Caterham Assembly Guide July 2010

PRELIMINARY INFORMATION

PRE 01Page 1

ASSEMBLY GUIDE

DE DION CHASSIS FITTED WITH FORD SIGMA VARIANTS

TABLE OF CONTENTS

Para Page

List of sections (this page) .......................................................................................... 1List of abbreviations .................................................................................................... 2

1 General warnings and cautions .................................................................................. 32 Specific warnings and cautions .................................................................................. 3

LIST OF SECTIONS

Section

1 Introduction2 Pre-Assembly Information3 Steering4 Front Suspension5 Fitment of Gearbox to Engine6 Installation of Engine and Gearbox7 Preparation and Installation of the Differential8 Rear Suspension9 Interior Trim

10 Fibreglass11 Lighting12 Weather Equipment13 Wheel Fitment14 Start up Procedure and Final Checks15 Single Vehicle Approval and Registration16 Options17 Electrical

Index


PRE 01Page 2

LIST OF ABBREVIATIONS

A/F Across Flats

CKD Complete Knock Down

CV Constant Velocity (joint)

DVLA Driver and Vehicle Licensing Agency

EC European Community

ECU Engine Control Unit

EMU Engine Management Unit

FIA Federation Internationale De L'Automobile

Kph Kilometres Per Hour

lbft Pounds Feet

LED Light Emitting Diode

LH Left-Hand

LSD Limited Slip Differential

MAC Ministers Approval Certificate

MAP Manifold Air Pressure

mm Millimetre

mph Miles Per Hour

MSA Motor Sports Association

Nm Newton Metre

OAT Organic Acid Technology

psi Pounds Per Square Inch

QR Quick Release

RH Right-Hand

SVA Single Vehicle Approval

UNC Unified Coarse

UNF Unified Fine

VED Vehicle Excise Duty

VHPD Very High Performance Derivative

VRO Vehicle Registration Office


PRE 01Page 3

GENERAL WARNINGS AND CAUTIONS

1 The following warnings and cautionsindicate general and environmental hazardspresent during the building process:

WARNINGS

(1) Due consideration should be given tothe highly flammable nature of petroleum oralcohol based products and their vapours.Serious burns can result from incorrect use.

(2) Oils – prolonged and repeated contactmay cause serious skin disorders:

(a) Avoid contact with the skin as faras possible and wash thoroughly afterany contact.

(b) Keep out of reach of children.

(c) First aid treatment should beobtained for open cuts and wounds.

(d) Use appropriate barrier creams.

(3) Hydraulic fluid (brake fluid) ispoisonous. Wash affected areasimmediately in case of skin contact and seekmedical assistance if swallowed.

(4) Hydraulic fluid (brake fluid) ishygroscopic. Ensure only clean fresh fluid isused.

(5) Hydraulic fluid (brake fluid) iscorrosive to paintwork, powder coat andplastic components. Care should be taken toavoid spillage at any times.

CAUTIONS

(1) Protect the environment. It is illegal topollute drains, water course and soil.Authorised waste collection facilities includecivic amenity sites and garages whichprovide facilities for the disposal of oil andused oil filters. If in doubt ask the localauthority for advice.

SPECIFIC WARNINGS AND CAUTIONS

2 The following warnings and cautionsindicate specific hazards relating to theCaterham build process:

WARNINGS

(1) Never work underneath a car withoutsupporting it on axle stands or equivalent.Do not rely on a jack alone.

(2) Use appropriate eye protection whilstcarrying out drilling operations.

(3) Use appropriate eye protection whilstworking under the car.

(4) Cars fitted with electronic ignitionsystems have increased voltages comparedwith conventional systems. Ensure systemis switched off prior to carrying out anywork.

(5) The electric radiator fan is controlledby a thermostatic switch which operateswhen the ignition is in the 'on' position.Whilst working on a hot engine ensure thatthe ignition is switched off.

(6) Do not remove coolant expansionbottle cap whilst coolant is hot. Takeprecautions to prevent scalds.

(7) Correct use of fixings is required inorder to ensure full engagement of the nylocnut.

(8) Both imperial and metric threads areused on the De Dion brake pipes. Thethreads on the three way union are imperialwhilst those on the brake callipers aremetric. To aid recognition a small notch ismachined into the hexagon of the metricunions.

(9) Retighten wheel nuts after 200 miles.

(10) Ensure adhesive is applied in a wellventilated area. Follow instructions onadhesive packaging. Care must be takenwhilst working in a confined area, forinstance the footwell.

(11) Use a suitable face mask to preventinhalation of dust when drilling fibreglass orcarbon fibre.


PRE 01Page 4

CAUTIONS

(1) All brake connections must be keptspotlessly clean and contamination with oil,water and petrol should be avoided.

(2) When drilling fibreglass use tape onthe surface over the drill holes to preventdamage to the gel coat or painted finish.Slow drill speeds must be used.

(3) Do not over-tighten thermostatic fanswitch.

(4) If less than 43 mm is measured thenthe differential casing may be holed. If morethan 43 mm is measured it is possible thatthe De Dion tube may hit the differential.

SECTION 1 - INTRODUCTION

Section 1 INT 01Page 1

TABLE OF CONTENTS

Para Page

1 Introduction ................................................................................................................. 24 Contact information..................................................................................................... 26 Part recognition/shortages.......................................................................................... 27 Technical help............................................................................................................. 28 Post build check.......................................................................................................... 2

12 Single vehicle approval ............................................................................................... 313 Aftersales .................................................................................................................... 3

Disclaimer ................................................................................................................... 3Suggested build sequence ......................................................................................... 4



INTRODUCTION

1 It is recommended that the entireassembly guide is read before commencingbuilding of the car. This will allow planningahead for the procurement of tools,consumables and equipment required during thebuild process.

2 Whilst it is possible for many of the buildprocesses to be undertaken simultaneouslythere are some areas where the correct buildsequence is critical. A suggested buildsequence is included at the end of this section.

3 The chassis and packages supplied havebeen engineered to enable a Ford Sigma engineto be installed in conjunction with either a FordType 9 close ratio 5-speed or Caterham 6-speedgearbox. A Ford Sierra differential is utilised.There are several different versions of theseengines, gearboxes and differentials available.If you have not purchased your entire kit fromCaterham you should ensure that you sourcethe correct parts by calling Caterham for furtherinformation.

CONTACT INFORMATION

4 For aftersales service and all otherenquiries, contact Caterham Cars at Dartford ontelephone number 01322 625800 (Fax 01322625810).

5 Ensure that you make a note of your salesorder number (top RH side of invoice) and yourcustomer number as these are the references bywhich we know you and your kit and will ensurethat, no matter how long you take to assembleyour car, subsequent packages will becompatible.

PART RECOGNITION/SHORTAGES

6 The kit provided by Caterham Cars (fromthe factory at Dartford) includes all the itemsrequired to build the car. However, due to thesheer number of different components it ispossible that some parts are omitted orduplicated. Kits should be checked to ensure allcomponents (including contents of fastenerpacks) are present prior to starting construction.If there are any shortages contact the CustomerLiaison Department at the factory.

TECHNICAL HELP

7 Caterham Cars will happily providetechnical assistance when required. When indoubt, ask.

POST BUILD CHECK

8 When your Caterham Seven is finallycompleted and ready for the road it is stronglyrecommended that you make use of our PostBuild Check facility. All customers are sent afree voucher covering the first three hours of thePost Build Check (this is ample time to check acompleted kit, which can be carried out at thefactory in Dartford, at Caterham Midlands or atone of our approved services agents). TheSeven even in its lowest state of tune possessesacceleration and cornering abilities far in excessof most road going cars and it is thereforeextremely important that it is assembled and setup correctly.

9 We are also keen to ensure that ourcustomers do not suffer disappointment as aresult of sub-standard performance or prematurecomponent failure resulting from incorrectassembly.

10 The Post Build Check therefore includes:

Inspection of all safety related items.

Inspection of all operating systems(Clutch, Gearbox, Axle etc).

A written report on any matters causingconcern or requiring attention.

Completion of any agreed warranty work.

Post Build Inspection Certificate when thecar has passed inspection.

Check to ensure compliance to SVArequirements (if required).

11 The inspection will take approximatelythree hours and we suggest that you give atleast two weeks notice when booking your carin. If additional work is required please notifythe Service Manager at the time of booking toensure that sufficient time can be madeavailable. Any additional work will be chargedon an hourly basis.


INT 01 Section 1Page 3

SINGLE VEHICLE APPROVAL

12 The requirements for Single VehicleApproval (SVA) are detailed in Section 15. Foradvice or assistance on SVA matters contact theAftersales Department. SVA is a requirement forUK markets only therefore the additional partswill not be supplied with overseas orders.

AFTERSALES

13 To maximise the enjoyment of yourSeven, the safety and integrity of the car mustbe maintained by careful adherence to themaintenance schedules. Further information onwhen servicing is required and where best to getit done can be found in the Owners Handbooksupplied with your car.

DISCLAIMER

The Caterham Seven is supplied in kit form andis supplied for amateur construction.

The builder must assume that all nuts, bolts andfasteners may be loose and takes theresponsibility to ensure road worthiness.

Sound engineering principles must always befollowed.

A free post build check is available from thefactory or from one of Caterham Cars agents.

NOTE

In the UK, the assembled kit cannot legally bedriven to the post build inspection (prior tosuccessful completion of an SVA test).



SUGGESTED BUILD SEQUENCE

WORK AREA DETAIL COMMENT

FRONT

Steering Initial fit

Steering rack

SVA sleeves

Track rod ends

Front Suspension

Lower wishbones

Upper wishbones

Headlight brackets

Damper units

Uprights

Wingstays

Anti-roll bar On R400 Back radiator cowling shouldbe fitted before anti roll bar

Front flexible brake hoses

Headlights and front indicators Can be left until after engineinstallation

ENGINE & GEARBOX

Speedo drive plugs (large andsmall)

Gearbox rubber mounting

Gearbox to bell housing

Clutch release mechanism

Gearbox to engine

Prep Engine

Oil pressure sender Normally fitted to the engine, if notplease fit it before engine installation

Starter motor

Wiring loom (starter toalternator)

‘J’ hose

Intermediate top hose ( ‘U’ hose)

Gearbox filler plug Loosen

Gearbox tail shaft plug Remove

ENGINE BAY

Engine mount blocks Fit to Chassis

Earth lead




Wiper reservoir

Oil separation tank mountings Optional fitment

Alternate header tank mountingplate

Optional fitment

Horns Standard location only

Install engine/gearbox

Engine mounts Fit to Engine

Earth lead

Engine/chassis loomconnections

Starter/battery leads

ECU

MAP unit

Reverse light switch

Gear stick

Fuel pipe

Primary exhaust pipes

Collector box/cat

Lambda probe

Oil separation tank Optional

Header tank mounting Optional

Horns Alternate location

Steering column

Steering wheel

Bottom hose

Top hose

Radiator bobbins

Fan and inner cowl Cowling is Only on R400

Anti-roll bar Front suspension section

Fan switch

Radiator

Outer cowl Cowling is Only on R400

Heater May be fitted before engine

Heater hoses

Heater valve

Heater control cable

Header tank




Expansion hoses

Cycle wings and indicatorrepeaters

REAR CHASSIS

Prep and install diff

Handbrake and cables Initial assembly

Propshaft

Differential

Rear Suspension

Brake pipes and flexi hose

De Dion tube

Rear dampers Only If standard roll over barspecified

Radius arms Or optional Watts linkage

‘A’ frame

Drive shafts

Rear anti-roll bar Optional

De Dion ears

Hub carriers

Speed sensor Including anti-roll bar spacer ifspecified

Hubs/discs

Callipers

Attach handbrake cables Adjusted after brakes are bled

COCKPIT & BOOT

Transmission tunnel trim

Gear knob

Scuttle edge trim

Sill protectors Optional

Knee trim panels and interiorpanel piping

Depends on roll overprotection specified

Four and six-point harness lapand crutch straps

Optional

Carpets

Seats

Roll over bar/cage as specified

Head restraint Roll cage option only

Rear dampers If track day roll over bar or rollcage specified




Fuel filler shroud

BODYWORK AND HOOD

Front wings and indicatorrepeater lights

May be fitted immediately afterfitting front anti-roll bar

Rear wing protectors

Rear wings

Exhaust pipe bracket

Exhaust silencer

Heat shields Silencer and collector/cat

Hood sticks

Hood fasteners

Side screens

SVA

PAGE INTENTIONALLY BLANK

SECTION 2 - PRE-ASSEMBLY INFORMATION

PRE 01 Section 2Page 1

TABLE OF CONTENTS

Para Page

1 Package contents ....................................................................................................... 23 Basic definitions .......................................................................................................... 45 Tools and equipment .................................................................................................. 4

11 Nuts, bolts and washers.............................................................................................. 520 General build information (Warning)........................................................................... 825 Useful web sites.......................................................................................................... 8

Table

1 Package contents ....................................................................................................... 22 Tools required ............................................................................................................. 43 Additional tools and equipment................................................................................... 44 Consumables .............................................................................................................. 55 Recommended lubricants ........................................................................................... 56 General torque figures ................................................................................................ 5

Fig

1 Complete kit (less engine) .......................................................................................... 32 Cut down Allen key ..................................................................................................... 43 Fastener pack ............................................................................................................. 74 Front axle stands ........................................................................................................ 85 Rear axle stands ......................................................................................................... 8

Annex

A Kit contents ................................................................................................................. 1


Section 2 PRE 01Page 2

PACKAGE CONTENTS

1 This section has been included to aidrecognition of parts and to give a basic idea asto where they might be found. Due to thecomplexity of the range of options available andsubsequent variations on packages it isimpossible to list every permutation; howeverTable 1 (below) and Annex A (at the end of thissection) show the normal location of parts in astandard CKD kit.

2 Kits supplied from Caterham Cars arriveas shown in Fig 1. Due to packaging constraintssome items may be located in differentpackages.

TABLE 1 PACKAGE CONTENTS

BOX Package Contents

BOX 1 Steering, Exhaust,Gearbox assembly,Drive shafts

Steering rack, rack clamps, upper and lower steering columns, column bush,column clamp, track rod ends. Grub screws, silencer assembly (standardsystem). Primary pipes (4), collector or catalyst collector, silencer(competition system), exhaust guard, mounting brackets and bobbins, wheelnuts, centre caps, badges, bell-housing, clutch release mechanism, speedsensor and threaded adapter, reverse light switch, mounting rubber,gearknob, anti-roll bar and fixings, cycle wingstays, 'A' frame, differentialdriveshafts and nuts, De Dion Tube, brake pipes, propshaft

BOX 2 Axle (De Dion) Disc pads and callipers, drive flanges, De Dion ears, hub, bearings

BOX 3 Differential Differential assembly

BOX 4 Front Suspension,Rear Suspension

Spring damper units, upper and lower wishbones, spring damper units,radius arms/Watts linkage, anti-roll bar and fixings

BOX 5 Cooling Coolant hoses, water rail, cooling fan, heater (option on Superlight), bobbins,expansion bottle and cap, radiator cowling

BOX 6 Lighting Headlamp units, headlamp brackets (cycle wing only), indicator pods,indicators, number plate light, reversing light, fog light, side repeaters

BOX 7 Miscellaneous Pack Handbrake lever, interior mirror, battery cables, wheel brace, gear lever, toolbag, nosecone badge, engine mounting rubbers, scissor jack, windscreenwasher kit, stainless steel brake hoses, horns, windscreen wipers

BOX 8 Interior Trim Covered tunnel top, tunnel side carpets, footwell carpets, seat back carpets,seats, hood, sidescreens, hood sticks, boot cover, pulley and cables, throttlecable, clutch cable, rear wing protectors, steering wheel, spare wheelwishbone, seat belts and fixings, tonneau cover, seat runners, seat spacers,assembly guide, arm restraint, hardware packs, SVA packs, SVA mirrors, airbox and fixings

BOX 9 Weather equipment Hood straps, exterior mirrors, fuel filler cover, hinges (sidescreen), sillprotectors, wiper arms, wiper blades, hardware pack

OWN BOX Upright Front upright assemblies including brakes

PALLET Engine Complete engine and clutch, engine loom, engine mounting brackets

OWN BOX Gear box

OWN BOX Radiator

LOOSE Side exit catalyst

LOOSE Wheels and Tyres Alloy wheel and tyre assemblies

OWN BOX Roll over bar

ONCHASSIS

Chassis/ Body Unit Chassis, battery, body panels, pedals, master cylinder, instruments,switches, wiring loom, fuel tank, fuel pump, fuel lines, ignition module/ECU.Rear wings, front wings, nosecone, battery, battery clamp/tray, knee trimpanels, scuttle trim, econoseal plugs, steering column plate, grilles (Mesh 7),int panel trim, keys (ignition, fuel cap, battery master switch), aluminiumtonneau cover, paint touch bottles



Fig 1 Complete kit (less engine)



BASIC DEFINITIONS

3 The text in the assembly guide refers tothe Right Hand (RH) side or Left Hand (LH) sideof the car. For all purposes the RH side of thecar is taken to be the driver’s side of a RH drivecar.

4 Also mentioned in the assembly guide arethe terms inboard (pointing towards the centreline of the car) and outboard (pointing away fromthe centre line of the car).

TOOLS AND EQUIPMENT

5 All kits supplied by Caterham Cars arespecifically designed for the amateur car builderwith basic facilities. Table 2 details the generalpurpose tools that will be required during thebuild process.

TABLE 2 TOOLS REQUIRED

Item Remarks

Socket set Metric and imperial

Spanner set Metric and imperial

Screwdriver Flat point (various)

Screwdriver Phillips/posidrive (various)

Soft facedhammer

Rubber/plastic/copper/hide

Circlip pliers

Torque wrench 0 to 80 Nm

Allen keys Metric

Measuring tape

Hacksaw

Rivet gun

Goggles Eye protection

Twist drill bits Metric and imperial

Crimp pliers

Drill Preferably rechargeable

Axle stand Qty 4

Jug/small funnel

6 The tools detailed in Table 3 are notgenerally to hand in the amateur workshop.These will be required during the build process.

TABLE 3 ADDITIONAL TOOLS ANDEQUIPMENT

Item Remarks

Engine hoist SWL of 150 kg

Socket 41 mm

Torque wrench Up to 275 Nm

Cut down Allen key

3/8” – 6 speed

10 mm – 5 speed

Gearbox oil filler plug

Durable Dotfastening tool

76068 – supplied withchassis kit

7 The engine hoist should only be requiredfor a short time and can usually be sourced froma tool hire company. The 41 mm socket andtorque wrench will be required to tighten the rearhubs to the drive shafts and the cut down Allenkey is required to tighten the gearbox oil fillerplug, due to the restricted access in thetransmission tunnel. The key can be modifiedas shown in Fig 2.

Fig 2 Cut down Allen key

8 The consumables detailed in Table 4 andrecommended lubricants detailed in Table 5 arerequired during the build process.



TABLE 4 CONSUMABLES

Item Type Remarks

Rubberlubricant

Holts RL2R To ease assemblyand operation ofrubber bushes andgrommets

Coppergrease

CommaCopper Ease

Anti seize compoundwhere lubrication isnot required to ensureease of futuredisassembly

Threadlock LoctiteThreadlock242 or 243

Used where theapplication preventsthe use of nyloc nutsor spring washers

Siliconesealant

Clear To achieve awatertight seal. Itshould be appliedsparingly

Maskingtape

Duct tape Protection of body

Adhesive Contact Carpet/trim

TABLE 5 RECOMMENDED LUBRICANTS

Item Ford Sigma Duratec

Engine oil Ford engine oilFormula E-5W-30

CaterhamMotorsport oil5W-50

CaterhamMotorsport oil5W-50

Comma X-TEC5W-30 semisynthetic

Comma X-TEC5W-30 semisynthetic

Gearboxoil (5 and 6speed)

Caterhamgearbox oil EP 80grade

Caterhamgearbox oil EP80 grade

Differential(All)

Caterhamdifferential oilEP90

Caterhamdifferential oilEP90

LSD -additive

LubeguardLimited Slip Diffadditive

LubeguardLimited SlipDiff additive

Brake fluid Comma DOT4 Comma DOT4

Enginecoolant

CommaXstream Red orFord Super PlusAnti-frezz

CommaXstream Red orFord SuperPlus Anti-frezz

NOTEIt is recommended that non-synthetic standardmulti-grade oil is used for the first 500 miles toaid the running in process.

9 It is recommended that a sturdyworkbench and a good vice are made availablefor holding items stable.

10 The application of undue force should notbe necessary if assembly is carried out in thecorrect sequence.

NUTS, BOLTS AND WASHERS

11 As a general rule the fasteners used areRH thread and of Metric dimensions. SomeImperial fasteners are still used, particularlywithin the brakes and suspension.

12 Always assume that bolts and fastenersare not properly tightened until they have beenspecifically checked.

13 All safety critical fastenings supplied byCaterham Cars are high tensile conforming toBritish Standards 1768 (Imperial) and 3692(Metric). Customers supplying their ownfasteners should only use fasteners with headsmarked 10.9 and 12.9 particularly whenattaching suspension, steering, upright and axlekits. Any unmarked bolt should not be used.

14 Ensure that the correct tightening torqueis applied. Where torque figures are notspecified use the figures detailed in Table 6.Particular care must be taken when using thetorque wrench to tighten fastenings intoaluminium.

TABLE 6 GENERAL TORQUE FIGURES

Thread Socket size Torque(Nm)

1/4" UNF/UNC 7/16" A/F 7

5/16" UNF/UNC 1/2" A/F 20

3/8" UNF/UNC 9/16" A/F 34

7/16" UNF 5/8" or 11/16" A/F 47

1/2" UNF 3/4" A/F 61

5 mm 10 mm 6

6 mm 11 mm 7

8 mm 13 mm 20

10 mm 17 mm 47

12 mm 19 mm 61

15 It is good practice to mark the bolt head ornut with a spot of paint once it has been finallytightened. This provides a good visual means ofchecking that all fixings have been set to thecorrect torque.

16 Over tightening can often cause moreproblems than under tightening, such assheared bolts and studs and incorrect stresses.



17 The majority of fastenings have washersinserted between the nut and or bolt head andthe item being secured. Spring washers or lockwashers are usually placed next to the bolt heador nut then the plain washer. As a general rulethe following washers are used as detailed:

Plain washer

To protect the surface and spread a loadwhen attaching to a soft material such asglass fibre or aluminium.

To adjust the spacing of one componentto another use plain washers ofappropriate thickness and externaldiameter.

To present a uniform surface on which totighten a fastening onto a rough orirregular surface.

Spring washer

To lock a thread where there is apossibility of the nut or bolt working loose.Not used with a nyloc nut.

Large diameter, thin plain washer

To spread a load onto very thin material.

Large diameter plain washer

To prevent migration (sidewaysmovement) of rubber bushes.

The large plain chamfered washers areoften used in conjunction with themetallistic suspension bushes. Wherethis is the case the chamfered edge mustbe fitted towards the bush to preventcontact with the outer metal part of thebush.

18 Particular care should be taken to ensurethat the correct fastening is being used, since itis possible to use an overlong bolt only to findthat it is apparently missing when the onlyremaining bolts are too short.

19 The majority of fasteners supplied byCaterham are in polythene bags with an A4sheet on a card insert, refer to Fig 3. The A4sheet can be used to confirm that the contentsare correct. Each pack has a unique number,located at the top RH corner and each itemwithin the pack can be identified by a number atthe bottom LH corner of the part number box.Where fasteners are specified in the text, theunique pack number will be stated the first timeit is required along with the description and theItem Identification number in brackets. The nexttime an item from that pack is required it will beidentified by description and the ItemIdentification number only, for example:

Bolt (fastener pack 30P017A Item 2)identifies the Bolt M8 x 50 mm from thefastener pack illustrated at Fig 3.

At a later point in the same section of text‘nut (4)’ identifies the M8 nut from thesame fastener pack.

NOTE

Imperial and metric fasteners are suppliedtogether in some packs. Ensure that the correctthreadform is identified before use.



Fig 3 Fastener pack



GENERAL BUILD INFORMATION

20 Caterham Seven builders should takecare to observe basic safety precautions whilstassembling the kit since tools, parts andmaterials handled incorrectly may result ininjury.

21 Due to circumstances beyond the controlof Caterham Cars, occasionally it is necessaryto change suppliers and/or to make minorchanges to the car or kit specification.

22 If it is intended to build the car over ashort period (up to 4 weeks) it is recommendedthat an application for the SVA inspection issubmitted now. There is usually a wait of 2-3weeks, minimum. In addition it will take up to aweek for the Vehicle Inspectorate to process theapplication. Full details about applying for theSVA inspection can be found in Section 15.

WARNING

Never work underneath a car withoutsupporting it on axle stands or equivalent.Do not rely on a jack alone.

For SVA inspection you will needphotographic evidence of the car build.Caterham recommends that you should takesome photos of yourself working on the carat different build level.

23 It is recommended that the chassis issupported on 4 axle stands which will givestability for both safe working and ready access.Placing of the axle stands is made easier ifassistance is available. Lift the front of the carand place the axle stands at the outer ends ofthe second chassis cross tube adjacent to therear mounting of the lower front wishbonemounting, refer to Fig 4. If the car is raisedusing a jack, ensure that it is positioned underthe front cruciform and that the powder coatfinish is protected.

Fig 4 Front axle stands

24 The rear axle stands should be positionedat either end of the chassis tube that supportsthe front of the fuel tank, refer to Fig 5. If the caris raised using a jack, ensure that it is positionedcentrally and the powder coat finish on thechassis tube is protected.

Fig 5 Rear axle stands

USEFUL WEB SITES

25 Useful web sites where you can findinformation on Caterham services andrecommended consumables and lubricants:

www.caterham.co.ukwww.commaoil.comwww.loctite.uswww.holtsauto.com

SECTION 2 ANNEX A - KIT CONTENTS

ANA 01 Section 2 Annex APage 1

TABLE OF CONTENTS

Para Page

1 Introduction ................................................................................................................. 22 Packages .................................................................................................................... 2

Important note............................................................................................................. 23 Exhaust, steering, large suspension items, bell-housing and front wingstays.... 34 Rear axle ............................................................................................................. 65 Differential ........................................................................................................... 76 Driveshafts .......................................................................................................... 77 Suspension.......................................................................................................... 88 Cooling ................................................................................................................ 109 Lighting................................................................................................................ 11

10 Uprights ............................................................................................................... 1211 Interior trim, cable and options............................................................................ 1312 Miscellaneous...................................................................................................... 1613 Gearbox............................................................................................................... 1814 Chassis/body unit ................................................................................................ 1915 Weather gear (optional) ...................................................................................... 2016 Engine ................................................................................................................. 2117 Heater assembly ................................................................................................. 2118 Wheels ................................................................................................................ 2119 Seat ..................................................................................................................... 2120 Wings .................................................................................................................. 2221 Nosecone ............................................................................................................ 2222 Roll over bar ........................................................................................................ 22

Table

1 Polythene bag contents - exhaust, steering, suspension items, bell-housingand front wingstays ..................................................................................................... 4

2 Polythene bag contents - rear axle ............................................................................. 63 Polythene bag contents - suspension......................................................................... 94 Polythene bag contents - interior trim, cables and options......................................... 155 Polythene bag contents - miscellaneous .................................................................... 17

Fig

1 Exhaust ....................................................................................................................... 32 Steering, large suspension items, bell-housing and front wingstays.......................... 53 Rear axle items........................................................................................................... 64 Differential ................................................................................................................... 75 Driveshafts .................................................................................................................. 76 Suspension items........................................................................................................ 87 Cooling items .............................................................................................................. 108 Lighting items.............................................................................................................. 119 Uprights....................................................................................................................... 12

10 Boot carpet.................................................................................................................. 1311 Bulkhead carpet .......................................................................................................... 1312 Footwell carpet............................................................................................................ 14

(continued)


Section 2 Annex A ANA 01Page 2

TABLE OF CONTENTS (continued)

Fig Page

13 Rubber mats ................................................................................................................ 1414 Transmission tunnel top .............................................................................................. 1415 Miscellaneous items .................................................................................................... 1616 5-speed gearbox.......................................................................................................... 1817 6-speed gearbox (optional) ......................................................................................... 1818 Items loose in chassis ................................................................................................. 1919 Weather gear (optional)............................................................................................... 2020 1.6 engine 3/4 left ........................................................................................................ 2121 Heater assembly.......................................................................................................... 21

INTRODUCTION

1 The following pages include pictures and tables to assist with part recognition and location. Due tothe multiple permutations that can be produced it is impossible to show the exact locations of every part.However the pictures have been laid out in such a way that each picture represents what you shouldexpect to find in a particular box.

PACKAGES

2 The complete kit is supplied as follows:

Chassis/Body unit (CBU).

Composite panels (nosecone, rear wings and front wings).

Engine assembly.

Gearbox assembly.

Boxes of parts (approximately 10).

Wheel/tyre assemblies.

Seats.

Exhaust silencer.

Heater (in own box).

IMPORTANT NOTE

The following pages are provided as a guide to aid recognition of parts. The packages shown willnot be an exact representation of what you should expect to find in the packages supplied withyour kit and should therefore not be used as a parts check list.



Exhaust, steering, large suspension items, bell-housing and front wingstays

3 The exhaust, steering, large suspension items, bell-housing and front wingstay items are shown inFig 1 and Fig 2. The contents of the polythene bags are shown in Table 1.

1 Exhaust guard 5 Cat/collector2 Fastener pack ‘exhaust’ 6 Exhaust primary pipes3 Polythene bag 'exhaust' 7 Exhaust silencer4 Cat guard

Fig 1 Exhaust

NOTE

Items may differ from those illustrated.



TABLE 1 POLYTHENE BAG CONTENTS - EXHAUST, STEERING, SUSPENSION ITEMS, BELL-HOUSING AND FRONT WINGSTAYS

Identifier Description Qty

Gearbox Gearbox mounting rubber 1

Gear knob 1

Speedo drive cover 1

Reverse light switch 1

Grommet 2

Speedo blanking plug 1

Steering Track rod ends 2

Universal joint 1

Aluminium steering rack clamps 2 pairs

Steering column bush 1

Grommets 2

Grub screw 1

Steering column clamp 1

Steering column clamp plate 1

Steering column cheese wedge 1

Rivets 3

Exhaust Jubilee clips 5

Exhaust clamp 1

Exhaust mounting bracket 1

Mounting bobbins 2

Exhaust springs 2

Lambda sensor 1

Wheels Wheel nuts 16 or 18

Wheel nut washers 16 or 18

Centre caps 4 or 5

Centre cap badges 4 or 5



1 Fastener pack ‘steering’ 10 Front anti-roll bar2 Front wingstay 11 ‘A’ Frame3 Polythene bag 'gearbox' 12 De Dion tube4 Bell-housing 13 Brake pipe (short)5 Polythene bag 'steering’ 14 Brake pipe (long)6 Polythene bag 'wheels' 15 Propshaft7 Fastener pack ‘gearbox’ 16 Upper steering column and QR boss (optional)8 Steering rack 17 Lower steering column9 Rear anti-roll bar

Fig 2 Steering, large suspension items, bell-housing and front wingstays



Rear axle

4 The rear axle items are shown in Fig 3. The contents of the polythene bag are detailed in Table 2.

1 De Dion ears 4 Hub/bearing assembly (2)2 Brake calliper (2, LH and RH) 5 Polythene bag 'rear axle’3 Brake disc (2) 6 Fastener pack 30R011A

Fig 3 Rear axle items

TABLE 2 POLYTHENE BAG CONTENTS - REAR AXLE


Rear axle Cable ties -

Aluminium brake calliper spacers 4

Drive shaft washer 2

3-way brake union 1

Race washers 2

Copper washer 1

Rear wheel speed sensor 1

Rear wheel speed sensor bracket 1

Rear brake pads 4



Differential

5 The differential is shown in Fig 4.

Fig 4 Differential

Driveshafts

6 The driveshafts are shown in Fig 5.

1 RH driveshaft 4 Nyloc nut (white insert)2 Speed sensor ring 5 LH driveshaft assembly3 Nyloc nut (green insert)

Fig 5 Driveshafts



Suspension

7 The suspension items are shown in Fig 6. The contents of the polythene bags are detailed inTable 3.

1 Fastener pack 30R012A 8 Watts link (rear) radius arm2 Fastener pack 30R011A 9 Watts link (front) radius arm3 Lower wishbone (RH) 10 Polythene bag 'rear suspension'4 Spring damper unit (front) 11 Fastener pack 30F015A5 Spring damper unit (rear) 12 Lower wishbone (LH)6 Upper wishbone (RH) 13 Upper wishbone (LH)7 Polythene bag 'front suspension'

Fig 6 Suspension items



TABLE 3 POLYTHENE BAG CONTENTS - SUSPENSION


Rubber cotton reel bushes 2Frontsuspension Damper sleeves 4

Anti-roll bar rubber cover 2

Anti-roll bar ball ends 2

Cables ties -

Anti-roll bars mounting clamps 2

Wishbone sleeves 2

Special stepped nyloc nut (widetrack/SV) 2

Rubber cotton reel bushes 2

Aluminium mounting blocks 2 pairs

Rear damper spacers 4

Bellcrank (Watts link) 2

Rearsuspension(includingRear anti-rollbar option)

Bellcrank spacer 2

Rod end (Watts link) 4

ARB mounting boss 2

Anti-roll bar extension 2

Thrust washer 2



Cooling

8 The cooling items are shown in Fig 7.

1 Outer radiator cowl 11 Water rail2 Radiator 12 Engine/water rail hose3 Inner radiator cowl 13 Hose4 Blanking plug 14 Expansion bottle bracket5 Expansion bottle cap 15 Polythene bag ‘cooling’6 Cooling fan 16 Fastener pack ‘cooling’7 Engine breather hose 17 Expansion bottle8 Expansion bottle hose 18 Top radiator hose9 Engine/heater outlet hose 19 Bottom radiator hose

10 Water bleed pipe

Fig 7 Cooling items

NOTES

(1) A thermostatic fan switch may be supplied in lieu of a blanking plug (if supplied, the switch mustnot be connected to the vehicle wiring harness).

(2) If supplied, the water bleed pipe may be fitted to the engine.

(3) Items may differ from those illustrated, dependant on kit specification.



Lighting

9 The lighting items are shown in Fig 8.

1 Headlight 6 Headlight bracket2 Fastener pack 30L002A 7 Indicator (repeater)3 Indicator cones 8 Rear light cluster4 Indicator (front) 9 Cable tie5 Headlight 10 Number plate light

Fig 8 Lighting items



Uprights

10 The uprights are shown in Fig 9.

1 Upright assembly (RH)2 Upright assembly (LH)

Fig 9 Uprights



Interior trim, cables and options

11 The interior trim, cables and options items are shown in Fig 10, 11, 12, 13 and 14. The contents ofthe polythene bags are detailed in Table 4.

Fig 10 Boot carpet

Fig 11 Bulkhead carpet



Fig 12 Footwell carpet

Fig 13 Rubber mats

Fig 14 Transmission tunnel top



TABLE 4 POLYTHENE BAG CONTENTS - INTERIOR TRIM, CABLES AND OPTIONS


SVA Cable ties -

Track rod end sleeves 2

Track rod end bottom cap 2

Wing mirror pack 1

Sticky back foam (roll) 1

Edge trim (roll) 1

Large flat bolt head covers 6

Small domed caps 12

Long bonnet catch rubbers 2

Short bonnet catch rubbers 2

Large domed caps 2

Medium domed caps 4

Spare wheel Wheel nuts 2

Spare wheel bolt 1

Spacer 1

Mounting wishbone 1

Oil/air tank Temperature sender 1

Filler plug 1

Lower mounting platform 1

Upper mounting brackets 2

Cradle cable tie mount 10

Foam insert 1

Hose clips 2

Cable ties 10

Dowty seal 1

Adhesive strip 1



Miscellaneous

12 The miscellaneous items are shown in Fig 15. The contents of the polythene bag are detailed inTable 5.

1 Fastener pack 30P012A 8 Battery negative lead2 Polythene bag 'miscellaneous' 9 Horns3 Tool kit including bag 10 Gear lever4 Rear view mirror 11 Handbrake5 Cable tie 12 Brake hoses6 Earth lead engine/chassis 13 Washer bottle7 Battery positive lead

Fig 15 Miscellaneous items



TABLE 5 POLYTHENE BAG CONTENTS - MISCELLANEOUS


Miscellaneous Propshaft bolts 4

Handbrake clevis 1

Tunnel blanking grommet 2

R-clip 2

Clevis pin 1/4” 1

Clevis pin 5/16” 1

Pulley 1

Clutch pedal stop 1

Throttle pedal stop 1

Brake calliper banjo bolts 2

Shake proof washers 2

Nyloc 1/4” 2

Washers 1/4” 2

Washer jet 1

Seat spacers 4



Gearbox

13 The standard 5-speed gearbox is shown in Fig 16, the optional 6-speed gearbox is shown inFig 17.

Fig 16 5-speed gearbox

Fig 17 6-speed gearbox (optional)



Chassis/body unit

14 The chassis body unit comprises; chassis, body panels, pedals, master cylinder, instruments,switches, wiring loom, windscreen, wipers, fuel tank, fuel pump, fuel lines, ignition module and breather.Additional items placed loose in the chassis are shown in Fig 18.

1 Fastener pack chassis 6 SVA trim2 Fastener pack weather 7 Transmission tunnel cover3 Fastener pack wings 8 Wiper blades4 Side screen mirrors (optional) 9 Wiper arms5 Velcro strips (fuse box cover) 10 Fuel filler cover

Fig 18 Items loose in chassis

NOTE

If the optional weather gear has been specified, the side screen mirrors will be supplied in theweather gear pack.



Weather gear (optional)

15 The optional weather gear items are shown in Fig 19.

1 Hoodsticks 5 Mirrors2 Hood 6 Mirror plate (not required)3 Side screens 7 Hood straps4 Fastener pack ‘weather’ 8 Hinges

Fig 19 Weather gear (optional)



Engine

16 The engine, Fig 20, is supplied on a frame complete with engine mountings and lifting eyes. Theframe must be removed from the engine prior to fitting and returned to Caterham Cars. Once the engineis fitted the lifting eyes must be removed. The engine is supplied complete with wiring loom. The startermotor is not fitted as it is secured to the bell-housing.

Fig 20 1.6 engine 3/4 left

Heater assembly

17 The heater assembly, Fig 21, is packed into an unmarked cardboard box.

Fig 21 Heater assembly

Wheels

18 The alloy wheels are supplied with tyres already fitted. It should be noted that the tyres may behanded, that is, have a direction of rotation arrow showing the direction of travel. Wheels must be fittedwith the directional arrow in the correct direction.

Seat

19 The seats are supplied in protective covers. It is recommended that the covers are not removeduntil the seats are required for fitment.



Wings

20 The front and rear wings are supplied protected with bubble wrap. The two largest wings are forfitment to the rear of the car.

Nosecone

21 The nosecone is supplied in protective bubble wrap. It is recommended that it is left protected untilrequired for fitment.

Roll over bar

22 The roll over bar is protected by bubble wrap and is supplied in its own box.

SECTION 3 - STEERING

STR 01 Section 3Page 1

TABLE OF CONTENTS

Para Page

1 Steering rack (standard and wide track) (Warning) .................................................... 26 Steering column.......................................................................................................... 2

18 Steering wheel fitment ................................................................................................ 419 Motolita................................................................................................................ 423 Momo .................................................................................................................. 424 Quick release column.......................................................................................... 526 Associated tasks ......................................................................................................... 5

Table

1 Steering component torque figures............................................................................. 5

Fig

1 Steering rack assembly............................................................................................... 22 Pedal box .................................................................................................................... 23 Steering rack to steering column ................................................................................ 34 Upper steering column clamp..................................................................................... 35 Horn pushbutton - Motolita ......................................................................................... 4


Section 3 STR 01Page 2

STEERING RACK (STANDARD AND WIDETRACK)

1 The steering rack should be fitted beforethe front suspension. Before fitting the steeringrack it is advisable to protect the outside of thealuminium side panels around the circularcutouts through which the rack protrudes.Masking tape is sufficient for this purpose.

WARNING


2 Carefully pass the steering rack throughthe circular cutouts in the side panels until themachined areas of the rack line up with theholes in the rack platform. Ensure that the rackpinion exits the rack on the driver's side of thevehicle.

3 The steering rack is held in place by twopiece aluminium rack clamps (polythene bagmarked 'steering'). The rack clamps arematched pairs and clamp the steering rack intoposition as they are bolted into place, refer toFig 1.

1 Securing bolt and 6 Track rod endwasher 7 Securing nut

2 Steering rack 8 Steering arm3 Rack clamps (on upright)4 Nyloc nut 9 SVA cover5 Locknut 10 Steering rack

gaiter

Fig 1 Steering rack assembly

4 Clamp the rack loosely into place usingbolt (fastener pack 30S003A Item 1), nylocnuts (8) and washers (10). Ensure a washer isplaced between the rack clamp and the bolthead. The rack will be tightened later when thesteering column is correctly positioned.

5 Fit the SVA cover (polythene bag marked'SVA' (refer to Section 15) to the end of thesteering rack arm, ensure that the largerdiameter is outboard. Screw the locknut (Fig 1item 5) onto the steering rack arm then fit thetrack rod end. This should be screwed on 11 fullturns (S3) or 13 (SV) to give an approximatetrack setting. Do not tighten the locknuts.

NOTES

(1) The SVA covers are secured using cableties. However this should not be done at thisstage as final adjustment to the tracking will berequired.

(2) Tracking is adjusted during final checks,refer to Section 14.

STEERING COLUMN

6 The steering column should not be fitteduntil after the engine and gearbox have beeninstalled.

7 Remove the lid of the pedal box, refer toFig 2.

1 Lower steering column 3 Grommet2 Cheese wedge 4 Grommet

sealing box 5 Pedal box

Fig 2 Pedal box

(Clutch master cylinder and brake pipes omittedfor clarity)

8 The front of the pedal box is sealed usinga grommet inserted into the hole through whichthe steering column passes, refer to Fig 2. Theinside of the rubber grommet should be smearedwith rubber lubricant to prevent wear.



9 Position the ‘cheese wedge’ (refer toFig 2) on the pedal box, aligned with the hole forthe steering column (it may be necessary to trimthe top edge of the cheese wedge to avoidfouling the clutch master cylinder). Mark thethree hole positions using the holes in thecheese wedge as a guide. Drill the holes using1/8” drill bit (it may be necessary to remove theclutch master cylinder for access). Apply siliconesealant to the seating edges of the cheesewedge and secure the cheese wedge with rivets.Seal the edges with sealant. Fit the grommet tothe large hole at the rear of the cheese wedge.Coat the grommet with rubber lubricant.

10 The lower steering column is inserted,splined end first, through the dashboard underthe brake master cylinder, through the rubbergrommet in the 'cheese wedge', through thepedal box and finally through the rubbergrommet in the pedal box sealing plate.

1 Nyloc nut 5 Nyloc nut2 Bolt 6 Bolt3 Universal joint 7 Lower4 Steering rack steering

column

Fig 3 Steering rack to steering column

11 Position the front wheels (or uprights) inan approximate ‘straight ahead’ position andattach the universal joint (polythene bag marked'steering') using bolt (3) and nyloc nut (7) notinghow the bolt locates into the machined groove inthe splined end of the lower steering column.

NOTE

If insertion is difficult the universal joint can beopened up by inserting a flat blade screwdriverinto the split and twisting. To ensure linearity ofresponse it is recommended that the yoke of theuniversal joint is positioned with the cross

vertical/horizontal when the steering wheel is inthe straight ahead position.

12 Fit the lower end of the universal jointonto the rack, again clamping with the bolt andnyloc nut and tighten both bolts to 20 Nm. Theuniversal joint should be run as straight aspossible, continuing along the same angle asthe column, the steering rack can be turned in itsblocks to achieve this.

13 The upper steering column can now befitted.

NOTE

When fitting an optional, quick release, columnthe upper steering column bush can be fittedprior to inserting the upper steering column intothe steering column lock tube, refer to Para 15.

14 The lower column bush will have beenfitted by Caterham, but care must be taken whensliding the upper steering column down throughthe dashboard. Ensure that the lowest portion ofupper steering column is liberally coated withgrease and minimum force is exerted.Telescope the upper steering column over thelower steering column.

15 Slide the upper steering bush onto thecolumn and into the dash tube. Note how theraised rubber locators on the bush fit in theholes in the dash tube. To ease fitment lightlycoat the upper steering bush with rubberlubricant.

1 Locknut 4 Securing bolts2 Upper steering 5 Lower steering

column column3 Clamp 6 Grub screw

Fig 4 Upper steering column clamp


Section 3 STR 01Page 4

16 The two parts of the steering column areclamped together using the locking clamp, referto Fig 4. Insert the grub screw loosely into theclamp. Secure the two halves of the clamp usingtwo bolts (2), plain washers (10) and springwashers (11). Torque to 14 Nm. Tighten thegrub screw with an Allen key to eliminate anyfree play in the steering. Lock the grub screwinto place using locknut (6).

NOTE

Before tightening the clamp:

Fit the steering wheel boss onto its splineto ensure that the steering wheel bossdoes not foul the dashboard. Slide thesteering column/steering wheel bossaway from the dashboard to achieveclearance.

Check that the lower steering columndoes not foul the drive belt tensionmechanism on the engine. If necessaryrotate the steering rack in its clamps toprovide clearance.

17 Tighten the steering rack clampsto 11 Nm. Ensure that the two bolts securingthe steering column lock tube to the scuttle faceare tight.

STEERING WHEEL FITMENT

18 Two makes of steering wheel areavailable. The Motolita wheel has a centralpushbutton which activates the horn whilst theMomo wheel has a horn button mounted on thedashboard. Each steering wheel has a differenttype of mounting boss. It is recommended thatthe fitting of the steering wheel is left until theentire interior trim, including seats, has beencompleted.

Motolita

19 Before fitting the steering wheel it will benecessary to fit the horn contact ring, refer toFig 5, into the top of the steering column bush inthe chassis. This is an interference fit and willneed to be gently tapped into place, using a softhide hammer, over the steering column bush.The electrical wire from this ring must beconnected to the black/purple wire in the wiringloom adjacent to the steering column.

1 Steering wheel 5 Steering column2 Pencil contact 6 Mounting boss3 Horn contact ring 7 Fixing screw4 Purple and black wire 8 Horn push

Fig 5 Horn pushbutton - Motolita

(SVA pad omitted for clarity)

20 Attach the steering wheel to the mountingboss using the fixing screws and nuts providedtaking care not to damage the screw heads orscratch the surface finish on the steering wheel.Slide the pencil contact into the hole in themounting boss.

21 Release steering lock and centre the roadwheels to establish the straight ahead position.Fit the steering wheel over the steering columnsplines. Fit the washer (9) and secure thesteering wheel to the steering column usingnyloc nut (4) and tighten.

22 Feed the electrical connection from thepencil contact through the SVA pad and connectto the spring loaded steering wheel horn push.Push the SVA pad into the mounting boss andthen insert the horn push into the steeringwheel.

Momo

23 Loosely fit the mounting boss to thesteering wheel using the 6 mm x 16 mmcountersunk Allen bolts. Centre the road wheelsto establish the straight ahead position of thesteering wheel. Place the steering wheel andboss over the splines in the straight aheadposition. Remove the wheel and secure theboss to the column using nyloc nut (4) andwasher (9). Finally re-secure the wheel to theboss using the fixing provided.



Quick release column

24 The Quick Release (QR) column has akeyway in the QR boss and the steering wheelmust be centred by removing the upper bolt onthe lower steering column universal joint,withdrawing the column and then turning thesteering wheel and column to the straight aheadposition. Re-engage the column to the universaljoint, re-insert the bolt and tighten the securingnyloc nut to 20 Nm.

25 Ensure that the steering wheel can berotated smoothly with no tight spots. Tighten thesteering rack clamp bolts and steering columnuniversal joint bolts/nylocs to the torque figuresspecified in Table 1.

TABLE 1 STEERING COMPONENT TORQUEFIGURES

Location Washers Nut Torque

Steering rackclamps

Plain under bolthead

Nyloc 11 Nm

Universal joint None Nyloc 20 Nm

Column clamp Spring and plainunder bolt head

Bolt 14 Nm

ASSOCIATED TASKS

26 Whilst the pedal box lid is removed fit thebrake light switch harness and the throttle cable,refer to Section 6.

NOTE

Before refitting the pedal box lid, check that thepedal positions are acceptable and that thebrake switch operates correctly. Adjust asnecessary.

27 Refit the pedal box lid ensuring that thebrake pipes are not trapped or kinked and thatthe ‘P’ clips are secured under the pedal box lidscrews.


SECTION 4 - FRONT SUSPENSION

FRS 02 Section 4Page 1

TABLE OF CONTENTS

Para Page

1 Preparation ................................................................................................................. 25 Lower wishbones (Warning) ....................................................................................... 28 Upper wishbones ........................................................................................................ 2

11 Spring damper units.................................................................................................... 313 Upright attachment (Warnings)................................................................................... 319 Front anti-roll bar......................................................................................................... 423 Front brake hoses ....................................................................................................... 528 Final tightening............................................................................................................ 630 Cars fitted with adjustable damper platform ............................................................... 6

Table

1 Torque figures............................................................................................................. 6

Fig

1 Bodywork protection ................................................................................................... 22 Washer usage - lower wishbone (LH side) ................................................................. 23 Upper wishbone securing ........................................................................................... 34 Front suspension ........................................................................................................ 45 Brake pipe union ......................................................................................................... 56 Standard calliper ......................................................................................................... 57 Uprated calliper........................................................................................................... 5


Section 4 FRS 02Page 2

PREPARATION

1 It is recommended that the front wings arenot fitted until the front suspension is assembledand the engine installed. This reduces the riskof damage to the wings and maintains easyaccess to the engine bay.

2 It is recommended that the steering rackis fitted before assembling the front suspension,refer to Section 3.

3 When assembling the front suspension,there is a risk that the aluminium body skin canbe damaged, especially when fitting the topmounting bolts and the spring damper units. It istherefore advisable, particularly with paintedcars, to protect the bodywork with 2 or 3 layersof masking tape in key areas. It isrecommended that the bodywork under the frontbonnet catches is protected using card andmasking tape, refer to Fig 1.

4 Apply a thin coat of copper grease to allfixings prior to fitment (avoid contaminating anythreads where Loctite is to be used).

Fig 1 Bodywork protection

LOWER WISHBONES

WARNING


5 The lower wishbones are assembled withthe longer leg forward and the bearing retainingcirclip facing downward.

NOTE

Ensure that the circlip is correctly located in theretaining groove prior to assembling the lowerwishbone.

6 Fit the rear leg of the lower wishbonethrough the slot in the bottom skin immediatelybehind the vertical chassis member. Secureusing bolt (Fastener pack 30F015A Item 1) andnut (7) and inserting two plain washers (9) eitherside of the wishbone refer to Fig 2.

NOTEOn wide track front suspension, plain washerusage is shown in text boxes below the fig.

1 Bolt 5 Nyloc nut2 Spring washer 6 Rear chassis3 Plain washer mount4 Front chassis 7 Bolt5 mount 8 Lower wishbone

Fig 2 Washer usage - lower wishbone (LH side)

7 The front leg of the lower wishbone issecured to the front of the chassis using bolt (2),with washer (9) and spring washer (12) next tothe bolt head. Two washers (9) are insertedbetween the wishbone and the chassis, refer toFig 2.

UPPER WISHBONES

8 The upper wishbones are handed and areassembled with the longer leg facing the front ofthe car. Prior to locating the upper wishbone aspacer bush 10 mm ID x 1/2" OD x 35 mm(polythene bag marked 'front suspension'), mustbe inserted into the rear bush. The rear leg ofthe upper wishbone, refer to Fig 3, is secured tothe rear mount using bolts (3) inserted from thefront of the mounting. The spacer bush must becoated with copper slip. The bolt is secured witha nut (8). Do not tighten fixings.

Wide track 0 washer Wide track 4 washer Wide track 0 washer


Section 4FRS 02 Page 3

1 Headlight bracket2 Headlight bracket mounting3 Upper wishbone front mount4 Upper wishbone5 Spring damper unit6 Upper wishbone rear mount

Fig 3 Upper wishbone securing

9 The front leg of the upper wishbone issecured to the front mount using bolt (4). Priorto inserting the bolt the headlight bracket reararm must be inserted into the chassis mount (donot tighten the grubscrews at this stage. Thefront arm is secured at the rear of the upperwishbone front mounting by nut (8).

10 Since access to the upper and lowerwishbone mountings is restricted by othercomponents installed later in the build processthe mounting fasteners must be fully tightened atthis point. Hold the wishbone horizontal andtighten the upper wishbone mounting bolts/nutsto 34 Nm and the bottom wishbone to 81 Nm.

SPRING DAMPER UNITS

11 An aluminium spacer bush 8 mm id x 1/2”od x 32 mm (polythene bag marked ‘frontsuspension’) must be coated in copper slip andinserted into the top mounting bush of the frontspring damper unit. The spring damper issecured to the top mounting by the M8 cap headbolt supplied in the chassis with a spring washer(13) under the bolt head. This bolt should betorqued to 20 Nm.

NOTES

(1) It is necessary to gently press the bodypanel inwards to allow sufficient clearance forthe bolt to be located.

54To prevent damage to the paintwork it isrecommended that the plain washerand spring washer are placed closestto the spring damper mounting duringbolt location.

12 An aluminium spacer 8 mm id x 1/2”od x 32 mm must be coated in copper slip andinserted into the lower mounting bush of thespring damper unit. The spring damper unit issecured using an M8 caphead bolt (supplied inwishbone) which passes through the rear leg ofthe lower wishbone through the aluminiumspacer bush and into a captive thread on thefront leg. This bolt should be torqued to 20 Nm.

NOTE

Do not tighten any other fixings at this stage.

UPRIGHT ATTACHMENT

WARNING

Correct use of fixtures is required to ensurefull engagement of the nyloc nut.

13 Remove and retain the upper wishboneball-joint nyloc nut and the nyloc nut from thebottom of the upright assembly. The uprightassembly must be mounted with the steeringarm facing forward. Mount the upright assemblyas follows:

NOTE

The upright assemblies are marked RHS or LHSon the inside of the assembly.

Standard. The upright is located into thespherical joint on the lower wishbone andsecured using the retained 1/2” nyloc nut.Tighten the nyloc nut to 55 Nm.

WARNING

Correct use of fixings is required in order toensure full engagement of the nyloc nut.

Wide track. The upright is located into thespherical joint on the lower wishbone. Priorto locating the upright, a spacer (5/8” mmid x 3/4” od x 8 mm) located in the polythenebag marked ‘front suspension’) must beinserted onto the bottom of the upright. Theupright is secured using the special turneddown nyloc nut supplied. Tighten thespecial nyloc nut to 55 Nm.



14 The cycle wingstay locates on the upright.Remove and discard the 1/2” UNF nyloc nut andplain washer fitted to the inner end of the stubaxle. Place cycle wingstay over the stub axleand secure using the 1/2” UNF nyloc provided.Do not tighten.

NOTE

If uprated front brake callipers have beenspecified ensure that the brake pads areinstalled before fitting the cycle wingstays.

15 Pass the top wishbone ball-joint downthrough the top of the upright and through thewingstay. To fully engage the tapers of thewishbone and ball-joint, fit the M14 plain nut (6)from the fastener pack, apply pressure to the topof the ball-joint and tighten the plain nut. Oncethe ball-joint is locked in place remove the plainnut and replace it with the nyloc supplied on theball-joint. Tighten the nyloc nut to 54 Nm.

16 Tighten the inner stub axle nut to 82 Nmand ensure that the upright turns freely on thewishbones.

17 Remove and retain the nyloc nut from thetrack rod end. Remove and discard the hardplastic boot protector from the track rod endtaper and pass the tapered shaft down throughthe steering arm on the upright, secure with thenyloc nut. Tighten nyloc nut to 34 Nm.

18 Your front suspension should nowresemble that shown in Fig 4.

1 Cycle wingstay 4 Lower wishbone2 Anti-roll bar 5 Spring damper unit3 Inner radiator 6 Upright assembly

cowl

Fig 4 Front suspension

FRONT ANTI-ROLL BAR

NOTES

(1) On R400 the inner radiator cowl is locatedinboard of the anti-roll bar and must be fittedfirst, refer to section 6. (Sigma 125/150 does nothave radiator cowling please ignore the cowlingshown in the picture 4 in this section and fig 26in section 6)

54Check that the colour of the bushescorresponds to the colour marked onthe front anti-roll bar.

19 The anti-roll bar is attached to the front ofthe chassis using the special mounting bracketsand cotton reel shaped bushes (supplied in thepolythene bag marked ‘front suspension’).Liberally coat the bushes with rubber lubricantand fit the bushes into the brackets. Slide thebrackets over the ends of the anti-roll bar andaround so they will align with the holes drilled inthe front face of the chassis tube.

20 The rubber boots should be slid over theanti-roll bar, ensuring that the larger diameter ofthe rubber boot is outboard. Apply Loctite to thethreads at each end of the anti-roll bar and fit theplastic balls, tighten using protected grips.

21 Liberally coat the balls with bearinggrease. Assemble the anti-roll bar onto thechassis by pushing the plastic balls, one at atime, into the mounting cups in the upperwishbones. Fit the spring washers (13) to thebolts (5) and pass forward through the verticalchassis tubes and into the captive nuts on themounting brackets. Tighten to 20 Nm.

22 The rubber boots are slid over themounting cups and secured to the top wishboneusing cable ties which fit into the groovesprovided. A further cable tie is used to hold theboot onto the anti-roll bar itself with the tails ofthe cable tie being cut off underneath forneatness.


Section 4FRS 02 Page 5

FRONT BRAKE HOSES

NOTE

All connections should initially be made fingertight.

23 Three stainless steel braided brake hosesare supplied, two of equal length for the frontbrakes and one of longer length for the rearbrakes.

24 Attach the inner, threaded end of eachbrake hose through the hole in the aluminiumbody. Plain washers (fastener pack 30F015Aitem 11) should be fitted directly next to thealuminium body on both the inside and outsideof the body panel. Secure using the 3/8” nutand shakeproof washer (14). The shakeproofwasher must be between the nut and the plainwasher. Do not tighten.

1 Female union 3 Shakeproof washer(brake pipe) 4 Locknut

54 Plain washer

Fig 5 Brake pipe union

25 The outer end should be attached to thebrake calliper as follows:

Standard calliper. The outer end isattached to the brake calliper using thebanjo bolt provided. The large copperwasher is placed next to the bolt head andsmaller copper washer placed between thebanjo union and the calliper, refer to Fig 6.Do not over tighten. Torque to 10 Nm.

1 Banjo bolt 4 Banjo union2 Large copper 5 Braided brake

washer hose54 Small copper

washer

Fig 6 Standard calliper

Uprated calliper. On the uprated brakecalliper the braided brake hose has a femaleunion at the calliper end, refer to Fig 7. Thebraided hoses are supplied with an adaptorthat screws into a threaded drilling inboardof the calliper body. The adaptor must befitted with the tapered end outward, thisprovides the seal between the adaptor andthe braided brake hose female union, and acopper washer between the adaptor and thebrake calliper. The female union on thebraided hose screws directly to the adaptor.Do not over tighten. Torque to 10 Nm.

1 Copper washer 3 Braided brake hose2 Female union 4 Adaptor

Fig 7 Uprated calliper



26 Located on the inside of the body are thefemale unions, refer to Fig 5, on the end of thebrake pipes from the brake master cylinder. Fixthe female union to the braided brake hoseconnection and tighten to 10 Nm. Tighten thelocknut to 10 Nm.

27 Turn the steering from lock to lock andensure that the braided brake hoses do not foulon the suspension. If fouling is observedremove the braided brake hose from the calliperand twist the hose through 180. Refit thebraided brake hose to the calliper and tightenunions to 10 Nm.

FINAL TIGHTENING

28 All the remaining fixings should betightened according to Table 1.

TABLE 1 TORQUE FIGURES

Location Washer Torque

Stub axle 81 Nm

Damper to lowerwishbone (lower fixing)

N/A 20 Nm

Damper to chassis (topfixing)

N/A 20 Nm

Front anti-roll bar fixing Spring underhead

20 Nm

Upright top ball-joint None 54 Nm

Upright – bottom Spacer – widetrack only

54 Nm

Upper wishbone 34Nm

Lower wishbone front Spring underhead then plainas shown in Fig 2

81 Nm

Lower wishbone rear Plain spacers asshown in Fig 2

81 Nm

CARS FITTED WITH ADJUSTABLE DAMPERPLATFORM

29 Cars fitted with adjustable damperplatforms need to be adjusted to achieve theoptimum ride height. This is done by lowering orraising the height of the platforms on thethreaded sleeve. It is essential that this task iscarried out on level ground.

NOTE

Lowering the platforms will decrease ride height,and raising the platforms will increase rideheight. For the best results the ride heightshould be set with the driver in the car and fuelin the tank.

29.1 Start by adjusting the frontdampers to achieve a minimum distanceof 150 mm (this can be increased for roaduse to a maximum of 190 mm) betweenthe ground and the bottom of the lowerchassis rail, where the rear leg of the frontlower wishbone exits the side of the car.This measurement should be the same onboth sides with the car loaded.

29.2 Now adjust the rear dampers inthe same manner to achieve a height 15mm higher than the front, measured to theunderside of the lower chassis railimmediately in front of the 'A' framemounting point.

NOTE

Adjusting the rear may have an effect onthe front therefore it is good practice tocheck between front and rear severaltimes during adjustment.

29.3 Once the desired ride heightshave been set ensure that the platformsare locked together to avoid movement.

SECTION 5 - FITMENT OF GEARBOX TO ENGINE

GBX 01 Section 5Page 1

TABLE OF CONTENTS

Para Page

1 Assembly of gearbox kit - 5 and 6-speed ................................................................... 27 Fitting gearbox to engine ............................................................................................ 39 Starter motor ............................................................................................................... 3

Table

1 Torque figures............................................................................................................. 3

Fig

1 Clutch actuation mechanism....................................................................................... 22 Speedo drive plug ....................................................................................................... 23 Speedo shaft plug ....................................................................................................... 2


Section 5 GBX 01Page 2

ASSEMBLY OF GEARBOX KIT -5 AND 6-SPEED

1 Both the 5 and 6-speed gearboxes areinterchangeable and utilise all the sameancillaries. Assembly is identical for both 5and 6-speed gearboxes with the exception of thesealing method for bell-housing to gearbox.

2 To assemble the gearbox to bell-housing,proceed as follows:

5-Speed. Smear the gasket (polythene bag'miscellaneous') on both sides with siliconesealant and position on the bell-housing.Using the four cap-head bolts (fastener pack36G006A Item 9) and spring washers (12),bolt the bell-housing to the gearbox.Tighten the bolts to 47 Nm.

6-Speed. Apply a thin layer of siliconesealant to the front face of the gearbox andto the 'O' ring around the selector rod.Ensure sealant is applied to all of the 'O'ring. Using the four cap-head bolts(fastener pack 36G006A Item 9) and springwashers (12), bolt the bell-housing to thegearbox. Tighten the bolts to 47 Nm.

3 Place the clutch release mechanism inposition in the bell-housing and secure using thethree cap-head bolts (7) and springwashers (13), refer to Fig 1.

1 Clutch release bearing2 Hydraulic connection

Fig 1 Clutch actuation mechanism

4 Apply silicone sealant to the speedo driveopening on the LH side of the gearbox andinsert the large plug supplied, refer to Fig 2.

5 Apply RTV silicone gasket sealant to thespeedo output shaft opening on the RH side ofthe gearbox and insert the small plug supplied,refer to Fig 3.

NOTE

The plugs are a drive fit and are installed closedend first.

1 Gearbox2 Plug3 Gearbox mounting

Fig 2 Speedo drive plug

1 Gearbox2 Plug

Fig 3 Speedo shaft plug

6 Bolt the metal/rubber/metal gearboxmounting, chamfered edge rearward, refer toFig 2, to the underside of the tailshaft housingusing one bolt (8) and spring washer (12).Tighten to 61 Nm.


GBX 01 Section 5Page 3

FITTING GEARBOX TO ENGINE

7 Slide the gearbox into place on the rear ofthe engine. It may be necessary to rotate thegearbox assembly in order to line up thegearbox first motion shaft splines with thesplines of the clutch plate.

8 Using the fixings supplied, connect theengine and gearbox; two bolts (2) and springwashers (10), pass forward from the top of thebell-housing into the cylinder block, two morebolts (2) and spring washers, pass forward fromthe bottom of the bell-housing into the sump.Two bolts (1) and spring washers pass rearwardthrough the 'ears' on the engine assembly andinto the bell-housing on the RH side, one furtherbolt (1) and spring washer passes forward fromthe LH side of the engine into the bell-housing.

STARTER MOTOR

9 Install the starter motor into the front ofthe bell-housing and secure with twobolts (3) and spring washers (10) and onebolt (1) and spring washer. The short bolt fits inthe outermost hole of the top two.

10 Tighten all starter motor and bell-housingthe bolts to the torques specified in Table 1.


Fixing Torque

Bell-housing to gearbox 47 Nm

Gearbox rubber mounting totailshaft housing

61 Nm

Engine to bell-housing 47 Nm

Bell-housing to sump 20 Nm

Starter motor 34 Nm


SECTION 6 - INSTALLATION OF ENGINE AND GEARBOX (SIGMA 125)

ENG S125 02 Section 6Page 1

TABLE OF CONTENTS

Para Page

1 Preparation ................................................................................................................. 22 Screen wash/wipe ............................................................................................... 27 Engine preparation.............................................................................................. 2

10 Chassis preparation ............................................................................................ 317 Installation of engine/gearbox into chassis (Warnings) .............................................. 427 Electrical connections ................................................................................................. 539 Fuel system................................................................................................................. 641 Clutch hydraulic hose.................................................................................................. 643 Exhaust system........................................................................................................... 753 Cooling system (Caution) (Warning)........................................................................... 965 Water bleed hoses .............................................................................................. 1167 Heater and associated hoses.............................................................................. 1176 Throttle cable fitment .................................................................................................. 1378 Breather pipe fitment................................................................................................... 1479 Air filter fitment ............................................................................................................ 14

Table

1 Special tools required ................................................................................................. 22 Torque figures............................................................................................................. 4

Fig

1 Washer bottle bracket ................................................................................................. 22 Water rail and ‘U’ hose................................................................................................ 33 Horn location............................................................................................................... 34 ECU and MAP unit...................................................................................................... 55 Brake light switch harness .......................................................................................... 56 Fuel pipe connection................................................................................................... 67 Clutch master cylinder hose union.............................................................................. 68 Clutch hydraulic hose.................................................................................................. 69 Exhaust mounting ....................................................................................................... 7

10 Primary pipes and collector/catalyst ........................................................................... 711 Lambda probe connection .......................................................................................... 812 Exhaust arrangement.................................................................................................. 813 Coolant hoses ............................................................................................................. 914 Bottom hose engine connection ................................................................................. 915 Radiator/Fan prior to fitting ......................................................................................... 916 Standard radiator arrangement................................................................................... 1017 SV radiator arrangement ............................................................................................ 1018 Coolant expansion bottle mounting bracket ............................................................... 1119 Heater installation ....................................................................................................... 1120 Heater valve arrangement .......................................................................................... 1221 Heater control location ................................................................................................ 1222 Heater control cable.................................................................................................... 1323 Heater control cable attachment................................................................................. 1324 Throttle cable to throttle body ..................................................................................... 1325 Breather pipe .............................................................................................................. 1426 Engine bay overview................................................................................................... 15



PREPARATION

1 The special tools detailed in Table 1 willbe required.

TABLE 1 SPECIAL TOOLS REQUIRED

Item Description

Engine hoistand sling

SWL of 150 Kg (min)

Screen wash/wipe

NOTE

The bracket for the washer bottle must be fixedto the front of the passenger side foot box beforethe engine is installed.

2 Offer up the bracket with the washerbottle attached and mark the position of the twofixing holes. Remove the bracket and bottle anddrill the marked positions using a 3/16” drill.Secure the bracket with rivets. Drill a third holethrough the bracket and foot box, refer to Fig 1.Secure the third hole with a rivet and fit thewasher bottle.

1 Footbox2 Washer bottle bracket3 Third hole

Fig 1 Washer bottle bracket

3 Remove the securing nut from the base ofthe washer jet (polythene bag marked'miscellaneous') and pass the washer jet throughthe hole in the centre of the scuttle and securewith the plastic securing nut. Fit the clear plastictubing to the washer jet. Dip the end of the clearplastic tubing in hot water to soften in order tomake fitting easier.

4 Route the clear washer tubing along thewiring loom behind the dashboard and attachusing cable ties, to prevent it falling down intoview. Pass it down through the large grommetin the top of the transmission tunnel and alongthe engine bay diagonal tube until in line with thewasher bottle. Trim the tube to length andattach to the washer motor.

5 Connect the washer motor to the wiringloom via the two pin plug adjacent to the washerbottle mounting. To ease fitment of the two pinplug the washer motor can be removed from thewasher bottle, the two pin plug fitted and thewasher motor reinserted into the washer bottle.

6 The windscreen wipers must not be fitteduntil the wiper motor has been run and allowedto park in order to prevent damage to thepaintwork. Fit the wiper arms so that they arehorizontal when parked. The wiper arms mustmove smoothly through their range of travel.

NOTE

A small amount of water splashed on thewindscreen will prevent the wiper blades fromjuddering during test and adjustment.

Engine preparation

7 The large diameter pre-formed 'U' hoseshould be fitted onto the aluminium water outletlocated on the rear of the cylinder head, refer toFig 2. Apply rubber lubricant to the short end ofthe hose (hose may require trimming) and pushover the outlet; rotate the hose until the long endsits along the LH side of the engine within thecurve of the inlet manifold. Secure using a hoseclip (Polythene bag 'cooling').

8 Apply rubber lubricant to the end of thewater rail; pass the rail from the front of theengine, over the alternator, and through thecurve of the inlet manifold. Insert the pipe intothe long end of the ‘U’ hose and secure using ahose clip (Trim the ‘U’ hose as necessary). Alignthe rail mountings with the lugs on the inletmanifold and secure using screws, nuts andwashers provided.



1 Engine connection2 ‘U’ hose3 Water rail

Fig 2 Water rail and ‘U’ hose

9 Remove and retain the gearbox filler plug.Remove the plastic plug from the gearboxtailshaft housing. Removal of these plugs is notessential; however access is restricted within theconfines of the transmission tunnel.

Chassis preparation

10 Protect the appearance of the engine baychassis tubes and pedal box sides and edges bycovering with card and/or masking tape.

11 Ensure that all wires and connector plugsare secured and will not snag or catch theengine/gearbox as it is lowered.

NOTE

Before fitting engine mounting rubber blocks(polythene bag marked 'miscellaneous') ensurethat the large threaded (1/2" UNF) boss in thecentre is clear of rubber and that the bolt willthread in cleanly.

12 Fit the engine mounting rubber block tothe RH side of the engine bay. The two bolts(fastener pack 30P012A Item 3), plainwasher (12) are passed downwards through themounting, through the chassis and are securedwith nyloc nuts (9) and plain washers (12). Donot tighten.

13 Fit the engine mounting rubber block tothe LH side of the engine bay, locate the engineearth lead (a black earth lead approximately 300mm long supplied loose in a box), pass bolt (2)and washer (12) downwards through the lead,through the front hole of the engine mountingblock, through the chassis and secure with nylocnut (9) and plain washer (12). Remove a littlepaint from the chassis/mounting to ensure that agood electrical contact is made. Pass bolt (3),plain washer (12) downwards through the rearhole of the engine mounting block, through thechassis and secure with nyloc (9) and plainwasher (12). Do not tighten. (Other end of theearth lead needs to be connected to enginethrough engine mount after engine installation)

14 Locate the twin electric horns on the twostuds near the rear edge of the steering rackplatform. Before fitting the horns, loosen the 13mm nut in the centre of each horn, this will allowrotation of the horns so that the electricalconnections are closer together.

15 Secure the horns with the nyloc nutsprovided and ensure that it is not possible for thehorns to come into contact with each other, thesteering rack or other components in the enginebay refer to Fig 3.

Fig 3 Horn location

16 Tighten the 13 mm nut in the centre ofeach horn and connect the horns to theelectrical harness by the purple and yellow wiresand connectors located above the horns on thefront upper cross member.


Section 6 ENG S125 02Page 4

INSTALLATION OF ENGINE/GEARBOX INTOCHASSIS

NOTE

If the optional oil/air separator tank is to beinstalled then the mountings for the separatortank must be fitted before the engine is installedand the horns must be relocated to an alternateposition beneath the coolant expansion bottle(refer to Section 16).

WARNINGS(1) Never work underneath a car withoutsupporting it on axle stands or equivalent.Do not rely on a jack alone.(2) Use appropriate eye protection whilstworking under the car.(3) Care should be taken while droppingthe engine into the chassis to avoid anydamage to engine component or wiring.

17 Using the lifting hoist and sling detailed inTable 1, attach the engine/gearbox using thelifting eyes provided on the engine, lower theengine/gearbox assembly into the engine bay atan angle of between 30-40 (with the enginehigher than the gearbox). Insert the gearboxassembly into the transmission tunnel.

18 Continue to slide the engine/gearboxrearward until the holes in the gearbox mountingline up with the holes in the chassis crossmember. If the differential and propshaft havealready been fitted, ensure that the propshaftlocates into the gearbox tailshaft housing.

19 Attach the LH engine mounting using thetwo M8 x 25 mm bolts (fastener pack 36G006AItem 4) and one M8 x 30 mm bolt (5), use springwasher item (11) for each bolts. Connect theother end of the earth lead through one of theengine mount fixings. Do not tighten the bolts.

20 Attach the RH engine mounting using thetwo M8 x 35 mm bolts (6) and two M10 x 40 mmbolt (2), use spring washer item (10 & 11 ) foreach bolts, Do not fully tighten the enginemounting retaining bolts until advised later in thissection.

21 Lower the engine onto the rubber enginemountings and pass the bolts (fastener pack30P012A Item 1 (LHS) and 21 (RHS)) downthrough the tube on the outer end of the enginemounting brackets. Screw the bolts loosely intothe threaded bush in the centre of the rubberengine mounting. It is recommended that theengine is not removed from the hoist until all the

bolts have been tightened (detailed later in thissection).

22 Adjust the gearbox on its slottedmountings to achieve equal clearance within thetransmission tunnel. This must be checkedcarefully as clearances are tight and pooralignment can cause the gearbox to contact thechassis under cornering.

23 Bolt the gearbox mounting rubber to thechassis using bolts (fastener pack 30P012AItem 4) passed down through the outer metalpart of the rubber mounting and then through theelongated holes in the chassis. Secure with aplain washer (12) and nyloc nut (9) on each boltand tighten to 20 Nm.

24 Finally tighten the fixings detailed inTable 2.


Fixing Torque

Engine mounting to block 25 Nm

Engine mounting to mountingrubbers

41 Nm

Engine mounting rubbers tochassis

20 Nm

Gearbox mounting rubber tochassis

20 Nm

NOTES(1) It is now safe to remove the engine hoist.

(2) Wiring – Every effort is made to clearlyexplain and identify all the electrical connectionsas you go through this section; however theloom fitted to your car may have additional wiresand connectors that are not required on yourvehicle. To help clarify this, a wiring diagram canbe found in section 17.

25 Fit the gear lever to the top of gearboxtailshaft housing and secure with threesetscrews (7). No washers are required; tightento a torque of 20 Nm.

26 Fit the reverse light switch (polythenebag) into the side of the gearbox. This can beaccessed via the hole in the RH side of thetransmission tunnel. The switch should beinserted finger tight and then tightened a furtherquarter of a turn using a suitable sized spanner.Connect the wiring loom to the reverse lightswitch. From the cockpit, insert the largegrommet (polythene bag) to cover the accesshole in the transmission tunnel.



ELECTRICAL CONNECTIONS

27 The engine wiring loom is alreadyattached to the engine and some ancillaries,however it is necessary to link the engine wiringloom to the remaining ancillaries and the vehiclewiring loom. All the plastic connecting plugs arematched pairs so it is not possible to connectthem incorrectly.

28 Attach the grey, multi-pin plug to therespective socket on the Engine Control Unit(ECU), which is located on the passenger sideheater tray, forward of the battery. Make theconnection and ensure that the red retaining clipis pushed fully home, refer to Fig 4.

1 Fuel pipe 3 Multi-pin plugConnection 4 ECU

2 MAP unit 5 Air filter

Fig 4 ECU and MAP unit

29 Position the MAP unit adjacent to theECU and secure using two screws provided(fastener pack ZCH01 items 12 and 13).

30 Connect the green 3-pin plug on theengine loom to the connection on the MAP unit.Connect the short pipe on the MAP unit to thecorresponding connection on the throttle bodyusing the rubber vacuum hose provided.

31 Connect the black wire from the vehicleloom to the oil pressure sender on the LH side ofthe engine block.

32 The two, paired, black/yellow wires withring terminals in the engine loom are earthconnections. Attach both pairs to a suitableearth point on the bulkhead.

33 The green, green/purple pair (withgrommet) in the engine loom is for the brakelight switch. The brake light switch is inside thedrivers pedal box and the harness may beconnected during installation of the steeringcolumn, refer to Section 3. Pass the brake lightswitch harness through the hole in the rear ofthe pedal box, refer to Fig 5 and push the twofemale connectors onto the male connectors ofthe brake light switch (orientation is notimportant). Fit the grommet into the hole andensure that the harness will not foul the steeringcolumn or pedals.

1 Brake light switch 4 Sealant2 Cheese wedge 5 Brake light3 Grommet 6 Switch harness

Fig 5 Brake light switch harness

34 The longest wire from the engine loom(terminating in a 4-pin plug) is the connection forthe exhaust mounted lambda probe. This cannotbe connected until the exhaust primary pipesand collector/catalyst is fitted, refer to Para 50.

35 Remove the outermost Bell housingsecuring bolt and spring washer. Pass the Bellhousing mounting bolt and attached springwasher through the black battery earth lead andsecure to the bell-housing. Tighten to 34 Nm.

36 Connect the red lead from the startermotor to the battery. Also connect the black leadon the main vehicle loom to the starter motor onthe same terminal.

37 Connect the brown lead from thealternator to the starter.

38 Connect the brown/red wire (covered withblack insulation) from the chassis loom to thestarter solenoid.



NOTE: Make sure the leads are not touching toany surrounding metal component

FUEL SYSTEM

39 The black, corrugated plastic, highpressure fuel pipe from the fuel pump emergesfrom the transmission tunnel and is a push-fit onthe white elbow connection at the rear of the fuelrail, refer to Fig 6. Note that there is no fuelreturn pipe with this system.

1 Fuel rail connection2 Fuel pipe (from pump)

Fig 6 Fuel pipe connection

40 Once fitted the pipe cannot be removedwithout a special tool. Ensure that the pipe iskink free and routed away from possible snagsor chafe points. Push the connection on the pipefirmly onto the elbow and check that it issecurely attached. Secure the pipe with cableties if necessary.

CLUTCH HYDRAULIC HOSE

41 Remove all packaging from the clutchhydraulic hose. Fit a copper washer to the banjobolt and pass the banjo bolt through the union atthe end of the hose, refer to Fig 7. Fit thesecond copper washer to the banjo bolt andscrew the banjo bolt into the clutch mastercylinder outlet port (remove the port plug). Donot fully tighten the banjo bolt.

1 Banjo bolt 4 Hose union2 Copper washers 5 Clutch master

cylinder

Fig 7 Clutch master cylinder hose union

42 Route the hose down the side of the pedalbox, over the wiring loom (under the heater hoseif fitted) and across the top of the bell-housing,Refer to Fig 8. Push the end of the hose into theconnector in the clutch release bearingassembly and ensure that the hose is firmlyattached. Secure the hose with cable ties ifnecessary, to prevent chafing and tighten thebanjo bolt (the clutch system is filled and bledduring start-up/final checks, refer to Section 14.

Fig 8 Clutch hydraulic hose



EXHAUST SYSTEM

43 The standard exhaust system consists offour primary pipes, a collector assembly whichalso incorporates the catalytic converter and aone piece silencer and tail pipe.

44 Bolt the exhaust mounting bracket(polythene bag marked 'exhaust') to the RH sideof the car forward of the rear wheel, usingsetscrew (fastener pack 30X020A Item 1) andspring washers (3), refer to Fig 9. Secure thebobbin to the angle bracket with a nut (2) andspring washer (3).

1 Angle bracket 4 Bobbin2 Spring washer 5 Nut3 Setscrew

Fig 9 Exhaust mounting

45 Remove the exhaust gasket andassociated fasteners from the RH side of thecylinder head, remove any masking tapeprotecting the exhaust ports and clean off anyadhesive residue.

46 The exhaust primary pipes are markedwith their part numbers:

36X014A is for # 1 (front) cylinder.36X015A is for # 2 cylinder.36X016A is for # 3 cylinder.36X017A is for # 4 (rear) cylinder.

47 Protect the area around the squareaperture in the side panel with masking tape andcard, place the exhaust gasket over theremaining studs and fit the primary pipes in thefollowing sequence:

47.1 Pass the flanged end of # 4 pipeinwards, attach the flange loosely to the

cylinder head and ensure that the pipesits in the bottom LH corner of theaperture (viewed from outside).

47.2 Pass the flanged end of # 1 pipeinwards, attach the flange loosely to thecylinder head and ensure that the pipesits in the top RH corner of the aperture.

47.3 Pass the plain end of # 3 pipeoutwards, attach the flange loosely to thecylinder head and ensure that the pipesits in the bottom RH corner of theaperture.

47.4 Pass the plain end of # 2 pipeoutwards, attach the flange loosely to thecylinder head and ensure that the pipesits in the top LH corner of the aperture.

NOTEFor series 5 use the same procedure to fit theprimary, the sequence to fit the primary is4,3,1,2

56X005A is for #1(front) cylinder.56X006A is for #2 cylinder.56X007A is for #3 cylinder.56X008A is for #4 (rear) cylinder.

48 When the primary pipes are in place fitany remaining fasteners but do not tighten them.

49 Install the collector/catalyst over theassembled primary pipes with the threaded holefor the lambda probe faces towards the sidepanel. Secure the collector to the primary pipeswith the two springs, refer to Fig 10. Support theweight of the collector such that the primarypipes are not in contact with the sides of theaperture and tighten the primary pipe/cylinderhead fasteners to 34 Nm.

1 Primary pipe2 Collector/catalyst (guard fitted)

Fig 10 Primary pipes and collector/catalyst



50 Fit the Lambda probe into the threadedhole in the collector/catalyst and connect theprobe plug to the corresponding socket from theengine wiring loom. Secure the Lambda probeconnection and wiring to the chassis ensuringthat it cannot contact the hot exhaust or anymoving part, refer to Fig 11.

NOTE

The lambda probe wiring passes under the sideof the car below the lower chassis tube, it mustnot be routed through the primary pipe aperturein the side panel.

Fig 11 Lambda probe connection

51 Undo the large worm drive clips and feedthem through the channels on the inside of thesilencer and collector/catalyst guard. Fit thesilencer guard to the silencer body with thechannels offset towards the rear of the silencerand tighten the clips, refer to Fig 12. Ensure thatthe clip drives are not at the bottom of thesilencer where they could contact the road.Attach the collector/catalyst guard in the samemanner.

NOTES

(1) For a neater appearance position the clipswith the drive screw towards the ground so thatthe clip ‘tail’ is out of sight beneath the exhaust.

(2) To reduce the risk of damage it isadvisable to fit the silencer after the RH rearwing has been attached.

1 Silencer bracket 3 Lambda probe2 Worm drive clip 4 Band clamp

Fig 12 Exhaust arrangement

52 Loosely fit the single band clamp to thefront of the silencer and position the front of thesilencer over the collector/catalyst outlet pipe.Locate the bracket at the rear of the silence overthe bobbin on the silencer mounting bracket andsecure with a nut and spring washer. Tighten thenut and band clamp. It may be necessary toreposition the guards slightly.

.



COOLING SYSTEM

53 Position a hose clip on the flexible topradiator hose, apply rubber lubricant and fit thehose to the end of the water rail pipe emergingfrom the curve of the inlet manifold, Refer toFig 13. Do not tighten the clip.

1 Top radiator hose2 Water rail3 Hose to heater outlet4 Hose to cylinder block5 ‘T’ piece6 Hose to expansion tank7 Cable tie

Fig 13 Coolant hoses

54 Position a hose clip on the flexible bottomradiator hose, apply rubber lubricant and fit thehose to the larger of the two outlets on the LHside of the engine block, Refer to Fig 14. Thehose passes forwards along the LH side of theengine bay before turning to pass along the topof the steering rack and turns again to meet theradiator connection. Do not tighten the clip.

1 Hose to ‘T’ piece2 Bottom radiator hose

Fig 14 Bottom hose engine connection(viewed from below)

55 Fit the four rubber radiator mountings tothe front of the chassis and secure using nuts,plain washer and spring washers provided in thecooling pack.

56 Fit the four fan legs (polythene bagmarked 'cooling') to the cooling fan. Secure thefan complete with legs to the radiator, ensuringthat the fan electrical connector is located on theRH side of the radiator, using four nuts andwasher provided in fastener pack (fastener pack30C047A, Item 6 & 9). Refer fig 15

1 Top hose connection2 Fan3 Fan legs4 Fan power lead5 Bottom hose connection

Fig 15 Radiator/Fan prior to fitting



CAUTION

Do not over tighten the blanking plug.

57 Position the copper sealing washer on theblanking plug and fit the blanking plug into thethreaded boss in the radiator, adjacent to the tophose connection.

NOTE

The blanking plug occupies the locationpreviously used for a thermostatic fan switch. Inthe event that a switch is supplied in lieu of ablanking plug, fit the switch as described but donot connect it to the vehicle wiring harness.

58 Fit the radiator/fan assembly onto therubber radiator mountings ensuring that thehose connections face towards the engine.Secure using nuts, plain washers and springwashers.

1 Radiator2 Blanking plug3 Rubber mounting4 Fan

Fig 16 Standard radiator arrangement

59 The radiator mounting arrangement on SVmodels differs considerably from that shown. SVkits include LH and RH radiator mounting plates,refer to Fig 17; these plates must be fixed to thebody before attaching the rubber mountings andthe radiator

Fig 17 SV radiator arrangement

60 Position hose clips on the forward ends ofthe flexible top and bottom radiator hoses; applyrubber lubricant and fit the hoses over theconnections on the radiator. Tighten the clips atboth ends of both hoses.

NOTE

The flexible radiator hoses may need to betrimmed to length.

61 Locate the two-pin plug containing theblack/green and black wires situated on theupper front diagonal chassis member. Connectthe two-pin plug to the cooling fan electricalconnector. Secure the cable to the chassismembers using cable ties.

62 Fit the expansion bottle mounting bracketon the top of the cruciform, immediately behindthe radiator, refer to Fig 18, and secure usingbolt, plain washer and spring washer. Tightento 11 Nm.



1 Cruciform2 Expansion bottle mounting bracket

Fig 18 Coolant expansion bottle mountingbracket

63 The round coolant expansion bottle sitson the mounting bracket and is secured using asetscrew, plain washer and nyloc nut, refer toFig 26 for correct orientation of the expansiontank hose connections.

NOTE

If an oil/air separator kit has been fitted theexpansion bottle must be relocated, refer toSection 16.

Water bleed hoses

64 The smaller of the two inlets on thecoolant expansion bottle connects to the stem ofthe small ‘T’ piece in the 5/16” bore hose thatmust connect the top of the radiator (near theblanking plug) to the small diameter connector atthe rear RH side of the cylinder head, refer toFig 26.

NOTE

There may be a metal 'water bleed pipe' fitted tothe engine along the LH side and behind thecam cover. In this event, connect the 5/16" borehose to the front of the water bleed pipe andconnect the rear of the water bleed pipe to theconnection at the rear RH side of the cylinderhead using a short length of 5/16" hose. Secureall hose connections with hose clips.

65 Route the 5/16” bore hose, back from theradiator to the ‘T’ piece and from the ‘T’ piecealong the top radiator hose and fuel rail andaround the back of the cylinder head. Cut piecesof 5/16" hose to length, apply rubber lubricant toeach open end and fit to the connections and 'T'piece as described. Secure using hoseclips (10). Secure the hose to the top radiatorhose using cable ties.

Heater and associated hoses

66 Remove and retain the four screws, nylocnuts and washers and the two washer platessecuring the diffuser panel to the heater.Position the diffuser panel on the inside surfaceof the scuttle and insert the four screws from theinside. Pass the heater harness through thelarge hole in the scuttle panel and locate theheater over the screws, secure with the washerplates, nyloc nuts, washers and two additionalscrews from the fastener pack, refer to Fig 19.Connect the heater harness connector heater tothe matching plug, located under the dashboard.

NOTE

Cars not fitted with a heater will be supplied witha blanking plate. Apply a small amount of siliconsealant around the edge of the plate to seal it.

1 Washer plate 4 Heater outlet hose2 Heater 5 Heater control3 Heater inlet hose cable

Fig 19 Heater installation

67 Heater hose is supplied as three pre-formed pieces; a short ‘L’ shape, a long ‘L’shape and a long ‘J’ shape:

67.1 The short ‘L’ connects the ‘T’piece to the engine inlet next to thebottom radiator hose.



67.2 The long ‘L’ shape must be cut intwo to provide a long straight hose (toconnect the ‘T’ piece to the heater outlet)and a short ‘L’ shape (to connect theexpansion tank to the ‘T’ piece). Measurethe relevant distances carefully beforecutting the hose.

67.3 The long ‘J’ hose connects theheater inlet to the water outlet at the rearof the cylinder head (next to the top hose‘U’ bend). This hose must be trimmed tolength. Cut a 240 mm length of hose fromthe straight leg and cut this into two 120mm pieces. Use the 120 mm pieces toconnect the heater inlet and outlet to theheater valve.

68 The larger of the two inlets on the coolantexpansion bottle must connect to one end of thecross-bar of the large ‘T’ piece (near thealternator) that also connects to the heater valve(outlet side) and to the smaller of the twoconnections at the front LH side of the engineblock, refer to Fig 13. Measure and cut the long,5/8” bore, ‘L’ shaped hose as described at 67.Apply rubber lubricant to the hose and fit to thecoolant expansion bottle and ‘T’ piece securingwith a hose clip at each end.

69 Apply rubber lubricant and connect theshort ‘L’ shaped hose to the smaller of the twoconnections at the LH front of the engine block,connect this hose to the stem of the large ‘T’piece. Secure using hose clips.

70 Use the cut length of 5/8” bore hose (fromthe long ‘L’ hose) to connect the remaining leg ofthe ‘T’ piece to the upper (outlet) connection onthe heater valve, refer to Fig 20. Connect theother side of the heater valve upper (outlet)connection to the straight connector at the top ofthe heater. Apply rubber lubricant wherenecessary and secure using hose clips. Ensurethat the hose is routed to avoid chafing, usecable ties as necessary.

71 Trim to length and connect the long ‘J’hose between the lower (inlet) connection of theheater valve and the outlet at the back of thecylinder head (next to the top ‘U’ hose). Connectthe curved pipe on the heater valve to the lower(inlet) connection on the heater using a shortlength of 5/8” bore hose, refer to Fig 20. Applyrubber lubricant where necessary and secureusing hose clips. Ensure that the hose is routedto avoid chafing, use cable ties as necessary.Do not fully tighten the hose clips at the heaterend at this point.

NOTE

On cars where no heater is fitted the relevantconnections at the rear of the cylinder head andon the front LH side of the engine block must bejoined by a suitable length of hose.

1 Hose to large ‘T’ 5 Hose to cylinder2 Heater outlet head3 Heater inlet 6 Hose clip(s)4 Heater valve

Fig 20 Heater valve arrangement

72 Remove and retain the locknut andwasher from the heater control cable and pass itfrom inside the cockpit, through the hole in thefront face of the scuttle, refer to Figs 21 and 22.Secure the cable in place using the locknut andwasher provided.

Fig 21 Heater control location



1 Scuttle panel2 Heater control cable3 Locknut

Fig 22 Heater control cable

73 Connect the other end to the heatercontrol valve by sliding the eyelet on the innercable over the peg on the heater valve operatingarm then slide the outer cable under theadjacent clamp and tighten the screw to securein place, refer to Fig 23. Ensure that the valvetravels through its full range when operated frominside the car. This can be adjusted byslackening the clamp that locates the outercable to the valve and sliding the cable one wayor another.

1 Heater valve2 Heater control cable

Fig 23 Heater control cable attachment

WARNING

Due consideration should be given to thehighly flammable nature of petroleum oralcohol based products and their vapours.Serious burns can result from incorrect use.

74 Fill the cooling system with a 50%antifreeze solution (refer to Owner's Handbookfor Caterham recommended coolant). Add thecoolant solution to the expansion bottle. Placepaper or cloth on the scuttle in the area belowthe heater inlet/outlet hoses. Ensure that theheater valve is in the fully open position (controlknob pulled towards the driver) and remove theheater inlet (top connector) hose which waspreviously left loose. Temporarily seal off theheater valve inlet and at the same time back fillthe heater inlet hose with coolant solution.When the hose is full refit it to the heater inletand secure with the hose clip. This procedureshould minimise the amount of bleeding requiredonce the engine is running for the first time.

THROTTLE CABLE FITMENT

75 Attach the throttle cable to the linkage onthe throttle body by engaging the nipple in thethrottle operating lever and then clipping itssquare shaped black plastic adjuster onto theadjacent bracket. This adjuster can be threadedup and down the cable outer to adjust thethrottle pedal position, refer to Fig 24.

1 Throttle cable2 Throttle cable adjuster3 Throttle body linkage

Fig 24 Throttle cable to throttle body



76 Route the other end of the cable aroundthe front of the cam cover, refer to Fig 25 andthrough the 22 mm hole in the front of the pedalbox and clip the plastic seat into place. Theinner cable is fed into the slot on the top of thepedal with the portion of cable protruding pastthe cable termination located through the hole.The top of the pedal should be gently squeezedwith a pair of pliers to capture the cable andprevent it escaping.

NOTE

In order to obtain a preferred pedal height andachieve adequate cable tension it may benecessary to bend the top of the pedal prior tolocating the cable. This is done by inserting aPhillips screwdriver into the top of the pedal,bracing the bottom of the pedal with a block ofwood, and gently bending the top of the pedal soas to take up the slack in the cable. Finally usethe adjusting mechanism at the throttle body endof the cable to remove any free play.

BREATHER PIPE FITMENT

77 Fit the breather pipe between the throttlebody and engine cam cover, refer to Fig 25.Apply rubber lubricant where necessary andsecure using hose clips. Ensure that the pipe isrouted to avoid chafing, use cable ties asnecessary.

1 Cam cover2 Breather pipe3 Throttle body

Fig 25 Breather pipe

AIR FILTER FITMENT

78 Fit the Caterham air filter element to thethrottle body housing and secure using the hoseclip provided. The hose clip should not be overtightened as it is possible to distort the throttlebody and prevent smooth operation of thethrottle. Check that the throttle operatessmoothly without sticking.



1E

ng

ine

10

‘U’hose

19

Larg

e‘T

’pie

ce

2E

xhaust

prim

ary

pip

e11

Heate

rco

ntr

olcable

20

Wate

rra

il3

Thro

ttle

cab

le12

Heate

routlet

21

Top

rad

iato

rhose

4P

ed

albox

13

Batt

ery

22

Wate

rble

ed

hose

5B

rake

maste

rcylin

der

14

MA

Pun

it23

Sm

all

‘T’p

iece

6C

lutc

hm

aste

rcylin

der

15

EC

U24

Bla

nkin

gp

lug

7C

lutc

hhose

16

Air

filter

25

Expansio

nbott

le8

Heate

rin

let

hose

17

Washer

bott

le26

Radia

tor

9H

eate

r18

Heate

routlet

hose

27

Radia

tor

inn

er

cow

l

Fig 26 Sigma 125 Engine bay overview


SECTION 7 - PREPARATION AND INSTALLATION OF THE DIFFERENTIAL

DIF 01 Section 7Page 1

TABLE OF CONTENTS

Para Page

1 Preparation (Caution).................................................................................................. 26 Propshaft .................................................................................................................... 27 Fitting the differential (Warnings)................................................................................ 2

13 Propshaft to differential fitment ................................................................................... 314 Lubrication .................................................................................................................. 3

Fig

1 Differential material to be removed............................................................................. 22 Differential breather .................................................................................................... 23 Differential mounting in chassis .................................................................................. 34 Position of the differential in the chassis..................................................................... 3


Section 7 DIF 01Page 2

PREPARATION

1 In order to give clearance for the De Diontube, material may need to be removed from therear cover on the differential, refer to Fig 1. On aCaterham supplied part it is likely that this hasbeen removed prior to supply however if this isnot the case it can easily be removed using ahacksaw/file. Measure and mark 43 mm fromthe machined surface of the backplate where itmates with the main differential casing.

CAUTION

If less than 43 mm is measured then thedifferential casing may be holed. If morethan 43 mm is measured it is possible thatthe De Dion tube may hit the differential.

2 If a rear anti-roll bar is to be fitted thenyou may also need to remove some materialfrom the underside of the casing. Again on aCaterham supplied part this has most likelyalready been done, however if necessary,measure and mark a line on the differentialcasing 38 mm from the forward face of the lowermounting. Using a file remove material from thedifferential web, 15 mm either side of this line toa maximum depth of 5 mm.

1 Rear cover2 Underside

Fig 1 Differential material to be removed

3 Fit the plastic breather (this may be pre-fitted) (polythene bag 'rear axle') to the top of thedifferential assembly ensuring that the groove onthe breather is aligned with the pip on thedifferential, refer to Fig 2. The cutaway portionof the breather should face the rear of thedifferential in order to prevent oil splashing out ofthe breather. This part is a tight fit and it may benecessary to smooth the breather with fineemery paper to aid fitting. Remove the rubbertubing and place a 10 mm socket in place over

the breather. The breather can be gently tappedinto place. Remove the 10 mm socket andreplace the rubber tube.

4 Apply a thin coat of copper grease to allfixings prior to fitment (avoid contaminating anythreads where Loctite is to be used).

5 Slacken the differential oil level/filler plugbefore (once the differential is installed access islimited).

1 Rubber tube 4 Groove (plastic2 Plastic breather breather)3 Pip (differential)

Fig 2 Differential breather

PROPSHAFTNOTE

The handbrake mechanism and cable must beinstalled prior to installing the propshaft anddifferential, refer to Section 8.

6 Remove any protective packaging and laythe propshaft in the transmission tunnel with thebolt type flange towards the rear of the car. If thegearbox has been installed, engage the splinedsleeve at the front of the propshaft with themating spline on the gearbox tailshaft and pushthe propshaft fully forwards.

FITTING THE DIFFERENTIAL

7 Check that the upper mounting bolt,(fastener pack 30A001A Item 1), slides into theupper mounting bushes on the chassis prior tooffering up the differential, refer to Fig 3.


DIF 01 Section 7Page 3

WARNINGS

(1) Never work underneath a car withoutsupporting it on axle stands or equivalent.Do not rely on a jack.


1 Upper mounting 4 Lower mountingbolt bolt

2 Plain washer 5 Nyloc nut3 Differential

Fig 3 Differential mounting in chassis

8 Offer the differential assembly up to itsmounting points as shown. Suspend thedifferential from the upper mounting using metalrod (min 8mm thick & 300mm long).

9 The lower mounting is attached to thechassis using bolts (2) through the metallisticbushes with a plain washer (12) and a springwasher (16) between the bolt head and thebush. Spring washer should be placed inbetween plain washer and bolt head (springwasher is not shown in the fig.3 above). ApplyLoctite 243 on the bolt (2). Washers (13) arethen placed between the bushes and thedifferential to obtain correct position of thedifferential. The differential has to be locatedcentrally in the chassis, refer to Fig 4.

10 The position of the differential should bemeasured from the machined surface of the twounused lower mounting bosses, on the side ofthe differential casing, to the inner edge of theouter chassis tubes. This measurement 'X'should be identical on both sides 2 mm.

11 Use further washers (13) between themetallistic bushes and the differential. Caremust be taken not to force too many washersbetween the chassis and the differential sincethe small amount of movement allowed by the

rubber bushes will be eliminated thus causingexcessive noise and vibration to be transmittedinto the car. All free play must be taken up andwashers (15) are supplied to aid this.

1 Lower mounting bolts2 Upper mounting bolt3 Nyloc

Fig 4 Position of the differential in the chassis

NOTES

(1) Some tubes not shown for clarity.

(2) Washers not shown for clarity.

(3) Measurements 'X' to be identical 2 mm.

12 Slide the bolt (1) with washer (12) underthe bolt head into the upper mounting and pushthe metal rod out slowly. Centralise thedifferential using washers (13) and (15), asrequired, between the metallistic bushes and thedifferential. Use a further washer (12) and nylocnut (6) on the end of the bolt. Tighten the uppermounting bolt and lower mounting bolts to 54Nm. Check that the differential is central 2mm. Adjust if necessary.

PROPSHAFT TO DIFFERENTIAL FITMENT

13 Attach the propshaft to the differentialoutput flange using the four caphead bolts(polythene bag 'miscellaneous'). No washersare required. Tighten to 74 Nm.

LUBRICATION

14 The driveshafts must be inserted into thedifferential prior to oil being added. Instructionsfor installing the driveshafts and filling thedifferential can be found in Section 8.


SECTION 8 - REAR SUSPENSION

RRS 02 Section 8Page 1

TABLE OF CONTENTS

Para Page

1 General ....................................................................................................................... 23 Preparation ................................................................................................................. 24 Fitting of rear brake pipes (Warning) .......................................................................... 29 Rear brake hose ......................................................................................................... 2

11 Assembly of the rear suspension (Warnings)............................................................. 312 Rear spring damper assemblies ................................................................................. 314 Radius arms................................................................................................................ 317 Watts link assembly (optional) .................................................................................... 418 Construction of link arms..................................................................................... 419 Link arms to bellcrank ......................................................................................... 421 Link arms to chassis............................................................................................ 423 Bellcrank to De Dion tube ................................................................................... 424 Rear anti-roll bar (Warnings) ...................................................................................... 526 'A' frame ...................................................................................................................... 531 Assembly of De Dion tube (Caution) .......................................................................... 643 Anti-roll bar connection and adjustment ..................................................................... 745 Handbrake mechanism (Warnings) ............................................................................ 854 Handbrake adjustment................................................................................................ 1055 Final adjustments (Warnings) ..................................................................................... 1056 Filling of differential (Warning) .................................................................................... 10

Table

1 Special tools required ................................................................................................. 22 Torque figures............................................................................................................. 10

Fig

1 De Dion tube RH brake pipe fitting ............................................................................ 22 LH brake pipe fitting .................................................................................................... 33 Watts link - RH side .................................................................................................... 44 Watts link - RH top view.............................................................................................. 45 Rear anti-roll bar mounting ......................................................................................... 56 Metallistic bush - De Dion tube ................................................................................... 57 Forward 'A' frame mounting ........................................................................................ 68 De Dion tube end (LH) ................................................................................................ 69 Anti roll bar bracket & speed sensor……………………………………………………... 7

10 Speed sensor.............................................................................................................. 711 Anti-roll bar connections ............................................................................................. 812 Handbrake assembly .................................................................................................. 813 Handbrake cable arrangement ................................................................................... 914 Handbrake cable routing (non adjustable side) .......................................................... 915 Handbrake cable routing - adjustable side (SV model) .............................................. 916 Rear suspension arrangement ................................................................................... 10


Section 8 RRS 02Page 2

GENERAL

1 The special tools identified in Table 1 willbe required to tighten the rear hub nuts.

TABLE 1 SPECIAL TOOLS REQUIRED

Item Description

41 mm Socket

274 Nm Torque wrench

2 Copper grease should be applied to allfixings prior to assembly (excluding brake pipenuts and items secured with Loctite).

PREPARATION

3 It is recommended that the lower chassistubes that will be under the De Dion tube areprotected. Several layers of masking tape or athin card taped to the tubes is sufficient.

FITTING OF REAR BRAKE PIPES

4 Place the De Dion tube on the work benchwith the outer flange facing forward and thebuttress facing downwards.

5 Fit the aluminium De Dion ears and brakecalliper to the De Dion tube, refer to Para 31and 42. Do not use lock washers or Loctite atthis stage as the ears and brake callipers aretemporarily fitted to ensure correct alignmentand routing of the brake pipe.

NOTE

Please check section 16, page 14 for Brakecalliper sub assembly

WARNING

Both imperial and metric threads are used onthe De Dion brake pipes. The threads on thethree way union are imperial whilst those onthe brake callipers are metric. To aidrecognition a small notch is machined intothe hexagon of the metric unions on thepipes.

6 With the fixing boss offset towards the RHside of the tube fit the three way union(polythene bag marked 'rear axle') to thethreaded stud situated towards the RH end ofthe De Dion tube, refer to Fig 1, and secureusing a nyloc nut (fastener pack 30R011AItem 11). Ensure that the three-way union islocated with the input uppermost.

1 Brake pipe (RH) 4 Brake pipe (LH)2 'P' clip 5 De Dion ear (RH)3 Three way union

Fig 1 De Dion tube RH brake pipe fitting

7 Fit the RH short brake pipe loosely to thethree way union and secure the brake pipe tothe top of the De Dion tube using 'P' clips(fastener pack 30A001A Item 21) and rivet (20).The De Dion tube is predrilled with the correctspacing.

NOTE

The existing holes may require cleaning with a1/8” drill bit to remove paint but under nocircumstances should additional holes be drilled.

8 Fit the LH longer brake pipe loosely to thethree way union as shown in Fig 2. Ensure thatthe brake pipe runs along the centre of the top ofthe De Dion tube. Secure the brake pipe usingthe 'P' clips (21) and rivets (20). Remove thebrake callipers and De Dion ears.

NOTE

The existing holes may require cleaning with a1/8” drill bit to remove paint but under nocircumstances should additional holes be drilled.

REAR BRAKE HOSE

NOTE

All connections should initially be made fingertight.

9 The rear braided hose can now be fitted.Thread the locknut onto the male union on oneend of the hose then attach the braided hose tothe three way union on the De Dion tube andtighten to 10 Nm. Lock into place using thelocknut. The locknut supplied should not restrictthe union from tightening fully.



10 Place a plain washer over the male unionon the other end of the braided hose then passthe union forwards through the verticalaluminium panel, apply a further plain washerthen the shakeproof washer and secure in placewith the locknut provided. Finally, attach therigid brake pipe from the transmission tunnel.

NOTES

(1) The rigid brake pipe may need slightrealignment.

(2) Sharp kinks must not be created.

1 P-clip2 Brake pipe LH3 Three way connector

Fig 2 LH brake pipe fitting

ASSEMBLY OF THE REAR SUSPENSION

WARNINGS



11 Place the De Dion tube into the chassisfrom the RH side ensuring that the centralbuttress faces downwards and that the flangesface forward. Care must be taken to preventdamage to the brake pipes.

REAR SPRING DAMPER ASSEMBLIES

NOTES

(1) The rear spring damper units are onlyfitted at this point if the standard roll over bar isto be installed.

(2) If the track day roll over bar or roll cage isto be installed do not install the spring damperunits yet, refer to Section 16.

12 Insert a sleeve into the top bush of thedamper unit (close coils of spring are at the top),align the top bush with the top mounting andinsert the top mounting bolt (2) through theaccess holes provided in the seat back panel.Tighten to 54 Nm once the spring damper unithas been attached to the De Dion tube.

NOTE: Sometime it may be a tight interferencewhile fitting sleeve into the damper and mightneed pressing using a bench vice

13 The lower spring damper mounting issecured to the threaded boss welded to theunderside of the De Dion tube. Pass bolt (3)through spring washer (16), plain washer (13),the spring damper unit and plain washer andsecure to the De Dion tube. Tighten to 54 Nm.

NOTE

Because the suspension is not under load, thebottom bush of the damper unit and themounting on the De Dion tube will not be inalignment. Take great care not to cross-threadthe bottom mounting bolt. If necessary removethe mounting bolt from the rear of the ‘A’ frameto allow more movement of the De Dion tube.

RADIUS ARMS

14 If Watts link has been specified refer toPara 17.

15 Fit the radius arms to the upper chassisbush with the waisted section facing outboard, toprovide maximum clearance to the brakecalliper. The arms are fitted using M10 x 65 mmcap head bolts (fastener pack 30R011A Item 2)passed from the inside of the cockpit through theradius arm and secured with nyloc nut (8) andplain washer (14). The bolts should betightened to 34 Nm with the arms parallel to theground. This preloads the bushes in the correctposition for when the suspension is properlyloaded.

NOTE

On some series 3 chassis a lower fixing boss issupplied to give optimum suspension geometrywhen used only for race and track purposes.This setting is not recommended for road usage.

16 Fit the rear end of the radius arm betweenthe brackets on the top of the De Dion tubeusing bolt (3) passed inboard and secure usinga nyloc nut (6). Do not fully tighten.



WATTS LINK ASSEMBLY (OPTIONAL)

17 The Watts link replaces the conventionalsingle radius arm location of the De Dion tube byemploying two links, one facing forward and onefacing rearward connected via a bellcrank.

Construction of link arms

18 Thread the rod ends (polythene bagmarked 'rear suspension') with nut (fastenerpack 30R012A Item 6) and fit into the fourlinkage arms. Adjust the length of the link armsas shown in Fig 3. Tighten locknuts.

1 Bellcrank2 Rod end3 Locknut4 Link arm (forward)5 Link arm (rearward)

Fig 3 Watts link - RH side

Link arms to bellcrank

19 Fit the short rearward link arm (waistedsection inboard) to the larger offset mounting onthe bellcrank using bolt (3) passing from inboardto outboard and secure with nyloc nut (6).Ensure that the larger offset of the bellcrankfaces downwards and the links are inset towardsthe vehicle centre line.

20 Fit the long forward link arm to the uppermounting on the bellcrank using bolt (3) passingfrom inboard to outboard and secure with nylocnut (6). Ensure that the waisted sections in theforward link arm are facing outboard.

Link arms to chassis

21 With the De Dion tube in place attach theforward link arm to the chassis using capheadbolt (fastener pack 30R011A Item 2) pass frominside the cockpit, through the link arm. Secureusing nyloc nut (8) and plain washer (14).

NOTE

On Series 3 chassis this fixing must be locatedin the upper of the two possible radius armbushes.

22 The rear link arm attaches to the rear ofthe wheel arch into a threaded boss. ApplyLoctite to the thread and secure the rear link armto the boss using bolt (fastener pack 30R012AItem 2) spring washer (8) and plain washer (7).Hold link arms horizontally and tighten to 34 Nm.

Bellcrank to De Dion tube

23 Drop the bellcrank into the vertical flangeson top of the De Dion tube. It should be notedthat the bellcrank is secured using an M10 boltbut the vertical flanges have a 1/2" hole fortraditional radius arm fitment. Two bellcrankspacers are used on the inner sides of theflanges to centre the bolt in the hole, refer toFig 4. Assemble the bellcrank into the verticalflanges ensuring that the two bellcrank spacersare correctly located; pass bolt (1) and plainwasher (7) inboard through the vertical flanges.Secure with nyloc nut (4) and plain washer (7).Tighten to 34 Nm. It is essential that plainwashers are used on the outside of both flangesin order to pass the load to the flanges ratherthan the bellcrank spacers.

1 De Dion tube (RH) end2 Link arm (forward)3 Bellcrank4 Link arm (rearward)5 Bellcrank spacer

Fig 4 Watts link - RH top view



REAR ANTI-ROLL BAR (OPTIONAL)

WARNINGS



24 Ensure that the colour of the rubber'cotton reel' bushes (polythene bag marked 'rearsuspension') corresponds to the colour dot onthe rear anti-roll bar. Apply rubber lubricant tothe centre of the bushes and slide them downover the flat blades and onto the round sectionof the rear anti-roll bar.

25 Feed the rear anti-roll bar across the topof the lower chassis tubes and below thedifferential. The rear anti-roll bar is clamped tothe chassis by the aluminium anti-roll barmounting block and secured using bolt (fastenerpack 30R011A Item 4) and plain washer (15).The bolt is passed vertically up through thechassis tube, through the thin mounting block.Secure using plain washer (15) and nylocnut (10), refer to Fig 5. Tighten to 14 Nm.

1 Cotton reel bush 4 Anti-roll bar2 Clamp (upper thick) 5 Plain washer3 Clamp (lower thin) 6 Nut

Fig 5 Rear anti-roll bar mounting

'A' FRAME

26 The De Dion tube is located laterally usingan 'A' frame which has bushes fitted to theforward ends. The De Dion tube has ametallistic bush fitted to the attachment point forthe 'A' frame, refer to Fig 6. Place the 'A' frameunder the car with the forward mountings offsetupwards.

1 Metallistic bush 4 Nylon washers2 Bolt 5 Nyloc nut3 'A' frame

Fig 6 Metallistic bush - De Dion tube

27 Attach the 'A' frame to the De Dion tubeusing bolt (18) passed through the 'A' frame,through the metallistic bush and back throughthe 'A' frame. Secure using nyloc nut (6) but donot fully tighten unless the spring damperassemblies have been installed (spring damperinstallation depends on roll over bar/cagespecified).

NOTE

Nylon 'Race' washers are provided in someapplications and if supplied should be fitted overthe centre part of the bush between the De Diontube and the 'A' frame, refer to Fig 6.

28 Attach the forward ends of the 'A' frame tothe mounting provided on the chassis, refer toFig 7, using bolts (fastener pack 30R011AItem 1), passed inboard, with large diameterplain washers (13) either side of the 'A' framebushes and secure with nyloc nuts (7). Do nottighten the 'A' frame fixings.

29 Check that the De Dion tube is centralisedin the chassis. Measure the gaps between theDe Dion tube end plates and the outer edge ofthe chassis tube, these should be identical 2mm. If adjustment is required insert differentialspacing washers between the chassis and thelarge chamfered washer at the forward ends ofthe 'A' frame until the required position isachieved.



1 Nyloc nut2 Large diameter washers3 'A' frame4 Bolt5 Chassis mount6 Diff spacer washer (as required)

Fig 7 Forward 'A' frame mounting

30 Insert the unthreaded end of thedriveshaft into the differential taking care not todamage the seals in the differential. The longerdriveshaft is fitted to the RH side. The shorterdriveshaft is fitted to the LH side. To aidinsertion, lightly grease the splines of thedriveshaft and if necessary gently tap the outerend of the driveshaft with a soft faced hammer.Ensure that the driveshaft is held as straight aspossible to prevent damage to the boot.

ASSEMBLY OF DE DION TUBE

31 Position the aluminium ears over thedriveshaft and attach to the De Dion tube, referto Fig 8.

NOTES

(1) The ears are not handed however thecalliper fixing lugs protruding from the ear mustbe uppermost.

(2) The holes in the ears are not symmetricaland therefore will ensure correct orientation.

1 Brake calliper 9 Bolt2 Spacer 10 Hub carrier3 Nyloc nut 11 Bolt4 Plain washer 12 Rear disc/flange5 Spring washer assembly6 Bolt 13 Thrust washer7 De Dion tube 14 Nyloc nut (41 mm)8 De Dion ear 15 Driveshaft

Fig 8 De Dion tube end (LH)

32 Apply Loctite to the threads of bolt(fastener pack 30A001A Item 5) and bolt theears into place using spring washers (18) andplain washers (16) into the threaded holes at therear of the De Dion tube.

33 Locate the rear hub carrier, with therounded edge of the flange uppermost.Carefully slide the hub over the end of thedriveshaft taking care not to damage bearings orseals. Bolt the hubs to the ear by passing thetwo bolts (3) through the rear holes of the hub,the centre holes in the ear and the front holes inthe De Dion tube and tighten into place with thenyloc nuts (7). No washers are required onthese bolts.

34 Secure the hub to the ear via the forwardholes passing the two bolts (4) through the huband ear then securing into place with plainwashers (16) and nyloc nut (7).

NOTE

(1) For the cars fitted with rear ARB theARB bracket needs to be fitted to the Dion ear.The speed sensor also needs to be mounted onthe ARB bracket Refer fig 9.

(2) For the cars without rear Anti roll bar(ARB) the speed sensor bracket is mounted onthe forward two bolts on the inboard side of theear, refer to Fig 10.



1 Dion ear2 ARB bracket3 Anti roll bar4 Drive shaft5 Speed sensor

Fig 9 Anti roll bar bracket & speed sensor

35 In the case of cars fitted with a rear anti-roll bar, coat the threads of bolt (fastener pack30R011A Item 17) with Loctite and pass throughthe lower hole in the ARB bracket, through aplain washer (fastener pack 30A001A Item 16)and into the hexagonal, threaded, extensionpiece.

36 Tighten all fixings installed in Paras 32to 35 to a torque of 47 Nm.

37 Remove the outer locknut from the speedsensor. Pass the speed sensor through thebracket and replace the locknut ensuring thatthe serrated face is against the bracket. Adjustthe two locknuts until there is a 1 mm clearancebetween the sensor and the serrated disc on thedriveshaft. Tighten the locknuts withoutdisturbing this clearance. Refer fig 9 or 10 asappropriate.

38 Connect the sensor plug to the 3-pinconnector on the chassis loom near the ‘A’frame mounting boss. Secure the assembledconnector to the lower chassis rail ensuring thatthere is sufficient free play in the sensor lead toaccommodate suspension movement.

1 Serrated disc2 Speed sensor3 Speed sensor bracket

Fig 10 Speed sensor (non ARB)

39 Slide the rear disc/flange assembly overthe splined end of the driveshaft and ease intoposition through the seal in the hub until it istight against the bearing. (It may be necessaryto use the driveshaft nut and washer to pull theflange finally home). Place the thrust washerover the driveshaft and secure using the 41 mmnyloc nut (LH plain insert, RH green insert)noting that the LH nyloc nut has a LH thread.These can initially be tightened to 81 Nm.These nuts must be finally torqued to 270 Nm.This is most easily achieved once the brakeshave been bled and the foot brake is applied.

40 Check that there is clearance between theoutboard rubber boot on the driveshaft and thelower damper mounting bolt.

41 Check that the outboard driveshaft CVjoints do not foul the inner edges of the De Dionears. If contact occurs, slacken the bolts holdingthe hub carrier to the ear and adjust until there issufficient clearance. Re-tighten to the specifiedtorque figures.

42 The brake callipers are handed and mustbe fitted with the handbrake cable abutmentstowards the front of the car. Fit the correctbrake pads fully into the callipers ensuring thatthe range of movement of the pads is nothindered by the calliper body. Slide the calliperover the brake disc whilst separating the brakepads. Secure using bolt (fastener pack30A001A Item 4) with spring washer (18) andplain washer (16). Pass through the De Dionear, through the spacer (Fig 8 item 2) and into



the calliper. Tighten fixing bolts to 47 Nm.Finally attach and tighten the brake pipes.

ANTI-ROLL BAR CONNECTION ANDADJUSTMENT

43 Shorten the droplinks as much aspossible ensuring the threaded ends face in thesame direction. Tighten locknuts. Apply Loctiteto the threaded arm of the droplink and screwinto the extension piece (fitted in Para 35) usingwasher (16), refer to Fig 9. Pass the threadedportion of the lower droplink through the anti-rollbar and secure with nyloc nut (fastenerpack 30R011A Item 9).

1 Bolt 4 Droplink2 Plain washer 5 Anti-roll bar3 Extension piece

Fig 11 Anti-roll bar connections

NOTE

Droplink assembly and connections, shownrotated through 180 for clarity.

44 The position of the droplinks in the anti-roll bar determines the degree of the anti-rollgiven. Positioning the droplinks closer to thepivot (at the cotton reel bushes) will give moreroll resistance. The same position must be setboth LH and RH. The rearmost hole is thesoftest and forward most hole is the stiffestposition.

HANDBRAKE MECHANISM

WARNINGS



NOTES

(1) Prior to installing the handbrake cableensure that the adjustable boss is slackened offto allow easier location.

(2) The grommet and short section of flexibletubing on each section of outer cable are notrequired in this application and may be removed.

(3) The switch on the handbrake assembly isnot used in this application.

45 Install the handbrake mechanism andcables, refer to Paras 46 to 51, before installingthe differential and propshaft. The handbrakecables are connected to the rear brake callipersand adjusted later.

46 Pull the two sections of outer cable to theopposite ends of the inner cable with the nylonadjuster nuts to the right. Place the inner cable,refer to Fig 12, around the pulley (polythenebag). Install the pulley into the handbrake clevisand insert the thin clevis pin through thehandbrake clevis through the pulley and backinto the handbrake clevis. Secure the clevis pinin place with split pin (fastener pack 30P12AItem 14).

1 Handbrake inner cable2 Thin clevis pin and split pin3 Handbrake clevis4 Handbrake assembly5 Thick clevis pin and split pin6 Pulley

Fig 12 Handbrake assembly

47 Insert the handbrake cables into thetransmission tunnel with the nylon adjusting nutsto the LH side of the transmission tunnel; theinner cable should now cross over itselfimmediately behind the pulley, refer to Fig 13.



1 Pulley2 Handbrake cable twist

Fig 13 Handbrake cable arrangement

48 Locate the fixed nylon boss on the outercable into the RH bracket on the chassis abovethe differential and locate the adjuster on theouter cable into the LH bracket on the chassisabove the differential.

49 Secure the handbrake assembly to thechassis using the screws (fastenerpack 30P012A Item 4) and nyloc nuts (9). Thefront hole in the handbrake mechanism iselongated to allow adjustment of the handbrakelever in the 'off' position .

NOTE

For SV installation refer to fig 15 beforeproceeding.

50 The two ends of the handbrake cableemerge from the rear of the transmission tunnelrearwards. Each end of the handbrake cableshould be routed over the respective driveshaftthen turned through 180 under the driveshaftand secured to the chassis diagonals, usingcable ties, just outboard of the 'A' frame. Finallythe handbrake cable is turned back on itself andattached to the calliper through the abutments,refer to Fig 14.

NOTE

Ensure that cable cannot foul flexible brake pipeduring suspension movement.

1 Handbrake cable2 Cable tie3 'A' frame

Fig 14 Handbrake cable routing S3(non adjustable side)

51 On SV models the RH side of thehandbrake cable is routed as shown in Fig 12.Due to the design of the SV chassis LH side ofthe handbrake cable emerges from the rear ofthe transmission tunnel and is turnedthrough 90 across the seat back towards thewheel hub and is attached to the calliper throughthe abutment. Secure the handbrake cable tothe diagonal chassis member using cable ties,refer to Fig 15.

1 Handbrake adjuster 3 Cable tie2 Handbrake cable 4 Chassis

Fig 15 Handbrake cable routing - adjustableside (SV model)

52 The handbrake cable should not beadjusted until the transmission tunnel cover(interior trim) has been fitted as the handbrakelever is required to be in the vertical positionduring fitment of the trim.



53 The complete rear suspensionarrangement can be seen in Fig 16.

1 Watts link rear arm 5 Anti-roll bar2 Brake calliper 6 Handbrake cable3 Hub assembly 7 Watts link front arm4 Drop link

Fig 16 Rear suspension arrangement

HANDBRAKE ADJUSTMENT

54 Adjust the handbrake by rotating theknurled nut that locates in the bracket above thedifferential. The handbrake should be set to lockthe rear wheels on three clicks of the ratchetmechanism. Ensure that the pads are notbinding and tighten the second knurled nut tolock the adjuster.

FINAL ADJUSTMENTS

WARNINGS



55 If the damper units have been fitted, placethe axle stands under the De Dion tube so thatthe weight of the car is taken up through thespring damper units. Ensure that all thesuspension securing bolts are tightened asdetailed in Table 2.

FILLING OF DIFFERENTIAL

WARNING

Oils - prolonged and repeated contact maycause serious skin disorders:

(a) Avoid contact with the skin as far aspossible and wash thoroughly after anycontact.




56 Once the driveshafts have been locatedthe differential can be filled with oil. It isrecommended that the differential is filled withEP90 gear oil (Including those fitted with alimited slip differential). Refer to your Owner'sHandbook for a complete list of recommendedlubricants.

57 An LSD additive may be used in LSD's toreduce differential operating noise whencornering. This is available from Caterhamspare parts counter.

NOTE

This operation is made easier if the boot floorhas been removed to allow access.

58 Ensure the filler plug is to hand. Fill thedifferential with approximately 1.1 litres of EP90gear oil until the oil runs out of the filler hole.Screw the filler plug in and tighten.

59 Secure the boot floor to the chassis.


LocationTorque

(Nm)

Watts link locknut 20

Bellcrank to link 14

Watts link rear mount 34

Bellcrank to De Dion 34

Watts link front mount 34

Radius arm 34

'A' frame 81

Rear damper bolts (All) 54

Hub nuts 270

Hub mountings 47

Brake calliper 47

Rear anti-roll bar clamp 14

De Dion ears 47

SECTION 9 - INTERIOR & TRIM


TABLE OF CONTENTS

Para Page

1 General ....................................................................................................................... 25 Seat back carpets (Warning) ...................................................................................... 29 Transmission tunnel carpet......................................................................................... 2

12 Transmission tunnel top.............................................................................................. 315 Rubber footwell mats .................................................................................................. 316 Footwell carpets (CSR Model only) ............................................................................ 320 Under seat carpets (CSR Model only) ........................................................................ 321 Boot carpet.................................................................................................................. 324 Side and knee trim panels (Caution) .......................................................................... 330 Inertia reel seat belt (Warning) ................................................................................... 431 Four-point harness...................................................................................................... 5

Six-point harness35 Standard floor ........................................................................................................ 636 Low floor ................................................................................................................ 6

Seats (Warning)40 Standard cloth or leather seats.............................................................................. 6

Composite seats41 Adjustable seat ................................................................................................. 747 Fixed seat ......................................................................................................... 8

Minor trim items51 Scuttle edge trim.................................................................................................... 852 Nose badge............................................................................................................ 853 Rear view mirror (interior) ........................................................................................... 8

Table

1 Adhesive and special tools required ........................................................................... 2

Fig

1 Carpets ....................................................................................................................... 22 Side panel detail ......................................................................................................... 43 Trim fixings.................................................................................................................. 44 Mounting holes four-point harness upper ................................................................... 55 Shoulder strap with Track day roll over bar ................................................................ 56 Outboard lap strap ...................................................................................................... 57 Lap straps ................................................................................................................... 68 Crutch strap spacer location ....................................................................................... 69 Adjustable seat ........................................................................................................... 710 Composite seat and six-point harness........................................................................ 711 Fixed seat ................................................................................................................... 812 Completed interior....................................................................................................... 8



GENERAL

1 Superlight models are not supplied withany carpets unless otherwise specified.

2 Before fitting the carpets ensure that alloperations that require access under the carpetshave been completed.

3 The items specified in Table 1 will berequired during procedures detailed in thissection.

TABLE 1 ADHESIVE AND SPECIAL TOOLSREQUIRED

Item Remarks

Adhesive Contact adhesive

Durable dot fasteningtool (Part No. 76068)

Supplied in chassispack

4 It is recommended that a dry run iscompleted before cutting or gluing the carpets inthe final position.

Fig 1 Carpets

SEAT BACK CARPETS

WARNING

Ensure adhesive is applied in a well-ventilatedarea. Follow instructions on adhesivepackaging. Care must be taken whilst workingin a confined area e.g. the footwell.

5 The carpet that covers the seat back areahas a vinyl strip along the upper edge. Lay thecarpet into place ensuring that the carpet coversthe aluminium seat back right down to the floor.Apply adhesive to the vinyl strip and stick to thesquare tube at the top of the seat back panel.

6 The seatback carpet will need to be cut toallow the seat belt through it. Mark the carpetwhere the inertia reel seat belt exits the seatback and cut a slot.

7 The carpet must fit flat at the transmissiontunnel. If necessary small cuts should be madein the area of the corners to allow the tabs onthe carpet to hinge out against the transmissiontunnel.

8 Once the carpet has been fitted aroundthe transmission tunnel apply adhesive to thecarpet and press into position against the seatback. It is only necessary to apply adhesive asfar down as the top of the transmission tunnel asthe remainder of the carpet is behind the seats.

TRANSMISSION TUNNEL CARPET

9 Attach the small aluminium transmissiontunnel cover on the rear of the transmissiontunnel top using the 5/32" rivets provided.

10 Ensure that the reverse light switch andassociated blanking grommet have beeninstalled prior to fitting the transmission tunnelcarpets. The transmission tunnel carpets arehanded so ensure that the correct carpet is fittedto each side.

11 Coat the transmission tunnel withadhesive and stick the transmission tunnelcarpets to the transmission tunnel. Ensure thatgood adhesive coverage is maintained,particularly in the forward section of thetransmission tunnel.



TRANSMISSION TUNNEL TOP

NOTE

Do not attempt to fit the tunnel top until thetunnel carpet adhesive is dry completely.

12 The transmission tunnel top incorporatesa padded armrest, the gear lever gaiter and thehandbrake gaiter.

13 Pull the handbrake near vertical. Fit thetransmission tunnel top, ensuring that thehandbrake and gearlever locate in therespective gaiter and press firmly into positionover the sides of the transmission tunnelcarpets.

14 Screw the gearknob into position and lockwith a grubscrew.

RUBBER FOOTWELL MATS

15 Place the mats in the respective footwell(mats are handed). No fixings are required.

FOOTWELL CARPETS (CSR MODEL ONLY)

16 The footwell carpets are handed and aresecured into the footwell using the three poppersfitted at the rear of the footwell.

17 Attach 3 popper bases (fastener packZIT03 Item 2) to the rear of the front footwellusing rivets (1) through the pre-drilled holes inthe floor panel.

18 Stick masking tape to the underside of thecarpet in the approximate position of the floormounted poppers and lay the carpet intoposition. Press down firmly on the carpet so thatthe bases make an impression on the maskingtape. Make appropriate holes in the carpet andrivet together the popper (3) and fastenerbutton (4), using the Durable Dot fastening tool,refer to Table 1. Ensure that the fastener buttonis uppermost on the carpet.

NOTE

For correct use of the popper fastener tool referto Section 12.

19 Fit the footwell carpet into place andsecure using the poppers.

UNDER SEAT CARPETS (CSR MODEL ONLY)

20 The under seat carpets are handed andare secured into position by the seats. Place thecarpet into position ensuring that the four holesin the carpets align with the seat mounting holesin the cockpit floor.

BOOT CARPET

21 The boot carpet is laid into position andrequires no adhesive. It will be necessary to cutthe carpet to fit around the fuel filler pipe. Tuckthe edges of boot carpet down the sides of thealuminium honeycomb bootboard at the rear andthe sides taking care not to damage thealuminium body panel.

22 SV models are provided with carpet forthe boot interior side and front panels. Applyadhesive and secure the carpet shape into therelevant space.

23 Fit the fuel filler cover plate into positionand drill through the cover plate into the bootboard using a 2 mm drill. Attach the cover plateusing self tapping screws (fastener pack ZCH01Item 7). It may be necessary to relocate the fuelfiller hose clips to fit the cover.

SIDE AND KNEE TRIM PANELS

NOTES

(1) If specified, the optional sill protectors androll cage must be fitted before the installation ofthe knee trim panels, side panels andassociated piping can be completed.

(2) If the optional roll cage is to be fitted,shorten the sill protectors to 370 mm long andposition them towards the rear of the sill.

(3) If specified, optional Arm rest bracket(escutcheon bracket) must be fitted with sidepanel/sill protectors (sill protectors are optional)

24 Not all of the rivets used to secure theinterior side panels into place will have beenfitted. This is to allow fitting of sill protectors andto provide access to the front roll cagemountings, if required.

CAUTION

When drilling the sill protectors take care notto drill through both sides of the chassistube.



25 If necessary, position the sill protector onthe sill, with the long edge between the chassistube and trim panel, press down on the sillprotector and drill (5/32”) through the existingholes in the trim panel, through the sill protectorand through the existing holes in the chassistube. When all of the holes have been drilled,remove the sill protector and clear the holes ofswarf, burrs and raised edges.

26 Position a length of trim piping with the flatportion between the interior side panel and thechassis tube and cut to length. The pipingshould reach from the front of the knee trimpanel to just behind the point where the sidepanel meets the rear wheel arch panel, refer toFig 2. Ensure that the rounded edge of thepiping sits neatly along the top edge of the sidepanel.

1 Knee trim panel 4 Self-tapping2 Roll cage (optional) screws3 Piping

Fig 2 Side panel detail

27 Position the pre-bent and drilled knee trimpanel between the piping and the chassis tube,secure the knee trim panel, piping and sidepanel to the chassis tube using self-tappingscrews (fastener pack ZCH01 Item 8).

NOTE

If the optional roll cage is to be fitted leave thescrews out of the rearmost two holes.

For optional arm rest bracket fitment, do not fitrivets into 3-4 central rivet holes. (Please seesection 12 page 3)

28 Fit the sill protector between the pipingand the chassis rail and align the holes drilledpreviously. Drill through the holes again topierce the flat portion of the piping and secure

the sill protector, piping and side panel usingrivets (5), refer to Fig 3.

NOTE

If the optional roll cage is to be fitted leave therivets out of the forward three holes in thehorizontal row and the top three holes in thevertical row.

1 Piping 4 Chassis tube2 Sill protector 5 Side panel

(optional) 6 Rivet3 Body skin

Fig 3 Trim fixings

29 Fit the piping and secure the curvedsection of side panel in a similar manner. Ensurethat this section of piping overlays the horizontalsection. Cut a series of ‘V’ shaped notches inthe flat portion of the piping so that it follows thecurve of the side panel neatly.

INERTIA REEL SEAT BELT

30 If specified, the inertia reel seat belts willhave been positioned by Caterham, howevernone of the visible chassis mountings will betightened. The belts should be tightened at thesame time as the interior trim is fitted. The topand bottom mountings should be tightened to 47Nm.

WARNING

Use appropriate eye protection whilstworking under the car.



FOUR-POINT HARNESS

31 The harness should be fitted after the seatback carpet, tunnel carpets and boot cover havebeen fitted (if specified). Locate the threadedmounting holes in the top of the chassis, (referto Fig 4), and carefully cut away the materialcovering the holes.

1 Roll over bar mounting2 Roll over bar locating recess3 Drivers harness mounting4 Passenger harness mounting5 Chassis member6 Inertia reel mounting

Fig 4 Mounting holes four-point harness upper

32 From the mounting kit supplied with theharness, assemble a 7/16" UNF x 1 3/4" bolt,plain washer next to the bolt head, and passthrough the broad shoulder strap, crinkle washerand through the bush. Ensure the smallerdiameter of the bush is closest to the bolt head.Screw the bolt into the harness mounting point,refer to Fig 5.

1 Bolt 4 Bush2 Shoulder restraint 5 Plain washer3 Crinkle washer

Fig 5 Shoulder strap with Track day roll over bar(Shown with bolt loose)

33 To fit the outboard lap strap, assemblea 7/16" UNF x 1" bolt, with a plain washer nextto the bolt head, pass through the outboard lapstrap crinkle washer, and through the bush.Ensure the smaller diameter of the bush isclosest to the bolt head. Insert the bolt in thethreaded boss and tighten to 48 Nm refer toFig 6. Ensure lap strap buckle is uppermost.

NOTEUse of a longer bolt to secure the outer lap strapwill result in damage to outer body side panel.

1 Buckle2 Outboard lap strap

Fig 6 Outboard lap strap



34 To fit the inboard lap strap, assemblea 7/16" UNF x 1" bolt, with a plain washer nextto the bolt head, pass through the inboard lapstrap, crinkle washer, and through the bush.Ensure the smaller diameter of the bush isclosest to the bolt head. Insert the bolt into thethreaded boss and tighten to 47 Nm, refer toFig 7. Ensure lap strap buckle is uppermost.

1 Outboard lap strap2 Inboard lap strap3 Buckle

Fig 7 Lap straps

SIX-POINT HARNESS

Standard floor

35 To fit the crutch strap drill an 11 mm holethrough the two crutch strap mounting pointslocated at the rear of the cockpit and through thefloor of the cockpit. Assemble an M10 x 25 boltwith a plain washer next to the bolt head. Passthe bolt through the hole in the crutch strap,through the crinkle washer and top hat spacer,down through the chassis mounting ensuring thestrap is offset downwards, and through thecockpit floor. Secure the bolt in place using aplain washer and nyloc nut. Tighten to 47 Nm.Ensure the crutch strap fixing plate has the bendfacing the cockpit floor.

Low floor

36 Drill a 7/16” hole through the crutch strap-fixing bracket then through the floor pan directlybelow it.

37 Lay out the crutch strap to assure thecorrect orientation and assemble the harnesseyelets and spacers, refer to Fig 8.

38 Insert the long 7/16” x 3” bolt upwardsthrough the floor pan and assembled spacers

detailed above. Secure in place using the plainwashers and nyloc nuts supplied. Tighten allfixings to 61 Nm.

39 Fit the shoulder and lap straps as detailedin Paras 31 to 34.

1 Lowered floor pan2 Top hat spacer bush3 Crinkle washer4 Fixing eyelet5 Aluminium spacer6 Crutch strap fixing bracket

Fig 8 Crutch strap spacer location

SEATS

Standard cloth or leather seats

40 The adjustable seats are suppliedattached to the seat runner. Place the seat intoposition over the underseat carpet (SV only) andsecure the front mountings by passing setscrew(fastener pack ZSE03 Item 1) down through themounting and securing using plain washer (3)and nyloc nut (2). Slide the seat fully forwardand pass setscrew (1) down through the rearmountings and secure using plain washer (3)and nyloc nut (2). Tighten the fastenings.

Composite seats

Adjustable seat

41 Fit the runner with the adjusting handle tothe RH side of the seat with the handle facingforwards and inboard of the runner. Secure thefront mounting using reduced head cap headbolt (fastener pack ZSE06 Item 2) through theround hole then through two thick spacers (8)and into the threaded seat base. Secure therear with cap head bolt (2) through the squarehole, through 1 thick spacer (8) and 1 thinspacer (7) and into the threaded seat base, referto Fig 9.



1 Spacers2 Adjusting handle

Fig 9 Adjustable seat

42 Fit the LH runner in the same wayensuring that the outer part of the runner istowards the seat base. Secure using bolt (2),one thick spacer (8) and one thin spacer (7) oneach fixing ensuring they are between therunner and the seat. Torque all fixingsto 14 Nm.

43 Ensure that the harness option specifiedhas been installed prior to fitting the seat. Placethe seat into position feeding the lap andshoulder straps through the apertures in the seatbody and the crutch strap (if specified) throughthe aperture in the seat base, refer to Fig 10.Ensure that the harness straps are not twisted.

44 On low-floor cars the seat adjustinghandle must pass beneath the square chassistube and through the aperture in the verticalsection of aluminium panel.

45 Secure the front mountings with bolt (2)passed down through the runner and secureunder the floor using plain washer (5) and nylocnut (4).

46 Slide the seat fully forwards and pass abolt (2) down through the rear holes in therunner and secure under the floor using plainwasher (5) and nyloc nut (4).

NOTE

If the car has a honeycomb floor, bolt (1) ispassed through the runner, through spacer (6)and secured using plain washer (5) and nylocnut (4).

1 Composite seat2 Six-point harness3 Seat adjuster

Fig 10 Composite seat and six-point harness

Fixed seat

47 The fixed seat is bolted to the floor viatwo 25 mm square section, aluminium tubes.This tube has a series of cut-outs on one sideand plain holes in the opposite side. It isimportant that this tube is fitted in the correctorientation. The cut-outs must face away fromthe seat base allowing flush fitment to the floor.The large cut-out must be biased towards therear of the seat. Both tubes are identical andare fitted in the same orientation, refer to Fig 11.



1 Large recess2 Spacer

Fig 11 Fixed seat

48 Position the square section aluminiumtubes on the seat base and pass bolt (fastenerpack ZSE05 Item 2) through the large hole in theunderside of the spacer and into the small holeopposite, through one thick spacer (8) and intothe threaded seat base. Torque all fixingsto 14 Nm.

NOTE

If a track day roll over bar and Petty strut isinstalled, the seat can reclined slightly byreplacing the front fixing with bolt (1) andadditional thick plastic spacers (8) on each sideat the front, between the seat base and thealuminium tube.

49 Ensure that the harness option specifiedhas been installed prior to fitting the seat. Placethe seat into position feeding the lap andshoulder straps through the apertures in the seatbody and the crutch strap (if specified) throughthe aperture in the seat base, refer to Fig 4.Ensure that the harness straps are not twisted.

50 Secure the seat with bolts (2) and plainwashers (5) passed upwards through the floorinto the threaded bosses in the aluminium tubes.

MINOR TRIM ITEMS

Scuttle edge trim

51 This strip (chassis kit) is designed both tofinish off the scuttle around the dashboard tidilyand to protect the occupants from the hardaluminium edge. Cut the trim to length andsecure by firmly pushing the trim into place byhand. The scuttle edge trim is an SVArequirement, refer to Section 15.

Nose badge

52 The circular nose badge (polythene bagmarked 'miscellaneous') is mounted on the nosecone of the vehicle. It is self adhesive but hastwo locating dowels. Before removing the paperto reveal the adhesive on the underside of thebadge, carry out a trial fit to ensure the badgewill sit square. It may be necessary to removethe paint from the pre-drilled holes on the nosecone before fitting the badge.

REAR VIEW MIRROR (INTERIOR)

53 The centre mounted mirror is a legalrequirement and must be fitted. The mirror hasa self adhesive pad and should be stuck as highas possible on the interior of the windscreen onthe centre line of the car. Prior to removing thepaper backing from the self adhesive padensure the area where the mirror is to be placedhas been thoroughly cleaned using an alcoholbased degreaser. Note that the mirror can beinverted on its stalk to minimise windscreenobstruction.

54 On Superlight models without awindscreen, the mirror must be secured to thescuttle top on the centreline of the vehicle.Ensure that the area where the mirror is to beplaced has been thoroughly cleaned using analcohol based degreaser.

1 Rear bulkhead carpet2 Footwell carpet3 Tunnel carpet4 Tunnel top

Fig 12 Completed interior

NOTE

Items may differ from those shown, dependanton the chosen specification.


SECTION 10 - FIBREGLASS

FIB 01 Section 10Page 1

TABLE OF CONTENTS

Para Page

1 Cycle wings (Warnings) (Caution) .............................................................................. 216 Rear wing protectors (stone guards) ......................................................................... 320 Rear wings .................................................................................................................. 4

Table

1 Cycle wings................................................................................................................. 2

Fig

1 Indicator repeater wiring ............................................................................................. 32 Rear wing protector piping.......................................................................................... 33 Rear wing fitment ........................................................................................................ 44 Wing piping ................................................................................................................. 45 Rear wing.................................................................................................................... 5


Section 10 FIB 01Page 2

CYCLE WINGS

1 Cycle wings are supplied in two sizes;these are dependant upon wheel size. Ensurewheels and cycle wings are compatible, refer toTable 1.

TABLE 1 CYCLE WINGS

Wing size (approx.) Wheel size

78 cm over circumference 13", 14" and 15”

94 cm over circumference 16"

2 Piping (polythene bag marked 'SVA')should be fitted around the edge of the cyclewing. This is an SVA requirement, refer toSection 15.

3 It is easier to fit the front indicatorrepeaters to the cycle wings prior to fitting themto the cycle wingstay. Dismantle the repeaterassemblies removing and retaining both bulband lens. Remove the studs in the base anddiscard.

WARNINGS



CAUTION

When drilling fibreglass use tape on thesurface over the drill holes to preventdamage to the gel coat or painted finish.Slow drill speeds must be used.

4 Drill through the cycle wing at the pre-marked points using a 5 mm drill. Then enlargethe centre hole to 15 mm.

5 Feed the repeater wire through the cyclewing from the outside then secure the baseusing screws (fastener pack 30L002A) and nylocnuts. Replace the bulb and repeater lens.

6 The cycle wing will have been markedwith the positions for the front two mountingbolts for each wing. These should be drilledthrough using a 5 mm drill.

7 The front cycle wings bolt to the tubularwingstays which are rigidly mounted to the frontuprights.

8 Fit the front wheels ensuring that thesteering rack is centred. Place the cycle wingover the wingstay so that the bolt holes are overthe centre line of the forward wingstay tube suchthat the wing overhangs evenly on either side ofthe tyre. The wing can be held in position usingmasking tape. It is possible that the wingstaywill need to be bent to allow the cycle wing to fitcentrally over the tyre. Mark the positions forthe bolt holes onto the wingstay.

9 Remove the cycle wing and with the tyreprotected centre punch the wingstay. Drill theholes through the wingstay using a 6 mm drill.Ensure that the drill cannot contact the tyre.

10 Drill an additional hole in the underside ofthe front wingstay near the open end usinga 5/32” drill. Remove all sharp edges on theinside and outside of the wingstay tube.

11 Loosely fit the cycle wing to check thealignment of the cycle wing and wingstaysrelative to the tyre. The cycle wing should bechecked to ensure that it is centrally locatedover the tyre. Remove the cycle wing. Place astrip of masking tape across the tyre underneaththe drilled wingstay. Using a ruler held at 90 tothe surface of the tyre, mark the lateral positionsof the two holes. Rotate the wheel so that themasking tape is under the rear tube of thewingstay and transfer the bolt hole position tothe wingstay tube. Centre punch and drill usinga 6 mm drill as for the front holes.

12 Refit the cycle wing, loosely bolting it atthe front and aligning it over the tyre and thencarefully remove the wheel without disturbingthe wing. Masking tape can be used to hold thewing in place. Carefully mark the underneath ofthe wing with the bolt hole positions and thenremove the wing. Drill a small pilot hole fromunderneath the cycle wing, taking care not todamage the gel coat/painted surface. Checkalignment of the holes with the wingstays,adjusting if required, then drill through from thetop of the cycle wing with a 5 mm drill.



13 Place a strip of self adhesive foam(fastener pack ZFG12 Item 7) on the top of eachcycle wingstay tube. Cut two rubber grommetsin half to provide four rubber washers. Passscrew (5) through the manufactured washersand down through the cycle wing and wingstay.Secure using washers (4) and nyloc nuts (2).Tighten until the rubber washer is slightly largerthan the screw head. The black wire from theindicator repeater is the earth lead and shouldbe attached to the front wingstay using a pop-rivet in the 5/32” hole drilled at Para 10.Remove paint to ensure a good contact.

14 Route the green wire from the indicatorrepeater inside the wingstay until it emergesfrom the pre-drilled hole near the wingstaybrace. From the wingstay the wire must berouted along the rear of the upper wishbone balljoint, and the upper wishbone. Secure usingsmall cable ties at 50 mm intervals, refer toFig 1.

NOTE

To comply with SVA requirements the greenrepeater wire must be covered with heatshrinksleeving.

1 Upper wishbone 3 Repeater wire2 Front wingstay 4 Wingstay brace

Fig 1 Indicator repeater wiring

15 Once inside the aluminium body skin thegreen wire should be fitted into the 6 pineconoseal plug. It is recommended that thisconnection is made at the same time as theheadlamp and indicator wiring, refer toSection 11.

REAR WING PROTECTORS (STONEGUARDS)

NOTE

It is advisable to fit the wing protectors to thewings before fitting the wings to the car. Oncethe wings are fitted there is very little clearancebetween bodywork and drill chuck when drillingholes for the inner row of rivets.

16 The wing piping (fastener pack ZWS01 orZWS02 (option) Item 2) fits between the rearwing protector and the rear wing. Cut the pipingto length and fit around the top, outer and loweredges of the wing protector so the bead isagainst the edge of the protector. 'V' shapednotches (refer to Fig 2) should be cut to allowthe piping to smoothly follow the shape of theprotector. Position the piping under theprotector, ensure correct orientation of theprotector (refer to Fig 3) and drill through theexisting holes into the piping with a 1/8" drill.

1 'V' shaped notch2 Wing piping3 Holes

Fig 2 Rear wing protector piping

17 The wing protector should be placed onthe lower front of the rear wings. The correctposition can be obtained by placing the lowerangled edge approximately 5 mm up from thelower edge of the wing and the inboard side ofthe protector tight up against the inboard side ofthe wing (the side of the wing that bolts to thecar).

NOTES

(1) The protectors are supplied flat so willneed to be gently shaped to follow the contour ofthe wing.

(2) The protective film on stainless steel wingprotectors should be removed from around therivet heads before fitting. The protected sidefaces outward.


Section 10 FIB 01Page 4

(3) The LH wing protector is shorter thanthe RH protector to allow for the cut awaysection at the bottom of the LH wing. Both LHand RH protectors should be fitted equidistantfrom the bottom of the respective wing to ensurethe tops of both protectors are the same heighton the car.

18 Position the protector on the rear wingand mark one of the corner holes. Ensurecorrect spacing and orientation. Drill the holeusing a 1/8" drill. Fit the rear wing piping intoposition under the protector and rivet intoposition using rivet (1).

Carbon fibre wing protector uses black rivetsand the stainless steel wing protector uses plainrivets.

19 Attach the wing protector workingoutwards, one rivet at a time, from the cornerensuring that the wing piping is in the correctposition. Drill 1/8" holes and attach usingrivets (1).

REAR WINGS

20 The rear wings are provided pre-drilledwith both the wing fixing holes and further holesfor the suspension arms. To enable the wing tobe fitted to the car you will need to trim out thefibreglass from the larger holes to enable fitmentover the radius arm or Watts link arms, refer toFig 3). The wings are supplied in this way tomaintain their strength prior to them being fittedto the car. An alternative fixing method would beto remove the suspension arms then refit themonce the wing is secured in place.

1 Rear wing fixings2 Rear wing

Fig 3 Rear wing fitment

21 Offer the rear wing up to the side of thecar and bolt in place using a setscrew (fastenerpack ZFG12 Item 1) and plain washers (3) intorivnuts at the front of the rear wing and bolts (1),plain washers (3) through the rear of the wingand secured using plain washers (3) and nylocnuts (2). The setscrews used to secure the rearupper section of the wing should be passedthrough the body from inside the boot. Looselyfit all fasteners.

22 Wing piping (6) is provided to fit betweenthe rear wing and the car body. The wing pipingshould be positioned against the rear wing andcut to length. The wing piping has six ribsrunning longitudinally. 'V' shaped notches, referto Fig 4, should be cut to the sixth rib to allowthe piping to smoothly follow the curve of therear wing. Where the wing mounting boltsoccur, rectangular shapes should be cut to thefifth rib to accommodate.

1 Wing piping2 'V' shaped notches3 Rectangular notches

Fig 4 Wing piping

NOTE



23 Secure the rear wing ensuring that thebead of the wing piping is protruding. Do notover tighten fixings, refer to Fig 5.

1 Piping between wing and panel2 Piping on three sides of wing protector

Fig 5 Rear wing


SECTION 11 - LIGHTING

LTG 01 Section 11Page 1

TABLE OF CONTENTS

Para Page

1 General ....................................................................................................................... 23 Headlights and front indicators ................................................................................... 2

13 Front indicator repeaters............................................................................................. 214 Front wiring electrical connections.............................................................................. 316 Rear lights (Warnings) (Caution) ................................................................................ 324 Reversing light and fog light ....................................................................................... 425 Rear number plate light............................................................................................... 428 Testing ....................................................................................................................... 430 Headlight beam setting ............................................................................................... 4

Table

1 Front lighting wiring connections ................................................................................ 32 Rear lighting wiring connections ................................................................................. 4

Fig

1 Headlight and indicator LH ......................................................................................... 2


Section 11 LTG 01Page 2

GENERAL

1 The lighting kit includes all the partsneeded to make the car comply with the lightingrequirements of SVA. It is imperative that theseinstructions are adhered to in order to fulfil thelegal requirements of the lighting.

2 If fitted, remove the lead from the batterynegative terminal.

HEADLIGHTS AND FRONT INDICATORS

3 The headlight brackets will have beenfitted during assembly of the front suspension.

4 Fit a length of edge strip (polythene bag'SVA') to the underside edge of the indicatorcone. It is an SVA requirement that the edgestrip covers the entire edge of the mountingcone, including the portion directly beneath thelens.

5 Remove the lens from the front indicator.Ensure that the drainage hole on the indicatorseal is at the bottom, line up the holes in theindicator base with the holes in the indicatorcone and secure using three setscrews (fastenerpack 30L002A Item 3) and nyloc nuts (6). Donot over tighten. Replace the lens.

6 Tighten the two grub screws securingeach headlight bracket into the chassis. Tightento 7 Nm.

7 Remove the headlight rim by undoing theclamping screw located on top of the headlightbowl and unhooking the lens from the headlightbowl. Remove the plug from the back of theheadlight bulb and remove the sidelight housingfrom the reflector.

8 Remove the securing nut and lock washerfrom the headlight mounting stud and smear athin layer of oil to the thread. Insert theheadlight harness and headlight mounting studthrough the indicator cone and into the headlightbracket.

9 Refit the headlight securing nut and lockwasher and tighten until the headlight unitcannot move freely, this will aid assemblyhowever these nuts will need to be slackened offto allow the headlights to be correctly adjusted,refer to Fig 1.

NOTE

Ensure that the locating tang on the headlightshell engages with the recess in the mountingstud.

1 Headlight unit2 Headlight bracket3 Indicator cone4 Indicator

Fig 1 Headlight and indicator LH

10 Pass the black indicator earth wire(terminated in a ring terminal) through the hollowheadlight unit mounting stud and secure to theearth screw at the base of the headlight unit.Pull excess wire into headlight unit.

11 Refit the sidelight housing into thereflector and refit the plug to the headlight bulb.Hook the bottom of the headlight rim into the lipon the headlight bowl and swing the headlightrim up into position. Secure using the clampingscrew.

12 Feed the headlight wiring and the greenindicator wire through the hollow headlightbracket so that it exits into the engine bay.

FRONT INDICATOR REPEATERS

13 The front indicator repeaters are fitted atthe same time as the front cycle wings, refer toSection 10.


LTG 01 Section 11Page 3

FRONT WIRING ELECTRICALCONNECTIONS

14 Locate the 2 loose econoseal plugssupplied in the chassis pack (2 part black plugand yellow insert). Take the six wires (the sixthwire is the indicator repeater wire which may notbe fitted at this point) and push them into theback of the loose black plug ensuring that theconnections click into place. If they do notlocate correctly turn them through 180

oand try

again. Refer to Table 1 for the correct terminalposition within the connector.

TABLE 1 FRONT LIGHTING WIRINGCONNECTIONS

Function Wiring loomcolour

Light unit wirecolour

Earth Black Black

Headlight(Dip beam)

Blue/red Blue/red

Headlight(Main beam)

Blue/white Blue/white

Indicator Green/white Green

Repeater Green/white Green

Sidelight Red Red

15 Once the indicator repeaters have beenfitted and all the connections have been locatedinto the plug fit the yellow insert into the front ofthe plug. Connect the plug to the wiring loomand secure the cables to the chassis.

REAR LIGHTS

16 The kit includes two identical rear lightassemblies which comprise of tail, brake andindicator lights. They are mounted on rubberblocks which ensure that the lights are verticalwhen fitted and are secured with fourself-tapping screws. Turn one light unit aroundon the rubber block and ensure that the amberindicator lens is on the outside.

WARNINGS



CAUTION

When drilling fibreglass use tape on thesurface over the drill holes to preventdamage to the gel coat or painted finish.Slow drill speeds must be used.

17 The rear wings have been pre-drilled withtwo holes for the rear light assemblies. Theoutermost hole has been drilled to 30 mm andthis takes the wiring and the econoseal plug.The innermost takes one of the retaining screws.Enlarge the innermost hole using a 4 mm drill.

18 Remove the lenses from the rear lightassemblies along with the bulbs noting that theindicator uses a single filament bulb and thebrake light uses a double filament bulb.

NOTE

The rear light assemblies are not ‘handed’. Oneof the metal baseplates must be inverted tocreate a LH/RH pair with the indicator fitting tothe outside edge of each light.

19 Using the metal baseplate as a guide, drilla 4 mm hole through the rubber block in eachcorner. Ensure that the drill is kept at 90 to thebaseplate.

20 Feed the electrical wiring and theeconoseal plug through the 30 mm holeensuring that the grommet is passed through thehole. Attach the rear light unit at the lowerinboard corner using screw (2). Do not overtighten. Ensure that the rear light unit ishorizontal and drill through the rear light unit intothe rear wing. Remove the light unit. Clearaway the swarf and refit the light unit usingscrews (1) on the upper holes and screws (2) onthe lower holes. Do not over tighten. Replacethe bulbs and lens cover ensuring correctorientation of the lens cover (indicator to theoutside).

21 Connect the econoseal plug to thecorresponding socket protruding from a holeinside the rear wing. Ensure that the plugs arecorrectly mated and push the plug inside therear side panel. Fit the grommet to the hole inthe body side panel.


Section 11 LTG 01Page 4

22 For reference the rear electricalconnections are detailed in Table 2.

TABLE 2 REAR LIGHTING WIRINGCONNECTIONS

Function Wiring loomcolour

Light unit wirecolour

Rear light Red/white Red

Brake Green/mauve Green

Left indicator Green/red Green

Right indicator Green/white Green

Earth Black Black

23 Secure the wiring inside the body usingcable ties.

REVERSING LIGHT AND FOG LIGHT

24 The reversing light and the fog light arefixed to the rear panel and the wiringconnections have been made at the factory.

REAR NUMBER PLATE LIGHT

25 Remove and retain the cross-point screwretaining the light cover and lens; remove andretain the cover and lens. Remove and retainthe two nuts and spring washers from the metalbaseplate.

26 Pass the wire from the chassis loomthrough the RH upper hole of the light bracketon the chassis and through the back ofbaseplate. Fit the baseplate to the bracket andsecure with the nuts and spring washers. Ensurethat the baseplate studs earth to the bracketthrough the nuts (remove paint from the bracketas necessary).

NOTE

Cars that are not supplied with a spare wheelbracket will be pre-fitted with a number platelight bracket located below the lower chassistubes.

27 Remove and discard the two brass bulletconnectors supplied in the light. Shorten the wireto a convenient length, strip back sufficientinsulation and attach (crimp) a male bulletconnector. Insert the bullet connector into thecentral terminal on the light. Replace the lens,cover and cross-point screw.

TESTING

28 Reconnect the battery negative lead.Check all the lights for correct operation.

29 In the event that there are problems checkthat the bulbs have not been damaged duringtransit and replace as necessary. If the problempersists check every earth point on the chassisboth on the wiring loom and the battery earthlead. If the problem is related to a particularsystem or side, check the fuse box locatedunder the dashboard in the passenger side ofthe cockpit further information on fuseidentification can be found in your Owner'sHandbook.

HEADLIGHT BEAM SETTING

30 If possible the headlight beam settingshould be carried out using professionalequipment; if such equipment is not available,proceed as detailed below:

30.1 Position the car on a firm levelsurface, 2 m from a vertical surface(measured from the front edge of thelower lip of the nose cone). Slacken theheadlight securing nuts and switch on thelights (dipped). Adjust the lights until thebrightest spot of each light pool (at theapex of the dip-beam cut-off) is 650 mmabove the ground.

30.2 Measure the distance betweenthe centres of the headlights on the carand the distance between the centres ofthe bright spots on the wall. Adjust theheadlights as necessary until the twomeasurements are approximately thesame. When alignment is satisfactory, re-check the vertical measurement andtighten the headlight securing nuts.

30.3 The alignment will be tested andadjusted during the post build check. If thecar is not being submitted for a post buildcheck, we strongly advise kit builders toget the headlights professionally adjusted.

SECTION 12 - WEATHER EQUIPMENT

WET 01 Section 12Page 1

TABLE OF CONTENTS

Para Page

1 General ....................................................................................................................... 23 Fitting of hoodsticks and hoodstraps .......................................................................... 27 Hood fitting.................................................................................................................. 3

11 Sidescreen fitment (Warning) ..................................................................................... 3Exterior mirrors

21 Fitment to screen stanchion ................................................................................ 423 Fitment to side screens ....................................................................................... 525 Boot cover .................................................................................................................. 533 Tonneau cover ........................................................................................................... 642 Correct usage of fastener fixing tool ........................................................................... 8

Table

1 Additional tools............................................................................................................ 2

Fig

1 Weather equipment..................................................................................................... 22 Hoodstick spacing....................................................................................................... 23 Hoodstrap fixing .......................................................................................................... 34 Hood side fasteners .................................................................................................... 35 Hinge and sidescreen fitting ....................................................................................... 36 Sidescreen straps ....................................................................................................... 47 Arm rest bracket……………………………………………………………………………. 58 SVA mirror stalk adaptor............................................................................................. 59 Mirror fitted to sidescreen ........................................................................................... 6

10 Boot cover................................................................................................................... 611 Forward fastener boot cover....................................................................................... 712 Tonneau cover ............................................................................................................ 713 Tonneau cover positioning.......................................................................................... 714 Tonneau cover fasteners (front) ................................................................................. 715 Durable Dot fastener tool ............................................................................................ 8


Section 12 WET 01Page 2

GENERAL

1 This section explains how to perform theinitial fitment of the weather equipment, the toolidentified in Table 1 will be required. However, ifthe specification for your car included hoodfitment then instructions on how to refit, removeand fold for storage can be found in yourOwner's Handbook.

TABLE 1 ADDITIONAL TOOLS

Item Description

Durable Dot FasteningTool

Part No. 76068 (suppliedin fastener pack ZBC02)

2 Correctly fitted weather equipment isshown in Fig 1.

Fig 1 Weather equipment

FITTING OF HOODSTICKS ANDHOODSTRAPS

NOTE

Whichever option of roll over protection hasbeen specified must be fitted before thehoodsticks.

3 Remove the inner hoodstick from thehoodstick assembly and feed the end loop ofhoodstraps over the front hoodstick and loop inthe centre of the hoodstraps over the rearhoodstick ensuring that the adjusting bucklefaces downwards when the hoodsticks are erect,refer to Fig 2.

4 Reassemble the hoodstick assembly andattach to the triangular brackets on the chassisusing the fixings provided. Ensure that one plainwasher is fitted under the head of the screw andthe other between the fixing bracket and thehoodstick.

5 Before fitting the hood you must firstsecure the rearward part of the hoodstick in thecorrect position. Measure distance A from thetop surface of the rear chassis tube to the centreof the rear hoodstick to obtain the correctpositioning (standard chassis 395 mm orSV 420 mm), refer to Fig 2.

Fig 2 Hoodstick spacing

6 Drill two 7/64” holes into the upperchassis tube, one either side, on the inside rearedge of the boot, opposite the outermost popperbase (145 mm from the roll cage mounting lug).Make a small hole in the loose end of eachhoodstrap and using the two self-tapping screws(fastener pack ZWE05 Item 10) and washers, fixthe straps to the rear panel on the inside of thetop chassis rail, refer to Fig 3.

NOTES

(1) With the hoodstraps taut, check theposition of the rear hoodstick, as this will affectthe tension of the hood when finally adjusted.

(2) For a neater appearance, popper basesmay be used with the self-tapping screws usedto secure the hoodstraps.



1 Screw2 Washer (or popper base)3 Hoodstrap4 Rear body skin5 Chassis tube

Fig 3 Hoodstrap fixing

HOOD FITTING

7 With the hoodsticks in the upright positionand the adjusting buckle fully slackened, drapethe hood over the car and attach it to thewindscreen with the pre-fitted fasteners. Startwith the two outer most fasteners and ensurethat the felt seal is correctly located along thetop face of the windscreen frame.

8 Move to the rear of the car and attach theback of the hood again with the pre-fittedfasteners.

9 Tension the hood by adjusting thehoodstraps until the front hoodstick is in line withthe stitched darts in the hood. Use the Velcrolined sleeve stitched to the inside of the hood tocapture the front hoodstick as this will ensurethat it is correctly adjusted.

10 The front popper base for the side of thehood can now be fitted. To do this pull the sideof the hood down and assess the approximateposition for the popper base. Apply severallayers of masking tape to this area.

11 Pull the side of the hood down again andpress on the fastener to create an imprint in themasking tape. Drill a 3/32” hole through thecentre of the impression, remove the tape andsecure a popper base using a self-tappingscrew.

NOTE: Care should be taken while drilling holeon curve of the chassis tube.

12 Repeat the above procedure for theremaining popper bases along the cockpit andboot sides, refer to Fig 4.

1 Hoodstick2 Popper base3 Rear wing

Fig 4 Hood side fasteners

SIDESCREEN FITMENT

13 Using the setscrews (5) and nylocnuts (13) attach the sidescreen hinges to theoutside of the windscreen stanchions with theeyelet towards the rear of the car, refer to Fig 5.Fit the brass hinge pins (8) into the 4 remaininghinges. Now slide the hinges with the pins fittedinto the top of hinges attached to the car.

NOTE

SV sidescreens hinges are now supplied withpre-fitted hinge pins.

Fig 5 Hinge and sidescreen fitting

1 Windscreen stanchions2 Sidescreen hinges



14 The sidescreen is constructed using asteel frame around the window section. This iscovered with the vinyl which continues awayfrom the frame giving a soft flexible area ofabout 35 mm around the outside. The correctposition for the sidescreen is with the soft part atthe top tucked up between the two parts of thehood that make up the seal along the top of thedoor aperture and the soft area towards the fronttucked inside the stanchion. The lower rearradius of the sidescreen should follow the loweredge of the hood and the metal frame at the topshould be just below the top of the dooraperture.

15 With the hood still fitted and correctlytensioned, offer up the sidescreen into positionand mark the position of the four fixing holes.(For ease of marking it may help to run a strip ofmasking tape down the front edge of thesidescreen).

WARNING

Use appropriate eye protection whilstcarrying out drilling operations.

16 Next remove the sidescreen and place iton a solid surface and protect the window fromdamage caused by swarf before drilling theholes for the fixings. The metal frame inside thesidescreen is very hard so it is advisable tocentre punch and drill through with a 3 mm pilothole then finally with a 5 mm drill to enablefitment of the hinge.

17 Remove the top part of the hinges fromthe chassis and secure them to the outside ofthe sidescreen, using setscrew (5) and nylocnut (13), with the pin towards the front andpointing downwards. Fit SVA covers to the nutson the inside of the sidescreen and fit SVAprotectors to the non-chamfered ends of thehinge halves, refer to Fig 7 and Section 15.

18 Refit the sidescreen by sliding the pinsdown into the hinges on the car. With thesidescreen closed, tuck the top in between theflap of the hood.

19 Each sidescreen is held shut by two vinylstraps and fasteners. From inside the car, pullthe straps in over the top edge of the chassisand mark the place for the fastener base. Drilla 5/32" hole in line with the rivets holding theside panel in place. (You will be drilling into around tube so care should be taken to avoid thedrill wandering as it hits the tube).

1 Sidescreen2 Vinyl strap

Fig 6 Sidescreen straps

NOTE

Optional arm restraints are available. If thesehave been specified on your car then only thetop strap is required to locate the sidescreen.

20 Attach a popper base (2) using rivet (1).Next pull the strap down over the popper baseand mark the centre to position the fastener.Whilst doing this ensure the sidescreen is pulledtight up against the body of the car to reducedraughts and water ingress. Fix a fastener to themarked position on the strap using the durabledot tool, refer to Para 41. Repeat this processfor all fixing straps.

ARM REST BRACKET FITMENT(ESCUTCHEON BRACKET)

21 Optional arm rest bracket needs to befitted at this stage. SV/CSR cars comes with armrest attached to the side screen (it’s optional onS3). Stick the masking tape on the interior panelin the middle over the rivet holes. Hold the sidescreen tight against the car and press mark thearm rest popper position on the masking tape.Normally the popper line up with one of the rivetholes on the side panel. Push fit the escutcheonbracket and line up the marked position with thecentre of the bracket (Bracket should fit over theinside panel and rubber trim). Drill the markedpopper position through the bracket (5/32” drillsize). Refer the fig no 3



Fig 7 Arm Rest Bracket

EXTERIOR MIRRORS

NOTE

After the SVA inspection, the mirrors may befitted to the side screens but in order to passSVA inspection, the mirrors must be fitted to thewindscreen stanchions.

Fitment to screen stanchion

22 Remove and retain the central, slot-headscrew, in the screen stanchion and screw in theSVA mirror stalk adaptor, refer to Fig 8. Fit afibre washer and the mirror stalk over theadaptor and tighten the grubscrew to secure thestalk (ensure that the large recess in the stalkfaces rearwards).

1 SVA protector (1/2 grommet)2 Mirror stalk adaptor3 Hinge

Fig 8 SVA mirror stalk adaptor

23 Remove the mirror head from the originalstalk noting the relationship of all parts.Assemble the mirror head to the SVA stalk andadjust as required (retain the remains of theoriginal mirror for use post-SVA).

Fitment to side screens

24 Exterior mirrors are fitted to thesidescreens, towards the front, just below theclear window panel. Locate the holes pre-drilledin the metal frames (approximately 130 mm fromfront corner and 104 mm apart) then drill throughthe material with a sharp 5 mm drill. Attach themirrors to the hidden metal frame of thesidescreen using the countersunk screws (6),washers (14) and secure with nyloc nuts (13).



1 Mirror 3 Screen stanchion2 Hinges 4 Sidescreen

Fig 9 Mirror fitted to sidescreen

25 Plastic M5 caps (polythene bag marked'SVA') should be fitted to the nuts securing themirror to the sidescreen. These can be securedin place using a little silicone sealant.

BOOT COVER

26 When correctly fitted, the boot covershould be as shown in Fig 10.

Fig 10 Boot cover

27 The boot cover is designed to attachpermanently to the top of the bulkhead behindthe seat and clip onto the same fasteners asthose provided for the hood at the rear of thecar. It is designed to fit over the hoodstickswhen not in use therefore it is essential thatthese are fitted prior to fitting the boot cover.When the hood is erected, the boot cover isfolded away and stored in the boot.

28 The boot cover is designed to fit aroundthe roll bar, since these vary according tospecification, ensure the correct boot cover has

been supplied. There is a special boot coverdesigned for use with the roll cage.

NOTE

For cars fitted with harness type seat belts go toPara 29.

29 All boot covers have a metal insert alongthe forward edge, with pre-drilled holes to locatethe fastener bases. The forward edge of theboot cover should align with the front edge of theseat bulkhead. Ensure that the boot cover iscentrally located and mark the holes through theforward edge of the boot cover. Drill a 7/64”hole through each marked location and fit apopper base (fastener pack ZBC02 Item 5)secured with a self-tapping screw (6).

30 If harness type seat belts are being fittedthe metal insert in the boot cover must beremoved. Align the boot cover as previouslydescribed and mark the location of the fourthreaded bosses. Punch a hole in each of themarked locations and fit the harness shoulderstrap securing bolts through the boot cover, referto Section 9.

31 Additionally fit four fasteners (5) usingscrews (6) in the following locations; onefastener 1 1/4" either side of the car centrelineand one fastener at the midpoint between eachpair of shoulder restrains. If a tonneau cover isto be fitted, the position of the fasteners willhave to be adjusted accordingly.

32 Stretch the boot cover over the luggagearea. Secure around the rear stays of theroll over bar using the Velcro and establishlocations for the remaining fasteners (boot coverfastens to the hood fastenings on the body). Fitthe popper bases (3) and buttons (4) startingfrom the rear centre working outwards and thenforwards.

33 If a tonneau cover is to be fitted then theforward button on each side is substituted by apopper base (fastener pack ZTC01 Item 6),assembled as shown in Fig 10 and fitted to thefastener socket (4) using the punch provided (forcorrect usage of fastener fixing tool refer toPara 42).



1 Popper base2 Boot cover3 Fastener socket

Fig 11 Forward fastener boot cover

TONNEAU COVER

34 When correctly fitted the tonneau covershould be as shown in Fig 12.

Fig 12 Tonneau cover

35 Before the tonneau cover can be fittedboth the boot cover and seat belts must beinstalled and the detachable head restraintsmust be removed. The tonneau cover should befitted with the steering wheel in place. However,if a Quick Release (QR) column has beenspecified to function as an anti theft device andis intended to be removed when the car isunattended then this should also be removedprior to fitting the tonneau.

36 Carefully align the tonneau along thecentre line of the car and stretch it so that thereis about 25 mm of tonneau ahead of thefasteners fitted to the centre of the scuttle. Markand fit two fasteners (4) and buttons (5) in thetonneau to correspond with these fasteners.

37 Carefully measure the positioning of therear edge of the tonneau relative to the fastenerbases securing the front of the boot coverensuring that the rear edge of the tonneau is

exactly parallel to the seat bulkhead and it isproperly centred, refer to Fig 13. Mark theposition of the fastener bases and fit the sixfasteners (4) and buttons (5) across the back. Itis important that these fasteners are locatedcorrectly as these set the correct tension for thewhole cover. It should not be stretched so tightthat it puts tension on the fittings, bearing inmind it will not stretch so well in cold weather,nor so loose as to allow water to collect on it.

1 Tonneau cover2 Boot cover

Fig 13 Tonneau cover positioning

38 Starting with the passenger side, markand drill a 5/32" hole and fit a further fastener (3)securing the rivet (1) on the scuttle 45 mminward from the lower edge of the windscreensupport where it joins the triangular base, referto Fig 14. Stretch the tonneau carefully intoposition taking care to pull the tonneau farenough forward to achieve a little clearance infront of the rear wing, mark and drill a 5/32" holeand fit a further fastener (3) securing with arivet (1). Fit a fastener (4) and button (5) in thetonneau to correspond.

1 Windscreen support

Fig 14 Tonneau cover fasteners (front)



39 Mark and drill a 5/32" hole and fit a furtherfastener (3) securing with rivet (1) 38 mm belowthe rear lower edge of the scuttle, 19 mmrearward of the centreline of the large scuttlesecuring rivet. Stretch the tonneau and securewith a fastener (4) and button (5).

40 Mark, drill a 5/32" hole and fit a furtherfastener (3) securing with rivet (1) 50 mm downfrom the top rear of the sill and 45 mm forwardof the wheel arch. Pull down the tonneau andsecure with a fastener (4) and button (5).

41 Unzip the tonneau when fitting thefasteners to the driver's side, leaving the rearfasteners in place along the seat bulkhead.Repeat the fitting procedure as per thepassenger's side taking care to stretch thetonneau away from the vehicle centreline,towards the windscreen stanchion just sufficientto prevent bagginess in front of the steeringwheel.

42 Fastening the zip will correctly tension thetonneau.

NOTE

If a roll cage is fitted, additional fasteners mustbe fitted to the body to match the tonneau coverfasteners on either side of the Velcro-fastenedsplits for the roll cage forward supports.

CORRECT USAGE OF FASTENER FIXINGTOOL

43 The fastener tool, Fig 15, consists of twoparts; the dished base part and the punch.

Place the base on a solid surface dishedside upwards.

Put the fastener button through the materialand rest it in the dished part of the base.

Then place the fastener socket over thetube part of the button so that the cuppedsection is facing upwards.

Place the punch on the end of the tube andhit it with a hammer until the tube haspeened over gripping the two parts together.

1 Punch2 Dished base

Fig 15 Durable Dot fastener tool



SECTION 13 - WHEEL FITMENT

WHL 01 Section 13Page 1

TABLE OF CONTENTS

Para Page

1 Wheel fitment (Warning) ............................................................................................. 25 Spare wheel fitment .................................................................................................... 2

Fig

1 Spare wheel mounting items ...................................................................................... 2

SECTION 13 - WHEEL FITMENT

Section 13 WHL 01Page 2

WHEEL FITMENT

WARNING

Re-tighten wheel nuts after 200 miles.

1 Some Caterham supplied alloy wheels arefitted with steel inserts enabling securetightening of the wheel nuts. The wheel nutscan settle into the wheels over the first fewhundred miles causing loss of torque so shouldbe re-tightened to the correct torque afterapproximately 200 miles.

2 Many of the tyres supplied by Caterhamare directional. Check that the tyre orientation iscorrect before fitting the wheel to the car.

3 Fit the wheel using the wheel nutsprovided ensuring that the cone on each wheelnut is correctly located in the wheel. The wheelnuts should not be over tightened. It isrecommended that they are tightened whilst thecar wheels are on the ground. Tighten wheelnuts to 74 Nm.

4 Fit the wheel centre caps as follows:

13", 14" and 15" wheels. Place wheelcentre cap into wheel and push fully homeensuring correct seating.

16" wheels. Align securing screw in wheelcentre cap with corresponding thread insertin the wheel and secure using the toolprovided. Place wheel centre cap badgeinto the wheel centre cap and push fullyhome ensuring correct seating.

SPARE WHEEL FITMENT

NOTE

If specified for your kit, the spare wheel carrierwill have been fitted at the factory.

5 Locate the mounting wishbone, Fig 1 (1)(polythene bag marked 'spare wheel') andsecure to the spare wheel using two wheelnuts (2). The wishbone should be placed on theinboard side of the spare wheel.

6 Place the spare wheel in the spare wheelcarrier with the point of the mounting wishboneinboard of the wheel. Care must be taken toavoid damage to the paintwork whilst locatingthe spare wheel.

7 Assemble the spare wheel bolt (4), fibrewasher (3) (located in polythene bag marked'miscellaneous') and spacer (polythene bagmarked 'spare wheel') (5). Secure the sparewheel to the car using the assembled sparewheel bolt through the centre of the mountingwishbone. Ensure wheel nuts and spare wheelmounting bolt are tight.

8 Fit the wheel centre cap as detailed inPara 4.

1 Mounting wishbone2 Wheel nuts3 Fibre washer4 Spare wheel bolt5 Spacer

Fig 1 Spare wheel mounting items

NOTE

13" wheels fitted with low profile tyres aresecured to the spare wheel boss using a singlebolt and spacer located through one of thewheel stud holes.

SECTION 14 - START UP PROCEDURE AND FINAL CHECKS

FIN 02 Section 14Page 1

TABLE OF CONTENTS

Para Page

1 General ....................................................................................................................... 22 Brake system - filling and bleeding (Warnings) .......................................................... 25 Standard brakes.................................................................................................. 2

12 Uprated front brakes ........................................................................................... 218 Clutch system - filling and bleeding (Warnings) ......................................................... 324 Coolant........................................................................................................................ 325 Fuel (Warning) ............................................................................................................ 427 Engine/gearbox fasteners ........................................................................................... 428 Gearbox oil (Warning)................................................................................................. 431 Engine oil .................................................................................................................... 434 Cranking for oil pressure............................................................................................. 435 Start-up (Warnings)..................................................................................................... 545 Front suspension and steering alignment................................................................... 550 Final checks (Warning) .............................................................................................. 6

Table

1 Engine oil initial fill....................................................................................................... 42 Recommended suspension alignment - road use standard and wide track............... 53 Tyre pressures ............................................................................................................ 64 Torque figures............................................................................................................. 7

Fig

1 Clutch hydraulic connections ...................................................................................... 3


Section 14 FIN 02Page 2

GENERAL

1 This section details the operations,adjustments checks that should be carried outprior to starting the car for the first time. Referto your Owner's Handbook for recommendedlubricants and capacities.

BRAKE SYSTEM - FILLING AND BLEEDING

2 Prior to filling the brake master cylinderrecheck all brake connections, including factoryfitted connections, from the brake mastercylinder to each calliper and ensure that they areproperly tightened.

WARNINGS

(1) Brake fluid is poisonous; washaffected areas immediately in case of skincontact and seek medical assistance if fluidis swallowed or enters the eyes.

(2) Brake fluid is hygroscopic. Ensurethat fluid comes from freshly openedcontainer.

(3) Brake fluid is corrosive to paintwork,powder coat and plastic components. Careshould be taken to avoid spillage at all times.

3 Remove the brake master cylinder capand protect the surrounding scuttle paintworkwith clean cloths to prevent possible fluidleakage from causing damage to the paintwork.

4 Ensure all bleed nipples on the callipersare closed then fill the brake master cylinderwith fresh brake fluid that complies with SA3J1703F DOT 4 specification. Replace the mastercylinder cap.

Standard brakes

5 Remove and retain the dust cap from theLH rear brake calliper bleed screw. Place alength of flexible hose over the bleed screw andplace the other end of the tube into a clean glasscontainer and pour in sufficient brake fluid tocover the end of the tube.

6 Depress the brake pedal several times tobuild up pressure and maintain pressure on thebrake pedal.

7 With pressure maintained on the brakepedal unscrew the bleed screw and allow thecompressed air and brake fluid to flow into thecontainer. Tighten the bleed screw before thebrake pedal is released.

8 Repeat Paras 6 and 7 until no more airbubbles can be seen in the brake fluid.

NOTE

Ensure brake fluid level remains above half fulllevel in the brake master cylinder.

9 Tighten bleed screw and remove flexiblehose. Replace dust cap. Carry out Paras 5 to 7in the following sequence. RH rear calliper, LHfront calliper and finally RH front calliper.

10 As the rear callipers can be difficult tobleed, it may help to gently tap the calliper bodyduring the bleed process to release trapped airpockets.

11 It may be necessary to repeat the brakebleed procedure several times before a firm highbrake pedal is achieved.

Uprated front brakes

12 The uprated front callipers are usuallysupplied without the brake pads fitted. Beforebleeding the system fit the brake pads into thecalliper such that when viewed from the rear ofthe calliper the curve of the brake pad followsthe shape of the disc.

NOTE

The front wingstays obstruct access to theuprated callipers. Ensure that the brake padsare installed before fitting the wingstays.

13 Fit the anti-rattle clips behind the retainingpin (between the pin and the pads/disc). Rotatethe disc and ensure that the anti-rattle clip doesnot contact the disc at any time.

NOTE

Ensure that the arrow on anti-rattle clip points inthe direction of wheel rotation.

14 Bleed the brake system observing thesame order as for the standard brakes.



15 The uprated front brakes have two bleedscrews on each calliper. Remove the dust coverfrom the inboard bleed screw on the front LHcalliper. Connect the flexible tube to the bleedscrew and operate the brake pedal severaltimes. Whilst mounting pressure on the brakepedal open the bleed screw and allowcompressed air and brake fluid to flow into thecontainer. Tighten the bleed screw before thepedal is released. Repeat the procedure until noair bubbles are visible in the released brakefluid. Remove the flexible tube and replace thedust cap. Carry out the procedure for theoutboard bleed screw.

16 As a final check on system integrity, applypressure to the brake pedal and check allconnections and bleed screws for any sign ofleakage.

17 Initially brake pedal travel may seemexcessive despite the system being fully bled.However, the system will improve as the padsbed to the discs during the first 500-1000 miles.

CLUTCH SYSTEM - FILLING AND BLEEDING

18 Prior to filling the clutch master cylinder,check all connections to ensure that they areproperly tightened.

WARNINGS

(1) Brake fluid is poisonous; washaffected areas immediately in case of skincontact and seek medical assistance if fluidis swallowed or enters the eyes.

(2) Brake fluid is hygroscopic. Ensurethat fluid comes from a freshly openedcontainer.

(3) Brake fluid is corrosive to paintwork,powder coat and plastic components. Careshould be taken to avoid spillage at all times.

19 Remove the clutch master cylinder capand protect the surrounding scuttle paintworkwith clean cloths to prevent possible fluidleakage from causing damage to the paintwork.

20 Locate the bleed nipple/key on thegearbox bell-housing (refer to Fig 1) and removethe bleed nipple cover. Ensure that the bleedkey is in the position shown in Fig 1 (rotated fullyclockwise) and fill the clutch master cylinderreservoir with fresh brake fluid that complies withSA3J 1703F DOT 4 specification. Replace themaster cylinder cap.

21 Rotate the bleed key counter-clockwiseuntil it stops and place a length of flexible hoseover the bleed screw and place the other end ofthe tube into a clean glass container and pour insufficient brake fluid to cover the end of the tube.

22 Pump the clutch pedal until good pressureis felt and clear fluid, free of air bubbles, flowsfrom the bleed nipple. Rotate the bleed key fullyclockwise, remove the pipe and replace thebleed nipple cover.

1 Pipe to master cylinder2 Push-fit connector3 Bleed key

Fig 1 Clutch hydraulic connections

23 Mop up any spilled fluid, check for clutch‘feel’ and correct operation (repeat the bleedingprocedure if necessary); finally, hold down theclutch pedal and check for leaks.

NOTE

All sigma cars and R400 are fitted with throttleand clutch pedal stop.

For R400 the clutch bleed nipple is under theplate on top of the bellhousing

1) Throttle stop: The adjustment of thestop is critical in order to obtain fullthrottle at the throttle body end.Reaching down into the footbox, pressthe throttle pedal until the butterfly isfully open then adjust the throttle stop



up to the back of the pedal ball. Thismay take some time to get the correctadjustment. It is desired not to have anycable stretching at full throttle (whenbutterfly is fully open and pedal touchesstop).

2) Clutch pedal stop: the adjustment ofthe Clutch stop is critical in order toobtain full clutch operation. The clutchpedal is adjusted to the require lengthbut it might require fine tuningconsidering slight variation on differentcars. This may take some time to getthe correct adjustment.

COOLANT

24 Check all coolant hose securing clips aretight and that the coolant level is visible in thecoolant expansion bottle.

FUEL

WARNING

Due consideration should be given to thehighly flammable nature of petroleum oralcohol-based products and their vapours.Serious burns can result from incorrect use.

25 Check the security of the push-fit fuel pipeconnection at the fuel rail.

26 Remove the fuel filler cap and add 15litres of unleaded petrol to the fuel tank.

ENGINE/GEARBOX FASTENERS

27 Check that all engine and gearbox mountsand fasteners are tight.

GEARBOX OIL

WARNING

Oils - prolonged and repeated contact maycause serious skin disorders:

(a) Avoid contact with the skin as far aspossible and wash thoroughly after anycontact.




28 Remove the gearbox oil filler plug (if notremoved earlier) using the cut down 3/8” Allenkey.29 Add approximately 2 litres of gearbox oilto the gearbox until it dribbles out of the fillerhole. Replace the filler plug.

30 Due to the restricted access it may help tomake a filling tube using a small funnel andhose.

ENGINE OIL

31 The capacity of the engine oil system willvary dependant upon the specification of thevehicle. Refer to Table 1 for an initial fill quantitywhich is sufficient to start and run the engine atidle before checking and topping up as detailedin your Owner's Handbook (refer to Section 2 forrecommended lubricants).

TABLE 1 ENGINE OIL INITIAL FILL

Engine Type Initialfill Qty

Wet sump 4.5 litre

Wet sump and oil/air separator 6 litre

32 With all variants the engine oil should befilled via the screw cap on the top of the engine.Remove the cap from the cam cover and slowlypour in the oil allowing time for the oil to run tothe bottom of the engine. Replace the cap andtighten by hand only.

33 Check around the engine area both underthe vehicle and within the engine compartmentfor any visible leaks (oil or coolant). Check allwiring and hoses to ensure that they arecorrectly located particularly near any movingparts, for example, alternator or cooling fan.

CRANKING FOR OIL PRESSURE

34 Before running the engine for the first timeit is recommended that the following sequence iscarried out. This will ensure that the oil systemis capable of delivering lubricant throughout theengine.

Apply handbrake and check that thegear lever is in the Neutral position.

Disconnect the wires from the inertiaswitch, located on the bulkhead abovethe ECU.



Operate the ignition switch to crank theengine over until oil pressure registerson the gauge (oil pressure will be lowdue to the speed of the engine whenturned by the starter motor).

NOTE

It may be necessary to turn the engine overfor 30-40 seconds to achieve oil pressure. Onceoil pressure has been achieved, switch OFFignition and reconnect the inertia switch. Pressdown on the rubber button on top of the inertiaswitch to ensure that it has been de-activated.

START-UP

35 Apply handbrake and check that the gearlever is in the Neutral position.

WARNINGS

(1) The electric radiator fan is controlledby a thermostatic switch which operateswhen the ignition is in the on position.whilst working on a hot engine ensure thatthe ignition is switched off.

(2) Do not remove coolant expansionbottle cap whilst coolant is hot. Takeprecautions to prevent scalds.

36 Check under the car to ensure that thereare no visible leaks. De-activate the immobiliser

37 Turn the ignition key to position II andlisten for the fuel pump to prime. If no sound isheard, switch OFF the ignition and reset theinertia switch by pressing the rubber button ontop until it clicks. Turn ignition key to position IIagain and the pump should now prime.

38 Turn the ignition switch to position III sothat the engine turns over until the engine starts.Some models are fitted with a pushbutton starterswitch. If this is the case on your vehicle turnthe ignition switch to position II (red ignition lightON) and depress the button to operate thestarter motor.

39 Do not allow the engine to run for morethan one minute without checking the oil level.Using the dipstick as a level, top up the oilsystem until oil is visible between the 'Min' and'Max' marks. This will ensure enough oil is inthe engine to perform the initial run and warmup. The final check for the engine oil level willbe performed later in this Section. Check

around and under the engine for any visiblesigns of leaks.

40 Once you have checked and topped upthe oil level as required, restart the engine andleave running until it is warm. Ensure that the oilpressure gauge continues to indicate 2 bar(29 psi) or above at idle.

41 Allow the engine to run until the coolingfan cuts in (this should be at approximately92C). Switch off the engine.

NOTE

Should the temperature exceed 92C without thecooling fan cutting in, switch OFF the engineimmediately to avoid damage. Contact theCaterham technical helpline, as it is possiblethat there is an air lock in the cooling system.

42 Check the car for visible leaks. Re-checkthe hose clips for tightness as the rubber hosesbecome softer when warm.

43 Finally check the engine oil as detailed inthe Owner's Handbook ensuring the instructionsfor the correct engine specification are followed.If in any doubt please contact Caterham cars.

FRONT SUSPENSION AND STEERINGALIGNMENT

44 The front suspension is adjustable forboth camber and castor angles. The topwishbones normally come from the factory pre-adjusted although you may wish to reset orchange the basic settings. Factoryrecommended settings are shown in Table 2.



TABLE 2 RECOMMENDED SUSPENSIONALIGNMENT - ROAD USE STANDARD ANDWIDE TRACK

Front Rear

Tracking 0 20' 0 10'Toe-In

N/A

Camber 1 20' 0 15'(Negative)

1 30' 0 15'(Negative)

Castor 4 00' 1 00' (0 20' variation left toright, front)

45 Increased negative camber will tend toimprove the car's turn in characteristics in fastcorners but at the expense of possible tramliningon uneven surfaces and uneven tyre wear undernormal conditions. The factory settings shouldtherefore be adhered to except where the car isbeing prepared for motor sport.

46 The adjustment of castor is achieved bymoving the lower front wishbone backwards orforwards in the chassis using spacing washers,therefore altering the effective kingpin angle inside elevation. Increasing the angle away fromvertical will produce more pronounced selfcentring of the steering and hence a greaterfeeling of stability, but at the expense of heaviersteering.

47 Initial toe-in settings (standard track) fordriving to a service agent for post build checkingcan be set visually by ensuring the outside edgeof the front tyres lines up with a point on the reartyres ~ 50 mm in from the outside edge, with thesteering wheel centred. This approximatesetting will not cause either dangerous handlingor unnecessary tyre wear for limited initialmileage. Initial tracking of wide track cars canbe set by visually aligning the outside edges ofthe front and rear wheels.

48 It is recommended that distinctly differentsettings are used for race, hill climb or sprintapplications. Caterham can provide a range ofanti-roll bars and a competition parts brochure isavailable from the Parts Department at thefactory.

FINAL CHECKS

WARNING

Re-tighten wheel nuts after 200 miles.

49 The wheel/tyre combinations supplied byCaterham, are pre-inflated to approximately 40psi (2.8 bar) to ensure that the tyre is correctlyseated on the wheel rim and must be reducedprior to driving. Tyre pressures should bechecked in accordance with Table 3.

TABLE 3 TYRE PRESSURES

Wheel type Tyre type/ sizeFront(psi)

Rear(psi)

6J x 13 ACB10 6 x 20 x 13 18 18

CR500 175/55 x 13 18 18

6J x 14 AVON 185/60 x 14 20 20

6 1/2J x 13 CR500 175/55 x 13 18 -

8 1/2J x 13 CR500 205/55 x 13 - 20

6 1/2J x 15 CR500 195/45 x 15 18 18

7J x 16 AVON 205/45 x 16 16 16

50 Some tyres supplied by Caterham aredirectional. As a result any spare tyre suppliedwill only be treaded in the correct direction forone side of the car. If the spare tyre needs to befitted to the side where the rotation is incorrectthis should be done only as a means to get youhome and must be rectified before any furtheruse of the vehicle. Ensure that the tyres arefitted with the correct orientation.

51 Ensure that no wires or brake hoses arein such a position to chafe or to contact movingor hot components. Particular care should betaken with wires close to the exhaust manifold.

52 Before the car is used, ensure that allbolts securing suspension, steering and brakesare properly tightened, refer to Table 4.




Location WashersTorque

Nm

Front lower wishbone front Spring and plain 81

Front lower wishbone rear Plain spacers 81

Front upper wishbone front N/A 34

Front upper wishbone rear N/A 34

Front spring damper top Spring and plain 20

Front spring damper bottom Loctite 20

Upright top ball joint N/A 54

Upright bottom fixing Spacer (widetrack only) 54

Front anti-roll bar clamps N/A 20

Steering rack clamps Plain under bolt head 11

Steering column universal joint N/A 20

Steering column clamp plate Spring and plain under bolt head 14

Track rod end to upright N/A 34

Upper differential mounting Plain under bolt head and nut 54

Lower differential mounting Plain under bolt head 54

Propshaft N/A 74

Rear spring damper top N/A 54

Rear spring damper bottom Spring and plain 54

Watts link locknut N/A 20

Bellcrank to link N/A 14

Watts link rear mount 34

Watts link front mount 34

Bellcrank to De Dion 34

Radius arm 34

'A' frame N/A 81

Hub nuts Thrust 270

Hub mountings N/A 47

Brake calliper Plain and spring 47

Rear anti-roll bar clamp Plain under bolt head and spring under nut 14

De Dion ears Plain and spring 47

(continued)



TABLE 4 TORQUE FIGURES (continued)

Location WashersTorque

Nm

Gearbox to bell-housing Spring under bolt head 47

Gearbox mount Spring under bolt head 61

Engine to bell-housing Spring under bolt head 47

Bell-housing to sump N/A 20

Starter motor Spring under bolt head 34

LH engine mounting bracket Spring under bolt head 34

RH engine mounting bracket Spring under bolt head 34

Engine mounting rubbers Plain between chassis and nut 20

Engine mounting to rubbers Spring under bolt head 41

Gearbox mount to chassis Plain between chassis and nut 20

Exhaust manifold N/A 34

Expansion tank bracket Plain under bolt head and nut 10

Gearlever to tail-housing N/A 20

Brake banjo bolt Copper washer each side of banjo 10

Brake unions N/A 10

Seat belt / harness bolts See assembly instructions 47

All roll over bar fixings See assembly instructions 20

Petty bar See assembly instructions 47

Wheel nuts (2 part nut and tapered washer) Tapered 74

SECTION 15 - SINGLE VEHICLE APPROVAL AND REGISTRATION

SVA 01 Section 15Page 1

TABLE OF CONTENTS

Para Page

1 General ....................................................................................................................... 26 Requirements.............................................................................................................. 29 How to apply for the inspection................................................................................... 2

11 Travel to and from the test station .............................................................................. 312 Inspection refusal........................................................................................................ 3

Inspection data13 Design weight...................................................................................................... 314 Design speeds and maximum power engine speed ........................................... 315 Towing................................................................................................................. 316 Speedometer....................................................................................................... 317 Checking and preparing the car prior to inspection .................................................... 318 Wiper and washer system................................................................................... 319 Radio interface suppression................................................................................ 320 Lamps, reflectors and devices ............................................................................ 421 Rear view mirrors ................................................................................................ 422 Noise ................................................................................................................... 423 Emissions ............................................................................................................ 424 General construction ........................................................................................... 425 Protective steering .............................................................................................. 426 Brakes ................................................................................................................. 428 Interior and exterior projections...........................................................................41 Race cars and SVA..................................................................................................... 645 Registration procedure after SVA inspection.............................................................. 6

Table

1 Design speeds and maximum power engine speed................................................... 3

Fig

1 SVA bag contents ....................................................................................................... 42 SVA Scuttle trim and battery master switch................................................................ 53 Bonnet catches ........................................................................................................... 54 Front suspension ........................................................................................................ 55 Exhaust mounting ....................................................................................................... 66 Side screen hinges ..................................................................................................... 6

Annex

A Vehicle inspectorate test stations where the SVA test can be carried out ................. 1


Section 15 SVA 01Page 2

GENERAL

1 All Caterham cars will have to beinspected under the SVA regulations in order tobe registered for road use.

2 The inspectors have all been trained tothe same standard but may interpret certainregulations differently. Each test station willhave received a detailed explanation of what aCaterham is and what European regulations itcomplies with. The inspectors therefore shouldhave reasonable product knowledge and have acontact number at Caterham if required.

3 It is recommended that the car ispresented in a clean condition as this will greatlyimprove the inspector’s demeanour.

4 It is also advisable to take an emergencykit with you to the test station. This shouldconsist of a basic toolkit, cable ties, push on trimand a length of rubber hose. In the event ofcomponents needing tightening for adjustmentor a non-compliance, the emergency kit maysave you taking the car away and having tore-present it at a later date.

5 You should remember that anymodification made to the car subsequent topassing the SVA inspection may prevent it frompassing an MOT at a later date. For example ifa competition exhaust is fitted the originalcatalyst equipped system would need to beretained in order to meet MOT emissionstandards. The MOT is an inspection of thevehicles condition and will be carried out in thesame manner as for normal production cars.Items such as internal/external projections,noise and fields of visibility will not be inspectedat an MOT.

REQUIREMENTS

6 The following items are checked underthe SVA inspection:

Anti-theft Devices

Defrosting and Demister System

Wiper and Washer System

Seats and their Anchorages

Seat Belts

Seat Belt Anchorages

Installation of Seat Belts

Interior Projections

Radio Interference Suppression

Glass and Glazing

Lamp, Reflectors and Devices

Rear View Mirrors

Tyres

Exterior Projections

Protective Steering

Vehicle construction and design

Brakes

Noise

Exhaust Emissions

Speedometers

7 The examiner will conduct an engineeringassessment rather than the more thorough testthat full European Type Approval entails. Insome cases (brakes, noise, emissions etc) therewill be a physical test either on a rolling road orwithin the grounds of the test centre.

8 The inspection will not require any part ofthe car to be dismantled and will be carried outat Vehicle Inspectorate test stations. See AnnexA for the current stations. The inspection isanticipated to take approximately four hours andcan be booked between 0800-1700 Monday toThursday or 0800-1630 on Friday. There is afee payable for this service. An additional feewill be charged if an inspection is requiredoutside these hours.

HOW TO APPLY FOR THE INSPECTION

9 The inspection has to be formally bookedin advance therefore you must:

Obtain an application form from your localVehicle Registration Office (VRO) or VehicleInspectorate Office (HGV Station).

Complete the form and return it along withthe test fee to:

SVA sectionThe Vehicle and OperatorsServices Agency91/92 The StrandSwanseaSA1 2DH

0870 6060 440http://www.vosa.gov.uk



10 You will then receive confirmation of theinspection which will give details of the time andlocation. Where possible the inspection will becarried out at the Vehicle Inspectorate teststation you have selected.

TRAVEL TO AND FROM THE TEST STATION

11 In order to attend the inspection you willbe allowed to travel to and from the test stationwithout the vehicle being registered or fitted withtrade plates. Should any item require rectifyingyou will be permitted to drive to and from a placewhere rectification can be carried out. You arerequired to provide insurance cover for all suchjourneys.

NOTE

You will be able to secure insurance cover byquoting the car chassis number to your choseninsurers.

INSPECTION REFUSAL

12 The test station may refuse to inspectyour car for the following reasons:

You arrive at the test station later than yourappointment time.

You have not paid your fee.

There is insufficient fuel or oil for the test.You will be required to have a full tank offuel.

The car is presented in a dangerous or sucha dirty condition that the test is not feasible.

A device designed to be readily openedcannot be opened (e.g. bonnet padlocked).

The vehicle presenter does not remain withthe car to operate controls etc as requested.

INSPECTION DATA

Design weight

13 You will be asked to specify the maximumgross weights and maximum permitted axleweight during your application for a test date.This will then be checked by weighing the carwithout passengers and luggage (kerb weight)and then using a formula to calculate thetheoretical gross weight. The following weightsshould be quoted for all models.

Maximum Gross Weight 860 KgsMaximum Permitted Front Axle Weight 360 KgsMaximum Permitted Rear Axle Weight 500 Kgs

Design speeds and maximum engine speed

14 The design speeds and maximum powerengine speed for each model is detailed inTable 1.

TABLE 1 DESIGN SPEEDS AND MAXIMUMPOWER ENGINE SPEED

Model Engine MaxRPM

MaxMPH

Roadsport 125 1.6 6800 112

Roadsport 150 1.6 6850 122

Towing

15 It is not recommended that the Seven isused for towing, therefore, when asked thequestion; the answer is 'Not Applicable'.

Speedometer

16 The speedometer is compatible with thisvehicle.

CHECKING AND PREPARING THE CARPRIOR TO INSPECTION

17 It is recommended that the checks andoperations detailed in the following paragraphsare completed prior to taking the car for theinspection.

Wiper and washer system

18 Carry out a full system check prior to theinspection. Ensure the screen washer bottle isfull, the wiper blades contact the windscreen andthe washer jets are correctly adjusted. Ensure allhoses are secure as the system will be checkedunder pressure.

Radio interference suppression

19 Caterham supplied ignition leads aresuppressive. If you choose not to use theCaterham supplied ignition leads and havesupplied your own leads, ensure they are clearlymarked as suppressive.



Lamps, reflectors and devices

20 If you have built your car using thecomponents and information supplied, the carwill comply with SVA lighting requirements.Ensure that repeater indicators are fitted to thefront wings.

Rear view mirrors

21 These should be set up for maximumvisibility. Ensure that the windscreen mountedmirror and both screen stanchion mirrors are inplace. It is also worth removing the hood, orarriving without it altogether, as this improvesboth visibility and access.

Noise

22 Tailpipe noise will be tested. Though thesilencer is brand new, the efficiency is increasedwhen the internal packing has expanded againstthe inner wall. It is therefore recommended thatyou allow the car to idle as much as possibleprior to taking the car to the test centre. This willalso allow a layer of soot to settle which will helpdeaden the 'ring' of the new silencer.

Emissions

23 All Caterham cars are supplied withcatalytic converters and will meet the testrequirements.

General construction

24 This should be checked at the Post BuildCheck stage, however if you are not using thatservice ensure that chafing of brake pipes andthe wiring looms is not possible. If you havefollowed the procedures detailed in theAssembly Guide then you should not have anyproblems at this stage of the inspection.

Protective steering

25 All standard Caterham steering wheeltypes have a removable pad fitted. This padmust be in place during the inspection.

Brakes

26 The braking system will be subjected to athorough test (on brake rollers) so it isimperative that you take the time to bleed thebrakes correctly. The performance of the brakesoften improves dramatically after a small amountof use. Frequent application of the brakes onthe way to the test centre will help the brakesbed in.

27 Ensure the handbrake is correctlyadjusted and does actually lock the rear wheels.

Interior and exterior projections

28 Supplied with the kit is a polythene bagmarked 'SVA', refer to Fig 1. It is essential thatthese items are fitted prior to presentation at theSVA Testing station.

1 Scuttle trim2 Foam tape3 Edge trim4 Cable ties5 Track rod sleeve6 Flexible covers7 Bolt head covers8 Nut covers9 SVA mirror stalks and fixings

10 Rear bonnet catch cover11 Front bonnet catch cover

Fig 1 SVA bag contents



29 Ensure that the scuttle edge trim (Fig 2Item 1) is fitted to the edges of the scuttlearound the dashboard, refer to Section 9.

1 Scuttle edge trim2 Eyebrow edge trim3 SVA cover4 Battery master switch sheath5 SVA cover (optional roll cage)

Fig 2 SVA Scuttle trim and battery masterswitch

30 Apply the self-adhesive Velcro stripsaround the sides and bottom of the fuse boxcover. Attach the other half of the Velcrofastening to the Velcro already attached to thefuse box cover. Locate the cover over the fusebox sticking it in place. (R400 only)

31 The '7' in the nosecone grill is not SVAcompliant and therefore should be fitted behindthe mesh grill in order for your car to pass theSVA test.

32 The edge trim should also be secured tothe edges of the front cycle wings (Fig 3 Item 4),the edge of the black plastic housing around therear fog and reverse lights and the edges of theindicator cones. Cars fitted with the detachablewind deflector will also require edge trim alongthe top edge of the deflector and around theedges of the mirrors.

33 The caps (Fig 4 Item 3) should also befitted to the nut and bolt head of the topwishbone front mounting.

1 Rear bonnet catch cover2 Front bonnet catch cover3 Edge trim (indicator cone)4 Edge trim (cycle wing)

Fig 3 Bonnet catches

34 The bonnet catch covers (Fig 3 Items 1and 2) should be pushed over the respectivebonnet catch.

35 The covers (Fig 1 Item 7) should be fittedto the shoulder strap mounting bolts (Onlyrequired if this 4 or 6-point harness option isspecified).

36 The sleeves (Fig 4 Item 1) should havebeen fitted over the track rod locknuts during thefront suspension build.

1 Track rod sleeve2 Stub axle cover3 Steering arm nut cover4 Track rod end nut cover

Fig 4 Front suspension



37 Covers (Fig 4 Items 2, 3 and 4), should befitted over the inner stub axle nuts, the steeringarm nuts, the track rod end nuts and the twowheel nuts that hold the spare wheel to thespacer wishbone (if fitted).

38 Covers (Fig 5 Item 1) should be fitted tothe exposed nuts securing the exhaust bobbinand the exhaust bracket and an off-cut of scuttleedge trim should be fitted to the upper edge ofthe exhaust silencer bracket.

1 Nut covers2 Scuttle trim off-cut

Fig 5 Exhaust mounting

39 The sharp edge of each side screenhinges should be protected as shown in Fig 6.The protectors are made by cutting grommets inhalf and fixing them in place with superglue.

NOTE

If the side screens are fitted for the SVA testthen the hinge halves fitted to the side screensmust be protected in a similar manner.

40 Road wheels are exempt from externalprojections with the exception of the sparewheel. Ensure the wheel is positioned such thatany balance weights are behind the spare wheelcarrier.

1 Grommets2 Rear view mirrors (SVA position)

Fig 6 Side screen hinges

Race Cars and SVA

41 There are several parts that aremandatory on race cars which are not SVAfriendly. Ideally these parts should be fitted afterthe car has been submitted for its SVA test but ifthis is not possible then these parts will need tocomply with the SVA criteria.

42 Fire Extinguisher. The 'T' handle thatoperates the fire extinguisher will need to beremoved and the boss in the dash covered.

43 Track day roll over bar/roll cage. Allfixings will need to be covered. If the track dayroll over bar petty strut is supplied this will needto be removed and the hole in the side panelmust be covered.

44 Battery Master Switch. The edges of themaster switch key will not pass SVA; a rubbersheath for the key is included in the SVA kit andthis must be fitted for the test. The eyebrowmust be fitted with edge trim and the fixing boltswill need protective caps, refer to Fig 2.

REGISTRATION PROCEDURE AFTER SVAINSPECTION

45 If your vehicle fails the SVA inspection forany reason you will be allowed to take the caraway to rectify it.



46 Upon successful completion of the SVAinspection you will be issued with a certificate toconfirm that the car has passed to the standardrequired. This certificate is officially called aMinister's Approval Certificate (MAC) and mustbe retained. In order to register your car youmust submit the MAC, a completed applicationfor registration form (currently V55/5), insurancecertificate and your certificate of newness (withfull CKD De Dion kits only) along with yourVehicle Excise Duty (VED) fee for either sixmonths or twelve months to your local VehicleRegistration Office (VRO). In addition aregistration fee will be levied by DVLA to coveradministration costs throughout the vehicle's life(sending out VED reminders etc).

47 The car will be subjected to an MOTinspection three years after it was firstregistered.


SECTION 15 ANNEX A - VEHICLE INSPECTORATE TEST STATIONS WHERETHE SVA TEST CAN BE CARRIED OUT

SVA X01 Section 15 Annex APage 1

AberdeenCloverhillBridge of Don Industrial EstateAberdeen AB23 8EE01224 702357

BeverleyOldbeck RoadOff Grovehill RoadBeverleyEast Yorkshire HU17 0JG01482 881522

BirminghamGarretts Green Industrial EstateBirmingham B33 0SS0121 783 6560

Bristol (Avonmouth)Unit 10, I.O. CentrePoplar Way WestAvonmouthBristol BS11 0QL01179 381157

Cardiff (Llantrisant)School RoadMiskinPontyclunMid Glamorgan CF72 8YR01443 224701

CarlisleBrunthill RoadKingstown Industrial EstateCarlisle CA3 0EH01228 528106

ChelmsfordWidford Industrial EstateChelmsfordEssex CM1 3DR01245 259341

Derby:Curzon LaneAlvastonDerby DE21 7AY01332 571961

ExeterGrace RoadMarch Barton Trading EstateExeterDevon EX2 8PU01392 278267

GillinghamAmbley RoadGillinghamKent ME8 0SJ01634 232541

Glasgow (Bishopbriggs)Crosshill RoadBishopbriggsGlasgow G64 10A0141 772 6321

Leighton Buzzard:Stanbridge RoadLeighton BuzzardBedfordshire LU7 4QG01525 373074

Liverpool (Speke):C/O South Liverpool CommercialsWoodend AvenueSpekeLiverpool L24 9NB0151 4860050 or 0151 5474445

London–North (Edmonton)Anthony WharfLea Valley Trading EstateEdmonton N18 3JR020 8803 7733

London–South (Mitcham)Redhouse RoadCroydonSurrey CR0 3AQ020 8684 1499

London–West (Yeading)Cygnet WayWillow Tree LaneYeadingHayesMiddlesex UB4 9BS020 8841 9205

Manchester–North (Chadderton)BroadgateBroadway Business ParkChaddertonOldham OL9 9XA0161 947 1000

Newcastle-upon-TyneSandy LaneGosforthNewcastle-upon-Tyne NE3 5HB0191 236 5011

NorwichJupiter RoadHellesdenNorwich NR16 6SS01603 408128

NottinghamMain RoadWatnallNottingham NG160115 938 2591

ShrewsburyUnit 6 Levens DriveHarlescottShrewsbury SY3 7EG01743 462621

Southampton (Northam):Unit R, Centurian Industrial EstateBitterne Road WestSouthampton SO18 1UB02380 837397

SECTION 15 ANNEX A - VEHICLE INSPECTORATE TEST STATIONS WHERETHE SVA TEST CAN BE CARRIED OUT

Section 15 Annex A SVA X01Page 2

TauntonTaunton Trading EstateNorton FitzwarrenTauntonSomerset TA2 6RX01823 282525

SECTION 16 - OPTIONS

OPT 01 Section 16Page 1

TABLE OF CONTENTS

Para Page

1 Introduction ................................................................................................................. 3Oil/air separator/anti-cavitation system

3 General................................................................................................................ 34 Fitting instructions (Warning) .............................................................................. 3

15 Battery master switch.................................................................................................. 518 Standard roll over bar ................................................................................................. 520 Track day roll over bar (Warning) ............................................................................... 5

Roll cage (Warning) .................................................................................................... 631 Preparation.......................................................................................................... 636 Roll cage fitment ................................................................................................. 746 Head restraint (roll cage and roll over bar) ................................................................. 852 Fire extinguisher pull handle....................................................................................... 957 Aero fuel filler cap (Warnings) .................................................................................... 10

High level brake light67 Fitting the bracket (Warning)............................................................................... 1273 Light and wiring connections (Warning).............................................................. 1283 SVA mirror fitment…………………………………………………………………………. 15Table

1 Track day roll over bar mounting bolt torque figures .................................................. 62 Roll cage mounting bolt torque figures ....................................................................... 83 Head restraint fixings torque figures ........................................................................... 9

Fig1 Oil/air separator mountings......................................................................................... 32 Header tank location plate .......................................................................................... 43 Relocated horns.......................................................................................................... 44 Oil/air separator tank position ..................................................................................... 45 Standard roll over bar ................................................................................................. 56 Track roll over bar ....................................................................................................... 57 Front fixing boss location ............................................................................................ 78 Rear hoop bucket bushes........................................................................................... 79 Head restraint assembly ............................................................................................. 9

10 Fire extinguisher pull handle....................................................................................... 911 Fire extinguisher inner cable location ......................................................................... 1012 Kit contents ................................................................................................................. 1013 Filler cover and boot carpet removed ......................................................................... 1014 Drill out the six rivets................................................................................................... 1015 Old filler boss removed ............................................................................................... 1016 Gasket positioned on back panel................................................................................ 1117 Carefully drill new holes .............................................................................................. 1118 Spacer filled to filler neck............................................................................................ 1119 Fit flange ..................................................................................................................... 1120 Job complete............................................................................................................... 1121 Kit contents ................................................................................................................. 1222 Drilling central popper on SV ...................................................................................... 1223 Alignment of bracket ................................................................................................... 1224 Wire routing through light unit .................................................................................... 1325 Drilled hole above spare wheel boss .......................................................................... 1326 View from under RHS rear corner .............................................................................. 1327 Exploded view of assembly ........................................................................................ 1328 Wires from support tube entering boot ....................................................................... 1429 Completed assembly .................................................................................................. 1430 Wheel speed sensor plug .......................................................................................... 1431 Wheel speed sensor bracket ...................................................................................... 1432 Wheel speed sensor ................................................................................................... 1433 Brake caliper assembly…………………………………………………………………….. 1534 Brake Pad Assembly……………………………………………………………………….. 15


Section 16 OPT 01Page 2

35 Kit content …………………………………………………………….. ……… 1536 Dismantled mirror…………………………………………………………….. 1537 Assembled mirror…………………………………………………………….. 1638 Stud located on stanchion…………………………………………………… 1639 Final fitted assembly…………………………………………………………. 1640 Front Brake Caliper assembly……………………………………………… 1641 Front brake pad assembly…………………………………………………… 16



INTRODUCTION

1 These fitting instructions are supplied inaddition to the normal assembly guide deliveredwith your kit. They are specific to the additionalequipment required when using your car forcompetition purposes. This document issupplied with new kits and as instructions tocustomers purchasing upgrades for an older car.SVA notes have been included for customersneeding to register a new vehicle.

2 It is important that these instructions areread in conjunction with your assembly guide inparticular with regard to the preliminaryinformation that can be found at the front of theguide.

OIL/AIR SEPARATOR/ANTI-CAVITATIONSYSTEM

General

3 The oil/air separator has been designed tohelp separate oil and air in the engine. Atsustained high revs the engine can have atendency to draw air up into the oil galleries andthus decrease the lubrication efficiency. Thetangential spin created by the separator tankdraws the air from the oil before directing itthrough a restrictor and back into the enginecam cover.

Fitting instructions

WARNING


4 Fix self-adhesive foam padding strips(polythene bag marked 'oil/air separator') on thelower chassis cross members, refer to Fig 1.

1 Upper mountings2 Standard header tank mounting point3 Lower mounting4 Foam padding

Fig 1 Oil/air separator mountings

5 To locate the correct position for the topmountings, stand the tank on the foam paddingensuring that it is vertical. Where the tanktouches the upper chassis diagonals, mark asmall line (this should be at the centre of thewidth of the separator tank). Position an uppermounting bracket (polythene bag marked 'oil/airseparator') against the side of the tank with thetwo fixing holes either side of the line. Nowmark the two fixing holes. Remove the tank anddrill two 5/32" holes in the chassis crossmember. Repeat the marking and drillingprocedure for the second bracket. Secure theupper mounting brackets using the rivetsprovided.

6 The lower mounting must be riveted onthe centre line of steering rack platform (longend upwards), with the bend level with andpointing away from the top surface of the rackplatform.

7 To prevent contact with tank, attach asmall piece of self adhesive foam to the rearfacing surface of all three mountings.

8 Fitting the optional oil/air separator tankmeans that the standard header tank mountingpoint cannot be used. To provide an alternatelocation for the header tank a location plate mustbe riveted to the upper RH chassis tubesapproximately 110 mm from the centre of thestandard header tank mounting point (the pre-drilled rivet holes in the location plate should becentral on the chassis tubes), refer to Fig 2.



Fig 2 Header tank location plate

9 Fitting the optional oil/air separator tankobstructs the area normally used for the horns.Relocate the horns by bending the brackets andsecuring them to the underside of the headertank location plate using a 7 mm spacer on theM8 x 65 mm cap-head screw and locknut usedto secure the header tank mounting to thelocation plate, refer to Fig 3.

Fig 3 Relocated horns

10 Fit and tighten the magnetic drain plug(polythene bag marked 'oil/air separator') to thebase of the tank. Lubricate the thread and fit thetemperature sender into the side of the oil/airseparator tank.

NOTE

The temperature sender has a tapered thread toenable it to seal without the need for a washer.For this reason it will go tight before it hasscrewed fully home. Care should be taken notto over tighten.

11 Fit a dowty seal over one end of each thetwo large 5/8" male/male adapters and fit theminto the large threaded bosses in the side of theair separator tank. Screw in the adapters untilthe dowty seals just begin to grip, then carefullytighten using two spanners so as to avoiddamaging the soft aluminium tank.

12 Connect the two oil pipes from the engineto the tank ensuring that the longer oil pipe fromthe rear connection on the oil filter housing isconnected to the upper union on the tank, referto Fig 4. When tightening the oil pipes careshould be taken not to damage the softaluminium tank. Note that a large hexagon isprovided where the union attaches in order tofacilitate the use of an additional spanner. Placethe oil/air separator tank on the lower mountingbracket and secure to the upper securingbracket using the hose clip provided.

1 Braided hose 6 Upper oil pipe2 Right-angled union 7 Oil temperature3 Separator tank sender4 Upper union 8 Lower oil pipe5 Hose clip

Fig 4 Oil/air separator tank position

NOTES

(1) The black/yellow wire that exits the loomin the front LH corner of the chassis can be usedto provide an oil temperature reading byattaching it to the temperature sender.



(2) An additional switch and wiring to thetemperature gauge will also be required but thiscannot be fitted prior to SVA test. For furtherinformation please contact Aftersales who will behappy to carry out this work for you.

(3) Cars fitted with Stack instrumentationalso require an additional black earth lead.

13 Secure the upper and lower oil pipesusing the cable ties provided to ensure that theycannot come into contact with moving parts ofthe engine or suffer abrasion.

14 Attach the small braided hose from thetop of the tank to the front RH corner of the camcover via the right-angled union using thecopper washer provided.

BATTERY MASTER SWITCH

15 If specified the battery master switch willhave been fitted at the factory.

16 Locate the two thick red leads exiting thetransmission tunnel. Connect the lead marked'starter' to the starter solenoid along with thelarge brown lead (with black sleeve) from thealternator. Route the lead marked 'battery' tothe battery positive terminal. Do not connect.

17 Check that the lead to the battery isattached to the single connection of the masterswitch and the lead to the starter is attached tothe master switch connection along with adouble brown wire.

STANDARD ROLL OVER BAR

18 Insert the bosses; on the underside of theroll over bar main hoop into the bucket busheslocated at each end of the seat belt header railtowards the rear of the cockpit, refer to Fig 5.Locate the rear diagonals of the roll over bar intothe mounting brackets at the rear of the bootcompartment. Secure the roll over bar to thechassis using set screws (fastenerpack 30P010A Item 2), spring washers (6) andwasher (5).

19 The rear diagonals are secured to thebrackets by bolt (1) and nyloc nuts (4) with aplain washer (5) under the bolt head and nylocnut. Tighten all fastenings to 20 Nm.

1 Standard roll over bar 3 Spring washer2 Set screw 4 Plain washer

Fig 5 Standard roll over bar

TRACK DAY ROLL OVER BAR

20 Before fitting the Track day roll over bar itwill be necessary to remove the rear springdamper units in order to gain access to the lowermounting points, refer to Section 8.

21 The Track day roll over bar is fitted in thesame manner as the standard roll over bar withthe exception of additional fixings located in theends of the main hoop.

22 Having placed the roll over bar intoposition, but before finally tightening the fixings,pass from underneath bolt (3) supplied with theroll over bar z pack, into the threaded holes inthe ends the main hoop of the Track day rollover bar. Leave these fasteners loose until allfixings are in place.

1 Rear diagonal2 Track day roll over bar

Fig 6 Track roll over bar



23 An additional, optional Petty strut can beadded to the Track day bar to upgrade it to FIAspecification.

NOTES

(1) The Track day bar as supplied without theadditional Petty strut is not FIA approved.

(2) The Petty strut is not SVA compliant andtherefore should be removed for normal roadusage.

24 The forward end of the Petty strut issecured to a mounting boss located within thechassis that is normally hidden behind theinterior trim panel. It can be found in thepassenger side of the cockpit approximately oneinch below the point at which the dashboardtube is welded to the top of the chassis rail.

25 If a 7/16" hole is not visible, drill out thesix 5/32" rivets holding the top edge of the trimpanel surrounding this point and ease the trimpanel away from the chassis until the exactlocation of the mounting boss is identified.

WARNING


26 Drill a small pilot hole through the trimpanel taking great care not to touch the outerside skin and enlarge such that a 7/16" bolt canbe fitted through. Ensure that the inner thread inthe mounting boss is not damaged during thisprocess. Loosely fit bolt (fastener pack ZPS01Item 2) and secure the trim panel with rivets.

27 Remove bolt (2). Secure the Petty strut tothe roll over bar, using bolts (1), with plainwashers (4), under the head of the bolts. Passthe bolts through the plate on the Petty bar thenrearwards through the fixing holes in the centreof the main hoop, secure with plain washers (4)and nyloc nuts (3).

28 Attach the forward end of the Petty strut tothe previously uncovered boss using bolt (2)passed through spring washer (6), plainwasher (5) then the fixing plate at the forwardend of the bar. It may be necessary to use theadditional plain washer(s) (5) between the frontfixing plate and the side of the chassis toachieve the best fit.

29 Tighten additional roll over bar mountingbolts in accordance with Table 1.

TABLE 1 TRACK DAY ROLL OVER BARMOUNTING BOLT TORQUE FIGURES

Location Torque

Base of the bucket bushes 20 Nm

Mounting flange 5/16" UNF 20 Nm

Rear diagonals 5/16" UNF 20 Nm

Petty bar (all fixings) 47 Nm

30 It is recommended that all parts of the rollover bar likely to be contacted by either thedriver's or passenger's head to be protected withapproved roll bar padding. Suitable FIAapproved padding is available from theCaterham parts counter.

ROLL CAGE

WARNING


Preparation

31 Before fitting the roll cage it will benecessary to remove the rear spring damperunits in order to gain access to the roll cagelower mounting points, refer to Section 8.

NOTE

This roll cage is SVA-compliant howeverprotective covers will be required on the four boltheads that attach the front hoop to the chassis.You will also be required to have SVA compliantmirrors fitted to both the driver and passengersides of the car to ensure rear visibility ismaintained.

32 The lower ends of the hoop that forms thefront of the cage, attaches to two pre-fittedthreaded bushes. These bushes are located,behind the side panels; one on each side of thecar and approximately one inch below the pointat which the dashboard tube is welded to the topof the chassis rail, refer to Fig 7. Beforeattempting to fit the cage, these bushes willneed to be uncovered.



1 Front hoop saddle bracket2 Fixing bolt – in threaded bush3 Chassis top tube - sill

Fig 7 Front fixing boss location

WARNING


33 If a 7/16" hole is not visible in the sidepanel, drill out the 5/32" rivets holding the topedge of the trim panel surrounding this point andease the trim panel away from the chassis untilthe exact location of the mounting boss isidentified. Drill a 4 mm pilot hole through thetrim panel then enlarge to give clearance for a7/16" bolt. Ensure that the inner thread in themounting boss is not damaged during thisprocess.

34 Take a 10 mm drill bit and pass it throughthe threaded boss until the pointed end of thedrill touches the inside of the outer side panel.Gently tap the end of the drill bit until a smallwitness mark is visible on the outside of the sidepanel along the centre line of the bush. Using acentre dot, dot the outside of the side panel onthe witness mark and drill a 4 mm pilot hole,then enlarge such to give clearance for a 7/16"bolt. Ensure that the inner thread in themounting boss is not damaged during thisprocess.

35 Repeat this process on the other side ofthe car then run a 7/16" UNF bolt into bothbosses to ensure the threads are clean andundamaged.

NOTES

(1) Do not re-rivet the interior side panels atthis stage.

(2) If you intend to run sill protectors, you willneed to remove these prior to fitting the cage.They will also require trimming at the forwardend to enable them to be refitted around thecage.

(3) You are now ready to attach the roll cageto the chassis however due to the size andweight of this part it is strongly recommendedthat you obtain further assistance as an extrapair of hands to help guide the cage into positioncould prevent damage.

Roll cage fitment

36 Offer the cage up to the car and gentlyrest in place. Insert the bosses at the bottom ofthe rear hoop into the bucket bushes located ateach end of the seat back harness rail at therear of the cockpit, refer to Fig 8.

1 Bucket bush location2 Roll cage rear hoop3 Seat back harness rail

Fig 8 Rear hoop bucket bushes

37 Carefully lower the front of the cage untilthe saddle brackets at the ends of the front hooprest over the chassis top tube (sill). When fitted,the inner leg of the saddle should be betweenthe fixing boss and the interior side panel, referto Fig 7.

38 As the front of the cage is lowered intoplace the rear legs will rise and locatethemselves between the mounting plates at therear of the boot compartment. The bosses onthe ends of the rear hoop will drop into thebucket bushes.

39 The cage can now be bolted into placeusing the fixings provided. Align the holes oneby one and loosely fit all the fixings as detailedbelow. Do not finally tighten any of the fixingsuntil they are all in place.



40 Locate the underside of the bucketbushes and pass the reduced head bolts(fastener pack 30P017A Item 3) up through thebottom of the bush and into the threaded bosson the roll cage. No washers should be used onthese bolts as this will restrict damper clearance.Do not tighten at this stage.

41 Loosely fit bolt (2) through the interior sidepanel, the roll cage and into the threadedchassis boss. This will hold the side panel inplace whilst it is riveted back into place. If youintend to run sill protectors then these will needto be trimmed and re-fitted at this stage. Run thepiping between the interior side panel and thechassis side rivet into place through the predrilled holes using rivets (fastener pack ZCH 01Item 5).

NOTE

If you are building a new kit, refer to theassembly guide regarding fitment of knee trimpanels as these are also best fitted at this time.

42 Remove the loosely fitted bolt (fastenerpack 30P017A Item 2) and adding a plainwasher (5) pass through the interior side panel,roll cage saddle bracket and into the threadedboss. Do not tighten at this stage.

43 Repeat the above using bolts (2) andplain washers (5) passed through the outer legsof the saddle bracket and into the threaded bushin the chassis. Ensure that this bolt does not‘bottom out’ on the bolt inserted from inside thecockpit.

NOTES

(1) If you intend to fit a rear wheel protectionbar then the outer fixing bolt on the driver’s sideof the car will need to be removed again to allowfitment of this part.

(2) The rear wheel protection bar is notSVA-compliant and should not be fitted prior tothe SVA test.

44 The rear legs of the cage are secured tothe mounting plates at the rear of the bootcompartment using bolts (1) and nuts (4) passedthrough the plates and the holes in the end ofthe legs. Plain washers (6) must be fitted underboth the head of the bolt and the nut (these boltsmay appear to be undersize but they areintended to be only a loose fit in the respectiveholes).

45 With all the fixings in place they can befinally tightened in accordance with Table 2.See also note above.

TABLE 2 ROLL CAGE MOUNTING BOLTTORQUE FIGURES

Location Torque

Base of the bucket bushes 34 Nm

Rear legs 20 Nm

Forward hoop saddle brackets 47 Nm

HEAD RESTRAINT(Roll cage and roll over bar)

NOTE

The head restraint is not SVA-compliant andshould not be fitted prior to the SVA test.

46 The head restraint is supplied as twoparts, an adjusting bracket and a square headpad with a long adjusting stud.

47 Attach the self-adhesive foam pad(fastener pack 30P011A Item 5) to the front faceof the square head pad.

48 Attach the bracket to the cross section ofthe roll cage/bar so that the adjusting slot isvertical to ground so that the longer fixing legattaches to the lower cross tube, refer to Fig 9.

49 Bolt in place using bolts (1) and nylocnuts (2) with plain washers (4) under both thehead of the bolt and the nut.



1 Adjusting bracket2 Square head pad3 Foam pad4 Adjusting stud (head pad)5 Plain nuts and washers (x 2)6 Bolts and washers (x 2)7 Nyloc nuts and washers (x 2)

Fig 9 Head restraint assembly

50 Screw one of the plain nuts (3) onto thehead pad stud followed by one plain washer (4),pass the stud rearwards through the vertical slotin the adjusting bracket and fix into place withthe remaining plain washer (4) and plain nut (3).Finally tighten all fixings in accordance withTable 3.

TABLE 3 HEAD RESTRAINT FIXINGSTORQUE FIGURES

Location Torque

Bracket to roll cage/bar 34 Nm

Adjusting nuts (once adjusted) 34 Nm

51 When the car is complete and you haveobtained a comfortable driving position thisassembly can be adjusted up, down, forwardsand backwards to give the optimum position inrelation to your crash helmet. Once this positionhas been set, it is advisable to trim off any of theexcess studding.

FIRE EXTINGUISHER PULL HANDLE

NOTE

The fire extinguisher handle is notSVA-compliant and therefore will not have beenfitted at the factory, even though the rest of theextinguisher system may have been. The fireextinguisher system is intended for track use. Donot fit prior to SVA test.

52 Insert the inner cable through the hole inthe centre of the boss that has been pre fitted toyour dashboard. Ensure that the handle ispushed fully home, refer to Fig 10.

1 Pull handle2 Dash mounting boss

Fig 10 Fire extinguisher pull handle

53 Pass the inner cable through the hole inthe cable locater fitted to the extinguisher lowerhandle, then through the opposing hole in thetop handle.

54 Secure the inner cable in place using thesolder-less nipple supplied, refer to Fig 11.

55 Trim off excess cable to approximately 30mm.

56 Apply a small piece of tape or heat shrinkto the trimmed inner cable to prevent fraying.

NOTE

It is advisable to allow approximately 5 mm offree play, as the scrutineer may want to ensurethat the cable is free whilst scrutineering yourcar.



1 Outer cable 4 Top handle2 Inner cable 5 Solder-less nipple3 Cable locator

Fig 11 Fire extinguisher inner cable location

AERO FUEL FILLER CAP

1 Filler cap 5 M5 x 12 cap head2 Gasket screws (x2)3 Neck adaptor 6 M5 x 16 CSK4 Keys head screws (x6)

Fig 12 Kit contents

WARNING

There is always a risk of fire or explosionwhen working on fuel tanks. Take the utmostcare with preparations.

57 If the Aero filler cap is to be retro fitted,the original cap must first be removed asfollows. Undo the two self-tapping screws andremove the black filler neck cover inside theboot. Remove the boot carpet to prevent itgetting dirty.

Fig 13 Filler cover and boot carpet removed

WARNING

Wear appropriate eye protection whilstcarrying out drilling operations.

58 Remove the old cap with the the key andblock the filler hole with tape or cloth. Removethe two self-tapping screws that retain the top ofthe filler neck to the filler boss, the rubber hoseswill then allow the filler neck to be pulled out ofthe way.

59 Drill out the six rivets that retain the oldfiller boss. This must be done very carefully toavoid damage to the back panel. It isrecommended this is done with a hand or air drillto eliminate the sparks caused by an electricdrill.

Fig 14 Drill out the six rivets

60 The old filler boss can then be carefullypulled away from the back panel.

Fig 15 Old filler boss removed

123

5 4 6



61 Take the gasket supplied with the kit andcarefully align the hole in the gasket with thehole in the back panel. Ensure two of the fixingholes are positioned at 3 o’clock and 9 o’clock.

Fig 16 Gasket positioned on back panel

62 Mark the new hole positions and carefullycentre punch the marks. Taking great care, drillthe holes (6 mm diameter).

Fig 17 Carefully drill new holes

63 Fit the black spacer to the filler neck usingthe two M5 cap head screws supplied in the kit.The spacer will be a tight fit on the neck due tothe O-ring and it must be pulled up evenly. Theholes for the spacer are slotted to allow forcorrect alignment with the holes in the backpanel. Tighten the screws fully after thealignment has been checked.

Fig 18 Spacer fitted to filler neck

64 Re-position the filler neck and gasket upagainst the back panel. Push the filler flangethrough the hole in the panel. Care must betaken to ensure correct orientation of the flange(One of the four 'scallops' has been enlarged toenable a petrol pump nozzle to pass further intothe neck. It is important that this larger scallopis orientated towards the top), refer to Fig 19.Retain with the six M5 x 16 CSK head screwsand pull these up evenly to ensure the flangelocates correctly on the O-ring.

Fig 19 Fit flange

65 Remove all drillings from the inside of theboot and re-fit the boot carpet. Reposition thefiller neck cover and retain it using the two self-tapping screws.

Fig 20 Job complete

66 All that remains is to remove the tape orcloth from the neck and fit the new cap.

NOTES

(1) Remember to fit the key to the new cap toyour key ring.



HIGH LEVEL BRAKE LIGHT

1 Wiring sub-loom2 Wiring to high-level brake light3 Rivets (x2)4 Male Lucar terminals and shrouds (x2)5 Nut and plastic bolt from light kit6 Replacement popper7 Rubber grommet8 Sticky pad9 Cable ties

10 Larger spare wheel boss11 Cable insulation12 Light support bracket13 High level brake light

Fig 21 Kit contents

Fitting the bracket

67 If retro-fitting, the spare wheel must firstbe removed from the car.

68 Working from inside the boot, unscrewthe 5/8” nut which holds the spare wheel boss tothe back panel, and remove the boss, takingcare not to drop the large washers.

WARNING

Wear eye protection when carrying outdrilling operations.

69 Centre mark a point 25 mm below the topof the back panel, on the vehicle centre line.Centre punch this, and drill a 5/32” hole, takingcare not to damage the back panel. In the caseof the SV, simply remove the central hood/bootcover popper using a 5/32" drill, as shown inFig 22.

Fig 22 Drilling central popper on SV

70 Using masking tape to protect thepaintwork from damage, position the bracket asshown in Fig 23, passing the new, larger sparewheel boss through the bracket and back panel,ensuring only one large washer is used inbetween the back panel and spare wheelsupport channel. Secure the boss usingthe 5/32” nut, finger tight only.

Fig 23 Alignment of bracket

71 Using a spirit level, refer to Fig 23, adjustthe bracket until the light platform is exactlyparallel to the top of the back panel, and markfrom inside the boot through the previouslydrilled hole, onto the bracket.

72 Remove the bracket, centre punch anddrill the hole using a 5/32” drill. Re-fit thebracket, and secure the upper mounting usingthe large black rivet, or for an SV the smallercountersunk rivet passed through thereplacement popper. Apply threadlock, andtighten the 5/8” nut to 34 Nm.

Light and wiring connections

73 If painting of the light casing is required,follow the instructions supplied with the light.



74 Split the light and feed the terminated endof the supplied wires through both the hole in thebase of the light unit, and the nut supplied withthe light unit. Insert the plastic bolt from theunderside, and tighten nut to secure in place asshown in Fig 24. Connect the terminals to themale connectors on the metal strips on the bulbholder.

Fig 24 Wire routing through light unit

75 Centre mark a point on the vehicle centreline, 35 mm above the edge of the spare wheelmounting boss. Centre punch, and carefully drilla 1/4” hole, as shown in Fig 25. Masking tapecan be used to protect the paintwork. Push thesupplied rubber grommet into the hole.

Fig 25 Drilled hole above spare wheel boss

WARNING

Disconnect the negative (-) terminal from thebattery before carrying out electrical work.

76 Working from inside the boot, unscrew thefour retaining screws that secure the fuel fillerneck cover, and remove it. From under the rightand rear corner of the car, feed the terminatedend of the supplied sub-loom up into the bootarea, through the hole exposed by removing thefiller neck cover. Disconnect the wiring plugsleading to the rear light cluster, and connect theplugs from the sub loom in between, as shownin Fig 26.

Fig 26 View from under RHS rear corner

77 Re-assemble the light unit, and feed thecable insulation over the wires. Push themthrough the hole in the sticky pad and the hole inthe platform on the bracket, then use the stickypad to fix the light in place, shown in Fig 27.Feed the wires down through the RH supporttube of the bracket, then through the rubbergrommet into the boot area, shown in Fig 28.

Fig 27 Exploded view of assembly

78 Cut the wires from the light unit to lengthso the connections can be concealed behind thefiller neck cover, and terminate with the maleLucar terminals and shrouds. Connect these tothe sub-loom; grey/red to the green/purple, andgrey to the black wire. Use the cable tiesprovided to tidy and secure the wiring, and re-fitthe filler neck cover.



Fig 28 Wires from support tube entering boot

79 Reconnect the battery, and with the aid ofan assistant, check to ensure that the high-levelbrake light operates in conjunction with thebrake lights in the rear clusters, and re-fit thespare wheel. The completed assembly is shownin Fig 29.

Fig 29 Completed assembly

Stack dash speed sensor fitment

80 Route the speed sensor loom through thehole on the tunnel top along with main wiringloom to the front of the chassis near LHS wheel.Use cable ties to route the loom wherenecessary. Connect the speed sensor plug tothe plug on main wiring marked as wheel sensorrefer fig. 30

1 Plug on the wheel speed sensor loom2 Plug on the main wiring loom

Fig 30 Wheel speed sensor plug

81 Insert the speed sensor in to the bracketand secure with locknut (do not tighten). Referfig. 31. Remove 2 caphead bolts on the LHSbrake caliper and fit the bracket with speedsensor to the caliper (do not tighten). There arefour bolts on the brake disc, speed sensorshould be adjusted by aligning with one of thefour bolts. Select any of those bolt by rotatingthe disc and Adjust the speed sensor front edgeso that the gap between the sensor and the bolton the disk is 2-3 mm. tighten the lock nut on thesensor. Tighten the bolt on the caliper (50NM)and secured the bracket in place. Refer fig.32

1 Seed sensor Bracket2 Lock Nut3 Speed sensor

Fig 31 Wheel speed sensor Bracket

1 Caliper Caphead bolts2 Speed sensor3 Speed sensor Bracket

Fig 32 Wheel speed sensor



Rear Brake caliper subassembly

81 Insert the shim into the slot on the caliperassembly. Make sure the shim has seatedproperly. Please refer the fig. 33.

1 Brake caliper2 Caliper Bracket3 Shim

Fig. 33 Brake Caliper Assembly

82 Assemble caliper bracket and calipertogether using two bolts provided in the brakepads box. Do not tighten the bolt at this stage.Refer fig 33

1 Brake Caliper2 Caliper Bracket3 Brake Pads

Fig 34 Brake Pad assembly

83 Insert the brake pads into the Brakecaliper assembly. Check for the correctalignment of the brake pads. Refer fig.34. Now tighten the Caliper bracket boltto 20NM.

SVA Mirror Fitting Instructions

1 Mirror stalk2 Fibre washer3 M5 grub screw4 Fixing stud

Fig 35 - Kit Contents

84 Side screen mirror (part number 291 007401) must first be dismantled from itsmounting arm using a T20 Torx bit.Retaining the mirror section, Torx screw,plastic cup and setting aside the arm (seefig 36).

1. Torx screw2. Plastic cup3. Mirror

Fig 36 - Dismantled Mirror

85 Parts taken from the mirror (fig 36.) nowneed to be assembled with the mirrormount from fig. 1. Place the plastic cupagainst hole cut in mirror casing. Insidethe mirror section there is a smallswivelling arm this is placed into the

3

1

2

4

12

3



machined slot of the mirror mount. Theflat on the swivelling arm faces towardsthe right (looking at fig 35). The Torxscrew should then be inserted from therear of the mount to secure the stalk andmirror together (see figure37).

Fig 37 - Assembled Mirror

86 Insert M5 grub screw into threaded hole(right hand side of mount looking at Fig35) until top of screw is just flush withsurface of mount.

Fig 38 - Stud Located on Stanchion

87 If fitted remove the centre of threewindscreen-securing screws and replacewith supplied stud (shown in Fig 35) usingflat blade screwdriver. See Fig 38.

88 Place fibre washer over stud now locatedin side screen. The previously assembledmirror will now slide over the stud locatedon the side screen. See Fig 39.

Fig 39 - Final fitted assembly

89 Adjust the mirror position to allow foroptimum vision and lock in place bytightening M5 grub screw.

Front Brake caliper subassembly

90 Remove the bolts and washer from thevertical link on upright. Slide the caliperon to the brake disc (calipers anduprights are handed make sure forcorrect hand). Fit the bolt and washersin correct orientation. Torque the bolts to58NM.

Fig. 40 Front Brake Caliper assembly

91 Pull out the locking clips (‘R’ clip) oncaliper and remove the brake pad Pins.Slide the brake pads into the caliper andfit the brake pad pins. Fit the lockingclips (‘R’ clips)

Fig. 41 Front Brake pads assembly

Spring washer

Plain washer




SECTION 17 - ELECTRICAL

ELE 01 Section 17Page 1

TABLE OF CONTENTS

Para Page

1 General ....................................................................................................................... 2

Fig

1 Main vehicle wiring harness for all standard instrumentation, Ford Sigma variants .. 32 SVA engine harness (Sigma) ..................................................................................... 43 R400 Engine Harness …………. ................................................................................ 54 Main Chassis Harness (standard dash)………………………………………………….. 65 R400 Main Chassis Harness (Stack dash)………………………………………………. 7

SECTION 17 - ELECTRICAL

Section 17 ELE 01Page 2

GENERAL

NOTE

Before carrying out any work on the vehicle electrical system disconnect the battery earth lead.

1 It should be noted that 90% of electrical problems are caused by poor earth connections. Ifproblems are experienced check the following vehicle earth points in the first instance.

Battery to starter motor bolt.

Engine mount to chassis.

Instrumentation to chassis (at the wiper securing bolt under the dashboard).

Rear lights to chassis.

Headlamp earth and security of headlamp mounting bracket.

Engine loom to scuttle.

2 In the event of continuing problems contact the factory.

3 Wiring diagrams showing the vehicle loom layout including the fuse box and connectors for the carelectrical system are shown at Fig 1. Details of the engine loom layout are shown at Fig 2.

NOTE

In Fig 1 and Fig 2 all mouldings are shown as if viewed from the cable entry.

Fig 5 R400 Main Chassis Harness (Stack dash)

INDEX

IndexPage 1

Section andPara No.

AADJUSTABLE DAMPER PLATFORMS 4-30A-FRAME 8-26AFTERSALES 1-4AIR CLEANER 6-77ANTI-CAVITATION SYSTEM 16-3ANTI-ROLL BAR (FRONT) 4-19ANTI-ROLL BAR (REAR) 8-24

BBASIC DEFINITIONS 2-3BATTERY 6-36BATTERY MASTER SWITCH 16-15BELL-HOUSING 5-1BOOT COVER 12-24BOOT FLOOR 8-57BRAIDED BRAKE HOSE - FRONT 4-23BRAIDED BRAKE HOSE - REAR 4-23, 8-9BRAKE - FILLING AND BLEEDING 14-2BRAKE CALLIPER (FRONT) 4-25BRAKE CALLIPER (REAR) 8-5, 8-42BRAKE MASTER CYLINDER 3-10, 4-26, 14-2BRAKEPADS 8-41, 14-12BRAKEPIPES - FRONT 4-26, 15-24BRAKEPIPES - REAR 3-27, 15-24BRAKES 8-39, 14-5, 15-6BUILD INFORMATION (GENERAL) 2-20

CCARPET - BOOT 2A-11, 9-21, 16-57CARPET - FOOTWELL 9-16CARPET - SEATBACK 9-5, 9-31CARPET - TRANSMISSION TUNNEL 9-9CATALYST GUARD 6-51CLUTCH RELEASE MECHANISM 5-3CONSUMABLES 1-1, 2-8CONTACT INFORMATION 1-4COOLANT 2-8, 6-74, 14-24COOLANT HOSES 6-56,COOLING FAN 6-56, 6-61, 14-33COOLING SYSTEM 6-53CYCLE WING 10-1, 11-13, 15-32CYCLE WINGSTAY 4-14

DDE DION EARS 8-5, 8-31DE DION TUBE 7-1, 8-3DESIGN SPEEDS 15-14DESIGN WEIGHT 15-13DIFFERENTIAL BREATHER 7-3DIFFERENTIAL FITTING 7-7DIFFERENTIAL LUBRICATION 7-14, 8-56DISCLAIMER 1DRIVESHAFTS 3-30

INDEX

IndexPage 2

Section andPara No.

EELECTRICAL CONNECTIONS 6-27, 11-14ELECTRICAL CONNECTOR DIAGRAMS 17EMISSIONS 15-23ENGINE CONTROL UNIT (ECU) 6-28ENGINE MOUNTING BRACKETS AND RUBBERS 6-12ENGINE, SPEED – MAXIMUM 15-14EXHAUST SYSTEM 6-43EXPANSION BOTTLE 6-63, 14-24EXTERNAL PROJECTIONS 15-5

FFASTENER FIXING TOOL 12-42FIBREGLASS 10FRONT SUSPENSION AND STEERINGALIGNMENT

14-45

FUEL FILLER COVER 16-57FUEL SYSTEM 6-39

GGEAR LEVER 6-25GEARBOX 5GEARBOX OIL 14-28

HHANDBRAKE ADJUSTMENT 8-52, 8-54HANDBRAKE CABLE 8-46HANDBRAKE LEVER/MECHANISM 8-45HARNESS – FOUR POINT 9-31HARNESS – SIX POINT 9-35HEATER 6-66HOOD FITTING 12-7HOODSTICKS 12-3HOODSTRAPS 12-3HORN PUSHBUTTON 3-18HORNS 6-14, 16-9

IINDICATORS – FRONT 11-4INDICATORS – REPEATER 10-3INERTIA REEL SEATBELTS 9-30INTERIOR PROJECTIONS 15INTERIOR TRIM 9

KKNEE TRIM PANELS 9-26

LLAMBDA PROBE 6-50LIGHT – HEAD 11-7LIGHT – NUMBER PLATE 11-25LIGHT – REAR 11-16LIGHT – REAR FOG 11-24LIGHT – REVERSE 11-24

INDEX

IndexPage 3

Section andPara No.

LUBRICANTS 2-8

MMIRROR – EXTERIOR (SIDESCREEN) 12-23MIRROR – EXTERIOR (SCREEN STANCHION) 12-21MIRROR – INTERIOR (SUPERLIGHT) 9-54MIRROR – REAR VIEW INTERIOR 9-53

NNOISE 15-22NOSE BADGE 9-52

OOIL – ENGINE 2-8, 14-31OIL FILLING – DIFFERENTIAL 8-56OIL FILLING – GEARBOX 14-28OIL PRESSURE 14-34

PPACKAGE CONTENTS 2APARTS RECOGNITION 1-6, 2APEDAL ADJUSTMENT 3-26, 6-76PEDAL BOX 3-7, 3-26POST BUILD CHECK 1-8PROPSHAFT 7-6PROTECTIVE STEERING 15-25

RRACE CARS AND SVA 15-41RADIATOR 6-58RADIO INTERFERENCE SUPPRESSION 15-19RADIUS ARMS 8-14REAR SUSPENSION 8REGISTRATION PROCEDURE 15-45REVERSE LIGHT SWITCH 6-26ROLL OVER BAR – TRACK DAY/FIA 16-20ROLL OVER BAR – STANDARD 16-18

SSCREENWASHER 6-2SCUTTLE EDGE TRIM 9-51, 15-29SEATBELTS 9-30, 9-31, 9-35SEATS 9-40SIDESCREEN 12-13SINGLE VEHICLE APPROVAL 15SPEED SENSOR 8-37SPEEDOMETER 15-16SPRING DAMPER UNITS (FRONT) 4-11SPRING DAMPER UNITS (REAR) 8-12STARTER MOTOR 5-9START-UP 14STEERING – ARMS 3-5STEERING – COLUMN 3-6STEERING – RACK 3-1STEERING COLUMN (QR) 3-24STEERING WHEEL – MOMO 3-23

INDEX

IndexPage 4

Section andPara No.

STEERING WHEEL – MOTOLITA 3-19STEERING WHEEL FITMENT 3-18

TTECHNICAL HELP 1-7THERMOSTATIC FAN SWITCH 6-58THROTTLE CABLE 3-26, 6-75TONNEAU COVER 12-32TORQUE FIGURES 14-53TOWING 15-15TRACK ROD ENDS 3-5TRANSMISSION TUNNEL TOP 9-12TYRE PRESSURE 14-50TYRES 13-2

UUPRIGHTS 4-13

WWATTS LINK 8-17WHEEL FITMENT 13WINDSCREEN – WIPERS 6-6WING PROTECTORS 10-16WING – FRONT (CYCLE) 10-1WINGS – REAR 10-20WIRING DIAGRAMS 17WISHBONE - LOWER 4-5WISHBONE - UPPER 4-8

Caterham Assembly Guide July 2010

Documents

hydraulic fluid brake

specific warnings

following warnings

engine installation

incorrect use

fibreglass use tape

hot engine

brake connections