Page viewing: Fitting engine
Fitting Engine
 
The Watsons subframe is designed for the B16a2 engine and gearbox which has a hydraulic operated clutch, I am using a B16a1 with a Cable operated clutch.

The B16a1 left side engine mount and bracket have to be replaced with B16a2 mounts.

Parts No's of B16a2 mounts:
Honda dealer
Bracket x 1 - 11910P30000 - £66.28
Stud x 2 - 90041P01000 - £6.52 each
Nut x 1 - 9405012080 - 81p (needs 2 nuts but can re-use one of the B16a1 nuts)

Autoquip (cheapest I could find for the mount, Honda wanted £100)
Mount - PEM96 - £54.05

The B16a1 gearbox has a mounting that is different to the B16a2, Watsons can supply a replacement mounting (£50) that allows the B16a1 gearbox to mount up to the same location on the subframe as the B16a2 gearbox.

The left engine mount and gearbox top mount need spacers made up as were they bolt to the frame has a larger gap than the mount, Geoff of Watsons tells me this is to allow for different mounts to be used.

A short alternator belt is needed, due to my alloy crank pulley which is slighty smaller than the standard pulley I have used a 675mm belt (Unipart GMV40675), standard pulley needs a 685mm belt.

B16a1 and B16a2 mounts
engine mounts
Gearbox mounting conversion bracket
conversion bracket
Trial fit of engine/gearbox
trial fit of engine
Engine mounts needs spacers, large gap is to allow different mounts to be used
mount gap
Lug on gearbox hits the botton steering rack U bolt, U bolt has been cut off flush
trial fit of engine
This is the lug that hits the U bolt
mount gap
Lug cut off
trial fit of engine
Under car shot of the lug and U bolt
mount gap
Special gearbox mount fitted to box
trial fit of engine
Another shot of the bracket
mount gap
This inlet manifold bracket hits the bulkhead
trial fit of engine
Here it is removed
mount gap
Left mount in correct position
trial fit of engine
Left mount with spacers fitted
mount gap
Right mount in correct position
trial fit of engine
Right mount with spacers fitted
mount gap
Rear of inlet hits dash panal, so cutting required
trial fit of engine
Exhaust down pipes are very close to subframe
mount gap
Could not resist trying the front on
trial fit of engine
Ended up cutting the front of the subframe to make room for ther exhaust manifold
trial fit of engine
Also bulkhead needed a couple of good hits to make room for the inlet manifold pipes
trial fit of engine
Shot of the exhaust clearance with the engine fitted and frame cut
trial fit of engine
Fabricated brackets for rear gearbox/diff bracket
trial fit of engine
Trial fit of the brackets (left side)
trial fit of engine
Trial fit of the brackets (right side)
trial fit of engine
Floor reinforcing plate and bracing bar
trial fit of engine
Fitted brackets (left side)
trial fit of engine
Fitted brackets (right side)
trial fit of engine
Floor reinforcing plate and bracing bar painted
trial fit of engine
Engine fitted
trial fit of engine
Alternator bracket - holes do not line up
trial fit of engine
4mm gap between the bracket and alternator adjuster
trial fit of engine
Here is the modified bracket
trial fit of engine
Brackets fitted to block (unpainted)
trial fit of engine
Alternator fitted
trial fit of engine
Modified gear linkage
trial fit of engine
B16a1 uses cable clutch, here's the stock mini clutch pedal
trial fit of engine
1st stage of clutch pedal modification
trial fit of engine
Clutch pedal extended and modified to take cable
trial fit of engine
Here it is with the cable attached, a small split pin stops the cable un-hooking
trial fit of engine
Not very good pic - this is the spacer/adapter for the clutch cable were it fits through the bulkhead
trial fit of engine
Here's the spacer with cable attached
trial fit of engine
You can just see the hole were the cable will pass through the bulkhead and the modofied clutch pedal
trial fit of engine
Exhaust stepped sleeve 2" - 2 1/2"
trial fit of engine
Exhaust adapter honda to mini 2" system
exhaust adapter
Adapter lowers the exhaust so that it clears the gearlinkage
trial fit of engine
Here it is pretty much finished, it starts and runs ok
Engine in and working
 
 

Problems fitting engine

1. A lug on the diff casing hits the bottom steering rack U bolt, I have cut the U bolt off flush with the nut and cut off the lug, this has made enough clearance.

2. Spacers need to be made to fill the gaps between the engine mounts and subframe brackets.

3. Inlet manifold support bracket hits the bulkhead and so needs to be removed

4. The engine is sitting high on the left side (cam cover end), I have made a 12mm spacer to go between the engine mount and engine bracket to lower the engine, this has lowered the engine the right amount but now the rear of the inlet manifold hits the dash panal, I have cut the dash panal but 2 hoses from the inlet manifold are still touching the dash panal, further work is required to sort this out.
NOTE: Ended up cutting a bit off the front of the subframe and giving the bulkhead a couple of good hits with a big hammer to get the clearance for the hoses, the engine is also as far forward in the mounts as possible.

5. Lower alternator bracket holes do not align and also hits a lug on the engine, there is also a gap between the bottom bracket and the alternator adjuster.