A4 Assembly Guide Edition 1.2

ASSEMBLY GUIDE
EDITION 1.2
ASSEMBLY GUIDE
EDITION 1.2
Your feedback and comments are welcome: assemblyguide@caterham.com
For help and build support enquiries contact Derek Howlett: derek.howlett@caterham.com / 01322 625827
Welcome to your new Caterham kit
Building your own Caterham is immensely rewarding and satisfying. Of course, it should be remembered
that you are building a high performance sports car, not a flat-pack wardrobe, so it will be a little challenging
from time to time; but we’ve set out to make it as easy as possible for anyone, whatever their skill level and
help is just a phone call away.
But before you do anything else, pop the kettle on or pour yourself a G&T with a slice; and
READ THE NEXT THREE PAGES – THEY ARE REALLY IMPORTANT

No, they will not be very exciting unfortunately, but they are important nonetheless and you will regret it later
if you don’t.
i
ASSEMBLY GUIDE
So there are four important things we need to think about NOW before
picking up a spanner:
• This isn't the only guide you'll need
• When to apply for an IVA test
• Photography (no, really)
• Arranging a post build check
Although we have made this guide as comprehensive as possible, the requirements of IVA change from
time to time and even from test centre to test centre. Therefore, it MUST be read in conjunction with the ‘IVA
Checklist Guide’, the latest version of which can be downloaded from the Caterham website. You’ll find the
VOSA and the DVLA are a suspicious bunch and in order to register your car, you will need to provide proof
refer-to-IVA-manual symbol in the bottom of each illustration where attention is required. Reading through
that it is amateur built. When you apply for registration, you will need to include photos from various stages
it now, will save pain later! Don’t assume that because you’ve found a reference to one item relating to that
of you build, which will demonstrate to them that it is an ‘amateur build’.
page, it is the only one…
Recruiting a few extras (your kids, your spouse, the cat, etc.) and some props (last year’s Xmas tree, a radio
Once you have completed the assembly of your Seven, you are required by law to present it for an ‘Individual
from the 1980’s and a rusty bike) will all contribute to a more authentic home-garage feel; proving that no
Vehicle Approval’ test (better known as IVA), which is conducted by the Vehicle and Operator Services
professional help (i.e. commercial workshop/garage) was involved in the build. Of course, feel free to have
Agency (VOSA) at a regional test centre.
yourself working away on the kit in the photos if one of your ‘extras’ can be trusted with the camera (not the
cat; they never get the exposure right).
We STRONGLY recommend that you apply for your IVA appointment at least a month before you think you
will complete your build, to allow for the application form to be processed at the snail’s pace of bureaucracy.
Once accepted, your IVA application is valid for 6 months and test dates can be changed up to a minimum
of 3 working days prior to your appointment with VOSA (any later and you may incur a charge).
The application form and a guide on how to complete it, is contained within an envelope of documents
provided with your kit and which is probably acting as a coaster for your g&t at the moment. Take this
moment to find it and remove it from the garage and place it somewhere safe (and memorable).
ii iii
ASSEMBLY GUIDE ASSEMBLY GUIDE
Finally, we know you haven’t started yet, but we need to tell you about the Post Build Inspection now, due to
availability at our service centres and the time it takes to get you a slot. Plan ahead!
What is the Post Build Inspection? This is a free service offered by all Caterham service centres which we
wholeheartedly recommend you take up on prior to your IVA test. It ensures that your car is correctly
assembled and is road-worthy. All safety and operational aspects of your Seven will be checked, concluding
in a road test. This will enable us to advise you of any corrective work that may be required (which we will be
happy to carry out for you*). It is important to note that this is not the same as the IVA test and whilst every
effort will be made to ensure your car passes, there is NO GUARANTEE of a first time IVA pass.
That’s it, we’re ready to start assembly
*Obviously any additional work is not for free, but we will speak to you first so you can decide whether you
want to pay us to do the corrections or you want to do them yourself. ENJOY
REMEMBER: Post Build Inspection slots are in high demand at our service centres and there may be a
two-month lead time at busy times, so please check on availability and book ahead!
All our service centres will be able to offer you a Post Build Inspection and IVA service, where they take the
car to IVA on your behalf. This tends to increase the likelihood of a first time pass and means you don’t need
to take a day out to endure the test, which is beyond dull.
As a guide, the Post Build Inspection through to registration can take around 6 weeks to complete.
iv v
MY BUILD NOTES HINTS & TIPS
Download the IVA Checklist Guide: www.caterhamcars.com
A ‘nyloc’ nut is one with a nylon insert that gets cut by the bolt
Book IVA Test thread, making it resistant to unwinding itself. This means that
When using a torque wrench, listen/feel the click they should not be repeatedly re-used. This guide covers optional
Take plenty of photos and then stop. It does not need to be any tighter Chris B equipment your car may not have!
and you might actually weaken the fixing by Tiago O
Arrange post build check
‘over‑torquing’ it. Always wind your torque wrench
setting back to free when you’ve finished with it.
John K
When using a spanner, always use the ring end wherever

1Nm of torque equals 0.736lbft. Thread lock is used to stop possible. The open end is really only for those times that access
Mick F something coming undone, but is too limited for a ring spanner or socket.
it only needs a little drop on Mick A
the thread to be effective.
Jamie A
Generally, metric Nyloc nuts have a Left and right are as viewed
blue nylon insert and imperial ones a from the driver’s seat.
white nylon insert. Teabag, boiling water, then the milk, in that order. Harrison P
Grant P Simon L
A ‘caphead bolt’ has a circular head with a hexagonal drive

You can tell if you have ‘wide track suspension’ car by looking at the front inside it. It is tightened with an allen key or hex drive socket.
dampers. Wide track has a 25mm long hexagonal spacer between the top Capheads are useful where there is limited space around
spring retainer and the mounting bush. the head for a spanner or socket. They look nice too!
Richard T
Matt T
A ‘spring washer’ has a split in it and squashes up

A bolt size is described by its diameter (e.g. M10=10mm)
closed when a fixing is tightened. It is usually used
by the length not including the head (e.g. 65mm).
under a bolt head to help resist it coming undone.
James A
John S
This was more fun than I ever expected!
vi 1
F#©K!
$H@%
!
B?LL#
¢*$!
#©K!
F
%!
$H@
#¢*$!
L
B?L
Speak to our Expert Derek Howlett
derek.howlett@caterham.com
01322 625827
Video Guides
https://www.youtube.com/
user/OfficialCaterhamUK
F#©K! Playlist coming soon
$H@%
!
B?LL#
¢*$!
2 3
KEY KEY
S Y M B O L S F I X I N G S T O O L S
A
SERIAL
44
Pack
NUMBER
A
PACK NUMBER
1
SERIAL
44
Item number Pack 30F015B
NUMBER
Advice from factory PACK NUMBER

30F015B Flat head
professionals
FRONT SUSPENSION DeDION CARS (METRIC) Allen key Ruler Spray adhesive Trolley jack
FRONT SUSPENSION DeDION CARS (METRIC)
This pack may include extra fasteners to cover different options
This pack may include extra fasteners to cover different options screwdriver
AA
BASIC PART
ITEM
BASIC PART
QTY USED ON ILLUSTRATION ITEM QTY USED ON ILLUSTRATION
DESCRIPTION NUMBER DESCRIPTION NUMBER
AJ
Lower wishbone
Fixing item
Bolt M12 x 100
1 AA Grade 10.9
BM12X100 2
rear Bolt M12 x 100 Lower wishbone
1 AA BM12X100 2
Grade 10.9 rear
AM
+
Bolt M12 x 65 Lower wishbone
2 AB 2
Scissors
BM12X65
front
Assistance Grease Spray lube WD40
Grade 10.9
Now is a good time to take 2 AB

Bolt M12 x 65
Grade 10.9
BM12X65 2
Lower wishbone
front
some photos
Bolt M10 x 65 Upper wishbone
3 AC BM10X65 2
Grade 10.9 rear
S Pack / R Pack Bolt M10 x 60 Upper wishbone

3 AC
Bolt M10 x 65
Grade 10.9
BM10X65 2
Upper wishbone
rear
specific instructions
4 AD BM10X60 2
Grade 10.9 front
x4 (Indicates number
front of each fixing required)
Bolt M8 x 40 Anti-roll bar Bolt M10 x 60 Upper wishbone
5 AE Grade 10.9
BM8X40 4
mounting brackets
4 AD Grade 10.92 BM10X60
35 Nm
Axle stand Junior hacksaw Side cutters Stanley knife
mm Required torque (where applicable) 6 AF
Plain Nut M14
x 1.5 thread
NMPH14 1
Temporary use to
help lock upper
wishbone ball joint Bolt M8 x 40 Anti-roll bar
5 AE BM8X40 4
Grade 10.9 mounting brackets
Reminder to apply for your IVA test 7 AG Nyloc Nut M12 NMYF12 2
Lower wishbone
rear
Temporary use to
S3 6 AF
Plain Nut M14
x 1.5 thread
NMPH14 1 help lock upper
S3 / S5 chassis specific instructions 8 AH Nyloc Nut M10 NMYF10 4 Upper wishbone

wishbone ball joint
S5 Plain Washer
7 AG Nyloc Nut M12 NMYF12 2
Lower wishbone Cable tie Latex gloves Silicon Super glue
9 AJ M12 WPCM12 18 Lower wishbone rear
Chamfered
Repeat on other side

Plain Washer
Refer to IVA Checklist Guide

Anti-roll bar
(Greyed out4 area indicates fixings are not

10 AK M8 WPHM8 4
REPEAT Heavy duty mounting brackets 8 AH Nyloc Nut M10 Upper wishbone
NMYF10
11 AL
Plain Washer
⅜" x ¾"
Heavy duty
WPH3/8 2 Brake pipe required for current step)
Plain Washer
9 AJ 18 Lower wishbone
Combination
M12 WPCM12
Drawings are for illustrative purposes only and are not to scale. Page 1 of 2 Chamfered
Long nose pliers Silicon gun Tape

Plain Washer
Anti-roll bar
spanner
10 AK M8 WPHM8 4
Heavy duty mounting brackets
Plain Washer
11 AL ⅜" x ¾" WPH3/8 2 Brake pipe
Heavy duty
Drawings are for illustrative purposes only and are not to scale. Page 1 of 2
Copper grease Muscle Socket wrench Tape measure
Socket wrench Thread lock /
LO
Drill Pop rivet gun
CT
IT
E
(allen) LocTite
Drill bit Power adhesive Spanner Torque wrench
Pozidrive
Engine hoist Spirit level Torx
screwdriver
4 5
LET’S GET READY LET’S GET READY
P A R T S T O O L S
x3
F I X I N G S T I P S
When deciding how high your axle stands Some tape or foam on the
should be (the higher the better for working top of the axle stands will
on), don’t forget that a complete car will stop them scratching the
need to come down off them, so make sure chassis.
your trolley jack can reach and lift the Matt T
height you set them too!
Mick F
6 7
START WITH THE SUSPENSION WISHBONES START WITH THE SUSPENSION WISHBONES
P A R T S T O O L S
1 Lower wishbone
17mm AC35
35 47Nm
19mm mm
AH
mm
2 Upper wishbone
17mm
3 Wishbone bush sleeve
19mm
AD
35
mm
35
mm
47Nm 3
AH
94
A A
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER
PACK NUMBER
30F015B
PACK NUMBER
30F015B For now, only tighten the nuts/bolts lightly and then Leave bolt AD AA
This pack may include extra fasteners to cover different options torque them up when the car is finished and on the loose for now, 35
mm
AJ
35
mm
81Nm
ground. This sets the bushes correctly and ensures as we have to

BASIC PART BASIC PART
AG
ITEM QTY USED ON ILLUSTRATION ITEM QTY USED ON ILLUSTRATION
Bolt M12 x 100 Lower wishbone

x2 Spring Washer Lower wishbone
x2
the best handling. take it back out
1 AA BM12X100 2 12 AM WSHM12 2
Grade 10.9 rear M12 front
Anti-roll bar
2 AB
Bolt M12 x 65
Grade 10.9
BM12X65 2
Lower wishbone
front x2 13 AN
Spring Washer
M8
WSHM8 6
mounting brackets &
upper damper
mount Harrison P again to put
3 AC
Bolt M10 x 65
Grade 10.9
BM10X65 2
Upper wishbone
rear x2 14 AP
Washer ⅜"
Shake-proof
WSS3/8 2 Brake pipe
the headlight AJ
4 AD
Bolt M10 x 60
Grade 10.9
BM10X60 2
Upper wishbone
front x2 15 AR Nyloc Nut ½"
Half height
NFYH1/2 2 Wing stay
bracket on later.
5 AE
Bolt M8 x 40
Grade 10.9
BM8X40 4
Anti-roll bar
mounting brackets
16 AS Nyloc Nut ½"
Full height
NFYF1/2 2
Front brake, upright
mounting (std track
ONLY)
The big washers are chamfered and John K
6 AF
Plain Nut M14
x 1.5 thread
NMPH14 1
Temporary use to
help lock upper
wishbone ball joint
the chamfered side should be towards 1
7 AG 2
Lower wishbone
x2
the wishbone.
AB
Nyloc Nut M12 NMYF12
rear
Alex H
8 AH Nyloc Nut M10 NMYF10 4 Upper wishbone
x4 35
mm
35
mm
81Nm AJ
x14
Plain Washer
AM
9 AJ M12 WPCM12 18 Lower wishbone
Chamfered
10 AK
Plain Washer
M8 WPHM8 4
Anti-roll bar
mounting brackets
REPEAT
Heavy duty
Plain Washer
Heavy duty
8 9
NOW FOR THE STEERING RACK NOW FOR THE STEERING RACK
P A R T S T O O L S
1 Steering rack
13mm
BC
35 35 20Nm
2 Rack clamps mm mm
BG
3
3 Column universal joint 5mm
4 Track rod end

10mm
13mm BA
5 IVA cover 22mm
¾"
B
SERIAL
55
Pack
NUMBER
PACK NUMBER
30S003B Finding the right IVA cover isn’t The trackrod end needs to screw on
STEERING DeDION CARS (METRIC)
This pack may include extra fasteners to cover different options obvious because it is effectively about 12 turns (it will be properly set
BH
a long cap. To use it, you cut the later when the tracking is done).
BASIC PART
35 35 11Nm
ITEM QTY USED ON ILLUSTRATION
DESCRIPTION NUMBER
mm mm
x4 BK 1
Caphead Bolt
closed end off.

1 BA M6 x 70 BMCH6X70 4 Rack clamps
DIN 912
Matthew H
2 BB Bolt ¼" x 1½" BF1/4X1.1/2 2 Column clamp
Jamie A
3 BC
Bolt M8 x 35
Grade 8.8
BM8X35 2
Column to rack
universal joint x2
Nyloc Nut ½"
4 BD Half height
NFYH1/2 1 Steering wheel boss
5 BE Plain Nut ½" NFPF1/2 2 Track rod lock nut

x2 Don't fully 5
tighten steering 2
Column clamp
4
Plain Nut ⁷⁄₁₆"
6 BF NFPFH7/16 1
Half height grubscrew locknut
7 BG Nyloc Nut M8 NMYF8 2

Column to rack
universal joint x2 rack for now.
Dan D
8 BH Nyloc Nut M6 NMYF6 4
Steering rack
clamps x4
Plain Washer
9 BJ ½" x 1⅛" WPH1/2 1 Steering wheel boss
Chamfered
x4
Plain Washer
Rack clamps and
10 BK ¼" WPH1/4 6
Heavy duty column clamp
BE
Spring Washer ¼
11 BL Heavy duty
WSH1/4 2 Column clamp
10 11
AND THEN THE DAMPERS AND THEN THE DAMPERS
P A R T S T O O L S
1 Spring / damper
6mm
2 Lower damper sleeve
3 Upper damper sleeve 6mm

7 3
6mm 7
94
A A 35 35
AN 25Nm
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER
mm
Put the top of the damper on first The bottom can be a tight fit!
PACK NUMBER PACK NUMBER mm
30F015B 30F015B

This pack may include extra fasteners to cover different options and be careful not to let it swing into Mick F
the side of the chassis.
Bolt M12 x 100 Lower wishbone Spring Washer Lower wishbone

1 AA BM12X100 2 12 AM WSHM12 2
Anti-roll bar
Grant P
2 AB
Bolt M12 x 65
Grade 10.9
BM12X65 2
Lower wishbone
front
13 AN
Spring Washer
M8
WSHM8 6
mounting brackets &
upper damper
mount
x2
Bolt M10 x 65 Upper wishbone Washer ⅜"
3 AC BM10X65 2 14 AP WSS3/8 2 Brake pipe
Grade 10.9 rear Shake-proof
Bolt M10 x 60 Upper wishbone Nyloc Nut ½"

4 AD BM10X60 2 15 AR NFYH1/2 2 Wing stay
Grade 10.9 front Half height
1
Bolt M8 x 40 Anti-roll bar Nyloc Nut ½"
5 AE BM8X40 4 16 AS NFYF1/2 2 mounting (std track
Grade 10.9 mounting brackets Full height
ONLY)
Temporary use to
Plain Nut M14
6 AF x 1.5 thread
wishbone ball joint

Lower wishbone
Fixings not contained in the pack will be
supplied loosely fitted to the chassis and
rear
35 35 25Nm
mm
the wishbone mm
Plain Washer
Chamfered
Plain Washer
Anti-roll bar
10 AK M8 WPHM8 4
2
Plain Washer
Heavy duty
12 13
IT’S TIME FOR THE WINGSTAYS IT’S TIME FOR THE WINGSTAYS
P A R T S T O O L S
1 Wingstay 19mm
22mm
¾" 1 x ⅛"
2 Front brake & upright assembly
22mm
⅛"
T I P S 1
The drilled hole is for the side repeater earth that we’ll fit later. It’s easier to
drill from the top and down through both sides of the tube, rather than through
one side from the bottom (where the earth will be fixed).
F I X I N G S Tiago O
35 35 61Nm
mm mm
94
A A
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER
PACK NUMBER PACK NUMBER

30F015B 30F015B

Put the ‘upright’ into the lower Some of the fixings
35 35
ITEM
BASIC
DESCRIPTION
PART
NUMBER
QTY USED ON ILLUSTRATION ITEM
BASIC
DESCRIPTION
PART
NUMBER
QTY USED ON ILLUSTRATION
wishbone joint then attach required and shown on the mm mm
81Nm AR 2
1 AA
Bolt M12 x 100
Grade 10.9
BM12X100 2
Lower wishbone
rear
12 AM
Spring Washer
M12
WSHM12 2
Lower wishbone
front
the steering before tightening drawings, such as the ball
the bottom nut. This stops it joint nut, are already on
Anti-roll bar
Bolt M12 x 65 Lower wishbone Spring Washer mounting brackets &
2 AB BM12X65 2 13 AN WSHM8 6
Grade 10.9 front M8 upper damper
mount
3 AC
Bolt M10 x 65
Grade 10.9
BM10X65 2
Upper wishbone
rear
14 AP
Washer ⅜"
Shake-proof
WSS3/8 2 Brake pipe all swinging around hitting the the part and not in the
side of the chassis. fixing pack. Use the plain
4 AD
Bolt M10 x 60
BM10X60 2
Upper wishbone
15 AR Nyloc Nut ½" NFYH1/2 2 Wing stay
x2
nut to pull the
Front brake, upright John S Anthony L

x2
top ball joint
ONLY)
Temporary use to
6 AF
Plain Nut M14
x 1.5 thread
wishbone ball joint x1 home before
Lower wishbone
rear
using a nyloc,
Remove and discard the washer that comes on the back of otherwise the 35 35
AS 54Nm
9 AJ
Plain Washer
M12
Chamfered
WPCM12 18 Lower wishbone the assembly before fitting the wingstay; it's not needed. thread will spin. mm mm
Chris N WIDE
Rich T
STANDARD TRACK
Plain Washer
Anti-roll bar
35 35 54Nm
TRACK
10 AK M8 WPHM8 4
REPEAT
mounting brackets
mm
Heavy duty
mm
Plain Washer
Heavy duty
14 15
Now is a good time to take some photos Have you applied for your IVA yet?
16 17
LET THERE BE LIGHTS LET THERE BE LIGHTS
P A R T S T O O L S
1 Headlight assembly
17mm
2 Indicator pod
1
17mm
3 Indicator assembly 17mm
24mm
4 Headlight bracket
5 IVA trim
T I P S
2
It's very important to read the IVA Guide This is the trickiest CA 5
before starting this job to ensure grommets job on the car, so once
and sheathing are in the right place. It's very done you can breathe a
F I X I N G S difficult to add them once fitted! sigh of relief! 3
John S Tiago A
C
SERIAL
45
Pack
NUMBER
PACK NUMBER
4
30L002B
7
LIGHTING & HORNS
BASIC PART
DESCRIPTION NUMBER
x6
Screw 10 x ¾" Indictor assembly to
The wiring for the headlights is attached to the chassis when you receive your
1 CA 71080 6
Black Supaflange indicator pod
7
kit. The wires go through the hole in the end of the headlight bracket and out of
Screw 8 x ½" Side repeater earth
2 CB 71077 2
Black Supaflange on wingstay
the other hole in order to go up into the headlight and over to the indicator.
Screw 12 x 1½" Rear light cluster
3 CC 71079 4
Self tapping upper fixing
Screw 12 x 1" Rear light cluster

4 CD Self tapping
71078 4
lower fixing Jamie A
Horn bracket to
steering rack
5 CE Nyloc Nut M6 NMYF6 2
platform
(160/270/310)
Horn bracket to
Plain Washer
steering rack
6 CF ¼" WPH1/4 2
Heavy duty platform
(160/270/310)
7 CG
Bolt M8 x 5
Grade 8.8
BM8X50 1
Through steering
rack platform &
spacer
(420)
The tab on the headlight bracket 4 hooks
8 CH
Plain Washer
5/16"
WPH5/16 2 Bolt head/nut Glue IVA trim all around the under the wishbone bracket on the chassis.
9 CI
Nyloc Nut
M8
NMYF8 1 Horn bolt
edge of the pod before fitting. Harrison P
Chris B
REPEAT
18 19
LAST PART OF THE FRONT SUSPENSION: CONNECTING THE TWO SIDES TOGETHER LAST PART OF THE FRONT SUSPENSION: CONNECTING THE TWO SIDES TOGETHER
P A R T S T O O L S
4
1 Anti-roll bar
13mm
5
2 Anti-roll bar bracket
3 Anti-roll bar rubber AE

35 35 20Nm
mm AK
mm
4 Anti-roll bar ball AN
LO
CT
IT
E
5 Anti-roll bar dust cover
94
A
44
A
44
1
SERIAL SERIAL
Pack Pack
NUMBER NUMBER
PACK NUMBER
30F015B
PACK NUMBER
30F015B Use four small cable ties to Grease the balls and cups generously.
BASIC
BASIC
This pack may include extra fasteners to cover different options secure the dust cover. Matt T
PART PART
Mick F
1 AA BM12X100 2 12 AM WSHM12 2
Anti-roll bar
2 AB
Bolt M12 x 65
2
Lower wishbone
13 AN
Spring Washer
6
mounting brackets &
x4
Getting the assembled
BM12X65 WSHM8
mount
Upper wishbone Washer ⅜"
Check that the colour of the mounting 2

anti-roll bar fully into
Bolt M10 x 65
3 AC BM10X65 2 14 AP WSS3/8 2 Brake pipe
Grade 10.9 rear Shake-proof
4 AD
Bolt M10 x 60
Grade 10.9
BM10X60 2
Upper wishbone
front
15 AR Nyloc Nut ½"
Half height
NFYH1/2 2 Wing stay
rubbers matches the colour spot on the bar. both cups on the upper
John K wishbone can be a bit
5 AE
Bolt M8 x 40
Grade 10.9
BM8X40 4
Anti-roll bar
mounting brackets x4 16 AS Nyloc Nut ½"
Full height
NFYF1/2 2 mounting (std track
ONLY)
of a fight. It’s made of

Temporary use to
Plain Nut M14
6 AF x 1.5 thread
wishbone ball joint
LO
springy stuff, so don’t
C
Lower wishbone
TI
rear
worry that you are
TE
Use the thread lock on the thread of the
3
9 AJ
Plain Washer
M12 WPCM12 18 Lower wishbone
anti-roll bar, not in the thread of the ball. bending it.
Chamfered
Dan D Jamie A
x4
Plain Washer
Anti-roll bar
10 AK M8 WPHM8 4
REPEAT
Plain Washer
Heavy duty
20 21
FITTING THE BRAKE HOSES FITTING THE BRAKE HOSES
P A R T S T O O L S
1 Brake hose
13mm (x2)
⁹⁄₁₆"
2 Copper washer
F I X I N G S T I P S 7
94
1
A A
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER
The hose will want to curve once fitted. Brake hoses come in
30F015B 30F015B
Make sure the curve points towards packs of 3: 2 front, 1 back. 2

FRONT SUSPENSION DeDION CARS (METRIC) FRONT SUSPENSION DeDION CARS (METRIC)
This pack may include extra fasteners to cover different options This pack may include extra fasteners to cover different options
BASIC BASIC
the front of the car.

PART PART
Anthony L
1 AA BM12X100 2 12 AM WSHM12 2
Anti-roll bar
Khalfani D
Bolt M12 x 65 Lower wishbone Spring Washer mounting brackets &
2 AB BM12X65 2 13 AN WSHM8 6
mount
3 AC
Bolt M10 x 65
Grade 10.9
BM10X65 2
Upper wishbone
rear
14 AP
Washer ⅜"
Shake-proof
WSS3/8 2 Brake pipe
x2
Bolt M10 x 60 Upper wishbone Nyloc Nut ½"
4 AD BM10X60 2 15 AR NFYH1/2 2 Wing stay

ONLY)
Temporary use to
The copper washer should

Plain Nut M14
6 AF x 1.5 thread
wishbone ball joint

Lower wishbone
rear be this size.
8 AH Nyloc Nut M10 NMYF10 4 Upper wishbone James A
Plain Washer
Chamfered
Plain Washer
Anti-roll bar
10 AK M8 WPHM8 4
Plain Washer
11 AL ⅜" x ¾"
Heavy duty
WPH3/8 2 Brake pipe
x2
22 23
LET'S MAKE SOME NOISE LET'S MAKE SOME NOISE
P A R T S T O O L S 270/310/360 420
1 Horn kit (x2)

10mm
2 Spacer (miscellaneous box)
3 Bolt for spacer 13mm
1 x 8mm 11xx8mm
8mm
6mm
Miscellaneous box
2
1
24 25
FITTING THE RADIATOR ON THE STANDARD CHASSIS FITTING THE RADIATOR ON THE STANDARD CHASSIS
P A R T S T O O L S 270/310/360
STANDARD CHASSIS
1 Radiator
13mm
10mm
2 Fan brackets (x2)
3 DF
3 Fan 13mm
4 Radiator bobbins (x4)

DD
D D
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER
PACK NUMBER
30C047B
PACK NUMBER
30C047B The fan may have four The fan may have a Be careful to tighten
COOLING SIGMA
COOLING SIGMA
This pack may include extra fasteners to cover different options plastic legs or feet 'flat' section on the the fan on gently
that slot into it. rim. This should be and just with a nip.
Plain Washer
Expansion tank Expansion tank
at the top.
Bolt M8 X 50
1 DA BM8X50 1 12 DL 1/4" X 7/8" WPH1/4X7/8 1
Grade 8.8 bracket to chassis bracket
Vincent M Lloyd D
Heavy duty
x8
Spring Washer
Setscrew 1/4" Expansion tank to 8 x Radiator bobbin
2 DB SF1/4X3/4 1 13 DM 5/16" WSH5/17 9
James S
X 3/4" bracket 1 x Expansion tank
Heavy duty
2 x U shape hose to
Setscrew M8X20 Hose Clip water rail
3 DC Grade 8.8
SM6X20 4 SV radiator bracket 14 DN 30 - 40mm
SGT25-40 6 2 x Top radiator hose
2 x Bottom radiator hose
1 x Engine outlet to
4 DD
Bolt M6 X 16 with
square section
30Z1072A 4 Fan brackets to fan
x4 15 DO
Hose Clip
23 - 35mm
SGT23-35 2
big T piece
heater inlet
6 x Heater inlet/outlet
1
3 x Big T-piece
Setscrew M6X16 Fan to radiator Hose Clip 1 x Expansion tank
5 DE SPHM6X16 4 16 DP SGT16-25 18
Panhead Pozi cowling - SV only 17 - 25mm 2 x Modine
4 x Dry Sump
2 x Submarine
x4 Fan to radiator
6 DF Nyloc Nut M6 NMYF6 8 x4 SV radiator
bracket x4 17 DQ
Hose Clip
8 - 16mm
SGT8-16 6
Expansion tank
small T-piece
7 DG Plain Nut M8 NMPF8 8 Radiator bobbin

x8 18 DR Rivet - Black
5/32" X 0.47"
1610-01015 12 Cowling flap
DJ
Expansion tank
8 DH Nyloc Nut 1/4" NFYF1/4 1
bracket
8 x SV rad bracket
Plain Washer 1/4" 4 x Fan fixings
9 DI WPH1/4 13
1 x Expansion tank
DG
Heavy duty
2 4
braket
Plain Washer
x4
Radiator bobbin
10 DJ 5/16" WPH5/16 4
DM
Heavy duty back
Plain Washer
Radiator bobbin
11 DK 4
x4 DK
5/16" X 7/8" WPH5/17X7/8
Heavy duty front
26 27
THE RADIATOR MOUNTING FOR THE WIDE-BODIED CHASSIS IS SLIGHTLY DIFFERENT THE RADIATOR MOUNTING FOR THE WIDE-BODIED CHASSIS IS SLIGHTLY DIFFERENT
P A R T S T O O L S 270/310/360
WIDE CHASSIS
1 Radiator
13mm
10mm
2 Fan brackets (x2) DF
DI
10mm
3 Fan
13mm
DD
4 Radiator bobbins (x4)
DJ
5 Brackets 3
D D
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER
PACK NUMBER
30C047B
PACK NUMBER
30C047B The fan may have four The fan may have a Be careful to tighten
COOLING SIGMA
COOLING SIGMA
This pack may include extra fasteners to cover different options plastic legs or feet 'flat' section on the the fan on gently
that slot into it. rim. This should be and just with a nip.
Plain Washer
Expansion tank Expansion tank
at the top.
Bolt M8 X 50
1 DA BM8X50 1 12 DL 1/4" X 7/8" WPH1/4X7/8 1
Vincent M Lloyd D
Heavy duty
x8
Spring Washer
2 DB SF1/4X3/4 1 13 DM 5/16" WSH5/17 9
James S
X 3/4" bracket 1 x Expansion tank
Heavy duty
2 x U shape hose to
3 DC
Setscrew M8X20
Grade 8.8
SM6X20 4 SV radiator bracket
x4 14 DN
Hose Clip
30 - 40mm
SGT25-40 6
water rail
2 x Top radiator hose
4 DD
Bolt M6 X 16 with
square section
30Z1072A 4 Fan brackets to fan
x4 15 DO
Hose Clip
23 - 35mm
SGT23-35 2
big T piece
heater inlet
1
3 x Big T-piece
5 DE SPHM6X16 4 16 DP SGT16-25 18
4 x Dry Sump
2 x Submarine
x4 Fan to radiator
6 DF Nyloc Nut M6 NMYF6 8 x4 SV radiator
bracket x4 17 DQ
Hose Clip
8 - 16mm
SGT8-16 6
Expansion tank
small T-piece
7 DG Plain Nut M8 NMPF8 8 Radiator bobbin

x8 18 DR Rivet - Black
5
DC
5/32" X 0.47"
Expansion tank
DI
bracket
8 x SV rad bracket
x12
9 DI WPH1/4 13
2 DF
Heavy duty 1 x Expansion tank
Plain Washer
braket
DG
x4
Radiator bobbin
10 DJ 5/16" WPH5/16 4
back
DM
Heavy duty
4
Plain Washer
Radiator bobbin
11 DK 4
x4
5/16" X 7/8" WPH5/17X7/8
DK
Heavy duty front
28 29
THINGS ARE HEATING UP THINGS ARE HEATING UP
P A R T S T O O L S
1 Heater
10mm
7mm
2 Valve
3 Heater cable 19mm

3
4 Lower hose 110mm (cut from long length)
5 Upper hose 120mm (cut from long length)
6 Grommet
DE 6
D D
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER
PACK NUMBER
30C047B
PACK NUMBER
30C047B Remember to remove bungs Use 7mm for jubilee clips but not
COOLING SIGMA
COOLING SIGMA
This pack may include extra fasteners to cover different options from heater. too tight!
Jamie A Chris B
Plain Washer
Bolt M8 X 50 Expansion tank Expansion tank
1 DA BM8X50 1 12 DL 1/4" X 7/8" WPH1/4X7/8 1
Grade 8.8 bracket to chassis Heavy duty bracket
Spring Washer
2
2 DB X 3/4"
SF1/4X3/4 1 13 DM 5/16" WSH5/17 9
bracket Heavy duty 1 x Expansion tank
2 x U shape hose to
3 DC Grade 8.8
It’s worth re-tightening the jubilee 5

Bolt M6 X 16 with Hose Clip big T piece
4 DD square section
30Z1072A 4 Fan brackets to fan 15 DO SGT23-35 2
23 - 35mm 1 x Engine outlet to
heater inlet
clips after a couple of uses of car.

x2 x4
3 x Big T-piece
5 DE SPHM6X16 4 16 DP SGT16-25 18
4 x Dry Sump
2 x Submarine
6 DF Nyloc Nut M6 NMYF6 8

x4 Fan to radiator
x4 SV radiator 17 DQ
Hose Clip
SGT8-16 6
Expansion tank
John S
bracket
8 - 16mm small T-piece
7 DG Plain Nut M8 NMPF8 8 Radiator bobbin 18 DR Rivet - Black

5/32" X 0.47"
1610-01015 12 Cowling flap DP
Expansion tank
bracket
8 x SV rad bracket
9 DI WPH1/4 13
braket
Plain Washer
Radiator bobbin
10 DJ 5/16" WPH5/16 4
Heavy duty back
4
Plain Washer
Radiator bobbin
11 DK 5/16" X 7/8" WPH5/17X7/8 4
Heavy duty front
30 31
KEEPING THE AIR CLEAN KEEPING THE AIR CLEAN
P A R T S T O O L S
1 Air box
2 Air filter
1
3 Rubber mounts
4 Trim
8mm
Unmarked bag:
• M5 (x6) Bobbins are screwed into The rubber lip of the trim should 'flare out'
• Spring (x6) the car by hand. from the intake hole, not in.
• Flats (x6) John K Grant P
• Nylocs M5 (x3)
4
• 3⁄16 washers (x3)
• ¾ washers (x3)
• Screws (x20)
32 33
GETTING READY TO PUT THE ENGINE IN GETTING READY TO PUT THE ENGINE IN
P A R T S T O O L S
1 Engine mount
6mm
8mm
2 Starter motor 3
3 Bellhousing
You will need to remove the engine Remember wher the bolts go.
mounts and starter motor but Dan P
don’t throw away the bolts – keep
them safe! 2
Chris N
34 35
ATTACH THE GEARBOX TO THE BELLHOUSING ATTACH THE GEARBOX TO THE BELLHOUSING
P A R T S T O O L S
1 Gearbox
10mm
2 Bell housing
E E
SERIAL
66
SERIAL
66
Pack Pack
NUMBER NUMBER
3EZ1105F 3EZ1105F
SIGMA GEARBOX 5 SPEED SIGMA GEARBOX 5 SPEED
1
BASIC PART
BASIC PART ITEM QTY USED ON ILLUSTRATION
ITEM QTY USED ON ILLUSTRATION DESCRIPTION NUMBER
DESCRIPTION NUMBER
Buttonhead Bolt
M6 X 10
Bolt M14 X 40 12 EL Grade 10.9
3GZ1163A 3 Gear Lever
1 EA Grade 12.9
3EZ1137A 2 AV Mount Internal Hex
Plain Washer
Caphead Bolt 13 EM M14
WPH14 2 AV Mount
2 EB M8 X 40 30Z1076A 4 AV Mount
Grade 12.9
Caphead Bolt 14 EN
Plain Washer
30Z2031A 4 Gearbox
x4
x4
M12
M12 X 50
3 EC Grade 12.9
3EZ1142A 4 Gearbox
Coarse Thread
15 EO Plain Washer M6 WPHM6 3 Gear Lever

Caphead Bolt
1 x Bellhousing
4 ED M10 X 60 BMCH10X60 4
Grade 12.9 3 x Starter Motor
Plain Washer
16 EP 5/16"
WPH5/16 8 AV Mount
Caphead Bolt
5 EE M10 X 55 BMCH10X55 3 Bellhousing
Grade 12.9
Caphead Bolt
17 EQ
Spring Washer
M12
WSHM12 4 Gearbox
x4
6 EF M10 X 40 BMCH10X40 3 Bellhousing
Grade 12.9
EC
Spring Washer x 7 Bellhousing x
18 ER M10
WSHM10 10
3 Engine Mount
Caphead Bolt
Engine Mount
7 EG M10 X 35 BMCH10X35 2
Grade 12.9 RHS Top
35 35 68Nm EN
Wire Spring
19 ES Washer M10
WSHM10 3 Starter Motor
Caphead Bolt M8 Engine Mount mm mm

8 EH X 25 Grade BMCH8X25 2 1 x LHS Top
12.9 1 x LHS Bottom
EQ
Spring Washer
20 ET M8
WSHM8 5 Engine Mount
Caphead Bolt M8
Engine Mount
9 EI X 30 Grade BMCH8X30 1
12.9 LHS Bottom Spring Washer Clutch Slave
21 EU M6
WSHM6 3
Cylinder
Caphead Bolt M8
Engine Mount
10 EJ X 35 Grade BMCH8X35 2
12.9 RHS Bottom Myloc Nut
22 EV M8
NMYF8 4 AV Mount
Caphead Bolt
Clutch Slave
11 EK M6 X 25 BMCH6X25 3
Grade 12.9 Cylinder 23 EW
Spring Washer
30Z2030A 2 AV Mount
M14
36 37
AND THEN THE GEARBOX TO THE ENGINE AND THEN THE GEARBOX TO THE ENGINE
P A R T S T O O L S
8mm
ED
E E
SERIAL
66
SERIAL
66
Pack Pack
NUMBER NUMBER
PACK NUMBER
3EZ1105F
PACK NUMBER
3EZ1105F
35 EE
35 47Nm
mm mm
EF
SIGMA GEARBOX 5 SPEED SIGMA GEARBOX 5 SPEED
BASIC PART
BASIC PART ITEM QTY USED ON ILLUSTRATION
ER
ITEM QTY USED ON ILLUSTRATION DESCRIPTION NUMBER
DESCRIPTION NUMBER
Buttonhead Bolt
M6 X 10
Bolt M14 X 40 12 EL Grade 10.9
1 EA Grade 12.9
3EZ1137A 2 AV Mount Internal Hex
Plain Washer
Caphead Bolt 13 EM M14
WPH14 2 AV Mount
2 EB M8 X 40 30Z1076A 4 AV Mount
Grade 12.9
Plain Washer
Caphead Bolt 14 EN M12
30Z2031A 4 Gearbox
M12 X 50
3 EC Grade 12.9
3EZ1142A 4 Gearbox
Coarse Thread
15 EO Plain Washer M6 WPHM6 3 Gear Lever
x1
Caphead Bolt
1 x Bellhousing
4 ED M10 X 60 BMCH10X60 4
Grade 12.9 3 x Starter Motor
Plain Washer
16 EP 5/16"
WPH5/16 8 AV Mount
x3
Caphead Bolt
5 EE M10 X 55 BMCH10X55 3 Bellhousing
Grade 12.9
Spring Washer
17 EQ M12
WSHM12 4 Gearbox
x3
Caphead Bolt
6 EF M10 X 40 BMCH10X40 3 Bellhousing
Grade 12.9
Caphead Bolt
Engine Mount
18 ER
Spring Washer
M10
WSHM10 10
x 7 Bellhousing
3 Engine Mount
x
x7
7 EG M10 X 35 BMCH10X35 2
Grade 12.9 RHS Top
Wire Spring
19 ES Washer M10
Caphead Bolt M8 Engine Mount

8 EH X 25 Grade BMCH8X25 2 1 x LHS Top
12.9 1 x LHS Bottom Spring Washer
20 ET M8
Caphead Bolt M8
Engine Mount
9 EI X 30 Grade BMCH8X30 1
ED
12.9 LHS Bottom Spring Washer Clutch Slave
21 EU M6
WSHM6 3
Cylinder
Caphead Bolt M8 35 35 54Nm

10 EJ 2
Engine Mount
mm mm
ES
X 35 Grade BMCH8X35
12.9 RHS Bottom Myloc Nut
22 EV M8
NMYF8 4 AV Mount
Caphead Bolt
Clutch Slave
11 EK M6 X 25 BMCH6X25 3
Grade 12.9 Cylinder 23 EW
Spring Washer
30Z2030A 2 AV Mount
M14
38 39
AT LAST, THE ENGINE IS GOING IN AT LAST, THE ENGINE IS GOING IN
P A R T S T O O L S
1 Engine mounts
+
2 Engine rubbers
6mm
3 Tensioner 8mm
⅜”
13mm
13mm
15mm
3 1
2
Miscellaneous pack
• Bolt ½˝ x 2 ½˝ (x1) When fitting the engine rubbers and mounts, It's 47asNm for the
• Bolt ½˝ x 1˝ (x1) do them as loosely as possible so you can The shorter ½˝ bolt fits the nearside bolts tightened with
• Bolt M8 x 50 (x1) wiggle things to get bolts in. Tighten it all up of the chassis. the 8mm hex socket
• Bolt M8 x 45 (x3) gradually once all the bolts are in. & 30Nm for the 6mm
Dan P
• Washer M8 (x4)
• Nyloc M8 (x4) Jamie A hex socket.
Grant P
It will fit – keep at it!

Protect the chassis with soft stuff such as Rich T
cardboard or folded towels/blankets. Just Removing the

not your fingers. tensioner will make
Tiago O things much easier.
James A
40 41
AND THE GEARBOX IS FIXED IN PLACE AND THE GEARBOX IS FIXED IN PLACE
P A R T S T O O L S 5 SPEED 6 SPEED
5 Speed 6 Speed
13mm 13mm
22mm 19mm
6mm 6mm
13mm
Once the engine is in, the See IVA guide – how to secure a loom.
wiring can be connected to the Grant P
car's loom. It should be self
explanatory.
Chris B
42 43
FILLING THE ENGINE AND GEARBOX WITH OIL FILLING THE ENGINE AND GEARBOX WITH OIL
P A R T S T O O L S
Engine oil SW-30
Gear oil GL4
Ford 1.6L Engine = 3.8 Litres (Pre-Filled)

5 Speed Gearbox = (Pre-Filled)
Before Installation. You can double check the oil
level by removing the plug on the side. The oil
should be to this level.
6 Speed Gearbox = Fill to level of filling point
on the side of gearbox
44 45
START PLUMBING START PLUMBING
P A R T S T O O L S
1 Lower radiator hose
7mm 1
DN
D D
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER
PACK NUMBER
30C047B
PACK NUMBER
30C047B Reminder for later on: nip up the Fit the hose to the larger
COOLING SIGMA
COOLING SIGMA
This pack may include extra fasteners to cover different options clips once the car has been run. outlet on the engine.
Grant P Mick F
Plain Washer
1 DA BM8X50 1 12 DL 1/4" X 7/8" WPH1/4X7/8 1
Spring Washer
2 DB X 3/4"
SF1/4X3/4 1 13 DM 5/16" WSH5/17 9
2 x U shape hose to
3 DC
Setscrew M8X20
Grade 8.8
SM6X20 4 SV radiator bracket 14 DN
Hose Clip
30 - 40mm
SGT25-40 6
water rail
x2
Support hose by cable tying to chassis

4 DD square section
heater inlet
3 x Big T-piece
rails – make sure they are clear of the

5 DE SPHM6X16 4 16 DP SGT16-25 18
4 x Dry Sump
2 x Submarine
steering rack.
x4 Fan to radiator
6 DF Nyloc Nut M6 NMYF6 8 x4 SV radiator Hose Clip Expansion tank
17 DQ SGT8-16 6
bracket

5/32" X 0.47"
1610-01015 12 Cowling flap Lee A
Expansion tank
bracket
8 x SV rad bracket
9 DI WPH1/4 13
braket
Plain Washer
Radiator bobbin
10 DJ 5/16" WPH5/16 4
Heavy duty back
Plain Washer
Radiator bobbin
11 DK 5/16" X 7/8" WPH5/17X7/8 4
Heavy duty front
46 47
AND KEEP PLUMBING AND KEEP PLUMBING
P A R T S T O O L S
1 Upper radiator hose

DN 1
7mm
D D
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER
PACK NUMBER
30C047B
PACK NUMBER
30C047B Reminder for later on: nip up the
COOLING SIGMA
COOLING SIGMA
This pack may include extra fasteners to cover different options clips once the car has been run.
James A
Plain Washer
1 DA BM8X50 1 12 DL 1/4" X 7/8" WPH1/4X7/8 1
Spring Washer
2 DB X 3/4"
SF1/4X3/4 1 13 DM 5/16" WSH5/17 9
2 x U shape hose to
3 DC
Setscrew M8X20
Grade 8.8
Hose Clip
30 - 40mm
SGT25-40 6
water rail
x2
4 DD square section
heater inlet
3 x Big T-piece
5 DE SPHM6X16 4 16 DP SGT16-25 18
4 x Dry Sump
2 x Submarine
x4 Fan to radiator
17 DQ SGT8-16 6
bracket

5/32" X 0.47"
Expansion tank
bracket
8 x SV rad bracket
9 DI WPH1/4 13
braket
Plain Washer
Radiator bobbin
10 DJ 5/16" WPH5/16 4
Heavy duty back
Plain Washer
Radiator bobbin
11 DK 5/16" X 7/8" WPH5/17X7/8 4
Heavy duty front
48 49
50 51
A BIT OF SUB-ASSEMBLY – SOME HOSES NEED MODIFYING A BIT OF SUB-ASSEMBLY – SOME HOSES NEED MODIFYING
P A R T S T O O L S
1 Silicone hoses

Don't throw away the long
piece of hose after cutting.
Rich T
52 53
SUB-ASSEMBLY – TEMPERATURE SENSOR SUB-ASSEMBLY – TEMPERATURE SENSOR
P A R T S T O O L S
1 Temperature sender
2 Earth tag
7mm
3 Cooling submarine
8mm
13mm 1
LO
DP
CT
IT
E
D D
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER
PACK NUMBER
30C047B
PACK NUMBER
30C047B Use a drop of LocTite on the sender. Be careful not to over-tighten
COOLING SIGMA COOLING SIGMA
ITEM
BASIC
PART
QTY USED ON ILLUSTRATION ITEM
BASIC
PART
Tiago O the sender.
Bolt M8 X 50 Expansion tank Plain Washer

Expansion tank
Jamie A
1 DA BM8X50 1 12 DL 1/4" X 7/8" WPH1/4X7/8 1
Spring Washer
2 DB X 3/4"
SF1/4X3/4 1 13 DM 5/16" WSH5/17 9
2 x U shape hose to
3 DC Grade 8.8
4 DD square section
heater inlet
3 x Big T-piece
5 DE
Setscrew M6X16
Panhead Pozi
SPHM6X16 4
Fan to radiator
cowling - SV only 16 DP
Hose Clip
17 - 25mm
SGT16-25 18
1 x Expansion tank
2 x Modine
4 x Dry Sump
x2
2 x Submarine
x4 Fan to radiator
17 DQ SGT8-16 6
bracket

5/32" X 0.47"
Expansion tank
bracket
8 x SV rad bracket
9 DI WPH1/4 13
braket
Plain Washer
Radiator bobbin
10 DJ 5/16" WPH5/16 4
Heavy duty back
Plain Washer
Radiator bobbin
11 DK 5/16" X 7/8" WPH5/17X7/8 4
Heavy duty front
54 55
BACK TO THE PLUMBING BACK TO THE PLUMBING
P A R T S T O O L S
1 Submarine assembly
7mm
1
D D
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER

30C047B 30C047B

Plain Washer
1 DA BM8X50 1 12 DL 1/4" X 7/8" WPH1/4X7/8 1
Spring Washer
2 DB X 3/4"
SF1/4X3/4 1 13 DM 5/16" WSH5/17 9
2 x U shape hose to
3 DC Grade 8.8
4 DD square section
heater inlet
3 x Big T-piece
x1
5 DE SPHM6X16 4 16 DP SGT16-25 18
4 x Dry Sump
2 x Submarine
x4 Fan to radiator
17 DQ SGT8-16 6
bracket

5/32" X 0.47"
Expansion tank
bracket
8 x SV rad bracket
9 DI WPH1/4 13
braket
Plain Washer
Radiator bobbin
10 DJ 5/16" WPH5/16 4
Heavy duty back
Plain Washer
Radiator bobbin
11 DK 5/16" X 7/8" WPH5/17X7/8 4
Heavy duty front
56 57
MORE PLUMBING MORE PLUMBING
P A R T S T O O L S
DP
D D
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER

30C047B 30C047B

Plain Washer
1 DA BM8X50 1 12 DL 1/4" X 7/8" WPH1/4X7/8 1
Spring Washer
2 DB X 3/4"
SF1/4X3/4 1 13 DM 5/16" WSH5/17 9
2 x U shape hose to
3 DC Grade 8.8
4 DD square section
heater inlet
x1
3 x Big T-piece
5 DE SPHM6X16 4 16 DP SGT16-25 18
4 x Dry Sump
2 x Submarine
x4 Fan to radiator
17 DQ SGT8-16 6
bracket

5/32" X 0.47"
Expansion tank
bracket
8 x SV rad bracket
9 DI WPH1/4 13
braket
Plain Washer
Radiator bobbin
10 DJ 5/16" WPH5/16 4
Heavy duty back
Plain Washer
Radiator bobbin
11 DK 5/16" X 7/8" WPH5/17X7/8 4
Heavy duty front
58 59
STILL MORE PLUMBING STILL MORE PLUMBING
P A R T S T O O L S
1 U shape hose
120mm
7mm
120mm
DN 1
D D
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER

30C047B 30C047B

Plain Washer
1 DA BM8X50 1 12 DL 1/4" X 7/8" WPH1/4X7/8 1
Spring Washer
2 DB X 3/4"
SF1/4X3/4 1 13 DM 5/16" WSH5/17 9
2 x U shape hose to
3 DC
Setscrew M8X20
Grade 8.8
Hose Clip
30 - 40mm
SGT25-40 6
water rail
x2
4 DD square section
heater inlet
3 x Big T-piece
5 DE SPHM6X16 4 16 DP SGT16-25 18
4 x Dry Sump
2 x Submarine
x4 Fan to radiator
17 DQ SGT8-16 6
bracket

5/32" X 0.47"
Expansion tank
bracket
8 x SV rad bracket
9 DI WPH1/4 13
braket
Plain Washer
Radiator bobbin
10 DJ 5/16" WPH5/16 4
Heavy duty back
Plain Washer
Radiator bobbin
11 DK 5/16" X 7/8" WPH5/17X7/8 4
Heavy duty front
60 61
A BREAK FROM PLUMBING TO FIT THE EXPANSION BOTTLE A BREAK FROM PLUMBING TO FIT THE EXPANSION BOTTLE
P A R T S T O O L S
1 Expansion bottle
13mm 1 2
11mm
2 Expansion bottle cap
3 Expansion bottle bracket 11mm
DB
DL
DH
DI
DA
DM
3
D D
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER
PACK NUMBER
30C047B
PACK NUMBER
30C047B Throw away the red cap that
COOLING SIGMA
COOLING SIGMA
This pack may include extra fasteners to cover different options came on the expansion bottle.
Grant P
1 DA
Bolt M8 X 50
Grade 8.8
BM8X50 1
Expansion tank
bracket to chassis x1 12 DL
Plain Washer
1/4" X 7/8"
Heavy duty
WPH1/4X7/8 1
Expansion tank
bracket x1
2 DB
Setscrew
X 3/4"
1/4"
SF1/4X3/4 1
Expansion tank to
bracket x1 13 DM
Spring Washer
5/16"
Heavy duty
WSH5/17 9
8 x Radiator bobbin
1 x Expansion tank x1
2 x U shape hose to
3 DC Grade 8.8
4 DD square section
heater inlet
3 x Big T-piece
5 DE SPHM6X16 4 16 DP SGT16-25 18
4 x Dry Sump
2 x Submarine
x4 Fan to radiator
17 DQ SGT8-16 6
bracket

5/32" X 0.47"
Expansion tank
bracket x1
8 x SV rad bracket
9 DI
Plain Washer 1/4"
Heavy duty
WPH1/4 13
4 x Fan fixings
1 x Expansion tank
braket
x1
Plain Washer
Radiator bobbin
10 DJ 5/16" WPH5/16 4
Heavy duty back
Plain Washer
Radiator bobbin
11 DK 5/16" X 7/8" WPH5/17X7/8 4
Heavy duty front
62 63
SOME MORE HOSE MODIFICATION SOME MORE HOSE MODIFICATION
P A R T S T O O L S
1 T-Piece
7mm
D
44
D
44
1 DP
SERIAL SERIAL
Pack Pack
NUMBER NUMBER
PACK NUMBER
30C047B
PACK NUMBER
30C047B The short 'L' shaped hose is pre-formed.
This pack may include extra fasteners to cover different options This pack may include extra fasteners to cover different options John S
Plain Washer
1 DA BM8X50 1 12 DL 1/4" X 7/8" WPH1/4X7/8 1
Spring Washer
2 DB X 3/4"
SF1/4X3/4 1 13 DM 5/16" WSH5/17 9
2 x U shape hose to
3 DC Grade 8.8
4 DD square section
heater inlet
x3
3 x Big T-piece
5 DE SPHM6X16 4 16 DP SGT16-25 18
4 x Dry Sump
2 x Submarine
x4 Fan to radiator
17 DQ SGT8-16 6
bracket

5/32" X 0.47"
Expansion tank
bracket
8 x SV rad bracket
9 DI WPH1/4 13
braket
Plain Washer
Radiator bobbin
10 DJ 5/16" WPH5/16 4
Heavy duty back
Plain Washer
Radiator bobbin
11 DK 5/16" X 7/8" WPH5/17X7/8 4
Heavy duty front
64 65
AND BACK TO PLUMBING AND BACK TO PLUMBING
P A R T S T O O L S
1 T-Piece assembly
DP
7mm
D D
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER

30C047B 30C047B

Plain Washer
1 DA BM8X50 1 12 DL 1/4" X 7/8" WPH1/4X7/8 1
Spring Washer
2 DB X 3/4"
SF1/4X3/4 1 13 DM 5/16" WSH5/17 9
1
2 x U shape hose to
3 DC Grade 8.8
4 DD square section
heater inlet
x1
3 x Big T-piece
5 DE SPHM6X16 4 16 DP SGT16-25 18
4 x Dry Sump
2 x Submarine
x4 Fan to radiator
17 DQ SGT8-16 6
bracket

5/32" X 0.47"
Expansion tank
bracket
8 x SV rad bracket
9 DI WPH1/4 13
braket
Plain Washer
Radiator bobbin
10 DJ 5/16" WPH5/16 4
Heavy duty back
Plain Washer
Radiator bobbin
11 DK 5/16" X 7/8" WPH5/17X7/8 4
Heavy duty front
66 67
LAST BIT OF PLUMBING LAST BIT OF PLUMBING
P A R T S T O O L S
1 5⁄16" Hose
7mm
1 DQ
D D
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER

30C047B 30C047B

Plain Washer
1 DA BM8X50 1 12 DL 1/4" X 7/8" WPH1/4X7/8 1
Spring Washer
2 DB X 3/4"
SF1/4X3/4 1 13 DM 5/16" WSH5/17 9
2 x U shape hose to
3 DC Grade 8.8
4 DD square section
heater inlet
3 x Big T-piece
5 DE SPHM6X16 4 16 DP SGT16-25 18
4 x Dry Sump
2 x Submarine
x4 Fan to radiator
x2
17 DQ SGT8-16 6
bracket

5/32" X 0.47"
Expansion tank
bracket
8 x SV rad bracket
9 DI WPH1/4 13
braket
Plain Washer
Radiator bobbin
10 DJ 5/16" WPH5/16 4
Heavy duty back
Plain Washer
Radiator bobbin
11 DK 5/16" X 7/8" WPH5/17X7/8 4
Heavy duty front
68 69
CONNECTING THE FUEL LINE CONNECTING THE FUEL LINE
P A R T S T O O L S
70 71
FIT THROTTLE CABLE FIT THROTTLE CABLE
P A R T S T O O L S
1 Throttle cable
Fixings are supplied loosely attached to the engine in place
The silicone goes in the top of the Max throttle pedal travel may
pedal to prevent the cable coming out. need adjusting in the pedalbox.
1
Rich T Jamie A
72 73
PROTECTING & ATTACHING THE CLUTCH HOSE PROTECTING & ATTACHING THE CLUTCH HOSE
P A R T S T O O L S
1 8mm water hose

14mm
Nip up the banjo bolt. The hose is used to stop chaffing.

John K James A
74 75
CONNECTING THE BATTERY (POSITIVE / RED FIRST) CONNECTING THE BATTERY (POSITIVE / RED FIRST)
P A R T S T O O L S
10mm (x2)
Always connect live side of battery first Make the battery the
(red wire). last thing you connect.
Chris B Jamie A
Be careful to ensure that the red leads go to

the + side and the black wires to the – side.
Dan D
76 77
IT LIVES! IT LIVES!
P A R T S T O O L S
Add a plain M8 or 5⁄16 washer

underneath the earth lead to chassis.
Dan P
78 79
ONE LAST BIT OF PLUMBING… ONE LAST BIT OF PLUMBING…
P A R T S T O O L S
1 Hose
7mm
D D
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER
PACK NUMBER
30C047B
PACK NUMBER
30C047B Cut off hook and trim if required.
This pack may include extra fasteners to cover different options This pack may include extra fasteners to cover different options Grant P
Plain Washer
1 DA BM8X50 1 12 DL 1/4" X 7/8" WPH1/4X7/8 1
Spring Washer
2 DB X 3/4"
SF1/4X3/4 1 13 DM 5/16" WSH5/17 9
2 x U shape hose to
3 DC Grade 8.8
4 DD square section
heater inlet
3 x Big T-piece
x1
5 DE SPHM6X16 4 16 DP SGT16-25 18
4 x Dry Sump
2 x Submarine
x4 Fan to radiator
17 DQ SGT8-16 6
bracket

5/32" X 0.47"
Expansion tank
bracket
8 x SV rad bracket
9 DI WPH1/4 13
braket
Plain Washer
Radiator bobbin
10 DJ 5/16" WPH5/16 4
Heavy duty back
Plain Washer
Radiator bobbin
11 DK 5/16" X 7/8" WPH5/17X7/8 4
Heavy duty front
80 81
…TO CONNECT THE HEATER …TO CONNECT THE HEATER
P A R T S T O O L S
7mm
D D
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER
PACK NUMBER
30C047B
PACK NUMBER
30C047B The coolant concentrate should
COOLING SIGMA
COOLING SIGMA
This pack may include extra fasteners to cover different options be diluted 50/50 with water. It
does not need to be exact!
Plain Washer
1 DA BM8X50 1 12 DL 1/4" X 7/8" WPH1/4X7/8 1
Anthony L
Heavy duty
Spring Washer
2 DB X 3/4"
SF1/4X3/4 1 13 DM 5/16" WSH5/17 9
2 x U shape hose to
3 DC Grade 8.8
4 DD square section
heater inlet
x1
3 x Big T-piece
5 DE SPHM6X16 4 16 DP SGT16-25 18
4 x Dry Sump
2 x Submarine
x4 Fan to radiator
17 DQ SGT8-16 6
bracket

5/32" X 0.47"
Expansion tank
bracket
8 x SV rad bracket
9 DI WPH1/4 13
braket
Plain Washer
Radiator bobbin
10 DJ 5/16" WPH5/16 4
Heavy duty back
Plain Washer
Radiator bobbin
11 DK 5/16" X 7/8" WPH5/17X7/8 4
Heavy duty front
82 83
FILL WITH COOLANT FILL WITH COOLANT
P A R T S T O O L S
Coolant concentrate
Fill expansion bottle to max mark
84 85
CONNECT THE AIRBOX TO THE ENGINE CONNECT THE AIRBOX TO THE ENGINE
P A R T S T O O L S
1 Airbox hose
7mm
2 Insert set 2
3 Hose clip
1
All fixings for this step should be in the supplied airbox box
3
To help push insert in Spray brake cleaner in the
use the work bench. hose and on the insert.
Rich T John K
86 87
GIVING IT SOME DIRECTION GIVING IT SOME DIRECTION
P A R T S T O O L S
2
1 Lower steering column
⁷⁄₁₆"
2 Upper steering column

4
3 Steering column clamp 13mm BF 6 BD
BJ
4 Steering column clamp plate 5
⁷⁄₃₂"
5 Grub screw 13mm
3
6 Steering column bush
¹¹⁄₁₆"
35 35 14Nm
mm mm
1 BB
BK
BL
B
SERIAL
55
Pack
NUMBER
PACK NUMBER
30S003B Check clearance between Put the clamp in the middle of column with Grease the steering bushes.
STEERING DeDION CARS (METRIC)
This pack may include extra fasteners to cover different options steering column & Aux the grooved face of the clamp plate 4 Lee A
belt tensioner once engine against the column.
BASIC PART
DESCRIPTION NUMBER
Caphead Bolt
is installed. If necessary,
1 BA M6 x 70 BMCH6X70 4 Rack clamps
DIN 912
Jamie A
2 BB Bolt ¼" x 1½" BF1/4X1.1/2 2 Column clamp
rotate steering rack.
3 BC
Bolt M8 x 35
Grade 8.8
BM8X35 2
Column to rack
universal joint x2 Dan P
4 BD
Nyloc Nut ½"
Half height
NFYH1/2 1 Steering wheel boss x1 Fit the clamp bolts first,
5 BE Plain Nut ½" NFPF1/2 2 Track rod lock nut
then grubscrew & finish
6 BF
Plain Nut ⁷⁄₁₆"
Half height
NFPFH7/16 1
Column clamp
grubscrew locknut
Steering rack to be rotated to fit column – with the locking nut.
don't forget to tighten rack brackets!. 35 35
BC
7 BG Nyloc Nut M8 NMYF8 2
Column to rack
x2 Tiago O 20Nm
universal joint mm mm
Harrison P BG
Steering rack
8 BH Nyloc Nut M6 NMYF6 4
clamps
9 BJ
Plain Washer
½" x 1⅛"
Chamfered
WPH1/2 1 Steering wheel boss x1
10 BK
Plain Washer
6
Rack clamps and
35 35
BC
20Nm
¼" WPH1/4
Heavy duty column clamp
mm mm
11 BL
Spring Washer ¼
Heavy duty
BG
Drawings are for illustrative purposes only and are not to scale. Page 1 of 1 7 7
7 7
88 89
THIS IS EXHAUSTING THIS IS EXHAUSTING
P A R T S T O O L S
1 Exhaust manifold gasket

8mm to follow Extension
1
2 Exhaust primary pipes
3 Cat / Collector 8mm
4 Exhaust collector springs

17mm
35 35 47Nm
(270 & 310 only) mm mm
4
Fixings are supplied loosely attached to the engine in place
Use cable ties to compress A pair of pliers are best to help hook over.
exhaust spring. James A
Mick F
Put masking tape round

exhaust hole to prevent 2
scratches.
Work out which primary pipe goes where, Chris B
individually then put all four in plane, starting
with the front one & working back. Take care
with the hooks on your paintwork.
Chris N
90 91
FITTING THE HANDBRAKE FITTING THE HANDBRAKE
P A R T S T O O L S
1 Handbrake assembly STANDARD CHASSIS

13mm (x2) CROSS CABLES AS
SHOWN
2 Handbrake pulley
WIDE BODY CHASSIS
DO NOT CROSS
3 Handbrake clevis
CABLES
4 Pulley clevis pin 1 4 2 6
5 Handbrake clevis pin 3
6 Handbrake cable
Miscellaneous pack
• Setscrew 8 (x25) Remember to Cable tie adjuster end of cable to diff.
• Washer M8 put a loop in Dan D
• Washer M6 inner cable
around pulley.
Grant P Use pliers to bend the legs of the split-pins
once in place, which then holds them loosely 5
in the clevis pins.
Chris B
Handbrake wire connector

goes to top of terminal &
After plugging in connector, cable
ties up.
tie and secure any excess wiring.
Jamie A
Dan P
92 93
SLIDE IN THE PROPSHAFT SLIDE IN THE PROPSHAFT
P A R T S T O O L S
1 Propshaft
Line the splines in the Grease prop if necessary,

propshaft to the gearbox. it will have a grease nipple.
Anthony L John S
94 95
HEAVY STUFF: FITTING THE DIFF HEAVY STUFF: FITTING THE DIFF
P A R T S T O O L S
1 Differential
LO
19mm
CT
IT
E
35 35 61Nm
mm mm
19mm
IM
IA
10mm IQ
to follow Extension
8mm IH
IQ
+
IB
IQ
F I X I N G S T I P S 35 35 47Nm IF
LO
CT
mm
IT
mm
E
I I
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER
PACK NUMBER
30Z1067B
PACK NUMBER
30Z1067B Start at bottom right with Make sure propshaft is in first! 35
mm
35
mm
81Nm
BASIC PART
AXLE DEDION METRIC
BASIC
AXLE DEDION METRIC
PART
spanner & work your way around. Harry P
Chris B
1 IA
Bolt 1/2" X 11"
UNF
BF1/2X11 1
Upper diff mounting
bolt x1 12 IL
Plain washer 1/2"
X 7/8" Thin
WPT1/2X7/8 16
Fine tuning diff
setup
x2 *
Caphead Bolt
Lower diff mounting Plain washer 1/2"
2 IB M12 X 65 BMCH12X55 2 13 IM X 3/4" Thin
79017 8 Free play on diff
Grade 10.9 bolt
Plain washer 1/2"

Bolt M10 X 65 Rear hub through
3 IC Grade 10.9
BM10X65 4 14 IN X 3/4" X 17G 79029 14 Diff shim washers
ear to front DeDion Thick
x 4 Front hub
Rear DeDion
Bolt M10 X 55 through ear Washer
4 ID Grade 10.9
BM10X55 8 15 IO M10
WPHM10 16 Caliper Carrier
x 4 Caliper carrier
Lower diff bolts may require more than

Hub
bolts
Through rear of ear

Bolt M10 X 40 Spring Washer Rear DeDion Tube
5 IE BM10X40 4 into threaded 16 IP WSHM10 16
one washer – try to keep them even.

Grade 10.9 M10 Caliper Carrier
DeDion holes
x4 x4
Caphead Bolt
Schnorr washer Behind bolt heads
6 IF M10 X 20 BMCH10X20 4 Propshaft bolts 17 IQ M12 4
Grade 12.9 on diff
Tiago O
Caphead Bolt
Shakeproof
7 IG M12 X 25 BMCH12X25 2 Diff cage 18 IR washer 3/8"
WSS3/8 1 Braided brake hose
Grade 8.8
8 IH
Half Nyloc
1/2" "T" Type
NFYH1/2 1 Upper diff bolt
x1 19 IS
Rivet
1/8" X 0.51"
1661-0414 5
P-clips on DeDion
for brake pipe
Nyloc Nut Hub through ear to Brake pipe on

9 II M10
NMYF10 8 20 IT P-Clip NX1 5
DeDion DeDion
1
1/2" Nyloc Nut Rear anti roll bar
10 IJ M8
NMYH8 4
droplink
Plain washer 3/8"

11 IK X 7/8"
WPH3/8X7/8 2 Brake pipe
* Use as required for spacing
96 97
FILL THE DIFFERENTIAL WITH OIL FILL THE DIFFERENTIAL WITH OIL
P A R T S T O O L S
Differential oil
Differential = 0.8L
98 99
PREPARING THE DEDION TUBE PREPARING THE DEDION TUBE
P A R T S T O O L S
IK
1 DeDion tube
2 LHS brake pipe
3 RHS brake pipe ⅛" 5

IR
4 3 way union
5 Brake hose
IS
11mm IT
13mm
14mm
5 xx⅛"
5 1.8mm
3
1
H I I
SERIAL
53 SERIAL
44 SERIAL
44
Pack Pack Pack
NUMBER NUMBER NUMBER
PACK NUMBER
30R011D
PACK NUMBER
30Z1067B
PACK NUMBER
30Z1067B The upper brake hose fittings will
REAR SUSPENSION DEDION METRIC
AXLE DEDION METRIC
AXLE DEDION METRIC
This pack may include extra fasteners to cover different options become self explanatory on the rear
HK
BASIC BASIC BASIC
damper installation page.

PART PART PART
ITEM QTY USED ON ILLUSTRATION ITEM QTY USED ON ILLUSTRATION ITEM QTY USED ON ILLUSTRATION
DESCRIPTION NUMBER DESCRIPTION NUMBER DESCRIPTION NUMBER
Bolt M12 X 100 A-frame fromt Bolt 1/2" X 11" Upper diff mounting Plain washer 1/2" Fine tuning diff
1 HA Grade 10.9
BM12X100 2 1 IA UNF
BF1/2X11 1 12 IL X 7/8" Thin
WPT1/2X7/8 16
mountings bolt setup
John K
Caphead Bolt
Caphead Bolt Front radius arm Lower diff mounting Plain washer 1/2"
2 HB M10 X 65
BMCH10X65 2 2 IB M12 X 65 BMCH12X55 2 13 IM X 3/4" Thin
(through cockpit) Grade 10.9 bolt
4
Bolt x 2 Lower Rear Plain washer 1/2"
3 HC 1/2" X 2.1/2" BF1/2X2.1/2 4 Damper x 3 IC Grade 10.9
Grade 10.9 ear to front DeDion Thick
2 Rear Radius Arm
x 4 Front hub
Rear DeDion
Bolt M6 X 80 Rear Anti Roll Bar Bolt M10 X 55 through ear Washer
4 HD Grade 10.9
BM6X80 4 4 ID Grade 10.9
BM10X55 8 15 IO M10
Mounting Blocks x 4 Caliper carrier
Hub
bolts
Tighten the braided pipe 5 into the

Through rear of ear
Bolt 1/2" X 2.3/4" Bolt M10 X 40 Spring Washer Rear DeDion Tube
5 HE Grade 10.9
BF1/2X2.3/4 1 A-frame to DeDion 5 IE Grade 10.9
BM10X40 4 into threaded 16 IP M10
WSHM10 16
Caliper Carrier
DeDion holes
union before nipping up the locknut.

x 2 Rear Radius Caphead Bolt
Half Nyloc Schnorr washer Behind bolt heads
6 HF 1/2" UNF
NFYH1/2 3 Arm x 6 IF M10 X 20 BMCH10X20 4 Propshaft bolts 17 IQ M12 4
Grade 12.9 on diff
1 A-frame to DeDion
x1 Chris N
Caphead Bolt
Nyloc Nut A-frame front Shakeproof
7 HG M12
NMYF12 2 7 IG M12 X 25 BMCH12X25 2 Diff cage 18 IR washer 3/8"
mounts Grade 8.8
8 HH
Nyloc Nut
M10
NMYF10 2
Front radius arm
(through cockpit)
8 IH
Half Nyloc
1/2" "T" Type
NFYH1/2 1 Upper diff bolt 19 IS
Rivet
1/8" X 0.51"
1661-0414 5
P-clips on DeDion
for brake pipe x5 2
9 HI
Half Nyloc
M8
NMYH8 2
Rear Anti Roll Bar
Drop Link
9 II
Nyloc Nut
M10
NMYF10 8
Hub through ear to
DeDion
20 IT P-Clip NX1 5
Brake pipe on
DeDion x5
Nyloc Nut Rear Anti Roll Bar 1/2" Nyloc Nut Rear anti roll bar
10 HJ M6
NMYF6 4 10 IJ M8
NMYH8 4
Mounting Blocks droplink
Brake pipe washers and nuts are included with

11 HK Nyloc Nut 1/4" NFYF1/4 1
3 - way union on
DeDion tube x1 11 IK
Plain washer 3/8"
X 7/8"
x2 the hose
Drawings are for illustrative purposes only and are not to scale. Page 1 of 2 Drawings are for illustrative purposes only and are not to scale. Page 1 of 2
100 101
AND FITTING IT IN PLACE AND FITTING IT IN PLACE
P A R T S T O O L S
102 103
ATTACHING THE REAR DAMPERS ATTACHING THE REAR DAMPERS
P A R T S T O O L S
1 Rear damper assembly

13mm
14mm 35 35
mm
47Nm
2
mm
Rear damper sleeve
8mm
19mm
H H
SERIAL
53 SERIAL
53
Pack Pack
NUMBER NUMBER
PACK NUMBER
30R011D
PACK NUMBER
30R011D Although we show the fitting of the dampers here as part
BASIC
BASIC
This pack may include extra fasteners to cover different options of the rear suspension, it is better to leave this step until
you've fitted the roll over bar much later in the process.
PART PART
Bolt M12 X 100 A-frame fromt

1 HA Grade 10.9
BM12X100 2 12 HL Washer 79029 10 Differential Isolation
mountings
x 2 Lower Damper
Jamie A
2 HB
Caphead Bolt
M10 X 65
BMCH10X65 2
Front radius arm
(through cockpit)
13 HM
Plain Washer
1/2" Chamferred
WPH1/2 20
x 10 A-frame
washers
4 Radius Arm
x x4
x 2 Lower Rear
x2
Bolt
Plain Washer
3 HC 1/2" X 2.1/2" BF1/2X2.1/2 4 Damper x 14 HN 3/8" X 7/8"
WPH3/8X7/8 2 Front Radius Arm
Grade 10.9 2 Rear Radius Arm
Bolt M6 X 80 Rear Anti Roll Bar Plain Washer Rear Anti Roll Bar
4 HD Grade 10.9
BM6X80 4 15 HO M6
WPHM6 4
Mounting Blocks Mounting Block
5 HE
Bolt 1/2" X 2.3/4"
Grade 10.9
BF1/2X2.3/4 1 A-frame to DeDion 16 HP
Schnorr Washer
M12
30Z1069A 2 Lower Damper
x2
6 HF
Half Nyloc
1/2" UNF
NFYH1/2 3
x 2 Rear Radius
Arm x
1 A-frame to DeDion
1
Nyloc Nut A-frame front
7 HG M12
NMYF12 2
mounts
Nyloc Nut Front radius arm

8 HH M10
NMYF10 2
(through cockpit)
Half Nyloc Rear Anti Roll Bar

9 HI M8
NMYH8 2
Drop Link
HC
Nyloc Nut Rear Anti Roll Bar
10 HJ NMYF6 4
35 35
M6
81Nm HM
Mounting Blocks
mm mm
3 - way union on
HP
DeDion tube
104 105
THEN THE RADIUS ARM THEN THE RADIUS ARM
P A R T S T O O L S
1 Radius arm
19mm
8mm
17mm
19mm
HB
HF
HM
H H
SERIAL
53 SERIAL
53
Pack Pack
NUMBER NUMBER
PACK NUMBER
30R011D
PACK NUMBER
30R011D Before torquing up these bolts, reposition the
BASIC
BASIC
This pack may include extra fasteners to cover different options axle stands to under the DeDion tube (to hold up
the suspension). Make sure front has two axle
PART PART
stands so it is steady when jacking up the rear!

1 HA Grade 10.9
mountings
HC
x 2 Lower Damper
2 HB
Caphead Bolt
M10 X 65
BMCH10X65 2
Front radius arm
(through cockpit) x2 13 HM
Plain Washer
1/2" Chamferred
WPH1/2 20
x 10 A-frame
washers
4 Radius Arm
x x4 Mick F
3 HC
Bolt
1/2" X 2.1/2"
Grade 10.9
BF1/2X2.1/2 4
x 2 Lower Rear
Damper
2 Rear Radius Arm
x
x2 14 HN
Plain Washer
3/8" X 7/8"
WPH3/8X7/8 2 Front Radius Arm
x2 HH HM
4 HD
Bolt M6 X 80
Grade 10.9
BM6X80 4
Rear Anti Roll Bar
Mounting Blocks
15 HO
Plain Washer
M6
WPHM6 4
Rear Anti Roll Bar
Mounting Block
HN
35 35 81Nm
mm mm
Bolt 1/2" X 2.3/4" Schnorr Washer
5 HE Grade 10.9
BF1/2X2.3/4 1 A-frame to DeDion 16 HP M12
35 35 34Nm
mm mm
x2
x 2 Rear Radius
Half Nyloc
6 HF 1/2" UNF
NFYH1/2 3 Arm x
1 A-frame to DeDion

7 HG M12
NMYF12 2
mounts
8 HH
Nyloc Nut
M10
NMYF10 2
Front radius arm
(through cockpit) x2
9 HI M8
NMYH8 2
Drop Link

10 HJ M6
NMYF6 4
Mounting Blocks
3 - way union on
DeDion tube
106 107
AND NOW THE (CAREFULLY SPACED) A-FRAME AND NOW THE (CAREFULLY SPACED) A-FRAME
P A R T S T O O L S
1 A-frame
19mm
2 White nylon anti-squeak washers
19mm (x2)
35 35
HA 81Nm
mm mm
H H
SERIAL
53 SERIAL
53
Pack Pack
NUMBER NUMBER
PACK NUMBER
30R011D
PACK NUMBER
30R011D Make sure the DeDion tube Use as many HM washers as
BASIC
PART BASIC
PART
is equal on both sides. required to space A-frame. 2
Tiago O John K
= =
1 HA
Bolt M12 X 100
Grade 10.9
BM12X100 2
A-frame fromt
mountings x2 12 HL Washer 79029 10 Differential Isolation
*
x 2 Lower Damper
Caphead Bolt Front radius arm Plain Washer x 10 A-frame
2 HB M10 X 65
BMCH10X65 2 13 HM 1/2" Chamferred
WPH1/2 20
(through cockpit) washers x
Bolt x 2 Lower Rear

4 Radius Arm
HE
Plain Washer
3 HC 1/2" X 2.1/2" BF1/2X2.1/2 4 Damper x 14 HN WPH3/8X7/8 2 Front Radius Arm
HF
3/8" X 7/8"
Take care to use the correct nuts as there is a

Bolt M6 X 80 Rear Anti Roll Bar Plain Washer Rear Anti Roll Bar
4 HD BM6X80 4 15 HO WPHM6 4
The A-frame has

Grade 10.9 Mounting Blocks M6 Mounting Block
x1 mixture of metric and imperial here. 35 35 81Nm

a 'way up'. The

5 HE Grade 10.9
mm mm
x1
x 2 Rear Radius
arms should be Lee A

Half Nyloc
6 HF 1/2" UNF
NFYH1/2 3 Arm x
1 A-frame to DeDion
x2 offset downwards
7 HG NMYF12 2
HM
M12 mounts
1
8 HH
Nyloc Nut
M10
NMYF10 2
Front radius arm
(through cockpit) in relation to the HG
9 HI
Half Nyloc
NMYH8 2
Rear Anti Roll Bar
front bushes. Torque up as before on axle stands.
IF REQUIRED
M8 Drop Link
10 HJ
Nyloc Nut
M6
NMYF6 4
Rear Anti Roll Bar
Mounting Blocks
Chris N Rich T
3 - way union on
DeDion tube
* Use as required for spacing
108 109
IF YOU HAVE THE OPTIONAL REAR ANTI-ROLL BAR, IT GOES ON LIKE THIS IF YOU HAVE THE OPTIONAL REAR ANTI-ROLL BAR, IT GOES ON LIKE THIS
P A R T S T O O L S
1 Rear anti roll bar
2 Anti roll bar rubber
3 Rear anti roll bar clamp
10mm
10mm
H H
SERIAL
53 SERIAL
53
Pack Pack
NUMBER NUMBER
PACK NUMBER
30R011D
PACK NUMBER
30R011D Be careful not to slip with the screwdriver!
REAR SUSPENSION DEDION METRIC REAR SUSPENSION DEDION METRIC
John S
2
HJ
1 HA Grade 10.9
mountings
x 2 Lower Damper
HO
Caphead Bolt Front radius arm Plain Washer x 10 A-frame
2 HB M10 X 65
BMCH10X65 2 13 HM 1/2" Chamferred
WPH1/2 20
(through cockpit) washers x
4 Radius Arm
Bolt x 2 Lower Rear

Plain Washer
3 HC 1/2" X 2.1/2" BF1/2X2.1/2 4 Damper x 14 HN WPH3/8X7/8 2 Front Radius Arm
3
3/8" X 7/8"
4 HD
Bolt M6 X 80
Grade 10.9
BM6X80 4
Rear Anti Roll Bar
Mounting Blocks x4 15 HO
Plain Washer
M6
WPHM6 4
Rear Anti Roll Bar
Mounting Block x8
5 HE Grade 10.9
x 2 Rear Radius
Half Nyloc
6 HF 1/2" UNF
NFYH1/2 3 Arm x
1 A-frame to DeDion
7 HG
Nyloc Nut
M12
NMYF12 2
A-frame front
mounts
HD
8 HH
Nyloc Nut
M10
NMYF10 2
Front radius arm
(through cockpit)
HO
9 HI M8
NMYH8 2
Drop Link
10 HJ
Nyloc Nut
M6
NMYF6 4
Rear Anti Roll Bar
Mounting Blocks x4
3 - way union on
DeDion tube
110 111
INSERT THE DRIVESHAFTS INSERT THE DRIVESHAFTS
P A R T S T O O L S
1 Driveshaft
2 Driveshaft nut
Driveshafts are handed, and so are the nuts,

the left hand nut tightens anti-clockwise.
James A
112 113
FITTING THE REAR HUB FITTING THE REAR HUB
P A R T S T O O L S
1 Rear brake disc / flange assembly 8 Brake pads
2 Rear hub 9 Driveshaft nut

6
3 DeDion ear 10 Driveshaft washer
4 Anti roll bar bracket

12mm
13mm
5 Anti roll bar drop link 15mm
17mm (x2)
6 Brake calliper
17mm
ID
7 Brake calliper mount 8
35
mm
IO
35
mm
47Nm
IP
I I
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER
PACK NUMBER
30Z1067B
PACK NUMBER
30Z1067B Swap the plain nuts on Remember the driveshaft nuts are handed. IJ
IE
BASIC
AXLE DEDION METRIC
PART BASIC
AXLE DEDION METRIC
PART
the droplinks for nylons. Grant P 35
mm
35
IO
mm
47Nm
IP
Chris B
Upper diff mounting Fine tuning diff
35
IC
35 47Nm
Bolt 1/2" X 11" Plain washer 1/2"
1 IA UNF
BF1/2X11 1 12 IL X 7/8" Thin
WPT1/2X7/8 16
bolt setup
mm mm
2 IB
Caphead Bolt
M12 X 65 BMCH12X55 2
Lower diff mounting
13 IM
Plain washer 1/2"
X 3/4" Thin
II
Grade 10.9 bolt
x4 10 9
Plain washer 1/2"
3 IC Grade 10.9
ear to front DeDion Thick
x 4 Front hub
Rear DeDion
Bolt M10 X 55 through ear
x8 Washer
x16
If you don't have an anti roll bar you will
4 ID Grade 10.9
BM10X55 8 15 IO M10
x 4 Caliper carrier
Hub
Torque up the bearing and

bolts
Through rear of ear

5 IE
Bolt M10 X 40
Grade 10.9
BM10X40 4 into threaded
x4 16 IP
Spring Washer
M10
WSHM10 16
Rear DeDion Tube
Caliper Carrier x8 only have one bracket (for the right hand
ear before fitting the disc.
DeDion holes
side) which holds the speed sensor.

Caphead Bolt
Schnorr washer Behind bolt heads
6 IF M10 X 20 BMCH10X20 4 Propshaft bolts 17 IQ M12 4
Grade 12.9 on diff
Caphead Bolt
Dan D
Rich T
Shakeproof
7 IG M12 X 25 BMCH12X25 2 Diff cage 18 IR washer 3/8"
Grade 8.8
8 IH
Half Nyloc
1/2" "T" Type
NFYH1/2 1 Upper diff bolt 19 IS
Rivet
1/8" X 0.51"
1661-0414 5
P-clips on DeDion
for brake pipe 4 3 2 35
mm
35
mm 270Nm
9 II
Nyloc Nut
M10
NMYF10 8
Hub through ear to
DeDion x8 20 IT P-Clip NX1 5
Brake pipe on
DeDion
Drawings are for illustrative purposes only and are not to scale. Page 2 of 2 ID
10 IJ
1/2" Nyloc Nut
M8
NMYH8 4
Rear anti roll bar
droplink x4
35
mm
35
mm
47Nm IO
5 1
Plain washer 3/8"
11 IK X 7/8"
Drawings are for illustrative purposes only and are not to scale. Page 1 of 2 II
114 115
AND SPEED SENSOR (ONE SIDE ONLY) AND SPEED SENSOR (ONE SIDE ONLY)
P A R T S T O O L S
1 Speed sensor
1 x 5⁄32"
30mm
Ensure there is enough slack in the Adjust sensor gap to

wire to allow for suspension travel. approx. 0.8–0.9mm.
Tiago O Lloyd D
116 117
118 119
JUST WING IT JUST WING IT
P A R T S T O O L S
1 Cycle wing
2 Wheel
3 Wheel nuts
Key the wing & wingstay You may need to bend the arms of
before using adhesive. the wingstay to make the wing level.
John S Anthony L
2
The 1⁄8" hole you drilled earlier is for the indicator earth.
Harry P 3
Do a 'dry run' first to make

The distance from the front edge of the sure the wings are level
wing to the wingstay should be 80mm. before using power adhesive.
Lee A Chris N
120 121
TAPE IN PLACE FOR 24 HOURS TAPE IN PLACE FOR 24 HOURS
P A R T S T O O L S
122 123
SOME EXTRA ADHESIVE UNDERNEATH JUST WING IT
P A R T S T O O L S
The WD40 will help spread the adhesive.

Mick F
124 125
FINISH WITH TRIM FINISH WITH TRIM
P A R T S T O O L S
126 127
FITTING THE REAR WINGS FITTING THE REAR WINGS
P A R T S T O O L S
1 Rear wing
to follow Sanding Drum

1
7
7
8mm
8mm
Q
SERIAL
31
Pack
NUMBER
PACK NUMBER
ZFG12 Cut the supplied piping in half and it Don’t forget the fuel tank
REAR WINGS
This pack may include extra fasteners to cover different options will be enough for both wings. earth strap gets bolted to
7
BASIC
the RH wing bolt.

PART
DESCRIPTION NUMBER
Rich T
1 QA
Set Screw
M5 X 20
SM5X20 20 Rear Wings
x20 QB
Tiago O
2 QB
Nyloc Nut
M5
NMYF5 10
Rear wings through
boot x10 QC
x30
Plain Washer
3 QC WP3/16X3/4 30 Wing washers
7
3/16" X 3/4"
x4
Wing Piping Between wing and
4 QD 1/4" X 1"
76902 4m
body
QA
QD QC
128 129
AND THE WING PROTECTORS AND THE WING PROTECTORS
P A R T S T O O L S
1 Wing protector
⅛"
x12 x1
For stainless steel protectors For carbon fibre protectors
When drilling through protector start Carbon fibre protectors will not
O P
SERIAL SERIAL
Pack Pack
NUMBER NUMBER
PACK NUMBER
ZWS01
PACK NUMBER
ZWS02 on the closest edge to the body. This have the protective film shown.
WING PROTECTORS STAINLESS STEEL
WING PROTECTORS CARBON FIBRE
This pack may include extra fasteners to cover different options will help the protector fit correctly. Anthony L
Chris B
Rivet Wing protector to Rivet Black Wing protector to
1 OA 1/8" X 0.51"
1661-0414 30 1 PA 1/8" X 0.51"
1610-01049 30
wing wing
Between wing Between wing

2 OB Wing Piping 76901 2m 2 PB Wing Piping 76901 2m
protector and wing protector and wing
x1
130 131
FITTING THE LIGHTS FITTING THE LIGHTS
P A R T S T O O L S
1 Side repeater
8mm
2 Rear light 7
1
3 Numberplate lamp
7
CC
CD
C
SERIAL
45
Pack
NUMBER
Use a cradle clip & cable tie to keep

PACK NUMBER
30L002B
BASIC PART
FASTENER PACK - LIGHTING
the rear light loom out of the way. Rubber grommet on rear light
goes in the body not the wing.

DESCRIPTION NUMBER
John S
Screw 10 x ¾" Indictor assembly to
1 CA 71080 6
Jamie A
3
Screw 8 x ½" Side repeater earth
2 CB 71077 2
Black Supaflange on wingstay
3 CC Screw 12 x 1½"
Self tapping
71079 4
Rear light cluster
upper fixing x4
4 CD Screw 12 x 1"
Self tapping
71078 4
Rear light cluster
lower fixing x4
Indicator repeater wires
go through the wingstay.
Chris B
132
7 133
FUSE BOX COVER & KNEE TRIM PADS FUSE BOX COVER & KNEE TRIM PADS
P A R T S T O O L S
7 x ⁵⁄₃₂"
⁵⁄₃₂"
Chassis fastener pack ZCH01 supplied loose:
• Screw ¾" x 10 Building an Academy Car? If so you'll need to leave the
• Rivet 5⁄32 x 0.47" riveting-in of the side panels until after you've fitted the
roll cage (p154–155) as the front legs go behind the
panel, not over the top of it.
John S
134 135
FIT THE TUNNEL CARPET FIT THE TUNNEL CARPET
P A R T S T O O L S
Spray on both tunnel Allow the adhesive to

panel and carpet. go tacky before fitting.
John K Harry P
136 137
AND THE BOOT CARPET AND THE BOOT CARPET
P A R T S T O O L S
S-Pack cars have a fully carpeted boot. It's

something of a jigsaw pattern, but the parts
are simply glued in place like the bigger bits.
John S
138 139
THIS IS A COVER UP THIS IS A COVER UP
P A R T S T O O L S
1 Fuel filler cove 1
2 Tunnel closing panel
⁵⁄₃₂"
Supplied loose:
• Rivets The fuel filler cover just screws to the boot floor.
• Screws Drill two holes and use self tapping screws.
Rich T
140 141
NOW FIT THE TUNNEL TOP NOW FIT THE TUNNEL TOP
P A R T S T O O L S
⅛"
The hole can be seen if you

flip the tunnel top over.
Mick F
142 143
BELT UP BELT UP
P A R T S T O O L S
35 35 47Nm
mm mm
Supplied with seat belts
These will be loosely fitted already –
you'll need to tighten & torque.
Chris N
35 35 47Nm
mm mm
144 145
FITTING THE FOUR-POINT HARNESS FITTING THE FOUR-POINT HARNESS
P A R T S T O O L S
17mm IMPORTANT
For Academy cars with 35
mm
35
mm
47Nm
Schroth Harnesses see
page 148
All fixings supplied with the harnesses
The buckle is attached to a lap strap and
this should be fitted to the tunnel side.
Chris N
For Academy cars with Schroth

Harnesses see Page 148.
Dan P
146 147
FITTING SCHROTH HARNESSES – ACADEMY CARS FITTING SCHROTH HARNESSES – ACADEMY CARS
SHOULDER STRAP MOUNTING ORIENTATION WAIST STRAP MOUNTING ORIENTATION CRUTCH STRAP MOUNTING ORIENTATION
SL 65 S 156
35 35 40Nm Harness mounting plate Swivelling insert Spacer washer NFYF 7⁄16 nyloc
mm mm
WPH 7⁄16 washer

Chassis
SG 96 7⁄16 x 52mm bolt 30Z2042A 30P065A spacer

7⁄16 x 30 thin head
Loctite Threadlock
Harness mounting plate
Harness mounting plate
35 35
mm
40Nm Chassis
mm
S65L swivelling insert
S 156 spacer washer

S 65L swivelling insert Chassis
S 156 spacer washer WPH 7⁄16 washer
Chassis
SF 7⁄16 x2 bolt
Loctite
Threadlock
35 35 40Nm
mm mm
148 149
FITTING THE SIX-POINT HARNESS FITTING THE SIX-POINT HARNESS
P A R T S T O O L S
35 35 47Nm
mm mm
7⁄16"
16mm
17mm
16mm
17mm
All fixings supplied with the harnesses
The buckle is attached to a lap strap and
this should be fitted to the tunnel side.
Lee A
35 35 47Nm
mm mm
150 151
FITTING CLOTH OR LEATHER SEATS FITTING CLOTH OR LEATHER SEATS
P A R T S T O O L S
1 Seat
13mm 3
2 Seat base
3 Headrest 6mm
+
2 1
L
SERIAL
62
Pack
NUMBER
Loosely fit the rear bolts to help Nip up all bolts once fitted.
PACK NUMBER
30Z1058B
CLOTH/LEATHER SEATS ALL CARS

This pack may include extra fasteners to cover different options locate the front. Anthony L LA
BASIC PART
DESCRIPTION NUMBER
Dan D
x4
Caphead Bolt
Through seat runner
1 LA M8 X 20 SMCH8X20 4
Grade 12.9 & floor
x4
Nyloc Nut
2 LB M8
NMYF8 4 Under floor
x4
Plain Washer
3 LC M8 X 30
WPH8X30 4 Under floor
LB
LC
152 153
OR FITTING THE RACE SEATS OR FITTING THE RACE SEATS
P A R T S T O O L S
1 Seat
13mm 1
2 Adjustable runner
3 Fixed seat spacer 6mm
LO
CT
IT
E
+
For fixed seats For adjustable seats
NE
Put a bit of LocTite on bolts that go Runners / seat spacers NF
M N MF
63 64
NF MF
SERIAL SERIAL
Pack Pack
NUMBER NUMBER
PACK NUMBER
30Z1062A
PACK NUMBER
30Z1063A into the seat on the runner version. can be fitted to seat NF
MF MG
SEATS FIXED TILLETT RACING
SEATS ADJUSTABLE TILLETT RACING
This pack may include extra fasteners to cover different options Chris B before putting in car.
Mick F
x4 x4
Caphead Bolt Spacer box section Caphead Bolt
1 MA M8 X 25
BMCH8X25 4 1 NA M8 X 25
BMCH8X25 4 Runner to seat
to seat
2 MB
Caphead Bolt
M8 X 20
SMCH8X20 4
Floor to rivnut in
spacer box section x4 2 NB
Caphead Bolt
M8 X 20
SMCH8X20 4 Runner to floor
x4 Loosely fit the rear bolts 2 3
3 MC
Spring Washer
5/16"
WSH5/16 8 Bolt heads
x8 3 NC
Washer
5/16" X 1 1/4"
WP5/16X1.1/4 4 Under floor
x4 to help locate the front.
x4 Harry P
x4
Washer Nyloc Nut
4 MD 5/16" X 1 1/4"
WP5/16X1.1/4 4 Under floor 4 ND NMYF8 4 Under floor
M8
5 ME
Washer
M8 X 18
WPM8X18X1 4
Spacer box section
to seat x4 5 NE
Spacer Black
Plastic
TW2 3 Seat spacer
x3 NB
NA MA
7 MF
Spacer Black
Plastic
TW2 3 Seat spacer
x3 The fixed position seat is for the passenger side!
6 NF
Spacer Black
Plastic
TW3 5 Seat spacer
x5
Chris N
8 MG
Spacer Black
Plastic
TW3 5 Seat spacer
x5
MB
Drawings are for illustrative purposes only and are not to scale. Page 1 of 1 NC MC MC
ND ME MD
154 155
FITTING THE ROLL OVER BAR FITTING THE ROLL OVER BAR
P A R T S T O O L S
1 Roll over bar

13mm
17mm
1
8mm
JB
35 35 25Nm JE
17mm mm mm
JF
F I X I N G S T I P S JA
35 35 47Nm
mm mm
JD
J
SERIAL
47
Pack
NUMBER
PACK NUMBER
30P010A If you've fitted the rear dampers they'll JG
JC
BASIC
ROLL OVER & TRACK DAY BAR SERIES 3 METRIC
PART
need to come off again to do this properly.
35 35
47Nm
DESCRIPTION NUMBER
Chris B mm mm
x2
Rear diagonals of
Bolt M10 X 60
1 JA Grade 8.8
BM10X60 2 roll over bar to
mounting brackets
x2
Setscrew
Roll over bar bracket
2 JB M8 X 20 SM8X20 2
Grade 8.8 to chassis
3 JC
Caphead Bolt
M10 X 20
BMCH10X20 2 Roll over bar boss
x2
x2
Rear diagonals of
Nyloc Nut
4 JD M10
NMYF10 2 roll over bar to
mounting brackets
5 JE
Plain Washer
M8
WPHM8 2
to chassis x2
6 JF
Spring Washer
M8
WSHM8 2
to chassis x2
x4
Rear diagonals of
Plain Washer
7 JG M10
WPHM10 4 roll over bar to
mounting brackets
JC
156 157
OR THE ROLL CAGE FOR ACADEMY CARS OR THE ROLL CAGE FOR ACADEMY CARS
P A R T S T O O L S
17mm
IMPORTANT
Never remove or paint
over the homologation
8mm identity label
17mm
+
KA 35 35
mm JCmm 47Nm
35 35
KEmm 47Nm
mm
KD
K
SERIAL
47
Pack
NUMBER
PACK NUMBER
30P017A Mask up the paintwork before fitting to avoid scratches.
ROLL CAGE SERIES 3 METRIC
This pack may include extra fasteners to cover different options John S
BASIC PART
DESCRIPTION NUMBER
Rear diagonals of
x2
Bolt M10 X 60
1 KA Grade 8.8
BM10X60 2 roll over bar to
mounting brackets
Setscrew
2 KB M8 X 16
Grade 8.8
SM10X16 4 Front cage bracket
x4 The front legs go over the sill
x2 and inside the inner panel, not
Caphead Bolt
3 KC M10 X 20
The front leg has two bolts – one from

x2 over the panel.
Rear diagonals of
Nyloc Nut
4 KD NMYF10 2 roll over bar to
the inside & one from the outside.

M10
mounting brackets
x 4 Front cage
5 KE
Plain Washer
M10
WPHM10 8 bracket
Rear diagonals
x4
x8 Great care should be taken to ensure Mick F
they go in straight.
James A.
35 35
KB
mm mm
47Nm
KE
158 159
AND THE SIDE IMPACT BAR AND THE SIDE IMPACT BAR
P A R T S T O O L S
17mm
19mm
RB
35 35 47Nm
mm mm
RE
5⁄16"
19mm
Use washers from rollcage pack
R
SERIAL
46
Pack
NUMBER
PACK NUMBER
30P009C
SIDE PROTECTION BAR SERIES 3

BASIC PART
DESCRIPTION NUMBER
x1
Bolt M12 X 120
1 RA Grade 10.9
BM12X120 1 A-frame
x1
Caphead Bolt Boss on top of
2 RB 7/16" X 1 1/2"
BFCH7/16X1.5 1
chassis
Set screw M10

3 RC X 25 Grade
10.9
SM10X25 1 Front cage bracket
x1 RC
x1
Plain Washer
4 RD M10
WPHM10 1 Front cage bracket
x1
Spring Washer Boss on top of
5 RE 7/16"
WSH7/16 1
chassis
35 35 47Nm
mm mm
RA
160 161
EVEN MORE EXHAUSTING EVEN MORE EXHAUSTING
P A R T S T O O L S
1 Silencer 7mm
10mm
13mm
2 Exhaust clamp
3 Lambda sensor ⅞"
4 Cat guard GB
GC
5 Clip GD
6 Silencer mounting bracket
7 Exhaust mounting bobbin
F I X I N G S T I P S GA
GC
4
G
SERIAL
56
Pack GD
NUMBER
PACK NUMBER
30X020B Cable tie the Lambda sensor lead neatly out of the way.
EXHAUST
This pack may include extra fasteners to cover different options Lee A
7 6
ITEM
BASIC
DESCRIPTION
PART
NUMBER
5
x1
Setscrew
Exhaust Mounting
1 GA M8 X 25 SM8X25 1
Grade 8.8 Bracket
x2
Plain Nut
2 GB M8
NFPF8 2 Exhaust Bobbin
x 1 Exhaust
3 GC
Spring Washer
M8
WSHM8 3 Mounting Bracket x
2 Exhaust Bobbin x3
GB
GC
GD
1
3
2
162 163
THE NOSE CONE BADGE THE NOSE CONE BADGE
P A R T S T O O L S
1 Nose cone
2 Bonnet 1 2
3 Badge
The nose cone goes on Stick the supplied foam around the edge
before the bonnet. of the nose and scuttle where the bonnet
Anthony L will sit (if you've not done already).
Harry P
164 165
FITTING THE WIPERS FITTING THE WIPERS
P A R T S T O O L S
1 Wiper arm
2 Wiper blade
1 2
Ensure wipers are in paused position Now would be a good time to fill
before fitting the wiper arms. the washer bottle with fluid and
John S test the washers and wipers.
Chris B
166 167
AND FINALLY, AT LAST, THE WING MIRRORS AND FINALLY, AT LAST, THE WING MIRRORS
P A R T S T O O L S
00 Mirror head
00 Mirror mount
00 Mirror mount stud 2.5mm
00 Grub screw
T20
00 Fibre washer
4 3
Wing mirror bag
You may have to unclick the
glass out to tighten up.
Mick F 5
168 169
WIRING THE STARTER MOTOR WIRING THE STARTER MOTOR
P A R T S T O O L S
1 Starter motor
Cable from altenator

2
2 (brown wire with black sheath)
Cable from battery

3 (positive – red wire)
2 cables from main loom

4 (2 brown wires joined)
Cable from engine loom

5 (white wire with red stripe)
1
170 171
THE LAST FEW STEPS… 5 Using the 10mm spanner, ‘crack off’ the nipple about half of a turn.
Your car is almost complete, but before you can drive triumphantly out of the garage (and legally, as far as 6 sk your assistant to pump the pedal a few times. You should see bubbly fluid flowing through the
A
the end of your driveway) there are a few important things that need to be done. These are, bleeding the pipe. When the bubbles die down, ask them to hold the pedal down, then tighten the nipple back up.
brakes, preparing the engine for the its first grand firing-up ceremony (it will feel like that, even if you are Check and top of the fluid level in the reservoir as necessary.
doing it on your own) and lastly torquing up the suspension.
7 Ask them to lift off, then pump it a couple of times, then press the pedal down and hold it down.
So, on with bleeding the brakes which cannot be explained with a simple diagram unfortunately:
8 rack off the nipple again and let the fluid and bubbles flow. It will stop flowing as soon as your
C
1 ssemble the things you’ll need: Brake fluid, both a 10mm and an 11mm spanner, a length of washer
A assistant has run out of brake pedal travel. Tighten the nipple.
hose (or similar clear plastic hose) and a waster fluid receptacle (some form of used bottle is ideal;
you won’t want to use it again after this) 9 epeat steps 8 and 9 until you get 100% bubble free fluid passing through the pipe, remembering to
R
check and top up the reservoir. You will waste quite a lot of brake fluid during this process.
2 ind a volunteer. They need to be able to reach and press the brake pedal, plus respond to your
F
instructions, so whilst a child is fine for this job, someone’s might be more inclined to listen to you. 10 nce you are satisfied that there are no more bubbles (no more air in the caliper), then you can
O
remove the washer hose and refit the dust cover.
3 ill the brake master cylinder with fresh brake fluid and leave the cap off. BE CAREFUL NOT TO
F
SPILL ANY ONTO THE PAINTWORK; if you do, wipe it off immediately. Brake fluid will react with the 11 epeat steps 5 to 10 for the remaining brakes in this order, right rear next, then right front and lastly
R
paintwork causing it to blister and peel. left front. The front brake nipples use an 11mm spanner.
4 tarting at the left rear corner, locate the bleed nipple on the caliper. It will have a rubber cap on it.
S 12 lthough tedious, getting all the air out of the braking system is important and will give you a good,
A
Remove the cap, remember where you put it, and attach the washer hose to the nipple and put the firm brake pedal, which is what you need; not a soft spongy one like you have in a regular car. You
other end in the waste bottle. This sometimes needs the hose warming up in a cup of hot water to may need to repeat the whole process after the first drive or two (or even after the car has had a ride
allow it to stretch over the nipple. on a trailer); air in the braking system is very good at hiding.
172 173
Brakes bled and we are ready to fire up the engine. Again, it’s easier to explain in writing than draw a
diagram. The only thing you’ll need for this job is to ensure that you have put some fuel in the car. The
shape of the Caterham fuel tank does not lend itself to making use of every last drop, so we recommend
an absolute minimum of 10 litres in the tank before trying to start the car. With the tank filled, we are ready
for initialisation.
But before anything else:

YOU DID REMEMBER TO PUT OIL IN THE ENGINE AND GEARBOX, RIGHT?
1 Reassure yourself the engine is full of oil.

That’s it. Your car is complete! Well done – you have built a car; a real live car; not many people can say
2 Disconnect the inertia switch; it’s the black thing attached to the engine bay bulkhead under the that. If you remembered to put in gearbox and differential oil, and fill the system with coolant, then a
windscreen that has rubber cap on top and a plug with two wires connecting from underneath. By tentative edge out onto the driveway is in order. You’ll need to pop the wheels on and lower it from the
disconnecting the inertia switch, the fuel pump will not work, so intentionally, the engine will not fire. axle stands and just tighten the suspension first.
3 Ensure the gearbox is in neutral, then turn the ignition key and press and hold the start button. Let’s just run through that quickly:
4 As the engine cranks over, watch the oil pressure gauge. Keep cranking until the needle starts to i. Put a wheel on and do the nuts up a few turns by hand (to ensure they do not cross-thread).
climb, then steadies out. ii. Tighten them up the best you can with the wheels off the ground.
5 We now have oil pressure circulating in the engine, which means the engine is ready to be started. iii. Lower the car from the axle stands, front first; taking care that it doesn’t lean back on the axle
stands at the back (a helper might be handy).
6 Reconnect the inertia switch.
iv. Torque the wheel nuts to 65lbft (about 85Nm).
7 Take a deep breath, mutter 'this is it', cross your fingers and brace yourself.
v. Flick back to the pages where we put the wishbones on and torque as shown
8 Turn the ignition key, press and hold the start button. It will take a few moments for the fuel to get
vi. That’s it, you’re ready to go!
through, so do not expect an instant start.
9 All things willing, the engine will start. Hooray! If it stops straight away, don’t worry. Try again and once Take care and good luck with the IVA and registration process.
it starts give it a little rev.
You will soon be experiencing the sheer pleasure of being a Caterham driver. Once again, enjoy!
174 175
APPENDIX
177
ASSEMBLY GUIDE
FIXING PACKS FIXING PACKS
94
A A B C
SERIAL
44 SERIAL
44 SERIAL
55 SERIAL
45
Pack Pack Pack Pack
NUMBER NUMBER NUMBER NUMBER
PACK NUMBER PACK NUMBER PACK NUMBER PACK NUMBER

30F015B 30F015B 30S003B 30L002B
FRONT SUSPENSION DeDION CARS (METRIC) FRONT SUSPENSION DeDION CARS (METRIC) STEERING DeDION CARS (METRIC) LIGHTING & HORNS
This pack may include extra fasteners to cover different options This pack may include extra fasteners to cover different options This pack may include extra fasteners to cover different options
BASIC PART BASIC PART BASIC PART BASIC PART
ITEM QTY USED ON ILLUSTRATION ITEM QTY USED ON ILLUSTRATION ITEM QTY USED ON ILLUSTRATION ITEM QTY USED ON ILLUSTRATION
DESCRIPTION NUMBER DESCRIPTION NUMBER DESCRIPTION NUMBER DESCRIPTION NUMBER
Caphead Bolt
Bolt M12 x 100 Lower wishbone Spring Washer Lower wishbone Screw 10 x ¾" Indictor assembly to
1 AA BM12X100 2 12 AM WSHM12 2 1 BA M6 x 70 BMCH6X70 4 Rack clamps 1 CA 71080 6
Grade 10.9 rear M12 front DIN 912
Anti-roll bar
Bolt M12 x 65 Lower wishbone Spring Washer mounting brackets & Screw 8 x ½" Side repeater earth
2 AB BM12X65 2 13 AN WSHM8 6 2 BB Bolt ¼" x 1½" BF1/4X1.1/2 2 Column clamp 2 CB 71077 2
Grade 10.9 front M8 upper damper Black Supaflange on wingstay
mount
Bolt M10 x 65 Upper wishbone Washer ⅜" Bolt M8 x 35 Column to rack Screw 12 x 1½" Rear light cluster
3 AC BM10X65 2 14 AP WSS3/8 2 Brake pipe 3 BC BM8X35 2 3 CC 71079 4
Grade 10.9 rear Shake-proof Grade 8.8 universal joint Self tapping upper fixing
Bolt M10 x 60 Upper wishbone Nyloc Nut ½" Nyloc Nut ½" Screw 12 x 1" Rear light cluster
4 AD BM10X60 2 15 AR NFYH1/2 2 Wing stay 4 BD NFYH1/2 1 Steering wheel boss 4 CD 71078 4
Grade 10.9 front Half height Half height Self tapping lower fixing
Horn bracket to
Bolt M8 x 40 Anti-roll bar Nyloc Nut ½" steering rack
5 AE BM8X40 4 16 AS NFYF1/2 2 mounting (std track 5 BE Plain Nut ½" NFPF1/2 2 Track rod lock nut 5 CE Nyloc Nut M6 NMYF6 2
Grade 10.9 mounting brackets Full height platform
ONLY)
(160/270/310)
Drawings are for illustrative purposes only and are not to scale. Page 2 of 2 Horn bracket to
Temporary use to Plain Washer
Plain Nut M14 Plain Nut ⁷⁄₁₆" Column clamp steering rack
6 AF NMPH14 1 help lock upper 6 BF NFPFH7/16 1 6 CF ¼" WPH1/4 2
x 1.5 thread Half height grubscrew locknut Heavy duty platform
wishbone ball joint
(160/270/310)
Through steering
Lower wishbone Column to rack Bolt M8 x 5 rack platform &
7 AG Nyloc Nut M12 NMYF12 2 7 BG Nyloc Nut M8 NMYF8 2 7 CG BM8X50 1
rear universal joint Grade 8.8 spacer
(420)
Steering rack Plain Washer

8 AH Nyloc Nut M10 NMYF10 4 Upper wishbone 8 BH Nyloc Nut M6 NMYF6 4 8 CH 5/16"
WPH5/16 2 Bolt head/nut
clamps
Plain Washer Plain Washer

Nyloc Nut
9 AJ M12 WPCM12 18 Lower wishbone 9 BJ ½" x 1⅛" WPH1/2 1 Steering wheel boss 9 CI M8
NMYF8 1 Horn bolt
Chamfered Chamfered
Plain Washer Plain Washer
Anti-roll bar Rack clamps and
10 AK M8 WPHM8 4 10 BK ¼" WPH1/4 6
Heavy duty mounting brackets Heavy duty column clamp
Plain Washer
Spring Washer ¼
11 AL ⅜" x ¾" WPH3/8 2 Brake pipe 11 BL Heavy duty
Heavy duty
178 179
D D E E
SERIAL
44 SERIAL
44 SERIAL
66
SERIAL
66
Pack Pack Pack Pack
NUMBER
PACK NUMBER PACK NUMBER PACK NUMBER

PACK NUMBER
30C047B 30C047B 3EZ1105F
3EZ1105F
COOLING SIGMA COOLING SIGMA SIGMA GEARBOX 5 SPEED

SIGMA GEARBOX 5 SPEED
BASIC PART
BASIC PART BASIC PART BASIC PART DESCRIPTION NUMBER
Buttonhead Bolt
M6 X 10
Plain Washer 12 EL Grade 10.9
Bolt M8 X 50 Expansion tank Expansion tank Bolt M14 X 40
1 DA BM8X50 1 12 DL 1/4" X 7/8" WPH1/4X7/8 1 1 EA 3EZ1137A 2 AV Mount Internal Hex
Grade 8.8 bracket to chassis Heavy duty bracket Grade 12.9
Plain Washer
Spring Washer Caphead Bolt
13 EM M14
WPH14 2 AV Mount
2 DB X 3/4"
SF1/4X3/4 1 13 DM 5/16" WSH5/17 9 2 EB M8 X 40 30Z1076A 4 AV Mount
bracket Heavy duty 1 x Expansion tank Grade 12.9
Plain Washer
2 x U shape hose to Caphead Bolt 14 EN M12
30Z2031A 4 Gearbox
Setscrew M8X20 Hose Clip water rail M12 X 50
3 DC Grade 8.8
SGT25-40 6 2 x Top radiator hose 3 EC Grade 12.9
3EZ1142A 4 Gearbox
2 x Bottom radiator hose Coarse Thread
1 x Engine outlet to 15 EO Plain Washer M6 WPHM6 3 Gear Lever

Caphead Bolt
Bolt M6 X 16 with Hose Clip big T piece 1 x Bellhousing
4 DD square section
30Z1072A 4 Fan brackets to fan 15 DO SGT23-35 2 4 ED M10 X 60 BMCH10X60 4
23 - 35mm 1 x Engine outlet to Grade 12.9 3 x Starter Motor
heater inlet Plain Washer
6 x Heater inlet/outlet 16 EP 5/16"
WPH5/16 8 AV Mount
3 x Big T-piece Caphead Bolt
5 DE SPHM6X16 4 16 DP SGT16-25 18 5 EE M10 X 55 BMCH10X55 3 Bellhousing
Panhead Pozi cowling - SV only 17 - 25mm 2 x Modine Grade 12.9
4 x Dry Sump Spring Washer
2 x Submarine 17 EQ M12
WSHM12 4 Gearbox
x4 Fan to radiator Caphead Bolt
6 DF Nyloc Nut M6 NMYF6 8 x4 SV radiator Hose Clip Expansion tank 6 EF M10 X 40 BMCH10X40 3 Bellhousing
17 DQ SGT8-16 6
bracket
8 - 16mm small T-piece Grade 12.9
Spring Washer x 7 Bellhousing x
18 ER M10
WSHM10 10
3 Engine Mount
Caphead Bolt
Engine Mount
1610-01015 12 Cowling flap 7 EG M10 X 35 BMCH10X35 2
5/32" X 0.47" Grade 12.9 RHS Top Wire Spring
19 ES Washer M10
Drawings are for illustrative purposes only and are not to scale. Page 1 of 2 Engine Mount
Caphead Bolt M8
Expansion tank
8 DH Nyloc Nut 1/4" NFYF1/4 1 8 EH X 25 Grade BMCH8X25 2 1 x LHS Top
bracket 12.9 Spring Washer
1 x LHS Bottom 20 ET M8
8 x SV rad bracket
Caphead Bolt M8
Plain Washer 1/4" 4 x Fan fixings Engine Mount
9 DI WPH1/4 13 9 EI X 30 Grade BMCH8X30 1 Clutch Slave
Heavy duty 1 x Expansion tank 12.9 LHS Bottom 21 EU
Spring Washer
WSHM6 3
M6 Cylinder
braket
Plain Washer Caphead Bolt M8

Radiator bobbin Engine Mount
10 DJ 5/16" WPH5/16 4 10 EJ X 35 Grade BMCH8X35 2 Myloc Nut
Heavy duty back 12.9 RHS Bottom 22 EV M8
NMYF8 4 AV Mount
Plain Washer Caphead Bolt

Radiator bobbin Clutch Slave Spring Washer
11 DK 5/16" X 7/8" WPH5/17X7/8 4 11 EK M6 X 25 BMCH6X25 3 23 EW 30Z2030A 2 AV Mount
Heavy duty front Grade 12.9 Cylinder M14
Drawings are for illustrative purposes only and are not to scale. Page 1 of 2 Drawings are for illustrative purposes only and are not to scale. Page 1 of 2 Drawings are for illustrative purposes only and are not to scale. Page 2 of 2
180 181
F F G
SERIAL
66
SERIAL
66 SERIAL
56
Pack Pack Pack
PACK NUMBER PACK NUMBER PACK NUMBER
3EZ2029B 3EZ2029B 30X020B
DURATEC GEARBOX 5 SPEED DURATEC GEARBOX 5 SPEED EXHAUST

BASIC PART BASIC PART BASIC PART
Bolt Setscrew
Exhaust Mounting
1 FA M14 X 30 X 1.5 30Z2032A 2 AV Mount 12 FL Plain Washer M6 WPHM6 3 Gear Lever 1 GA M8 X 25 SM8X25 1
Grade 12.9 Grade 8.8 Bracket
Caphead
Spring Washer Plain Nut
2 FB M12 X 40 X 1.75 BMCH12X40 4 Bellhousing 13 FM M14
30Z2030A 2 AV Mount 2 GB M8
NFPF8 2 Exhaust Bobbin
Grade 12.9
Caphead Bolt x 1 Exhaust

Spring Washer Spring Washer
3 FC M10 X 90 BMCH10X90 1 Bellhousing 14 FN M12
WSHM12 4 Gearbox 3 GC M8
WSHM8 3 Mounting Bracket x
Grade 12.9 2 Exhaust Bobbin
Caphead Bolt
Spring Washer x 2 Starter Motor x
4 FD M10 X 55 BMCH10X55 3 Bellhousing 15 FO M10
WSHM10 4
Grade 12.9 2 Front Bellhousing
Caphead Bolt
x 5 Bellhousing x Spring Washer Clutch Slave
5 FE M10 X 45 BMCH10X45 7 16 FP M6
WSHM6 3
Grade 12.9 2 Starter Motor Cylinder
Caphead Bolt
6 FF M8 X 40 30Z1076A 4 AV Mount
Grade 12.9
Caphead Bolt
Clutch Release
7 FG M6 X 25 BMCH6X25 3
Grade 12.9 Bearing
Buttonhead Bolt
M6 X 10
8 FH Grade 10.9
Internal Hex
Nyloc Nut
9 FI M8
NMYF8 4 AV Mount
Plain Washer
10 FJ M14
WPH14 2 AV Mount
Plain Washer
11 FK M12
30Z2031A 4 Bellhousing
182 183
H H J O
SERIAL
53
SERIAL
53 SERIAL
47 SERIAL
Pack Pack Pack Pack

NUMBER NUMBER NUMBER NUMBER
PACK NUMBER PACK NUMBER PACK NUMBER PACK NUMBER
30R011D 30R011D 30P010A ZWS01
REAR SUSPENSION DEDION METRIC REAR SUSPENSION DEDION METRIC ROLL OVER & TRACK DAY BAR SERIES 3 METRIC WING PROTECTORS STAINLESS STEEL
This pack may include extra fasteners to cover different options This pack may include extra fasteners to cover different options This pack may include extra fasteners to cover different options This pack may include extra fasteners to cover different options
BASIC PART BASIC PART BASIC PART BASIC PART
ITEM QTY USED ON ILLUSTRATION ITEM QTY USED ON ILLUSTRATION ITEM QTY USED ON ILLUSTRATION ITEM QTY USED ON ILLUSTRATION
DESCRIPTION NUMBER DESCRIPTION NUMBER DESCRIPTION NUMBER DESCRIPTION NUMBER
Rear diagonals of
Bolt M12 X 100 A-frame fromt Bolt M10 X 60 Rivet Wing protector to
1 HA BM12X100 2 12 HL Washer 79029 10 Differential Isolation 1 JA Grade 8.8
BM10X60 2 roll over bar to 1 OA 1/8" X 0.51"
1661-0414 30
Grade 10.9 mountings wing
mounting brackets
x 2 Lower Damper
Setscrew
Caphead Bolt Front radius arm Plain Washer x 10 A-frame Roll over bar bracket Between wing
2 HB BMCH10X65 2 13 HM WPH1/2 20 2 JB M8 X 20 SM8X20 2 2 OB Wing Piping 76901 2m
M10 X 65 (through cockpit) 1/2" Chamferred washers x Grade 8.8 to chassis protector and wing
4 Radius Arm
Bolt x 2 Lower Rear Plain Washer Caphead Bolt
3 HC 1/2" X 2.1/2" BF1/2X2.1/2 4 Damper x 14 HN 3/8" X 7/8"
WPH3/8X7/8 2 Front Radius Arm 3 JC M10 X 20
Rear diagonals of
Bolt M6 X 80 Rear Anti Roll Bar Plain Washer Rear Anti Roll Bar Nyloc Nut
4 HD BM6X80 4 15 HO M6
WPHM6 4 4 JD M10
NMYF10 2 roll over bar to
Grade 10.9 Mounting Blocks Mounting Block
mounting brackets
Bolt 1/2" X 2.3/4" Schnorr Washer Plain Washer Roll over bar bracket
5 HE BF1/2X2.3/4 1 A-frame to DeDion 16 HP 30Z1069A 2 Lower Damper 5 JE M8
WPHM8 2
Grade 10.9 M12 to chassis
x 2 Rear Radius Spring Washer Roll over bar bracket
Half Nyloc
6 HF NFYH1/2 3 Arm x 6 JF M8
WSHM8 2
1/2" UNF to chassis
1 A-frame to DeDion
Rear diagonals of
Nyloc Nut A-frame front Plain Washer
7 HG NMYF12 2 7 JG M10
WPHM10 4 roll over bar to
M12 mounts mounting brackets
Nyloc Nut Front radius arm
8 HH M10
NMYF10 2
(through cockpit)

9 HI M8
NMYH8 2
Drop Link

10 HJ M6
NMYF6 4
Mounting Blocks
3 - way union on
DeDion tube
184 185
FIXING PACKS
P Q
SERIAL SERIAL
31
Pack Pack
NUMBER NUMBER

ZWS02 ZFG12
WING PROTECTORS CARBON FIBRE REAR WINGS

Rivet Black Wing protector to Set Screw

1 PA 1/8" X 0.51"
1610-01049 30 1 QA M5 X 20
SM5X20 20 Rear Wings
wing
Between wing Nyloc Nut Rear wings through

2 PB Wing Piping 76901 2m 2 QB M5
NMYF5 10
protector and wing boot
Plain Washer
3 QC 3/16" X 3/4"
WP3/16X3/4 30 Wing washers
Wing Piping Between wing and

4 QD 1/4" X 1"
76902 4m
body
186
ASSEMBLY GUIDE
Caterham Cars Limited, 2–3 Kennet Road, Dartford, Kent, DA1 4QN
+44 (0) 1322 625800
/CaterhamCars @caterhamcars
Content is subject to change without notice.

© Caterham 2017
Edition 1.1 04/18
Images are for illustrative purposes only.

A4 Assembly Guide Edition 1.2

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ASSEMBLY GUIDE

Your feedback and comments are welcome: assemblyguide@caterham.com

READ THE NEXT THREE PAGES – THEY ARE REALLY IMPORTANT

When using a spanner, always use the ring end wherever

A ‘caphead bolt’ has a circular head with a hexagonal drive

A ‘spring washer’ has a split in it and squashes up

This was more fun than I ever expected!

Advice from factory PACK NUMBER

Now is a good time to take 2 AB

S Pack / R Pack Bolt M10 x 60 Upper wishbone

S3 / S5 chassis specific instructions 8 AH Nyloc Nut M10 NMYF10 4 Upper wishbone

Repeat on other side

Refer to IVA Checklist Guide

(Greyed out4 area indicates fixings are not

Long nose pliers Silicon gun Tape

Copper grease Muscle Socket wrench Tape measure

Socket wrench Thread lock /

Drill bit Power adhesive Spanner Torque wrench

ground. This sets the bushes correctly and ensures as we have to

Bolt M12 x 100 Lower wishbone

4 Track rod end

closed end off.

5 BE Plain Nut ½" NFPF1/2 2 Track rod lock nut

7 BG Nyloc Nut M8 NMYF8 2

2 Lower damper sleeve

3 Upper damper sleeve 6mm

FRONT SUSPENSION DeDION CARS (METRIC)

Bolt M12 x 100 Lower wishbone Spring Washer Lower wishbone

Bolt M10 x 60 Upper wishbone Nyloc Nut ½"

7 AG Nyloc Nut M12 NMYF12 2

PACK NUMBER PACK NUMBER

FRONT SUSPENSION DeDION CARS (METRIC)

Front brake, upright John S Anthony L

Screw 12 x 1" Rear light cluster

3 Anti-roll bar rubber AE

4 Anti-roll bar ball AN

Upper wishbone Washer ⅜"

Check that the colour of the mounting 2

of a fight. It’s made of

worry that you are

Make sure the curve points towards packs of 3: 2 front, 1 back. 2

the front of the car.

Front brake, upright

The copper washer should

7 AG Nyloc Nut M12 NMYF12 2

1 Horn kit (x2)

2 Spacer (miscellaneous box)

3 Bolt for spacer 13mm

4 Radiator bobbins (x4)

7 DG Plain Nut M8 NMPF8 8 Radiator bobbin

7 DG Plain Nut M8 NMPF8 8 Radiator bobbin

3 Heater cable 19mm

5 Upper hose 120mm (cut from long length)

It’s worth re-tightening the jubilee 5

clips after a couple of uses of car.

6 DF Nyloc Nut M6 NMYF6 8

7 DG Plain Nut M8 NMPF8 8 Radiator bobbin 18 DR Rivet - Black

PACK NUMBER PACK NUMBER

SIGMA GEARBOX 5 SPEED SIGMA GEARBOX 5 SPEED

15 EO Plain Washer M6 WPHM6 3 Gear Lever

Caphead Bolt M8 Engine Mount mm mm

15 EO Plain Washer M6 WPHM6 3 Gear Lever

Caphead Bolt M8 Engine Mount