 5th gear selector rod assembly can now be inserted through the sandwich plate and the 3rd 4th gear selector fork placed around its hub Engage 2ND GEAR and push the mainshaft away from you to the ful
89. to 3mm The hole must be enlarged throughout its depth approximately 40mm until it joins with the larger diameter part of the gallery section taking extra care to follow the path of the existing angled hole Make sure that the oil passages do not contain any residual swarf after completion of the modification Follow standard procedures for cylinder head refurbishing The production Nova Corsa 1600 engine features exhaust gas recirculation This is part of the emission control system where regulated quantities of the exhaust gasses are recycled through the inlet tracts under certain throttle E ENGINE opening conditions The take off position for this system can be found on the inlet face of the cylinder head below the inlet ports for cylinders No 2 and 3 This hole must be blanked off using the alloy blanking plug provided The hole in the angled abutment on the camshaft housing camshaft case for the standard breather system should also be blanked off Apply studlock or similar product to give additional retention The photographs show the two finished conditions The standard valves must be retained They can be slightly modified behind the valve head to improve gas flow and the stem heights above the cylinder head face can be adjusted for optimum performance but these operations should only be carried out by suitably qualified personnel AND with close reference to the homologated dimensions Heavy duty valve spr
90. ts from a different source but the alternative seats must have at least the same MINIMUM weight as the original seats This can be achieved by ballasting if necessary Ballast must be securely attached to the replacement seats for both safety and eligibility reasons All the interior trim must be fitted to the car including the rear seats although they may not necessarily function as a seat once the roll cage is installed ROLL CAGE The Group A Clubman Kit safety roll cage can be fitted and holes through the trim panels can be made if necessary to enable this component to be attached The section in this manual specifically outline the fitting procedure for the Group A car but applies equally for a Group N installation A front suspension brace is permitted between the suspension mounting points on condition that it is fixed exclusively by bolts on to the suspension mounting points ELECTRICAL This section of the manual applies equally to Group N preparation Brakes transmission exhaust suspension and engine preparation chapters are exclusively for the Group A car and have no compatibility with the requirements of Group N GM Eurosport do not have any specific components for the Group N car although certain components from the Group A Clubmans Kit can be used These are restricted to the following parts Body Strengthening Kit Fuel tank Guard Strut brace tube Strutbrace brackets LH RH Roll cage assembly Rear beam b
91. ushes Rear road springs Rear shock absorbers Engine mounting rubbers set of 3 re rey Ng H957 EBM Mobil d 2 Dave Metcalfe in the Vauxhall Dealer Sport Nova GSi CLUBMANS KIT AV d po 1 9 MICHELIN er De E raw Lh Se CLUBMANS KIT BUILD LIST THE ASTERIX ON THE RIGHT HAND SIDE OF THE PAGE DENOTES THAT PARTICULAR PART IS NOT INCLUDED IN THE KIT BODYSHELL BUILD LIST 5 501 DESCRIPTION PART NUMBER CAR QTY NOT INCL LOCK TAB SXTO3AW060 2 DAMPER BOT NUT 11041034 2 ROLL CAGE ASSY 5 501 001 1 TOP STRUT MOUNT 5 503 023 2 SUMP GUARD 5 501 002 1 BUSH MOUNT 5 503 024 2 STRUT BRACE TUBE 5 501 004 NUT DAMPER 5 503 025 2 STRUT BRACE BREKT L H 5 501 005 1 LOWER SPRING SEAT 5 503 026 2 STRUT BRACE BRKT 5 501 006 1 UPPER SPRING SEAT 5 503 029 2 BODY STRENGTHENING PLATE KIT 5 501 007 1 LOCK RING FOR SEAT 5 503 030 2 FUEL TANK GUARD 5 501 008 SPRING GRAVEL 5 503 031 2 COOLER MTG BRKT 5 501 009 1 SPRING EUROTAR 5 503 032 2 HAND BRAKE MTG BRKT 5 501 010 SPRING SPANISH TAR 5 503 033 2 SPRING LOW SPANISH TAR 5 503 041 SPHERICAL BEARING SXTO3AWO31 6 FRONT SUSPENSION BUILD LIST 5 503 CIRCLIP 5 9 6 STRUT SEAL 5 503 038 2 DESCRIPTION PART NUMBER CAR QTY
92. ve and has been developed specially for the Clubmans Kit package Therefore it is the only unit that should be fitted GROUP N Although this manual is not primarily concerned with group N preparation you will find that at the end of the specimen homologation sheets there are a number pertaining to group N These are additional sheets which are only required when entering the group N category and are additional to the group A sheets Thus a group N entrant must have both the A and sections of the homologation documents when submitting a vehicle for event scrutiny FIA YEARBOOK This manual should provide all the information and detail required to build a car to group A specification The full details of what exactly is permitted in both the and N categories is published in the FIA Yearbook available from bookshops or direct from Editions V M 116 bd Malesherbes 75017 PARIS France Tel 1 42 27 25 44 Fax 1 47 66 57 74 Interior rear wheel arch 15 above but with reinforcing plate he suspension brace installed Gear linkage access hole BODYSHELL The Bodyshell preparation and strengthening procedures outlined in this manual are fundamental to the success of the finished project They will both extend the competition life of the shell and by increasing its torsional stiffness contribute favourably towards the handling characteristics of the finished vehicle FIA Regulations A
93. wheelarch require special attention Using either a spotweld cutting tool or drill bit carefully cut through ONE THICKNESS of the seam in between each production spotweld and fill hole with weld forming a puddle weld In addition to this operation certain areas require further reinforcement by welding on additional specially profiled mild steel plates These are supplied in the kit their profile following that of the original area and by double skinning give the additional strength required Final positioning will be apparent when the plates are placed against the designated area and should not require further modification prior to welding in place The inner pivot point for the bottom wishbone can be further strengthened by welding a large metal washer onto the forward face The hole through the pivot should then be opened out to 12mm to accommodate the larger diameter bolt The bodyshell also has in excess of 20 drain holes in the floorpan these must be closed off by welding the circular discs supplied over the holes The side lift jacking point can now be fitted Place the strengthening plate against the sill and mark the centre of the hole required This should be 22 5cm rear of the front wing joint on the sill Cut a 35mm hole through outer skin only The inner 35mm hole should be formed with its centre 55mm above the floor panel so that when the tube is introduced it is not parallel to the ground but slopes upwards towards
94. xle and the rear axle beam Fit the wheel bearings and the grease seal into the alloy rear wheel hub supplied and fit the wheel studs Assemble on to the stub axles securing the outer taper roller bearing with its locking washer castle nut and split pin following the normal service procedure at all times for this operation The brake discs and calipers can now be fitted Connect up brake pipes and secure neatly to rear axle beam where required Rear wheel brake assembly Brake pedal box and adjuster Hydraulic handbrake fully mstalled A selection of pads Caliper bracket Alloy hub THE BRAKING SYSTEM E NOTE The brake master cylinder combination supplied will give adequate brake balance compensation for almost every surface condition However should the balance become a problem on events that include a large percentage of extremely tortuous downhill sections on dry tarmac the rear braking can be reduced even further by fitting a 7 8 master cylinder to the REAR brake system BRAKE MATERIAL INFORMATION From our experience we would suggest fitting Ferodo 2459 material for both front and rear brake pads This will give good all round braking performance and satisfactory brake balance control for both tarmac and loose surface conditions There are of course alternatives Ferodo 3466 is a softer material and DS 11 a much harder material Under some operating conditions a harder material on the
95. y match those developed for the Group A Kadett GSi and Astra GTE models This minimises the torque steer effects usually associated with high powered front wheel drive cars and considerably reduces driver fatigue INSTALLATION Before attempting to fit the steering rack assembly the hole in the bulkhead where the steering column enters the engine compartment must be enlarged significantly to accommodate the power steering valve body A template of this hole is provided as a single removable page in the rear of the manual To prevent the possibility of the power assistance ram becoming loose at its attachment points on to the actual steering rack the two bolts must be removed and drilled prior to reassembling and then safety wired The steering rack assembly can now be placed on its mountings but before tightening the securing nuts establish that the rack body sits correctly on the bulkhead mounting positions Tolerances in the body shell may dictate that some metal may have to be removed from the steering rack body to improve this condition The steering rack can now be attached to the bulkhead A body sealing rubber gaiter is provided and fits over the valve body from the inside of the vehicle prior to fitting the column assembly This gaiter will require slight trimming to achieve a satisfactory fit around the valve body prior to attaching it permanently to the bulkhead using adhesive or other means The oil reservoir can be atta
96. ypical auxiliary lights wiring circuit for a works team INSTRUMENTATION The introduction of the face lifted Nova Corsa GSi model range for the 1991 model year also gave the car a completely revised interior trim package including a redesigned dashboard assembly In Group A the standard dashboard must be retained although different instruments may be fitted to it and in a different layout However the trimmings below the dashboard and which are not a part of it may be removed The standard centre console can therefore be removed and replaced by a panel for the mounting of auxiliary components such as the battery master switch fire extinguisher controls and fuses etc As the speedometer is inoperative reference to the tyre section will give the miles kilometres per hour per 1000 RPM in 5th gear so that the rev counter can also be used as a speed indicator AUXILIARY LAMP CIRCUIT 22 AWG or 0 5mm2 INPUT SIDE OF FUSE 3 DOUBLE THROW SWITCH ON OFF ON 20 30 AMP RELAY 10 AMP FUSES 22 AWG or 0 5 LAMPS IN PAIRS UP TO 100W LAMP EARTH SUB GROUP 12 ELECTRICAL EQUIPMENT 2539604 2875025 3440489 3466309 5973881 5973882 7838194 7976636 7976636 9281299 9281299 9285485 9287542 11040051 11042153 11054192 11072781 11072781 11079701 12015845 19808425 22031055 22084016 25061216 25061898 25061900 25061902 25061903 25061896 25065331 90016767 9

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