Factory Five Racing GTM Supercar User manual

REVISION 2D , APRIL 2014

2014 Factory Five Racing Inc.
9 Tow Rd
Wareham, MA 02571
Phone [phone] • Fax [phone]

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Table of Contents
Table of Contents...................................................................................ii
General Information....................................................................1
Foreword.........................................................................................1
Safety Notice...................................................................................4
Safety Tips......................................................................................5
How to use This Book.....................................................................6
What You Get .................................................................................6
What You Need...............................................................................7
Serial Number Identification............................................................7
Tools List.........................................................................................8
Required Supplies...........................................................................9
Helpful Tools...................................................................................9
Donor Parts and Parts needed.................................................10
Donor Part Selection Tips.............................................................11
Price – Donor Car .........................................................................11
Price – Transaxle..........................................................................12
Running Gear................................................................................12
Corvette Parts......................................................................................13
Porsche Parts......................................................................................14
Disassembly of a Corvette Donor for Parts...................................14
Doors...................................................................................................14
Hood....................................................................................................22
Radiator/Coolant Reservoir..................................................................25
Horn Assembly ....................................................................................30
Windshield Wiper.................................................................................31
Exhaust ...............................................................................................33
Engine Removal/Suspension/Transmission..........................................36
Cross Member/Front Suspension Tear-Down.......................................70
Rear Suspension/Transmission Removal.............................................70
Electrical..............................................................................................77
Fuel Tanks...........................................................................................78
Emergency Brake................................................................................81
Trim Plate – IP Accessory....................................................................87
Knee Bolster........................................................................................89
Steering Column..................................................................................90
Ignition.................................................................................................98
Shifter (Automatic)...............................................................................99
Upper Dash Pad ................................................................................101
Passenger Air Bag.............................................................................102

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Stereo and Heater Controls................................................................103
Dash Cluster......................................................................................104
Pedal Bracket ....................................................................................104
Hood Release Handle and Cables .....................................................108
Trim Panels .......................................................................................109
Door Sill.............................................................................................109
Side Panel (Coupe)............................................................................110
Upper Roof Bow Panel (Coupe).........................................................111
Rear Compartment – Front Side (Coupe)...........................................111
HVAC Unit.........................................................................................112
Wiring, Computer, Fuse Panel ...........................................................122
Donor Part Preparation............................................................... 124
Engine...............................................................................................124
Fuel Tanks.........................................................................................145
Steering Column (Non-Telescoping)...................................................161
Steering Column (Telescoping)..........................................................169
Seat Belts..........................................................................................177
Wiring Harness/Computer..................................................................182
Computer Bracket..............................................................................199
Disassembly of the kit ............................................................202
Unpacking Your GTM Kit ............................................................ 203
Removal of Body......................................................................... 203
Aluminum Removal and Preparation........................................... 203
Chassis Assembly..................................................................208
Steering Rack Installation ........................................................... 209
Inner Wheel Wells....................................................................... 210
Battery Tray and Front/Center Undercarriage Aluminum............ 215
Front Suspension........................................................................218
Coil-Over Shock Assembly.................................................................222
Rear Suspension Mounting to Chassis.......................................224
Rear Coil-Over Shock and mount.......................................................226
Rear Tie Rod.....................................................................................230
Footbox Aluminum......................................................................232
Steering Column/Shafts.............................................................. 238
Non-Telescoping Column...................................................................238
(Optional) Telescoping Column..........................................................241
Pedal Box and Master Cylinders.................................................251
Gas Pedal...................................................................................256
Fuel Tank Finish Panels.............................................................. 259

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Pre-engine preparation ............................................................... 260
Engine Installation....................................................................... 261
Alternator Installation ..................................................................263
Transaxle Adapter Plate Preparation and Installation................. 273
Throwout Bearing Assembly...............................................................277
Transaxle Install..........................................................................280
1990 and Later G50...........................................................................280
Brake Line Routing......................................................................285
Clutch Line Routing..................................................................... 294
Battery Install..............................................................................298
Radiator Aluminum and Radiator Install...................................... 299
Cooling System........................................................................... 304
Surge Tank and Soft Coolant Line Routing................................. 310
Emergency Brake and Cables .................................................... 317
Cockpit/Tunnel Aluminum........................................................... 320
Axles and CV joints..................................................................... 323
Speedometer Gear ............................................................................325
CV Axle Install ...................................................................................326
Chassis Wiring............................................................................ 328
Fuse Panel ........................................................................................328
Main Harness Routing........................................................................330
Steering column plug.........................................................................334
Hazard Wiring....................................................................................335
Fog light wiring...................................................................................336
Headlight relays.................................................................................337
Windshield Wiper Harness.................................................................340
Ignition Switch....................................................................................343
Brake Light Switch.............................................................................344
Engine Harness Fuse Panel Connection............................................348
Fuse panel mounting..........................................................................352
Underdash light..................................................................................355
Computer Bracket Mount ...................................................................356
Computer/Engine Harness.................................................................360
Instrument sending units....................................................................373
Vehicle Speed Sensor........................................................................382
OBD II Diagnostic Plug ......................................................................386
Battery Cables ............................................................................392
Steering Wheel and Horn............................................................ 394
Battery Install..............................................................................398

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Shifter Linkage............................................................................404
Catalytic Exhaust Pipe Installation..............................................415
Fuel Tank and Fuel line Routing................................................. 419
1997–2002 Fuel Tanks......................................................................419
Fuel tank Crossover Tube..................................................................420
Fuel line Routing................................................................................422
2002-2004 Fuel Tanks.......................................................................430
Drive/Test Chassis (Go-Cart)...................................................... 435
Front Suspension...............................................................................435
Fluid Levels and Grease ....................................................................435
Wheels..............................................................................................436
Rattle Patrol.......................................................................................436
Foot Box Front Wall, Top Panel, and Tunnel Cover Aluminum... 437
Main Body mounting...................................................................440
Door area mounting...........................................................................442
Rear body mount ...............................................................................443
Firewall mounting........................................................................ 444
Taillights...................................................................................... 449
Fuel Filler Caps........................................................................... 451
Rear Quarter Windows................................................................ 453
Rear Hatch Hinge........................................................................453
Rear Hatch Latch........................................................................461
Wipers......................................................................................... 465
Diffuser........................................................................................ 467
Doors .......................................................................................... 475
Door Hinge ........................................................................................476
Power Window Track.........................................................................481
Windows ..................................................................................... 492
Side Mirrors................................................................................. 504
Vents and Screens...................................................................... 508
Hood Preparation........................................................................512
Headlight and Turn Signal Mounting........................................... 513
Front wheel well panel .......................................................................517
Headlight Lenses........................................................................ 520
Hood Hinge/Hood mounting........................................................521
Gas strut Installation..........................................................................527
Hood Latches.............................................................................. 530
Final Paint Prep/ Body Shop Tips...............................................533
Interior - Rear Wall...................................................................... 540

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Roll Bar Padding.........................................................................545
Front Cross Bar .................................................................................545
Side Bars...........................................................................................549
Vinyl Installation.......................................................................... 554
Fuel Tank Covers...............................................................................554
Rear Wall...........................................................................................560
Tunnel – Driver and Passenger Side..................................................566
Cockpit Side Wall (Upper)..................................................................578
Cockpit – Door Sill Inside Panel Installation........................................579
Carpet Installation.......................................................................582
Footbox Outside Wall, Upper .............................................................582
Footbox Outside Wall, Lower .............................................................583
Footbox Front Wall.............................................................................584
Floor..................................................................................................585
Cockpit Rear Window.................................................................. 589
Interior Engine Cover.................................................................. 593
Fuel Tank Cover Installation ....................................................... 596
Undercarriage Aluminum Installation..........................................599
Engine Floor/Engine Access Panel.....................................................599
Tunnel Floor ......................................................................................600
Rear Quarter Floor (R, L)...................................................................602
Fuel Tank Floor (R, L)........................................................................603
Undercarriage – Floor Pan (R, L).......................................................603
Seat Belts.................................................................................... 605
Seats........................................................................................... 607
Dash Wiring and Gauge Installation............................................613
Power Window Wiring........................................................................614
Gauge Installation..............................................................................617
Headliner..................................................................................... 620
Body Final Installation................................................................. 622
Taillights...................................................................................... 623
Fog Lights................................................................................... 625
Headlight wiring ..........................................................................629
Headlight covers......................................................................... 632
Aluminum Mesh .......................................................................... 632
Aluminum Firewall....................................................................... 633
Fuel Filler Installation.................................................................. 635
1997-2002 Fuel tanks........................................................................636
2003-2004 Fuel tanks........................................................................638

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Windshield Wipers and Washer Fluid Tank ................................ 640
Door Handles/ Liners..................................................................653
Rear Splash Guards....................................................................664
Exhaust/ Rear Mesh.................................................................... 669
License Plate Lights....................................................................676
Diffuser........................................................................................ 677
Dash............................................................................................ 678
Dash Vents........................................................................................678
Center Console..................................................................................681
Dash Pods.........................................................................................686
Gauge panel......................................................................................693
Fog Light Switch................................................................................695
Hazard switch....................................................................................696
Power window switches .....................................................................696
Shifter boot, ring and knob.................................................................696
Column Cover Installation..................................................................697
Emergency Brake Cover Plate....................................................698
Front Upper Wheel Well and Pedal Box Cover Aluminum.......... 700
Front Wheel Well Rear Splash Guard Aluminum........................ 704
Body Close-out Panels................................................................ 707
Front..................................................................................................707
Rear ..................................................................................................708
Door Sill Carpet........................................................................... 710
Aluminum Door Sill Covers......................................................... 712
Cockpit Upper Side Walls and Rear Hatch Release ................... 713
Rear Hatch Release Cable .........................................................717
Hood Release Cable...................................................................717
Windshield, rear hatch and side window glass............................ 720
Finishing Touches....................................................................... 721
Headlight Alignment...........................................................................721
Alignment Specifications....................................................................723
Appendix A - Torque Specifications.......................................724
Suspension Bolts ........................................................................724
General Bolt torque specifications*............................................. 724
Appendix B – Donor Specs by Year ......................................726
Appendix C – Donor Parts Required......................................727
Appendix D – Heat & A/C Installation ....................................733
GTM A/C Evaporator Kit ............................................................. 733
Installation Instructions.......................................................................733

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GTM A/C Hose............................................................................746
Installation Instructions.......................................................................746
Heat & A/C Hose kit Routing Diagram ........................................ 754
Heat & A/C Servicing Procedure.................................................755

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GeneralInformation
Foreword
f you are reading
this, you are
embarking on a
mission to build
your own car, or at
least considering doing
so. I wanted to share
with you some of my
experiences and lessons
learned while working
with literally thousands
of people who have
completed this
undertaking with
us. The lessons learned
here are important and
will hopefully help
with your decisions as
well as with the project
and the completed car.
First of all, the idea of
building your own car
is NOT for
everyone. It is a
serious endeavor that
should be undertaken with care and consideration. The desire to build your
own custom car goes way back. It is part of our uniquely American car-
centric culture, and those who build their own cars are at the very center of
this. Since the earliest days of Hot Rodding, literally tens of thousands of
people have built their own cars. Even more have done restorations and
major customizations to existing cars. As fun as this project is, a person
should be candid about their abilities turning a wrench. This is not a place
for novices. That is even truer in racing, where danger and risk are part of the
Chapter
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