Assembly Guide SUZUKI Edition 1.2

ASSEMBLY GUIDE
SUZUKI – EDITION 1.2

ASSEMBLY GUIDE
SUZUKI – EDITION 1.2
Your feedback and comments are welcome: assemblyguide@caterham.com
For help and build support enquiries contact: buildsupport@caterham.com
For help and support with IVA and registrations contact: ivaapplications@caterham.com
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 available should you need it.
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 – SUZUKI
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
refer-to-IVA-manual symbol in the bottom of each illustration where attention is required. Reading through
it now, will save pain later! Don’t assume that because you’ve found a reference to one item relating to that
page, it is the only one…
Once you have completed the assembly of your Seven, you are required by law to present it for an ‘Individual
Vehicle Approval’ test (better known as IVA), which is conducted by the Vehicle and Operator Services
Agency (VOSA) at a regional test centre.
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 IVA and Registration application forms, and a guide on how to complete them, are sent out on request
when you are midway or nearing completion of your build. Please email ivaapplications@caterham.com for
a copy of your prefilled documents.
ii
VOSA and the DVLA are a suspicious bunch and in order to register your car, you will need to provide proof
that it is amateur built. When you apply for registration, you will need to include photos from various stages
of you build, which will demonstrate to them that it is an ‘amateur build’.
Recruiting a few extras (your kids, your spouse, the cat, etc.) and some props (last year’s Xmas tree, a radio
from the 1980’s and a rusty bike) will all contribute to a more authentic home-garage feel; proving that no
professional help (i.e. commercial workshop/garage) was involved in the build. Of course, feel free to have
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).
iii
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.
*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.
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.
iv
That’s it, we’re ready to start assembly
ENJOY
v
MY BUILD NOTES
Download the IVA Checklist Guide: www.caterhamcars.com
Book IVA Test
Take plenty of photos
Arrange post build check
This was more fun than I ever expected!
vi
HINTS & TIPS
A ‘nyloc’ nut is one with a nylon insert that gets cut by the bolt
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
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
‘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

Thread lock is used to stop possible. The open end is really only for those times that access
something coming undone, but is too limited for a ring spanner or socket.
it only needs a little drop on
Generally, metric Nyloc nuts have a Mick A
the thread to be effective.
blue nylon insert and imperial ones a
Jamie A
white nylon insert.
Grant P Left and right are as viewed
from the driver’s seat.
Teabag, boiling water, then the milk, in that order. Harrison P
Simon L
1Nm of torque
equals 0.736lbft. A ‘caphead bolt’ has a circular head with a hexagonal drive
Mick F
It’s good practise to keep your work inside it. It is tightened with an allen key or hex drive socket.
area clean and tidy, as you don’t want Capheads are useful where there is limited space around
to damage yourself or your new car! the head for a spanner or socket. They look nice too!
Lee B
Richard T
A ‘spring washer’ has a split in it and squashes up

A bolt size is described by its thread diameter (e.g. closed when a fixing is tightened. It is usually used
M10=10mm) by the length not including the head (e.g. 65mm). under a bolt head to help resist it coming undone.
James A John S
1
2
$H@%
!
B?LL#
¢*$!
#©K!
F
H @%!
$
L#¢*$!
B?L
Speak to an expert
buildsupport@caterham.com
F#©K!
$H@%
!
B?LL#
¢*$!
3
KEY
S Y M B O L S F I X I N G S
A
SERIAL
44
Pack
NUMBER
A
PACK NUMBER
1
SERIAL
44
Item number Pack 3ACZ0001A
NUMBER
Advice from factory PACK NUMBER

3ACZ0001A
FRONT SUSPENSION DeDION CARS (METRIC)
professionals FRONT SUSPENSION DeDION CARS (METRIC)
This pack may include extra fasteners to cover different options
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 BM12X65 2
Grade 10.9 front
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 Required torque (where applicable) Temporary use to

mm 6 AF
Plain Nut M14
x 1.5 thread
NMPH14 1 help lock upper
Bolt M8 x 40 Anti-roll bar
wishbone ball joint 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
Plain Nut M14
6 AF x 1.5 thread
wishbone ball joint
REPEAT Repeat on other side 8 AH Nyloc Nut M10 NMYF10 4 Upper wishbone
Lower wishbone
Plain Washer
7 AG Nyloc Nut M12 NMYF12 2
9 AJ M12 WPCM12 18 Lower wishbone rear
Chamfered
Plain Washer
Refer to IVA Checklist Guide

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

10 AK M8 WPHM8 4
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 M12 WPCM12 18 Lower wishbone
Drawings are for illustrative purposes only and are not to scale. Page 1 of 2 Chamfered
Plain Washer
Anti-roll bar
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
4
KEY
T O O L S
Adjustable Instant Power Socket Tape

Drill bit
spanner gasket adhesive wrench measure
Socket
Engine Junior Pozidrive Torque
Allen key wrench
hoist hacksaw screwdriver wrench
(allen)
Latex
+ Assistance File
gloves
Ruler Spanner Torx
Flat head Sanding
LO
Axle stand Loctite Spirit level Trolley jack
CT
IT
E
screwdriver Drum
Brake Long nose Spray

Foam tape Scissors WD40
cleaner pliers adhesive
Cloth Funnel Mallet Seal drift Spray lube
Combination Masking Side Stanley

Grease
spanner tape cutters knife
Copper Stepped
Heat gun Muscle Silicone
grease drill bit
Hose Pop rivet Silicone

Drill Super glue
cutters gun gun
5
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
LET’S GET READY
7
LET'S MAKE SOME NOISE
P A R T S T O O L S
1 Horn kit (x2)

10mm
13mm
C
SERIAL
45
Pack
NUMBER
PACK NUMBER
3ACZ0003A
LIGHTING & HORNS You may need to loosen the 13mm nuts
ITEM
BASIC
DESCRIPTION
PART
NUMBER
QTY USED ON ILLUSTRATION and rotate the horns in order to bring the
1 CA Screw 10 x ¾"
Black Supaflange
71080 6
Indictor assembly to
indicator pod electrical connectors closer together.
2 CB Screw 8 x ½"
Black Supaflange
71077 2
Side repeater earth
on wingstay
Rich T
Screw 12 x 1½" Rear light cluster

3 CC 71079 4
Self tapping upper fixing
Screw 12 x 1" Rear light cluster

4 CD 71078 4
Self tapping lower fixing
Horn bracket to
5 CE Nyloc Nut M6 NMYF6 2
steering rack
platform
(160/270/310)
x2
Horn bracket to
x2
Plain Washer
steering rack
6 CF ¼" WPH1/4 2
Heavy duty platform
(160/270/310)
Through steering
Bolt M8 x 5 rack platform &
7 CG BM8X50 1
Grade 8.8 spacer
(420)
Plain Washer
8 CH 5/16"
WPH5/16 2 Bolt head/nut
Nyloc Nut
9 CI M8
NMYF8 1 Horn bolt
8
LET'S MAKE SOME NOISE
CE
CF
9
START WITH THE SUSPENSION WISHBONES
P A R T S T O O L S
1 Lower wishbone (LH & RH)

17mm
19mm
2 Upper wishbone (LH & RH)
17mm
3 Wishbone bush sleeve (x2)
19mm
94
A A
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER
PACK NUMBER
3ACZ0001A
PACK NUMBER
3ACZ0001A For now, only tighten the nuts/bolts lightly and then Leave bolt AD
This pack may include extra fasteners to cover different options torque them up when the car is finished and on the loose for now,
ground. This sets the bushes correctly and ensures as we have to
BASIC PART BASIC PART
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
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
Lower wishbone
rear x2
the wishbone.
Alex H
8 AH Nyloc Nut M10 NMYF10 4 Upper wishbone
x4
x14
Plain Washer
Chamfered
Plain Washer
Anti-roll bar
10 AK M8 WPHM8 4
Plain Washer
Heavy duty
10
START WITH THE SUSPENSION WISHBONES
35
AC35
mm mm
47Nm
AH
AD
35
mm
35
mm
47Nm 3
AH
AA
35
mm
AJ
35
mm
81Nm
AG
AJ
1
AB
35 81Nm AJ
mm
AM
REPEAT
11
NOW FOR THE STEERING RACK
P A R T S T O O L S
1 Steering rack
10mm
13mm
2 Rack clamps (x2)
3 Column universal joint 5mm
4 Track rod end (x2)

13mm
5 IVA cover (x2) 22mm
B
SERIAL
55
Pack
NUMBER
PACK NUMBER
3ACZ0002B
RELEASED NOV-19
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
a long cap. To use it, you cut the later when the tracking is done).
BASIC PART
ITEM QTY USED ON ILLUSTRATION
DESCRIPTION NUMBER
x4
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
x2
Bolt M8 x 40 Column to rack
3 BC BM8X40 2
Grade 10.9 universal joint
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 Apply grease to the inner
6 BF
Plain Nut ⁷⁄₁₆"
Half height
NFPFH7/16 1
Column clamp
grubscrew locknut surfaces of the rack Remove the protective
clamps which will make plastic cups from the
7 BG Nyloc Nut M8 NMYF8 2
Column to rack
x2 Don't fully tighten
track rod ends before
universal joint
x4 the steering rack it easier to rotate the

fitting.
8 BH Nyloc Nut M6 NMYF6 4 Steering rack clamps
9 BJ
Plain Washer
½" x 1⅛" WPH1/2 1 Steering wheel boss for now. steering rack later on.
Lee B
Chamfered
Plain Washer
Dan D Chris B
x4
Rack clamps and
10 BK ¼" WPH1/4 6
Heavy duty column clamp
Spring Washer ¼
11 BL Heavy duty
WSH1/4 2 Column clamp
12
NOW FOR THE STEERING RACK
BC
35 35 38Nm
mm mm
BG
3
BA
REAR
7
RHD
5
4
LHD 2 1
35 35
BH
11Nm
mm mm
BK BE
13
AND THEN THE DAMPERS
P A R T S T O O L S
1 Spring / damper (x2)

6mm
2 Bush sleeves (x4)
T I P S
F I X I N G S Put the top of the damper on first

and be careful not to let it swing into The bottom can be a tight fit!
94
A A the side of the chassis. Mick F

SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER
PACK NUMBER PACK NUMBER

3ACZ0001A 3ACZ0001A
FRONT SUSPENSION DeDION CARS (METRIC) FRONT SUSPENSION DeDION CARS (METRIC) Grant P
This pack may include extra fasteners to cover different options This pack may include extra fasteners to cover different options
Bolt M12 x 100 Lower wishbone Spring Washer Lower wishbone

1 AA BM12X100 2 12 AM WSHM12 2
2 AB
Bolt M12 x 65
Grade 10.9
BM12X65 2
Lower wishbone
front
13 AN
Spring Washer
M8
WSHM8 6
Anti-roll bar
mounting brackets &
upper damper x2
You may need to press inwards the side skin to make
sufficient clearance for the upper damper bolt. Don’t worry,
mount
Bolt M10 x 65 Upper wishbone Washer ⅜"

3 AC BM10X65 2 14 AP WSS3/8 2 Brake pipe
you won’t damage your paint in doing this.

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
James A
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
Fixings not contained in the pack will be

Lower wishbone
rear
supplied loosely fitted to the chassis and
The front damper bush sleeves It is much easier to tighten the
the wishbone are identical and can be fitted in top damper bolt using a 6mm ball
9 AJ
Plain Washer
M12
Chamfered
WPCM12 18 Lower wishbone
either the top or bottom bushes. ended Allen socket.
10 AK
Plain Washer
M8 WPHM8 4
Anti-roll bar
Richard T Lee B
Plain Washer
Heavy duty
14
AND THEN THE DAMPERS
2
7
�
7
35 35
AN 25Nm
mm mm
1
�
35 35 25Nm
mm mm
REPEAT
15
IT’S TIME FOR THE WINGSTAYS
P A R T S T O O L S
1 Wingstay (LH & RH)

19mm
22mm
2 Front brake & upright assembly (LH & RH)
3 Steel wheel hub spacers (x2) 22mm
4 Screws (x4)
⅛" 2.5mm
T I P S
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).
Tiago O
F I X I N G S Some of the fixings
94 Put the upright assembly into required and shown on
A A the lower wishbone spherical
44 44
the drawings, such as
SERIAL SERIAL
Pack Pack
NUMBER NUMBER

3ACZ0001A 3ACZ0001A
FRONT SUSPENSION DeDION CARS (METRIC) FRONT SUSPENSION DeDION CARS (METRIC)
joint, then attach the track rod the ball joint nut, are
ITEM
BASIC
DESCRIPTION
PART
NUMBER
QTY USED ON ILLUSTRATION ITEM
BASIC
DESCRIPTION
PART
NUMBER
QTY USED ON ILLUSTRATION
end before tightening the lower already on the part and
1 AA
Bolt M12 x 100
Grade 10.9
BM12X100 2
Lower wishbone
rear
12 AM
Spring Washer
M12
WSHM12 2
Lower wishbone
front
upright nut. This will prevent not in the fixing pack. Use the plain
2 AB
Bolt M12 x 65
BM12X65 2
Lower wishbone
13 AN
Spring Washer
WSHM8 6
Anti-roll bar
mounting brackets &
the assembly from turning and Anthony L nut to pull the
contacting the side skin.
Grade 10.9 front M8 upper damper
top ball joint

mount

home before
John S
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
x2 using a nyloc,
otherwise the
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 mounting (std track
x2
Hub spacers are
ONLY)
Remove and discard the washer and full thread will spin.
Temporary use to
Plain Nut M14
x1
only required
6 AF x 1.5 thread
wishbone ball joint
nyloc that comes fitted on the back of Chris N

when using steel
Lower wishbone
rear
the stub axle before fitting the wingstay.

A half nyloc from the fixings pack should wheels.

Grant P
Plain Washer
9 AJ 18 Lower wishbone
then be fitted but without a washer.
M12 WPCM12
Chamfered
Plain Washer
Anti-roll bar
10 AK 4
Rich T
M8 WPHM8
Plain Washer
Heavy duty
16
IT’S TIME FOR THE WINGSTAYS
AF
1 x1/8”
35 35 61Nm
mm mm
2
35 35 81Nm
mm mm AR
35 35
AS 54Nm
mm mm
REPEAT
17
ASSEMBLY GUIDE – DURATEC
Now is a good time to take some photos
18
Have you applied for your IVA yet?
19
LET THERE BE LIGHTS
P A R T S T O O L S
1 Headlight assembly (x2)

17mm
2 Indicator pod (LH & RH)
8mm
3 Indicator assembly (x2) 17mm
24mm
4 Headlight bracket (LH & RH)
5 IVA trim
6 Heat shrink
T I P S
7 Grommet (x2) It's very important to read the IVA Guide This is the trickiest
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
difficult to add them once fitted! sigh of relief!
F I X I N G S
John S Tiago A
C
SERIAL
45
Pack
NUMBER
PACK NUMBER
3ACZ0003A
LIGHTING & HORNS
Do not attach the econoseal plug onto the headlight wires until they have passed
BASIC PART
DESCRIPTION NUMBER
x6
Screw 10 x ¾" Indictor assembly to
through the upper wishbone bracket. Leave this unplugged from the chassis
1 CA 71080 6
Black Supaflange indicator pod
connector for the time being as you will need to add another wire later on.
Screw 8 x ½" Side repeater earth
2 CB 71077 2
Black Supaflange on wingstay

Jamie A
3 CC 71079 4

4 CD 71078 4
Horn bracket to
steering rack
platform
6 CF
Plain Washer
WPH1/4 2
(160/270/310)
Horn bracket to
steering rack
The tab on the headlight bracket 4 hooks
under the wishbone bracket on the chassis.
¼"
Glue IVA trim all around the

Heavy duty platform
(160/270/310)
Through steering
rack platform &
The wires exiting the headlight bracket

Bolt M8 x 5
edge of the pod before fitting.

7 CG BM8X50 1
Grade 8.8 spacer
(420)
The smaller side should face are then fed through the hole in the upper
Plain Washer
8 CH 5/16"
9 CI
Nyloc Nut
M8
NMYF8 1 Horn bolt
outwards. wishbone bracket.
Chris B Harrison P
20
LET THERE BE LIGHTS
2 6
CA 5
4
7
7
7
REPEAT
21
FITTING THE BRAKE HOSES
P A R T S T O O L S
1 Brake hose kit

13mm (x2)
⁹⁄₁₆"
2 Copper washer (x2)
94
A A
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER
The hose will want to curve once fitted. Brake hoses come in
3ACZ0001A 3ACZ0001A
BASIC
BASIC
This pack may include extra fasteners to cover different options Make sure the curve points towards packs of 3: 2 front, 1 rear.
the rear 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
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
mounting (std track
ONLY) Discard the gold coloured Do not use the small copper washers
6 AF
Plain Nut M14
x 1.5 thread
NMPH14 1
Temporary use to
help lock upper
wishbone ball joint
adaptors and fit the grey supplied with the brake hoses. The
Lower wishbone
rear
coloured adaptors which correct ones are supplied separately
have a step for the copper and measure 18mm external diameter.
9 AJ
Plain Washer
M12 WPCM12 18 Lower wishbone
washer to locate over. Mick F
Chamfered
Plain Washer
Simon L
Anti-roll bar
10 AK M8 WPHM8 4
Plain Washer
11 AL ⅜" x ¾"
Heavy duty
WPH3/8 2 Brake pipe
x2
22
FITTING THE BRAKE HOSES
AP
AL
REPEAT
23
LAST PART OF THE FRONT SUSPENSION: CONNECTING THE TWO SIDES TOGETHER
P A R T S T O O L S
1 Anti-roll bar
13mm
2 Anti-roll bar bracket (x2)
3 Anti-roll bar rubber (x2)
4 Anti-roll bar ball (x2)
LO
Loctite 243
CT
IT
E
5 Anti-roll bar dust cover (x2)
94
A A
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER
PACK NUMBER
3ACZ0001A
PACK NUMBER
3ACZ0001A Grease the balls and cups generously. Getting the
This pack may include extra fasteners to cover different options Matt T assembled anti-roll
bar fully into both
cups on the upper

1 AA BM12X100 2 12 AM WSHM12 2
Anti-roll bar
x4 wishbone can be a bit

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
Check that the colour of the mounting of a fight. It’s made
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. of springy stuff, so
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)
John K don’t worry that you
6 AF
Plain Nut M14
x 1.5 thread
NMPH14 1
Temporary use to
help lock upper
are bending it.
wishbone ball joint
Lower wishbone
Jamie A
rear
8 AH Nyloc Nut M10 NMYF10 4 Upper wishbone Use the thread lock on the thread of the
9 AJ
Plain Washer
M12
Chamfered
WPCM12 18 Lower wishbone
anti-roll bar, not in the thread of the ball.
Dan D
x4
Plain Washer
Anti-roll bar
10 AK M8 WPHM8 4
Plain Washer
Heavy duty
24
LAST PART OF THE FRONT SUSPENSION: CONNECTING THE TWO SIDES TOGETHER
AE
35 35 20Nm
mm AK
mm
AN
25
FITTING THE RADIATOR
P A R T S T O O L S
1 Radiator
13mm
10mm
2 Fan
3 Radiator bobbins (x4) 13mm
4 Fan mounting feet (x4)
D D
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER
PACK NUMBER
3ACZ0004A
PACK NUMBER
3ACZ0004A Be careful to tighten the The fan should have a ‘flat’ section on the
COOLING SIGMA
COOLING SIGMA
This pack may include extra fasteners to cover different options fan gently and with just rim. This should be at the top and bottom.
a nip.
Grant P
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 bracket
Dan P
Heavy duty
x8
Spring Washer
Setscrew 1/4" Expansion tank to 8 x Radiator bobbin
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
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
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
6 x Heater inlet/outlet
3 x Big T-piece
Setscrew M6X16 Fan to radiator Hose Clip 1 x Expansion tank
Be careful when tightening the rubber

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
bobbins as they can twist and split.
7 DG Plain Nut M8 NMPF8 8 Radiator bobbin
x8 18 DR Rivet - Black
5/32" X 0.47"
1610-01015 12 Cowling flap
James A
Expansion tank
8 DH Nyloc Nut 1/4" NFYF1/4 1
bracket
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
x4
Plain Washer
x4
Radiator bobbin
10 DJ 5/16" WPH5/16 4
Heavy duty back
Plain Washer
Radiator bobbin
11 DK 4
x4
5/16" X 7/8" WPH5/17X7/8
Heavy duty front
26
FITTING THE RADIATOR
DI
DF
2
DG
DJ
DM
DG
DK
DM
27
THINGS ARE HEATING UP
P A R T S T O O L S
1 Heater 8 Cradle clip

10mm
7mm
2 Valve 9 5/32 rivet
¼"
3 Heater cable 5/32
19mm
4 Lower hose 110mm (cut from long length)
5 Upper hose 120mm (cut from long length)
6 Grommet
7 Cable tie
D D
SERIAL
44 SERIAL
44
Pack Pack
You’ll know when you have adjusted the cable
NUMBER NUMBER

3ACZ0004A 3ACZ0004A
COOLING SIGMA COOLING SIGMA Remember to remove correctly as the valve will be able to reach
bungs from heater.
both the fully open and fully closed positions.

Plain Washer
1 DA
Bolt M8 X 50
Grade 8.8
BM8X50 1
Expansion tank
bracket to chassis
12 DL 1/4" X 7/8" WPH1/4X7/8 1
Expansion tank
bracket Jamie A
Chris B
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
It’s worth re-tightening the jubilee

4 DD 30Z1072A 4 Fan brackets to fan 15 DO SGT23-35 2
clips after a couple of journeys.

square section 23 - 35mm 1 x Engine outlet to
heater inlet
x2 x4
3 x Big T-piece
5 DE SPHM6X16 4 16 DP SGT16-25 18
John S
4 x Dry Sump
2 x Submarine
Cutting and gluing the

x4 Fan to radiator
6 DF Nyloc Nut M6 NMYF6 8 x4 SV radiator Hose Clip Expansion tank
17 DQ SGT8-16 6
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 grommet back together
Expansion tank
bracket
If you don’t have a cradle clip and a is easier than removing
9 DI
Plain Washer 1/4"
Heavy duty
WPH1/4 13
8 x SV rad bracket
4 x Fan fixings
1 x Expansion tank
rivet to hand, you will find some in the wires from the plug.
10 DJ
Plain Washer
5/16" WPH5/16 4
braket
Radiator bobbin
the chassis fixture pack (ZCH01). Anthony L
Heavy duty back
Plain Washer
Lee B
Radiator bobbin
11 DK 5/16" X 7/8" WPH5/17X7/8 4
Heavy duty front
28
THINGS ARE HEATING UP
7 8 9
DE 6
DP
29
THE ENGINE GOES IN
P A R T S T O O L S
1 Engine / gearbox assembly

Engine crane
2 Engine mounting rubbers (x2)
10mm socket
13mm socket
13mm
SERIAL NUMBER PACK NUMBER SERIAL NUMBER PACK NUMBER
49 30P012A 49 30P012A
When fitting engine rubbers Tighten gradually once all bolts are in.
FASTNER PACK – MISCELLANEOUS (METRIC)
Please note: This pack may include extra fastners to cover different options
FASTNER PACK – MISCELLANEOUS (METRIC)
Please note: This pack may include extra fastners to cover different options and mounts, fit as loosely Chris N
as possible so you can wiggle
No DESCRIPTION PART NUMBER QTY DRAWING No DESCRIPTION PART NUMBER QTY DRAWING
Bolt 1/2" X 2 1/2" UNF
Caphead Bolt with plain Washer M8
1 BFCH1/2X2.5 2 12 WPHM8 13
section & imperial threaded Plain Washer Heavy-Duty
section
Bolt M8 X 50 Grade 8.8

things to get bolts in.
2 Bolt with plain section & BM8X50 1 13 Split pin 1/16" X 3/4" SP1/16X3/4 1
Metric threaded section
James A
4
Setscrew M8 X 25
Grade 8.8
Hexagonal head & metric full
SM8X25 2 15
Washer 1/2"
Spring Washer Heavy-Duty
WSH1/2 2 Protect the chassis with soft
threaded section
5
Setscrew M8 X 20
Grade 8.8
SM8X20 4 16
Washer M8
WSHM8 3
stuff such as cardboard or
folded towels / blankets.
threaded section
Setscrew M6 X 20
Grade 8.8 Washer 3/8" X 3/4"
6 SM6X20 2 17 WPH3/8 6
Be careful not to damage

Hexagon head & metric full Plain Washer Heavy-Duty
threaded section
Setscrew M8 X 16 Harry P
Grade 8.8 Washer M6 X 25
the fuel purge valve when

7 SM8X16 3 18 WPHM6X25 2
threaded section
Setscrew M6 X 16
manoeuvring the gearbox

Grade 8.8 Washer M6
8 SM6X16 4 19 WPHM6 8
threaded section
into position.
Nut M8
Washer M5 X 20
9 With Metric thread & Nyloc NMYF8 10 20 WPHM5X20 1
Plain Washer Heavy-Duty
locking mechanism
Bolt 1/2" X 1" UNF

Nut M6
10 With Metric thread & Nyloc
locking mechanism
NMYF6 2 21
Caphead bolt with plain
section & imperial threaded
BFCH1/2X1 1 Lee B
section
Please note: Drawings are not to scale Page 2 of 2
Nut M6
11 Plain nut with metric thread NMPF6 2
full size
30
THE ENGINE GOES IN
≈ 20°
1
35 35 20Nm
mm mm
� 2
REPEAT
31
THE ENGINE IS FINALLY IN
P A R T S T O O L S
1 Engine mounts (x2)

10mm
2 Turbo inlet housing

5mm
6mm
8mm
⅜"
Unmarked bag:
• M6 bolts (x1) Once the engine is in, the See IVA guide – how to secure a loom.
• M8 bolts (x2) wiring can be connected to the Grant P
• M10 bolts (x5) car's loom. It should be self

explanatory.
Chris B
32
THE ENGINE IS FINALLY IN
M8 M10
M6 M8
35 35M6 12Nm
mm mm
35 35 35 20Nm35 81Nm
mm mmM8 mm mm
35 35
M10 35Nm
mm mm
35 35 35Nm
mm mm
M10
M10
35 35 35Nm
mm mm
35 35 81Nm
mm mm
33
FINISHING THE GEARBOX
P A R T S T O O L S
1 Gear lever
13mm
2 Gear lever mount
3 Gearbox mount 6mm
13mm
Fixings packed with engine

It can be fiddly to align the gearbox You will need to unwind the
mounting bolts… a bit of patience two gear lever housing bolts to
and perseverance will help. allow the gear lever to drop into
Mick F place. These bolts can then be
re-tightened and the plastic cup
inserted on top.
Chris B
34
FINISHING THE GEARBOX
35 35 20Nm
mm mm
35 35 20Nm
mm mm
35 35 20Nm
mm mm
35
FILLING AND CHECKING THE ENGINE AND GEARBOX OILS
P A R T S T O O L S
Gearbox Oil (S4 AT 75W-90)

19mm
The engine is supplied pre-filled with oil from the factory, but
it is always best to double check the level on the dipstick
before starting the engine.
Lee B
Remove the 19mm filler plug on the

top of the gearbox, add the correct
quantity of oil and re-fit the filler plug.
Harry P
36
FILLING AND CHECKING THE ENGINE AND GEARBOX OILS
Suzuki 660cc Turbo Charged Engine

Engine oil capacity = 2.35 Litres
Gearbox oil capacity = 1.25 Litres
37
FITTING THE AIRBOX INFO
P A R T S T O O L S
1 Airbox
5mm
2 Air filter
3 Sealing rubber 6mm
4 Rubber bobbins (x3)
8mm
5 MAF sensor
10mm
fixings packed with airbox:
• Cross head screws (x6) If the MAF sensor is a tight fit The sealing rubber can be hard
• Shake proof washers (x6) then you can enlarge the airbox to push onto the airbox edge, so
• M5 plain washers (x3) opening using some sandpaper. holding the inside of the inlet tube
• M5 spring washers (x3) Lee A will prevent it from splitting.
• M5 plain nuts (x3) Dan P
• M6 cap head bolts (x2)
• M6 plain washers (x2)
• M6 nyloc nuts (x2)
38
FITTING THE AIRBOX INFO
Ø6mm
x2
2
”
5
1
39
FITTING THE EXPANSION BOTTLE
P A R T S T O O L S
1 Expansion bottle
13mm socket
2 Expansion bottle cap
10mm (x2)
3 Expansion bottle bracket
13mm
4 Mounting bar
3mm
Fixings packed in cooling box

You may find it easier to assemble Simply tighten the
these parts on the workbench. bottle cap until it clicks.
Jamie A Chris N
40
FITTING THE EXPANSION BOTTLE
2 1
41
FITTING THE BOTTOM RADIATOR HOSE
P A R T S T O O L S
1 Bottom radiator hose

7mm
D D
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER
PACK NUMBER
3ACZ0004A
PACK NUMBER
3ACZ0004A If the hose is a tight fit then a
COOLING SIGMA
COOLING SIGMA
This pack may include extra fasteners to cover different options squirt of rubber lubricant will help.
Grant P
Plain Washer
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 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
2 x Top radiator hose
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
Plain Washer 1/4" 4 x Fan fixings
9 DI WPH1/4 13
Heavy duty 1 x Expansion tank
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
42
FITTING THE BOTTOM RADIATOR HOSE
DN
43
FITTING THE TOP RADIATOR HOSE
P A R T S T O O L S
1 Top radiator hose

7mm
D D
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER
PACK NUMBER
3ACZ0004A
PACK NUMBER
3ACZ0004A If the hose is a tight fit then a
COOLING SIGMA
COOLING SIGMA
This pack may include extra fasteners to cover different options squirt of rubber lubricant will help.
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
Setscrew M8X20
Grade 8.8
SM6X20 4 SV radiator bracket 14 DN
Hose Clip
30 - 40mm
SGT25-40 6
water rail
2 x Top radiator hose
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
44
FITTING THE TOP RADIATOR HOSE
DN
45
FITTING THE RETURN HOSE
P A R T S T O O L S
1 Straight plastic joiner

7mm
2 ⁵⁄₁₆ hose reel
D D
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER
Although the hose is labelled as fuel The hose reel length

3ACZ0004A 3ACZ0004A
BASIC PART
COOLING SIGMA
BASIC
COOLING SIGMA
PART
hose, this is also coolant resistant. supplied is plentiful and will
need to be cut to size.
Plain Washer
Rich T
1 DA BM8X50 1 12 DL 1/4" X 7/8" WPH1/4X7/8 1
Tiago O
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
6 DF Nyloc Nut M6 NMYF6 8 x4 SV radiator
bracket
17 DQ
Hose Clip
8 - 16mm
SGT8-16 6
Expansion tank
small T-piece x3
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
46
FITTING THE RETURN HOSE
DQ
47
FINISH THE TURBO PLUMBING AND CONNECT THE FUEL HOSE
P A R T S T O O L S
1 Turbo casting assembly

10mm
5mm
Make sure that you remove any

protective tape covering the
exhaust gasket before assembling.
Anthony L
48
FINISH THE TURBO PLUMBING AND CONNECT THE FUEL HOSE
�
49
FITTING THE INTERCOOLER
P A R T S T O O L S
1 Intercooler
8mm
2 Rubber bobbins (x4)
8mm
Unmarked bag:
• M5 plain washers (x8) Don’t overtighten the bobbins
• M5 spring washers (x8) as they can twist and split.
• M5 plain nuts (x8) John S
50
FITTING THE INTERCOOLER
51
FITTING THE THOTTLE BODY HOSE
P A R T S T O O L S
1 Throttle body hose

7mm
Fixings packed with airbox
If the hose is a tight fit then a
squirt of rubber lubricant will help.
Grant P
52
FITTING THE THOTTLE BODY HOSE
53
FITTING THE INTERCOOLER INLET HOSE
P A R T S T O O L S
1 Intercooler hose
7mm
Grant P
54
FITTING THE INTERCOOLER INLET HOSE
55
FITTING THE PURGE VALVE HOSE
P A R T S T O O L S
1 7.9mm hose reel

7mm
Fixings packed in cooling box
Grant P
56
FITTING THE PURGE VALVE HOSE
57
FITTING THE LOWER HEATER VALVE HOSE
P A R T S T O O L S
1 Lower heater valve hose

7mm
D D
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER

3ACZ0004A 3ACZ0004A
BASIC PART
COOLING SIGMA
BASIC
COOLING SIGMA
PART
Plain Washer
Grant P
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
x2
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
FITTING THE LOWER HEATER VALVE HOSE
DP
1
59
FITTING THE UPPER HEATER VALVE HOSE
P A R T S T O O L S
1 Upper heater valve hose

7mm
D D
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER

3ACZ0004A 3ACZ0004A
BASIC PART
COOLING SIGMA
BASIC
COOLING SIGMA
PART
Plain Washer
Grant P
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
x3
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
FITTING THE UPPER HEATER VALVE HOSE
DP
61
FITTING THE AIRBOX HOSE
P A R T S T O O L S
1 Airbox hose
7mm
2 Cable tie
Grant P
62
FITTING THE AIRBOX HOSE
2
1
63
FITTING THE TURBO SOLENOID PIPES
P A R T S T O O L S
1 Solenoid pipes (x5)

5mm
2 P-clip
3 M6 cap head bolt 10mm
4 M6 plain washer
5 M6 nyloc nut
Fixings packed with engine
It is very important that these
pipes are connected to the
It is important that these pipes
correct places so take your time.
are not restricted or kinked in
Chris N
any way, therefore you should be
careful not to overtighten your
cable ties.
Lee B
64
FITTING THE TURBO SOLENOID PIPES
3 A B D
2
4
E
1
C
C D
B
E
65
FITTING THE CLUTCH HOSE
P A R T S T O O L S
1 Clutch hose
⁹⁄₁₆
⁷⁄₁₆
2 Adaptor
3 Banjo bolt
4 Copper washers (x2)
Fixings supplied in clutch hose kit
Once fully tightened, ensure that The locking clip is supplied pre-
the hose is not kinked or twisted. fitted to the slave cylinder;
John S therefore, you will need to remove
this before fitting the adaptor
and refitting the clip.
Mick F
66
FITTING THE CLUTCH HOSE
2
4
67
FITTING THE PROPSHAFT
P A R T S T O O L S
1 Propshaft
Be careful when inserting the propshaft

Remove the plastic bung into the tail of the gearbox, as you do
from the tail of the not want to damage the oil seal.
gearbox before attempting
Mick F
to fit the propshaft.
John S
68
FITTING THE PROPSHAFT
69
ASSEMBLING THE AXLE
P A R T S T O O L S
1 Differential 8 Breather spring

12mm
19mm
2 Axle 9 Breather seal
3 Copper brake pipe 10 Differential bolts (x8)
4 Brake pipe clips (x5)
5 Oil filler plug & washer
6 Oil drain plug & washer
LO
Loctite 577
CT
IT
E
7 Breather cap
Fixings packed with axle
It’s easier to push the clip bases The plastic washer is for
into the axle brackets, followed by the filler plug, not the
fitting the clip jaws and lastly the drain plug.
brake pipe. Chris N
Lee A
The indentations in the breather cap are designed to fit

into the slot in the axle breather. A tap with a mallet
will help to get it seated.
John K
70
ASSEMBLING THE AXLE
8
4
9
4
2
LO
CT
IT
35
5
35 41Nm
E
mm mm
35
mm
35
mm
25Nm 10
4
1
6
35
mm
35
mm
25Nm 10
35 35 23Nm
mm mm
71
INSTALLING THE AXLE AND CONNECTING THE PROPSHAFT
P A R T S T O O L S
1 M8 bolts (x4)
12mm
2 M8 spring washers (x4)
Lifting the axle into the chassis The diff is the heaviest part
is a two-person job, one laying so the axle will always try
underneath the chassis and the and rotate downwards.
other feeding the axle in from the Chris B
left-hand side.
John S
72
INSTALLING THE AXLE AND CONNECTING THE PROPSHAFT
35
mm
35
mm
23Nm 1
73
FITTING THE RADIUS ARMS
P A R T S T O O L S
1 Radius arms (x2)

17mm
19mm
2 Bush sleeves (x2)
10mm
19mm
8mm
SERIAL SERIAL
Pack 74 Pack 74
NUMBER NUMBER
If necessary, run a 10mm drill bit

3G0Z0001A 3G0Z0001A
through the chassis bosses to

FASTENER PACK - SEVEN 160/165 LIVE AXLE & A-FRAME FASTENER PACK - SEVEN 160/165 LIVE AXLE & A-FRAME
ITEM
BASIC PART
ILLUSTRATION
BASIC PART
It is best to torque the rear
clear any excess powder coat.
QTY USED ON ITEM QTY USED ON ILLUSTRATION
suspension fixings under

Plain Washer
Bolt M12 X 100 Drop bracket to
1 Grade 10.9
BM12X100 2 12 M12 X 1.5 X 30 WPHM12 2
A-Frame Form C
Chris B
2
Bolt M12 X 65
Grade 8.8
3GZ2002A 2
Drop bracket to
chassis 13
Plain Washer
1/2"
WPH1/2 16 A-frame spacing load, to prevent the bushes
3
Bolt 1/2" X 2.3/4"
Grade 10.9
BF1/2X2.3/4 1 A-frame to diff 14
Washer
M10 X 1.5 X 30
Penny Washer
3GZ2007A 6 Damper from becoming stressed.
4
Bolt M10 X 130
Grade 10.9
3GZ2022A 2 Damper 15
Plain Washer
M6
WPHM6 8 Drop bracket fixings
John S
Caphead Shakeproof
Radius arm to
5 M10 X 70 3GZ2004A 2 16 Washer WSS3/8 1
Grade 8.8 chassis 3/8" ID
Caphead Drop bracket to

6 M6 X 45 BMCH6X45 4 chassis through ARB Nylon Washer
17 17.5 X 32 X 1mm
ZZ021463 2 A-frame
Grade 10.9 mount
Drop bracket to A-
Nyloc Nut
7 M12
NMYF12 4 fram & drop bracket
to chassis
Half Nyloc
8 1/2" UNF
NFYH1/2 1 A-frame to diff
Nyloc Nut
9 M10
3GZ2023A 4 Damper
Nyloc Nut
10 M6
NMYF6 4 Drop bracket fixings
Plain Washer
11 M12 3GZ2006A 13
Form A
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
74
FITTING THE RADIUS ARMS
2
1
35 35 47Nm
mm mm
35 35 81Nm
mm mm
REPEAT
75
FITTING THE REAR DAMPERS
P A R T S T O O L S
1 Dampers (x2)
17mm
2 Damper sleeves (x4)
17mm
8mm
SERIAL SERIAL
Pack 74 Pack 74
NUMBER NUMBER
It’s easier to fit the top of the

3G0Z0001A 3G0Z0001A
damper into the chassis before

tackling the bottom.

Plain Washer
1 Grade 10.9
BM12X100 2 12 M12 X 1.5 X 30 WPHM12 2
A-Frame Form C
Lloyd D
Bolt M12 X 65 Drop bracket to Plain Washer
2 Grade 8.8
3GZ2002A 2 13 WPH1/2 16 A-frame spacing
chassis 1/2"
Bolt 1/2" X 2.3/4" Washer

3 Grade 10.9
BF1/2X2.3/4 1 A-frame to diff 14 M10 X 1.5 X 30 3GZ2007A 6 Damper
Penny Washer
Bolt M10 X 130 Plain Washer

4 Grade 10.9
3GZ2022A 2 Damper 15 WPHM6 8 Drop bracket fixings
M6
Caphead Shakeproof
Radius arm to
5 M10 X 70 3GZ2004A 2 16 Washer WSS3/8 1

17 17.5 X 32 X 1mm
ZZ021463 2 A-frame
Grade 10.9 mount
Drop bracket to A-
Nyloc Nut
7 M12
to chassis
Half Nyloc
8 1/2" UNF
Nyloc Nut
9 M10
3GZ2023A 4 Damper
Nyloc Nut
10 M6
Plain Washer
11 M12 3GZ2006A 13
Form A
76
FITTING THE REAR DAMPERS
35 35 47Nm
mm mm
35 35 70Nm
mm mm
REPEAT 2
77
FITTING THE HALF SHAFTS
P A R T S T O O L S
1 Half shaft assembly (x2)
2 Wheel speed sensor (x2)
10mm
3 Oil seal (x2)
12mm
4 Oil seal protector (x2)
60mm
5 M8 bolts (x8)
6 M6 bolts (x2)
The seals should be fitted with the Carefully hit the oil seal into
hollow side facing inwards. place until it seats against
John K the plastic seal protector.
Jamie A
The speedo sensors are handed, as

the wires should be facing downwards.
Lloyd D
78
FITTING THE HALF SHAFTS
REPEAT
35
mm 5
35
mm
25Nm
1
6 2
35
mm
35
mm
25Nm 5
79
FITTING THE A-FRAME
P A R T S T O O L S
1 A-frame
19mm (x2)
2 Nylon washers (x2)
19mm
SERIAL SERIAL
Pack 74 Pack 74
NUMBER NUMBER
You are aiming to centralise the axle in the chassis,

3G0Z0001A 3G0Z0001A
by adjusting the number of spacing washers between

ITEM ILLUSTRATION
the forward bushes and the chassis.

QTY USED ON ITEM QTY USED ON ILLUSTRATION
Plain Washer
1 Grade 10.9
BM12X100 2 12 M12 X 1.5 X 30 WPHM12 2
A-Frame Form C
Vincent M
2 Grade 8.8
3GZ2002A 2 13 WPH1/2 16 A-frame spacing
chassis 1/2"
Bolt 1/2" X 2.3/4" Washer

3 Grade 10.9
Penny Washer
It is best to torque these fixings under

4 Grade 10.9
3GZ2022A 2 Damper 15 WPHM6 8 Drop bracket fixings
M6
Caphead Shakeproof
Radius arm to
load to prevent the bushes from twisting.

5 M10 X 70 3GZ2004A 2 16 Washer WSS3/8 1

17 ZZ021463 2 A-frame
Mick F
Grade 10.9 17.5 X 32 X 1mm
mount
Drop bracket to A-
Nyloc Nut
7 M12
to chassis
Half Nyloc
8 1/2" UNF
Nyloc Nut
9 M10
3GZ2023A 4 Damper
Nyloc Nut
10 M6
Plain Washer
11 M12 3GZ2006A 13
Form A
80
FITTING THE A-FRAME
35 35 81Nm
mm mm
35 35 81Nm
mm mm
= =
ADJUST AS
REQUIRED
81
FITTING THE HANDBRAKE
P A R T S T O O L S
1 Handbrake assembly
2 Handbrake clevis pin
10mm (x2)
3 Handbrake clevis
13mm (x2)
4 Clevis pivot
5 Clevis pivot bolt
6 Cable locking pins (x2)
7 Handbrake cable
T I P S
F I X I N G S
Connect the handbrake warning light connector
SERIAL NUMBER
49
PACK NUMBER
30P012A
SERIAL NUMBER
49
PACK NUMBER
30P012A
The clevis pivot does not onto the upper of the two terminals.
FASTNER PACK – MISCELLANEOUS (METRIC) FASTNER PACK – MISCELLANEOUS (METRIC)
want to be locked. Doing Dan D
No
DESCRIPTION PART NUMBER QTY DRAWING No

DESCRIPTION PART NUMBER QTY DRAWING the fixings up tight and

then loosening by ¼ of a
Bolt 1/2" X 2 1/2" UNF
1 BFCH1/2X2.5 2 12 WPHM8 13
section
2
Bolt with plain section &
BM8X50 1 13 Split pin 1/16" X 3/4" SP1/16X3/4 1 turn is a good guide. The handbrake lever bracket
3
Bolt with plain section &
BM8X45 3 14 Split pin 7/64" X 3/4" SP7/64X3/4 1
Grant P should be mounted in the
4
Setscrew M8 X 25
Grade 8.8
SM8X25 2 15
Washer 1/2"
WSH1/2 2 lower of the two holes.
threaded section
5
Setscrew M8 X 20
Grade 8.8
SM8X20 4 16
Washer M8
WSHM8 3
Anthony L
Hexagonal head & metric full Spring Washer Heavy-Duty
threaded section
Setscrew M6 X 20
6 SM6X20 2 17 WPH3/8 6
Use pliers to bend the legs of

threaded section
Setscrew M8 X 16
the split-pins once in place,

7 SM8X16 3 18 WPHM6X25 2
threaded section
Setscrew M6 X 16
8
Grade 8.8
Hexagon head & metric full
threaded section
SM6X16 4 19
Washer M6
WPHM6 8
which then holds them loosely After plugging on the connector,
9
Nut M8
With Metric thread & Nyloc
locking mechanism
NMYF8 10 20
Washer M5 X 20
WPHM5X20 1
in the clevis pins. secure any excess wire with a cable tie.
Bolt 1/2" X 1" UNF
10
Nut M6
With Metric thread & Nyloc NMYF6 2 21
BFCH1/2X1 1
Chris B Dan P
locking mechanism
section
Nut M6
full size
82
FITTING THE HANDBRAKE
4 6
7
3 5
1
83
FILLING THE DIFFERENTIAL OIL
P A R T S T O O L S
1 Diff oil (S3 AX 80W-90)

³⁄₈" Drive
You can use the square drive of the

ratchet to loosen the filler plug.
Tiago O
84
FILLING THE DIFFERENTIAL OIL
Differential = 1.3L
85
Now is a good time to take some photos
86
Have you applied for your IVA yet?
87
FITTING THE EXHAUST
P A R T S T O O L S
1 Catalyst
10mm
13mm
2 Link pipe
13mm
3 Silencer
22mm
4 Mounting brackets (x2)
5 Bobbins (x2)
6 Clamps (x2)
7 Lambda sensor
Fixings packed with exhaust
Don’t overtighten the bobbins
as they can twist and split.
Harry P
88
FITTING THE EXHAUST
4
2
89
GIVING IT SOME DIRECTION
P A R T S T O O L S
1 Lower steering column

5mm
4mm
2 Upper steering column
⁷⁄₁₆"
3 Steering column clamp 10mm
13mm
4 Steering column clamp plate

⁷⁄₃₂"
5 Grub screw
6 Steering column bush

¹¹⁄₁₆"
B
SERIAL
55
Pack
NUMBER
PACK NUMBER
3ACZ0002B
RELEASED NOV-19
Check clearance along 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 the length of the steering the grooved face of the clamp plate 4 Lee A
column to ensure that it against the column.
BASIC PART
DESCRIPTION NUMBER
Caphead Bolt
does not foul against any

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
x2 components. If necessary,
x2 rotate the steering rack.
3 BC BM8X40 2
Grade 10.9 universal joint
x1
Nyloc Nut ½"
Dan P
4 BD NFYH1/2 1 Steering wheel boss
When fitting the steering column

Half height
clamp, begin by fitting the two clamp

5 BE Plain Nut ½" NFPF1/2 2 Track rod lock nut
x1 bolts, then tighten the grub screw

Plain Nut ⁷⁄₁₆" Column clamp
6 BF NFPFH7/16 1
Once the steering rack is in the correct

Half height grubscrew locknut
x2 and finally secure it with the locknut.

Column to rack
position, you can go ahead and tighten the

universal joint
rack clamp fixings. Tiago O

Plain Washer
9 BJ ½" x 1⅛"
Chamfered
WPH1/2 1 Steering wheel boss
x1 Harrison P
Plain Washer
x2
Rack clamps and
10 BK ¼" WPH1/4 6
x2
Spring Washer ¼
11 BL Heavy duty
90
GIVING IT SOME DIRECTION
6
35
BD
35
mm mm
60Nm
6 BJ
4
3
BF
2
2
BB
5 BK
BL
35 35
BC
mm mm
38Nm
BG
7
91
JUST WING IT
P A R T S T O O L S
1 Cycle wing (x2)

19mm
2 Wheel (x2)
3 Wheel nuts (x8)
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
Do a 'dry run' first to make

sure the wings are level The distance from
before using power adhesive. the front edge of the
Chris N
wing to the wingstay
should be 75mm.
Lee A
92
JUST WING IT
1
75
75
REPEAT
93
TAPE IN PLACE FOR 24 HOURS
P A R T S T O O L S
Once you are happy with the wing position, apply

tape with one hand whilst preventing the wheel
from turning with the other.
Anthony L
94
TAPE IN PLACE FOR 24 HOURS
REPEAT
95
SOME EXTRA ADHESIVE UNDERNEATH
P A R T S T O O L S
The WD40 will help spread the adhesive. Make sure that you do not
Mick F cover up the wingstay hole
which you drilled earlier.
Anthony L
96
SOME EXTRA ADHESIVE UNDERNEATH
REPEAT
97
FINISH WITH TRIM
P A R T S T O O L S
1 Rubber trim
It’s best to test fit and cut Fit the wider section on the
to size before sticking. underside of the cycle wing.
Chris B Mick F
Hide the rubber trim join on the

inside of the cycle wing, behind the
rear leg of the wingstay. It will look
much neater.
Rich T
98
FINISH WITH TRIM
REPEAT
99
FITTING THE SIDE REPEATERS
P A R T S T O O L S
1 Side repeaters (x2)

8mm
2 Cable ties
3 Cable tie brackets (x2)
4 Heat shrink
5mm
5 Grommets (x2)
C
SERIAL
45
Pack
NUMBER
PACK NUMBER
3ACZ0003A Trying to feed the wire out from inside Before securing the wire to
BASIC
LIGHTING & HORNS
the wingstay can be tricky. Do this before the upper wishbone, make
fitting the grommet into the wingstay hole. sure that the steering can
PART
DESCRIPTION NUMBER
Screw 10 x ¾" Indictor assembly to
reach full lock without the

1 CA 71080 6
Black Supaflange indicator pod
Rich T
x2 side repeater wire snagging.
Screw 8 x ½" Side repeater earth
2 CB 71077 2

3 CC 71079 4
Tiago O
4 CD 71078 4
Horn bracket to
steering rack
platform
(160/270/310)
The side repeater holes are pre-drilled with smaller

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
pilot holes. Enlarge the outer pilot holes to 5mm
(420)
8 CH
Plain Washer
5/16"
and enlarge the centre hole to 13mm, but go slowly
9 CI
Nyloc Nut
M8
NMYF8 1 Horn bolt
as you do not want to damage the paint!
Drawings are for illustrative purposes only and are not to scale. Page 1 of 1 Jamie A
100
FITTING THE SIDE REPEATERS
7
1
3
GREEN
CB
5
REPEAT
101
FITTING THE REAR WINGS
P A R T S T O O L S
1 Rear wing (x2)
8mm
8mm
8mm
Q
SERIAL
31
Pack
NUMBER
PACK NUMBER
3ACZ0017A Cut the supplied piping in half and it
REAR WINGS
This pack may include extra fasteners to cover different options will be enough for both wings.
ITEM
BASIC
DESCRIPTION
PART
NUMBER
QTY USED ON ILLUSTRATION
Rich T
You may need to clear the wing
x20 mounting holes with a drill bit.
Set Screw
1 QA M5 X 20
SM5X20 20 Rear Wings
x10
Nyloc Nut Rear wings through
2 QB M5
NMYF5 10
boot Chris N
x30
Plain Washer
3 QC 3/16" X 3/4"
WP3/16X3/4 30 Wing washers
x4
Wing Piping Between wing and
4 QD 1/4" X 1"
76902 4m
body
A slot will need to be cut to make way for the

radius arm. Cut with a hacksaw and neaten with
a drum sander.
Lee B
102
FITTING THE REAR WINGS
QB
QC
REPEAT
QA
QD QC
103
ADD THE WING PROTECTORS
P A R T S T O O L S
1 Wing protector (x2)
⅛"
For stainless steel protectors For carbon fibre protectors
When fitting the wing protector, start Carbon fibre protectors will not
O P
SERIAL SERIAL
Pack Pack
NUMBER NUMBER
PACK NUMBER
3ACZ0015A
PACK NUMBER
3ACZ0016A with the top hole closest to the body. have the protective film shown.
WING PROTECTORS STAINLESS STEEL
WING PROTECTORS CARBON FIBRE
This pack may include extra fasteners to cover different options Whilst holding the wing protector Anthony L
flat against the wing, work your way
Rivet Wing protector to Rivet Black Wing protector to
across the top and then evenly down

1 OA 1/8" X 0.51"
1661-0414 30 1 PA 1/8" X 0.51"
1610-01049 30
wing wing
the sides.
Between wing Between wing
2 OB Wing Piping 76901 2m 2 PB Wing Piping 76901 2m
protector and wing protector and wing
Chris B
Position the wing protector slightly above the

bottom edge of the wing, so that the piping
will sit flush with the bottom of the wing.
Harrison P
104
ADD THE WING PROTECTORS
x12 x1
x1
105
FITTING THE REAR LIGHTS
P A R T S T O O L S
1 Light cluster (x2)

7⁄₁₆"
2 Light housing (x2)
3 Rubber gasket (x2)
4 Spacer (x4)
10mm
5 Bolt (x4)
6 P-clip (x2)
Fixings packed in lighting box
The rear light cluster holes are pre-drilled with
smaller pilot holes. Enlarge the outer pilot holes to
10mm and enlarge the centre hole to 32mm, but go
slowly as you do not want to damage the paint.
Tiago O
106
FITTING THE REAR LIGHTS
6
3
5 4
4
5
REPEAT
107
FITTING THE TUNNEL CARPET
P A R T S T O O L S
1 Carpet
Brake cleaner is great for You can use masking tape to prevent
removing any excess glue. glue from getting where it isn’t wanted.
John K Harry P
Make sure that you apply glue to both

the panel and the carpet, paying extra
attention to the edges.
Lee B
108
FITTING THE TUNNEL CARPET
109
THIS IS A COVER UP
P A R T S T O O L S
1 Tunnel blanking plate
2 Boot boards
3 Boot carpet
4 Fuel filler neck cover
5 Grommets (x2)
6 Rubber trim ⅛"

5⁄32"
10mm
SERIAL NUMBER PACK NUMBER
57 ZCH01
FASTNER PACK – CHASSIS FIXTURE (KIT CAR ONLY)

You will need to drill a pair of holes in the front of the
No DESCRIPTION
Screw 6 x 1/2"
PART NUMBER QTY DRAWING
fuel filler neck cover in order to feed through your washer
pump wires and washer tube from under the boot floor.
1 PD8 6
Pan Head Pozi
2 Rivet 1/8" X 0.39" 1661-0410 4
Tiago O
3 Rivet 1/8” X 0.51" 1661-0414 4
4 Rivet 5/32" X 0.47" 1661-0512 5
5 Rivet – black 5/32" X 0.47" 1610-01015 110
6 Rivet – black 5/32" X 0.59" 1610-9931 6
Screw 8mm X 1/2"

7 71077 4
superflange
Screw 10mm X 3/4"

8 71080 14
superflange
hose clip
9 SGT 9.5-12 2
9.5mm to 12mm
Setscrew Panhead opzi

10 76227 2
5mm X 16mm
11 Cradle clip KR6GS 5
Setscrew Panhead Pozi SPHM5X35

12 2
5mm X 35mm map sensor
Setscrew Panhead Pozi

13 76227S 2
5mm X 16mm
110
THIS IS A COVER UP
4
6
5
111
NOW FIT THE TUNNEL TOP
P A R T S T O O L S
1 Tunnel top
2.5mm
2 Gear knob
5⁄32"
57 ZCH01

No DESCRIPTION PART NUMBER QTY DRAWING
Screw 6 x 1/2"
1 PD8 6
Pan Head Pozi
2 Rivet 1/8" X 0.39" 1661-0410 4
3 Rivet 1/8” X 0.51" 1661-0414 4
4 Rivet 5/32" X 0.47" 1661-0512 5
5 Rivet – black 5/32" X 0.47" 1610-01015 110
6 Rivet – black 5/32" X 0.59" 1610-9931 6
Screw 8mm X 1/2"

7 71077 4
superflange
Screw 10mm X 3/4"

8 71080 14
superflange
hose clip
9 SGT 9.5-12 2
9.5mm to 12mm

10 76227 2
5mm X 16mm

12 2

13 76227S 2
5mm X 16mm
112
NOW FIT THE TUNNEL TOP
113
BELT UP
P A R T S T O O L S
17mm
Supplied with seat belts
These will be loosely fitted already –
you'll need to tighten & torque.
Chris N
114
BELT UP
35 35 47Nm
mm mm
35 35 47Nm
mm mm
REPEAT
115
FITTING THE FOUR-POINT HARNESS
P A R T S T O O L S
1 Harness kit (x2)

17mm
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
116
FITTING THE FOUR-POINT HARNESS
35 35 47Nm
mm mm
REPEAT
117
FITTING THE ROLL OVER BAR
P A R T S T O O L S
1 Roll over bar

13mm
LO
Loctite 243
CT
IT
17mm
E
8mm
17mm
J
SERIAL
47
Pack
NUMBER
PACK NUMBER
3ACZ0010A You will need to remove the rear dampers in order
BASIC
ROLL OVER & TRACK DAY BAR SERIES 3 METRIC
PART
to install the lower roll over bar mounting bolts.
DESCRIPTION NUMBER
Chris B
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
x2 Begin by fitting the cap head bolts from

Caphead Bolt
3 JC M10 X 20
BMCH10X20 2 Roll over bar boss
x2 underneath, followed by the small hex

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 bolts and lastly the rear mounting bolts.
Fit all the bolts finger James A
6 JF
Spring Washer
WSHM8 2
x2
tight and then torque
M8 to chassis
x4
Rear diagonals of
Plain Washer
at the end.
7 JG M10
WPHM10 4 roll over bar to
mounting brackets
Harry P
118
FITTING THE ROLL OVER BAR
JB
35 35 25Nm JE
mm mm
JF
LO
CT
IT
E
35 35 47Nm
JA
mm mm
JD
JG
JC
35 35 47Nm
mm mm
LO
CT
IT
E
JC
119
FITTING THE FUSE BOX COVER AND KNEE TRIM PANELS
P A R T S T O O L S
1 Knee trim panels (LH & RH)
2 Fuse box cover
3 Velcro 5/32
57 ZCH01 If you’re fitting a 12v power socket then you will

need to push the outer plastic ring into the fuse
No DESCRIPTION
Screw 6 x 1/2"
PART NUMBER QTY DRAWING
box cover before inserting the power socket.
1 PD8 6
Pan Head Pozi
John S
2 Rivet 1/8" X 0.39" 1661-0410 4
3 Rivet 1/8” X 0.51" 1661-0414 4
4 Rivet 5/32" X 0.47" 1661-0512 5
5 Rivet – black 5/32" X 0.47" 1610-01015 110

Apply foam tape to the flat section
6 Rivet – black 5/32" X 0.59" 1610-9931 6
of the fuse box cover and Velcro to
the four mounting tabs.
Screw 8mm X 1/2"
7 71077 4
superflange
Screw 10mm X 3/4"

8 71080 14
superflange
Tiago O
hose clip
9 SGT 9.5-12 2
9.5mm to 12mm

10 76227 2
5mm X 16mm

12 2

13 76227S 2
5mm X 16mm
120
FITTING THE FUSE BOX COVER AND KNEE TRIM PANELS
121
FITTING LEATHER SEATS
P A R T S T O O L S
1 Seat (x2)
13mm
2 Seat base (x2)
3 Headrest (x2) 6mm
L
SERIAL
62
Pack
NUMBER
It’s best to start by loosely This can be a fiddly job, so patience

PACK NUMBER
3ACZ0012A
BASIC
CLOTH/LEATHER SEATS ALL CARS
PART
fitting the rear bolts, followed by is key.
the fronts. Once all the bolts are
DESCRIPTION NUMBER
Anthony L
x4
Caphead Bolt
Through seat runner
1 LA 4
located you can fully torque them.

M8 X 20 SMCH8X20
Grade 12.9 & floor
x4
Nyloc Nut
2 LB M8
NMYF8 4 Under floor
Dan D
x4
Plain Washer
3 LC M8 X 30
WPH8X30 4 Under floor
You will find it much easier to tighten

these bolts using a ball ended socket
for the rears, and a short Allen key for
the fronts.
Lee A
122
FITTING LEATHER SEATS
2 1
LA
35 35 20Nm
mm mm
35 35
LB
mm mm
20Nm
LC
123
FITTING THE RACE SEATS
P A R T S T O O L S
1 Seat
13mm
2 Adjustable runner
3 Fixed seat spacer 6mm
LO
Loctite 243
CT
IT
E
+
For fixed seats For adjustable seats
Apply Loctite to the bolts which Runners / seat spacers can be
M N
SERIAL
63 SERIAL
64
Pack Pack
NUMBER NUMBER
PACK NUMBER
3ACZ0013A
PACK NUMBER
3ACZ0014A secure the runners to the seat base. fitted to seat before putting in car.
SEATS FIXED TILLETT RACING SEATS ADJUSTABLE TILLETT RACING
This pack may include extra fasteners to cover different options This pack may include extra fasteners to cover different options Chris B 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
Spring Washer
x8
Loosely fit the rear bolts
x4
3 MC 5/16"
WSH5/16 8 Bolt heads Washer
3 NC WP5/16X1.1/4 4 Under floor
to help locate the front.

5/16" X 1 1/4"
4 MD
Washer
5/16" X 1 1/4"
WP5/16X1.1/4 4 Under floor
x4 4 ND
Nyloc Nut
M8
NMYF8 4 Under floor
x4 You will need to fit one thin and one Harry P
thick spacer in each corner between
5 ME
Washer
M8 X 18
WPM8X18X1 4
Spacer box section
to seat x4 5 NE
Spacer Black
TW2 3 Seat spacer
x3
the seat base and the runners,
Plastic
7 MF
Spacer Black
Plastic
TW2 3 Seat spacer
x3 except for the right front corner
6 NF
Spacer Black
TW3 5 Seat spacer
x5 The fixed position seat is
which will need two thick washers.
Plastic
8 MG
Spacer Black
Plastic
TW3 5 Seat spacer
x5
Grant P
for the passenger side!
Drawings are for illustrative purposes only and are not to scale. Page 1 of 1 Chris N
124
FITTING THE RACE SEATS
NE
NF MF
NF MF
NF MG
MF
2 3
NB
NA MA
MB
NC MC MC
ND ME MD
125
CONNECTING THE BATTERY – NON MASTER SWITCH
P A R T S T O O L S
1 Starter motor
10mm
13mm
10mm (x2)
F I X I N G S W I R I N G K E Y
SERIAL NUMBER PACK NUMBER SERIAL NUMBER PACK NUMBER 1 Starter motor – alternator
49 30P012A 49 30P012A
FASTNER PACK – MISCELLANEOUS (METRIC) FASTNER PACK – MISCELLANEOUS (METRIC) 2 Starter motor – battery positive
Please note: This pack may include extra fastners to cover different options Please note: This pack may include extra fastners to cover different options
1
Bolt 1/2" X 2 1/2" UNF
Caphead Bolt with plain
BFCH1/2X2.5 2 12
Washer M8
WPHM8 13
3 Solenoid trigger wire
section

2 Bolt with plain section &
4 Main loom feed – battery positive
Setscrew M8 X 25
Grade 8.8 Washer 1/2"
4 SM8X25 2 15 WSH1/2 2
threaded section
Setscrew M8 X 20
Grade 8.8 Washer M8
5 SM8X20 4 16 WSHM8 3
threaded section
Setscrew M6 X 20
6 SM6X20 2 17 WPH3/8 6
threaded section
Setscrew M8 X 16
7 SM8X16 3 18 WPHM6X25 2
threaded section
Setscrew M6 X 16
Grade 8.8 Washer M6
8 SM6X16 4 19 WPHM6 8
threaded section
Nut M8
Washer M5 X 20
locking mechanism
Bolt 1/2" X 1" UNF

Nut M6
10 With Metric thread & Nyloc NMYF6 2 21 BFCH1/2X1 1
locking mechanism section & imperial threaded
section
Nut M6
full size
126
CONNECTING THE BATTERY – NON MASTER SWITCH
Main Loom Positive 4
127
CONNECTING THE BATTERY – MASTER SWITCH
P A R T S T O O L S
1 Starter motor
10mm
13mm
10mm (x2)
F I X I N G S W I R I N G K E Y
SERIAL NUMBER PACK NUMBER SERIAL NUMBER PACK NUMBER 1 Starter motor – alternator
49 30P012A 49 30P012A
FASTNER PACK – MISCELLANEOUS (METRIC) FASTNER PACK – MISCELLANEOUS (METRIC) 2 Starter motor – battery master switch
1
Bolt 1/2" X 2 1/2" UNF
Caphead Bolt with plain
BFCH1/2X2.5 2 12
Washer M8
WPHM8 13
3 Solenoid trigger wire
section

2 Bolt with plain section &
4 Battery master switch to battery positive
Setscrew M8 X 25
4 SM8X25 2 15 WSH1/2 2
threaded section
Setscrew M8 X 20
Grade 8.8 Washer M8
5 SM8X20 4 16 WSHM8 3
threaded section
Setscrew M6 X 20
6 SM6X20 2 17 WPH3/8 6
threaded section
Setscrew M8 X 16
7 SM8X16 3 18 WPHM6X25 2
threaded section
Setscrew M6 X 16
Grade 8.8 Washer M6
8 SM6X16 4 19 WPHM6 8
threaded section
Nut M8
Washer M5 X 20
locking mechanism
Bolt 1/2" X 1" UNF

Nut M6
section
Nut M6
full size
128
CONNECTING THE BATTERY – MASTER SWITCH
4 Battery Master Switch Positive
129
CONNECTING THE BATTERY EARTHS
P A R T S T O O L S
1 Earth cables (x2)

14mm
10mm (x2)
6mm
49 30P012A 49 30P012A

Bolt 1/2" X 2 1/2" UNF
1 BFCH1/2X2.5 2 12 WPHM8 13
section


Setscrew M8 X 25
4 SM8X25 2 15 WSH1/2 2
threaded section
Setscrew M8 X 20
Grade 8.8 Washer M8
5 SM8X20 4 16 WSHM8 3
threaded section
Setscrew M6 X 20
6 SM6X20 2 17 WPH3/8 6
threaded section
Setscrew M8 X 16
7 SM8X16 3 18 WPHM6X25 2
threaded section
Setscrew M6 X 16
Grade 8.8 Washer M6
8 SM6X16 4 19 WPHM6 8
threaded section
Nut M8
Washer M5 X 20
locking mechanism
Bolt 1/2" X 1" UNF

Nut M6
section
Nut M6
full size
130
CONNECTING THE BATTERY EARTHS
131
FITTING THE WIPERS AND INTERIOR MIRROR
P A R T S T O O L S
1 Wiper arm (x2)
2 Wiper blade (x2)
3 Interior mirror
Ensure that the wiper motor is in Now would be a good time to fill
the parked position before fitting the washer bottle with fluid and
the wiper arms. test the washers and wipers.
John S Chris B
132
FITTING THE WIPERS AND INTERIOR MIRROR
133
FITTING THE SIDE MIRRORS
P A R T S T O O L S
1 Mirror head (x2)
2 Mirror mount (x2)
3 Grub screw (x2) 2.5mm
4 Mirror mount stud (x2)
T20
5 Fibre washer (x2)
Fixings packed with mirrors
You will need to pop off the surround and
remove the glass from the mirror housing
in order to attach the mirror mount.
Mick F
134
FITTING THE SIDE MIRRORS
REPEAT
4 3
135
FILL WITH COOLANT
P A R T S T O O L S
Coolant concentrate
17mm
The bleed bolt on the top of the radiator will

need to be removed before filling the coolant.
Grant P
Coolant will flow out of the bleed

Open the heater valve by bolt hole when all the air is expelled.
pulling the cable which will Vincent M
allow the heater matrix to
fill with coolant.
Lloyd D
136
FILL WITH COOLANT
Fill expansion bottle to max mark
137
THE LAST FEW STEPS…
Your car is almost complete, but before you can drive triumphantly out of the garage (and legally, as far as
the end of your driveway) there are a few important things that need to be done. These are, bleeding the
brakes, preparing the engine for the its first grand firing-up ceremony (it will feel like that, even if you are
doing it on your own) and lastly torquing up the suspension.
So, on with bleeding the brakes which cannot be explained with a simple diagram unfortunately:
1 ssemble the things you’ll need: Brake fluid, both an 8mm and an 11mm spanner, a length of washer
A
hose (or similar clear plastic hose) and a waste fluid receptacle (some form of used bottle is ideal; you
won’t want to use it again after this)
2 ind a volunteer. They need to be able to reach and press the brake pedal whilst responding to your
F
instructions, so although a child could do this job, you may wish to find somebody more inclined to
listen to you.
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
paintwork causing it to blister and peel.
4 tarting at the left rear corner, locate the bleed nipple on the backplate. It will have a rubber cap on it.
S
Remove the cap, remember where you put it, and attach the washer hose to the nipple and put the
other end in the waste bottle. This sometimes needs the hose warming up in a cup of hot water to
allow it to stretch over the nipple.
5 Using the 8mm spanner, ‘crack off’ the nipple about half of a turn.
138
6 sk your assistant to pump the pedal a few times. You should see bubbly fluid flowing through the
A
pipe. When the bubbles die down, ask them to hold the pedal down, then tighten the nipple back up.
Check and top up the fluid level in the reservoir as necessary.
7 Ask them to lift off, then pump it a couple of times, then press the pedal down and hold it down.
8 rack off the nipple again and let the fluid and bubbles flow. It will stop flowing as soon as your
C
assistant has run out of brake pedal travel. Whilst still holding the pedal to the floor, tighten the nipple.
9 epeat steps 7 and 8 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.
10 nce you are satisfied that there are no more bubbles, tighten the nipple and remove the washer
O
hose. You can then clean any residue from the area and refit the dust cover.
11 epeat steps 5–10 for the front calipers, (left then right). The front brake nipples will require an 11mm
R
spanner.
12 lthough tedious, getting all the air out of the braking system is important and will give you a good,
A
firm brake pedal, which is what you need; not a soft spongy one like you have in a regular car. You
may need to repeat the whole process after the first drive or two (or even after the car has had a ride
on a trailer); air in the braking system is very good at hiding.
13 The clutch system will need to be bled using exactly the same principle as the brake system,
however you’ll be pleased to learn that it’s much quicker to do as there is only one bleed nipple to
expel the air from.
139
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:

1 Reassure yourself the engine is full of oil.
2 Disconnect the inertia switch; it’s the black thing attached to the engine bay bulkhead under the
windscreen that has rubber cap on top and a plug with two wires connecting from underneath. By
disconnecting the inertia switch, the fuel pump will not work, so intentionally, the engine will not fire.
3 Ensure the gearbox is in neutral, then turn the ignition key and press and hold the start button.
4 As the engine cranks over, watch the oil pressure gauge. Keep cranking until the needle starts to
climb, then steadies out.
5 We now have oil pressure circulating in the engine, which means the engine is ready to be started.
6 Reconnect the inertia switch.
7 Take a deep breath, mutter 'this is it', cross your fingers and brace yourself.
8 Turn the ignition key, press and hold the start button. It will take a few moments for the fuel to get
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
it starts give it a little rev.
140
That’s it. Your car is complete! Well done – you have built a car; a real live car; not many people can say
that. If you remembered to put in gearbox and differential oil, and fill the system with coolant, then a
tentative edge out onto the driveway is in order. You’ll need to pop the wheels on and lower it from the
axle stands and just tighten the suspension first.
Let’s just run through that quickly:

i. Put a wheel on and do the nuts up a few turns by hand (to ensure they do not cross-thread).
ii. Tighten them up the best you can with the wheels off the ground.
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).
iv. Torque the wheel nuts to 65lbft (about 85Nm).
v. Flick back to the pages where we put the wishbones on and torque as shown
vi. That’s it, you’re ready to go!
Take care and good luck with the IVA and registration process.
You will soon be experiencing the sheer pleasure of being a Caterham driver. Once again, enjoy!
141
APPENDIX
143
FIXING PACKS
94
A A
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER

3ACZ0001A 3ACZ0001A
FRONT SUSPENSION DeDION CARS (METRIC) FRONT SUSPENSION DeDION CARS (METRIC)

1 AA BM12X100 2 12 AM WSHM12 2
Anti-roll bar
2 AB BM12X65 2 13 AN WSHM8 6
mount



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
rear
Plain Washer
Chamfered
Plain Washer
Anti-roll bar
10 AK M8 WPHM8 4
Plain Washer
Heavy duty
144
FIXING PACKS
B C
SERIAL
55 SERIAL
45
Pack Pack
NUMBER NUMBER

3ACZ0002B 3ACZ0003A
RELEASED NOV-19
STEERING DeDION CARS (METRIC) LIGHTING & HORNS

BASIC PART BASIC
ITEM QTY USED ON ILLUSTRATION PART
DESCRIPTION NUMBER ITEM QTY USED ON ILLUSTRATION
DESCRIPTION NUMBER
Caphead Bolt
1 BA M6 x 70 BMCH6X70 4 Rack clamps Screw 10 x ¾" Indictor assembly to
1 CA 71080 6
DIN 912 Black Supaflange indicator pod
2 BB Bolt ¼" x 1½" BF1/4X1.1/2 2 Column clamp Screw 8 x ½" Side repeater earth
2 CB 71077 2

3 BC BM8X40 2 Screw 12 x 1½" Rear light cluster
Grade 10.9 universal joint 3 CC 71079 4
Nyloc Nut ½"

4 BD Half height
NFYH1/2 1 Steering wheel boss Screw 12 x 1" Rear light cluster
4 CD 71078 4
Horn bracket to
5 BE Plain Nut ½" NFPF1/2 2 Track rod lock nut steering rack
platform
(160/270/310)
Plain Nut ⁷⁄₁₆" Column clamp Horn bracket to
6 BF NFPFH7/16 1 Plain Washer
steering rack
Half height grubscrew locknut 6 CF ¼" WPH1/4 2
Heavy duty platform
(160/270/310)
Column to rack Through steering
universal joint Bolt M8 x 5 rack platform &
7 CG BM8X50 1
Grade 8.8 spacer
(420)

Plain Washer
8 CH 5/16"
Plain Washer
9 BJ ½" x 1⅛" WPH1/2 1 Steering wheel boss
Chamfered Nyloc Nut
9 CI M8
NMYF8 1 Horn bolt
Plain Washer
Rack clamps and Drawings are for illustrative purposes only and are not to scale. Page 1 of 1
10 BK ¼" WPH1/4 6
Spring Washer ¼
11 BL Heavy duty
145
FIXING PACKS
D D
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER

3ACZ0004A 3ACZ0004A
COOLING SIGMA COOLING SIGMA

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
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
146
FIXING PACKS
J L
SERIAL
47 SERIAL
62
Pack Pack
NUMBER NUMBER

3ACZ0010A 3ACZ0012A
ROLL OVER & TRACK DAY BAR SERIES 3 METRIC CLOTH/LEATHER SEATS ALL CARS
Rear diagonals of Caphead Bolt

Bolt M10 X 60 Through seat runner
1 JA Grade 8.8
BM10X60 2 roll over bar to 1 LA M8 X 20 SMCH8X20 4
Grade 12.9 & floor
mounting brackets
Setscrew
Roll over bar bracket Nyloc Nut
2 JB M8 X 20 SM8X20 2 2 LB M8
NMYF8 4 Under floor
Grade 8.8 to chassis
Caphead Bolt
3 JC M10 X 20
BMCH10X20 2 Roll over bar boss
Plain Washer
3 LC M8 X 30
WPH8X30 4 Under floor
Rear diagonals of
Nyloc Nut
4 JD M10
NMYF10 2 roll over bar to
mounting brackets Drawings are for illustrative purposes only and are not to scale. Page 1 of 1
Plain Washer Roll over bar bracket

5 JE M8
WPHM8 2
to chassis
Spring Washer Roll over bar bracket

6 JF M8
WSHM8 2
to chassis
Rear diagonals of
Plain Washer
7 JG M10
WPHM10 4 roll over bar to
mounting brackets
147
FIXING PACKS
M N
SERIAL
63 SERIAL
64
Pack Pack
NUMBER NUMBER

3ACZ0013A 3ACZ0014A
SEATS FIXED TILLETT RACING SEATS ADJUSTABLE TILLETT RACING

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
Caphead Bolt Floor to rivnut in Caphead Bolt

2 MB M8 X 20
SMCH8X20 4 2 NB M8 X 20
SMCH8X20 4 Runner to floor
spacer box section
Spring Washer
3 MC 5/16"
WSH5/16 8 Bolt heads Washer
3 NC 5/16" X 1 1/4"
WP5/16X1.1/4 4 Under floor
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
Washer Spacer box section

5 ME WPM8X18X1 4 Spacer Black
M8 X 18 to seat 5 NE Plastic
TW2 3 Seat spacer
Spacer Black
7 MF Plastic
TW2 3 Seat spacer
Spacer Black
6 NF Plastic
TW3 5 Seat spacer
Spacer Black Drawings are for illustrative purposes only and are not to scale. Page 1 of 1
8 MG Plastic
TW3 5 Seat spacer
148
FIXING PACKS
O P
SERIAL SERIAL
Pack Pack
NUMBER NUMBER

3ACZ0015A 3ACZ0016A
WING PROTECTORS STAINLESS STEEL WING PROTECTORS CARBON FIBRE

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
149
FIXING PACKS
Q
SERIAL
31 SERIAL NUMBER PACK NUMBER
Pack
NUMBER
PACK NUMBER
3ACZ0017A 57 ZCH01
REAR WINGS FASTNER PACK – CHASSIS FIXTURE (KIT CAR ONLY)

BASIC PART
DESCRIPTION NUMBER No DESCRIPTION PART NUMBER QTY DRAWING
Screw 6 x 1/2"
Set Screw 1 PD8 6
1 QA M5 X 20
SM5X20 20 Rear Wings Pan Head Pozi
2 Rivet 1/8" X 0.39" 1661-0410 4

Nyloc Nut Rear wings through
2 QB M5
NMYF5 10
boot
3 Rivet 1/8” X 0.51" 1661-0414 4
Plain Washer
3 QC 3/16" X 3/4"
WP3/16X3/4 30 Wing washers
4 Rivet 5/32" X 0.47" 1661-0512 5
Wing Piping Between wing and

4 QD 1/4" X 1"
76902 4m 5 Rivet – black 5/32" X 0.47" 1610-01015 110
body
6 Rivet – black 5/32" X 0.59" 1610-9931 6
Screw 8mm X 1/2"

7 71077 4
superflange
Screw 10mm X 3/4"

8 71080 14
superflange
hose clip
9 SGT 9.5-12 2
9.5mm to 12mm

10 76227 2
5mm X 16mm

12 2

13 76227S 2
5mm X 16mm
150
FIXING PACKS
SERIAL SERIAL
Pack 74 Pack 74
NUMBER NUMBER

3G0Z0001A 3G0Z0001A
Plain Washer
1 Grade 10.9
BM12X100 2 12 M12 X 1.5 X 30 WPHM12 2
A-Frame Form C

2 Grade 8.8
3GZ2002A 2 13 1/2"
WPH1/2 16 A-frame spacing
chassis
Washer
Bolt 1/2" X 2.3/4"
3 Grade 10.9
Penny Washer

4 Grade 10.9
3GZ2022A 2 Damper 15 M6
WPHM6 8 Drop bracket fixings
Caphead Shakeproof
Radius arm to
5 M10 X 70 3GZ2004A 2 16 Washer WSS3/8 1

Nylon Washer
6 M6 X 45 BMCH6X45 4 chassis through ARB 17 17.5 X 32 X 1mm
ZZ021463 2 A-frame
Grade 10.9 mount
Drop bracket to A-
Nyloc Nut
7 M12
to chassis
Half Nyloc
8 1/2" UNF
Nyloc Nut
9 M10
3GZ2023A 4 Damper
Nyloc Nut
10 M6
Plain Washer
11 M12 3GZ2006A 13
Form A
FIXING PACKS
49 30P012A 49 30P012A

Bolt 1/2" X 2 1/2" UNF
1 BFCH1/2X2.5 2 12 WPHM8 13
section


Setscrew M8 X 25
4 SM8X25 2 15 WSH1/2 2
threaded section
Setscrew M8 X 20
Grade 8.8 Washer M8
5 SM8X20 4 16 WSHM8 3
threaded section
Setscrew M6 X 20
6 SM6X20 2 17 WPH3/8 6
threaded section
Setscrew M8 X 16
7 SM8X16 3 18 WPHM6X25 2
threaded section
Setscrew M6 X 16
Grade 8.8 Washer M6
8 SM6X16 4 19 WPHM6 8
threaded section
Nut M8
Washer M5 X 20
locking mechanism
Bolt 1/2" X 1" UNF

Nut M6
section
Nut M6
full size
152
Caterham Cars Limited, 2–3 Kennet Road, Dartford, Kent, DA1 4QN
+44 (0) 1322 625800
/CaterhamCars @caterhamcars caterhamcarsltd
Content is subject to change without notice.

© Caterham 2022 | Edition 1.1 04/22
Images are for illustrative purposes only.

Assembly Guide SUZUKI Edition 1.2

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Assembly Guide SUZUKI Edition 1.2

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ASSEMBLY GUIDE

SUZUKI – EDITION 1.2

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

For help and build support enquiries contact: buildsupport@caterham.com

READ THE NEXT THREE PAGES – THEY ARE REALLY IMPORTANT

Book IVA Test

Take plenty of photos

Arrange post build check

This was more fun than I ever expected!

‘over‑torquing’ it. Always wind your torque wrench

When using a spanner, always use the ring end wherever

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

Advice from factory PACK NUMBER

Now is a good time to take 2 AB

S Pack / R Pack Bolt M10 x 60 Upper wishbone

35 Nm Required torque (where applicable) Temporary use to

Refer to IVA Checklist Guide

(Greyed out4 area indicates fixings are not

Adjustable Instant Power Socket Tape

Flat head Sanding

Brake Long nose Spray

Cloth Funnel Mallet Seal drift Spray lube

Combination Masking Side Stanley

Hose Pop rivet Silicone

1 Horn kit (x2)

Screw 12 x 1½" Rear light cluster

Screw 12 x 1" Rear light cluster

1 Lower wishbone (LH & RH)

Bolt M12 x 100 Lower wishbone

3 Column universal joint 5mm

4 Track rod end (x2)

closed end off.

Nyloc Nut ½"

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

x4 the steering rack it easier to rotate the

1 Spring / damper (x2)

2 Bush sleeves (x4)

F I X I N G S Put the top of the damper on first

A A the side of the chassis. Mick F

PACK NUMBER PACK NUMBER

Bolt M12 x 100 Lower wishbone Spring Washer Lower wishbone

Bolt M10 x 65 Upper wishbone Washer ⅜"

you won’t damage your paint in doing this.

Bolt M10 x 60 Upper wishbone Nyloc Nut ½"

Fixings not contained in the pack will be

1 Wingstay (LH & RH)

3 Steel wheel hub spacers (x2) 22mm

PACK NUMBER PACK NUMBER

top ball joint

Bolt M10 x 65 Upper wishbone Washer ⅜"

nyloc that comes fitted on the back of Chris N

the stub axle before fitting the wingstay.

A half nyloc from the fixings pack should wheels.

1 Headlight assembly (x2)

2 Indicator pod (LH & RH)

4 Headlight bracket (LH & RH)

LIGHTING & HORNS

Screw 12 x 1½" Rear light cluster

Screw 12 x 1" Rear light cluster

Glue IVA trim all around the

The wires exiting the headlight bracket

edge of the pod before fitting.

1 Brake hose kit