MTB2 Kit: Honda B Series Conversions for the Classic Mini. MTB2 Installation Manual For Classic Minis

Transcription

1 MTB2 Kit: Honda B Series Conversions for the Classic Mini MTB2 Installation Manual For Classic Minis

2 Dear Customer, We welcome you to the Honda Powered Mini World. Thank you and Congratulations for your purchase. You can be certain that you have made a wise choice with this upgrade. This kit was designed to help put you on the right track when building your ultimate Mini. With the help of this MTB2 Kit, you will be driving your Super Fast Mini soon. Mini has been made in many variations with many subtle tweaks and varying build quality over its lifetime. It is impossible to account for all these, and some will even be unique to your car. Additionally, your car is likely years old, with all that has happened to it in that time. With all that said, your MTB2 kit and these instructions are designed to try to allow for some of these differences. For others, you will have to field fit or adjust as you go. We ll do all we can to help keep your project moving along. Please keep in mind that pictures will be of great help, so if you don t have a digital camera, (or always wanted one) now is a good time to get one. In fact, you should take LOTS of pictures to document your project. Your project may seem overwhelming at times, but if you take it one step at a time, in a logical sequence and take an occasional break from it, you ll do great. The purpose of this kit is to make your Honda VTEC installation easy and hassle free. We have taken the research and development headaches out of the install so that you do not have to deal with all of that. The sub-frame mounts to the car. The engine mounts to the sub-frame. And after a few other small connections, you are ready to crank and drive your Super Fast Mini. We have broken the whole VTEC Mini build up into sections, from start to finish. We hope that this will be a pleasurable experience for you and we will do everything that we can to make it that. Just remember, we are available to help you 5 days a week. Just give us a call or drop us an . Thanks and have fun, 2 Mini Tec, L.L.C.

3 Parts This Section contains a list and description of the parts included in the MTB2 Kit, and a list of parts that you will need in addition to the MTB2 Kit. Your MTB2 Kit Contains: - MTB2 Subframe - RH Adjustable Upper Suspension Arm - LH Adjustable Upper Suspension Arm - RH Lower Suspension Arm - LH Lower Suspension Arm - Shock Mounting Brackets - Rear Transmission Stabilizer - Alternator Relocation Bracket - Mounting Hardware (Not Shown) - 2 Mini/Honda Chromoly Axle Shafts 3

4 Additional Parts Needed: - Honda B Series Engine/Transmission (See List) - Coil-Over Shocks - Front Disc Brake System: Mini Tec s Superbrake, Mini 8.4 Disc Brakes, Other - Wheels with a 7mm Offset to the outside (needed for turning radius clearance) or wheel spacers - Honda Engine and ECU Wiring Harness - Modified Honda ECU OBD1 - Electronic Speedometer (Mechanical Gauges may not work with the Honda Engine) - Honda Civic Radiator or Mini Tec s MTB2 Aluminum Radiator Kit - Honda Shifter Preparation Step 1: Remove stock Mini engine and sub-frame. Then remove everything else in the engine compartment. Step 2: Remove inner fenders: Cut and remove both inner fenders as shown. You will need this extra space for the width of the subframe. 4

5 Step 3: Cut out metal just below stock shock mount. This is needed to fit the MTD subframe (See following two photos). Step 5: Cut out behind grille: You will need to remove any excess metal behind your grille (See Photo below). This will give you maximum flow and cooling ability. 5

6 Cutting and relocating the front lower valance is NO longer required. Step 7: Cut body for alternator clearance. Cut out the section that is drawn in RED. This will allow the alternator pulley to not interfere with the bulkhead. You can leave 1/8 along the vertical cut for support. Your Mini should now be prepared for the installation process. 6

7 Installation Installing Engine into frame: Step 1: Lower engine into frame. Attach engine to frame using stock engine mount (use 12mm bolt) and stock transmission mount (use 12mm bolt). Note: Your engine may need to be rotated once installed into car for clearance. 7

8 Install Engine and Subframe into Mini: Step 1: By lowering the car onto the frame, attach it to the car using the two large frame mounting bolts just like the standard Mini frame attaches. If your car is an earlier model and does not have these two large ¾ diameter bolts, then you will 8

9 need our MK1/2 Subframe Mounting Kit. Standard Mini mounting bolts are circled in red in the following photo. Do not tighten completely at this point. You will need to attach the frame and the bottom first. Step 2: Drill six holes to support the bottom of the frame using a 5/16 drill bit. Use the six supplied 5/16 bolts with plates to fasten the frame to the car on the lower side. The plates will go inside of the car to give the floor panel extra support. After the six bolts are in place and tightened, tighten the two large frame mounting bolts on top of the frame. See photos. 9

10 Your subframe and engine should now be attached to your Mini. Coil-Over Shock Installation: Step 1: mounts. Replace Mini upper shock mounts with the provided upper strut 10

11 Step 2: Attach lower side of shock as shown in photos. Do the same for both sides. Step 3: Attach top shock to upper strut mount. See Photo. Do the same for both sides. Axles: Assembly and Installation Parts needed for Assembly: *Chromoly Axle Shafts, Complete Inner Honda CV Joint Assemblies, and Complete Outer Mini CV Joint Assemblies. (See Photo Below) 11

12 Step 1: Assemble Small end of axle shaft with the Mini cv joint assembly as done on a stock Mini but replace ball bearing gear with supplied gear. 12

13 Honda Axle End Assembly: Assemble large splinned side of axle with the Honda cv joint assembly. (See following four Photos) Note: The Honda race will need to be driven onto the axle shaft using a hammer and socket to seat properly. 13

14 Axle Installation: Simply slide one of the axles into the transmission and the other into the engine mid-shaft until the axles lock into place. Swivel Hubs and Brakes: Install the Swivel Hubs and Brakes as done on stock Mini. Master Cylinder: Depending on your setup, you may have to relocate one of your master cylinders. If you have both master cylinders on the right side of the car, then they are clear. If you have both master cylinders on the left side, then the brake master cylinder will have to be relocated. We recommend getting a left hand drive conversion pedal box. This will allow you to mount the master cylinder on the right side of the car, clear of any objects. Note: For best clearance, check out Mini Tec s Aluminum Racing Pedal Kit. Shifter Linkage: Use Honda Shifter linkage for the conversion. Step 1: Cut all four ends off of the shifter linkage. Step 2: Hang shifter in stock Mini location. New holes will need to be drilled. (See following Photo) 14

15 Step 3: Hang shifter ends on the transmission. (See following Photo) Step 4: Reattach lower shifter end (as shown in following photo). The shifter rod reducers will be needed to rebuild the shifter linkage (shifter rod reducers are shown being held in previous and following photos). 15

16 Step 5: Rebuild the shifter linkage using ¾ metal pipe. Bend and weld pipes so that all gears can be easily shifted to and from without hitting the body or anything else. (See following photo) Fuel System: Change your fuel pump to one that ranges from 32 to 48 PSI. A return line will be needed on certain models that do not have them. Cooling System: The MTB2 Subframe is designed to use the Honda Civic radiator model. There are two tabs located on the front of the sub-frame for mounting this radiator. Alternative: Mini Tec Radiator Kit comes with everything you need to keep your Honda Mini running at the correct operating temperature. Items included are: Aluminum Radiator, Radiator fan, radiator hoses, and a catch can. 16

17 Compatible Honda B Series Engines: Here is a list of available B Series Honda engines that you can use with your MTB2 Kit. B16A VTEC Found in: o JDM Honda Integra RSi/XSi (DA6/DA8) o JDM Honda CRX SiR (EF8) o JDM Honda Civic SiR/SiRII (EF9) Displacement: 1595 cm³ Compression: 10.2:1 Rod/stroke ratio: 1.74 Power: rpm & 112 ft 7000 rpm Transmission: S1/J1/Y1/A1/YS1 o JDM Honda Civic SiR/SiRII (EG6/EG9) Displacement: 1595 cm³ Compression: 10.4:1 Power: rpm & 116 ft 7300 rpm Transmission: S4C o EDM Honda Civic VTi Displacement: 1595 cm³ Compression: 10.4:1 Power: rpm & 116 ft 7300 rpm o JDM Honda CR-X del Sol SiR Displacement: 1595 cm³ Compression: 10.4:1 Power: 158 hp hp & 111 ft lbf ft lbf B16A1 VTEC Found in: o EUDM Honda CRX 1.6i/VTi (EE8/ED) o EUDM Honda Civic 1.6iVT (EE9) Displacement: 1595 cm³ Compression: 10.2:1 Power: 150 hp ( rpm & 111 ft lbf (151 N 7000 rpm B16A2 VTEC Found in: o Honda Civic EDM VTi (EG & EK) Displacement: 1595 cm³ Compression: 10.2:1 Power: rpm & 113 ft lbf (153 N 7300 rpm Transmission: Y21 o Honda Civic Si (EM1) Displacement: 1595 cm³ Compression: 10.2:1 Power: 160 hp ( rpm & 111 ft lbf (151 N 7000 rpm 17

18 o Transmission: Y21 S4C Honda Del Sol VTEC (EG) Displacement: 1595 cm³ Compression: 10.4:1 Power: 160 hp ( rpm & 111 ft lbf (152 N 7000 rpm Transmission: Y21 B16A3 VTEC Found in: o Honda Del Sol VTEC (EG) Displacement: 1595 cm³ Compression: 10.4:1 Power: 160 hp ( rpm & 111 ft lbf (152 N 7000 rpm Transmission: Y21 Redline: 8200 rpm B16A6 VTEC Found in: o Honda Civic - South Africa VTEC (EK) Displacement: 1595 cm³ Compression: 10.2:1 Power: 160 hp ( rpm & 160 N 7400 rpm Transmission: Y21 B16B VTEC Found in: o Civic Type-R[EK9] Displacement: 1595 cm³ Compression: 10.8:1 Power: 185 hp ( rpm & 118 ft lbf (160 N 7500 rpm Transmission: S4C With LSD B17A1 VTEC Found in: o Integra GS-R (DB2) Displacement: 1608 cm³ Compression: 9.6:1 Power: rpm & 197 ft lbf (159 N 2200 rpm Transmission: cable~ XS1 B18A1 Found in: o Integra RS/LS/GS (DA) Displacement: 1834 cm³ Compression: 9.2:1 Bore: 81 mm Stroke: 89 mm Power: : 130 hp ( rpm & 121 ft lbf (164 N 5000 rpm : 140 hp ( rpm & 127 ft lbf (173 N 5200 rpm 18

19 Transmission: YS1 B18B1 Found in: o Acura Integra "RS/LS/GS" (DC4/DB7) Displacement: 1834 cc Compression: 9.2:1 Bore: 81 mm Stroke: 89 mm Power: rpm & 127 ft 5200 rpm Transmission: S88 B18C VTEC Found in: JDM Spec Honda Integra ITR Power: 200ps ( rpm 134 ft 6200 rpm Transmission Type: 5-speed standard Displacement: 1797 cm³ Compression: 11.1:1 (JDM) - The USDM Integra Type-R 10.6:1 Transmission: Y80 B18C1 VTEC Found in: o Integra GS-R (DC2 & DB8) o Displacement: 1797 cm³ o Compression: 10.0:1 o Power: 7600 rpm 128 ft 6200 rpm o Transmission: S80 B18C3 VTEC Found in: o Acura Integra Type R o Power: 195hp B18C4 VTEC Found in: o UK Civic 1.8i VTi 5-door Hatch o UK Civic Aerodeck 1.8i VTi 5-door Wagon o EU Civic Aerodeck 1.8i VTi 5-door Wagon o EU Civic 1.8i VTi 5-door Hatch o Displacement: 1797 cm³ o Compression: 10.0:1 o Power: 169 hp ( rpm & 129 ft lbf (174 N 7500 rpm o Transmission: S9B B18C5 VTEC Found in: o Integra Type-R o Displacement: 1797 cm³ o Compression: 11.0:1 o Power: rpm & 130 ft lbf (176 N 7500 rpm o Transmission: S80 19

20 B18C6 VTEC Found in: o Honda Integra UK and Euro Spec Type R o Power: 190 ps (147 kw), 187 Nm B18C7 VTEC Found in: o Honda Integra Type R (Australia) o Power: 200 hp (140 kw), 136 ft lbf Wiring: Because the Mini is a stand alone system, only OBD1 computers can be used. Pinouts can be found on the web. Contact your local Honda tuner for more information. Intake Modification: You will need to shorten or modify your intake so that it does not interfere with the bulkhead. We suggest cutting the intake and adding 90 degree silicone elbows as shown below. Silicone hoses can be purchased through various racing parts dealers such as 20

21 Alternator Mounting: You will need to relocate your alternator using the bracket provided. After mounting the alternator, measure the distance around the alternator and crankshaft pulley to determine belt length needed. Suspension Setup: These figures are for daily driving. You may want to set up the car differently if planning on racing your Mini. - Front Caster Setting = 2.5 to 3.5 Degrees (2.5 for a lighter steering wheel, 3.5 for a heavier steering wheel) 21

22 - Front Camber Setting = -0.5 to -1 Degree (Less for street driving, more for racing) Check List: For your safety, please check - That every suspension component - For a firm brake pedal. is fastened tightly. - That the engine is stationary. - That the steering system is - All fluid levels are full. fastened properly and all nuts and - Tires are inflated properly. bolts are secure. - All lug nuts are tightened Test Drive: For your first test drive, go slow and easy to make sure that there are no problems. Listen to the car as you drive it for odd noises. Drive the car easily for a few miles and then go over the Check List again. After driving the car for 100 miles, check front suspension alignment again. Periodically, you will need to check all of your suspension components for wear. After that, have fun! Disclaimer of Warranty Neither the seller nor the manufacturer will be liable for any loss, damage or injury directly or indirectly arising from the use or inability to determine the use of this product. Before using, the use shall determine the suitability of the products for its intended use, and the user should assume full responsibility and risk in connection herewith. For off road use only! Copyright 2006 Mini Tec, L.L.C. All rights reserved. 22