ÿþM icrosoft W ord - 0 0 - prelims . doc

ÿþM icrosoft W ord - 0 0 - prelims . doc
PRELIMINARY INFORMATION
ASSEMBLY GUIDE
DE DION CHASSIS FITTED WITH FORD SIGMA VARIANTS
TABLE OF CONTENTS
Para
1
2
Page
List of sections (this page) .........................................................................................
List of abbreviations ...................................................................................................
General warnings and cautions..................................................................................
Specific warnings and cautions..................................................................................
1
2
3
3
LIST OF SECTIONS
Section
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Introduction
Pre-Assembly Information
Steering
Front Suspension
Fitment of Gearbox to Engine
Installation of Engine and Gearbox
Preparation and Installation of the Differential
Rear Suspension
Interior Trim
Fibreglass
Lighting
Weather Equipment
Wheel Fitment
Start up Procedure and Final Checks
Single Vehicle Approval and Registration
Options
Electrical
Index
PRE 01
Page 1
PRELIMINARY INFORMATION
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 01
Page 2
PRELIMINARY INFORMATION
GENERAL WARNINGS AND CAUTIONS
SPECIFIC WARNINGS AND CAUTIONS
1
The following warnings and cautions
indicate general and environmental hazards
present during the building process:
2
The following warnings and cautions
indicate specific hazards relating to the
Caterham build process:
WARNINGS
WARNINGS
(1)
Due consideration should be given to
the highly flammable nature of petroleum or
alcohol based products and their vapours.
Serious burns can result from incorrect use.
(1)
Never work underneath a car without
supporting it on axle stands or equivalent.
Do not rely on a jack alone.
(2)
Oils – prolonged and repeated contact
may cause serious skin disorders:
(a)
Avoid contact with the skin as far
as possible and wash thoroughly after
any contact.
(b)
Keep out of reach of children.
(c)
First aid treatment should be
obtained for open cuts and wounds.
(d)
Use appropriate barrier creams.
(3)
Hydraulic fluid (brake fluid) is
poisonous.
Wash
affected
areas
immediately in case of skin contact and seek
medical assistance if swallowed.
(4)
Hydraulic fluid (brake fluid) is
hygroscopic. Ensure only clean fresh fluid is
used.
(5)
Hydraulic fluid (brake fluid) is
corrosive to paintwork, powder coat and
plastic components. Care should be taken to
avoid spillage at any times.
CAUTIONS
(1)
Protect the environment. It is illegal to
pollute drains, water course and soil.
Authorised waste collection facilities include
civic amenity sites and garages which
provide facilities for the disposal of oil and
used oil filters. If in doubt ask the local
authority for advice.
(2)
Use appropriate eye protection whilst
carrying out drilling operations.
(3)
Use appropriate eye protection whilst
working under the car.
(4)
Cars fitted with electronic ignition
systems have increased voltages compared
with conventional systems. Ensure system
is switched off prior to carrying out any
work.
(5)
The electric radiator fan is controlled
by a thermostatic switch which operates
when the ignition is in the 'on' position.
Whilst working on a hot engine ensure that
the ignition is switched off.
(6)
Do not remove coolant expansion
bottle cap whilst coolant is hot.
Take
precautions to prevent scalds.
(7)
Correct use of fixings is required in
order to ensure full engagement of the nyloc
nut.
(8)
Both imperial and metric threads are
used on the De Dion brake pipes. The
threads on the three way union are imperial
whilst those on the brake callipers are
metric. To aid recognition a small notch is
machined into the hexagon of the metric
unions.
(9)
Retighten wheel nuts after 200 miles.
(10) Ensure adhesive is applied in a well
ventilated area.
Follow instructions on
adhesive packaging. Care must be taken
whilst working in a confined area, for
instance the footwell.
(11) Use a suitable face mask to prevent
inhalation of dust when drilling fibreglass or
carbon fibre.
PRE 01
Page 3
PRELIMINARY INFORMATION
CAUTIONS
(1)
All brake connections must be kept
spotlessly clean and contamination with oil,
water and petrol should be avoided.
(2)
When drilling fibreglass use tape on
the surface over the drill holes to prevent
damage to the gel coat or painted finish.
Slow drill speeds must be used.
(3)
Do not over-tighten thermostatic fan
switch.
(4)
If less than 43 mm is measured then
the differential casing may be holed. If more
than 43 mm is measured it is possible that
the De Dion tube may hit the differential.
PRE 01
Page 4
SECTION 1 - INTRODUCTION
TABLE OF CONTENTS
Para
1
4
6
7
8
12
13
Section 1
Page 1
Page
Introduction ................................................................................................................
Contact information ....................................................................................................
Part recognition/shortages .........................................................................................
Technical help............................................................................................................
Post build check .........................................................................................................
Single vehicle approval ..............................................................................................
Aftersales ...................................................................................................................
Disclaimer ..................................................................................................................
Suggested build sequence.........................................................................................
2
2
2
2
2
3
3
3
4
INT 01
SECTION 1 - INTRODUCTION
INTRODUCTION
TECHNICAL HELP
1
It is recommended that the entire
assembly guide is read before commencing
building of the car. This will allow planning
ahead for the procurement of tools,
consumables and equipment required during the
build process.
7
Caterham Cars will happily provide
technical assistance when required. When in
doubt, ask.
2
Whilst it is possible for many of the build
processes to be undertaken simultaneously
there are some areas where the correct build
sequence is critical.
A suggested build
sequence is included at the end of this section.
3
The chassis and packages supplied have
been engineered to enable a Ford Sigma engine
to be installed in conjunction with either a Ford
Type 9 close ratio 5-speed or Caterham 6-speed
gearbox. A Ford Sierra differential is utilised.
There are several different versions of these
engines, gearboxes and differentials available.
If you have not purchased your entire kit from
Caterham you should ensure that you source
the correct parts by calling Caterham for further
information.
CONTACT INFORMATION
4
For aftersales service and all other
enquiries, contact Caterham Cars at Dartford on
telephone number 01322 625800 (Fax 01322
625810).
5
Ensure that you make a note of your sales
order number (top RH side of invoice) and your
customer number as these are the references by
which we know you and your kit and will ensure
that, no matter how long you take to assemble
your car, subsequent packages will be
compatible.
POST BUILD CHECK
8
When your Caterham Seven is finally
completed and ready for the road it is strongly
recommended that you make use of our Post
Build Check facility. All customers are sent a
free voucher covering the first three hours of the
Post Build Check (this is ample time to check a
completed kit, which can be carried out at the
factory in Dartford, at Caterham Midlands or at
one of our approved services agents). The
Seven even in its lowest state of tune possesses
acceleration and cornering abilities far in excess
of most road going cars and it is therefore
extremely important that it is assembled and set
up correctly.
9
We are also keen to ensure that our
customers do not suffer disappointment as a
result of sub-standard performance or premature
component failure resulting from incorrect
assembly.
10
The Post Build Check therefore includes:

Inspection of all safety related items.

Inspection of all operating
(Clutch, Gearbox, Axle etc).

A written report on any matters causing
concern or requiring attention.

Completion of any agreed warranty work.

Post Build Inspection Certificate when the
car has passed inspection.

Check to ensure compliance to SVA
requirements (if required).
PART RECOGNITION/SHORTAGES
6
The kit provided by Caterham Cars (from
the factory at Dartford) includes all the items
required to build the car. However, due to the
sheer number of different components it is
possible that some parts are omitted or
duplicated. Kits should be checked to ensure all
components (including contents of fastener
packs) are present prior to starting construction.
If there are any shortages contact the Customer
Liaison Department at the factory.
Section 1
Page 2
systems
11
The inspection will take approximately
three hours and we suggest that you give at
least two weeks notice when booking your car
in. If additional work is required please notify
the Service Manager at the time of booking to
ensure that sufficient time can be made
available. Any additional work will be charged
on an hourly basis.
INT 01
SECTION 1 - INTRODUCTION
SINGLE VEHICLE APPROVAL
12
The requirements for Single Vehicle
Approval (SVA) are detailed in Section 15. For
advice or assistance on SVA matters contact the
Aftersales Department. SVA is a requirement for
UK markets only therefore the additional parts
will not be supplied with overseas orders.
AFTERSALES
13
To maximise the enjoyment of your
Seven, the safety and integrity of the car must
be maintained by careful adherence to the
maintenance schedules. Further information on
when servicing is required and where best to get
it done can be found in the Owners Handbook
supplied with your car.
DISCLAIMER
The Caterham Seven is supplied in kit form and
is supplied for amateur construction.
The builder must assume that all nuts, bolts and
fasteners may be loose and takes the
responsibility to ensure road worthiness.
Sound engineering principles must always be
followed.
A free post build check is available from the
factory or from one of Caterham Cars agents.
NOTE
In the UK, the assembled kit cannot legally be
driven to the post build inspection (prior to
successful completion of an SVA test).
INT 01
Section 1
Page 3
SECTION 1 - INTRODUCTION
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 should
be fitted before anti roll bar
Front flexible brake hoses
Headlights and front indicators
Can be left until after engine
installation
ENGINE & GEARBOX
Speedo drive plugs (large and
small)
Gearbox rubber mounting
Gearbox to bell housing
Clutch release mechanism
Gearbox to engine
Prep Engine
Oil pressure sender
Starter motor
Wiring loom (starter to
alternator)
‘J’ hose
Intermediate top hose
Gearbox filler plug
Loosen
Gearbox tail shaft plug
Remove
Engine mount blocks
Fit to Chassis
ENGINE BAY
Earth lead
Wiper reservoir
Section 1
Page 4
INT 01
SECTION 1 - INTRODUCTION
WORK AREA
DETAIL
COMMENT
Oil separation tank mountings
Optional fitment
Alternate header tank mounting
plate
Optional fitment
Horns
Standard location only
Install engine/gearbox
Engine mounts
Fit to Engine
Earth lead
Engine/chassis loom
connections
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
INT 01
Section 1
Page 5
SECTION 1 - INTRODUCTION
WORK AREA
DETAIL
COMMENT
Cycle wings and indicator
repeaters
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 bar
specified
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 if
specified
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 interior
panel piping
Depends
on
roll
protection specified
Four and six-point harness lap
and crutch straps
Optional
over
Carpets
Seats
Roll over bar/cage as specified
Section 1
Page 6
Head restraint
Roll cage option only
Rear dampers
If track day roll over bar or roll
cage specified
INT 01
SECTION 1 - INTRODUCTION
WORK AREA
DETAIL
COMMENT
Fuel filler shroud
BODYWORK AND HOOD
Front wings and indicator
repeater lights
May be fitted immediately after
fitting 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
INT 01
Section 1
Page 7
PAGE INTENTIONALLY BLANK
SECTION 2 - PRE-ASSEMBLY INFORMATION
TABLE OF CONTENTS
Para
1
3
5
11
20
25
Page
Package contents.......................................................................................................
Basic definitions .........................................................................................................
Tools and equipment..................................................................................................
Nuts, bolts and washers.............................................................................................
General build information (Warning) ..........................................................................
Useful web sites .........................................................................................................
2
4
4
5
8
8
Package contents.......................................................................................................
Tools required ............................................................................................................
Additional tools and equipment ..................................................................................
Consumables .............................................................................................................
Recommended lubricants ..........................................................................................
General torque figures ...............................................................................................
2
4
4
5
5
5
Complete kit (less engine)..........................................................................................
Cut down Allen key ....................................................................................................
Fastener pack ............................................................................................................
Front axle stands........................................................................................................
Rear axle stands ........................................................................................................
3
4
7
8
8
Kit contents ................................................................................................................
1
Table
1
2
3
4
5
6
Fig
1
2
3
4
5
Annex
A
PRE 01
Section 2
Page 1
SECTION 2 - PRE-ASSEMBLY INFORMATION
PACKAGE CONTENTS
2
Kits supplied from Caterham Cars arrive
as shown in Fig 1. Due to packaging constraints
some items may be located in different
packages.
1
This section has been included to aid
recognition of parts and to give a basic idea as
to where they might be found. Due to the
complexity of the range of options available and
subsequent variations on packages it is
impossible to list every permutation; however
Table 1 (below) and Annex A (at the end of this
section) show the normal location of parts in a
standard CKD kit.
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 (standard
system). Primary pipes (4), collector or catalyst collector, silencer
(competition system), exhaust guard, mounting brackets and bobbins, wheel
nuts, centre caps, badges, bell-housing, clutch release mechanism, speed
sensor and threaded adapter, reverse light switch, mounting rubber,
gearknob, anti-roll bar and fixings, cycle wingstays, 'A' frame, differential
driveshafts 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, tool
bag, nosecone badge, engine mounting rubbers, scissor jack, windscreen
washer 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, throttle
cable, clutch cable, rear wing protectors, steering wheel, spare wheel
wishbone, seat belts and fixings, tonneau cover, seat runners, seat spacers,
assembly guide, arm restraint, hardware packs, SVA packs, SVA mirrors, air
box and fixings
BOX 9
Weather equipment
Hood straps, exterior mirrors, fuel filler cover, hinges (sidescreen), sill
protectors, wiper arms, wiper blades, hardware pack
Upright
Front upright assemblies including brakes
Engine
Complete engine and clutch, engine loom, engine mounting brackets
OWN BOX
PALLET
OWN BOX
Gear box
OWN BOX
Radiator
LOOSE
Side exit catalyst
LOOSE
Wheels and Tyres
OWN BOX
Roll over bar
ON
CHASSIS
Chassis/ Body Unit
Section 2
Page 2
Alloy wheel and tyre assemblies
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 trim
panels, scuttle trim, econoseal plugs, steering column plate, grilles (Mesh 7),
int panel trim, keys (ignition, fuel cap, battery master switch), aluminium
tonneau cover, paint touch bottles
PRE 01
SECTION 2 - PRE-ASSEMBLY INFORMATION
Fig 1 Complete kit (less engine)
PRE 01
Section 2
Page 3
SECTION 2 - PRE-ASSEMBLY INFORMATION
BASIC DEFINITIONS
3
The text in the assembly guide refers to
the Right Hand (RH) side or Left Hand (LH) side
of the car. For all purposes the RH side of the
car is taken to be the driver’s side of a RH drive
car.
6
The tools detailed in Table 3 are not
generally to hand in the amateur workshop.
These will be required during the build process.
TABLE 3 ADDITIONAL TOOLS AND
EQUIPMENT
Item
4
Also mentioned in the assembly guide are
the terms inboard (pointing towards the centre
line of the car) and outboard (pointing away from
the centre line of the car).
Remarks
Engine hoist
SWL of 150 kg
Socket 41 mm
Torque wrench
Up to 275 Nm
TOOLS AND EQUIPMENT
Cut down 3/8”
Allen key
Gearbox oil filler plug
5
All kits supplied by Caterham Cars are
specifically designed for the amateur car builder
with basic facilities. Table 2 details the general
purpose tools that will be required during the
build process.
Durable Dot
fastening tool
76068 – supplied with chassis
kit
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 faced
hammer
Rubber/plastic/copper/hide
7
The engine hoist should only be required
for a short time and can usually be sourced from
a tool hire company. The 41 mm socket and
torque wrench will be required to tighten the rear
hubs to the drive shafts and the cut down Allen
key is required to tighten the gearbox oil filler
plug, due to the restricted access in the
transmission tunnel. The key can be modified
as shown in Fig 2.
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
Fig 2 Cut down Allen key
Crimp pliers
Drill
Preferably rechargeable
Axle stand
Qty 4
Jug/small funnel
Section 2
Page 4
PRE 01
SECTION 2 - PRE-ASSEMBLY INFORMATION
8
The consumables detailed in Table 4 and
recommended lubricants detailed in Table 5 are
required during the build process.
TABLE 4 CONSUMABLES
Item
Type
Remarks
Rubber
lubricant
Holts RL2R
Copper
grease
Comma
Copper Ease
Threadlock
Loctite
Threadlock
242 or 243
Silicone
sealant
Clear
Masking
tape
Adhesive
Duct tape
To ease assembly
and operation of
rubber bushes and
grommets
Anti seize compound
where lubrication is
not required to ensure
ease of future
disassembly
Used where the
application prevents
the use of nyloc nuts
or spring washers
To achieve a
watertight seal. It
should be applied
sparingly
Protection of body
Contact
Carpet/trim
TABLE 5 RECOMMENDED LUBRICANTS
Item
Engine oil
Gearbox
oil (5 and 6
speed)
Differential
(All)
LSD additive
Brake fluid
Engine
coolant
Type
Comma Syner-Z
synthetic OW-40
Caterham
Motorsport oil
5W-50
Caterham
gearbox oil GL4
grade
Caterham
differential oil
NUTS, BOLTS AND WASHERS
11
As a general rule the fasteners used are
RH thread and of Metric dimensions. Some
Imperial fasteners are still used, particularly
within the brakes and suspension.
12
Always assume that bolts and fasteners
are not properly tightened until they have been
specifically checked.
13
All safety critical fastenings supplied by
Caterham Cars are high tensile conforming to
British Standards 1768 (Imperial) and 3692
(Metric).
Customers supplying their own
fasteners should only use fasteners with heads
marked 10.9 and 12.9 particularly when
attaching suspension, steering, upright and axle
kits. Any unmarked bolt should not be used.
14
Ensure that the correct tightening torque
is applied.
Where torque figures are not
specified use the figures detailed in Table 6.
Particular care must be taken when using the
torque wrench to tighten fastenings into
aluminium.
Remarks
Road usage
Performance/
Track driving
Under no
circumstances
use GL5 grade oil
EP90
Use in LSD’s only
Comma DOT4
Comma
Xstream Red
10
The application of undue force should not
be necessary if assembly is carried out in the
correct sequence.
OAT
NOTE
TABLE 6 GENERAL TORQUE FIGURES
Thread
Socket size
Torque
(Nm)
1/4" UNF/UNC
5/16" UNF/UNC
3/8" UNF/UNC
7/16" UNF
1/2" UNF
5 mm
6 mm
8 mm
10 mm
12 mm
7/16" A/F
1/2" A/F
9/16" A/F
5/8" or 11/16" A/F
3/4" A/F
10 mm
11 mm
13 mm
17 mm
19 mm
7
20
34
47
61
6
7
20
47
61
It is recommended that non-synthetic standard
multi-grade oil is used for the first 500 miles to
aid the running in process.
15
It is good practice to mark the bolt head or
nut with a spot of paint once it has been finally
tightened. This provides a good visual means of
checking that all fixings have been set to the
correct torque.
9
It is recommended that a sturdy
workbench and a good vice are made available
for holding items stable.
16
Over tightening can often cause more
problems than under tightening, such as
sheared bolts and studs and incorrect stresses.
PRE 01
Section 2
Page 5
SECTION 2 - PRE-ASSEMBLY INFORMATION
17
The majority of fastenings have washers
inserted between the nut and or bolt head and
the item being secured. Spring washers or lock
washers are usually placed next to the bolt head
or nut then the plain washer. As a general rule
the following washers are used as detailed:
Plain washer

To protect the surface and spread a load
when attaching to a soft material such as
glass fibre or aluminium.

To adjust the spacing of one component
to another use plain washers of
appropriate thickness and external
diameter.

To present a uniform surface on which to
tighten a fastening onto a rough or
irregular surface.
Spring washer

To lock a thread where there is a
possibility 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.
19
The majority of fasteners supplied by
Caterham are in polythene bags with an A4
sheet on a card insert, refer to Fig 3. The A4
sheet can be used to confirm that the contents
are correct. Each pack has a unique number,
located at the top RH corner and each item
within the pack can be identified by a number at
the bottom LH corner of the part number box.
Where fasteners are specified in the text, the
unique pack number will be stated the first time
it is required along with the description and the
Item Identification number in brackets. The next
time an item from that pack is required it will be
identified by description and the Item
Identification number only, for example:

Bolt (fastener pack 30P017A Item 2)
identifies the Bolt M8 x 50 mm from the
fastener pack illustrated at Fig 3.

At a later point in the same section of text
‘nut (4)’ identifies the M8 nut from the
same fastener pack.
NOTE
Imperial and metric fasteners are supplied
together in some packs. Ensure that the correct
threadform is identified before use.
Large diameter plain washer

To
prevent
migration
movement) of rubber bushes.

The large plain chamfered washers are
often used in conjunction with the
metallistic suspension bushes. Where
this is the case the chamfered edge must
be fitted towards the bush to prevent
contact with the outer metal part of the
bush.
(sideways
18
Particular care should be taken to ensure
that the correct fastening is being used, since it
is possible to use an overlong bolt only to find
that it is apparently missing when the only
remaining bolts are too short.
Section 2
Page 6
PRE 01
SECTION 2 - PRE-ASSEMBLY INFORMATION
Fig 3 Fastener pack
PRE 01
Section 2
Page 7
SECTION 2 - PRE-ASSEMBLY INFORMATION
GENERAL BUILD INFORMATION
20
Caterham Seven builders should take
care to observe basic safety precautions whilst
assembling the kit since tools, parts and
materials handled incorrectly may result in
injury.
24
The rear axle stands should be positioned
at either end of the chassis tube that supports
the front of the fuel tank, refer to Fig 5. If the car
is raised using a jack, ensure that it is positioned
centrally and the powder coat finish on the
chassis tube is protected.
21
Due to circumstances beyond the control
of Caterham Cars, occasionally it is necessary
to change suppliers and/or to make minor
changes to the car or kit specification.
22
If it is intended to build the car over a
short period (up to 4 weeks) it is recommended
that an application for the SVA inspection is
submitted now. There is usually a wait of 2-3
weeks, minimum. In addition it will take up to a
week for the Vehicle Inspectorate to process the
application. Full details about applying for the
SVA inspection can be found in Section 15.
WARNING
Never work underneath a car without
supporting it on axle stands or equivalent.
Do not rely on a jack alone.
23
It is recommended that the chassis is
supported on 4 axle stands which will give
stability for both safe working and ready access.
Placing of the axle stands is made easier if
assistance is available. Lift the front of the car
and place the axle stands at the outer ends of
the second chassis cross tube adjacent to the
rear mounting of the lower front wishbone
mounting, refer to Fig 4. If the car is raised
using a jack, ensure that it is positioned under
the front cruciform and that the powder coat
finish is protected.
Fig 5 Rear axle stands
USEFUL WEB SITES
25
Useful web sites where you can find
information on Caterham services and
recommended consumables and lubricants:
www.caterham.co.uk
www.commaoil.com
www.loctite.us
www.holtsauto.com
Fig 4 Front axle stands
Section 2
Page 8
PRE 01
SECTION 2 ANNEX A - KIT CONTENTS
TABLE OF CONTENTS
Para
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Page
Introduction ................................................................................................................
Packages ...................................................................................................................
Important note............................................................................................................
Exhaust, steering, large suspension items, bell-housing and front wingstays ....
Rear axle ............................................................................................................
Differential ..........................................................................................................
Driveshafts .........................................................................................................
Suspension.........................................................................................................
Cooling ...............................................................................................................
Lighting...............................................................................................................
Uprights ..............................................................................................................
Interior trim, cable and options ...........................................................................
Miscellaneous.....................................................................................................
Gearbox..............................................................................................................
Chassis/body unit ...............................................................................................
Weather gear (optional)......................................................................................
Engine ................................................................................................................
Heater assembly ................................................................................................
Wheels ...............................................................................................................
Seat ....................................................................................................................
Wings .................................................................................................................
Nosecone ...........................................................................................................
Roll over bar .......................................................................................................
2
2
2
3
6
7
7
8
10
11
12
13
16
18
19
20
21
21
21
21
22
22
22
Polythene bag contents - exhaust, steering, suspension items, bell-housing
and front wingstays ....................................................................................................
Polythene bag contents - rear axle ............................................................................
Polythene bag contents - suspension ........................................................................
Polythene bag contents - interior trim, cables and options.........................................
Polythene bag contents - miscellaneous....................................................................
4
6
9
15
17
Exhaust ......................................................................................................................
Steering, large suspension items, bell-housing and front wingstays ..........................
Rear axle items ..........................................................................................................
Differential..................................................................................................................
Driveshafts .................................................................................................................
Suspension items.......................................................................................................
Cooling items .............................................................................................................
Lighting items.............................................................................................................
Uprights......................................................................................................................
Boot carpet.................................................................................................................
Bulkhead carpet .........................................................................................................
Footwell carpet...........................................................................................................
3
5
6
7
7
8
10
11
12
13
13
14
Table
1
2
3
4
5
Fig
1
2
3
4
5
6
7
8
9
10
11
12
(continued)
ANA 01
Section 2 Annex A
Page 1
SECTION 2 ANNEX A - KIT CONTENTS
TABLE OF CONTENTS (continued)
Fig
13
14
15
16
17
18
19
20
21
Page
Rubber mats..............................................................................................................
Transmission tunnel top ............................................................................................
Miscellaneous items ..................................................................................................
5-speed gearbox .......................................................................................................
6-speed gearbox (optional)........................................................................................
Items loose in chassis ...............................................................................................
Weather gear (optional).............................................................................................
1.6 engine 3/4 left......................................................................................................
Heater assembly .......................................................................................................
14
14
16
18
18
19
20
21
21
INTRODUCTION
1
The following pages include pictures and tables to assist with part recognition and location. Due to
the 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 should
expect 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 will
not be an exact representation of what you should expect to find in the packages supplied with
your kit and should therefore not be used as a parts check list.
Section 2 Annex A
Page 2
ANA 01
SECTION 2 ANNEX A - KIT CONTENTS
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 in
Fig 1 and Fig 2. The contents of the polythene bags are shown in Table 1.
1
2
3
4
Exhaust guard
Fastener pack ‘exhaust’
Polythene bag 'exhaust'
Cat guard
5
6
7
Cat/collector
Exhaust primary pipes
Exhaust silencer
Fig 1 Exhaust
NOTE
Items may differ from those illustrated.
ANA 01
Section 2 Annex A
Page 3
SECTION 2 ANNEX A - KIT CONTENTS
TABLE 1 POLYTHENE BAG CONTENTS - EXHAUST, STEERING, SUSPENSION ITEMS, BELLHOUSING AND FRONT WINGSTAYS
Identifier
Gearbox
Steering
Exhaust
Wheels
Section 2 Annex A
Page 4
Description
Gearbox mounting rubber
Gear knob
Speedo drive cover
Reverse light switch
Grommet
Speedo blanking plug
Track rod ends
Universal joint
Aluminium steering rack clamps
Steering column bush
Grommets
Grub screw
Steering column clamp
Steering column clamp plate
Steering column cheese wedge
Rivets
Jubilee clips
Exhaust clamp
Exhaust mounting bracket
Mounting bobbins
Exhaust springs
Lambda sensor
Wheel nuts
Wheel nut washers
Centre caps
Centre cap badges
Qty
1
1
1
1
2
1
2
1
2 pairs
1
2
1
1
1
1
3
5
1
1
2
2
1
16 or 18
16 or 18
4 or 5
4 or 5
ANA 01
SECTION 2 ANNEX A - KIT CONTENTS
1
2
3
4
5
6
7
8
9
Fastener pack ‘steering’
Front wingstay
Polythene bag 'gearbox'
Bell-housing
Polythene bag 'steering’
Polythene bag 'wheels'
Fastener pack ‘gearbox’
Steering rack
Rear anti-roll bar
10
11
12
13
14
15
16
17
Front anti-roll bar
‘A’ Frame
De Dion tube
Brake pipe (short)
Brake pipe (long)
Propshaft
Upper steering column and QR boss (optional)
Lower steering column
Fig 2 Steering, large suspension items, bell-housing and front wingstays
ANA 01
Section 2 Annex A
Page 5
SECTION 2 ANNEX A - KIT CONTENTS
Rear axle
4
The rear axle items are shown in Fig 3. The contents of the polythene bag are detailed in Table 2.
1
2
3
De Dion ears
Brake calliper (2, LH and RH)
Brake disc (2)
4
5
6
Hub/bearing assembly (2)
Polythene bag 'rear axle’
Fastener pack 30R011A
Fig 3 Rear axle items
TABLE 2 POLYTHENE BAG CONTENTS - REAR AXLE
Identifier
Rear axle
Section 2 Annex A
Page 6
Description
Cable ties
Aluminium brake calliper spacers
Drive shaft washer
3-way brake union
Race washers
Copper washer
Rear wheel speed sensor
Rear wheel speed sensor bracket
Rear brake pads
Qty
4
2
1
2
1
1
1
4
ANA 01
SECTION 2 ANNEX A - KIT CONTENTS
Differential
5
The differential is shown in Fig 4.
Fig 4 Differential
Driveshafts
6
The driveshafts are shown in Fig 5.
1
2
3
RH driveshaft
Speed sensor ring
Nyloc nut (green insert)
4
5
Nyloc nut (white insert)
LH driveshaft assembly
Fig 5 Driveshafts
ANA 01
Section 2 Annex A
Page 7
SECTION 2 ANNEX A - KIT CONTENTS
Suspension
7
The suspension items are shown in Fig 6. The contents of the polythene bags are detailed in
Table 3.
1
2
3
4
5
6
7
Fastener pack 30R012A
Fastener pack 30R011A
Lower wishbone (RH)
Spring damper unit (front)
Spring damper unit (rear)
Upper wishbone (RH)
Polythene bag 'front suspension'
8
9
10
11
12
13
Watts link (rear) radius arm
Watts link (front) radius arm
Polythene bag 'rear suspension'
Fastener pack 30F015A
Lower wishbone (LH)
Upper wishbone (LH)
Fig 6 Suspension items
Section 2 Annex A
Page 8
ANA 01
SECTION 2 ANNEX A - KIT CONTENTS
TABLE 3 POLYTHENE BAG CONTENTS - SUSPENSION
Identifier
Front
suspension
Rear
suspension
(including
Rear anti-roll
bar option)
ANA 01
Description
Rubber cotton reel bushes
Damper sleeves
Anti-roll bar rubber cover
Anti-roll bar ball ends
Cables ties
Anti-roll bars mounting clamps
Wishbone sleeves
Special stepped nyloc nut (widetrack/SV)
Rubber cotton reel bushes
Aluminium mounting blocks
Rear damper spacers
Bellcrank (Watts link)
Bellcrank spacer
Rod end (Watts link)
ARB mounting boss
Anti-roll bar extension
Thrust washer
Qty
2
4
2
2
2
2
2
2
2 pairs
4
2
2
4
2
2
2
Section 2 Annex A
Page 9
SECTION 2 ANNEX A - KIT CONTENTS
Cooling
8
The cooling items are shown in Fig 7.
1
2
3
4
5
6
7
8
9
10
Outer radiator cowl
Radiator
Inner radiator cowl
Blanking plug
Expansion bottle cap
Cooling fan
Engine breather hose
Expansion bottle hose
Engine/heater outlet hose
Water bleed pipe
11
12
13
14
15
16
17
18
19
Water rail
Engine/water rail hose
Hose
Expansion bottle bracket
Polythene bag ‘cooling’
Fastener pack ‘cooling’
Expansion bottle
Top radiator hose
Bottom radiator hose
Fig 7 Cooling items
NOTES
(1)
A thermostatic fan switch may be supplied in lieu of a blanking plug (if supplied, the switch must
not 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.
Section 2 Annex A
Page 10
ANA 01
SECTION 2 ANNEX A - KIT CONTENTS
Lighting
9
The lighting items are shown in Fig 8.
1
2
3
4
5
Headlight
Fastener pack 30L002A
Indicator cones
Indicator (front)
Headlight
6
7
8
9
10
Headlight bracket
Indicator (repeater)
Rear light cluster
Cable tie
Number plate light
Fig 8 Lighting items
ANA 01
Section 2 Annex A
Page 11
SECTION 2 ANNEX A - KIT CONTENTS
Uprights
10
The uprights are shown in Fig 9.
1
2
Upright assembly (RH)
Upright assembly (LH)
Fig 9 Uprights
Section 2 Annex A
Page 12
ANA 01
SECTION 2 ANNEX A - KIT CONTENTS
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 of
the polythene bags are detailed in Table 4.
Fig 10 Boot carpet
Fig 11 Bulkhead carpet
ANA 01
Section 2 Annex A
Page 13
SECTION 2 ANNEX A - KIT CONTENTS
Fig 12 Footwell carpet
Fig 13 Rubber mats
Fig 14 Transmission tunnel top
Section 2 Annex A
Page 14
ANA 01
SECTION 2 ANNEX A - KIT CONTENTS
TABLE 4 POLYTHENE BAG CONTENTS - INTERIOR TRIM, CABLES AND OPTIONS
Identifier
SVA
Spare wheel
Oil/air tank
ANA 01
Description
Cable ties
Track rod end sleeves
Track rod end bottom cap
Wing mirror pack
Sticky back foam (roll)
Edge trim (roll)
Large flat bolt head covers
Small domed caps
Long bonnet catch rubbers
Short bonnet catch rubbers
Large domed caps
Medium domed caps
Wheel nuts
Spare wheel bolt
Spacer
Mounting wishbone
Temperature sender
Filler plug
Lower mounting platform
Upper mounting brackets
Cradle cable tie mount
Foam insert
Hose clips
Cable ties
Dowty seal
Adhesive strip
Qty
2
2
1
1
1
6
12
2
2
2
4
2
1
1
1
1
1
1
2
10
1
2
10
1
1
Section 2 Annex A
Page 15
SECTION 2 ANNEX A - KIT CONTENTS
Miscellaneous
12
The miscellaneous items are shown in Fig 15. The contents of the polythene bag are detailed in
Table 5.
1
2
3
4
5
6
7
Fastener pack 30P012A
Polythene bag 'miscellaneous'
Tool kit including bag
Rear view mirror
Cable tie
Earth lead engine/chassis
Battery positive lead
8
9
10
11
12
13
Battery negative lead
Horns
Gear lever
Handbrake
Brake hoses
Washer bottle
Fig 15 Miscellaneous items
Section 2 Annex A
Page 16
ANA 01
SECTION 2 ANNEX A - KIT CONTENTS
TABLE 5 POLYTHENE BAG CONTENTS - MISCELLANEOUS
Identifier
Miscellaneous
ANA 01
Description
Propshaft bolts
Handbrake clevis
Tunnel blanking grommet
R-clip
Clevis pin 1/4”
Clevis pin 5/16”
Pulley
Clutch pedal stop
Throttle pedal stop
Brake calliper banjo bolts
Shake proof washers
Nyloc 1/4”
Washers 1/4”
Washer jet
Seat spacers
Qty
4
1
2
2
1
1
1
1
1
2
2
2
2
1
4
Section 2 Annex A
Page 17
SECTION 2 ANNEX A - KIT CONTENTS
Gearbox
13
The standard 5-speed gearbox is shown in Fig 16, the optional 6-speed gearbox is shown in
Fig 17.
Fig 16 5-speed gearbox
Fig 17 6-speed gearbox (optional)
Section 2 Annex A
Page 18
ANA 01
SECTION 2 ANNEX A - KIT CONTENTS
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
2
3
4
5
Fastener pack ZCH
Fastener pack ZWE
Fastener pack 30P016A
Side screen mirrors
Velcro strips
6
7
8
9
10
SVA trim
Transmission tunnel cover
Wiper blades
Wiper arms
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 the
weather gear pack.
ANA 01
Section 2 Annex A
Page 19
SECTION 2 ANNEX A - KIT CONTENTS
Weather gear (optional)
15
The optional weather gear items are shown in Fig 19.
1
2
3
4
Hoodsticks
Hood
Side screens
Fastener pack ‘weather’
5
6
7
8
Mirrors
Mirror plate (not required)
Hood straps
Hinges
Fig 19 Weather gear (optional)
Section 2 Annex A
Page 20
ANA 01
SECTION 2 ANNEX A - KIT CONTENTS
Engine
16
The engine, Fig 20, is supplied on a frame complete with engine mountings and lifting eyes. The
frame must be removed from the engine prior to fitting and returned to Caterham Cars. Once the engine
is fitted the lifting eyes must be removed. The engine is supplied complete with wiring loom. The starter
motor 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 be
handed, that is, have a direction of rotation arrow showing the direction of travel. Wheels must be fitted
with the directional arrow in the correct direction.
Seat
19
The seats are supplied in protective covers. It is recommended that the covers are not removed
until the seats are required for fitment.
ANA 01
Section 2 Annex A
Page 21
SECTION 2 ANNEX A - KIT CONTENTS
Wings
20
The front and rear wings are supplied protected with bubble wrap. The two largest wings are for
fitment to the rear of the car.
Nosecone
21
The nosecone is supplied in protective bubble wrap. It is recommended that it is left protected until
required for fitment.
Roll over bar
22
The roll over bar is protected by bubble wrap and is supplied in its own box.
Section 2 Annex A
Page 22
ANA 01
SECTION 3 - STEERING
TABLE OF CONTENTS
Para
1
6
18
19
23
24
26
Page
Steering rack (standard and wide track) (Warning)....................................................
Steering column .........................................................................................................
Steering wheel fitment................................................................................................
Motolita...............................................................................................................
Momo .................................................................................................................
Quick release column .........................................................................................
Associated tasks ........................................................................................................
2
2
4
4
4
5
5
1
Steering component torque figures ............................................................................
5
1
2
3
4
5
Steering rack assembly..............................................................................................
Pedal box ...................................................................................................................
Steering rack to steering column................................................................................
Upper steering column clamp ....................................................................................
Horn pushbutton - Motolita.........................................................................................
2
2
3
3
4
Table
Fig
STR 01
Section 3
Page 1
SECTION 3 - STEERING
STEERING RACK (STANDARD AND WIDE
TRACK)
1
The steering rack should be fitted before
the front suspension. Before fitting the steering
rack it is advisable to protect the outside of the
aluminium side panels around the circular
cutouts through which the rack protrudes.
Masking tape is sufficient for this purpose.
5
Fit the SVA cover (polythene bag marked
'SVA' (refer to Section 15) to the end of the
steering rack arm, ensure that the larger
diameter is outboard. Screw the locknut (Fig 1
item 5) onto the steering rack arm then fit the
track rod end. This should be screwed on 11 full
turns (S3) or 13 (SV) to give an approximate
track setting. Do not tighten the locknuts.
NOTES
WARNING
Never work underneath a car without
supporting it on axle stands or equivalent.
Do not rely on a jack alone.
2
Carefully pass the steering rack through
the circular cutouts in the side panels until the
machined areas of the rack line up with the
holes in the rack platform. Ensure that the rack
pinion exits the rack on the driver's side of the
vehicle.
3
The steering rack is held in place by two
piece aluminium rack clamps (polythene bag
marked 'steering').
The rack clamps are
matched pairs and clamp the steering rack into
position as they are bolted into place, refer to
Fig 1.
1
2
3
4
5
Securing bolt and
washer
Steering rack
Rack clamps
Nyloc nut
Locknut
6
7
8
9
10
Track rod end
Securing nut
Steering arm
(on upright)
SVA cover
Steering rack
gaiter
Fig 1 Steering rack assembly
4
Clamp the rack loosely into place using
bolt (fastener pack 30S003A Item 1), nyloc
nuts (8) and washers (10). Ensure a washer is
placed between the rack clamp and the bolt
head. The rack will be tightened later when the
steering column is correctly positioned.
Section 3
Page 2
(1)
The SVA covers are secured using cable
ties. However this should not be done at this
stage as final adjustment to the tracking will be
required.
(2)
Tracking is adjusted during final checks,
refer to Section 14.
STEERING COLUMN
6
The steering column should not be fitted
until after the engine and gearbox have been
installed.
7
Remove the lid of the pedal box, refer to
Fig 2.
1
2
Lower steering column 3
Cheese wedge
4
sealing box
5
Grommet
Grommet
Pedal box
Fig 2 Pedal box
(Clutch master cylinder and brake pipes omitted
for clarity)
8
The front of the pedal box is sealed using
a grommet inserted into the hole through which
the steering column passes, refer to Fig 2. The
inside of the rubber grommet should be smeared
with rubber lubricant to prevent wear.
STR 01
SECTION 3 - STEERING
9
Position the ‘cheese wedge’ (refer to
Fig 2) on the pedal box, aligned with the hole for
the steering column (it may be necessary to trim
the top edge of the cheese wedge to avoid
fouling the clutch master cylinder). Mark the
three hole positions using the holes in the
cheese wedge as a guide. Drill the holes using
1/8” drill bit (it may be necessary to remove the
clutch master cylinder for access). Apply silicone
sealant to the seating edges of the cheese
wedge and secure the cheese wedge with rivets.
Seal the edges with sealant. Fit the grommet to
the large hole at the rear of the cheese wedge.
Coat the grommet with rubber lubricant.
vertical/horizontal when the steering wheel is in
the straight ahead position.
12
Fit the lower end of the universal joint
onto the rack, again clamping with the bolt and
nyloc nut and tighten both bolts to 20 Nm. The
universal joint should be run as straight as
possible, continuing along the same angle as
the column, the steering rack can be turned in its
blocks to achieve this.
13
The upper steering column can now be
fitted.
NOTE
10
The lower steering column is inserted,
splined end first, through the dashboard under
the brake master cylinder, through the rubber
grommet in the 'cheese wedge', through the
pedal box and finally through the rubber
grommet in the pedal box sealing plate.
When fitting an optional, quick release, column
the upper steering column bush can be fitted
prior to inserting the upper steering column into
the steering column lock tube, refer to Para 15.
14
The lower column bush will have been
fitted by Caterham, but care must be taken when
sliding the upper steering column down through
the dashboard. Ensure that the lowest portion of
upper steering column is liberally coated with
grease and minimum force is exerted.
Telescope the upper steering column over the
lower steering column.
15
Slide the upper steering bush onto the
column and into the dash tube. Note how the
raised rubber locators on the bush fit in the
holes in the dash tube. To ease fitment lightly
coat the upper steering bush with rubber
lubricant.
1
2
3
4
Nyloc nut
Bolt
Universal joint
Steering rack
5
6
7
Nyloc nut
Bolt
Lower
steering
column
Fig 3 Steering rack to steering column
11
Position the front wheels (or uprights) in
an approximate ‘straight ahead’ position and
attach the universal joint (polythene bag marked
'steering') using bolt (3) and nyloc nut (7) noting
how the bolt locates into the machined groove in
the splined end of the lower steering column.
1
2
NOTE
3
If insertion is difficult the universal joint can be
opened up by inserting a flat blade screwdriver
into the split and twisting. To ensure linearity of
response it is recommended that the yoke of the
universal joint is positioned with the cross
STR 01
Locknut
Upper steering
column
Clamp
4
5
6
Securing bolts
Lower steering
column
Grub screw
Fig 4 Upper steering column clamp
Section 3
Page 3
SECTION 3 - STEERING
16
The two parts of the steering column are
clamped together using the locking clamp, refer
to Fig 4. Insert the grub screw loosely into the
clamp. Secure the two halves of the clamp using
two bolts (2), plain washers (10) and spring
washers (11). Torque to 14 Nm. Tighten the
grub screw with an Allen key to eliminate any
free play in the steering. Lock the grub screw
into place using locknut (6).
NOTE
Before tightening the clamp:
Fit the steering wheel boss onto its spline
to ensure that the steering wheel boss
does not foul the dashboard. Slide the
steering column/steering wheel boss
away from the dashboard to achieve
clearance.
Check that the lower steering column
does not foul the drive belt tension
mechanism on the engine. If necessary
rotate the steering rack in its clamps to
provide clearance.
17
Tighten the steering rack clamps
to 11 Nm. Ensure that the two bolts securing
the steering column lock tube to the scuttle face
are tight.
STEERING WHEEL FITMENT
18
Two makes of steering wheel are
available. The Motolita wheel has a central
pushbutton which activates the horn whilst the
Momo wheel has a horn button mounted on the
dashboard. Each steering wheel has a different
type of mounting boss. It is recommended that
the fitting of the steering wheel is left until the
entire interior trim, including seats, has been
completed.
1
2
3
4
Steering wheel
Pencil contact
Horn contact ring
Purple and black wire
5
6
7
8
Steering column
Mounting boss
Fixing screw
Horn push
Fig 5 Horn pushbutton - Motolita
(SVA pad omitted for clarity)
20
Attach the steering wheel to the mounting
boss using the fixing screws and nuts provided
taking care not to damage the screw heads or
scratch the surface finish on the steering wheel.
Slide the pencil contact into the hole in the
mounting boss.
21
Release steering lock and centre the road
wheels to establish the straight ahead position.
Fit the steering wheel over the steering column
splines. Fit the washer (9) and secure the
steering wheel to the steering column using
nyloc nut (4) and tighten.
22
Feed the electrical connection from the
pencil contact through the SVA pad and connect
to the spring loaded steering wheel horn push.
Push the SVA pad into the mounting boss and
then insert the horn push into the steering
wheel.
Motolita
Momo
19
Before fitting the steering wheel it will be
necessary to fit the horn contact ring, refer to
Fig 5, into the top of the steering column bush in
the chassis. This is an interference fit and will
need to be gently tapped into place, using a soft
hide hammer, over the steering column bush.
The electrical wire from this ring must be
connected to the black/purple wire in the wiring
loom adjacent to the steering column.
23
Loosely fit the mounting boss to the
steering wheel using the 6 mm x 16 mm
countersunk Allen bolts. Centre the road wheels
to establish the straight ahead position of the
steering wheel. Place the steering wheel and
boss over the splines in the straight ahead
position. Remove the wheel and secure the
boss to the column using nyloc nut (4) and
washer (9). Finally re-secure the wheel to the
boss using the fixing provided.
Section 3
Page 4
STR 01
SECTION 3 - STEERING
Quick release column
24
The Quick Release (QR) column has a
keyway in the QR boss and the steering wheel
must be centred by removing the upper bolt on
the lower steering column universal joint,
withdrawing the column and then turning the
steering wheel and column to the straight ahead
position. Re-engage the column to the universal
joint, re-insert the bolt and tighten the securing
nyloc nut to 20 Nm.
25
Ensure that the steering wheel can be
rotated smoothly with no tight spots. Tighten the
steering rack clamp bolts and steering column
universal joint bolts/nylocs to the torque figures
specified in Table 1.
TABLE 1 STEERING COMPONENT TORQUE
FIGURES
Location
Washers
Nut Torque
Plain under bolt
head
Nyloc 11 Nm
Universal joint
None
Nyloc 20 Nm
Column clamp
Spring and plain
under bolt head
Bolt
Steering
clamps
rack
14 Nm
ASSOCIATED TASKS
26
Whilst the pedal box lid is removed fit the
brake light switch harness and the throttle cable,
refer to Section 6.
NOTE
Before refitting the pedal box lid, check that the
pedal positions are acceptable and that the
brake switch operates correctly. Adjust as
necessary.
27
Refit the pedal box lid ensuring that the
brake pipes are not trapped or kinked and that
the ‘P’ clips are secured under the pedal box lid
screws.
STR 01
Section 3
Page 5
PAGE INTENTIONALLY BLANK
SECTION 4 - FRONT SUSPENSION
TABLE OF CONTENTS
Para
1
5
8
11
13
19
23
28
30
Page
Preparation ................................................................................................................
Lower wishbones (Warning).......................................................................................
Upper wishbones .......................................................................................................
Spring damper units ...................................................................................................
Upright attachment (Warnings) ..................................................................................
Front anti-roll bar........................................................................................................
Front brake hoses ......................................................................................................
Final tightening...........................................................................................................
Cars fitted with adjustable damper platform ...............................................................
2
2
2
3
3
4
5
6
6
Torque figures............................................................................................................
Torque figures............................................................................................................
6
6
Bodywork protection...................................................................................................
Washer usage - lower wishbone (LH side).................................................................
Upper wishbone securing...........................................................................................
Front suspension........................................................................................................
Brake pipe union ........................................................................................................
Standard calliper ........................................................................................................
Uprated calliper..........................................................................................................
2
2
3
4
5
5
5
Table
1
2
Fig
1
2
3
4
5
6
7
FRS 02
Section 4
Page 1
SECTION 4 - FRONT SUSPENSION
PREPARATION
NOTE
1
It is recommended that the front wings are
not fitted until the front suspension is assembled
and the engine installed. This reduces the risk
of damage to the wings and maintains easy
access to the engine bay.
2
It is recommended that the steering rack
is 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 can
be damaged, especially when fitting the top
mounting bolts and the spring damper units. It is
therefore advisable, particularly with painted
cars, to protect the bodywork with 2 or 3 layers
of masking tape in key areas.
It is
recommended that the bodywork under the front
bonnet catches is protected using card and
masking tape, refer to Fig 1.
Ensure that the circlip is correctly located in the
retaining groove prior to assembling the lower
wishbone.
6
Fit the rear leg of the lower wishbone
through the slot in the bottom skin immediately
behind the vertical chassis member. Secure
using bolt (Fastener pack 30F015A Item 1) and
nut (7) and inserting two plain washers (9) either
side of the wishbone refer to Fig 2.
NOTE
On wide track front suspension, plain washer
usage is shown in text boxes below the fig.
4
Apply a thin coat of copper grease to all
fixings prior to fitment (avoid contaminating any
threads where Loctite is to be used).
Wide track 0 washer
1
2
3
4
5
Wide track 4 washer
Bolt
Spring washer
Plain washer
Front chassis
mount
5
6
7
8
Wide track 0 washer
Nyloc nut
Rear chassis
mount
Bolt
Lower wishbone
Fig 2 Washer usage - lower wishbone (LH side)
7
The front leg of the lower wishbone is
secured to the front of the chassis using bolt (2),
with washer (9) and spring washer (12) next to
the bolt head. Two washers (9) are inserted
between the wishbone and the chassis, refer to
Fig 2.
Fig 1 Bodywork protection
UPPER WISHBONES
LOWER WISHBONES
WARNING
Never work underneath a car without
supporting it on axle stands or equivalent.
Do not rely on a jack alone.
5
The lower wishbones are assembled with
the longer leg forward and the bearing retaining
circlip facing downward.
Section 4
Page 2
8
The upper wishbones are handed and are
assembled with the longer leg facing the front of
the car. Prior to locating the upper wishbone a
spacer bush 10 mm id x 1/2" od x 35 mm
(polythene bag marked 'front suspension'), must
be inserted into the rear bush. The rear leg of
the upper wishbone, refer to Fig 3, is secured to
the rear mount using bolts (3) inserted from the
front of the mounting. The spacer bush must be
coated with copper slip. The bolt is secured with
a nut (8). Do not tighten fixings.
FRS 02
SECTION 4 - FRONT SUSPENSION
(2)
To prevent damage to the paintwork it is
recommended that the plain washer and spring
washer are placed closest to the spring damper
mounting during bolt location.
12
An aluminium spacer 8 mm id x 1/2"
od x 32 mm must be coated in copper slip and
inserted into the lower mounting bush of the
spring damper unit. The spring damper unit is
secured using an M8 caphead bolt (supplied in
wishbone) which passes through the rear leg of
the lower wishbone through the aluminium
spacer bush and into a captive thread on the
front leg. This bolt should be torqued to 20 Nm.
1
2
3
4
5
6
Headlight bracket
Headlight bracket mounting
Upper wishbone front mount
Upper wishbone
Spring damper unit
Upper wishbone rear mount
NOTE
Do not tighten any other fixings at this stage.
UPRIGHT ATTACHMENT
WARNING
Fig 3 Upper wishbone securing
9
The front leg of the upper wishbone is
secured to the front mount using bolt (4). Prior
to inserting the bolt the headlight bracket rear
arm must be inserted into the chassis mount (do
not tighten the grubscrews at this stage. The
front arm is secured at the rear of the upper
wishbone front mounting by nut (8).
10
Since access to the upper and lower
wishbone mountings is restricted by other
components installed later in the build process
the mounting fasteners must be fully tightened at
this point. Hold the wishbone horizontal and
tighten the upper and lower wishbone mounting
bolts/nuts to 34 Nm.
Correct use of fixtures is required to ensure
full engagement of the nyloc nut.
13
Remove and retain the upper wishbone
ball-joint nyloc nut and the nyloc nut from the
bottom of the upright assembly. The upright
assembly must be mounted with the steering
arm facing forward. Mount the upright assembly
as follows:
NOTE
The upright assemblies are marked RHS or LHS
on the inside of the assembly.

SPRING DAMPER UNITS
11
An aluminium spacer bush 8 mm id x 1/2"
od x 32 mm (polythene bag marked 'front
suspension') must be coated in copper slip and
inserted into the top mounting bush of the front
spring damper unit. The spring damper is
secured to the top mounting by the M8 cap head
bolt supplied in the chassis with a spring washer
(13) under the bolt head. This bolt should be
torqued to 20 Nm.
NOTES
(1)
It is necessary to gently press the body
panel inwards to allow sufficient clearance for
the bolt to be located.
FRS 02
Standard. The upright is located into the
spherical joint on the lower wishbone and
secured using the retained 1/2" nyloc nut.
Tighten the nyloc nut to 55 Nm.
WARNING
Correct use of fixings is required in order to
ensure full engagement of the nyloc nut.

Wide track. The upright is located into the
spherical joint on the lower wishbone. Prior
to locating the upright, a spacer (5/8" mm
id x 3/4" od x 8 mm) located in the polythene
bag marked 'front suspension') must be
inserted onto the bottom of the upright. The
upright is secured using the special turned
down nyloc nut supplied.
Tighten the
special nyloc nut to 55 Nm.
Section 4
Page 3
SECTION 4 - FRONT SUSPENSION
14
The cycle wingstay locates on the upright.
Remove and discard the 1/2" UNF nyloc nut and
plain washer fitted to the inner end of the stub
axle. Place cycle wingstay over the stub axle
and secure using the 1/2" UNF nyloc provided.
Do not tighten.
NOTE
If uprated front brake callipers have been
specified ensure that the brake pads are
installed before fitting the cycle wingstays.
15
Pass the top wishbone ball-joint down
through the top of the upright and through the
wingstay. To fully engage the tapers of the
wishbone and ball-joint, fit the M14 plain nut (6)
from the fastener pack, apply pressure to the top
of the ball-joint and tighten the plain nut. Once
the ball-joint is locked in place remove the plain
nut and replace it with the nyloc supplied on the
ball-joint. Tighten the nyloc nut to 55 Nm.
16
Tighten the inner stub axle nut to 82 Nm
and ensure that the upright turns freely on the
wishbones.
17
Remove and retain the nyloc nut from the
track rod end. Remove and discard the hard
plastic boot protector from the track rod end
taper and pass the tapered shaft down through
the steering arm on the upright, secure with the
nyloc nut. Tighten nyloc nut to 34 Nm.
18
Your front suspension
resemble that shown in Fig 4.
should
now
FRONT ANTI-ROLL BAR
NOTES
(1)
On R400 the inner radiator cowl is located
inboard of the anti-roll bar and must be fitted
first, refer to section 6. (Sigma 125/150 does not
have radiator cowling please ignore the cowling
shown in the picture 4 in this section and fig 26
in section 6)
(2)
Check that the colour of the bushes
corresponds to the colour marked on the front
anti-roll bar.
19
The anti-roll bar is attached to the front of
the chassis using the special mounting brackets
and cotton reel shaped bushes (supplied in the
polythene bag marked 'front suspension').
Liberally coat the bushes with rubber lubricant
and fit the bushes into the brackets. Slide the
brackets over the ends of the anti-roll bar and
around so they will align with the holes drilled in
the front face of the chassis tube.
20
The rubber boots should be slid over the
anti-roll bar, ensuring that the larger diameter of
the rubber boot is outboard. Apply Loctite to the
threads at each end of the anti-roll bar and fit the
plastic balls, tighten using protected grips.
21
Liberally coat the balls with bearing
grease. Assemble the anti-roll bar onto the
chassis by pushing the plastic balls, one at a
time, into the mounting cups in the upper
wishbones. Fit the spring washers (13) to the
bolts (5) and pass forward through the vertical
chassis tubes and into the captive nuts on the
mounting brackets. Tighten to 20 Nm.
22
The rubber boots are slid over the
mounting cups and secured to the top wishbone
using cable ties which fit into the grooves
provided. A further cable tie is used to hold the
boot onto the anti-roll bar itself with the tails of
the cable tie being cut off underneath for
neatness.
1
2
3
Cycle wingstay
Anti-roll bar
Inner radiator
cowl
4
5
6
Lower wishbone
Spring damper unit
Upright assembly
Fig 4 Front suspension
Section 4
Page 4
FRS 02
SECTION 4 - FRONT SUSPENSION
FRONT BRAKE HOSES
NOTE
All connections should initially be made finger
tight.
23
Three stainless steel braided brake hoses
are supplied, two of equal length for the front
brakes and one of longer length for the rear
brakes.
24
Attach the inner, threaded end of each
brake hose through the hole in the aluminium
body. Plain washers (fastener pack 30F015A
item 11) should be fitted directly next to the
aluminium body on both the inside and outside
of the body panel. Secure using the 3/8" nut
and shakeproof washer (14). The shakeproof
washer must be between the nut and the plain
washer. Do not tighten.
1
2
3
2
Female union
(brake pipe)
Plain washer
3
4
4
5
Banjo union
Braided brake
hose
Fig 6 Standard calliper

1
Banjo bolt
Large copper
washer
Small copper
washer
Uprated calliper. On the uprated brake
calliper the braided brake hose has a female
union at the calliper end, refer to Fig 7. The
braided hoses are supplied with an adaptor
that screws into a threaded drilling inboard
of the calliper body. The adaptor must be
fitted with the tapered end outward, this
provides the seal between the adaptor and
the braided brake hose female union, and a
copper washer between the adaptor and the
brake calliper. The female union on the
braided hose screws directly to the adaptor.
Do not over tighten. Torque to 10 Nm.
Shakeproof washer
Locknut
Fig 5 Brake pipe union
25
The outer end should be attached to the
brake calliper as follows:

Standard calliper.
The outer end is
attached to the brake calliper using the
banjo bolt provided.
The large copper
washer is placed next to the bolt head and
smaller copper washer placed between the
banjo union and the calliper, refer to Fig 6.
Do not over tighten. Torque to 10 Nm.
FRS 02
1
2
Copper washer
Female union
3
4
Braided brake hose
Adaptor
Fig 7 Uprated calliper
Section 4
Page 5
SECTION 4 - FRONT SUSPENSION
26
Located on the inside of the body are the
female unions, refer to Fig 5, on the end of the
brake pipes from the brake master cylinder. Fix
the female union to the braided brake hose
connection and tighten to 10 Nm. Tighten the
locknut to 10 Nm.
27
Turn the steering from lock to lock and
ensure that the braided brake hoses do not foul
on the suspension.
If fouling is observed
remove the braided brake hose from the calliper
and twist the hose through 180. Refit the
braided brake hose to the calliper and tighten
unions to 10 Nm.
FINAL TIGHTENING
28
Tighten the fixings detailed in Table 1
now.
TABLE 1 TORQUE FIGURES
Location
Washer
Torque
Stub axle
81 Nm
Damper to lower
wishbone (lower fixing)
20 Nm
Damper to chassis (top
fixing)
20 Nm
Front anti-roll bar fixing
20 Nm
Upright top ball-joint
None
54 Nm
Upright - bottom
Spacer - wide
track only
54 Nm
29
The remaining front suspension fixings
should not be tightened until the suspension is
loaded. This is achieved when the engine is in
place and the car wheels are on the ground.
This ensures that the rubber bushes are
correctly preloaded. All bolts should then be
tightened according to Table 2.
TABLE 2 TORQUE FIGURES
Washer
Torque
Lower wishbone
front
Location
Spring under head
then plain as
shown in Fig 2
81 Nm
Lower wishbone
rear
Plain spacers as
shown in Fig 2
81 Nm
Section 4
Page 6
CARS FITTED WITH ADJUSTABLE DAMPER
PLATFORM
30
Cars fitted with adjustable damper
platforms need to be adjusted to achieve the
optimum ride height. This is done by lowering or
raising the height of the platforms on the
threaded sleeve. It is essential that this task is
carried out on level ground.
NOTE
Lowering the platforms will decrease ride height,
and raising the platforms will increase ride
height. For the best results the ride height
should be set with the driver in the car and fuel
in the tank.
30.1
Start by adjusting the front
dampers to achieve a minimum distance
of 150 mm (this can be increased for road
use to a maximum of 190 mm) between
the ground and the bottom of the lower
chassis rail, where the rear leg of the front
lower wishbone exits the side of the car.
This measurement should be the same on
both sides with the car loaded.
30.2
Now adjust the rear dampers in
the same manner to achieve a height 15
mm higher than the front, measured to the
underside of the lower chassis rail
immediately in front of the 'A' frame
mounting point.
NOTE
Adjusting the rear may have an effect on
the front therefore it is good practice to
check between front and rear several
times during adjustment.
30.3
Once the desired ride heights
have been set ensure that the platforms
are locked together to avoid movement.
FRS 02
SECTION 5 - FITMENT OF GEARBOX TO ENGINE
TABLE OF CONTENTS
Para
1
7
9
Page
Assembly of gearbox kit - 5 and 6-speed ...................................................................
Fitting gearbox to engine............................................................................................
Starter motor ..............................................................................................................
2
3
3
Torque figures............................................................................................................
3
Clutch actuation mechanism ......................................................................................
Speedo drive plug ......................................................................................................
Speedo shaft plug ......................................................................................................
2
2
2
Table
1
Fig
1
2
3
GBX 01
Section 5
Page 1
SECTION 5 - FITMENT OF GEARBOX TO ENGINE
ASSEMBLY OF GEARBOX KIT 5 AND 6-SPEED
1
Both the 5 and 6-speed gearboxes are
interchangeable and utilise all the same
ancillaries. Assembly is identical for both 5
and 6-speed gearboxes with the exception of the
sealing method for bell-housing to gearbox.
5
Apply RTV silicone gasket sealant to the
speedo output shaft opening on the RH side of
the gearbox and insert the small plug supplied,
refer to Fig 3.
NOTE
The plugs are a drive fit and are installed closed
end first.
2
To assemble the gearbox to bell-housing,
proceed as follows:

5-Speed. Smear the gasket (polythene bag
'miscellaneous') on both sides with silicone
sealant and position on the bell-housing.
Using the four cap-head bolts (fastener pack
36G006A 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 silicone
sealant to the front face of the gearbox and
to 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 spring
washers (12), bolt the bell-housing to the
gearbox. Tighten the bolts to 47 Nm.
1
2
3
Gearbox
Plug
Gearbox mounting
Fig 2 Speedo drive plug
3
Place the clutch release mechanism in
position in the bell-housing and secure using the
three cap-head bolts (7) and spring
washers (13), refer to Fig 1.
1
2
1
2
Clutch release bearing
Hydraulic connection
Fig 1 Clutch actuation mechanism
4
Apply RTV silicone gasket sealant to the
speedo drive opening on the LH side of the
gearbox and insert the large plug supplied, refer
to Fig 2.
Section 5
Page 2
Gearbox
Plug
Fig 3 Speedo shaft plug
6
Bolt the metal/rubber/metal gearbox
mounting, chamfered edge rearward, refer to
Fig 2, to the underside of the tailshaft housing
using one bolt (8) and spring washer (12).
Tighten to 61 Nm.
GBX 01
SECTION 5 - FITMENT OF GEARBOX TO ENGINE
FITTING GEARBOX TO ENGINE
7
Slide the gearbox into place on the rear of
the engine. It may be necessary to rotate the
gearbox assembly in order to line up the
gearbox first motion shaft splines with the
splines of the clutch plate.
8
Using the fixings supplied, connect the
engine and gearbox; two bolts (2) and spring
washers (10), pass forward from the top of the
bell-housing into the cylinder block, two more
bolts (2) and spring washers, pass forward from
the bottom of the bell-housing into the sump.
Two bolts (1) and spring washers pass rearward
through the 'ears' on the engine assembly and
into the bell-housing on the RH side, one further
bolt (1) and spring washer passes rearward from
the LH side of the engine into the bell-housing.
STARTER MOTOR
9
Install the starter motor into the front of
the bell-housing and secure with two
bolts (3) and spring washers (10) and one
bolt (1) and spring washer. The short bolt fits in
the outermost hole of the top two.
10
Tighten all starter motor and bell-housing
the bolts to the torques specified in Table 1.
TABLE 1 TORQUE FIGURES
Fixing
Torque
Bell-housing to gearbox
47 Nm
Gearbox rubber mounting to
tailshaft housing
61 Nm
Engine to bell-housing
47 Nm
Bell-housing to sump
20 Nm
Starter motor
34 Nm
GBX 01
Section 5
Page 3
PAGE INTENTIONALLY BLANK
SECTION 6 - INSTALLATION OF ENGINE AND GEARBOX (SIGMA 125)
TABLE OF CONTENTS
Para
1
2
7
10
17
27
39
41
43
53
65
67
76
78
79
Page
Preparation ................................................................................................................
Screen wash/wipe ..............................................................................................
Engine preparation .............................................................................................
Chassis preparation............................................................................................
Installation of engine/gearbox into chassis (Warnings) ..............................................
Electrical connections ................................................................................................
Fuel system................................................................................................................
Clutch hydraulic hose.................................................................................................
Exhaust system..........................................................................................................
Cooling system (Caution) (Warning) ..........................................................................
Water bleed hoses..............................................................................................
Heater and associated hoses .............................................................................
Throttle cable fitment..................................................................................................
Breather pipe fitment..................................................................................................
Air filter fitment ...........................................................................................................
2
2
2
3
4
5
6
6
7
9
11
11
13
14
14
Special tools required.................................................................................................
Torque figures............................................................................................................
2
4
Washer bottle bracket ................................................................................................
Water rail and ‘U’ hose...............................................................................................
Horn location..............................................................................................................
ECU and MAP unit .....................................................................................................
Brake light switch harness .........................................................................................
Fuel pipe connection ..................................................................................................
Clutch master cylinder hose union .............................................................................
Clutch hydraulic hose.................................................................................................
Exhaust mounting ......................................................................................................
Primary pipes and collector/catalyst...........................................................................
Lambda probe connection..........................................................................................
Exhaust arrangement.................................................................................................
Coolant hoses ............................................................................................................
Bottom hose engine connection.................................................................................
Radiator/Fan prior to fitting.........................................................................................
Standard radiator arrangement ..................................................................................
SV radiator arrangement............................................................................................
Coolant expansion bottle mounting bracket ...............................................................
Heater installation ......................................................................................................
Heater valve arrangement..........................................................................................
Heater control location ...............................................................................................
Heater control cable ...................................................................................................
Heater control cable attachment ................................................................................
Throttle cable to throttle body.....................................................................................
Breather pipe .............................................................................................................
Engine bay overview ..................................................................................................
2
3
3
5
5
6
6
6
7
7
8
8
9
9
9
10
10
11
11
12
12
13
13
13
14
15
Table
1
2
Fig
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
ENG S125 02
Section 6
Page 1
SECTION 6 - INSTALLATION OF ENGINE AND GEARBOX (SIGMA 125)
PREPARATION
1
The special tools detailed in Table 1 will
be required.
TABLE 1 SPECIAL TOOLS REQUIRED
Item
Description
Engine hoist
and sling
SWL of 150 Kg (min)
Screen wash/wipe
NOTE
The bracket for the washer bottle must be fixed
to the front of the passenger side foot box before
the engine is installed.
2
Offer up the bracket with the washer
bottle attached and mark the position of the two
fixing holes. Remove the bracket and bottle and
drill the marked positions using a 3/16” drill.
Secure the bracket with rivets. Drill a third hole
through the bracket and foot box, refer to Fig 1.
Secure the third hole with a rivet and fit the
washer bottle.
4
Route the clear washer tubing along the
wiring loom behind the dashboard and attach
using cable ties, to prevent it falling down into
view. Pass it down through the large grommet
in the top of the transmission tunnel and along
the engine bay diagonal tube until in line with the
washer bottle. Trim the tube to length and
attach to the washer motor.
5
Connect the washer motor to the wiring
loom via the two pin plug adjacent to the washer
bottle mounting. To ease fitment of the two pin
plug the washer motor can be removed from the
washer bottle, the two pin plug fitted and the
washer motor reinserted into the washer bottle.
6
The windscreen wipers must not be fitted
until the wiper motor has been run and allowed
to park in order to prevent damage to the
paintwork. Fit the wiper arms so that they are
horizontal when parked. The wiper arms must
move smoothly through their range of travel.
NOTE
A small amount of water splashed on the
windscreen will prevent the wiper blades from
juddering during test and adjustment.
Engine preparation
7
The large diameter pre-formed 'U' hose
should be fitted onto the aluminium water outlet
located on the rear of the cylinder head, refer to
Fig 2. Apply rubber lubricant to the short end of
the hose (hose may require trimming) and push
over the outlet; rotate the hose until the long end
sits along the LH side of the engine within the
curve of the inlet manifold. Secure using a hose
clip (Polythene bag 'cooling').
1
2
3
Footbox
Washer bottle bracket
Third hole
Fig 1 Washer bottle bracket
3
Remove the securing nut from the base of
the washer jet (polythene bag marked
'miscellaneous') and pass the washer jet through
the hole in the centre of the scuttle and secure
with the plastic securing nut. Fit the clear plastic
tubing to the washer jet. Dip the end of the clear
plastic tubing in hot water to soften in order to
make fitting easier.
ENG S125 02
8
Apply rubber lubricant to the end of the
water rail; pass the rail from the front of the
engine, over the alternator, and through the
curve of the inlet manifold. Insert the pipe into
the long end of the ‘U’ hose and secure using a
hose clip (Trim the ‘U’ hose as necessary). Align
the rail mountings with the lugs on the inlet
manifold and secure using screws, nuts and
washers provided.
Section 6
Page 2
SECTION 6 - INSTALLATION OF ENGINE AND GEARBOX (SIGMA 125)
13
Fit the engine mounting rubber block to
the LH side of the engine bay, locate the engine
earth lead (a black lead approximately 300 mm
long), pass bolt (2) and washer (12) downwards
through the lead, through the front hole of the
engine mounting block, through the chassis and
secure with nyloc nut (9) and plain washer (12).
Remove a little paint from the chassis/mounting
to ensure that a good electrical contact is made.
Pass bolt (3), plain washer (12) downwards
through the rear hole of the engine mounting
block, through the chassis and secure with
nyloc (9) and plain washer (12). Do not tighten.
1
2
3
Engine connection
‘U’ hose
Water rail
Fig 2 Water rail and ‘U’ hose
9
Remove and retain the gearbox filler plug.
Remove the plastic plug from the gearbox
tailshaft housing. Removal of these plugs is not
essential; however access is restricted within the
confines of the transmission tunnel.
14
Locate the twin electric horns on the two
studs near the rear edge of the steering rack
platform. Before fitting the horns, loosen the 13
mm nut in the centre of each horn, this will allow
rotation of the horns so that the electrical
connections are closer together.
15
Secure the horns with the nyloc nuts
provided and ensure that it is not possible for the
horns to come into contact with each other, the
steering rack or other components in the engine
bay refer to Fig 3.
Chassis preparation
10
Protect the appearance of the engine bay
chassis tubes and pedal box sides and edges by
covering with card and/or masking tape.
11
Ensure that all wires and connector plugs
are secured and will not snag or catch the
engine/gearbox as it is lowered.
NOTE
Before fitting engine mounting rubber blocks
(polythene bag marked 'miscellaneous') ensure
that the large threaded (1/2" UNF) boss in the
centre is clear of rubber and that the bolt will
thread in cleanly.
12
Fit the engine mounting rubber block to
the RH side of the engine bay. The two bolts
(fastener pack 30P012A Item 3), plain
washer (12) are passed downwards through the
mounting, through the chassis and are secured
with nyloc nuts (9) and plain washers (12). Do
not tighten.
ENG S125 02
Fig 3 Horn location
16
Tighten the 13 mm nut in the centre of
each horn and connect the horns to the
electrical harness by the purple and yellow wires
and connectors located above the horns on the
front upper cross member.
Section 6
Page 3
SECTION 6 - INSTALLATION OF ENGINE AND GEARBOX (SIGMA 125)
INSTALLATION OF ENGINE/GEARBOX INTO
CHASSIS
NOTE
If the optional oil/air separator tank is to be
installed then the mountings for the separator
tank must be fitted before the engine is installed
and the horns must be relocated to an alternate
position beneath the coolant expansion bottle
(refer to Section 16).
WARNINGS
(1)
Never work underneath a car without
supporting it on axle stands or equivalent.
Do not rely on a jack alone.
22
Adjust the gearbox on its slotted
mountings to achieve equal clearance within the
transmission tunnel. This must be checked
carefully as clearances are tight and poor
alignment can cause the gearbox to contact the
chassis under cornering.
23
Bolt the gearbox mounting rubber to the
chassis using bolts (fastener pack 30P012A
Item 4) passed down through the outer metal
part of the rubber mounting and then through the
elongated holes in the chassis. Secure with a
plain washer (12) and nyloc nut (9) on each bolt
and tighten to 20 Nm.
24
Finally tighten the fixings detailed in
Table 2.
(2)
Use appropriate eye protection whilst
working under the car.
TABLE 2 TORQUE FIGURES
Fixing
17
Using the lifting hoist and sling detailed in
Table 1, attach the engine/gearbox using the
lifting eyes provided on the engine, lower the
engine/gearbox assembly into the engine bay at
an angle of between 30-40 (with the engine
higher than the gearbox). Insert the gearbox
assembly into the transmission tunnel.
18
Continue to slide the engine/gearbox
rearward until the holes in the gearbox mounting
line up with the holes in the chassis cross
member. If the differential and propshaft have
already been fitted, ensure that the propshaft
locates into the gearbox tailshaft housing.
19
Attach the LH engine mounting using the
two M8 x 20 mm bolts (fastener pack 36G006A
Item 4) and one M8 x 30 mm bolt (5), do not fully
tighten the bolts.
Torque
Engine mounting to block
34 Nm
Engine mounting to mounting
rubbers
41 Nm
Engine mounting rubbers to
chassis
20 Nm
Gearbox mounting rubber to
chassis
20 Nm
NOTES
(1)
It is now safe to remove the engine hoist.
(2)
Wiring – Every effort is made to clearly
explain and identify all the electrical connections
as you go through this section; however the
loom fitted to your car may have additional wires
and connectors that are not required on your
vehicle. To help clarify this, a wiring diagram can
be found in section 17.
20
Attach the RH engine mounting using the
two M8 x 35 mm bolts (6) and one M10 x 40 mm
bolt (2). Do not finally tighten the engine
mounting retaining bolts until advised later in this
section.
25
Fit the gear lever to the top of gearbox
tailshaft housing and secure with three
setscrews (7). No washers are required; tighten
to a torque of 20 Nm.
21
Lower the engine onto the rubber engine
mountings and pass the bolts (fastener pack
30P012A Item 1 (LHS) and 21 (RHS)) down
through the tube on the outer end of the engine
mounting brackets. Screw the bolts loosely into
the threaded bush in the centre of the rubber
engine mounting. It is recommended that the
engine is not removed from the hoist until all the
bolts have been tightened (detailed later in this
section).
26
Fit the reverse light switch (polythene
bag) into the side of the gearbox. This can be
accessed via the hole in the RH side of the
transmission tunnel. The switch should be
inserted finger tight and then tightened a further
quarter of a turn using a suitable sized spanner.
Connect the wiring loom to the reverse light
switch. From the cockpit, insert the large
grommet (polythene bag) to cover the access
hole in the transmission tunnel.
Section 6
Page 4
ENG S125 02
SECTION 6 - INSTALLATION OF ENGINE AND GEARBOX (SIGMA 125)
ELECTRICAL CONNECTIONS
27
The engine wiring loom is already
attached to the engine and some ancillaries,
however it is necessary to link the engine wiring
loom to the remaining ancillaries and the vehicle
wiring loom. All the plastic connecting plugs are
matched pairs so it is not possible to connect
them incorrectly.
28
Attach the grey, multi-pin plug to the
respective socket on the Engine Control Unit
(ECU), which is located on the passenger side
heater tray, forward of the battery. Make the
connection and ensure that the red retaining clip
is pushed fully home, refer to Fig 4.
33
The green, green/purple pair (with
grommet) in the engine loom is for the brake
light switch. The brake light switch is inside the
drivers pedal box and the harness may be
connected during installation of the steering
column, refer to Section 3. Pass the brake light
switch harness through the hole in the rear of
the pedal box, refer to Fig 5 and push the two
female connectors onto the male connectors of
the brake light switch (orientation is not
important). Fit the grommet into the hole and
ensure that the harness will not foul the steering
column or pedals.
1
2
3
1
2
Fuel pipe
connection
MAP unit
3
4
5
Multi-pin plug
ECU
Air filter
Fig 4 ECU and MAP unit
29
Position the MAP unit adjacent to the
ECU and secure using two screws provided
(fastener pack ZCH01 items 12 and 13).
30
Connect the green 3-pin plug on the
engine loom to the connection on the MAP unit.
Connect the short pipe on the MAP unit to the
corresponding connection on the throttle body
using the rubber vacuum hose provided.
31
Connect the white/brown wire from the
vehicle loom to the oil pressure sender on the
LH side of the engine block.
32
The two, paired, black/yellow wires with
ring terminals in the engine loom are earth
connections. Attach both pairs to a suitable
earth point on the bulkhead.
ENG S125 02
Brake light switch
Cheese wedge
Grommet
4
5
Sealant
Brake light
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 for
the exhaust mounted lambda probe. This cannot
be connected until the exhaust primary pipes
and collector/catalyst is fitted, refer to Para 50.
35
Remove the outermost Bell housing
securing bolt and spring washer. Pass the Bell
housing mounting bolt and attached spring
washer through the black battery earth lead and
secure to the bell-housing. Tighten to 34 Nm.
36
Connect the red lead from the starter
motor to the battery. Also connect the black lead
on the main vehicle loom to the starter motor on
the same terminal.
37
Connect the brown
alternator to the starter.
lead
from
the
38
Connect the brown/red wire from the
chassis loom to the starter solenoid.
Section 6
Page 5
SECTION 6 - INSTALLATION OF ENGINE AND GEARBOX (SIGMA 125)
FUEL SYSTEM
39
The black, corrugated plastic, high
pressure fuel pipe from the fuel pump emerges
from the transmission tunnel and is a push-fit on
the white elbow connection at the rear of the fuel
rail, refer to Fig 6. Note that there is no fuel
return pipe with this system.
1
2
Banjo bolt
Copper washers
4
5
Hose union
Clutch master
cylinder
Fig 7 Clutch master cylinder hose union
1
2
Fuel rail connection
Fuel pipe (from pump)
Fig 6 Fuel pipe connection
42
Route the hose down the side of the pedal
box, over the wiring loom (under the heater hose
if fitted) and across the top of the bell-housing,
Refer to Fig 8. Push the end of the hose into the
connector in the clutch release bearing
assembly and ensure that the hose is firmly
attached. Secure the hose with cable ties if
necessary, to prevent chafing and tighten the
banjo bolt (the clutch system is filled and bled
during start-up/final checks, refer to Section 14.
40
Once fitted the pipe cannot be removed
without a special tool. Ensure that the pipe is
kink free and routed away from possible snags
or chafe points. Push the connection on the pipe
firmly onto the elbow and check that it is
securely attached. Secure the pipe with cable
ties if necessary.
CLUTCH HYDRAULIC HOSE
41
Remove all packaging from the clutch
hydraulic hose. Fit a copper washer to the banjo
bolt and pass the banjo bolt through the union at
the end of the hose, refer to Fig 7. Fit the
second copper washer to the banjo bolt and
screw the banjo bolt into the clutch master
cylinder outlet port (remove the port plug). Do
not fully tighten the banjo bolt.
Fig 8 Clutch hydraulic hose
Section 6
Page 6
ENG S125 02
SECTION 6 - INSTALLATION OF ENGINE AND GEARBOX (SIGMA 125)
EXHAUST SYSTEM
43
The standard exhaust system consists of
four primary pipes, a collector assembly which
also incorporates the catalytic converter and a
one piece silencer and tail pipe.
44
Bolt the exhaust mounting bracket
(polythene bag marked 'exhaust') to the RH side
of the car forward of the rear wheel, using
setscrew (fastener pack 30X020A Item 1) and
spring washers (3), refer to Fig 9. Secure the
bobbin to the angle bracket with a nut (2) and
spring washer (3).
cylinder head and ensure that the pipe
sits in the bottom LH corner of the
aperture (viewed from outside).
47.2
Pass the flanged end of # 1 pipe
inwards, attach the flange loosely to the
cylinder head and ensure that the pipe
sits in the top RH corner of the aperture.
47.3
Pass the plain end of # 3 pipe
outwards, attach the flange loosely to the
cylinder head and ensure that the pipe
sits in the bottom RH corner of the
aperture.
47.4
Pass the plain end of # 2 pipe
outwards, attach the flange loosely to the
cylinder head and ensure that the pipe
sits in the top LH corner of the aperture.
NOTE
For series 5 use the same procedure to fit the
primary, the sequence to fit the primary is
4,3,1,2
56X005A is for #1(front) cylinder.
56X006A is for #2 cylinder.
56X007A is for #3 cylinder.
56X008A is for #4 (rear) cylinder.
1
2
3
Angle bracket
Spring washer
Setscrew
4
5
Bobbin
Nut
Fig 9 Exhaust mounting
45
Remove the exhaust gasket and
associated fasteners from the RH side of the
cylinder head, remove any masking tape
protecting the exhaust ports and clean off any
adhesive residue.
48
When the primary pipes are in place fit
any remaining fasteners but do not tighten them.
49
Install the collector/catalyst over the
assembled primary pipes with the threaded hole
for the lambda probe faces towards the side
panel. Secure the collector to the primary pipes
with the two springs, refer to Fig 10. Support the
weight of the collector such that the primary
pipes are not in contact with the sides of the
aperture and tighten the primary pipe/cylinder
head fasteners to 34 Nm.
46
The exhaust primary pipes are marked
with 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 square
aperture in the side panel with masking tape and
card, place the exhaust gasket over the
remaining studs and fit the primary pipes in the
following sequence:
47.1
Pass the flanged end of # 4 pipe
inwards, attach the flange loosely to the
ENG S125 02
1
2
Primary pipe
Collector/catalyst (guard fitted)
Fig 10 Primary pipes and collector/catalyst
Section 6
Page 7
SECTION 6 - INSTALLATION OF ENGINE AND GEARBOX (SIGMA 125)
50
Fit the Lambda probe into the threaded
hole in the collector/catalyst and connect the
probe plug to the corresponding socket from the
engine wiring loom. Secure the Lambda probe
connection and wiring to the chassis ensuring
that it cannot contact the hot exhaust or any
moving part, refer to Fig 11.
NOTE
The lambda probe wiring passes under the side
of the car below the lower chassis tube, it must
not be routed through the primary pipe aperture
in the side panel.
1
2
Silencer bracket
Worm drive clip
3
4
Lambda probe
Band clamp
Fig 12 Exhaust arrangement
Fig 11 Lambda probe connection
51
Undo the large worm drive clips and feed
them through the channels on the inside of the
silencer and collector/catalyst guard. Fit the
silencer guard to the silencer body with the
channels offset towards the rear of the silencer
and tighten the clips, refer to Fig 12. Ensure that
the clip drives are not at the bottom of the
silencer where they could contact the road.
Attach the collector/catalyst guard in the same
manner.
NOTES
52
Loosely fit the single band clamp to the
front of the silencer and position the front of the
silencer over the collector/catalyst outlet pipe.
Locate the bracket at the rear of the silence over
the bobbin on the silencer mounting bracket and
secure with a nut and spring washer. Tighten the
nut and band clamp. It may be necessary to
reposition the guards slightly.
.
(1)
For a neater appearance position the clips
with the drive screw towards the ground so that
the clip ‘tail’ is out of sight beneath the exhaust.
(2)
To reduce the risk of damage it is
advisable to fit the silencer after the RH rear
wing has been attached.
Section 6
Page 8
ENG S125 02
SECTION 6 - INSTALLATION OF ENGINE AND GEARBOX (SIGMA 125)
COOLING SYSTEM
53
Position a hose clip on the flexible top
radiator hose, apply rubber lubricant and fit the
hose to the end of the water rail pipe emerging
from the curve of the inlet manifold, Refer to
Fig 13. Do not tighten the clip.
1
2
Hose to ‘T’ piece
Bottom radiator hose
Fig 14 Bottom hose engine connection
(viewed from below)
1
2
3
4
5
6
7
Top radiator hose
Water rail
Hose to heater outlet
Hose to cylinder block
‘T’ piece
Hose to expansion tank
Cable tie
Fig 13 Coolant hoses
54
Position a hose clip on the flexible bottom
radiator hose, apply rubber lubricant and fit the
hose to the larger of the two outlets on the LH
side of the engine block, Refer to Fig 14. The
hose passes forwards along the LH side of the
engine bay before turning to pass along the top
of the steering rack and turns again to meet the
radiator connection. Do not tighten the clip.
55
Fit the four rubber radiator mountings to
the front of the chassis and secure using nuts,
plain washer and spring washers provided in the
cooling pack.
56
Fit the four fan legs (polythene bag
marked 'cooling') to the cooling fan. Secure the
fan complete with legs to the radiator, ensuring
that the fan electrical connector is located on the
RH side of the radiator, using four nuts and
washer provided in fastener pack (fastener pack
30C047A, Item 6 & 9). Refer fig 15
1
2
3
4
5
Top hose connection
Fan
Fan legs
Fan power lead
Bottom hose connection
Fig 15 Radiator/Fan prior to fitting
ENG S125 02
Section 6
Page 9
SECTION 6 - INSTALLATION OF ENGINE AND GEARBOX (SIGMA 125)
CAUTION
Do not over tighten the blanking plug.
57
Position the copper sealing washer on the
blanking plug and fit the blanking plug into the
threaded boss in the radiator, adjacent to the top
hose connection.
NOTE
The blanking plug occupies the location
previously used for a thermostatic fan switch. In
the event that a switch is supplied in lieu of a
blanking plug, fit the switch as described but do
not connect it to the vehicle wiring harness.
58
Fit the radiator/fan assembly onto the
rubber radiator mountings ensuring that the
hose connections face towards the engine.
Secure using nuts, plain washers and spring
washers.
Fig 17 SV radiator arrangement
60
Position hose clips on the forward ends of
the flexible top and bottom radiator hoses; apply
rubber lubricant and fit the hoses over the
connections on the radiator. Tighten the clips at
both ends of both hoses.
NOTE
The flexible radiator hoses may need to be
trimmed to length.
1
2
3
4
Radiator
Blanking plug
Rubber mounting
Fan
Fig 16 Standard radiator arrangement
59
The radiator mounting arrangement on SV
models differs considerably from that shown. SV
kits include LH and RH radiator mounting plates,
refer to Fig 17; these plates must be fixed to the
body before attaching the rubber mountings and
the radiator
Section 6
Page 10
61
Locate the two-pin plug containing the
black/green and black wires situated on the
upper front diagonal chassis member. Connect
the two-pin plug to the cooling fan electrical
connector. Secure the cable to the chassis
members using cable ties.
62
Fit the expansion bottle mounting bracket
on the top of the cruciform, immediately behind
the radiator, refer to Fig 18, and secure using
bolt, plain washer and spring washer. Tighten
to 11 Nm.
ENG S125 02
SECTION 6 - INSTALLATION OF ENGINE AND GEARBOX (SIGMA 125)
65
Route the 5/16” bore hose, back from the
radiator to the ‘T’ piece and from the ‘T’ piece
along the top radiator hose and fuel rail and
around the back of the cylinder head. Cut pieces
of 5/16" hose to length, apply rubber lubricant to
each open end and fit to the connections and 'T'
piece as described.
Secure using hose
clips (10). Secure the hose to the top radiator
hose using cable ties.
Heater and associated hoses
1 Cruciform
2 Expansion bottle mounting bracket
Fig 18 Coolant expansion bottle mounting
bracket
63
The round coolant expansion bottle sits
on the mounting bracket and is secured using a
setscrew, plain washer and nyloc nut, refer to
Fig 26 for correct orientation of the expansion
tank hose connections.
66
Remove and retain the four screws, nyloc
nuts and washers and the two washer plates
securing the diffuser panel to the heater.
Position the diffuser panel on the inside surface
of the scuttle and insert the four screws from the
inside. Pass the heater harness through the
large hole in the scuttle panel and locate the
heater over the screws, secure with the washer
plates, nyloc nuts, washers and two additional
screws from the fastener pack, refer to Fig 19.
Connect the heater harness connector heater to
the matching plug, located under the dashboard.
NOTE
NOTE
If an oil/air separator kit has been fitted the
expansion bottle must be relocated, refer to
Section 16.
Cars not fitted with a heater will be supplied with
a blanking plate. Apply a small amount of silicon
sealant around the edge of the plate to seal it.
Water bleed hoses
64
The smaller of the two inlets on the
coolant expansion bottle connects to the stem of
the small ‘T’ piece in the 5/16” bore hose that
must connect the top of the radiator (near the
blanking plug) to the small diameter connector at
the rear RH side of the cylinder head, refer to
Fig 26.
NOTE
There may be a metal 'water bleed pipe' fitted to
the engine along the LH side and behind the
cam cover. In this event, connect the 5/16" bore
hose to the front of the water bleed pipe and
connect the rear of the water bleed pipe to the
connection at the rear RH side of the cylinder
head using a short length of 5/16" hose. Secure
all hose connections with hose clips.
1
2
3
Washer plate
Heater
Heater inlet hose
4
5
Heater outlet hose
Heater control
cable
Fig 19 Heater installation
67
Heater hose is supplied as three preformed 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 the
bottom radiator hose.
ENG S125 02
Section 6
Page 11
SECTION 6 - INSTALLATION OF ENGINE AND GEARBOX (SIGMA 125)
67.2
The long ‘L’ shape must be cut in
two to provide a long straight hose (to
connect the ‘T’ piece to the heater outlet)
and a short ‘L’ shape (to connect the
expansion tank to the ‘T’ piece). Measure
the relevant distances carefully before
cutting the hose.
NOTE
On cars where no heater is fitted the relevant
connections at the rear of the cylinder head and
on the front LH side of the engine block must be
joined by a suitable length of hose.
67.3
The long ‘J’ hose connects the
heater inlet to the water outlet at the rear
of the cylinder head (next to the top hose
‘U’ bend). This hose must be trimmed to
length. Cut a 240 mm length of hose from
the straight leg and cut this into two 120
mm pieces. Use the 120 mm pieces to
connect the heater inlet and outlet to the
heater valve.
68
The larger of the two inlets on the coolant
expansion bottle must connect to one end of the
cross-bar of the large ‘T’ piece (near the
alternator) that also connects to the heater valve
(outlet side) and to the smaller of the two
connections at the front LH side of the engine
block, 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 the
coolant expansion bottle and ‘T’ piece securing
with a hose clip at each end.
69
Apply rubber lubricant and connect the
short ‘L’ shaped hose to the smaller of the two
connections at the LH front of the engine block,
connect this hose to the stem of the large ‘T’
piece. Secure using hose clips.
1
2
3
4
Hose to large ‘T’
Heater outlet
Heater inlet
Heater valve
5
6
Hose to cylinder
head
Hose clip(s)
Fig 20 Heater valve arrangement
72
Remove and retain the locknut and
washer from the heater control cable and pass it
from inside the cockpit, through the hole in the
front face of the scuttle, refer to Figs 21 and 22.
Secure the cable in place using the locknut and
washer provided.
70
Use the cut length of 5/8” bore hose (from
the long ‘L’ hose) to connect the remaining leg of
the ‘T’ piece to the upper (outlet) connection on
the heater valve, refer to Fig 20. Connect the
other side of the heater valve upper (outlet)
connection to the straight connector at the top of
the heater. Apply rubber lubricant where
necessary and secure using hose clips. Ensure
that the hose is routed to avoid chafing, use
cable ties as necessary.
71
Trim to length and connect the long ‘J’
hose between the lower (inlet) connection of the
heater valve and the outlet at the back of the
cylinder head (next to the top ‘U’ hose). Connect
the curved pipe on the heater valve to the lower
(inlet) connection on the heater using a short
length of 5/8” bore hose, refer to Fig 20. Apply
rubber lubricant where necessary and secure
using hose clips. Ensure that the hose is routed
to avoid chafing, use cable ties as necessary.
Do not fully tighten the hose clips at the heater
end at this point.
Section 6
Page 12
Fig 21 Heater control location
ENG S125 02
SECTION 6 - INSTALLATION OF ENGINE AND GEARBOX (SIGMA 125)
WARNING
Due consideration should be given to the
highly flammable nature of petroleum or
alcohol based products and their vapours.
Serious burns can result from incorrect use.
1
2
3
Scuttle panel
Heater control cable
Locknut
Fig 22 Heater control cable
73
Connect the other end to the heater
control valve by sliding the eyelet on the inner
cable over the peg on the heater valve operating
arm then slide the outer cable under the
adjacent clamp and tighten the screw to secure
in place, refer to Fig 23. Ensure that the valve
travels through its full range when operated from
inside the car.
This can be adjusted by
slackening the clamp that locates the outer
cable to the valve and sliding the cable one way
or another.
1
2
74
Fill the cooling system with a 50%
antifreeze solution (refer to Owner's Handbook
for Caterham recommended coolant). Add the
coolant solution to the expansion bottle. Place
paper or cloth on the scuttle in the area below
the heater inlet/outlet hoses. Ensure that the
heater valve is in the fully open position (control
knob pulled towards the driver) and remove the
heater inlet (top connector) hose which was
previously left loose. Temporarily seal off the
heater valve inlet and at the same time back fill
the heater inlet hose with coolant solution.
When the hose is full refit it to the heater inlet
and secure with the hose clip. This procedure
should minimise the amount of bleeding required
once the engine is running for the first time.
THROTTLE CABLE FITMENT
75
Attach the throttle cable to the linkage on
the throttle body by engaging the nipple in the
throttle operating lever and then clipping its
square shaped black plastic adjuster onto the
adjacent bracket. This adjuster can be threaded
up and down the cable outer to adjust the
throttle pedal position, refer to Fig 24.
Heater valve
Heater control cable
Fig 23 Heater control cable attachment
1
2
3
Throttle cable
Throttle cable adjuster
Throttle body linkage
Fig 24 Throttle cable to throttle body
ENG S125 02
Section 6
Page 13
SECTION 6 - INSTALLATION OF ENGINE AND GEARBOX (SIGMA 125)
76
Route the other end of the cable around
the front of the cam cover, refer to Fig 25 and
through the 22 mm hole in the front of the pedal
box and clip the plastic seat into place. The
inner cable is fed into the slot on the top of the
pedal with the portion of cable protruding past
the cable termination located through the hole.
The top of the pedal should be gently squeezed
with a pair of pliers to capture the cable and
prevent it escaping.
AIR FILTER FITMENT
78
Fit the Caterham air filter element to the
throttle body housing and secure using the hose
clip provided. The hose clip should not be over
tightened as it is possible to distort the throttle
body and prevent smooth operation of the
throttle.
Check that the throttle operates
smoothly without sticking.
NOTE
In order to obtain a preferred pedal height and
achieve adequate cable tension it may be
necessary to bend the top of the pedal prior to
locating the cable. This is done by inserting a
Phillips screwdriver into the top of the pedal,
bracing the bottom of the pedal with a block of
wood, and gently bending the top of the pedal so
as to take up the slack in the cable. Finally use
the adjusting mechanism at the throttle body end
of the cable to remove any free play.
BREATHER PIPE FITMENT
77
Fit the breather pipe between the throttle
body and engine cam cover, refer to Fig 25.
Apply rubber lubricant where necessary and
secure using hose clips. Ensure that the pipe is
routed to avoid chafing, use cable ties as
necessary.
1
2
3
Cam cover
Breather pipe
Throttle body
Fig 25 Breather pipe
Section 6
Page 14
ENG S125 02
1
2
3
4
5
6
7
8
9
Engine
Exhaust primary pipe
Throttle cable
Pedal box
Brake master cylinder
Clutch master cylinder
Clutch hose
Heater inlet hose
Heater
10
11
12
13
14
15
16
17
18
‘U’ hose
Heater control cable
Heater outlet
Battery
MAP unit
ECU
Air filter
Washer bottle
Heater outlet hose
19
20
21
22
23
24
25
26
27
Large ‘T’ piece
Water rail
Top radiator hose
Water bleed hose
Small ‘T’ piece
Blanking plug
Expansion bottle
Radiator
Radiator inner cowl
SECTION 6 - INSTALLATION OF ENGINE AND GEARBOX (SIGMA 125)
Fig 26 Sigma 125 Engine bay overview
ENG S125 02
Section 6
Page 15
PAGE INTENTIONALLY BLANK
SECTION 7 - PREPARATION AND INSTALLATION OF THE DIFFERENTIAL
TABLE OF CONTENTS
Para
1
6
7
13
14
Page
Preparation (Caution).................................................................................................
Propshaft ...................................................................................................................
Fitting the differential (Warnings) ...............................................................................
Propshaft to differential fitment ..................................................................................
Lubrication .................................................................................................................
2
2
2
3
3
Differential material to be removed ............................................................................
Differential breather....................................................................................................
Differential mounting in chassis .................................................................................
Position of the differential in the chassis ....................................................................
2
2
3
3
Fig
1
2
3
4
DIF 01
Section 7
Page 1
SECTION 7 - PREPARATION AND INSTALLATION OF THE DIFFERENTIAL
PREPARATION
1
In order to give clearance for the De Dion
tube, material may need to be removed from the
rear cover on the differential, refer to Fig 1. On a
Caterham supplied part it is likely that this has
been removed prior to supply however if this is
not the case it can easily be removed using a
hacksaw/file. Measure and mark 43 mm from
the machined surface of the backplate where it
mates with the main differential casing.
the breather. The breather can be gently tapped
into place. Remove the 10 mm socket and
replace the rubber tube.
4
Apply a thin coat of copper grease to all
fixings prior to fitment (avoid contaminating any
threads where Loctite is to be used).
5
Slacken the differential oil level/filler plug
before (once the differential is installed access is
limited).
CAUTION
If less than 43 mm is measured then the
differential casing may be holed. If more
than 43 mm is measured it is possible that
the De Dion tube may hit the differential.
2
If a rear anti-roll bar is to be fitted then
you may also need to remove some material
from the underside of the casing. Again on a
Caterham supplied part this has most likely
already been done, however if necessary,
measure and mark a line on the differential
casing 38 mm from the forward face of the lower
mounting. Using a file remove material from the
differential web, 15 mm either side of this line to
a maximum depth of 5 mm.
1
2
3
Rubber tube
Plastic breather
Pip (differential)
4
Groove (plastic
breather)
Fig 2 Differential breather
PROPSHAFT
NOTE
The handbrake mechanism and cable must be
installed prior to installing the propshaft and
differential, refer to Section 8.
1
2
Rear cover
Underside
Fig 1 Differential material to be removed
3
Fit the plastic breather (this may be prefitted) (polythene bag 'rear axle') to the top of the
differential assembly ensuring that the groove on
the breather is aligned with the pip on the
differential, refer to Fig 2. The cutaway portion
of the breather should face the rear of the
differential in order to prevent oil splashing out of
the breather. This part is a tight fit and it may be
necessary to smooth the breather with fine
emery paper to aid fitting. Remove the rubber
tubing and place a 10 mm socket in place over
Section 7
Page 2
6
Remove any protective packaging and lay
the propshaft in the transmission tunnel with the
bolt type flange towards the rear of the car. If the
gearbox has been installed, engage the splined
sleeve at the front of the propshaft with the
mating spline on the gearbox tailshaft and push
the propshaft fully forwards.
FITTING THE DIFFERENTIAL
7
Check that the upper mounting bolt,
(fastener pack 30A001A Item 1), slides into the
upper mounting bushes on the chassis prior to
offering up the differential, refer to Fig 3.
DIF 01
SECTION 7 - PREPARATION AND INSTALLATION OF THE DIFFERENTIAL
WARNINGS
(1)
Never work underneath a car without
supporting it on axle stands or equivalent.
Do not rely on a jack.
(2)
Use appropriate eye protection whilst
working under the car.
1
2
3
Lower mounting bolts
Upper mounting bolt
Nyloc
Fig 4 Position of the differential in the chassis
NOTES
1
2
3
Upper mounting
bolt
Plain washer
Differential
4
5
Lower mounting
bolt
Nyloc nut
(1)
Some tubes not shown for clarity.
(2)
Washers not shown for clarity.
(3)
Measurements 'X' to be identical  2 mm.
Fig 3 Differential mounting in chassis
8
Offer the differential assembly up to its
mounting points as shown.
Suspend the
differential from the upper mounting using
bolt (1). Do not secure.
9
The lower mounting is attached to the
chassis using bolts (2) through the metallistic
bushes with a washer (12) between the bolt
head and the bush. Washers (13) are then
placed between the bushes and the differential
to obtain correct position of the differential. The
differential has to be located centrally in the
chassis, refer to Fig 4.
10
The position of the differential should be
measured from the machined surface of the two
unused lower mounting bosses, on the side of
the differential casing, to the inner edge of the
outer chassis tubes. This measurement 'X'
should be identical on both sides  2 mm.
11
Use further washers (13) between the
metallistic bushes and the differential. Care
must be taken not to force too many washers
between the chassis and the differential since
the small amount of movement allowed by the
rubber bushes will be eliminated thus causing
excessive noise and vibration to be transmitted
into the car. All free play must be taken up and
washers (15) are supplied to aid this.
DIF 01
12
Remove the upper mounting bolt (1) and
refit with washer (12) under the bolt head.
Centralise the differential using washers (13)
and (15), as required, between the metallistic
bushes and the differential. Use a further
washer (12) and nyloc nut (6) on the end of the
bolt. Tighten the upper mounting bolt and lower
mounting bolts to 54 Nm. Check that the
differential is central  2 mm.
Adjust if
necessary.
PROPSHAFT TO DIFFERENTIAL FITMENT
13
Attach the propshaft to the differential
output flange using the four caphead bolts
(polythene bag 'miscellaneous'). No washers
are required. Tighten to 74 Nm.
LUBRICATION
14
The driveshafts must be inserted into the
differential prior to oil being added. Instructions
for installing the driveshafts and filling the
differential can be found in Section 8.
Section 7
Page 3
PAGE INTENTIONALLY BLANK
SECTION 8 - REAR SUSPENSION
TABLE OF CONTENTS
Para
1
3
4
9
11
12
14
17
18
19
21
23
24
26
31
43
45
54
55
56
Page
General ......................................................................................................................
Preparation ................................................................................................................
Fitting of rear brake pipes (Warning)..........................................................................
Rear brake hose.........................................................................................................
Assembly of the rear suspension (Warnings).............................................................
Rear spring damper assemblies ................................................................................
Radius arms...............................................................................................................
Watts link assembly (optional) ...................................................................................
Construction of link arms ....................................................................................
Link arms to bellcrank.........................................................................................
Link arms to chassis ...........................................................................................
Bellcrank to De Dion tube...................................................................................
Rear anti-roll bar (Warnings)......................................................................................
'A' frame .....................................................................................................................
Assembly of De Dion tube (Caution)..........................................................................
Anti-roll bar connection and adjustment .....................................................................
Handbrake mechanism (Warnings)............................................................................
Handbrake adjustment ...............................................................................................
Final adjustments (Warnings) ....................................................................................
Filling of differential (Warning) ...................................................................................
2
2
2
2
3
3
3
4
4
4
4
4
5
5
6
7
8
10
10
10
Special tools required.................................................................................................
Torque figures............................................................................................................
2
10
De Dion tube RH brake pipe fitting ............................................................................
LH brake pipe fitting ...................................................................................................
Watts link - RH side....................................................................................................
Watts link - RH top view .............................................................................................
Rear anti-roll bar mounting.........................................................................................
Metallistic bush - De Dion tube ..................................................................................
Forward 'A' frame mounting .......................................................................................
De Dion tube end (LH) ...............................................................................................
Speed sensor.............................................................................................................
Anti-roll bar connections.............................................................................................
Handbrake assembly .................................................................................................
Handbrake cable arrangement...................................................................................
Handbrake cable routing (non adjustable side)..........................................................
Handbrake cable routing - adjustable side (SV model) ..............................................
Rear suspension arrangement...................................................................................
2
3
4
4
5
5
6
6
7
8
8
8
9
9
9
Table
1
2
Fig
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
RRS 02
Section 8
Page 1
SECTION 8 - REAR SUSPENSION
GENERAL
1
The special tools identified in Table 1 will
be required to tighten the rear hub nuts.
TABLE 1 SPECIAL TOOLS REQUIRED
Item
41 mm
274 Nm
Description
Socket
Torque wrench
2
Copper grease should be applied to all
fixings prior to assembly (excluding brake pipe
nuts and items secured with Loctite).
PREPARATION
3
It is recommended that the lower chassis
tubes that will be under the De Dion tube are
protected. Several layers of masking tape or a
thin card taped to the tubes is sufficient.
FITTING OF REAR BRAKE PIPES
4
Place the De Dion tube on the work bench
with the outer flange facing forward and the
buttress facing downwards.
5
Fit the aluminium De Dion ears and brake
calliper to the De Dion tube, refer to Para 31
and 42. Do not use lock washers or Loctite at
this stage as the ears and brake callipers are
temporarily fitted to ensure correct alignment
and routing of the brake pipe.
WARNING
Both imperial and metric threads are used on
the De Dion brake pipes. The threads on the
three way union are imperial whilst those on
the brake callipers are metric.
To aid
recognition a small notch is machined into
the hexagon of the metric unions on the
pipes.
6
With the fixing boss offset towards the RH
side of the tube fit the three way union
(polythene bag marked 'rear axle')
to the
threaded stud situated towards the RH end of
the De Dion tube, refer to Fig 1, and secure
using a nyloc nut (fastener pack 30R011A
Item 11). Ensure that the three-way union is
located with the input uppermost.
Section 8
Page 2
1
2
3
Brake pipe (RH)
'P' clip
Three way union
4
5
Brake pipe (LH)
De Dion ear (RH)
Fig 1 De Dion tube RH brake pipe fitting
7
Fit the RH short brake pipe loosely to the
three way union and secure the brake pipe to
the 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 correct
spacing.
NOTE
The existing holes may require cleaning with a
1/8” drill bit to remove paint but under no
circumstances should additional holes be drilled.
8
Fit the LH longer brake pipe loosely to the
three way union as shown in Fig 2. Ensure that
the brake pipe runs along the centre of the top of
the De Dion tube. Secure the brake pipe using
the 'P' clips (21) and rivets (20). Remove the
brake callipers and De Dion ears.
NOTE
The existing holes may require cleaning with a
1/8” drill bit to remove paint but under no
circumstances should additional holes be drilled.
REAR BRAKE HOSE
NOTE
All connections should initially be made finger
tight.
9
The rear braided hose can now be fitted.
Thread the locknut onto the male union on one
end of the hose then attach the braided hose to
the three way union on the De Dion tube and
tighten to 10 Nm. Lock into place using the
locknut. The locknut supplied should not restrict
the union from tightening fully.
RRS 02
SECTION 8 - REAR SUSPENSION
10
Place a plain washer over the male union
on the other end of the braided hose then pass
the union forwards through the vertical
aluminium panel, apply a further plain washer
then the shakeproof washer and secure in place
with the locknut provided. Finally, attach the
rigid brake pipe from the transmission tunnel.
12
Insert a sleeve into the top bush of the
damper unit (close coils of spring are at the top),
align the top bush with the top mounting and
insert the top mounting bolt (4) through the
access holes provided in the seat back panel.
Tighten to 54 Nm once the spring damper unit
has been attached to the De Dion tube.
NOTES
13
The lower spring damper mounting is
secured to the threaded boss welded to the
underside of the De Dion tube. Pass bolt (3)
through spring washer (16), plain washer (13),
the spring damper unit and plain washer and
secure to the De Dion tube. Tighten to 54 Nm.
(1)
The rigid brake pipe may need slight
realignment.
(2)
Sharp kinks must not be created.
NOTE
Because the suspension is not under load, the
bottom bush of the damper unit and the
mounting on the De Dion tube will not be in
alignment. Take great care not to cross-thread
the bottom mounting bolt. If necessary remove
the mounting bolt from the rear of the ‘A’ frame
to allow more movement of the De Dion tube.
RADIUS ARMS
1
2
3
P-clip
Brake pipe LH
Three way connector
14
If Watts link has been specified refer to
Para 17.
Fig 2 LH brake pipe fitting
ASSEMBLY OF THE REAR SUSPENSION
WARNINGS
(1)
Never work underneath a car without
supporting it on axle stands or equivalent.
Do not rely on a jack alone.
(2)
Use appropriate eye protection whilst
working under the car.
11
Place the De Dion tube into the
from the RH side ensuring that the
buttress faces downwards and that the
face forward. Care must be taken to
damage to the brake pipes.
chassis
central
flanges
prevent
REAR SPRING DAMPER ASSEMBLIES
NOTES
(1)
The rear spring damper units are only
fitted at this point if the standard roll over bar is
to be installed.
15
Fit the radius arms to the upper chassis
bush with the waisted section facing outboard, to
provide maximum clearance to the brake
calliper. The arms are fitted using M10 x 65 mm
cap head bolts (fastener pack 30R011A Item 2)
passed from the inside of the cockpit through the
radius arm and secured with nyloc nut (8) and
plain washer (14).
The bolts should be
tightened to 34 Nm with the arms parallel to the
ground. This preloads the bushes in the correct
position for when the suspension is properly
loaded.
NOTE
On some series 3 chassis a lower fixing boss is
supplied to give optimum suspension geometry
when used only for race and track purposes.
This setting is not recommended for road usage.
16
Fit the rear end of the radius arm between
the brackets on the top of the De Dion tube
using bolt (3) passed inboard and secure using
a nyloc nut (6). Do not fully tighten.
(2)
If the track day roll over bar or roll cage is
to be installed do not install the spring damper
units yet, refer to Section 16.
RRS 02
Section 8
Page 3
SECTION 8 - REAR SUSPENSION
WATTS LINK ASSEMBLY (OPTIONAL)
17
The Watts link replaces the conventional
single radius arm location of the De Dion tube by
employing two links, one facing forward and one
facing rearward connected via a bellcrank.
Construction of link arms
18
Thread the rod ends (polythene bag
marked 'rear suspension') with nut (fastener
pack 30R012A Item 6) and fit into the four
linkage arms. Adjust the length of the link arms
as shown in Fig 3. Tighten locknuts.
1
2
3
4
5
Bellcrank
Rod end
Locknut
Link arm (forward)
Link arm (rearward)
NOTE
On Series 3 chassis this fixing must be located
in the upper of the two possible radius arm
bushes.
22
The rear link arm attaches to the rear of
the wheel arch into a threaded boss. Apply
Loctite to the thread and secure the rear link arm
to the boss using bolt (fastener pack 30R012A
Item 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 flanges
on top of the De Dion tube. It should be noted
that the bellcrank is secured using an M10 bolt
but the vertical flanges have a 1/2" hole for
traditional radius arm fitment. Two bellcrank
spacers are used on the inner sides of the
flanges to centre the bolt in the hole, refer to
Fig 4. Assemble the bellcrank into the vertical
flanges ensuring that the two bellcrank spacers
are correctly located; pass bolt (1) and plain
washer (7) inboard through the vertical flanges.
Secure with nyloc nut (4) and plain washer (7).
Tighten to 34 Nm. It is essential that plain
washers are used on the outside of both flanges
in order to pass the load to the flanges rather
than the bellcrank spacers.
Fig 3 Watts link - RH side
Link arms to bellcrank
19
Fit the short rearward link arm (waisted
section inboard) to the larger offset mounting on
the bellcrank using bolt (3) passing from inboard
to outboard and secure with nyloc nut (6).
Ensure that the larger offset of the bellcrank
faces downwards and the links are inset towards
the vehicle centre line.
20
Fit the long forward link arm to the upper
mounting on the bellcrank using bolt (3) passing
from inboard to outboard and secure with nyloc
nut (6). Ensure that the waisted sections in the
forward link arm are facing outboard.
Link arms to chassis
21
With the De Dion tube in place attach the
forward link arm to the chassis using caphead
bolt (fastener pack 30R011A Item 2) pass from
inside the cockpit, through the link arm. Secure
using nyloc nut (8) and plain washer (14).
Section 8
Page 4
1
2
3
4
5
De Dion tube (RH) end
Link arm (forward)
Bellcrank
Link arm (rearward)
Bellcrank spacer
Fig 4 Watts link - RH top view
RRS 02
SECTION 8 - REAR SUSPENSION
REAR ANTI-ROLL BAR (OPTIONAL)
WARNINGS
(1)
Never work underneath a car without
supporting it on axle stands or equivalent.
Do not rely on a jack alone.
(2)
Use appropriate eye protection whilst
working under the car.
24
Ensure that the colour of the rubber
'cotton reel' bushes (polythene bag marked 'rear
suspension') corresponds to the colour dot on
the rear anti-roll bar. Apply rubber lubricant to
the centre of the bushes and slide them down
over the flat blades and onto the round section
of the rear anti-roll bar.
25
Feed the rear anti-roll bar across the top
of the lower chassis tubes and below the
differential. The rear anti-roll bar is clamped to
the chassis by the aluminium anti-roll bar
mounting block and secured using bolt (fastener
pack 30R011A Item 4) and plain washer (15).
The bolt is passed vertically up through the
chassis tube, through the thin mounting block.
Secure using plain washer (15) and nyloc
nut (10), refer to Fig 5. Tighten to 14 Nm.
1
2
3
Metallistic bush
Bolt
'A' frame
4
5
Nylon washers
Nyloc nut
Fig 6 Metallistic bush - De Dion tube
27
Attach the 'A' frame to the De Dion tube
using bolt (18) passed through the 'A' frame,
through the metallistic bush and back through
the 'A' frame. Secure using nyloc nut (6) but do
not fully tighten unless the spring damper
assemblies have been installed (spring damper
installation depends on roll over bar/cage
specified).
NOTE
Nylon 'Race' washers are provided in some
applications and if supplied should be fitted over
the centre part of the bush between the De Dion
tube and the 'A' frame, refer to Fig 6.
28
Attach the forward ends of the 'A' frame to
the mounting provided on the chassis, refer to
Fig 7, using bolts (fastener pack 30R011A
Item 1), passed inboard, with large diameter
plain washers (13) either side of the 'A' frame
bushes and secure with nyloc nuts (7). Do not
tighten the 'A' frame fixings.
1
2
3
Cotton reel bush
Clamp (upper thick)
Clamp (lower thin)
4
5
6
Anti-roll bar
Plain washer
Nut
Fig 5 Rear anti-roll bar mounting
'A' FRAME
29
Check that the De Dion tube is centralised
in the chassis. Measure the gaps between the
De Dion tube end plates and the outer edge of
the chassis tube, these should be identical  2
mm. If adjustment is required insert differential
spacing washers between the chassis and the
large chamfered washer at the forward ends of
the 'A' frame until the required position is
achieved.
26
The De Dion tube is located laterally using
an 'A' frame which has bushes fitted to the
forward ends.
The De Dion tube has a
metallistic bush fitted to the attachment point for
the 'A' frame, refer to Fig 6. Place the 'A' frame
under the car with the forward mountings offset
upwards.
RRS 02
Section 8
Page 5
SECTION 8 - REAR SUSPENSION
1
2
3
4
5
6
Nyloc nut
Large diameter washers
'A' frame
Bolt
Chassis mount
Diff spacer washer (as required)
Fig 7 Forward 'A' frame mounting
30
Insert the unthreaded end of the
driveshaft into the differential taking care not to
damage the seals in the differential. The longer
driveshaft is fitted to the RH side. The shorter
driveshaft is fitted to the LH side. To aid
insertion, lightly grease the splines of the
driveshaft and if necessary gently tap the outer
end of the driveshaft with a soft faced hammer.
Ensure that the driveshaft is held as straight as
possible to prevent damage to the boot.
ASSEMBLY OF DE DION TUBE
31
Position the aluminium ears over the
driveshaft and attach to the De Dion tube, refer
to Fig 8.
NOTES
(1)
The ears are not handed however the
calliper fixing lugs protruding from the ear must
be uppermost.
(2)
The holes in the ears are not symmetrical
and therefore will ensure correct orientation.
1
2
3
4
5
6
7
8
Brake calliper
Spacer
Nyloc nut
Plain washer
Spring washer
Bolt
De Dion tube
De Dion ear
9
10
11
12
13
14
15
Bolt
Hub carrier
Bolt
Rear disc/flange
assembly
Thrust washer
Nyloc nut (41 mm)
Driveshaft
Fig 8 De Dion tube end (LH)
32
Apply Loctite to the threads of bolt
(fastener pack 30A001A Item 5) and bolt the
ears into place using spring washers (18) and
plain washers (16) into the threaded holes at the
rear of the De Dion tube.
33
Locate the rear hub carrier, with the
rounded edge of the flange uppermost.
Carefully slide the hub over the end of the
driveshaft taking care not to damage bearings or
seals. Bolt the hubs to the ear by passing the
two bolts (3) through the rear holes of the hub,
the centre holes in the ear and the front holes in
the De Dion tube and tighten into place with the
nyloc nuts (7). No washers are required on
these bolts.
34
Secure the hub to the ear via the forward
holes passing the two bolts (4) through the hub
and ear then securing into place with plain
washers (16) and nyloc nut (7).
NOTE
On the RH side only, the speed sensor bracket
is mounted on the forward two bolts on the
inboard side of the ear, refer to Fig 9.
35
In the case of cars fitted with a rear antiroll bar, coat the threads of bolt (fastener pack
30R011A Item 17) with Loctite and pass through
the lower front hole in the speed sensor bracket,
through a plain washer (fastener pack 30A001A
Item 16) and into the hexagonal, threaded,
extension piece.
Section 8
Page 6
RRS 02
SECTION 8 - REAR SUSPENSION
36
Tighten all fixings installed in Paras 32
to 35 to a torque of 47 Nm.
37
Remove the outer locknut from the speed
sensor. Pass the speed sensor through the
bracket and replace the locknut ensuring that
the serrated face is against the bracket. Adjust
the two locknuts until there is a 1 mm clearance
between the sensor and the serrated disc on the
driveshaft. Tighten the locknuts without
disturbing this clearance.
40
Check that there is clearance between the
outboard rubber boot on the driveshaft and the
lower damper mounting bolt.
41
Check that the outboard driveshaft CV
joints do not foul the inner edges of the De Dion
ears. If contact occurs, slacken the bolts holding
the hub carrier to the ear and adjust until there is
sufficient clearance. Re-tighten to the specified
torque figures.
CAUTION
38
Connect the sensor plug to the 3-pin
connector on the chassis loom near the ‘A’
frame mounting boss. Secure the assembled
connector to the lower chassis rail ensuring that
there is sufficient free play in the sensor lead to
accommodate suspension movement.
1
2
3
4
Serrated disc
Speed sensor
Anti-roll bar extension piece
Speed sensor bracket
Fig 9 Speed sensor
39
Slide the rear disc/flange assembly over
the splined end of the driveshaft and ease into
position through the seal in the hub until it is
tight against the bearing. (It may be necessary
to use the driveshaft nut and washer to pull the
flange finally home). Place the thrust washer
over the driveshaft and secure using the 41 mm
nyloc 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 brakes
have been bled and the foot brake is applied.
RRS 02
The brake pads fitted to the REAR callipers
may be incorrect. Cars equipped with
standard FRONT brakes should bear the
number 3460 on the REAR pads. Cars
equipped with uprated FRONT brakes,
should have blue tabs on the REAR pads.
Using the incorrect rear brake pads will
result in SVA failure.
42
The brake callipers are handed and must
be fitted with the handbrake cable abutments
towards the front of the car. Fit the correct
brake pads fully into the callipers ensuring that
the range of movement of the pads is not
hindered by the calliper body. Slide the calliper
over the brake disc whilst separating the brake
pads.
Secure using bolt (fastener pack
30A001A Item 4) with spring washer (18) and
plain washer (16). Pass through the De Dion
ear, 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 AND
ADJUSTMENT
43
Shorten the droplinks as much as
possible ensuring the threaded ends face in the
same direction. Tighten locknuts. Apply Loctite
to the threaded arm of the droplink and screw
into the extension piece (fitted in Para 35) using
washer (16), refer to Fig 10. Pass the threaded
portion of the lower droplink through the anti-roll
bar and secure with nyloc nut (fastener
pack 30R011A Item 9).
Section 8
Page 7
SECTION 8 - REAR SUSPENSION
45
Install the handbrake mechanism and
cables, refer to Paras 46 to 51, before installing
the differential and propshaft. The handbrake
cables are connected to the rear brake callipers
and adjusted later.
1
2
3
Bolt
Plain washer
Extension piece
4
5
Droplink
Anti-roll bar
46
Pull the two sections of outer cable to the
opposite ends of the inner cable with the nylon
adjuster nuts to the right. Place the inner cable,
refer to Fig 11, around the pulley (polythene
bag). Install the pulley into the handbrake clevis
and insert the thin clevis pin through the
handbrake clevis through the pulley and back
into the handbrake clevis. Secure the clevis pin
in place with split pin (fastener pack 30P12A
Item 14).
Fig 10 Anti-roll bar connections
NOTE
Droplink assembly and connections, shown
rotated through 180 for clarity.
44
The position of the droplinks in the antiroll bar determines the degree of the anti-roll
given. Positioning the droplinks closer to the
pivot (at the cotton reel bushes) will give more
roll resistance. The same position must be set
both LH and RH. The rearmost hole is the
softest and forward most hole is the stiffest
position.
HANDBRAKE MECHANISM
WARNINGS
(1)
Never work underneath a car without
supporting it on axle stands or equivalent.
Do not rely on a jack alone.
1
2
3
4
5
6
Handbrake inner cable
Thin clevis pin and split pin
Handbrake clevis
Handbrake assembly
Thick clevis pin and split pin
Pulley
Fig 11 Handbrake assembly
47
Insert the handbrake cables into the
transmission tunnel with the nylon adjusting nuts
to the LH side of the transmission tunnel; the
inner cable should now cross over itself
immediately behind the pulley, refer to Fig 12.
(2)
Use appropriate eye protection whilst
working under the car.
NOTES
(1)
Prior to installing the handbrake cable
ensure that the adjustable boss is slackened off
to allow easier location.
(2)
The grommet and short section of flexible
tubing on each section of outer cable are not
required in this application and may be removed.
(3)
The switch on the handbrake assembly is
not used in this application.
Section 8
Page 8
1
2
Pulley
Handbrake cable twist
Fig 12 Handbrake cable arrangement
RRS 02
SECTION 8 - REAR SUSPENSION
48
Locate the fixed nylon boss on the outer
cable into the RH bracket on the chassis above
the differential and locate the adjuster on the
outer cable into the LH bracket on the chassis
above the differential.
49
Secure the handbrake assembly to the
chassis
using
the
screws
(fastener
pack 30P012A Item 4) and nyloc nuts (9). The
front hole in the handbrake mechanism is
elongated to allow adjustment of the handbrake
lever in the 'off' position .
51
On SV models the RH side of the
handbrake cable is routed as shown in Fig 12.
Due to the design of the SV chassis LH side of
the handbrake cable emerges from the rear of
the transmission tunnel and is turned
through 90 across the seat back towards the
wheel hub and is attached to the calliper through
the abutment. Secure the handbrake cable to
the diagonal chassis member using cable ties,
refer to Fig 14.
NOTE
For SV installation refer to Section 15 before
proceeding.
50
The two ends of the handbrake cable
emerge from the rear of the transmission tunnel
rearwards. Each end of the handbrake cable
should be routed over the respective driveshaft
then turned through 180 under the driveshaft
and secured to the chassis diagonals, using
cable ties, just outboard of the 'A' frame. Finally
the handbrake cable is turned back on itself and
attached to the calliper through the abutments,
refer to Fig 13.
1
2
Handbrake adjuster
Handbrake cable
3
4
Cable tie
Chassis
Fig 14 Handbrake cable routing - adjustable
side (SV model)
NOTE
Ensure that cable cannot foul flexible brake pipe
during suspension movement.
52
The handbrake cable should not be
adjusted until the transmission tunnel cover
(interior trim) has been fitted as the handbrake
lever is required to be in the vertical position
during fitment of the trim.
53
The
complete
rear
suspension
arrangement can be seen in Fig 15.
1
2
3
Handbrake cable
Cable tie
'A' frame
Fig 13 Handbrake cable routing
(non adjustable side)
1
2
3
4
Watts link rear arm 5
Brake calliper
6
Hub assembly
7
Drop link
Anti-roll bar
Handbrake cable
Watts link front arm
Fig 15 Rear suspension arrangement
RRS 02
Section 8
Page 9
SECTION 8 - REAR SUSPENSION
HANDBRAKE ADJUSTMENT
FILLING OF DIFFERENTIAL
54
Adjust the handbrake by rotating the
knurled nut that locates in the bracket above the
differential. The handbrake should be set to lock
the rear wheels on three clicks of the ratchet
mechanism. Ensure that the pads are not
binding and tighten the second knurled nut to
lock the adjuster.
WARNING
Oils - prolonged and repeated contact may
cause serious skin disorders:
(a) Avoid contact with the skin as far as
possible and wash thoroughly after any
contact.
FINAL ADJUSTMENTS
(b) Keep out of reach of children.
WARNINGS
(c) First aid treatment should
obtained for open cuts and wounds.
(1)
Never work underneath a car without
supporting it on axle stands or equivalent.
Do not rely on a jack alone.
(2)
Use appropriate eye protection whilst
working under the car.
55
If the damper units have been fitted, place
the axle stands under the De Dion tube so that
the weight of the car is taken up through the
spring damper units.
Ensure that all the
suspension securing bolts are tightened as
detailed in Table 2.
TABLE 2 TORQUE FIGURES
Location
Watts link locknut
Bellcrank to link
Watts link rear mount
Bellcrank to De Dion
Watts link front mount
Radius arm
'A' frame
Rear damper bolts (All)
Hub nuts
Hub mountings
Brake calliper
Rear anti-roll bar clamp
De Dion ears
Section 8
Page 10
(d) Use appropriate barrier creams.
56
Once the driveshafts have been located
the differential can be filled with oil. It is
recommended that the differential is filled with
EP90 gear oil (Including those fitted with a
limited slip differential). Refer to your Owner's
Handbook for a complete list of recommended
lubricants.
57
An LSD additive may be used in LSD's to
reduce differential operating noise when
cornering. This is available from Caterham
spare parts counter.
Torque
(Nm)
20
14
34
34
34
34
81
54
270
47
47
14
47
be
NOTE
This operation is made easier if the boot floor
has been removed to allow access.
58
Ensure the filler plug is to hand. Fill the
differential with approximately 1.1 litres of EP90
gear 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.
RRS 02
SECTION 9 - INTERIOR & TRIM
TABLE OF CONTENTS
Para
1
5
9
12
15
16
20
21
24
30
31
35
36
40
41
47
51
52
53
Page
General ......................................................................................................................
Seat back carpets (Warning)......................................................................................
Transmission tunnel carpet ........................................................................................
Transmission tunnel top .............................................................................................
Rubber footwell mats .................................................................................................
Footwell carpets (SV Model only)...............................................................................
Under seat carpets (SV Model only) ..........................................................................
Boot carpet.................................................................................................................
Side and knee trim panels (Caution)..........................................................................
Inertia reel seat belt (Warning)...................................................................................
Four-point harness .....................................................................................................
Six-point harness
Standard floor .......................................................................................................
Low floor ...............................................................................................................
Seats (Warning)
Standard cloth or leather seats .............................................................................
Composite seats
Adjustable seat ................................................................................................
Fixed seat ........................................................................................................
Minor trim items
Scuttle edge trim ...................................................................................................
Nose badge...........................................................................................................
Rear view mirror (interior) ..........................................................................................
2
2
2
3
3
3
3
3
3
4
5
Adhesive and special tools required...........................................................................
2
Carpets ......................................................................................................................
Side panel detail ........................................................................................................
Trim fixings.................................................................................................................
Mounting holes four-point harness upper...................................................................
Shoulder strap with Track day roll over bar................................................................
Outboard lap strap .....................................................................................................
Lap straps ..................................................................................................................
Crutch strap spacer location ......................................................................................
Adjustable seat ..........................................................................................................
Composite seat and six-point harness .......................................................................
Fixed seat ..................................................................................................................
Completed interior......................................................................................................
2
4
4
5
5
5
6
6
7
7
8
9
6
6
6
7
8
8
8
8
Table
1
Fig
1
2
3
4
5
6
7
8
9
10
11
12
INT 01
Section 9
Page 1
SECTION 9 - INTERIOR & TRIM
GENERAL
SEAT BACK CARPETS
1
Superlight models are not supplied with
any carpets unless otherwise specified.
2
Before fitting the carpets ensure that all
operations that require access under the carpets
have been completed.
3
The items specified in Table 1 will be
required during procedures detailed in this
section.
TABLE 1 ADHESIVE AND SPECIAL TOOLS
REQUIRED
Item
Remarks
Adhesive
Contact adhesive
Durable dot fastening
tool (Part No. 76068)
Supplied in chassis
pack
4
It is recommended that a dry run is
completed before cutting or gluing the carpets in
the final position.
WARNING
Ensure adhesive is applied in a well-ventilated
area. Follow instructions on adhesive
packaging. Care must be taken whilst working
in a confined area e.g. the footwell.
5
The carpet that covers the seat back area
has a vinyl strip along the upper edge. Lay the
carpet into place ensuring that the carpet covers
the aluminium seat back right down to the floor.
Apply adhesive to the vinyl strip and stick to the
square tube at the top of the seat back panel.
6
The seatback carpet will need to be cut to
allow the seat belt through it. Mark the carpet
where the inertia reel seat belt exits the seat
back and cut a slot.
7
The carpet must fit flat at the transmission
tunnel. If necessary small cuts should be made
in the area of the corners to allow the tabs on
the carpet to hinge out against the transmission
tunnel.
8
Once the carpet has been fitted around
the transmission tunnel apply adhesive to the
carpet and press into position against the seat
back. It is only necessary to apply adhesive as
far down as the top of the transmission tunnel as
the remainder of the carpet is behind the seats.
TRANSMISSION TUNNEL CARPET
9
Attach the small aluminium transmission
tunnel cover on the rear of the transmission
tunnel top using the 5/32" rivets provided.
10
Ensure that the reverse light switch and
associated blanking grommet have been
installed prior to fitting the transmission tunnel
carpets. The transmission tunnel carpets are
handed so ensure that the correct carpet is fitted
to each side.
Fig 1 Carpets
Section 9
Page 2
11
Coat the transmission tunnel with
adhesive and stick the transmission tunnel
carpets to the transmission tunnel. Ensure that
good adhesive coverage is maintained,
particularly in the forward section of the
transmission tunnel.
INT 01
SECTION 9 - INTERIOR & TRIM
TRANSMISSION TUNNEL TOP
NOTE
Do not attempt to fit the tunnel top until the
tunnel carpet adhesive is dry completely.
12
The transmission tunnel top incorporates
a padded armrest, the gear lever gaiter and the
handbrake gaiter.
13
Pull the handbrake near vertical. Fit the
transmission tunnel top, ensuring that the
handbrake and gearlever locate in the
respective gaiter and press firmly into position
over the sides of the transmission tunnel
carpets.
14
Screw the gearknob into position and lock
with a grubscrew.
RUBBER FOOTWELL MATS
15
Place the mats in the respective footwell
(mats are handed). No fixings are required.
FOOTWELL CARPETS (SV MODEL ONLY)
16
The footwell carpets are handed and are
secured into the footwell using the three poppers
fitted at the rear of the footwell.
17
Attach 3 popper bases (fastener pack
ZIT03 Item 2) to the rear of the front footwell
using rivets (1) through the pre-drilled holes in
the floor panel.
18
Stick masking tape to the underside of the
carpet in the approximate position of the floor
mounted poppers and lay the carpet into
position. Press down firmly on the carpet so that
the bases make an impression on the masking
tape. Make appropriate holes in the carpet and
rivet together the popper (3) and fastener
button (4), using the Durable Dot fastening tool,
refer to Table 1. Ensure that the fastener button
is uppermost on the carpet.
NOTE
For correct use of the popper fastener tool refer
to Section 12.
19
Fit the footwell carpet into place and
secure using the poppers.
INT 01
UNDER SEAT CARPETS (SV MODEL ONLY)
20
The under seat carpets are handed and
are secured into position by the seats. Place the
carpet into position ensuring that the four holes
in the carpets align with the seat mounting holes
in the cockpit floor.
BOOT CARPET
21
The boot carpet is laid into position and
requires no adhesive. It will be necessary to cut
the carpet to fit around the fuel filler pipe. Tuck
the edges of boot carpet down the sides of the
aluminium honeycomb bootboard at the rear and
the sides taking care not to damage the
aluminium body panel.
22
SV models are provided with carpet for
the boot interior side and front panels. Apply
adhesive and secure the carpet shape into the
relevant space.
23
Fit the fuel filler cover plate into position
and drill through the cover plate into the boot
board using a 2 mm drill. Attach the cover plate
using self tapping screws (fastener pack ZCH01
Item 7). It may be necessary to relocate the fuel
filler hose clips to fit the cover.
SIDE AND KNEE TRIM PANELS
NOTES
(1)
If specified, the optional sill protectors and
roll cage must be fitted before the installation of
the knee trim panels, side panels and
associated piping can be completed.
(2)
If the optional roll cage is to be fitted,
shorten the sill protectors to 370 mm long and
position them towards the rear of the sill.
24
Not all of the rivets used to secure the
interior side panels into place will have been
fitted. This is to allow fitting of sill protectors and
to provide access to the front roll cage
mountings, if required.
CAUTION
When drilling the sill protectors take care not
to drill through both sides of the chassis
tube.
Section 9
Page 3
SECTION 9 - INTERIOR & TRIM
25
If necessary, position the sill protector on
the sill, with the long edge between the chassis
tube and trim panel, press down on the sill
protector and drill (5/32”) through the existing
holes in the trim panel, through the sill protector
and through the existing holes in the chassis
tube. When all of the holes have been drilled,
remove the sill protector and clear the holes of
swarf, burrs and raised edges.
NOTE
If the optional roll cage is to be fitted leave the
rivets out of the forward three holes in the
horizontal row and the top three holes in the
vertical row.
26
Position a length of trim piping with the flat
portion between the interior side panel and the
chassis tube and cut to length. The piping
should reach from the front of the knee trim
panel to just behind the point where the side
panel meets the rear wheel arch panel, refer to
Fig 2. Ensure that the rounded edge of the
piping sits neatly along the top edge of the side
panel.
1
2
3
Piping
Sill protector
(optional)
Body skin
4
5
6
Chassis tube
Side panel
Rivet
Fig 3 Trim fixings
1
2
3
Knee trim panel
Roll cage (optional)
Piping
4
Self-tapping
screws
Fig 2 Side panel detail
27
Position the pre-bent and drilled knee trim
panel between the piping and the chassis tube,
secure the knee trim panel, piping and side
panel to the chassis tube using self-tapping
screws (fastener pack ZCH01 Item 8).
NOTE
If the optional roll cage is to be fitted leave the
screws out of the rearmost two holes.
28
Fit the sill protector between the piping
and the chassis rail and align the holes drilled
previously. Drill through the holes again to
pierce the flat portion of the piping and secure
the sill protector, piping and side panel using
rivets (5), refer to Fig 3.
Section 9
Page 4
29
Fit the piping and secure the curved
section of side panel in a similar manner. Ensure
that this section of piping overlays the horizontal
section. Cut a series of ‘V’ shaped notches in
the flat portion of the piping so that it follows the
curve of the side panel neatly.
INERTIA REEL SEAT BELT
30
If specified, the inertia reel seat belts will
have been positioned by Caterham, however
none of the visible chassis mountings will be
tightened. The belts should be tightened at the
same time as the interior trim is fitted. The top
and bottom mountings should be tightened to 47
Nm.
WARNING
Use appropriate eye
working under the car.
protection
whilst
INT 01
SECTION 9 - INTERIOR & TRIM
FOUR-POINT HARNESS
31
The harness should be fitted after the seat
back carpet, tunnel carpets and boot cover have
been fitted (if specified). Locate the threaded
mounting holes in the top of the chassis, (refer
to Fig 4), and carefully cut away the material
covering the holes.
1
2
3
Bolt
Shoulder restraint
Crinkle washer
4
5
Bush
Plain washer
Fig 5 Shoulder strap with Track day roll over bar
(Shown with bolt loose)
1
2
3
4
5
6
Roll over bar mounting
Roll over bar locating recess
Drivers harness mounting
Passenger harness mounting
Chassis member
Inertia reel mounting
Fig 4 Mounting holes four-point harness upper
32
From the mounting kit supplied with the
harness, assemble a 7/16" UNF x 1 3/4" bolt,
plain washer next to the bolt head, and pass
through the broad shoulder strap, crinkle washer
and through the bush. Ensure the smaller
diameter of the bush is closest to the bolt head.
Screw the bolt into the harness mounting point,
refer to Fig 5.
33
To fit the outboard lap strap, assemble
a 7/16" UNF x 1" bolt, with a plain washer next
to the bolt head, pass through the outboard lap
strap crinkle washer, and through the bush.
Ensure the smaller diameter of the bush is
closest to the bolt head. Insert the bolt in the
threaded boss and tighten to 48 Nm refer to
Fig 6. Ensure lap strap buckle is uppermost.
NOTE
Use of a longer bolt to secure the outer lap strap
will result in damage to outer body side panel.
1
2
Buckle
Outboard lap strap
Fig 6 Outboard lap strap
INT 01
Section 9
Page 5
SECTION 9 - INTERIOR & TRIM
34
To fit the inboard lap strap, assemble
a 7/16" UNF x 1" bolt, with a plain washer next
to the bolt head, pass through the inboard lap
strap, crinkle washer, and through the bush.
Ensure the smaller diameter of the bush is
closest to the bolt head. Insert the bolt into the
threaded boss and tighten to 47 Nm, refer to
Fig 7. Ensure lap strap buckle is uppermost.
1
2
3
38
Insert the long 7/16” x 3” bolt upwards
through the floor pan and assembled spacers
detailed above. Secure in place using the plain
washers and nyloc nuts supplied. Tighten all
fixings to 61 Nm.
39
Fit the shoulder and lap straps as detailed
in Paras 31 to 34.
1
2
3
4
5
6
Outboard lap strap
Inboard lap strap
Buckle
Fig 7 Lap straps
SIX-POINT HARNESS
Standard floor
35
To fit the crutch strap drill an 11 mm hole
through the two crutch strap mounting points
located at the rear of the cockpit and through the
floor of the cockpit. Assemble an M10 x 25 bolt
with a plain washer next to the bolt head. Pass
the bolt through the hole in the crutch strap,
through the crinkle washer and top hat spacer,
down through the chassis mounting ensuring the
strap is offset downwards, and through the
cockpit floor. Secure the bolt in place using a
plain washer and nyloc nut. Tighten to 47 Nm.
Ensure the crutch strap fixing plate has the bend
facing the cockpit floor.
Lowered floor pan
Top hat spacer bush
Crinkle washer
Fixing eyelet
Aluminium spacer
Crutch strap fixing bracket
Fig 8 Crutch strap spacer location
SEATS
Standard cloth or leather seats
40
The adjustable seats are supplied
attached to the seat runner. Place the seat into
position over the underseat carpet (SV only) and
secure the front mountings by passing setscrew
(fastener pack ZSE03 Item 1) down through the
mounting and securing using plain washer (3)
and nyloc nut (2). Slide the seat fully forward
and pass setscrew (1) down through the rear
mountings and secure using plain washer (3)
and nyloc nut (2). Tighten the fastenings.
Low floor
36
Drill a 7/16” hole through the crutch strapfixing bracket then through the floor pan directly
below it.
37
Lay out the crutch strap to assure the
correct orientation and assemble the harness
eyelets and spacers, refer to Fig 8.
Section 9
Page 6
INT 01
SECTION 9 - INTERIOR & TRIM
Composite seats
Adjustable seat
41
Fit the runner with the adjusting handle to
the RH side of the seat with the handle facing
forwards and inboard of the runner. Secure the
front mounting using reduced head cap head
bolt (fastener pack ZSE06 Item 2) through the
round hole then through two thick spacers (8)
and into the threaded seat base. Secure the
rear with cap head bolt (2) through the square
hole, through 1 thick spacer (8) and 1 thin
spacer (7) and into the threaded seat base, refer
to Fig 9.
1
2
45
Secure the front mountings with bolt (2)
passed down through the runner and secure
under the floor using plain washer (5) and nyloc
nut (4).
46
Slide the seat fully forwards and pass a
bolt (2) down through the rear holes in the
runner and secure under the floor using plain
washer (5) and nyloc nut (4).
NOTE
If the car has a honeycomb floor, bolt (1) is
passed through the runner, through spacer (6)
and secured using plain washer (5) and nyloc
nut (4).
Spacers
Adjusting handle
Fig 9 Adjustable seat
42
Fit the LH runner in the same way
ensuring that the outer part of the runner is
towards the seat base. Secure using bolt (2),
one thick spacer (8) and one thin spacer (7) on
each fixing ensuring they are between the
runner and the seat.
Torque all fixings
to 14 Nm.
43
Ensure that the harness option specified
has been installed prior to fitting the seat. Place
the seat into position feeding the lap and
shoulder straps through the apertures in the seat
body and the crutch strap (if specified) through
the aperture in the seat base, refer to Fig 10.
Ensure that the harness straps are not twisted.
1
2
3
Composite seat
Six-point harness
Seat adjuster
Fig 10 Composite seat and six-point harness
44
On low-floor cars the seat adjusting
handle must pass beneath the square chassis
tube and through the aperture in the vertical
section of aluminium panel.
INT 01
Section 9
Page 7
SECTION 9 - INTERIOR & TRIM
Fixed seat
47
The fixed seat is bolted to the floor via
two 25 mm square section, aluminium tubes.
This tube has a series of cut-outs on one side
and plain holes in the opposite side. It is
important that this tube is fitted in the correct
orientation. The cut-outs must face away from
the seat base allowing flush fitment to the floor.
The large cut-out must be biased towards the
rear of the seat. Both tubes are identical and
are fitted in the same orientation, refer to Fig 11.
50
Secure the seat with bolts (2) and plain
washers (5) passed upwards through the floor
into the threaded bosses in the aluminium tubes.
MINOR TRIM ITEMS
Scuttle edge trim
51
This strip (chassis kit) is designed both to
finish off the scuttle around the dashboard tidily
and to protect the occupants from the hard
aluminium edge. Cut the trim to length and
secure by firmly pushing the trim into place by
hand. The scuttle edge trim is an SVA
requirement, refer to Section 15.
Nose badge
52
The circular nose badge (polythene bag
marked 'miscellaneous') is mounted on the nose
cone of the vehicle. It is self adhesive but has
two locating dowels. Before removing the paper
to reveal the adhesive on the underside of the
badge, carry out a trial fit to ensure the badge
will sit square. It may be necessary to remove
the paint from the pre-drilled holes on the nose
cone before fitting the badge.
1
2
Large recess
Spacer
Fig 11 Fixed seat
48
Position the square section aluminium
tubes on the seat base and pass bolt (fastener
pack ZSE05 Item 2) through the large hole in the
underside of the spacer and into the small hole
opposite, through one thick spacer (8) and into
the threaded seat base. Torque all fixings
to 14 Nm.
NOTE
If a track day roll over bar and Petty strut is
installed, the seat can reclined slightly by
replacing the front fixing with bolt (1) and
additional thick plastic spacers (8) on each side
at the front, between the seat base and the
aluminium tube.
REAR VIEW MIRROR (INTERIOR)
53
The centre mounted mirror is a legal
requirement and must be fitted. The mirror has
a self adhesive pad and should be stuck as high
as possible on the interior of the windscreen on
the centre line of the car. Prior to removing the
paper backing from the self adhesive pad
ensure the area where the mirror is to be placed
has been thoroughly cleaned using an alcohol
based degreaser. Note that the mirror can be
inverted on its stalk to minimise windscreen
obstruction.
54
On Superlight models without a
windscreen, the mirror must be secured to the
scuttle top on the centreline of the vehicle.
Ensure that the area where the mirror is to be
placed has been thoroughly cleaned using an
alcohol based degreaser.
49
Ensure that the harness option specified
has been installed prior to fitting the seat. Place
the seat into position feeding the lap and
shoulder straps through the apertures in the seat
body and the crutch strap (if specified) through
the aperture in the seat base, refer to Fig 4.
Ensure that the harness straps are not twisted.
Section 9
Page 8
INT 01
SECTION 9 - INTERIOR & TRIM
1
2
3
4
Rear bulkhead carpet
Footwell carpet
Tunnel carpet
Tunnel top
Fig 12 Completed interior
NOTE
Items may differ from those shown, dependant
on the chosen specification.
INT 01
Section 9
Page 9
PAGE INTENTIONALLY BLANK
SECTION 10 - FIBREGLASS
TABLE OF CONTENTS
Para
1
16
20
Page
Cycle wings (Warnings) (Caution)..............................................................................
Rear wing protectors (stone guards) .........................................................................
Rear wings .................................................................................................................
2
3
4
Cycle wings................................................................................................................
2
Indicator repeater wiring.............................................................................................
Rear wing protector piping .........................................................................................
Rear wing fitment .......................................................................................................
Wing piping ................................................................................................................
Rear wing...................................................................................................................
3
3
4
4
5
Table
1
Fig
1
2
3
4
5
FIB 01
Section 10
Page 1
SECTION 10 - FIBREGLASS
CYCLE WINGS
1
Cycle wings are supplied in two sizes;
these are dependant upon wheel size. Ensure
wheels and cycle wings are compatible, refer to
Table 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 cycle
wing. This is an SVA requirement, refer to
Section 15.
3
It is easier to fit the front indicator
repeaters to the cycle wings prior to fitting them
to the cycle wingstay. Dismantle the repeater
assemblies removing and retaining both bulb
and lens. Remove the studs in the base and
discard.
WARNINGS
(1)
Use appropriate eye protection whilst
carrying out drilling operations.
(2)
Use a suitable face mask to prevent
inhalation of dust when drilling fibreglass or
carbon fibre.
CAUTION
When drilling fibreglass use tape on the
surface over the drill holes to prevent
damage to the gel coat or painted finish.
Slow drill speeds must be used.
4
Drill through the cycle wing at the premarked points using a 5 mm drill. Then enlarge
the centre hole to 15 mm.
5
Feed the repeater wire through the cycle
wing from the outside then secure the base
using screws (fastener pack 30L002A) and nyloc
nuts. Replace the bulb and repeater lens.
7
The front cycle wings bolt to the tubular
wingstays which are rigidly mounted to the front
uprights.
8
Fit the front wheels ensuring that the
steering rack is centred. Place the cycle wing
over the wingstay so that the bolt holes are over
the centre line of the forward wingstay tube such
that the wing overhangs evenly on either side of
the tyre. The wing can be held in position using
masking tape. It is possible that the wingstay
will need to be bent to allow the cycle wing to fit
centrally over the tyre. Mark the positions for
the bolt holes onto the wingstay.
9
Remove the cycle wing and with the tyre
protected centre punch the wingstay. Drill the
holes through the wingstay using a 6 mm drill.
Ensure that the drill cannot contact the tyre.
10
Drill an additional hole in the underside of
the front wingstay near the open end using
a 5/32” drill. Remove all sharp edges on the
inside and outside of the wingstay tube.
11
Loosely fit the cycle wing to check the
alignment of the cycle wing and wingstays
relative to the tyre. The cycle wing should be
checked to ensure that it is centrally located
over the tyre. Remove the cycle wing. Place a
strip of masking tape across the tyre underneath
the drilled wingstay. Using a ruler held at 90 to
the surface of the tyre, mark the lateral positions
of the two holes. Rotate the wheel so that the
masking tape is under the rear tube of the
wingstay and transfer the bolt hole position to
the wingstay tube. Centre punch and drill using
a 6 mm drill as for the front holes.
12
Refit the cycle wing, loosely bolting it at
the front and aligning it over the tyre and then
carefully remove the wheel without disturbing
the wing. Masking tape can be used to hold the
wing in place. Carefully mark the underneath of
the wing with the bolt hole positions and then
remove the wing. Drill a small pilot hole from
underneath the cycle wing, taking care not to
damage the gel coat/painted surface. Check
alignment of the holes with the wingstays,
adjusting if required, then drill through from the
top of the cycle wing with a 5 mm drill.
6
The cycle wing will have been marked
with the positions for the front two mounting
bolts for each wing. These should be drilled
through using a 5 mm drill.
Section 10
Page 2
FIB 01
SECTION 10 - FIBREGLASS
13
Place a strip of self adhesive foam
(fastener pack ZFG12 Item 7) on the top of each
cycle wingstay tube. Cut two rubber grommets
in half to provide four rubber washers. Pass
screw (5) through the manufactured washers
and down through the cycle wing and wingstay.
Secure using washers (4) and nyloc nuts (2).
Tighten until the rubber washer is slightly larger
than the screw head. The black wire from the
indicator repeater is the earth lead and should
be attached to the front wingstay using a poprivet in the 5/32” hole drilled at Para 10.
Remove paint to ensure a good contact.
14
Route the green wire from the indicator
repeater inside the wingstay until it emerges
from the pre-drilled hole near the wingstay
brace. From the wingstay the wire must be
routed along the rear of the upper wishbone ball
joint, and the upper wishbone. Secure using
small cable ties at 50 mm intervals, refer to
Fig 1.
REAR WING PROTECTORS (STONE
GUARDS)
NOTE
It is advisable to fit the wing protectors to the
wings before fitting the wings to the car. Once
the wings are fitted there is very little clearance
between bodywork and drill chuck when drilling
holes for the inner row of rivets.
16
The wing piping (fastener pack ZWS01 or
ZWS02 (option) Item 2) fits between the rear
wing protector and the rear wing. Cut the piping
to length and fit around the top, outer and lower
edges of the wing protector so the bead is
against the edge of the protector. 'V' shaped
notches (refer to Fig 2) should be cut to allow
the piping to smoothly follow the shape of the
protector. Position the piping under the
protector, ensure correct orientation of the
protector (refer to Fig 3) and drill through the
existing holes into the piping with a 1/8" drill.
NOTE
To comply with SVA requirements the green
repeater wire must be covered with heatshrink
sleeving.
1
2
3
'V' shaped notch
Wing piping
Holes
Fig 2 Rear wing protector piping
1
2
Upper wishbone 3
Front wingstay 4
Repeater wire
Wingstay brace
Fig 1 Indicator repeater wiring
15
Once inside the aluminium body skin the
green wire should be fitted into the 6 pin
econoseal plug. It is recommended that this
connection is made at the same time as the
headlamp and indicator wiring, refer to
Section 11.
FIB 01
17
The wing protector should be placed on
the lower front of the rear wings. The correct
position can be obtained by placing the lower
angled edge approximately 5 mm up from the
lower edge of the wing and the inboard side of
the protector tight up against the inboard side of
the wing (the side of the wing that bolts to the
car).
NOTES
(1)
The protectors are supplied flat so will
need to be gently shaped to follow the contour of
the wing.
(2)
The protective film on stainless steel wing
protectors should be removed from around the
rivet heads before fitting. The protected side
faces outward.
Section 10
Page 3
SECTION 10 - FIBREGLASS
(3)
The LH wing protector is shorter than
the RH protector to allow for the cut away
section at the bottom of the LH wing. Both LH
and RH protectors should be fitted equidistant
from the bottom of the respective wing to ensure
the tops of both protectors are the same height
on the car.
18
Position the protector on the rear wing
and mark one of the corner holes. Ensure
correct spacing and orientation. Drill the hole
using a 1/8" drill. Fit the rear wing piping into
position under the protector and rivet into
position using rivet (1).
NOTE
Carbon fibre wing protector uses black rivets
and the stainless steel wing protector uses plain
rivets.
19
Attach the wing protector working
outwards, one rivet at a time, from the corner
ensuring that the wing piping is in the correct
position. Drill 1/8" holes and attach using
rivets (1).
REAR WINGS
20
The rear wings are provided pre-drilled
with both the wing fixing holes and further holes
for the suspension arms. To enable the wing to
be fitted to the car you will need to trim out the
fibreglass from the larger holes to enable fitment
over the radius arm or Watts link arms, refer to
Fig 3). The wings are supplied in this way to
maintain their strength prior to them being fitted
to the car. An alternative fixing method would be
to remove the suspension arms then refit them
once the wing is secured in place.
1
2
Rear wing fixings
Rear wing
Fig 3 Rear wing fitment
21
Offer the rear wing up to the side of the
car and bolt in place using a setscrew (fastener
pack ZFG12 Item 1) and plain washers (3) into
rivnuts at the front of the rear wing and bolts (1),
plain washers (3) through the rear of the wing
and secured using plain washers (3) and nyloc
nuts (2). The setscrews used to secure the rear
upper section of the wing should be passed
through the body from inside the boot. Loosely
fit all fasteners.
22
Wing piping (6) is provided to fit between
the rear wing and the car body. The wing piping
should be positioned against the rear wing and
cut to length. The wing piping has six ribs
running longitudinally. 'V' shaped notches, refer
to Fig 4, should be cut to the sixth rib to allow
the piping to smoothly follow the curve of the
rear wing. Where the wing mounting bolts
occur, rectangular shapes should be cut to the
fifth rib to accommodate.
1
2
3
Wing piping
'V' shaped notches
Rectangular notches
Fig 4 Wing piping
Section 10
Page 4
FIB 01
SECTION 10 - FIBREGLASS
23
Secure the rear wing ensuring that the
bead of the wing piping is protruding. Do not
over tighten fixings, refer to Fig 5.
1
2
Piping between wing and panel
Piping on three sides of wing protector
Fig 5 Rear wing
FIB 01
Section 10
Page 5
PAGE INTENTIONALLY BLANK
SECTION 11 - LIGHTING
TABLE OF CONTENTS
Para
1
3
13
14
16
24
25
28
30
Page
General ......................................................................................................................
Headlights and front indicators...................................................................................
Front indicator repeaters ............................................................................................
Front wiring electrical connections .............................................................................
Rear lights (Warnings) (Caution)................................................................................
Reversing light and fog light.......................................................................................
Rear number plate light..............................................................................................
Testing ......................................................................................................................
Headlight beam setting ..............................................................................................
2
2
2
3
3
4
4
4
4
Front lighting wiring connections................................................................................
Rear lighting wiring connections ................................................................................
3
4
Headlight and indicator LH.........................................................................................
2
Table
1
2
Fig
1
LTG 01
Section 11
Page 1
SECTION 11 - LIGHTING
GENERAL
1
The lighting kit includes all the parts
needed to make the car comply with the lighting
requirements of SVA. It is imperative that these
instructions are adhered to in order to fulfil the
legal requirements of the lighting.
NOTE
Ensure that the locating tang on the headlight
shell engages with the recess in the mounting
stud.
2
If fitted, remove the lead from the battery
negative terminal.
HEADLIGHTS AND FRONT INDICATORS
3
The headlight brackets will have been
fitted during assembly of the front suspension.
4
Fit a length of edge strip (polythene bag
'SVA') to the underside edge of the indicator
cone. It is an SVA requirement that the edge
strip covers the entire edge of the mounting
cone, including the portion directly beneath the
lens.
5
Remove the lens from the front indicator.
Ensure that the drainage hole on the indicator
seal is at the bottom, line up the holes in the
indicator base with the holes in the indicator
cone and secure using three setscrews (fastener
pack 30L002A Item 3) and nyloc nuts (6). Do
not over tighten. Replace the lens.
6
Tighten the two grub screws securing
each headlight bracket into the chassis. Tighten
to 7 Nm.
7
Remove the headlight rim by undoing the
clamping screw located on top of the headlight
bowl and unhooking the lens from the headlight
bowl. Remove the plug from the back of the
headlight bulb and remove the sidelight housing
from the reflector.
8
Remove the securing nut and lock washer
from the headlight mounting stud and smear a
thin layer of oil to the thread. Insert the
headlight harness and headlight mounting stud
through the indicator cone and into the headlight
bracket.
9
Refit the headlight securing nut and lock
washer and tighten until the headlight unit
cannot move freely, this will aid assembly
however these nuts will need to be slackened off
to allow the headlights to be correctly adjusted,
refer to Fig 1.
Section 11
Page 2
1
2
3
4
Headlight unit
Headlight bracket
Indicator cone
Indicator
Fig 1 Headlight and indicator LH
10
Pass the black indicator earth wire
(terminated in a ring terminal) through the hollow
headlight unit mounting stud and secure to the
earth screw at the base of the headlight unit.
Pull excess wire into headlight unit.
11
Refit the sidelight housing into the
reflector and refit the plug to the headlight bulb.
Hook the bottom of the headlight rim into the lip
on the headlight bowl and swing the headlight
rim up into position. Secure using the clamping
screw.
12
Feed the headlight wiring and the green
indicator wire through the hollow headlight
bracket so that it exits into the engine bay.
FRONT INDICATOR REPEATERS
13
The front indicator repeaters are fitted at
the same time as the front cycle wings, refer to
Section 10.
LTG 01
SECTION 11 - LIGHTING
FRONT WIRING ELECTRICAL
CONNECTIONS
CAUTION
14
Locate the 2 loose econoseal plugs
supplied in the chassis pack (2 part black plug
and yellow insert). Take the six wires (the sixth
wire is the indicator repeater wire which may not
be fitted at this point) and push them into the
back of the loose black plug ensuring that the
connections click into place. If they do not
o
locate correctly turn them through 180 and try
again. Refer to Table 1 for the correct terminal
position within the connector.
TABLE 1 FRONT LIGHTING WIRING
CONNECTIONS
Function
Wiring loom
colour
Light unit wire
colour
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 been
fitted and all the connections have been located
into the plug fit the yellow insert into the front of
the plug. Connect the plug to the wiring loom
and secure the cables to the chassis.
REAR LIGHTS
16
The kit includes two identical rear light
assemblies which comprise of tail, brake and
indicator lights. They are mounted on rubber
blocks which ensure that the lights are vertical
when fitted and are secured with four
self-tapping screws. Turn one light unit around
on the rubber block and ensure that the amber
indicator lens is on the outside.
WARNINGS
(1)
Use appropriate eye protection whilst
carrying out drilling operations.
When drilling fibreglass use tape on the
surface over the drill holes to prevent
damage to the gel coat or painted finish.
Slow drill speeds must be used.
17
The rear wings have been pre-drilled with
two holes for the rear light assemblies. The
outermost hole has been drilled to 30 mm and
this 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 light
assemblies along with the bulbs noting that the
indicator uses a single filament bulb and the
brake light uses a double filament bulb.
NOTE
The rear light assemblies are not ‘handed’. One
of the metal baseplates must be inverted to
create a LH/RH pair with the indicator fitting to
the outside edge of each light.
19
Using the metal baseplate as a guide, drill
a 4 mm hole through the rubber block in each
corner. Ensure that the drill is kept at 90 to the
baseplate.
20
Feed the electrical wiring and the
econoseal plug through the 30 mm hole
ensuring that the grommet is passed through the
hole. Attach the rear light unit at the lower
inboard corner using screw (2). Do not over
tighten.
Ensure that the rear light unit is
horizontal and drill through the rear light unit into
the rear wing. Remove the light unit. Clear
away the swarf and refit the light unit using
screws (1) on the upper holes and screws (2) on
the lower holes. Do not over tighten. Replace
the bulbs and lens cover ensuring correct
orientation of the lens cover (indicator to the
outside).
21
Connect the econoseal plug to the
corresponding socket protruding from a hole
inside the rear wing. Ensure that the plugs are
correctly mated and push the plug inside the
rear side panel. Fit the grommet to the hole in
the body side panel.
(2)
Use a suitable face mask to prevent
inhalation of dust when drilling fibreglass or
carbon fibre.
LTG 01
Section 11
Page 3
SECTION 11 - LIGHTING
22
For reference the rear
connections are detailed in Table 2.
electrical
TABLE 2 REAR LIGHTING WIRING
CONNECTIONS
Function
Wiring loom
colour
Light unit wire
colour
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 using
cable ties.
REVERSING LIGHT AND FOG LIGHT
24
The reversing light and the fog light are
fixed to the rear panel and the wiring
connections have been made at the factory.
REAR NUMBER PLATE LIGHT
25
Remove and retain the cross-point screw
retaining the light cover and lens; remove and
retain the cover and lens. Remove and retain
the two nuts and spring washers from the metal
baseplate.
26
Pass the wire from the chassis loom
through the RH upper hole of the light bracket
on the chassis and through the back of
baseplate. Fit the baseplate to the bracket and
secure with the nuts and spring washers. Ensure
that the baseplate studs earth to the bracket
through the nuts (remove paint from the bracket
as necessary).
NOTE
Cars that are not supplied with a spare wheel
bracket will be pre-fitted with a number plate
light bracket located below the lower chassis
tubes.
27
Remove and discard the two brass bullet
connectors supplied in the light. Shorten the wire
to a convenient length, strip back sufficient
insulation and attach (crimp) a male bullet
connector. Insert the bullet connector into the
central 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 check
that the bulbs have not been damaged during
transit and replace as necessary. If the problem
persists check every earth point on the chassis
both on the wiring loom and the battery earth
lead. If the problem is related to a particular
system or side, check the fuse box located
under the dashboard in the passenger side of
the cockpit further information on fuse
identification can be found in your Owner's
Handbook.
HEADLIGHT BEAM SETTING
30
If possible the headlight beam setting
should be carried out using professional
equipment; if such equipment is not available,
proceed as detailed below:
30.1
Position the car on a firm level
surface, 2 m from a vertical surface
(measured from the front edge of the
lower lip of the nose cone). Slacken the
headlight securing nuts and switch on the
lights (dipped). Adjust the lights until the
brightest spot of each light pool (at the
apex of the dip-beam cut-off) is 650 mm
above the ground.
30.2
Measure the distance between
the centres of the headlights on the car
and the distance between the centres of
the bright spots on the wall. Adjust the
headlights as necessary until the two
measurements are approximately the
same. When alignment is satisfactory, recheck the vertical measurement and
tighten the headlight securing nuts.
30.3
The alignment will be tested and
adjusted during the post build check. If the
car is not being submitted for a post build
check, we strongly advise kit builders to
get the headlights professionally adjusted.
Section 11
Page 4
LTG 01
SECTION 12 - WEATHER EQUIPMENT
TABLE OF CONTENTS
Para
1
3
7
11
21
23
25
33
42
Page
General ......................................................................................................................
Fitting of hoodsticks and hoodstraps..........................................................................
Hood fitting.................................................................................................................
Sidescreen fitment (Warning).....................................................................................
Exterior mirrors
Fitment to screen stanchion ...............................................................................
Fitment to side screens ......................................................................................
Boot cover .................................................................................................................
Tonneau cover ..........................................................................................................
Correct usage of fastener fixing tool...........................................................................
2
2
3
3
Additional tools...........................................................................................................
2
Weather equipment....................................................................................................
Hoodstick spacing......................................................................................................
Hoodstrap fixing .........................................................................................................
Hood side fasteners ...................................................................................................
Hinge and sidescreen fitting.......................................................................................
Sidescreen straps ......................................................................................................
SVA mirror stalk adaptor ............................................................................................
Mirror fitted to sidescreen...........................................................................................
Boot cover..................................................................................................................
Forward fastener boot cover ......................................................................................
Tonneau cover ...........................................................................................................
Tonneau cover positioning .........................................................................................
Tonneau cover fasteners (front).................................................................................
Durable Dot fastener tool ...........................................................................................
2
2
3
3
3
4
5
5
5
6
6
7
7
8
4
5
5
6
8
Table
1
Fig
1
2
3
4
5
6
7
8
9
10
11
12
13
14
WET 01
Section 12
Page 1
SECTION 12 - WEATHER EQUIPMENT
GENERAL
1
This section explains how to perform the
initial fitment of the weather equipment, the tool
identified in Table 1 will be required. However, if
the specification for your car included hood
fitment then instructions on how to refit, remove
and fold for storage can be found in your
Owner's Handbook.
5
Before fitting the hood you must first
secure the rearward part of the hoodstick in the
correct position. Measure distance A from the
top surface of the rear chassis tube to the centre
of the rear hoodstick to obtain the correct
positioning (standard chassis 395 mm or
SV 420 mm), refer to Fig 2.
TABLE 1 ADDITIONAL TOOLS
Item
Durable Dot Fastening
Tool
Description
Part No. 76068 (supplied
in fastener pack ZBC02)
2
Correctly fitted weather equipment is
shown in Fig 1.
Fig 2 Hoodstick spacing
Fig 1 Weather equipment
FITTING OF HOODSTICKS AND
HOODSTRAPS
NOTE
Whichever option of roll over protection has
been specified must be fitted before the
hoodsticks.
6
Drill two 7/64” holes into the upper
chassis tube, one either side, on the inside rear
edge of the boot, opposite the outermost popper
base (145 mm from the roll cage mounting lug).
Make a small hole in the loose end of each
hoodstrap and using the two self-tapping screws
(fastener pack ZWE05 Item 10) and washers, fix
the straps to the rear panel on the inside of the
top chassis rail, refer to Fig 3.
NOTES
(1)
With the hoodstraps taut, check the
position of the rear hoodstick, as this will affect
the tension of the hood when finally adjusted.
(2)
For a neater appearance, popper bases
may be used with the self-tapping screws used
to secure the hoodstraps.
3
Remove the inner hoodstick from the
hoodstick assembly and feed the end loop of
hoodstraps over the front hoodstick and loop in
the centre of the hoodstraps over the rear
hoodstick ensuring that the adjusting buckle
faces downwards when the hoodsticks are erect,
refer to Fig 2.
4
Reassemble the hoodstick assembly and
attach to the triangular brackets on the chassis
using the fixings provided. Ensure that one plain
washer is fitted under the head of the screw and
the other between the fixing bracket and the
hoodstick.
Section 12
Page 2
WET 01
SECTION 12 - WEATHER EQUIPMENT
1
2
3
4
5
Screw
Washer (or popper base)
Hoodstrap
Rear body skin
Chassis tube
Fig 3 Hoodstrap fixing
HOOD FITTING
7
With the hoodsticks in the upright position
and the adjusting buckle fully slackened, drape
the hood over the car and attach it to the
windscreen with the pre-fitted fasteners. Start
with the two outer most fasteners and ensure
that the felt seal is correctly located along the
top face of the windscreen frame.
8
Move to the rear of the car and attach the
back of the hood again with the pre-fitted
fasteners.
1
2
3
Hoodsticks
Popper base
Rear wing
Fig 4 Hood side fasteners
SIDESCREEN FITMENT
13
Using the setscrews (5) and nyloc
nuts (13) attach the sidescreen hinges to the
outside of the windscreen stanchions with the
eyelet towards the rear of the car, refer to Fig 5.
Fit the brass hinge pins (8) into the 4 remaining
hinges. Now slide the hinges with the pins fitted
into the top of hinges attached to the car.
NOTE
SV sidescreens hinges are now supplied with
pre-fitted hinge pins.
9
Tension the hood by adjusting the
hoodstraps until the front hoodstick is in line with
the stitched darts in the hood. Use the Velcro
lined sleeve stitched to the inside of the hood to
capture the front hoodstick as this will ensure
that it is correctly adjusted.
10
The front popper base for the side of the
hood can now be fitted. To do this pull the side
of the hood down and assess the approximate
position for the popper base. Apply several
layers of masking tape to this area.
11
Pull the side of the hood down again and
press on the fastener to create an imprint in the
masking tape. Drill a 3/32” hole through the
centre of the impression, remove the tape and
secure a popper base using a self-tapping
screw.
Fig 5 Hinge and sidescreen fitting
12
Repeat the above procedure for the
remaining popper bases along the cockpit and
boot sides, refer to Fig 4.
WET 01
Section 12
Page 3
SECTION 12 - WEATHER EQUIPMENT
14
The sidescreen is constructed using a
steel frame around the window section. This is
covered with the vinyl which continues away
from the frame giving a soft flexible area of
about 35 mm around the outside. The correct
position for the sidescreen is with the soft part at
the top tucked up between the two parts of the
hood that make up the seal along the top of the
door aperture and the soft area towards the front
tucked inside the stanchion. The lower rear
radius of the sidescreen should follow the lower
edge of the hood and the metal frame at the top
should be just below the top of the door
aperture.
15
With the hood still fitted and correctly
tensioned, offer up the sidescreen into position
and mark the position of the four fixing holes.
(For ease of marking it may help to run a strip of
masking tape down the front edge of the
sidescreen).
WARNING
Use appropriate eye protection
carrying out drilling operations.
whilst
16
Next remove the sidescreen and place it
on a solid surface and protect the window from
damage caused by swarf before drilling the
holes for the fixings. The metal frame inside the
sidescreen is very hard so it is advisable to
centre punch and drill through with a 3 mm pilot
hole then finally with a 5 mm drill to enable
fitment of the hinge.
1
2
Sidescreen
Vinyl strap
Fig 6 Sidescreen straps
NOTE
Optional arm restraints are available. If these
have been specified on your car then only the
top strap is required to locate the sidescreen.
20
Attach a popper base (2) using rivet (1).
Next pull the strap down over the popper base
and mark the centre to position the fastener.
Whilst doing this ensure the sidescreen is pulled
tight up against the body of the car to reduce
draughts and water ingress. Fix a fastener to the
marked position on the strap using the durable
dot tool, refer to Para 41. Repeat this process
for all fixing straps.
EXTERIOR MIRRORS
17
Remove the top part of the hinges from
the chassis and secure them to the outside of
the sidescreen, using setscrew (5) and nyloc
nut (13), with the pin towards the front and
pointing downwards. Fit SVA covers to the nuts
on the inside of the sidescreen and fit SVA
protectors to the non-chamfered ends of the
hinge halves, refer to Fig 7 and Section 15.
NOTE
After the SVA inspection, the mirrors may be
fitted to the side screens but in order to pass
SVA inspection, the mirrors must be fitted to the
windscreen stanchions.
Fitment to screen stanchion
18
Refit the sidescreen by sliding the pins
down into the hinges on the car. With the
sidescreen closed, tuck the top in between the
flap of the hood.
19
Each sidescreen is held shut by two vinyl
straps and fasteners. From inside the car, pull
the straps in over the top edge of the chassis
and mark the place for the fastener base. Drill
a 7/64" hole in line with the rivets holding the
side panel in place. (You will be drilling into a
round tube so care should be taken to avoid the
drill wandering as it hits the tube).
Section 12
Page 4
21
Remove and retain the central, slot-head
screw, in the screen stanchion and screw in the
SVA mirror stalk adaptor, refer to Fig 7. Fit a
fibre washer and the mirror stalk over the
adaptor and tighten the grubscrew to secure the
stalk (ensure that the large recess in the stalk
faces rearwards).
WET 01
SECTION 12 - WEATHER EQUIPMENT
1
2
Mirror
Hinges
3
4
Screen stanchion
Sidescreen
Fig 8 Mirror fitted to sidescreen
24
Plastic M5 caps (polythene bag marked
'SVA') should be fitted to the nuts securing the
mirror to the sidescreen. These can be secured
in place using a little silicone sealant.
BOOT COVER
1
2
3
SVA protector (1/2 grommet)
Mirror stalk adaptor
Hinge
25
When correctly fitted, the boot cover
should be as shown in Fig 9.
Fig 7 SVA mirror stalk adaptor
22
Remove the mirror head from the original
stalk noting the relationship of all parts.
Assemble the mirror head to the SVA stalk and
adjust as required (retain the remains of the
original mirror for use post-SVA).
Fitment to side screens
23
Exterior mirrors are fitted to the
sidescreens, towards the front, just below the
clear window panel. Locate the holes pre-drilled
in the metal frames (approximately 130 mm from
front corner and 104 mm apart) then drill through
the material with a sharp 5 mm drill. Attach the
mirrors to the hidden metal frame of the
sidescreen using the countersunk screws (6),
washers (14) and secure with nyloc nuts (13).
WET 01
Fig 9 Boot cover
26
The boot cover is designed to attach
permanently to the top of the bulkhead behind
the seat and clip onto the same fasteners as
those provided for the hood at the rear of the
car. It is designed to fit over the hoodsticks
when not in use therefore it is essential that
these are fitted prior to fitting the boot cover.
When the hood is erected, the boot cover is
folded away and stored in the boot.
Section 12
Page 5
SECTION 12 - WEATHER EQUIPMENT
27
The boot cover is designed to fit around
the roll bar, since these vary according to
specification, ensure the correct boot cover has
been supplied. There is a special boot cover
designed for use with the roll cage.
NOTE
For cars fitted with harness type seat belts go to
Para 29.
28
All boot covers have a metal insert along
the forward edge, with pre-drilled holes to locate
the fastener bases. The forward edge of the
boot cover should align with the front edge of the
seat bulkhead. Ensure that the boot cover is
centrally located and mark the holes through the
forward edge of the boot cover. Drill a 7/64”
hole through each marked location and fit a
popper base (fastener pack ZBC02 Item 5)
secured with a self-tapping screw (6).
1
2
3
Popper base
Boot cover
Fastener socket
Fig 10 Forward fastener boot cover
TONNEAU COVER
33
When correctly fitted the tonneau cover
should be as shown in Fig 11.
29
If harness type seat belts are being fitted
the metal insert in the boot cover must be
removed. Align the boot cover as previously
described and mark the location of the four
threaded bosses. Punch a hole in each of the
marked locations and fit the harness shoulder
strap securing bolts through the boot cover, refer
to Section 9.
30
Additionally fit four fasteners (5) using
screws (6) in the following locations; one
fastener 1 1/4" either side of the car centreline
and one fastener at the midpoint between each
pair of shoulder restrains. If a tonneau cover is
to be fitted, the position of the fasteners will
have to be adjusted accordingly.
31
Stretch the boot cover over the luggage
area. Secure around the rear stays of the
roll over bar using the Velcro and establish
locations for the remaining fasteners (boot cover
fastens to the hood fastenings on the body). Fit
the popper bases (3) and buttons (4) starting
from the rear centre working outwards and then
forwards.
32
If a tonneau cover is to be fitted then the
forward button on each side is substituted by a
popper base (fastener pack ZTC01 Item 6),
assembled as shown in Fig 10 and fitted to the
fastener socket (4) using the punch provided (for
correct usage of fastener fixing tool refer to
Para 42).
Section 12
Page 6
Fig 11 Tonneau cover
34
Before the tonneau cover can be fitted
both the boot cover and seat belts must be
installed and the detachable head restraints
must be removed. The tonneau cover should be
fitted with the steering wheel in place. However,
if a Quick Release (QR) column has been
specified to function as an anti theft device and
is intended to be removed when the car is
unattended then this should also be removed
prior to fitting the tonneau.
35
Carefully align the tonneau along the
centre line of the car and stretch it so that there
is about 25 mm of tonneau ahead of the
fasteners fitted to the centre of the scuttle. Mark
and fit two fasteners (4) and buttons (5) in the
tonneau to correspond with these fasteners.
WET 01
SECTION 12 - WEATHER EQUIPMENT
36
Carefully measure the positioning of the
rear edge of the tonneau relative to the fastener
bases securing the front of the boot cover
ensuring that the rear edge of the tonneau is
exactly parallel to the seat bulkhead and it is
properly centred, refer to Fig 12. Mark the
position of the fastener bases and fit the six
fasteners (4) and buttons (5) across the back. It
is important that these fasteners are located
correctly as these set the correct tension for the
whole cover. It should not be stretched so tight
that it puts tension on the fittings, bearing in
mind it will not stretch so well in cold weather,
nor so loose as to allow water to collect on it.
1
Windscreen support
Fig 13 Tonneau cover fasteners (front)
38
Mark and drill a 5/32" hole and fit a further
fastener (3) securing with rivet (1) 38 mm below
the rear lower edge of the scuttle, 19 mm
rearward of the centreline of the large scuttle
securing rivet. Stretch the tonneau and secure
with a fastener (4) and button (5).
39
Mark, drill a 5/32" hole and fit a further
fastener (3) securing with rivet (1) 50 mm down
from the top rear of the sill and 45 mm forward
of the wheel arch. Pull down the tonneau and
secure with a fastener (4) and button (5).
1
2
Tonneau cover
Boot cover
Fig 12 Tonneau cover positioning
37
Starting with the passenger side, mark
and drill a 5/32" hole and fit a further fastener (3)
securing the rivet (1) on the scuttle 45 mm
inward from the lower edge of the windscreen
support where it joins the triangular base, refer
to Fig 13. Stretch the tonneau carefully into
position taking care to pull the tonneau far
enough forward to achieve a little clearance in
front of the rear wing, mark and drill a 5/32" hole
and fit a further fastener (3) securing with a
rivet (1). Fit a fastener (4) and button (5) in the
tonneau to correspond.
WET 01
40
Unzip the tonneau when fitting the
fasteners to the driver's side, leaving the rear
fasteners in place along the seat bulkhead.
Repeat the fitting procedure as per the
passenger's side taking care to stretch the
tonneau away from the vehicle centreline,
towards the windscreen stanchion just sufficient
to prevent bagginess in front of the steering
wheel.
41
Fastening the zip will correctly tension the
tonneau.
NOTE
If a roll cage is fitted, additional fasteners must
be fitted to the body to match the tonneau cover
fasteners on either side of the Velcro-fastened
splits for the roll cage forward supports.
Section 12
Page 7
SECTION 12 - WEATHER EQUIPMENT
CORRECT USAGE OF FASTENER FIXING
TOOL
42
The fastener tool, Fig 14, consists of two
parts; the dished base part and the punch.

Place the base on a solid surface dished
side upwards.

Put the fastener button through the material
and rest it in the dished part of the base.

Then place the fastener socket over the
tube part of the button so that the cupped
section is facing upwards.

Place the punch on the end of the tube and
hit it with a hammer until the tube has
peened over gripping the two parts together.
1
2
Punch
Dished base
Fig 14 Durable Dot fastener tool
Section 12
Page 8
WET 01
SECTION 13 - WHEEL FITMENT
TABLE OF CONTENTS
Para
1
5
Page
Wheel fitment (Warning) ............................................................................................
Spare wheel fitment ...................................................................................................
2
2
Spare wheel mounting items......................................................................................
2
Fig
1
WHL 01
Section 13
Page 1
SECTION 13 - WHEEL FITMENT
WHEEL FITMENT
WARNING
Re-tighten wheel nuts after 200 miles.
1
Some Caterham supplied alloy wheels are
fitted with steel inserts enabling secure
tightening of the wheel nuts. The wheel nuts
can settle into the wheels over the first few
hundred miles causing loss of torque so should
be re-tightened to the correct torque after
approximately 200 miles.
7
Assemble the spare wheel bolt (4), fibre
washer (3) (located in polythene bag marked
'miscellaneous') and spacer (polythene bag
marked 'spare wheel') (5). Secure the spare
wheel to the car using the assembled spare
wheel bolt through the centre of the mounting
wishbone. Ensure wheel nuts and spare wheel
mounting bolt are tight.
8
Fit the wheel centre cap as detailed in
Para 4.
2
Many of the tyres supplied by Caterham
are directional. Check that the tyre orientation is
correct before fitting the wheel to the car.
3
Fit the wheel using the wheel nuts
provided ensuring that the cone on each wheel
nut is correctly located in the wheel. The wheel
nuts should not be over tightened. It is
recommended that they are tightened whilst the
car wheels are on the ground. Tighten wheel
nuts to 74 Nm.
4
Fit the wheel centre caps as follows:

13", 14" and 15" wheels. Place wheel
centre cap into wheel and push fully home
ensuring correct seating.

16" wheels. Align securing screw in wheel
centre cap with corresponding thread insert
in the wheel and secure using the tool
provided. Place wheel centre cap badge
into the wheel centre cap and push fully
home ensuring correct seating.
SPARE WHEEL FITMENT
NOTE
1
2
3
4
5
Mounting wishbone
Wheel nuts
Fibre washer
Spare wheel bolt
Spacer
Fig 1 Spare wheel mounting items
NOTE
13" wheels fitted with low profile tyres are
secured to the spare wheel boss using a single
bolt and spacer located through one of the
wheel stud holes.
If specified for your kit, the spare wheel carrier
will have been fitted at the factory.
5
Locate the mounting wishbone, Fig 1 (1)
(polythene bag marked 'spare wheel') and
secure to the spare wheel using two wheel
nuts (2). The wishbone should be placed on the
inboard side of the spare wheel.
6
Place the spare wheel in the spare wheel
carrier with the point of the mounting wishbone
inboard of the wheel. Care must be taken to
avoid damage to the paintwork whilst locating
the spare wheel.
Section 13
Page 2
WHL 01
SECTION 14 - START UP PROCEDURE AND FINAL CHECKS
TABLE OF CONTENTS
Para
1
2
5
12
18
24
25
27
28
31
34
35
45
50
Page
General ......................................................................................................................
Brake system - filling and bleeding (Warnings) ..........................................................
Standard brakes .................................................................................................
Uprated front brakes...........................................................................................
Clutch system - filling and bleeding (Warnings) .........................................................
Coolant.......................................................................................................................
Fuel (Warning) ...........................................................................................................
Engine/gearbox fasteners ..........................................................................................
Gearbox oil (Warning) ................................................................................................
Engine oil ...................................................................................................................
Cranking for oil pressure ............................................................................................
Start-up (Warnings)....................................................................................................
Front suspension and steering alignment ..................................................................
Final checks (Warning) .............................................................................................
2
2
2
2
3
3
4
4
4
4
4
5
5
6
Engine oil initial fill......................................................................................................
Recommended suspension alignment - road use standard and wide track ...............
Tyre pressures ...........................................................................................................
Torque figures............................................................................................................
4
5
6
7
Clutch hydraulic connections .....................................................................................
3
Table
1
2
3
4
Fig
1
FIN 02
Section 14
Page 1
SECTION 14 - START UP PROCEDURE AND FINAL CHECKS
GENERAL
1
This section details the operations,
adjustments checks that should be carried out
prior to starting the car for the first time. Refer
to your Owner's Handbook for recommended
lubricants and capacities.
7
With pressure maintained on the brake
pedal unscrew the bleed screw and allow the
compressed air and brake fluid to flow into the
container. Tighten the bleed screw before the
brake pedal is released.
8
Repeat Paras 6 and 7 until no more air
bubbles can be seen in the brake fluid.
BRAKE SYSTEM - FILLING AND BLEEDING
NOTE
2
Prior to filling the brake master cylinder
recheck all brake connections, including factory
fitted connections, from the brake master
cylinder to each calliper and ensure that they are
properly tightened.
WARNINGS
(1)
Brake fluid is poisonous; wash
affected areas immediately in case of skin
contact and seek medical assistance if fluid
is swallowed or enters the eyes.
(2)
Brake fluid is hygroscopic.
that fluid comes from freshly
container.
Ensure
opened
Ensure brake fluid level remains above half full
level in the brake master cylinder.
9
Tighten bleed screw and remove flexible
hose. Replace dust cap. Carry out Paras 5 to 7
in the following sequence. RH rear calliper, LH
front calliper and finally RH front calliper.
10
As the rear callipers can be difficult to
bleed, it may help to gently tap the calliper body
during the bleed process to release trapped air
pockets.
11
It may be necessary to repeat the brake
bleed procedure several times before a firm high
brake pedal is achieved.
(3)
Brake fluid is corrosive to paintwork,
powder coat and plastic components. Care
should be taken to avoid spillage at all times.
Uprated front brakes
3
Remove the brake master cylinder cap
and protect the surrounding scuttle paintwork
with clean cloths to prevent possible fluid
leakage from causing damage to the paintwork.
12
The uprated front callipers are usually
supplied without the brake pads fitted. Before
bleeding the system fit the brake pads into the
calliper such that when viewed from the rear of
the calliper the curve of the brake pad follows
the shape of the disc.
4
Ensure all bleed nipples on the callipers
are closed then fill the brake master cylinder
with fresh brake fluid that complies with SA3J
1703F DOT 4 specification. Replace the master
cylinder cap.
NOTE
The front wingstays obstruct access to the
uprated callipers. Ensure that the brake pads
are installed before fitting the wingstays.
Standard brakes
5
Remove and retain the dust cap from the
LH rear brake calliper bleed screw. Place a
length of flexible hose over the bleed screw and
place the other end of the tube into a clean glass
container and pour in sufficient brake fluid to
cover the end of the tube.
6
Depress the brake pedal several times to
build up pressure and maintain pressure on the
brake pedal.
Section 14
Page 2
13
Fit the anti-rattle clips behind the retaining
pin (between the pin and the pads/disc). Rotate
the disc and ensure that the anti-rattle clip does
not contact the disc at any time.
NOTE
Ensure that the arrow on anti-rattle clip points in
the direction of wheel rotation.
14
Bleed the brake system observing the
same order as for the standard brakes.
FIN 02
SECTION 14 - START UP PROCEDURE AND FINAL CHECKS
15
The uprated front brakes have two bleed
screws on each calliper. Remove the dust cover
from the inboard bleed screw on the front LH
calliper. Connect the flexible tube to the bleed
screw and operate the brake pedal several
times. Whilst mounting pressure on the brake
pedal open the bleed screw and allow
compressed air and brake fluid to flow into the
container. Tighten the bleed screw before the
pedal is released. Repeat the procedure until no
air bubbles are visible in the released brake
fluid. Remove the flexible tube and replace the
dust cap. Carry out the procedure for the
outboard bleed screw.
21
Rotate the bleed key counter-clockwise
until it stops and place a length of flexible hose
over the bleed screw and place the other end of
the tube into a clean glass container and pour in
sufficient brake fluid to cover the end of the tube.
22
Pump the clutch pedal until good pressure
is felt and clear fluid, free of air bubbles, flows
from the bleed nipple. Rotate the bleed key fully
clockwise, remove the pipe and replace the
bleed nipple cover.
16
As a final check on system integrity, apply
pressure to the brake pedal and check all
connections and bleed screws for any sign of
leakage.
17
Initially brake pedal travel may seem
excessive despite the system being fully bled.
However, the system will improve as the pads
bed 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 are
properly tightened.
WARNINGS
(1)
Brake fluid is poisonous; wash
affected areas immediately in case of skin
contact and seek medical assistance if fluid
is swallowed or enters the eyes.
(2)
Brake fluid is hygroscopic. Ensure
that fluid comes from a freshly opened
container.
(3)
Brake fluid is corrosive to paintwork,
powder coat and plastic components. Care
should be taken to avoid spillage at all times.
19
Remove the clutch master cylinder cap
and protect the surrounding scuttle paintwork
with clean cloths to prevent possible fluid
leakage from causing damage to the paintwork.
20
Locate the bleed nipple/key on the
gearbox bell-housing (refer to Fig 1) and remove
the bleed nipple cover. Ensure that the bleed
key is in the position shown in Fig 1 (rotated fully
clockwise) and fill the clutch master cylinder
reservoir with fresh brake fluid that complies with
SA3J 1703F DOT 4 specification. Replace the
master cylinder cap.
FIN 02
1
2
3
Pipe to master cylinder
Push-fit connector
Bleed key
Fig 1 Clutch hydraulic connections
23
Mop up any spilled fluid, check for clutch
‘feel’ and correct operation (repeat the bleeding
procedure if necessary); finally, hold down the
clutch pedal and check for leaks.
NOTE
All sigma cars and R400 are fitted with throttle
and clutch pedal stop.
1) Throttle stop: The adjustment of the
stop is critical in order to obtain full
throttle at the throttle body end.
Reaching down into the footbox, press
the throttle pedal until the butterfly is
fully open then adjust the throttle stop
up to the back of the pedal ball. This
may take some time to get the correct
adjustment. It is desired not to have any
Section 14
Page 3
SECTION 14 - START UP PROCEDURE AND FINAL CHECKS
cable stretching at full throttle (when
butterfly is fully open and pedal touches
stop).
2) Clutch pedal stop: the adjustment of
the Clutch stop is critical in order to
obtain full clutch operation. The clutch
pedal is adjusted to the require length
but it might require fine tuning
considering slight variation on different
cars. This may take some time to get
the correct adjustment.
COOLANT
24
Check all coolant hose securing clips are
tight and that the coolant level is visible in the
coolant expansion bottle.
29
Add approximately 2 litres of gearbox oil
to the gearbox until it dribbles out of the filler
hole. Replace the filler plug.
30
Due to the restricted access it may help to
make a filling tube using a small funnel and
hose.
ENGINE OIL
31
The capacity of the engine oil system will
vary dependant upon the specification of the
vehicle. Refer to Table 1 for an initial fill quantity
which is sufficient to start and run the engine at
idle before checking and topping up as detailed
in your Owner's Handbook (refer to Section 2 for
recommended lubricants).
FUEL
TABLE 1 ENGINE OIL INITIAL FILL
WARNING
Due consideration should be given to the
highly flammable nature of petroleum or
alcohol-based products and their vapours.
Serious burns can result from incorrect use.
25
Check the security of the push-fit fuel pipe
connection at the fuel rail.
26
Remove the fuel filler cap and add 15
litres of unleaded petrol to the fuel tank.
ENGINE/GEARBOX FASTENERS
27
Check that all engine and gearbox mounts
and fasteners are tight.
GEARBOX OIL
WARNING
Engine Type
Initial
fill Qty
Wet sump
3.5 litre
Wet sump and oil/air separator
6 litre
32
With all variants the engine oil should be
filled via the screw cap on the top of the engine.
Remove the cap from the cam cover and slowly
pour in the oil allowing time for the oil to run to
the bottom of the engine. Replace the cap and
tighten by hand only.
33
Check around the engine area both under
the vehicle and within the engine compartment
for any visible leaks (oil or coolant). Check all
wiring and hoses to ensure that they are
correctly located particularly near any moving
parts, for example, alternator or cooling fan.
CRANKING FOR OIL PRESSURE
Oils - prolonged and repeated contact may
cause serious skin disorders:
(a)
Avoid contact with the skin as far as
possible and wash thoroughly after any
contact.
(b)
Keep out of reach of children.
(c)
First aid treatment should
obtained for open cuts and wounds.
(d)
34
Before running the engine for the first time
it is recommended that the following sequence is
carried out. This will ensure that the oil system
is capable of delivering lubricant throughout the
engine.

Apply handbrake and check that the
gear lever is in the Neutral position.

Disconnect the wires from the inertia
switch, located on the bulkhead above
the ECU.

Operate the ignition switch to crank the
engine over until oil pressure registers
be
Use appropriate barrier creams.
28
Remove the gearbox oil filler plug (if not
removed earlier) using the cut down 3/8” Allen
key.
Section 14
Page 4
FIN 02
SECTION 14 - START UP PROCEDURE AND FINAL CHECKS
on the gauge (oil pressure will be low
due to the speed of the engine when
turned by the starter motor).
NOTE
It may be necessary to turn the engine over
for 30-40 seconds to achieve oil pressure. Once
oil pressure has been achieved, switch OFF
ignition and reconnect the inertia switch. Press
down on the rubber button on top of the inertia
switch to ensure that it has been de-activated.
START-UP
35
Apply handbrake and check that the gear
lever is in the Neutral position.
WARNINGS
(1)
The electric radiator fan is controlled
by a thermostatic switch which operates
when the ignition is in the on position.
whilst working on a hot engine ensure that
the ignition is switched off.
'Max' marks. This will ensure enough oil is in
the engine to perform the initial run and warm
up. The final check for the engine oil level will
be performed later in this Section. Check
around and under the engine for any visible
signs of leaks.
40
Once you have checked and topped up
the oil level as required, restart the engine and
leave running until it is warm. Ensure that the oil
pressure gauge continues to indicate 2 bar
(29 psi) or above at idle.
41
As the engine temperature rises slacken
off the bleed screw in the top of the radiator. It
may be necessary to remove the bleed screw
and partially cover the hole until the coolant
appears. Replace the bleed screw and tighten.
This will allow any air trapped in the system to
escape.
42
Allow the engine to run until the cooling
fan cuts in (this should be at approximately
92C). Switch off the engine.
NOTE
(2)
Do not remove coolant expansion
bottle cap whilst coolant is hot.
Take
precautions to prevent scalds.
36
Check under the car to ensure that there
are no visible leaks. De-activate the immobiliser
by pressing the smooth button on the
immobiliser handset.
NOTE
It may be necessary to press the button several
times for initial operation.
37
Turn the ignition key to position II and
listen for the fuel pump to prime. If no sound is
heard, switch OFF the ignition and reset the
inertia switch by pressing the rubber button on
top until it clicks. Turn ignition key to position II
again and the pump should now prime.
38
Turn the ignition switch to position III so
that the engine turns over until the engine starts.
Some models are fitted with a pushbutton starter
switch. If this is the case on your vehicle turn
the ignition switch to position II (red ignition light
ON) and depress the button to operate the
starter motor.
Should the temperature exceed 92C without the
cooling fan cutting in, switch OFF the engine
immediately to avoid damage. Contact the
Caterham technical helpline, as it is possible
that there is an air lock in the cooling system.
43
Check the car for visible leaks. Re-check
the hose clips for tightness as the rubber hoses
become softer when warm.
44
Finally check the engine oil as detailed in
the Owner's Handbook ensuring the instructions
for the correct engine specification are followed.
If in any doubt please contact Caterham cars.
FRONT SUSPENSION AND STEERING
ALIGNMENT
45
The front suspension is adjustable for
both camber and castor angles.
The top
wishbones normally come from the factory preadjusted although you may wish to reset or
change
the
basic
settings.
Factory
recommended settings are shown in Table 2.
39
Do not allow the engine to run for more
than one minute without checking the oil level.
Using the dipstick as a level, top up the oil
system until oil is visible between the 'Min' and
FIN 02
Section 14
Page 5
SECTION 14 - START UP PROCEDURE AND FINAL CHECKS
TABLE 2 RECOMMENDED SUSPENSION
ALIGNMENT - ROAD USE STANDARD AND
WIDE 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 to
right, front)
46
Increased negative camber will tend to
improve the car's turn in characteristics in fast
corners but at the expense of possible tramlining
on uneven surfaces and uneven tyre wear under
normal conditions. The factory settings should
therefore be adhered to except where the car is
being prepared for motor sport.
47
The adjustment of castor is achieved by
moving the lower front wishbone backwards or
forwards in the chassis using spacing washers,
therefore altering the effective kingpin angle in
side elevation. Increasing the angle away from
vertical will produce more pronounced self
centring of the steering and hence a greater
feeling of stability, but at the expense of heavier
steering.
48
Initial toe-in settings for driving to a
service agent for post build checking can be set
visually by ensuring the outside edge of the front
tyres lines up with a point on the rear tyres ~ 50
mm in from the outside edge, with the steering
wheel centred. This approximate setting will not
cause
either
dangerous
handling
or
unnecessary tyre wear for limited initial mileage.
Initial tracking of wide track cars can be set by
visually aligning the outside edges of the front
and rear wheels.
49
It is recommended that distinctly different
settings are used for race, hill climb or sprint
applications. Caterham can provide a range of
anti-roll bars and a competition parts brochure is
available from the Parts Department at the
factory.
Section 14
Page 6
FINAL CHECKS
WARNING
Re-tighten wheel nuts after 200 miles.
50
The wheel/tyre combinations supplied by
Caterham, are pre-inflated to approximately 40
psi (2.8 bar) to ensure that the tyre is correctly
seated on the wheel rim and must be reduced
prior to driving. Tyre pressures should be
checked in accordance with Table 3.
TABLE 3 TYRE PRESSURES
Wheel type
Tyre type/ size
Front
(psi)
Rear
(psi)
18
18
6J x 13
ACB10 6 x 20 x 13
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
51
Some tyres supplied by Caterham are
directional. As a result any spare tyre supplied
will only be treaded in the correct direction for
one side of the car. If the spare tyre needs to be
fitted to the side where the rotation is incorrect
this should be done only as a means to get you
home and must be rectified before any further
use of the vehicle. Ensure that the tyres are
fitted with the correct orientation.
52
Ensure that no wires or brake hoses are
in such a position to chafe or to contact moving
or hot components. Particular care should be
taken with wires close to the exhaust manifold.
53
Before the car is used, ensure that all
bolts securing suspension, steering and brakes
are properly tightened, refer to Table 4.
FIN 02
SECTION 14 - START UP PROCEDURE AND FINAL CHECKS
TABLE 4 TORQUE FIGURES
Location
Washers
Torque
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
Spring and plain
20
Loctite
20
Upright top ball joint
N/A
54
Upright bottom fixing
Spacer (widetrack only)
54
N/A
20
Plain under bolt head
11
N/A
20
Spring and plain under bolt head
14
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
Spring and plain
54
Watts link locknut
N/A
20
Bellcrank to link
N/A
14
Front spring damper top
Front spring damper bottom
Front anti-roll bar clamps
Steering rack clamps
Steering column universal joint
Steering column clamp plate
Track rod end to upright
Rear spring damper bottom
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
N/A
47
Plain and spring
47
Plain under bolt head and spring under nut
14
Plain and spring
47
(continued)
Hub mountings
Brake calliper
Rear anti-roll bar clamp
De Dion ears
FIN 02
Section 14
Page 7
SECTION 14 - START UP PROCEDURE AND FINAL CHECKS
TABLE 4 TORQUE FIGURES (continued)
Location
Washers
Torque
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
Plain between chassis and nut
20
Spring under bolt head
41
Plain between chassis and nut
20
N/A
34
Expansion tank bracket
Plain under bolt head and nut
10
Gearlever to tail-housing
N/A
20
Copper washer each side of banjo
10
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
Tapered
74
Engine mounting rubbers
Engine mounting to rubbers
Gearbox mount to chassis
Exhaust manifold
Brake banjo bolt
Brake unions
Wheel nuts (2 part nut and tapered washer)
Section 14
Page 8
FIN 02
SECTION 15 - SINGLE VEHICLE APPROVAL AND REGISTRATION
TABLE OF CONTENTS
Para
1
6
9
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
28
41
45
Page
General ......................................................................................................................
Requirements.............................................................................................................
How to apply for the inspection ..................................................................................
Travel to and from the test station..............................................................................
Inspection refusal.......................................................................................................
Inspection data
Design weight.....................................................................................................
Design speeds and maximum power engine speed ...........................................
Towing................................................................................................................
Speedometer......................................................................................................
Checking and preparing the car prior to inspection....................................................
Wiper and washer system ..................................................................................
Radio interface suppression ...............................................................................
Lamps, reflectors and devices............................................................................
Rear view mirrors ...............................................................................................
Noise ..................................................................................................................
Emissions ...........................................................................................................
General construction ..........................................................................................
Protective steering..............................................................................................
Brakes ................................................................................................................
Interior and exterior projections ..........................................................................
Race cars and SVA....................................................................................................
Registration procedure after SVA inspection .............................................................
2
2
2
3
3
Design speeds and maximum power engine speed...................................................
3
SVA bag contents ......................................................................................................
SVA Scuttle trim and battery master switch ...............................................................
Bonnet catches ..........................................................................................................
Front suspension........................................................................................................
Exhaust mounting ......................................................................................................
Side screen hinges.....................................................................................................
4
5
5
5
6
6
Vehicle inspectorate test stations where the SVA test can be carried out..................
1
3
3
3
3
3
3
3
4
4
4
4
4
4
4
6
6
Table
1
Fig
1
2
3
4
5
6
Annex
A
SVA 01
Section 15
Page 1
SECTION 15 - SINGLE VEHICLE APPROVAL AND REGISTRATION
GENERAL
Radio Interference Suppression
Glass and Glazing
1
All Caterham cars will have to be
inspected under the SVA regulations in order to
be registered for road use.
Lamp, Reflectors and Devices
Rear View Mirrors
2
The inspectors have all been trained to
the same standard but may interpret certain
regulations differently. Each test station will
have received a detailed explanation of what a
Caterham is and what European regulations it
complies with. The inspectors therefore should
have reasonable product knowledge and have a
contact number at Caterham if required.
Tyres
3
It is recommended that the car is
presented in a clean condition as this will greatly
improve the inspector’s demeanour.
Exhaust Emissions
4
It is also advisable to take an emergency
kit with you to the test station. This should
consist of a basic toolkit, cable ties, push on trim
and a length of rubber hose. In the event of
components needing tightening for adjustment
or a non-compliance, the emergency kit may
save you taking the car away and having to
re-present it at a later date.
5
You
should
remember
that
any
modification made to the car subsequent to
passing the SVA inspection may prevent it from
passing an MOT at a later date. For example if
a competition exhaust is fitted the original
catalyst equipped system would need to be
retained in order to meet MOT emission
standards. The MOT is an inspection of the
vehicles condition and will be carried out in the
same manner as for normal production cars.
Items such as internal/external projections,
noise and fields of visibility will not be inspected
at an MOT.
Exterior Projections
Protective Steering
Vehicle construction and design
Brakes
Noise
Speedometers
7
The examiner will conduct an engineering
assessment rather than the more thorough test
that full European Type Approval entails. In
some cases (brakes, noise, emissions etc) there
will be a physical test either on a rolling road or
within the grounds of the test centre.
8
The inspection will not require any part of
the car to be dismantled and will be carried out
at Vehicle Inspectorate test stations. See Annex
A for the current stations. The inspection is
anticipated to take approximately four hours and
can be booked between 0800-1700 Monday to
Thursday or 0800-1630 on Friday. There is a
fee payable for this service. An additional fee
will be charged if an inspection is required
outside these hours.
HOW TO APPLY FOR THE INSPECTION
9
The inspection has to be formally booked
in advance therefore you must:

Obtain an application form from your local
Vehicle Registration Office (VRO) or Vehicle
Inspectorate Office (HGV Station).

Complete the form and return it along with
the test fee to:
REQUIREMENTS
6
The following items are checked under
the 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
SVA section
The Vehicle and Operators
Services Agency
91/92 The Strand
Swansea
SA1 2DH
0870 6060 440
http://www.vosa.gov.uk
Interior Projections
Section 15
Page 2
SVA 01
SECTION 15 - SINGLE VEHICLE APPROVAL AND REGISTRATION
10
You will then receive confirmation of the
inspection which will give details of the time and
location. Where possible the inspection will be
carried out at the Vehicle Inspectorate test
station you have selected.
Maximum Gross Weight
860 Kgs
Maximum Permitted Front Axle Weight 360 Kgs
Maximum Permitted Rear Axle Weight 500 Kgs
TRAVEL TO AND FROM THE TEST STATION
14
The design speeds and maximum power
engine speed for each model is detailed in
Table 1.
11
In order to attend the inspection you will
be allowed to travel to and from the test station
without the vehicle being registered or fitted with
trade plates. Should any item require rectifying
you will be permitted to drive to and from a place
where rectification can be carried out. You are
required to provide insurance cover for all such
journeys.
NOTE
You will be able to secure insurance cover by
quoting the car chassis number to your chosen
insurers.
INSPECTION REFUSAL
12
The test station may refuse to inspect
your car for the following reasons:

You arrive at the test station later than your
appointment time.
Design speeds and maximum engine speed
TABLE 1 DESIGN SPEEDS AND MAXIMUM
POWER ENGINE SPEED
Model
Engine
Max
RPM
Max
MPH
Roadsport 125
1.6
6800
112
Roadsport 150
1.6
6850
122
Towing
15
It is not recommended that the Seven is
used for towing, therefore, when asked the
question; the answer is 'Not Applicable'.
Speedometer
16
The speedometer is compatible with this
vehicle.
CHECKING AND PREPARING THE CAR
PRIOR TO INSPECTION

You have not paid your fee.

There is insufficient fuel or oil for the test.
You will be required to have a full tank of
fuel.
17
It is recommended that the checks and
operations detailed in the following paragraphs
are completed prior to taking the car for the
inspection.

The car is presented in a dangerous or such
a dirty condition that the test is not feasible.
Wiper and washer system

A device designed to be readily opened
cannot be opened (e.g. bonnet padlocked).

The vehicle presenter does not remain with
the car to operate controls etc as requested.
INSPECTION DATA
Design weight
13
You will be asked to specify the maximum
gross weights and maximum permitted axle
weight during your application for a test date.
This will then be checked by weighing the car
without passengers and luggage (kerb weight)
and then using a formula to calculate the
theoretical gross weight. The following weights
should be quoted for all models.
SVA 01
18
Carry out a full system check prior to the
inspection. Ensure the screen washer bottle is
full, the wiper blades contact the windscreen and
the washer jets are correctly adjusted. Ensure all
hoses are secure as the system will be checked
under pressure.
Radio interference suppression
19
Caterham supplied ignition leads are
suppressive. If you choose not to use the
Caterham supplied ignition leads and have
supplied your own leads, ensure they are clearly
marked as suppressive.
Section 15
Page 3
SECTION 15 - SINGLE VEHICLE APPROVAL AND REGISTRATION
Lamps, reflectors and devices
Brakes
20
If you have built your car using the
components and information supplied, the car
will comply with SVA lighting requirements.
Ensure that repeater indicators are fitted to the
front wings.
26
The braking system will be subjected to a
thorough test (on brake rollers) so it is
imperative that you take the time to bleed the
brakes correctly. The performance of the brakes
often improves dramatically after a small amount
of use. Frequent application of the brakes on
the way to the test centre will help the brakes
bed in.
Rear view mirrors
21
These should be set up for maximum
visibility. Ensure that the windscreen mounted
mirror and both screen stanchion mirrors are in
place. It is also worth removing the hood, or
arriving without it altogether, as this improves
both visibility and access.
Noise
22
Tailpipe noise will be tested. Though the
silencer is brand new, the efficiency is increased
when the internal packing has expanded against
the inner wall. It is therefore recommended that
you allow the car to idle as much as possible
prior to taking the car to the test centre. This will
also allow a layer of soot to settle which will help
deaden the 'ring' of the new silencer.
27
Ensure the handbrake is correctly
adjusted and does actually lock the rear wheels.
Interior and exterior projections
28
Supplied with the kit is a polythene bag
marked 'SVA', refer to Fig 1. It is essential that
these items are fitted prior to presentation at the
SVA Testing station.
Emissions
23
All Caterham cars are supplied with
catalytic converters and will meet the test
requirements.
General construction
24
This should be checked at the Post Build
Check stage, however if you are not using that
service ensure that chafing of brake pipes and
the wiring looms is not possible. If you have
followed the procedures detailed in the
Assembly Guide then you should not have any
problems at this stage of the inspection.
Protective steering
25
All standard Caterham steering wheel
types have a removable pad fitted. This pad
must be in place during the inspection.
Section 15
Page 4
1
2
3
4
5
6
7
8
9
10
11
Scuttle trim
Foam tape
Edge trim
Cable ties
Track rod sleeve
Flexible covers
Bolt head covers
Nut covers
SVA mirror stalks and fixings
Rear bonnet catch cover
Front bonnet catch cover
Fig 1 SVA bag contents
SVA 01
SECTION 15 - SINGLE VEHICLE APPROVAL AND REGISTRATION
29
Ensure that the scuttle edge trim (Fig 2
Item 1) is fitted to the edges of the scuttle
around the dashboard, refer to Section 9.
1
2
3
4
5
Scuttle edge trim
Eyebrow edge trim
SVA cover
Battery master switch sheath
SVA cover (optional roll cage)
Fig 2 SVA Scuttle trim and battery master
switch
30
Apply the self-adhesive Velcro strips
around the sides and bottom of the fuse box
cover. Attach the other half of the Velcro
fastening to the Velcro already attached to the
fuse box cover. Locate the cover over the fuse
box sticking it in place. (R400 only)
1
2
3
4
Rear bonnet catch cover
Front bonnet catch cover
Edge trim (indicator cone)
Edge trim (cycle wing)
Fig 3 Bonnet catches
34
The bonnet catch covers (Fig 3 Items 1
and 2) should be pushed over the respective
bonnet catch.
35
The covers (Fig 1 Item 7) should be fitted
to the shoulder strap mounting bolts (Only
required if this 4 or 6-point harness option is
specified).
36
The sleeves (Fig 4 Item 1) should have
been fitted over the track rod locknuts during the
front suspension build.
31
The '7' in the nosecone grill is not SVA
compliant and therefore should be fitted behind
the mesh grill in order for your car to pass the
SVA test.
32
The edge trim should also be secured to
the edges of the front cycle wings (Fig 3 Item 4),
the edge of the black plastic housing around the
rear fog and reverse lights and the edges of the
indicator cones. Cars fitted with the detachable
wind deflector will also require edge trim along
the top edge of the deflector and around the
edges of the mirrors.
33
The caps (Fig 4 Item 3) should also be
fitted to the nut and bolt head of the top
wishbone front mounting.
1
2
3
4
Track rod sleeve
Stub axle cover
Steering arm nut cover
Track rod end nut cover
Fig 4 Front suspension
SVA 01
Section 15
Page 5
SECTION 15 - SINGLE VEHICLE APPROVAL AND REGISTRATION
37
Covers (Fig 4 Items 2, 3 and 4), should be
fitted over the inner stub axle nuts, the steering
arm nuts, the track rod end nuts and the two
wheel nuts that hold the spare wheel to the
spacer wishbone (if fitted).
38
Covers (Fig 5 Item 1) should be fitted to
the exposed nuts securing the exhaust bobbin
and the exhaust bracket and an off-cut of scuttle
edge trim should be fitted to the upper edge of
the exhaust silencer bracket.
1 Grommets
2 Rear view mirrors (SVA position)
Fig 6 Side screen hinges
Race Cars and SVA
1
2
Nut covers
Scuttle trim off-cut
Fig 5 Exhaust mounting
39
The sharp edge of each side screen
hinges should be protected as shown in Fig 6.
The protectors are made by cutting grommets in
half and fixing them in place with superglue.
NOTE
If the side screens are fitted for the SVA test
then the hinge halves fitted to the side screens
must be protected in a similar manner.
40
Road wheels are exempt from external
projections with the exception of the spare
wheel. Ensure the wheel is positioned such that
any balance weights are behind the spare wheel
carrier.
41
There are several parts that are
mandatory on race cars which are not SVA
friendly. Ideally these parts should be fitted after
the car has been submitted for its SVA test but if
this is not possible then these parts will need to
comply with the SVA criteria.
42
Fire Extinguisher. The 'T' handle that
operates the fire extinguisher will need to be
removed and the boss in the dash covered.
43
Track day roll over bar/roll cage. All
fixings will need to be covered. If the track day
roll over bar petty strut is supplied this will need
to be removed and the hole in the side panel
must be covered.
44
Battery Master Switch. The edges of the
master switch key will not pass SVA; a rubber
sheath for the key is included in the SVA kit and
this must be fitted for the test. The eyebrow
must be fitted with edge trim and the fixing bolts
will need protective caps, refer to Fig 2.
REGISTRATION PROCEDURE AFTER SVA
INSPECTION
45
If your vehicle fails the SVA inspection for
any reason you will be allowed to take the car
away to rectify it.
Section 15
Page 6
SVA 01
SECTION 15 - SINGLE VEHICLE APPROVAL AND REGISTRATION
46
Upon successful completion of the SVA
inspection you will be issued with a certificate to
confirm that the car has passed to the standard
required. This certificate is officially called a
Minister's Approval Certificate (MAC) and must
be retained. In order to register your car you
must submit the MAC, a completed application
for registration form (currently V55/5), insurance
certificate and your certificate of newness (with
full CKD De Dion kits only) along with your
Vehicle Excise Duty (VED) fee for either six
months or twelve months to your local Vehicle
Registration Office (VRO).
In addition a
registration fee will be levied by DVLA to cover
administration costs throughout the vehicle's life
(sending out VED reminders etc).
47
The car will be subjected to an MOT
inspection three years after it was first
registered.
SVA 01
Section 15
Page 7
PAGE INTENTIONALLY BLANK
SECTION 15 ANNEX A - VEHICLE INSPECTORATE TEST STATIONS WHERE
THE SVA TEST CAN BE CARRIED OUT
Aberdeen
Cloverhill
Bridge of Don Industrial Estate
Aberdeen AB23 8EE
01224 702357
Beverley
Oldbeck Road
Off Grovehill Road
Beverley
East Yorkshire HU17 0JG
01482 881522
Leighton Buzzard:
Stanbridge Road
Leighton Buzzard
Bedfordshire LU7 4QG
01525 373074
Liverpool (Speke):
C/O South Liverpool Commercials
Woodend Avenue
Speke
Liverpool L24 9NB
0151 4860050 or 0151 5474445
Birmingham
Garretts Green Industrial Estate
Birmingham B33 0SS
0121 783 6560
London–North (Edmonton)
Anthony Wharf
Lea Valley Trading Estate
Edmonton N18 3JR
020 8803 7733
Bristol (Avonmouth)
Unit 10, I.O. Centre
Poplar Way West
Avonmouth
Bristol BS11 0QL
01179 381157
London–South (Mitcham)
Redhouse Road
Croydon
Surrey CR0 3AQ
020 8684 1499
Cardiff (Llantrisant)
School Road
Miskin
Pontyclun
Mid Glamorgan CF72 8YR
01443 224701
Carlisle
Brunthill Road
Kingstown Industrial Estate
Carlisle CA3 0EH
01228 528106
Chelmsford
Widford Industrial Estate
Chelmsford
Essex CM1 3DR
01245 259341
Derby:
Curzon Lane
Alvaston
Derby DE21 7AY
01332 571961
Exeter
Grace Road
March Barton Trading Estate
Exeter
Devon EX2 8PU
01392 278267
Gillingham
Ambley Road
Gillingham
Kent ME8 0SJ
01634 232541
Glasgow (Bishopbriggs)
Crosshill Road
Bishopbriggs
Glasgow G64 10A
0141 772 6321
SVA X01
London–West (Yeading)
Cygnet Way
Willow Tree Lane
Yeading
Hayes
Middlesex UB4 9BS
020 8841 9205
Manchester–North (Chadderton)
Broadgate
Broadway Business Park
Chadderton
Oldham OL9 9XA
0161 947 1000
Newcastle-upon-Tyne
Sandy Lane
Gosforth
Newcastle-upon-Tyne NE3 5HB
0191 236 5011
Norwich
Jupiter Road
Hellesden
Norwich NR16 6SS
01603 408128
Nottingham
Main Road
Watnall
Nottingham NG16
0115 938 2591
Shrewsbury
Unit 6 Levens Drive
Harlescott
Shrewsbury SY3 7EG
01743 462621
Southampton (Northam):
Unit R, Centurian Industrial Estate
Bitterne Road West
Southampton SO18 1UB
02380 837397
Section 15 Annex A
Page 1
SECTION 15 ANNEX A - VEHICLE INSPECTORATE TEST STATIONS WHERE
THE SVA TEST CAN BE CARRIED OUT
Taunton
Taunton Trading Estate
Norton Fitzwarren
Taunton
Somerset TA2 6RX
01823 282525
Section 15 Annex A
Page 2
SVA X01
SECTION 16 - OPTIONS
TABLE OF CONTENTS
Para
1
3
4
15
18
20
31
36
46
52
57
67
73
Page
Introduction ................................................................................................................
Oil/air separator/anti-cavitation system
General...............................................................................................................
Fitting instructions (Warning)..............................................................................
Battery master switch.................................................................................................
Standard roll over bar.................................................................................................
Track day roll over bar (Warning)...............................................................................
Roll cage (Warning) ...................................................................................................
Preparation.........................................................................................................
Roll cage fitment.................................................................................................
Head restraint (roll cage and roll over bar).................................................................
Fire extinguisher pull handle ......................................................................................
Aero fuel filler cap (Warnings)....................................................................................
High level brake light
Fitting the bracket (Warning) ..............................................................................
Light and wiring connections (Warning)..............................................................
2
11
11
Track day roll over bar mounting bolt torque figures ..................................................
Roll cage mounting bolt torque figures.......................................................................
Head restraint fixings torque figures...........................................................................
5
7
8
Oil/air separator mountings ........................................................................................
Header tank location plate .........................................................................................
Relocated horns .........................................................................................................
Oil/air separator tank position ....................................................................................
Standard roll over bar.................................................................................................
Track roll over bar ......................................................................................................
Front fixing boss location ...........................................................................................
Rear hoop bucket bushes ..........................................................................................
Head restraint assembly ............................................................................................
Fire extinguisher pull handle ......................................................................................
Fire extinguisher inner cable location.........................................................................
Kit contents ................................................................................................................
Filler cover and boot carpet removed.........................................................................
Drill out the six rivets ..................................................................................................
Old filler boss removed ..............................................................................................
Gasket positioned on back panel ...............................................................................
Carefully drill new holes .............................................................................................
Spacer filled to filler neck ...........................................................................................
Fit flange ....................................................................................................................
Job complete..............................................................................................................
Kit contents ................................................................................................................
Drilling central popper on SV .....................................................................................
Alignment of bracket ..................................................................................................
Wire routing through light unit ...................................................................................
Drilled hole above spare wheel boss..........................................................................
View from under RHS rear corner ..............................................................................
Exploded view of assembly........................................................................................
Wires from support tube entering boot .......................................................................
Completed assembly..................................................................................................
2
3
3
3
4
4
6
6
8
8
9
9
9
9
9
10
10
10
10
10
11
11
11
12
12
12
12
13
13
2
2
4
4
4
5
5
6
7
8
9
Table
1
2
3
Fig
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
OPT 01
Section 16
Page 1
SECTION 16 - OPTIONS
INTRODUCTION
1
These fitting instructions are supplied in
addition to the normal assembly guide delivered
with your kit. They are specific to the additional
equipment required when using your car for
competition purposes. This document is
supplied with new kits and as instructions to
customers purchasing upgrades for an older car.
SVA notes have been included for customers
needing to register a new vehicle.
2
It is important that these instructions are
read in conjunction with your assembly guide in
particular with regard to the preliminary
information that can be found at the front of the
guide.
OIL/AIR SEPARATOR/ANTI-CAVITATION
SYSTEM
General
1
2
3
4
Upper mountings
Standard header tank mounting point
Lower mounting
Foam padding
Fig 1 Oil/air separator mountings
3
The oil/air separator has been designed to
help separate oil and air in the engine. At
sustained high revs the engine can have a
tendency to draw air up into the oil galleries and
thus decrease the lubrication efficiency. The
tangential spin created by the separator tank
draws the air from the oil before directing it
through a restrictor and back into the engine
cam cover.
Fitting instructions
WARNING
Use appropriate eye protection
carrying out drilling operations.
whilst
4
Fix self-adhesive foam padding strips
(polythene bag marked 'oil/air separator') on the
lower chassis cross members, refer to Fig 1.
5
To locate the correct position for the top
mountings, stand the tank on the foam padding
ensuring that it is vertical. Where the tank
touches the upper chassis diagonals, mark a
small line (this should be at the centre of the
width of the separator tank). Position an upper
mounting bracket (polythene bag marked 'oil/air
separator') against the side of the tank with the
two fixing holes either side of the line. Now
mark the two fixing holes. Remove the tank and
drill two 5/32" holes in the chassis cross
member. Repeat the marking and drilling
procedure for the second bracket. Secure the
upper mounting brackets using the rivets
provided.
6
The lower mounting must be riveted on
the centre line of steering rack platform (long
end upwards), with the bend level with and
pointing away from the top surface of the rack
platform.
7
To prevent contact with tank, attach a
small piece of self adhesive foam to the rear
facing surface of all three mountings.
8
Fitting the optional oil/air separator tank
means that the standard header tank mounting
point cannot be used. To provide an alternate
location for the header tank a location plate must
be riveted to the upper RH chassis tubes
approximately 110 mm from the centre of the
standard header tank mounting point (the predrilled rivet holes in the location plate should be
central on the chassis tubes), refer to Fig 2.
Section 16
Page 2
OPT 01
SECTION 16 - OPTIONS
11
Fit a dowty seal over one end of each the
two large 5/8" male/male adapters and fit them
into the large threaded bosses in the side of the
air separator tank. Screw in the adapters until
the dowty seals just begin to grip, then carefully
tighten using two spanners so as to avoid
damaging the soft aluminium tank.
Fig 2 Header tank location plate
9
Fitting the optional oil/air separator tank
obstructs the area normally used for the horns.
Relocate the horns by bending the brackets and
securing them to the underside of the header
tank location plate using a 7 mm spacer on the
M8 x 65 mm cap-head screw and locknut used
to secure the header tank mounting to the
location plate, refer to Fig 3.
Fig 3 Relocated horns
10
Fit and tighten the magnetic drain plug
(polythene bag marked 'oil/air separator') to the
base of the tank. Lubricate the thread and fit the
temperature sender into the side of the oil/air
separator tank.
NOTE
The temperature sender has a tapered thread to
enable it to seal without the need for a washer.
For this reason it will go tight before it has
screwed fully home. Care should be taken not
to over tighten.
OPT 01
12
Connect the two oil pipes from the engine
to the tank ensuring that the longer oil pipe from
the rear connection on the oil filter housing is
connected to the upper union on the tank, refer
to Fig 4. When tightening the oil pipes care
should be taken not to damage the soft
aluminium tank. Note that a large hexagon is
provided where the union attaches in order to
facilitate the use of an additional spanner. Place
the oil/air separator tank on the lower mounting
bracket and secure to the upper securing
bracket using the hose clip provided.
1
2
3
4
5
Braided hose
Right-angled union
Separator tank
Upper union
Hose clip
6
7
8
Upper oil pipe
Oil temperature
sender
Lower oil pipe
Fig 4 Oil/air separator tank position
NOTES
(1)
The black/yellow wire that exits the loom
in the front LH corner of the chassis can be used
to provide an oil temperature reading by
attaching it to the temperature sender.
Section 16
Page 3
SECTION 16 - OPTIONS
(2)
An additional switch and wiring to the
temperature gauge will also be required but this
cannot be fitted prior to SVA test. For further
information please contact Aftersales who will be
happy to carry out this work for you.
(3)
Cars fitted with Stack instrumentation
also require an additional black earth lead.
13
Secure the upper and lower oil pipes
using the cable ties provided to ensure that they
cannot come into contact with moving parts of
the engine or suffer abrasion.
14
Attach the small braided hose from the
top of the tank to the front RH corner of the cam
cover via the right-angled union using the
copper washer provided.
1
2
BATTERY MASTER SWITCH
TRACK DAY ROLL OVER BAR
15
If specified the battery master switch will
have been fitted at the factory.
20
Before fitting the Track day roll over bar it
will be necessary to remove the rear spring
damper units in order to gain access to the lower
mounting points, refer to Section 8.
16
Locate the two thick red leads exiting the
transmission tunnel. Connect the lead marked
'starter' to the starter solenoid along with the
large brown lead (with black sleeve) from the
alternator. Route the lead marked 'battery' to
the battery positive terminal. Do not connect.
17
Check that the lead to the battery is
attached to the single connection of the master
switch and the lead to the starter is attached to
the master switch connection along with a
double brown wire.
STANDARD ROLL OVER BAR
Standard roll over bar 3
Set screw
4
Spring washer
Plain washer
Fig 5 Standard roll over bar
21
The Track day roll over bar is fitted in the
same manner as the standard roll over bar with
the exception of additional fixings located in the
ends of the main hoop.
22
Having placed the roll over bar into
position, but before finally tightening the fixings,
pass from underneath the reduced head set
screws supplied with the roll over bar, into the
threaded holes in the ends the main hoop of the
Track day roll over bar. Leave these fasteners
loose until all fixings are in place.
18
Insert the bosses; on the underside of the
roll over bar main hoop into the bucket bushes
located at each end of the seat belt header rail
towards the rear of the cockpit, refer to Fig 5.
Locate the rear diagonals of the roll over bar into
the mounting brackets at the rear of the boot
compartment. Secure the roll over bar to the
chassis
using
set
screws
(fastener
pack 30P010A Item 2), spring washers (6) and
washer (5).
19
The rear diagonals are secured to the
brackets by bolt (1) and nyloc nuts (4) with a
plain washer (5) under the bolt head and nyloc
nut. Tighten all fastenings to 20 Nm.
1
2
Rear diagonal
Track day roll over bar
Fig 6 Track roll over bar
Section 16
Page 4
OPT 01
SECTION 16 - OPTIONS
23
An additional, optional Petty strut can be
added to the Track day bar to upgrade it to FIA
specification.
TABLE 1 TRACK DAY ROLL OVER BAR
MOUNTING BOLT TORQUE FIGURES
Location
NOTES
(1)
The Track day bar as supplied without the
additional Petty strut is not FIA approved.
(2)
The Petty strut is not SVA compliant and
therefore should be removed for normal road
usage.
24
The forward end of the Petty strut is
secured to a mounting boss located within the
chassis that is normally hidden behind the
interior trim panel. It can be found in the
passenger side of the cockpit approximately one
inch below the point at which the dashboard
tube is welded to the top of the chassis rail.
25
If a 7/16" hole is not visible, drill out the
six 5/32" rivets holding the top edge of the trim
panel surrounding this point and ease the trim
panel away from the chassis until the exact
location of the mounting boss is identified.
WARNING
Use appropriate eye protection
carrying out drilling operations.
Torque
Base of the bucket bushes
whilst
26
Drill a small pilot hole through the trim
panel taking great care not to touch the outer
side skin and enlarge such that a 7/16" bolt can
be fitted through. Ensure that the inner thread in
the mounting boss is not damaged during this
process. Loosely fit bolt (fastener pack ZPS01
Item 2) and secure the trim panel with rivets.
27
Remove bolt (2). Secure the Petty strut to
the roll over bar, using bolts (1), with plain
washers (4), under the head of the bolts. Pass
the bolts through the plate on the Petty bar then
rearwards through the fixing holes in the centre
of the main hoop, secure with plain washers (4)
and nyloc nuts (3).
28
Attach the forward end of the Petty strut to
the previously uncovered boss using bolt (2)
passed through spring washer (6), plain
washer (5) then the fixing plate at the forward
end of the bar. It may be necessary to use the
additional plain washer(s) (5) between the front
fixing plate and the side of the chassis to
achieve the best fit.
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 roll
over bar likely to be contacted by either the
driver's or passenger's head to be protected with
approved roll bar padding.
Suitable FIA
approved padding is available from the
Caterham parts counter.
ROLL CAGE
WARNING
Never work underneath a car without
supporting it on axle stands or equivalent.
Do not rely on a jack alone.
Preparation
31
Before fitting the roll cage it will be
necessary to remove the rear spring damper
units in order to gain access to the roll cage
lower mounting points, refer to Section 8.
NOTE
This roll cage is SVA-compliant however
protective covers will be required on the four bolt
heads that attach the front hoop to the chassis.
You will also be required to have SVA compliant
mirrors fitted to both the driver and passenger
sides of the car to ensure rear visibility is
maintained.
32
The lower ends of the hoop that forms the
front of the cage, attaches to two pre-fitted
threaded bushes. These bushes are located,
behind the side panels; one on each side of the
car and approximately one inch below the point
at which the dashboard tube is welded to the top
of the chassis rail, refer to Fig 7. Before
attempting to fit the cage, these bushes will
need to be uncovered.
29
Tighten additional roll over bar mounting
bolts in accordance with Table 1.
OPT 01
Section 16
Page 5
SECTION 16 - OPTIONS
(2)
If you intend to run sill protectors, you will
need to remove these prior to fitting the cage.
They will also require trimming at the forward
end to enable them to be refitted around the
cage.
1
2
3
Front hoop saddle bracket
Fixing bolt – in threaded bush
Chassis top tube - sill
Fig 7 Front fixing boss location
WARNING
Use appropriate eye protection
carrying out drilling operations.
whilst
(3)
You are now ready to attach the roll cage
to the chassis however due to the size and
weight of this part it is strongly recommended
that you obtain further assistance as an extra
pair of hands to help guide the cage into position
could prevent damage.
Roll cage fitment
36
Offer the cage up to the car and gently
rest in place. Insert the bosses at the bottom of
the rear hoop into the bucket bushes located at
each end of the seat back harness rail at the
rear of the cockpit, refer to Fig 8.
33
If a 7/16" hole is not visible in the side
panel, drill out the 5/32" rivets holding the top
edge of the trim panel surrounding this point and
ease the trim panel away from the chassis until
the exact location of the mounting boss is
identified. Drill a 4 mm pilot hole through the
trim panel then enlarge to give clearance for a
7/16" bolt. Ensure that the inner thread in the
mounting boss is not damaged during this
process.
34
Take a 10 mm drill bit and pass it through
the threaded boss until the pointed end of the
drill touches the inside of the outer side panel.
Gently tap the end of the drill bit until a small
witness mark is visible on the outside of the side
panel along the centre line of the bush. Using a
centre dot, dot the outside of the side panel on
the 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 the
mounting boss is not damaged during this
process.
35
Repeat this process on the other side of
the car then run a 7/16" UNF bolt into both
bosses to ensure the threads are clean and
undamaged.
NOTES
(1)
Do not re-rivet the interior side panels at
this stage.
Section 16
Page 6
1
2
3
Bucket bush location
Roll cage rear hoop
Seat back harness rail
Fig 8 Rear hoop bucket bushes
37
Carefully lower the front of the cage until
the saddle brackets at the ends of the front hoop
rest over the chassis top tube (sill). When fitted,
the inner leg of the saddle should be between
the fixing boss and the interior side panel, refer
to Fig 7.
38
As the front of the cage is lowered into
place the rear legs will rise and locate
themselves between the mounting plates at the
rear of the boot compartment. The bosses on
the ends of the rear hoop will drop into the
bucket bushes.
39
The cage can now be bolted into place
using the fixings provided. Align the holes one
by one and loosely fit all the fixings as detailed
below. Do not finally tighten any of the fixings
until they are all in place.
OPT 01
SECTION 16 - OPTIONS
40
Locate the underside of the bucket
bushes and pass the reduced head bolts
(fastener pack 30P017A Item 3) up through the
bottom of the bush and into the threaded boss
on the roll cage. No washers should be used on
these bolts as this will restrict damper clearance.
Do not tighten at this stage.
45
With all the fixings in place they can be
finally tightened in accordance with Table 2.
See also note above.
TABLE 2 ROLL CAGE MOUNTING BOLT
TORQUE FIGURES
Location
41
Loosely fit bolt (2) through the interior side
panel, the roll cage and into the threaded
chassis boss. This will hold the side panel in
place whilst it is riveted back into place. If you
intend to run sill protectors then these will need
to be trimmed and re-fitted at this stage. Run the
piping between the interior side panel and the
chassis side rivet into place through the pre
drilled holes using rivets (fastener pack ZCH 01
Item 5).
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
NOTE
The head restraint is not SVA-compliant and
should not be fitted prior to the SVA test.
If you are building a new kit, refer to the
assembly guide regarding fitment of knee trim
panels as these are also best fitted at this time.
46
The head restraint is supplied as two
parts, an adjusting bracket and a square head
pad with a long adjusting stud.
42
Remove the loosely fitted bolt (fastener
pack 30P017A Item 2) and adding a plain
washer (5) pass through the interior side panel,
roll cage saddle bracket and into the threaded
boss. Do not tighten at this stage.
47
Attach the self-adhesive foam pad
(fastener pack 30P011A Item 5) to the front face
of the square head pad.
43
Repeat the above using bolts (2) and
plain washers (5) passed through the outer legs
of the saddle bracket and into the threaded bush
in the chassis. Ensure that this bolt does not
‘bottom out’ on the bolt inserted from inside the
cockpit.
48
Attach the bracket to the cross section of
the roll cage/bar so that the adjusting slot is
vertical to ground so that the longer fixing leg
attaches to the lower cross tube, refer to Fig 9.
49
Bolt in place using bolts (1) and nyloc
nuts (2) with plain washers (4) under both the
head of the bolt and the nut.
NOTES
(1)
If you intend to fit a rear wheel protection
bar then the outer fixing bolt on the driver’s side
of the car will need to be removed again to allow
fitment of this part.
(2)
The rear wheel protection bar is not
SVA-compliant and should not be fitted prior to
the SVA test.
44
The rear legs of the cage are secured to
the mounting plates at the rear of the boot
compartment using bolts (1) and nuts (4) passed
through the plates and the holes in the end of
the legs. Plain washers (6) must be fitted under
both the head of the bolt and the nut (these bolts
may appear to be undersize but they are
intended to be only a loose fit in the respective
holes).
OPT 01
Section 16
Page 7
SECTION 16 - OPTIONS
52
Insert the inner cable through the hole in
the centre of the boss that has been pre fitted to
your dashboard. Ensure that the handle is
pushed fully home, refer to Fig 10.
1
2
3
4
5
6
7
Adjusting bracket
Square head pad
Foam pad
Adjusting stud (head pad)
Plain nuts and washers (x 2)
Bolts and washers (x 2)
Nyloc nuts and washers (x 2)
Fig 9 Head restraint assembly
50
Screw one of the plain nuts (3) onto the
head pad stud followed by one plain washer (4),
pass the stud rearwards through the vertical slot
in the adjusting bracket and fix into place with
the remaining plain washer (4) and plain nut (3).
Finally tighten all fixings in accordance with
Table 3.
TABLE 3 HEAD RESTRAINT FIXINGS
TORQUE FIGURES
Location
Torque
Bracket to roll cage/bar
34 Nm
Adjusting nuts (once adjusted)
34 Nm
51
When the car is complete and you have
obtained a comfortable driving position this
assembly can be adjusted up, down, forwards
and backwards to give the optimum position in
relation to your crash helmet. Once this position
has been set, it is advisable to trim off any of the
excess studding.
1 Pull handle
2 Dash mounting boss
Fig 10 Fire extinguisher pull handle
53
Pass the inner cable through the hole in
the cable locater fitted to the extinguisher lower
handle, then through the opposing hole in the
top handle.
54
Secure the inner cable in place using the
solder-less nipple supplied, refer to Fig 11.
55
Trim off excess cable to approximately 30
mm.
56
Apply a small piece of tape or heat shrink
to the trimmed inner cable to prevent fraying.
NOTE
It is advisable to allow approximately 5 mm of
free play, as the scrutineer may want to ensure
that the cable is free whilst scrutineering your
car.
FIRE EXTINGUISHER PULL HANDLE
NOTE
The
fire
extinguisher
handle
is
not
SVA-compliant and therefore will not have been
fitted at the factory, even though the rest of the
extinguisher system may have been. The fire
extinguisher system is intended for track use. Do
not fit prior to SVA test.
Section 16
Page 8
OPT 01
SECTION 16 - OPTIONS
Fig 13 Filler cover and boot carpet removed
WARNING
1
2
3
Outer cable
Inner cable
Cable locator
4
5
Top handle
Solder-less nipple
Wear appropriate eye protection
carrying out drilling operations.
Fig 11 Fire extinguisher inner cable location
AERO FUEL FILLER CAP
3
1
2
whilst
58
Remove the old cap with the the key and
block the filler hole with tape or cloth. Remove
the two self-tapping screws that retain the top of
the filler neck to the filler boss, the rubber hoses
will then allow the filler neck to be pulled out of
the way.
59
Drill out the six rivets that retain the old
filler boss. This must be done very carefully to
avoid damage to the back panel. It is
recommended this is done with a hand or air drill
to eliminate the sparks caused by an electric
drill.
5
1
2
3
4
4
Filler cap
Gasket
Neck adaptor
Keys
5
6
6
M5 x 12 cap head
screws (x2)
M5 x 16 CSK
head screws (x6)
Fig 12 Kit contents
WARNING
There is always a risk of fire or explosion
when working on fuel tanks. Take the utmost
care with preparations.
Fig 14 Drill out the six rivets
60
The old filler boss can then be carefully
pulled away from the back panel.
57
If the Aero filler cap is to be retro fitted,
the original cap must first be removed as
follows. Undo the two self-tapping screws and
remove the black filler neck cover inside the
boot. Remove the boot carpet to prevent it
getting dirty.
Fig 15 Old filler boss removed
OPT 01
Section 16
Page 9
SECTION 16 - OPTIONS
61
Take the gasket supplied with the kit and
carefully align the hole in the gasket with the
hole in the back panel. Ensure two of the fixing
holes are positioned at 3 o’clock and 9 o’clock.
64
Re-position the filler neck and gasket up
against the back panel. Push the filler flange
through the hole in the panel. Care must be
taken to ensure correct orientation of the flange
(One of the four 'scallops' has been enlarged to
enable a petrol pump nozzle to pass further into
the neck. It is important that this larger scallop
is orientated towards the top), refer to Fig 19.
Retain with the six M5 x 16 CSK head screws
and pull these up evenly to ensure the flange
locates correctly on the O-ring.
Fig 16 Gasket positioned on back panel
62
Mark the new hole positions and carefully
centre punch the marks. Taking great care, drill
the holes (6 mm diameter).
Fig 19 Fit flange
Fig 17 Carefully drill new holes
65
Remove all drillings from the inside of the
boot and re-fit the boot carpet. Reposition the
filler neck cover and retain it using the two selftapping screws.
63
Fit the black spacer to the filler neck using
the two M5 cap head screws supplied in the kit.
The spacer will be a tight fit on the neck due to
the O-ring and it must be pulled up evenly. The
holes for the spacer are slotted to allow for
correct alignment with the holes in the back
panel. Tighten the screws fully after the
alignment has been checked.
Fig 20 Job complete
66
All that remains is to remove the tape or
cloth from the neck and fit the new cap.
NOTES
(1)
Remember to fit the key to the new cap to
your key ring.
Fig 18 Spacer fitted to filler neck
Section 16
Page 10
(2)
On some older fuel filler necks it is
possible that the restrictor flap inside the neck
could prevent the fuel nozzle from entering the
neck fully. If this is the case with your neck then
a new neck will be required or the restrictor flap
will need to be removed.
OPT 01
SECTION 16 - OPTIONS
HIGH LEVEL BRAKE LIGHT
Fig 22 Drilling central popper on SV
1
2
3
4
5
6
7
8
9
10
11
12
13
Wiring sub-loom
Wiring to high-level brake light
Rivets (x2)
Male Lucar terminals and shrouds (x2)
Nut and plastic bolt from light kit
Replacement popper
Rubber grommet
Sticky pad
Cable ties
Larger spare wheel boss
Cable insulation
Light support bracket
High level brake light
70
Using masking tape to protect the
paintwork from damage, position the bracket as
shown in Fig 23, passing the new, larger spare
wheel boss through the bracket and back panel,
ensuring only one large washer is used in
between the back panel and spare wheel
support channel.
Secure the boss using
the 5/32” nut, finger tight only.
Fig 21 Kit contents
Fitting the bracket
67
If retro-fitting, the spare wheel must first
be removed from the car.
68
Working from inside the boot, unscrew
the 5/8” nut which holds the spare wheel boss to
the back panel, and remove the boss, taking
care not to drop the large washers.
WARNING
Wear eye protection when carrying out
drilling operations.
69
Centre mark a point 25 mm below the top
of the back panel, on the vehicle centre line.
Centre punch this, and drill a 5/32” hole, taking
care not to damage the back panel. In the case
of the SV, simply remove the central hood/boot
cover popper using a 5/32" drill, as shown in
Fig 22.
OPT 01
Fig 23 Alignment of bracket
71
Using a spirit level, refer to Fig 23, adjust
the bracket until the light platform is exactly
parallel to the top of the back panel, and mark
from inside the boot through the previously
drilled hole, onto the bracket.
72
Remove the bracket, centre punch and
drill the hole using a 5/32” drill. Re-fit the
bracket, and secure the upper mounting using
the large black rivet, or for an SV the smaller
countersunk
rivet
passed
through
the
replacement popper. Apply threadlock, and
tighten 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.
Section 16
Page 11
SECTION 16 - OPTIONS
74
Split the light and feed the terminated end
of the supplied wires through both the hole in the
base of the light unit, and the nut supplied with
the light unit. Insert the plastic bolt from the
underside, and tighten nut to secure in place as
shown in Fig 24. Connect the terminals to the
male connectors on the metal strips on the bulb
holder.
Fig 26 View from under RHS rear corner
Fig 24 Wire routing through light unit
75
Centre mark a point on the vehicle centre
line, 35 mm above the edge of the spare wheel
mounting boss. Centre punch, and carefully drill
a 1/4” hole, as shown in Fig 25. Masking tape
can be used to protect the paintwork. Push the
supplied rubber grommet into the hole.
77
Re-assemble the light unit, and feed the
cable insulation over the wires. Push them
through the hole in the sticky pad and the hole in
the platform on the bracket, then use the sticky
pad to fix the light in place, shown in Fig 27.
Feed the wires down through the RH support
tube of the bracket, then through the rubber
grommet into the boot area, shown in Fig 28.
Fig 25 Drilled hole above spare wheel boss
WARNING
Fig 27 Exploded view of assembly
Disconnect the negative (-) terminal from the
battery before carrying out electrical work.
78
Cut the wires from the light unit to length
so the connections can be concealed behind the
filler neck cover, and terminate with the male
Lucar terminals and shrouds. Connect these to
the sub-loom; grey/red to the green/purple, and
grey to the black wire. Use the cable ties
provided to tidy and secure the wiring, and re-fit
the filler neck cover.
76
Working from inside the boot, unscrew the
four retaining screws that secure the fuel filler
neck cover, and remove it. From under the right
and rear corner of the car, feed the terminated
end of the supplied sub-loom up into the boot
area, through the hole exposed by removing the
filler neck cover. Disconnect the wiring plugs
leading to the rear light cluster, and connect the
plugs from the sub loom in between, as shown
in Fig 26.
Section 16
Page 12
OPT 01
SECTION 16 - OPTIONS
1
2
Plug on the wheel speed sensor loom
Plug on the main wiring loom
Fig 28 Wires from support tube entering boot
Fig 30 Wheel speed sensor plug
79
Reconnect the battery, and with the aid of
an assistant, check to ensure that the high-level
brake light operates in conjunction with the
brake lights in the rear clusters, and re-fit the
spare wheel. The completed assembly is shown
in Fig 29.
81
Insert the speed sensor in to the bracket
and secure with locknut (do not tighten). Refer
fig. 31. Remove 2 caphead bolts on the LHS
brake caliper and fit the bracket with speed
sensor to the caliper (do not tighten). There are
four bolts on the brake dis
c, speed sensor should be adjusted by
aligning with one of the four bolts. Select any of
those bolt by rotating the disc and Adjust the
speed sensor front edge so that the gap
between the sensor and the bolt on the disk is 23 mm. tighten the lock nut on the sensor.
Tighten the bolt on the caliper (50NM) and
secured the bracket in place. Refer fig.32
Fig 29 Completed assembly
Stack dash speed sensor fitment
80
Route the speed sensor loom through the
hole on the tunnel top along with main wiring
loom to the front of the chassis near LHS wheel.
Use cable ties to route the loom where
necessary. Connect the speed sensor plug to
the plug on main wiring marked as wheel sensor
refer fig. 30
1
2
3
Seed sensor Bracket
Lock Nut
Speed sensor
Fig 31 Wheel speed sensor Bracket
OPT 01
Section 16
Page 13
1 Caliper Caphead bolts
2 Speed sensor
3 Speed sensor Bracket
Fig 32 Wheel speed sensor
SECTION 16 - OPTIONS
PAGE INTENTIONALLY BLANK
OPT 01
Section 16
Page 15
SECTION 17 - ELECTRICAL
TABLE OF CONTENTS
Para
1
Page
General ......................................................................................................................
2
Main vehicle wiring harness for all standard instrumentation, Ford Sigma variants ...
SVA engine harness (Sigma).....................................................................................
R400 Engine Harness ………….................................................................................
Main Chassis Harness (standard dash)…………………………………………………..
R400 Main Chassis Harness (Stack dash)……………………………………………….
3
4
5
6
7
Fig
1
2
3
4
5
ELE 01
Section 17
Page 1
SECTION 17 - ELECTRICAL
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.
problems are experienced check the following vehicle earth points in the first instance.
If
 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 car
electrical 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.
Section 17
Page 2
ELE 01
SECTION 17 - ELECTRICAL
Fig 1 Main wiring harness for all standard instrumentation, Ford Sigma variants
ELE 02
Section 17
Page 3
SECTION 17 - ELECTRICAL
Fig 2 Engine harness (Sigma)
ELE 02
Section 17
Page 4
SECTION 17 - ELECTRICAL
Fig 3 R400 Engine Harness
ELE 02
Section 17
Page 5
SECTION 17 - ELECTRICAL
Fig 4 R400 Main Chassis Harness (standard dash)
ELE 02
Section 17
Page 6
SECTION 17 - ELECTRICAL
Fig 5 R400 Main Chassis Harness (Stack dash)
ELE 02
Section 17
Page 7
INDEX
Section and
Para No.
A
ADJUSTABLE DAMPER PLATFORMS
A-FRAME
AFTERSALES
AIR CLEANER
ANTI-CAVITATION SYSTEM
ANTI-ROLL BAR (FRONT)
ANTI-ROLL BAR (REAR)
4-30
8-26
1-4
6-77
16-3
4-19
8-24
B
BASIC DEFINITIONS
BATTERY
BATTERY MASTER SWITCH
BELL-HOUSING
BOOT COVER
BOOT FLOOR
BRAIDED BRAKE HOSE - FRONT
BRAIDED BRAKE HOSE - REAR
BRAKE - FILLING AND BLEEDING
BRAKE CALLIPER (FRONT)
BRAKE CALLIPER (REAR)
BRAKE MASTER CYLINDER
BRAKEPADS
BRAKEPIPES - FRONT
BRAKEPIPES - REAR
BRAKES
BUILD INFORMATION (GENERAL)
2-3
6-36
16-15
5-1
12-24
8-57
4-23
4-23, 8-9
14-2
4-25
8-5, 8-42
3-10, 4-26, 14-2
8-41, 14-12
4-26, 15-24
3-27, 15-24
8-39, 14-5, 15-6
2-20
C
CARPET - BOOT
CARPET - FOOTWELL
CARPET - SEATBACK
CARPET - TRANSMISSION TUNNEL
CATALYST GUARD
CLUTCH RELEASE MECHANISM
CONSUMABLES
CONTACT INFORMATION
COOLANT
COOLANT HOSES
COOLING FAN
COOLING SYSTEM
CYCLE WING
CYCLE WINGSTAY
2A-11, 9-21, 16-57
9-16
9-5, 9-31
9-9
6-51
5-3
1-1, 2-8
1-4
2-8, 6-74, 14-24
6-56,
6-56, 6-61, 14-33
6-53
10-1, 11-13, 15-32
4-14
D
DE DION EARS
DE DION TUBE
DESIGN SPEEDS
DESIGN WEIGHT
DIFFERENTIAL BREATHER
DIFFERENTIAL FITTING
DIFFERENTIAL LUBRICATION
DISCLAIMER
DRIVESHAFTS
8-5, 8-31
7-1, 8-3
15-14
15-13
7-3
7-7
7-14, 8-56
1
3-30
Index
Page 1
INDEX
Section and
Para No.
E
ELECTRICAL CONNECTIONS
ELECTRICAL CONNECTOR DIAGRAMS
EMISSIONS
ENGINE CONTROL UNIT (ECU)
ENGINE MOUNTING BRACKETS AND RUBBERS
ENGINE, SPEED – MAXIMUM
EXHAUST SYSTEM
EXPANSION BOTTLE
EXTERNAL PROJECTIONS
6-27, 11-14
17
15-23
6-28
6-12
15-14
6-43
6-63, 14-24
15-5
F
FASTENER FIXING TOOL
FIBREGLASS
FRONT SUSPENSION AND STEERING
ALIGNMENT
FUEL FILLER COVER
FUEL SYSTEM
12-42
10
14-45
16-57
6-39
G
GEAR LEVER
GEARBOX
GEARBOX OIL
6-25
5
14-28
H
HANDBRAKE ADJUSTMENT
HANDBRAKE CABLE
HANDBRAKE LEVER/MECHANISM
HARNESS – FOUR POINT
HARNESS – SIX POINT
HEATER
HOOD FITTING
HOODSTICKS
HOODSTRAPS
HORN PUSHBUTTON
HORNS
8-52, 8-54
8-46
8-45
9-31
9-35
6-66
12-7
12-3
12-3
3-18
6-14, 16-9
I
INDICATORS – FRONT
INDICATORS – REPEATER
INERTIA REEL SEATBELTS
INTERIOR PROJECTIONS
INTERIOR TRIM
11-4
10-3
9-30
15
9
K
KNEE TRIM PANELS
9-26
L
LAMBDA PROBE
LIGHT – HEAD
LIGHT – NUMBER PLATE
LIGHT – REAR
LIGHT – REAR FOG
LIGHT – REVERSE
6-50
11-7
11-25
11-16
11-24
11-24
Index
Page 2
INDEX
LUBRICANTS
Section and
Para No.
2-8
M
MIRROR – EXTERIOR (SIDESCREEN)
MIRROR – EXTERIOR (SCREEN STANCHION)
MIRROR – INTERIOR (SUPERLIGHT)
MIRROR – REAR VIEW INTERIOR
12-23
12-21
9-54
9-53
N
NOISE
NOSE BADGE
15-22
9-52
O
OIL – ENGINE
OIL FILLING – DIFFERENTIAL
OIL FILLING – GEARBOX
OIL PRESSURE
2-8, 14-31
8-56
14-28
14-34
P
PACKAGE CONTENTS
PARTS RECOGNITION
PEDAL ADJUSTMENT
PEDAL BOX
POST BUILD CHECK
PROPSHAFT
PROTECTIVE STEERING
2A
1-6, 2A
3-26, 6-76
3-7, 3-26
1-8
7-6
15-25
R
RACE CARS AND SVA
RADIATOR
RADIO INTERFERENCE SUPPRESSION
RADIUS ARMS
REAR SUSPENSION
REGISTRATION PROCEDURE
REVERSE LIGHT SWITCH
ROLL OVER BAR – TRACK DAY/FIA
ROLL OVER BAR – STANDARD
15-41
6-58
15-19
8-14
8
15-45
6-26
16-20
16-18
S
SCREENWASHER
SCUTTLE EDGE TRIM
SEATBELTS
SEATS
SIDESCREEN
SINGLE VEHICLE APPROVAL
SPEED SENSOR
SPEEDOMETER
SPRING DAMPER UNITS (FRONT)
SPRING DAMPER UNITS (REAR)
STARTER MOTOR
START-UP
STEERING – ARMS
STEERING – COLUMN
STEERING – RACK
STEERING COLUMN (QR)
STEERING WHEEL – MOMO
6-2
9-51, 15-29
9-30, 9-31, 9-35
9-40
12-13
15
8-37
15-16
4-11
8-12
5-9
14
3-5
3-6
3-1
3-24
3-23
Index
Page 3
INDEX
STEERING WHEEL – MOTOLITA
STEERING WHEEL FITMENT
Section and
Para No.
3-19
3-18
T
TECHNICAL HELP
THERMOSTATIC FAN SWITCH
THROTTLE CABLE
TONNEAU COVER
TORQUE FIGURES
TOWING
TRACK ROD ENDS
TRANSMISSION TUNNEL TOP
TYRE PRESSURE
TYRES
1-7
6-58
3-26, 6-75
12-32
14-53
15-15
3-5
9-12
14-50
13-2
U
UPRIGHTS
4-13
W
WATTS LINK
WHEEL FITMENT
WINDSCREEN – WIPERS
WING PROTECTORS
WING – FRONT (CYCLE)
WINGS – REAR
WIRING DIAGRAMS
WISHBONE - LOWER
WISHBONE - UPPER
8-17
13
6-6
10-16
10-1
10-20
17
4-5
4-8
Index
Page 4
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