Webcon Alpha Pro 4 Gold Throttle Bodies Kit

I've opened up the box and the kit is very comprehensive.  There's even a fuel filter and mounting hardware.  I will use this to replace the existing budget filter and home made bracket.  Should have read the kit contents before try to complete the fuel lines!

I was a little disheartened to find a large wiring loom.  I thought my wiring chores were over.  To be fair it is probably fairly straight forward and everything is labelled.  That makes a change.

Yesterday I made a call to Webcon to discuss connecting the ECU tacho output to the digital dashboard - didn't want to fry anything.  They were very helpful and happy to answer my technical questions in great detail, explaining how the ECU is built and operates.  I hopefully won't need their help, but it is very reassuring to know there is somebody there who can help.  Main piece of advice for installation was: don't touch any of the factory set screws that are thread locked.  Point noted.

Joining the Engine and Gearbox

New clutch release bearing fitted to the clutch fork.  Lubrication applied as instructed in the clutch kit.

Engine and gearbox fitted together.  New cap head bolts, thread locked and torqued up to the correct amount.

With the Tiger ERA sump fitted the gearbox mounting holes in the lower crank case are no longer present.  Only the upper five bolt holes can be used.  Two dowels are still available to ensure gearbox alignment.  Next job is to crane the engine into the rolling chassis and make good the engine mounts.

Flywheel and Clutch

To add the new ring gear to the Tiger lightened flywheel the former was put in a hot oven and the latter in the freezer.  Once fitted the ring gear was held in place with weights until both had returned to room temperature.

Comparing old (Focus) and new lightened (Pinto) flywheels.  On the scales the Focus weighs in at 9.8kg and the Pinto at 5.8kg.  Hopefully this will give a good performance boost in terms of acceleration, along with a more responsive throttle response.

The flywheel bolts were shortened so that the same amount of thread (15mm) showed through the rear of the flywheel as in the original Focus installation (the lightened Pinto flywheel is thinner - no prizes there).  All good so far.  However, the edges of the bolts clash with the tapered edge of the flywheel.  Also the socket fouls on the flywheel.

Plan B was to use another, original length, set of flywheel bolts and use washers as spacers.  Two washers were needed for each bolt to compensate for the thickness of metal removed from the flywheel.  The washers nearest the flywheel needed filing down (from 5mm to 3mm) on one edge.  Okay, the edge was not there until I filed it!

Flywheel bolts installed with thread lock.  Each was marked to show that it had been torqued up to the correct value.  In the centre is the spigot bearing fitted.  Pushed in just flush with the outer edge.  It would've gone in further, but here it should provide maximum support for the gearbox input shaft.

Fitting the clutch using an old borrowed gearbox input shaft as a centring tool (Thanks Pete).  This made it very easy to get the perfect alignment of the clutch plate.