Honda HPD L15A7 Assembly Manual
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Honda HPD L15A7 Assembly Manual

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  • Page 2: Table Of Contents

    HPD L15A7 Engine Kit Assembly Manual Table of Contents 1. Safety Consideration and Warnings ............. Page 2 2. Title Page ....................Page 3 3. Remove Engine From Crate ..............Page 4 4. Prepare Engine For Race Kit Installation ..........Page 6 5.

  • Page 3: Safety Consideration And Warnings

    Any person who intends to use a replacement part, a service procedure, or a tool that is not recommended by Honda or the race sanctioning body, must determine the risk to their personal safety, and the safe operation of the vehicle.

  • Page 4: Title Page

    HPD L15A7 Engine Kit Assembly Manual This manual details the steps necessary to install the HPD L15A7 engine kit on Honda’s OE engine platform. Disassembly and assembly procedures for Honda’s OE L15A7 engine should be referenced in the 2009 / 2010 Honda Fit service manual, which is included in the HPD chassis / electrical kit.

  • Page 5: Remove Engine From Crate

    HPD L15A7 Engine Kit Assembly Manual Remove the OE L15A7 Honda engine from the crate Remove the lid and cross-bracing. Attach lifting straps as shown. Lift the engine from the crate. 8/2012...
  • Page 6 HPD L15A7 Engine Kit Assembly Manual Remove the OE L15A7 Honda engine from the crate cont’d Once removed from the engine crate, reference the Honda Fit Service Manual to remove the starter, clutch, and flywheel. Then, secure the engine onto an engine stand for the HPD engine kit installation.

  • Page 7: Prepare Engine For Race Kit Installation

    HPD L15A7 Engine Kit Assembly Manual Prepare The L15A7 Honda Engine For The Engine Kit Installation Remove oil drain plug to remove engine oil. Remove the A/F Sensor. Remove the heat shield. Remove the catalytic converter. Save the exhaust gasket and hardware for reuse in the HPD engine kit.
  • Page 8 HPD L15A7 Engine Kit Assembly Manual Prepare The L15A7 Honda Engine For The Engine Kit Installation Remove the EGR. Remove the EGR pipe (not shown). Refer to Emissions section of the Fit manual Remove the engine mounting stud. Use either a stud removal tool, or double-nut the stud to unscrew it from the engine.
  • Page 9 HPD L15A7 Engine Kit Assembly Manual Prepare The L15A7 Honda Engine For The Engine Kit Installation Remove the intake runner. Save the intake runner and gasket for reuse in the HPD engine kit. Remove the wiring harness and Wiring Harness and Bracket bracket.
  • Page 10 HPD L15A7 Engine Kit Assembly Manual Prepare The L15A7 Honda Engine For The Engine Kit Installation Remove the V-TEC pressure sensor. Save the O-ring for reuse in the HPD engine kit. V-TEC Pressure Sensor Remove the harmonic balancer. If not...
  • Page 11 HPD L15A7 Engine Kit Assembly Manual Prepare The L15A7 Honda Engine For The Engine Kit Installation Once the pan is removed from the engine, remove the locating dowels, crank position sensor, and threaded Crank Position Sensor oil filter mounting boss from the standard pan for reuse in the HPD engine kit oil pan.
  • Page 12 / 23 lb-ft. Check for clearance At this point, your L15A7 Honda engine is ready to accept the HPD engine kit parts. Ensure all parts necessary for the build are included in your kit, using the supplied bill of materials (BOM).

  • Page 13: Top End

    HPD L15A7 Engine Kit Assembly Manual Top End Water Outlet – The water outlet nipple has fine pitch threads with a thread locking agent. It is recommended that a MAP gas torch, or similar device be used to heat the...
  • Page 14 HPD L15A7 Engine Kit Assembly Manual Top End cont’d Install the EGR bypass plate. Install the metal gasket with the raised inner diameter facing out using the flange nuts from the EGR bypass pipe. · Torque the fasteners to 25 N m / 18 lb-ft.
  • Page 15 HPD L15A7 Engine Kit Assembly Manual Top End cont’d · Torque the fasteners to 9.8 N m / 7 lb-ft. Install the V-TEC block-off plug. Ensure the O-ring is in place. Torque the plug to 22 N m / 16 lb-ft.
  • Page 16 HPD L15A7 Engine Kit Assembly Manual Top End cont’d Remove the PCV nipple by tapping it out from the back of the intake runner. Be careful not to damage the bore. ° Heat the intake runner to 120 ° F. Install the PCV block off plug flush, with the chamfered end down.
  • Page 17 HPD L15A7 Engine Kit Assembly Manual Top End cont’d Insert the top hat spacer. Use an adhesive media to hold it in place. Install the bell housing adapter 12 x 12 x 28mm 28mm stud. Use Hondalock 3, thread adapter stud locking agent or equivalent.

  • Page 18: Wiring Harness

    HPD L15A7 Engine Kit Assembly Manual Engine Wiring Harness Install the HPD engine kit wiring harness. Use anchor points that minimize harness exposure to heat and chafing. cont’d 8/2012...
  • Page 19 HPD L15A7 Engine Kit Assembly Manual Engine Wiring Harness cont’d Install heat shield and intake plenum supports. 1. 8 x 25mm flange bolt 2. 8 x 20mm flange bolt 3. 6 x 20mm flange bolt 4. Spacer ‘A’ - 5 x 8mm 5.

  • Page 20: Induction

    HPD L15A7 Engine Kit Assembly Manual Induction Intake Plenum, gaskets, hardware and sensors. 1. 8 x 30mm flange bolt 2. 5 x 12mm socket head bolt/washer 3. OE MAP sensor w/fastener and 11 x 2.5mm O-ring 4. Air temperature sensor w/15 x 2mm o-ring 5.
  • Page 21 HPD L15A7 Engine Kit Assembly Manual Induction cont’d Install the intake plenum. Torque the 8 x 30mm plenum · fasteners to 24 N m / 17 lb-ft. Torque 5 x 12mm plenum support bracket fasteners to 70 kg-cm / 5 lb-ft.
  • Page 22 HPD L15A7 Engine Kit Assembly Manual Induction cont’d While managing the spring tension, remove the throttle lever from the shaft. Replace the OE throttle lever with the HPD engine kit throttle lever. The throttle lever can only be installed one way.
  • Page 23 HPD L15A7 Engine Kit Assembly Manual Induction cont’d Install the throttle body with the restrictor and gaskets onto the intake plenum. Match the orientation of the gaskets and restrictor to the throttle body. Torque the fasteners to 12 N·m / 8.8 lb-ft.

  • Page 24: Oil Scavenge Pump

    HPD L15A7 Engine Kit Assembly Manual Oil Scavenge Pump 1. O-Ring 1.78 x 53.7mm 5. Circlip External 12.7mm 2. O-Ring 1.78 x 47.37mm 6. Seal 15 x 35 x 7mm radial shaft 3. Circlip Internal 29mm 7. 6 x 20mm socket head bolts 4.
  • Page 25 HPD L15A7 Engine Kit Assembly Manual Oil Scavenge Pump cont’d Install the oil seal and retaining circlip. Oil Seal Circlip 35mm Insert the drive shaft from the front of the scavenge pump cover. Install the retaining circlip. Circlip 12.7mm 8/2012...
  • Page 26 HPD L15A7 Engine Kit Assembly Manual Oil Scavenge Pump cont’d Place the scavenge port ‘B’, with cutouts facing up. Locate the dowel cutout on the dowel pin. Ensure the Woodruff key fits in the slot on the shaft. Lapping of the key may be necessary.
  • Page 27 HPD L15A7 Engine Kit Assembly Manual Oil Scavenge Pump cont’d Install the outer rotor. Install the scavenge port ‘A’. The Port ‘A’ ports are identical, so the placement order is not critical. Repeat steps for remaining rotor and port installation.
  • Page 28 HPD L15A7 Engine Kit Assembly Manual Oil Scavenge Pump cont’d Place the 47.37 x 1.78mm O-ring onto the cartridge. Align the dowel pin cutout in the cartridge with the dowel pin on the scavenge pump cover. Dowel Pin Dowel Pin Cutout Install the cartridge over the rotors and scavenge ports.
  • Page 29 HPD L15A7 Engine Kit Assembly Manual Oil Scavenge Pump cont’d Install the scavenge port set screws. Sparingly apply Hondalock 2 thread locking agent or equivalent to the set screws. Torque the screws to 40 kg-cm / 35 in-lb. NOTE: Pick up / carry the pump by the front cover only.
  • Page 30 HPD L15A7 Engine Kit Assembly Manual Oil Scavenge Pump cont’d Install the 53.7 x 1.78mm O-ring into the groove in the scavenge pump cover. The scavenge pump is ready for installation. O-Ring 8/2012...

  • Page 31: Oil Pan

    HPD L15A7 Engine Kit Assembly Manual Oil Pan Inspect and deburr all edges of the pan, the oil ports and the oil baffle pan. The skid block is not included in the kit. Long Studs * (DB-1 / DB-6 only)
  • Page 32 HPD L15A7 Engine Kit Assembly Manual Oil Pan cont’d 1.78 x 14.0mm Install the O-rings onto the two scavenge filter/strainers. 2.95 x 23.47mm Lubricate the O-rings with liquid silicone, then install them into the scavenge ports. Inspect the O-ring condition by looking...
  • Page 33 HPD L15A7 Engine Kit Assembly Manual Oil Pan cont’d Lubricate the pre-installed 20.5 x 2.3mm O-ring with liquid silicone, then install the AN-8 port plug. Torque the plug to 34 N·m / 25 lb-ft. Lubricate the pre-installed 24 x 2.5mm...
  • Page 34 HPD L15A7 Engine Kit Assembly Manual Oil Pan cont’d Install the plug with a new sealing washer. It is located forward, on the right side of the oil pan. Torque the plug to 40 N·m / 30 lb-ft. Oil Pan Test Fit Checks:...
  • Page 35 HPD L15A7 Engine Kit Assembly Manual Oil Pan cont’d Install the oil pan baffle plate. Right Side Install 4 x 8mm button-head fasteners in the right side holes, and 4 x 10mm button-head fasteners in the left side holes. Use Hondalock 2 thread locking agent or equivalent.
  • Page 36 HPD L15A7 Engine Kit Assembly Manual Oil Pan cont’d Install the OE 22 x 2.5mm O-ring that was retained during disassembly from the OE oil pan. For the following items, reference the Honda Fit Service Manual: Install the oil pan gasket.
  • Page 37 HPD L15A7 Engine Kit Assembly Manual Oil Pan cont’d Lubricate the 47.37 x 1.78mm scavenge pump sealing O-ring with liquid silicone, then install it at the base of the scavenge pump bore. Lubricate the O-ring with liquid silicone. Align the scavenge pump...

  • Page 38: Engine Accessories

    HPD L15A7 Engine Kit Assembly Manual Engine Accessories Insert the Woodruff key for the pulley into the slot on the shaft. The key may need lapping for a proper fit. Install the pulley onto the scavenge pump shaft. Apply Hondalock 2 thread locking agent or equivalent to the threads of the bolt.
  • Page 39 HPD L15A7 Engine Kit Assembly Manual Engine Accessories cont’d Torque the alternator fasteners to 20 N·m / 15 lb-ft. Torque Torque the pulley retaining nut to 40 N·m / 30 lb-ft. Install the harmonic balancer with spacer, 14 x 53mm flange bolt, and the pulley per Honda Fit service manual procedure.
  • Page 40 HPD L15A7 Engine Kit Assembly Manual Engine Accessories cont’d HPD special tool – Excaliber. Available for purchase. Install the water pump and alternator drive belt, then the scavenge pump toothed drive belt. Install the flywheel per the 2009/2010 Honda Fit Service Manual.
  • Page 41 HPD L15A7 Engine Kit Assembly Manual Engine Accessories cont’d Install the coolant connecting pipe, thermostat housing (see engine kit installation notes), and thermostat per the 2009/2010 Honda Fit Service Coolant Connecting Pipe Manual. Thermostat Housing Install the starter motor. Torque the flange bolt to 64 N·m / 47 lb-ft.

  • Page 42: Engine Coolant Plumbing

    HPD L15A7 Engine Kit Assembly Manual Engine Coolant Plumbing Install the water cooling pipes appropriate to your chassis specifications. It is recommended that the pipes be installed prior to installing the engine in the chassis. The DB-1/ DB-6 configuration is pictured.

  • Page 43: Quick Reference Torque Specification Sheet

    HPD L15A7 Engine Kit Assembly Manual Quick Reference Torque Specification Sheet Cylinder Head · ° Cylinder Head Bolt 29 N m / 22 lb-ft + 130 · Camshaft Sprocket Bolt 56 N m / 41 lb-ft. · Camshaft Pulse Plate...
  • Page 44 HPD L15A7 Engine Kit Assembly Manual Quick Reference Torque Specification Sheet cont’d Cooling System Water Pump Pulley Bolt 14 N m / 10 lb-ft Water Pump Bolt 12 N m / 8.8 lb-ft Thermostat Cover Bolt 12 N m / 8.8 lb-ft Thermostat Housing Bolt 9.8 N m / 7.2 lb-ft...

  • Page 45: Race Kit Accessories

    HPD L15A7 Engine Kit Assembly Manual Optional Accessories Optional sensor kit assembly 1. Secondary harness 2. Fuel pressure sensor 3. Oil pressure sensor 4. Oil temperature sensor 8/2012...

  • Page 46: Hpd Engine Kit Installation Notes

    HPD L15A7 Engine Kit Assembly Manual HPD Engine Kit Installation Notes Before Thermostat Housing - Engines After purchased from HPD will be delivered with the housings already modified. Those who purchase a Honda Fit engine outside of HPD will need to...
  • Page 47 HPD L15A7 Engine Kit Assembly Manual HPD Engine Kit Installation Notes cont’d WOT Adjustment Attach the throttle cable to the throttle lever. With the throttle lever against the idle set screw, adjust the cable to show visible slack. Adjust the WOT set-point on the pedal so that there remains a 0.40mm gap between the...

  • Page 48: Throttle Position Sensor Calibration

    HPD L15A7 Engine Kit Assembly Manual Throttle Position Sensor Calibration Across VCC and VOut Resistance is .670 k Ohms at WOT, 4.470 k Ohms at idle, and 4.6 k Ohms at 0% throttle Voltage is 4.7 V at WOT, 0.5 V at idle, and 0.5 V at 0% throttle...

  • Page 49: Engine Operation Parameters

    HPD L15A7 Engine Kit Assembly Manual Engine Operation Parameters Water temperature minimum before going on the track - 75°C / 167°F Water temperature maximum – 100°C / 212°F Oil pressure minimum at idle / operating temperature – 340 kPA / 49 psi Oil pressure minimum at 5000 rpm / operating temperature –...

  • Page 50: Contact Information

    HPD L15A7 Engine Kit Assembly Manual Contact Information Honda Performance Development, Inc. 25145 Anza Drive Santa Clarita, CA 91355 661-294-7300 Honda Racing Line grmsadmin@hra.com Phone: 661-702-7777 Fax: 661-294-7310 8/2012...

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