VTEC Conversion Kit MTD Intallation Manual

Save This
Page

MTD Intallation Manual for Classic Minis 1959-2001

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 MTD 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 15-20 years old, with all
that has happened to it in that time.

With all that said, your MTD 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 email.

Thanks and have fun,
                    Mini Mania
  

Parts

This Section contains a list and description of the parts included in the MTD Kit, and
a list of parts that you will need in addition to the MTD Kit.

MTD Kit Contents:

Additional Parts Needed:

• Honda D Series Engine/Transmission
• Coil-Over Shocks or Mini Tec’s Coil-Over Shock Kit.
• 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
• Honda Civic Radiator or Mini Tec’s MTD 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.

Step 3: Cut out metal just below stock shock mount. This is needed to fit the MTD
subframe (See following two photos).

Step 4: Cut out behind grille: You will need to remove any excess metal behind your
grille. This will give you maximum flow and cooling ability.

Step 5: Remove all inner metal bracketry that is attached to the lower valence. Cut
off lower front valence 1” below bumper lip at intersection. At this point you will
need to reattach and weld valance to leading edge of bumper lip as shown.

Your Mini should now be prepared for the installation process.

Installation

Installing Engine into Subframe:

Step 1: Bore stock Honda engine and transmission mount to ½” using a drill bit.

Step 2: Attach engine to sub-frame using stock engine mount (use *1/2 x 4 ½ bolt)
and stock transmission mount (use ½ x 4 ½ bolt).

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)

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 MTD Subframe is designed to use the Honda Civic radiator 1992 – 1998 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.

Wiring:

Because the Mini is a stand alone system, only OBD1 computers can be used. Pin-
outs can be found on the web. Contact your local Honda tuner for more information.
We also offer plug-in wiring harnesses to relieve you of this step.

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 45 degree silicone elbows as
shown below. Silicone hoses can be purchased through various racing parts dealers
such as http://venair.com/?lang=en.

• Front Caster Setting = 2.5 Degrees
• Front Camber Setting = -1 Degree

Check List: For your safety, please check…

• That every suspension component
• is fastened tightly.
• That the steering system is
• fastened properly.
• For a firm brake pedal.
• That the engine is stationary.
• All fluid levels are full.
• Tires are inflated properly.
• All lug nuts are tight.
  

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 easy for a few miles and
then go over the Check List again. After driving the car for 100 miles, check front
suspension alignment.

Periodically check all suspension nuts and bolts for wear and/or tightness.

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!

Article Date: Mar 19, 2009
Car Accociations: MINI
Hits: 2592