Westfield XTR2 Construction Manual Download Page 25

Page: 25 / 159

3.4

Step 1: Cont’d,

Lubricate Bush With Copper

Slip BEFORE Installation

M8 x 45mm Bolt and Nyloc Nut.

DO NOT OVERTIGHTEN NUT

Ensure Quadrant Moves Freely
Do NOT Fit Pedal Push Rod At This Stage

Do NOT Fit Clutch Push Rod At This Stage

Quadrant Installation

Clutch Cylinder

Fit Spacers Either Side Of Cylinder
& Secure With M6 Bolts x 45 Long
& Nyloc Nuts

Clutch Cylinder Assembly / Installation

Clutch Cylinder Rod End Assembly

Clutch Switch Activation Plate

M6 Washer

M6 Plain Nut

Rod End

Pedal Stop Tubes – 2 Off Each Fixed

With M6 Bolt x 45 Long & Nyloc Nut

M6 Bolt x 25 Long & Nyloc Nut

Summary of Contents for XTR2

Page 1: ...Westfield Sports Cars Limited Unit One Gibbons Industrial Park Dudley Road Kingswinford West Midlands DY6 8XF 44 0 1384 400077 ...

Page 2: ...hts reserved Apart from any fair dealing for the purposes of private study research criticism or review as permitted under the Copyright Design and Patents Act 1988 no part of this publication may be reproduced stored in a retrieval system or transmitted in any form or by means electronic electrical chemical optical photocopying recording or otherwise without prior written permission All enquiries...

Page 3: ...1 1 Section 1 ...

Page 4: ...1 2 ...

Page 5: ...nd to rest on its laurels We are constantly improving our cars developing many options and additions with which to further the desirability of our product At WESTFIELD SPORTS CARS we believe that much of the enjoyment of the car should be in its actual construction this is why this CONSTRUCTION MANUAL has been produced The whole point of building a WESTFIELD is to realise a vehicle that will suit ...

Page 6: ...iring Loom 5 Pedals Brackets 6 Steering 7 Fuel Tank 8 Gear Change Lever Bracket 9 Hand Brake Lever Cable 10 Gear Lever Linkage 11 Front Suspension 12 Track Rods Front Brake Hoses 13 Rear Differential Sprocket 14 Anti Roll Bar Assembly 15 Rear Suspension 16 Fuel System 17 Dry Sump Tank Catch Tank 18 Dry Sump Kit 19 Engine Fitting Installation 20 Reverse Mechanism Linkage 21 Bodywork 22 Exhaust Inst...

Page 7: ...s that are Designed Specifically for the Purpose and are available from the Factory 4 DO NOT use Bricks Building Blocks or Wooden Packing Cases Bricks and building blocks are NOT suitable as they are liable to topple Wooden Packing Cases are NOT suitable as they are liable to Crush as the Weight of the Car increases during the Build Process 5 DO NOT Connect the Battery TVE Lead until the Wiring Lo...

Page 8: ...ich allow the various parts to be fitted IMPORTANT DO NOT ATTEMPT to MODIFY ANY of he items supplied without specific reference to the TECHNICAL HELPLINE at the FACTORY STORAGE OF BODYWORK The Bodywork MUST NOT be Stored in Plastic Sheet in Damp or Humid Conditions DO NOT Store Bodywork in Direct Sunlight in Greenhouses or Conservatories WESTFIELD SPORTS CARS WILL NOT accept any WARRANTY CLAIM for...

Page 9: ...at May Have Been Left In The Top Wishbone Threads 12 Hole Cutter 1 Diameter Steering Column 13 Hole Cutter 1 Diameter 45mm Loom 14 Hole Cutter 2 Diameter Gear Stick 15 Pop Rivet Gun 16 Brake Pipe Bending Tool 17 Rivnut Fixing Kit 18 Electric Drill 19 12 Hacksaw 20 Engineering Hammer 21 Centre Punch 22 Hide Hammer 23 Two G Clamps 24 Bench Vice Machine Type 25 Flat Blade Screwdrivers 1 Set 26 Philli...

Page 10: ...Plug Caps Regulator Rectifier Unit Fuel Pump Relay Dash Complete For Fault Finding Photo Copy Of Donor Log Book If Available IMPORTANT NOTES Never purchase engines with any damage to casings or without IDENTITY NUMBERS Establish if the safety recall has been completed on Timing Chain Tension Adjuster Suzuki Warranty If this has been done there will be a RECALL COMPLETION LABEL attached under the p...

Page 11: ...ounting Bolts 20 27 Steering Column Shaft Couplings 20 27 Steering Column Securing Clamp 28 38 Front Brake Caliper Mounting Bolts Steel 40 54 Shock Absorber to Chassis Mounting Bolts 30 40 Handbrake Mounting Bolts 22 30 Seat Belt Mounting Bolts 26 35 Steering Wheel Nut 35 47 Wheel Nuts Rimstock 65 90 Differential Unit Bolts to Chassis SEi 30 40 Rear Brake Caliper Mounting Bolts SEi 35 47 Drive Sha...

Page 12: ... Thread Locking Adhesive to threads when fitting Denotes MAXIMUM Torque Setting Suspension Bolt Tightening Notes i It is IMPORTANT to REMEMBER that ALL suspension bolts and Nyloc Nuts will be Torque tightened during the Set Up stage WESTFIELD SPORTS CARS STRONGLY RECOMMEND that during the assembly of the suspension that ALL suspension bolts and Nyloc Nuts are NIPPED ONLY and NOT Torque tightened ...

Page 13: ...d and has a plain upper section whereas a Setscrew is threaded along its whole length ii The Length of a BOLT or a SETSCREW is measured from the underside of the head refer to Diagrams above iii The Diameter of a BOLT is measured across the plain non threaded section iv The Diameter of a SETSCREW is measured across the top of the threads 30m 35m 40m 45m 50m 55m 60m 60mm Measure length from below h...

Page 14: ...1 12 ...

Page 15: ...2 1 Section 2 ...

Page 16: ...2 2 ...

Page 17: ... nuts bolts or moving parts To comply with SVA Regulations all pipes MUST be secured with clips spaced at a Maximum Distance of 300mm apart Tools Required Electric Drill 3 5 or 9 64 Dia Drill Bit Pop Rivet Gun Pipe Bending Tool 2 x 10mm Spanners 11mm Spanner 13mm Spanner 17mm Spanner Parts Required 1 x Brake Pipe Kit See Page 5 For List Of Pipes Supplied 2 x Brake Master Cylinders P Clips Pop Rive...

Page 18: ...ylinder Rear Brake Cylinder Copper Washer This Brake Line MUST Run Along the Side Edge of the Chassis Rail As Shown NOT Along the Top of the Chassis Rail 3 Way Brake Pipe Connector Drill Out Mounting Hole To Fit Onto M8 Bolt x 50 Long Prior To Installation 3 x M8 Bolts x 25 Long Plus 1x50 Long Bolt For Switch Mounting Insert Bolts From Inside Pedal Box Secure With Nyloc Nuts ...

Page 19: ...ew From Drivers Side Mid Section Of Chassis View From Drivers Side Engine Bay Area Of Chassis View From Rear Of Car Rear Section Of Chassis Oil Catch Tank Rear Brake Pipe Coupler Rear Brake Line Rear Brake Line 3 Way Brake Pipe Connector Rear Brake Line ...

Page 20: ... Way Connector 3 Way Brake Pipe Connector View From Front Step 4 Fit Front Drivers Side Brake Line View From Front Front Brake Line Drivers Side Step 5 Fit Front Passenger Side Brake Line View From Front Front Brake Line Passenger Side ...

Page 21: ...ar Brake Pipe Coupler To Rear T Piece 2312022 4 2 Brake Pipe 470 Front T Piece To Front Brakes 2312030 5 1 Brake Pipe 320 Rear T Piece To Rear Brake 2312052 6 1 Brake Pipe 250 Rear T Piece To Rear Brake 2312061 7 1 Brake Pipe 200 Rear Brake Cylinder To Brake Switch 2312070 8 1 Brake Pipe 2150 Brake Switch To Rear Brake Pipe Coupler 2312083 Note The Silver Fittings On Items 1 7 Are 5 16 UNF Fitting...

Page 22: ...3 1 Section 3 ...

Page 23: ...3 2 ...

Page 24: ...olts or moving parts Tools Required Electric Drill 3 5 or 9 64 Dia Drill Bit Pop Rivet Gun Pipe Bending Tool 2 x 10mm Spanners 11mm Spanner 13mm Spanner Parts Required 1 x Clutch Pipe See Page 5 Of Section 2 For Details Of Pipe Supplied 1 x Clutch Master Cylinder Kit Complete Step 1 Clutch Master Cylinder Assembly Clutch Switch Striker Plate Clutch Line Clutch Master Cylinder View From Passenger S...

Page 25: ...age Do NOT Fit Clutch Push Rod At This Stage Quadrant Installation Clutch Cylinder Fit Spacers Either Side Of Cylinder Secure With M6 Bolts x 45 Long Nyloc Nuts Clutch Cylinder Assembly Installation Clutch Cylinder Rod End Assembly Clutch Switch Activation Plate M6 Washer M6 Plain Nut Rod End Pedal Stop Tubes 2 Off Each Fixed With M6 Bolt x 45 Long Nyloc Nut M6 Bolt x 25 Long Nyloc Nut ...

Page 26: ...ch Line View From Front Of Car View From Passenger Side Front Section Of Chassis Clutch Line Clutch Line Clutch Line Clutch Line Must Be Fitted To The Edge Of The Tube as Shown And Not Along The Top Face 5 16 Rod End M6 Bolt x 30 Long M6 Nyloc Nut Pedal Push Rod ...

Page 27: ...f Car Clutch Reservoir Clutch Cylinder M6 Button Head Screw x 16 Long Nyloc Nut Rivet Bracket To Body Work After Final Body Fitting Leave Reservoir Loose For Now Clutch Line End Connector Clutch Line This Clutch Line MUST Run Along the Side Edge of the Chassis Rail As Shown NOT Along the Top of the Chassis Rail ...

Page 28: ...4 1 Section 4 ...

Page 29: ...4 2 ...

Page 30: ... Required Westfield Chassis Loom Loom Saddles 4 1mm Dia x 10mm Long Closed Pop Rivets Cable Ties 4 x M5 x 25mm Button Head Screws 4 x M5 Nyloc Nuts 4 x M5 Plain Washers 4 x Aluminum Spacers 1 Foam Tape Step 1 Fuse Box Mounting Plate View From Passenger Side Step 2 Loom Mounting Side Panels 4 Fuse Box Mounting Lugs Welded To The Top Frame Chassis Rails i Position Panels As Shown ii Trim Panels to F...

Page 31: ...ew From Passenger Side View From Passenger Side Mid Section Of Chassis Front Section Top Frame Of Chassis View From Drivers Side View From Passenger Side Mid Section Of Chassis Engine Bay Area Of Chassis ECU Mounting Plate Loom Saddles 3 Places Rivet Through Saddles Panel Into Chassis Rail 4 On Underside Of Top Rail Main Earth Lead Connection Point M6 Stud on Chassis 1 On Rear Of Side Rail ...

Page 32: ...g Light Horn Nose Loom Main Earth Lead Main Loom Battery ve supply Connects To Master Switch Earth For Resistor Circuit On Master Switch Auxiliary Plug Dash Loom Connectors Primary Fuel Pump Earth To High Pressure Fuel Pump Engine Loom Off Side Rear Light Cluster Fog Light Number Plate Light Near Side Rear Light Cluster Cooling Fan Motor Cooling Fan Switch Fuel Tank Sender ...

Page 33: ...Mounting Plate Under Scuttle Panel Fuse Box On Underside Of Brackets Main Battery Power Cables Run The 2 Red Main Battery Cables Supplied Along The Chassis With The Wiring Loom Wiring Loom Main Earth Lead View From Passenger Side Mid Section Of Chassis Main Positive Battery Lead Reverse Solenoid Positive Lead for Reverse Solenoid View From Passenger Side Engine Bay Area Of Chassis ...

Page 34: ...nt d Rear Of ECU Mounting Plate View From Rear Of Car Rear Section Of Chassis Rear Of ECU Mounting Plate View From Underside Drivers Side Of Car Rear Section Of Chassis View From Rear Of Car Rear Section Of Chassis ...

Page 35: ...ection Of Chassis View From Underside Of Switch Switch Removed From Chassis For Clarity Main Red Lead From Battery ve Master Switch Earth From Main Loom Main Red Lead To Reverse Gear Solenoid To Resistor Brown Wire From Main Loom Main Loom Power Feed To Resistor Resistor To Ignition Supply On Dashboard Loom NOTE THE MASTER SWITCH MUST BE WIRED AS SHOWN See Instructions Sheet In Master Switch Pack ...

Page 36: ...e labelled before removing them Label fuse boxes and connectors either 1 24 or A X to avoid confusion Place fuse boxes in required location with the fuses facing into the car using M6 x 16 button head screws and nuts View From Passenger Side Top Frame Section Of Chassis 4 9 Fixing Details Drill 4 Holes Through Battery Tray Floor Panel Run A Bead Of Silicone All Around The Bottom Of The Tray Fix Tr...

Page 37: ...Step 9 Main Power Cables In Engine Bay 4 10 Reverse Motor Starter Relay Reverse Solonoid ...

Page 38: ...HANDBRAKE SWITCH WIRES GREY BLACK ORIENTATION UNIMPORTANT NOSE LOOM 11 WIRE CONNECTOR BLOCK VARIOUS PRE WIRED HORN 2 FEMALE SPADE CONNECTORS BLACK BLACK TO ONE CONNECTOR PURPLE BLACK TO OTHER CONNECTOR ORIENTATION UNIMPORTANT NEAR SIDE INDICATOR CONNECTOR BLOCK BLACK GREEN RED PRE WIRED FUSE BOX 2 FUSE HOLDER BLOCKS VARIOUS PRE WIRED BUT TO BE LABELLED REMOVED REFITTED BY CUSTOMER AUAILIARY PLUG 4...

Page 39: ...EN WHITE BLACK WHITE RED PRE WIRED REVERSE SOLONOID 2 FEMALE SPADE CONNECTORS ORANGE BLACK GREEN TO SPADE TERMINALS ON SOLONOID ORIENTATION UNIMPORTANT LOOM REAR SECTION OFFSIDE REAR LIGHT CLUSTER 3 TERMINAL CONNECTOR BLOCK 2 TERMINAL CONNECTOR BLOCK BLACK 1 PAIR GREEN PURPLE RED ORANGE BLACK GREEN WHITE BRAKE SIDE LIGHT INDICATOR DRIVER SIDE NEAR SIDE REAR LIGHT CLUSTER 3 TERMINAL CONNECTOR BLOCK...

Page 40: ...meter Horn Off Side Indicator Main Loom Driver Off Side Of Car Passenger Near Side Of Car Ignition Feed Connect To Master Switch Black Wires Reverse Switch Indicator Timer Unit Separate From Loom Ignition Feed Connect To Immobiliser Switch Handbrake Warning Lamp Dashboard Sub Loom Connectors Hazard Warning Switch Relays 4 Off 4 13 ...

Page 41: ...4 14 Dashboard Wiring Loom Fitted to Chassis Relays Mounted Under Dashboard Chassis Rail Dashboard Loom Runs along Top of Chassis Rail ...

Page 42: ...ER 3 WAY BLACK CONNECTOR BLOCK GREEN 1 PAIR BLACK 1 PAIR WHITE BLACK PRE WIRED AUXILLARY 2 WAY BLACK CONNECTOR BLOCK BLACK 1 PAIR GREEN 1 PAIR PRE WIRED REVERSE SWITCH 2 FEMALE SPADE CONNECTORS ORANGE ORANGE BLACK PRE WIRED HORN 2 FEMALE SPADE CONNECTORS PURPLE PURPLE BLACK PRE WIRED OFF SIDE INDICATOR CONNECTOR BLOCK BLACK GREEN WHITE PRE WIRED INDICATOR TIMER UNIT PRE WIRED PLUG VARIOUS TIMER UN...

Page 43: ...4 15 ...

Page 44: ...s Step 11 ECU Mounting View From Passenger Side Engine Bay Area Of Chassis NOTE The Engine Loom Supplied MUST Be returned to Westfield Sports Cars For Modification Rectifier Unit Rectifier Cable Rear Of ECU Mounting Plate Main Loom Engine Loom See Note Below Front OF ECU Mounting Plate ECU Unit Starter Motor Relay ...

Page 45: ...Beam INNER LIGHT Black Common Earth Red Orange Sidelight Black Earth Green Red Indicator Black Earth RIGHT HAND CLUSTER Blue Pink Dipped Beam OUTER LIGHT Blue Slate Main Beam INNER LIGHT Black Common Earth Red Black Sidelight Black Earth Green White Indicator Black Earth There are some plastic clips on the inside of the Nose Bodywork section for you to fasten the front loom up away from the wheels...

Page 46: ...5 1 Section 5 ...

Page 47: ...5 2 ...

Page 48: ...1 x Spacer Zinc Plated 25mm Long 10 x M6 Button Head Screws x 16mm Long Washers Nyloc Nuts 2 x M6 Hexagon Head Setscrew x 20mm Long Plain Lock Nut 3 x 5 16 UNF Bolts X 1 1 2 Long Lock Nuts 2 x M5 Button Head Screws x 16mm Long Washers Nyloc Nuts Step 1 Fit Pedal Mounting Brackets View From Above Pedal Box iv Secure The Brackets To The Floor Using The Screws Supplied The Screws MUST Be Inserted Fro...

Page 49: ...ate The Steel Spacer Bushes with Copper Slip Before Inserting Into The Assembly You MUST Ensure All Pedals Move Freely After Tightening The Nyloc Nuts Cut Head Off 2x5 16 UNF Bolts Fit 2 Lock Nuts Brake Pedal Push Rods Lock Nut Rubber Gaitors Brake Pedal NOTE Clutch Pedal Push Rod Clevis Pin And Split Pin Clevis Fixed with 5 16 Bolt and Lock Nut The Brake Pedal Is Shown With An Adjustable Bias Bar...

Page 50: ...Cable M5 Button Head Screws Bracket M5 Button Head Screw Apply Loctite To Thread Before Fitting Do Not Tighten Down Completely Ensure The Cable Clevis Rotates Freely Cut Off One Leg Of Clevis To Form Angle Bracket As Shown View From Drivers Seat Area Throttle Cable Bracket Lock Nut Either Side Of Bracket ...

Page 51: ...6 1 Section 6 ...

Page 52: ...6 2 ...

Page 53: ...re Steering Column 1 x Steering Column Mounting Bracket 6 x M8 Bolts x 80mm Long Washers Nyloc Nuts 2 x M8 Cap Head Bolts x 35mm Long Nyloc Nuts Step 1 Install Steering Rack View From Front Of Car Bare Chassis Shown For Clarity Pedal Box Steering Rack Mounting Holes Front Of Car Steering Rack Rack Clamp Blocks M8 Bolts x 80mm Long Drill Through The Pedal Front Using The Steering Rack Mounting Hole...

Page 54: ...eat Upper Steering Column Column Mounting Bracket M8 Bolts x 80mm Long At Front Rear of Bracket Install Rack With Pinion Shaft Facing Up Towards The Passenger Seat Front Of Car Steering Rack Approximately As Shown NOTE Do NOT Fully Tighten The Clamp Bolts At This Stage Washer Nyloc Nut Washer ...

Page 55: ...ion Upper Connection Main Steering Column Steering Rack Pinch Bolt Main Steering Column Upper Steering Column Pinch Bolt NOTE Ensure That The Steering Column Rotates Freely BEFORE Tightening Up The Pinch Bolts And The Steering Column Mounting Block Bolts ...

Page 56: ...sing Gently tap tin cover plate through the 5 8 diameter hole to push out the second bearing blanking plate and shim washer Finally remove bearing from Pinion Re Assembly Place the Shim into the knurled housing followed by a bearing Replace the knurled housing back into the Rack Casing Slide the Rack back through the Housing Place the Pinion into the knurled housing splines end first and push thro...

Page 57: ...7 1 Section 7 ...

Page 58: ...7 2 ...

Page 59: ...h The Fuel Tank Up With The Hole In The Seat Back Panel To Ensure The Handbrake Cable And The Gear Change Rod Will Pass Through iv Line The Back Of The Tank Straps With Adhesive Backed Foam Strip And Position Onto The Tank In The Required Location v Mark The Strap Hole Positions In The Seat Back Panel And The Floor Panel For Both Straps Remove The Straps And Drill Through The Panels Where Marked v...

Page 60: ...8 1 Section 8 ...

Page 61: ...2 2 ...

Page 62: ...Westfield Gear lever Bracket 3 2mm Pop Rivets Place the Gear Lever Bracket onto the Top of the Tunnel as shown so that the Angle matches the Tunnel Top Step 1 Bracket Installation Drill All Of The 3 2mm Holes Through The Lever Plate Side And Then Rivet To The Tunnel Repeat For Both Sides Of Bracket View From Drivers Side Of Car ...

Page 63: ...9 1 Section 9 ...

Page 64: ...9 2 ...

Page 65: ...ng Nyloc Nuts Large Diameter Washers Step 1 Drill Through Seat Back Panel 28mm Drill 25mm Diameter Hole Through Seat Back Panel NOTE 70mm Be Careful Not To Hit Fuel Tank At Rear Of Panel View Of Drivers Side Seat Back Panel Tunnel Step 2 Assemble The Handbrake Lever Rod Handbrake Lever Side Plates Handbrake Rod Split Pin M8 Washers 3 Off Clevis Pin View From Underside of Assembly NOTE The Arrangem...

Page 66: ...OTE Fit Lever Rod Assembly So That The Rod Goes Through The 25mm Diameter Hole In The Seat Back Panel The Lever Sits On The M8 Studs M8 Stud Mounting Points Handbrake Lever Mounting Plate Front Of Car M8 Nyloc Nuts Fitted To Handbrake Lever Mounting Studs Spacer Handbrake Lever Mounting Plate Handbrake Lever Spacer Centre Tunnel Mounting Bracket Drivers Seat Area ...

Page 67: ...rake Mounting Plates Gearchange Rod Fuel Tank Handbrake Cable NOTE Rear Of Car i Once Cable Brackets Are In The Correct Position Mark The Mounting Plate Hole Positions Onto The Chassis Floor Remove Plates Cable ii Drill Through The Floor Fit Mounting Plates Using M5 Button Head Screws Ensure That Large Diameter Washers Are Fitted Underneath The Floor Panel And Secure Each Screw With A Nyloc Nut Ha...

Page 68: ...10 1 Section 10 ...

Page 69: ...10 2 ...

Page 70: ...he Plain Nuts into the end of the Long Aluminium Gearchange Rod fix one end to the Centre Position of the Gear Lever with a M6 x 25 Hex Bolt and Nyloc Nut Place the Inner Bush into the Pre Fitted DU Bushes in the Gear Lever Carefully Slide the Rod down through the Tunnel towards the Rear of the Car until the Lever is in its Operating Position View From Passenger Side Step 1 Installing The Gear Cha...

Page 71: ...olt x 50 Long Ensure Bolt Head Is This Side To Clear Handbrake Lever View From Rear Of Car NOTE The rest of the Linkage Cannot be fitted until the Engine is Installed Adjustment of the Rod Ends will be made after final installation ...

Page 72: ...11 1 Section 11 ...

Page 73: ...11 2 ...

Page 74: ...ront Upright Corners NOTE All Wishbones Will Be Pre assembled With Nylon Bushes Step 1 Lower Front Wishbones Bolt Lower Front Wishbone into chassis mountings as shown Repeat both sides of Car View From Drivers Side 2 Bolts 7 16 UNF x 2 Long with Washers and Nyloc Nuts Step 2 Top Front Wishbones Bolt the Top Front Wishbone into the chassis mountings as shown Ensure the Wishbone is installed with th...

Page 75: ... Mounting Blocks are supplied Bolted into the Top and Bottom of each Front Upright Remove the Blocks from the Upright then Fix them to the Tapered Bolt on the Top and Bottom Ball Joints using the special Nuts provided with the Ball Joints Note All the tapers are the same so you can use any block on any joint View From Front Of Car Passenger Side Mounting Blocks Important The Top and Bottom Ball Jo...

Page 76: ...ar Place the Upright onto the Lower Block and Assemble using Two Cap Screws Lower the Top Block into the Upright and Repeat the Assembly Procedure NOTE Do Not tighten the Top Cap Screws Fully at this Stage as the Set Up of the Car is Adjusted on this Joint M8 Cap Screws x 60 Long Top Ball Joint M8 Washers Nyloc Nuts Steering arm Bottom Ball Joint M8 Cap Screws x 60 Long M8 Washers Nyloc Nuts View ...

Page 77: ...12 1 Section 12 ...

Page 78: ...12 2 ...

Page 79: ...ds 3 8 UNF x 5 16 Hole 2 x 3 8 UNF Lock Nuts 2 x M8 Setscrews x 45mm Long 2 x M8 Nyloc Nuts 4 x M8 Washers 4 x 6mm Long Spacers 2 x Front Brake Hoses Step 1 Install Track Rod Track Rod View From Passenger Side Of Car View From Front Of Car 2 off Steel spacers x 6mm Long M8 Nyloc Nut Washers 3 8 UNF Locknut Passenger Side Upright M8 Setscrew x 45mm Long ...

Page 80: ...f Car Repeat Procedure For Other Side Of Car Step 2 Install Front Brake Hoses View From Rear Of Passenger Side Of Car NOTE Ensure The Brake Hose Is Finally Adjusted To Clear The Shock Absorber And Spring When The Steering Is Rotated From Lock To Lock Must Clear To Pass SVA Brake Hose ...

Page 81: ...13 1 Section 13 ...

Page 82: ...13 2 ...

Page 83: ...screws 12 x M10 Nyloc Nuts 2 x M10 Socket Cap Screw x 100mm Long 4 x M10 Lock Nuts Step 1 Assemble Differential Unit Slide Bearing Carriers Onto Differential As Shown Step 2 Install Differential Unit Fit Differential Into Chassis And Fix Into Place Using The Lower Mounting Points To Begin With 50 View From Rear Of Car Differential Unit NOTE There Are Two Grub Screws In The End Of Each Bearing DO N...

Page 84: ... Carrier M10 Bolt x 55mm Long With Washers Under Head M10 Socket Cap Screw x 100mm Long With Washers Lock Nuts Quadrant Plate Fit Washer Nyloc Nut On Other Side Of Quadrant Plate To Secure Bolt View From Passenger Side M10 Socket Cap Screw x 100mm Long Differential and Chain Adjustment Bolt Bearing Carrier View From Rear Of Car ...

Page 85: ...ain Fitted Are Lined Up Correctly The 4 Grub Screws In The Two Main Differential Bearing Carriers Need To Be Locked Up Tightly Use M10 x 30 Bolts and Nyloc Nuts Provided NOTE On the Internal Diameter of The Sprocket on One Side Only There Is A Chamfer This Must Go up To The Flange Face On The Diff ...

Page 86: ...14 1 Section 14 ...

Page 87: ...14 2 ...

Page 88: ...16 x Rod End Bushes 4 x M6 Bolts x 55mm Long 12 x M6 Bolts x 40mm Long 2 x M6 Bolts x 35mm Long 30 x M6 Washers 20 x M6 Nyloc Nuts 2 X 7 16 UNF Bolt X 2 Long 2 x 7 16 Washers Nyloc Nuts Step 1 Fit Front Anti Roll Bar View From Passenger Side Step 2 Assemble Front Drop Links Assemble 1 Pair For Front Front Of Car Mounting Blocks M6 Bolts x 55mm Long Washer Nyloc Nut Front Anti Roll Bar Upper Clevis...

Page 89: ...age Step 5 Assemble Rear Anti Roll Bar Mounting Bracket To Blocks And Bar Note The Rear Anti Roll Bar Assembly Can Be Completed On or Off The Car However the Anti Roll Bar Itself Cannot Be Fitted To The Car Until The Rear Upper Wishbones Have Been Installed As Shown In Section 15 Step 2 View Showing Fitting Of Roll Bar After Rear Upper Wishbone Has Been Installed Fit 2 x M6 Bolts x 40mm Long Throu...

Page 90: ...Through Upper Clevis Block Ensure That The Lower Bolt Passes Through The Upper Clevis Block The Shouldered Rod End Bushes and The Rod End Before Being Secured with A Washer and A Nyloc Nut Rear Drop Link Lower Wishbone Mounting Bracket NOTE DO NOT fit the Lower Bolt Into the Lower Wishbone Mounting Bracket At This Stage The Picture Above is to show where the Lower Bolt Will Fit Later DO NOT fully ...

Page 91: ...15 1 Section 15 ...

Page 92: ...15 2 ...

Page 93: ...16 UNF x 3 Long Bolts 4 x Reducing Sleeves For Rod Ends 4 x 7 16 Repair Washers NOTE All Wishbones Will Be Pre assembled With Nylon Bushes Bolt Lower Rear Wishbone into Chassis Mountings as shown Repeat Both Sides of Car Step 1 Lower Rear Wishbones 2 Bolts 7 16 UNF x 2 Long with Washers Under Head and Nyloc Nuts View From Drivers Side Step 2 Top Rear Wishbones Bolt the Top Rear Wishbone into the c...

Page 94: ...evis Block Assembly Anti Roll Bar Top Wishbone View From Rear Step 3 Fit Rod Ends UNF Lock Nut Upper Rod End And Sleeve NOTE For a start point set the Rod Ends with about 5mm of thread exposed Lower Rod End And Sleeve View From Drivers Side Rear Of Car UNF Lock Nut ...

Page 95: ...tep 5 Fit Upright Upper Fixing View From Above From Rear Of Car NOTE Do Not Fully Tighten the Top and Bottom Nyloc Nuts that secure the Rod Ends at this Stage as the Set Up of the Car is Adjusted on these Joints Lower Rod End 7 16 UNF x 3 Long Bolt Rear Of Car 7 16 Plain Washers x 3 Includes 1 Under Head Of 7 16 UNF x 3 Long Bolt 7 16 Repair Washer 7 16 Plain Washers 7 16 Nyloc Nuts 7 16 UNF x 2 L...

Page 96: ...r Brake Hose Rear Brake Caliper NOTE Ensure The Brake Hose Is Finally Adjusted To Clear Any Moving Parts Must Clear To Pass SVA Bleed Valve Hose Copper Washer Hole In ECU Mounting Plate Cable Tie To Wishbone Arm Handbrake Cable Connect Cable Ends To Lever On Calipers View From Rear Of Car ...

Page 97: ...16 1 Section 16 ...

Page 98: ...16 2 ...

Page 99: ...x 40mm Long 4 x M6 Washers 4 x M6 Nyloc Nuts 3 2mm Rivets Step 1 Swirl Pot Installation Place the Swirl Pot approximately in the position shown below Mark the Fixing Hole Centres and Drill through the seat back panel with a 6 5mm Drill Step 2 Main Fuel Pump Installation Position Bracket As Shown Mark Hole Centres Drill Through Floor Plate Using 3 2mm Drill Bit Rivet Bracket To Floor Secure Pump Wi...

Page 100: ...ket View From Inside Engine Bay Earth Lead Orange Secure Under Fixing Nut Power Lead Black Green Wire On Main Loom Fuel Tank Jubilee Clip Fuel Filter Fuel Filter Bracket Front Of Car Facet Fuel Pump Aluminium Chassis Bracket Rubber Mountings NOTE The Rubber Mountings MUST Be Fitted Between The Pump Bracket And The Aluminium Bracket Power Lead Black Earth Lead Orange Secure Under Fixing Nut Front O...

Page 101: ...cet Fuel Pump Again Secure with Jubilee Clips Fuel Pressure Regulator Top Engine Frame M6 Bolts x 40mm Long with Nyloc Nuts NOTE The Regulator Should Only Be Fitted After The Frame Has Been Bolted To The Engine and Installed In The Car Fuel Filter 8mm 5 16 Fuel Pipe Fit 2 x P Clips In Positions Shown And Rivet To Floor Plate NOTE Ensure Pipe Is Tight Up Against The Fuel Tank Floor To Clear The Han...

Page 102: ...l Tank Return 3 After Engine Fitting 8mm 5 16 Swirl Pot Fuel Pressure Regulator 4 8mm 5 16 Fuel Pressure Regulator Engine Injector Rail 5 8mm 5 16 Fuel Filter Engine Injector Rail 6 NOTE Return This Pipe To Westfields For Modification FACET FUEL PUMP MAIN FUEL PUMP FUEL FILTER FUEL TANK SWIRL POT FUEL PRESSURE REGULATOR 1 1 5 2 2 3 4 4 6 6 ENGINE INJECTOR RAIL 6 6 See Photos On Previous Pages For ...

Page 103: ...17 1 Section 17 ...

Page 104: ...17 2 ...

Page 105: ... the Floor Panel as shown and mark the position of the two fixing holes onto the Panel View From Drivers Side Of Car View From Inside Engine Bay Fit Spacer Between Tank And Floor Panel In 2 Places Secure The Tank With M6 Bolts x 35mm Long Fit Washers Under Heads Nyloc Nuts Dry Sump Tank Bracket Drill Through Bracket And Into Chassis Rail Fit 2 x Rivserts Into Chassis Rail Secure Bracket To Chassis...

Page 106: ...o Locate The Tank On The Bottom Of The Tank There Is A Drain Plug With A Protection Tube Around It The Tank Must Be Positioned So The Drain Point Tube Protrudes Through The Floor Panel Until The Bottom Of The Tank Sits On The Floor Drill a 40 Dia Hole In The Floor Panel To Clear The Tube View From Rear Of Car ...

Page 107: ...18 1 Section 18 ...

Page 108: ...18 2 ...

Page 109: ...MP KIT BEFORE Fitting The Pump Bracket To The Engine 1 Fit The Mounting Straps Into The Bracket Holes 2 Remove One Crank Case Bolt As Shown Below Item 5 Drive Pulley Assembled And Secured With M10 Socket Cap Screw Starter Motor Drive Cover Starter Clutch Cover Starter Clutch Cover Plug Location Replaced With Item 8 Seal Housing Item 7 Seal Pump Bracket Item 14 Pump Mounting Strap Item 39 Pump Moun...

Page 110: ...tem 1 M6 Washers Nyloc Nuts Scavenge Pipe Item 56 Oil Return Union Item 19 Re Fit Crank Case Bolt To Secure Tail End Of Bracket Use 2 Bolts From Starter Clutch Cover For Securing The Front End Of The Bracket Use Cap Head Bolt Item 13 To Secure Top Of Bracket Position Lever Bar As Shown To Hold The Nut At The Rear Of The Bracket This Will Assist With The Tightening Of The Bolt Lever Bar ...

Page 111: ...ck Up Pipe REMOVE DISCARD Oil Return Pipe Remove Shorten To Suit Drawing O Ring MUST BE Re Fitted Scavenge Pipe Item 55 Dry Sump Pan Sump Plug Tighten Scavenge Pipe Item 57 Scavenge Pipe Item 56 Scavenge Pipe Item 31 Oil Feed Pipe Item 53 Overflow Hose ...

Page 112: ...19 1 Section 19 ...

Page 113: ...19 2 ...

Page 114: ...er Trumpets Air Temperature Sensor Plastic Elbow Air Filter Exhaust Manifold Note It is easier to fit the Exhaust Manifold at this stage before the engine is fitted into the Chassis For instruction see Section 22 Step 1 Fit Clutch Slave Cylinder Secure Bracket To Clucth Cylinder With 2 M8 Setscrews x 20mm Long Spring Washers Secure Bracket To Engine With 1 M6 Setscrews x 35mm Long Spring Washer Cl...

Page 115: ...ngine if they have not been removed already Carefully clean the mounting surface on the Engine and fit the 8 Exhaust Manifold Mounting Studs supplied by Westfield Step 4 Oil Pressure Adaptor Dry Sump Pump Drive Pulley Oil Pressure Adaptor Connection Point Step 5 Gear Linkage Plates Mechanism Main Support Plate Dry Sump Pan M6 Fixing Bolts x 3 M8 x 55mm Long Bolt Washer Under Head M8 Repair Washer ...

Page 116: ...Ratio It Is Advisable To Reduce The Length Of This Lever From 65mm to 35mm Hole Position M6 Bolt x 20mm Long Spring Washer Rear Gear Change Rod dia Aluminium Step 6 Fit Loom Saddles To Engine Frame Fit Loom Saddles To Engine Frame As shown Before Fitting Engine Into Frame Offside Of Car Nearside Of Car 3 Loom Saddles On Under Side Of Main Side Tube 2 Loom Saddles On Under Side Of Support Tube 3 Lo...

Page 117: ... Pressure Sensor MAP Locate On End Of Fuel Rail As Shown Atmospheric Air Pressure Sensor Locate On Top Of Cross Brace Plates As Shown Throttle Position Sensor Already Located Fuel Rail Return Modified by Westfield Upon Request Rubber Trumpets NOTE 4 Trumpets Are Supplied With The Engine 2 Long 2 Short Keep The 2 Short Ones Discard The 2 Long Ones 2 Additional Short Ones Are Supplied By Westfield A...

Page 118: ...ipe Up Elbow Elbow Supplied By Westfield Connected to Engine Pulse Air Tube Step 11 Fit Engine to Earth Strap Engine end Fitted with M10 x 1 Bolt Chassis end Fitted To M6 Bolt Provided on Chassis With M6 Nyloc And Washer ...

Page 119: ...20 1 Section 20 ...

Page 120: ...20 2 ...

Page 121: ...th The Assembly Step 1 Install The Reverse Gear Lever Cable View From Drivers Side Gear Lever Cable Exploded Assembly Lever Mounting Bracket Welded To Chassis Rose Joint Cable Mounting Bracket Welded to Chassis Pivot Bolt M8 x 25mm Long M8 Washer Bracket Is In This Location Lever Inner Bush Gear Knob M6 Countersunk Head Screw x 16mm Long Gear Lever M8 Nyloc Nut M8 Washer M5 Countersunk Head Screw ...

Page 122: ... mechanism to make it easier to handle Place the mounting plate next to the engine drive flange with the plate to the left of the angle bracket on the to engine frame and behind to the right of the angle bracket on the bottom engine frame Now operate the small actuating lever which operates the drive dog and jam the dog away from the mounting plate as far as possible with a screwdriver Then line u...

Page 123: ... To Take M8 x 25mm Bolts If Required Place Washers As Spacers Between Mounting Plates To Keep The Plates And Flanges Parallel FRONT OF CAR Step 3 Fit Cable At Engine End And Check Operation Assemble Rod End To Lever With M6 x 35 Bolt Supplied To check Operation Operate the lever in the cockpit backward and forwards The drive dog should freely engage into the slots in the flange and then return rig...

Page 124: ...20 6 Step 4 Refit Electric Motor Solenoid For Reverse Mechanism Replace Motor Using 2 off M8X 25 Set screws and Washers Provided SEE WIRING DIAGRAM ON NEXT PAGE ...

Page 125: ...wards the driver The Engine End Of The Cable Small operating lever on reverse mechanism Cable abutment Is Already welded to chassis Inner fixed with two large washers and M5 Nyloc New Bracket Fixed to cable outer fixing nuts and loosely mounted to the lever arm with M5 dome head screw and Nyloc Close up of lever set up Chassis mounting With Two M5 Repair washers One either side and a M5 Nyloc ...

Page 126: ...20 8 ...

Page 127: ...20 9 CABLE LENGTH TERMINALS A 100 M6 M10 B 84 M8 M10 C 16 M6 M8 D 11 M6 M8 E 50 M6 M6 WIRING DIAGRAM XTR2 REVERSE MECHANISM ...

Page 128: ...2 1 Section 21 ...

Page 129: ...2 2 ...

Page 130: ...de Repeaters Step 1 Bodywork Trimming Most of the trimming of your bodywork should have been done for you before you receive it It is most important that you pre fit the bodywork to the chassis before you have it painted Check all these areas shown below before the pre fit 1 a Seat Belt Slots Seat Belt 1 b Light Holes Front and Rear Holes to suit rear light units Holes to suit front light unit s i...

Page 131: ... the six fixing holes as shown Centre Hole For Cable Two Smaller holes for M5 Retaining Studs Insert filler cap into pre cut hole and drill the six 5mm holes through 1 e Inner Rear Arches These Rear arches will be Pre trimmed but just check your clearance when you have the bodywork on the rolling chassis doing the Pre fit ...

Page 132: ...drill through the underside surface only with a 9mm drill This is to allow the M4 nut to clamp up on the correct face of the bodywork 1 g Oil Cooler Mounting Oil cooler in position mounted from two brackets supplied and bolted through the flanges front and rear of the right hand side air intake Mounted using M6 nuts and bolts View from Inside Bodywork Looking At Right Hand Side of Car ...

Page 133: ...rmostat switch socket and retained by the fan mounting kit Care is needed when pushing the fan mounting pins through the radiator so as not to pierce the tubes The four plastic bosses on the outside of the radiator need to be tapped M6 to the bottom of the blind hole Make Sure You Do Not Go To Deep And Break Into The Main Radiator ...

Page 134: ... back of the car and is bolted through the return flanges at either end using the M6 tapped holes View From Inside Engine Bay Towards The Left Side Air Intake 1 i Front Loom Connector Holes Front Loom Connector hole and fixing screw holes Clearance around clutch master cylinder reservoir bracket ...

Page 135: ...or panel Check in the areas shown that there is clearance behind the dashboard for the clocks and switches to pass through Mark them with a marker pen Remove the marked areas Drill through the dashboard mounting holes then remove dashboard and fit rivnuts into the interior panel in each position ...

Page 136: ... a 12mm hole correctly so that you can push the button whilst you are operating the lever forwards NOTE This Picture is of a Left Hand Drive Car 1 m Engine Cover The engine cover will already have a pre trimmed hole which will go over the engineand air filter Place the cover onto the main body section and check you have enough clearance around this area and also round the two rear roll over bar st...

Page 137: ...n each side of the bodywork at 380mm from the bottom of the body and 90mm from the nose location step Then file out the shape shown until it locates the side repeater correctly 90mm 380mm 300mm 125mm Drill one 8mm hole each side where shown for the mirror pedestal to fix ...

Page 138: ...so as not to damage the coating Lift the body over the chassis and lean it to one side and feed it over the outrigger down the cockpit side and then do the same on the other side The bottom edge of the side sections needs to be placed onto the 25mm section of aluminium floor that protrudes outside the lower chassis rails Then push the body section backwards as far as it will go so that the seatbac...

Page 139: ...body support stays need to be fitted from the outside face of each rear wing mounting bracket on the chassis up to the bodywork If you are going to fit a rear wing it is advisable to place the wing posts through the slots in the bodywork now to enable you to line up the bodywork to the posts Using an M6 bolt and nut secure the top wing post mounting to the chassis and then using just a bolt and th...

Page 140: ...tapped bushes along the front rail of the frame Use five M6 countersunk screws for the front rail and M6 button heads and Nyloc for the three rear fixings The Brake Ducting intake would be best fixed in position when you have finally pre fitted the nose so that you know it is in the correct position It needs to be a snug fit to the inside of the nose and then bolted through the splitter board with...

Page 141: ...d the nose sideways and down onto the splitter board If the two body sections do not meet correctly the angle of the splitter frame can be altered using the adjusters on the frame to achieve the best fit Then the over centre catches can be fitted in the recess on the two sections You are also supplied two location pins and gromets which can be fitted as shown Location Pin on this Face Gromet on No...

Page 142: ... and drill three holes down each side with a 5mm drill through both the lens and the fibreglass Then remove the lens and open up the holes in the bodywork and fit rinuts 6 x 5mm Stainless Dome headed screws fitted 3 down each side of the lens Picture after car is Painted ...

Page 143: ...2 16 ...

Page 144: ...2 17 ...

Page 145: ...2 18 ...

Page 146: ...2 1 Section 22 ...

Page 147: ...2 2 ...

Page 148: ...ocate all the clamping rings onto the studs and bolt up with the M8 Binx nuts supplied 8 x M8 Manifold Studs 8 x M8 Binx Nuts 4 x Clamping rings Note The Remainder of this Section can only be completed when the Bodywork is Finally fitted Step 2 Main Cat Silencer and Pipe If you are fitting a Rear Wing you need to fit the two Wing posts and cross stays before you can fit this section of the exhaust...

Page 149: ... Chassis do not have the flat plates with swaged holes Round End of Silencer with Catalyst Fitted Step 3 Rear Pipe and Small Silencer The later exhaust systems have a loose section of pipe that goes between the two silencers to make fitting slightly easier This is the section that goes through the rear Wing Post if you have fitted one ...

Page 150: ...iew Looking Towards The Back of the Car Inside the Engine Bay Small Rear Silencer Box and Link Pipe going through the Wing Mounting Post Silencer Mounting Strap bolted to the top of the Anti Roll Bar Blocks ...

Page 151: ...2 6 ...

Page 152: ...2 7 ...

Page 153: ...D Warning Lights Step 1 Assemble Dashboard First mount the three clocks in positions with the Speedo Tacho in the centre water temperature on the left and oil pressure temperature on the right Indicator LED s 2 off Green Self Canceling Indicator Switch Horn Push Button Water Temperature Neutral LED green Speedo Tachometer Tachometer Controls Oil Pressure Temperature ...

Page 154: ... Light Switch LED Red Main Beam Headlight LED Blue Hazard Warning Light Switch Side Lights Dip Beam Headlight Handbrake Warning Light Fuel Level Indicator Secondary Ignition Switch Immobiliser Ignition Switch Starter Button ...

Page 155: ... in position This Chassis Strap is the one you need to Drill the Rear Mounting Holes Through Assembled Seat Frame in Chassis On Adjustable Runners Step 3 Tunnel Protection and Gaiter Set NOTE These items must be fitted prior to an SVA test Two vinyl covered tunnel protectors are provided and need to be fixed to the top of the tunnel in front and behind the gear lever They can be fixed on with eith...

Page 156: ... Handbrake Lever Gaiter These panels will fit under the scuttle behind the dashboard and cover the triangular section of the chassis from the inside where the fuse boxes are located and the same on the opposite of the car The near side panel needs to be removable for access to the fuses from inside the car ...

Page 157: ...uter lower seatbelt straps are fixed using two special 7 16 UNF thin headed bolts and a 7 16 washer Centre Tunnel Mounting This centre tunnel monuting is one 7 16 unf x 4 inch long bolt staight through with nyloc and washers The top belt mountings are 4 x 7 16 unf bolts with special thin nyloc nuts and plain washers ...

Page 158: ...2 6 ...

Page 159: ...2 7 Tachometer Controls ...

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Westfield XTR2, Construction Manual

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