ASSEMBLY GUIDE

ALL CATERHAM SEVEN MODELS

Version 02.2014

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Contents

Contents ............................................................................................................................... 1

List of Tables .......................................................................................................................10

List of Figures ......................................................................................................................11

0.0) Preliminary information ..............................................................................................17

0.1) General warnings & cautions ....................................................................................17

0.2) Specific warnings & cautions ....................................................................................17

1.0) Introduction ................................................................................................................19

1.1) Contact information ...................................................................................................19

1.1.1) Customer Liaison .............................................................................................19

1.1.2) Caterham Aftersales ........................................................................................19

1.1.3) Caterham Parts ................................................................................................19

1.1.4) Technical Assistance .......................................................................................19

1.2) Post build check ........................................................................................................20

1.3) Individual Vehicle Approval .......................................................................................20

1.4) Disclaimer .................................................................................................................21

1.5) Suggested Build Sequence .......................................................................................22

2.0) Kit contents ................................................................................................................27

2.1) Packages ................................................................................................................27

2.1.1) Exhaust, steering, large suspension items, bell-housing and front wing stays ...27

2.1.2) Rear axle ............................................................................................................31

2.1.3) Differential ..........................................................................................................32

2.1.4) Driveshafts .........................................................................................................32

2.1.5) Suspension.........................................................................................................33

2.1.6) Cooling ...............................................................................................................35

2.1.7) Lighting ...............................................................................................................36

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 2.1.8) Head light brackets .............................................................................................37

2.1.9) Uprights ..............................................................................................................38

2.1.10) Interior trim, cables and options .......................................................................39

2.1.11) Gearbox ...........................................................................................................42

2.1.12) Chassis/body unit .............................................................................................43

2.1.13) Weather gear (optional) ....................................................................................44

2.1.14) Engine ..............................................................................................................45

2.1.15) Heater assembly ..............................................................................................45

2.1.16) Wheels .............................................................................................................46

2.1.17) Seat ..................................................................................................................46

2.1.18) Wings ...............................................................................................................46

2.1.19) Nosecone .........................................................................................................46

2.1.20) Roll over bar .....................................................................................................46

3.0) Pre-assembly information .............................................................................................47

3.1) Package contents .....................................................................................................47

3.2) Basic definitions ........................................................................................................50

3.3) Tools and equipment ................................................................................................50

3.4) Nuts, bolts and washers............................................................................................52

4.0) Steering ........................................................................................................................58

4.1) Steering rack (standard and wide rack) ....................................................................58

4.2) Steering column ........................................................................................................59

4.3.1) Motolita ...............................................................................................................62

4.3.2) Momo .................................................................................................................62

4.3.3) Quick release column .........................................................................................62

4.4) Associated tasks .......................................................................................................63

5.0) Front suspension ..........................................................................................................64

5.1) Preparation ...............................................................................................................64

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5.2) Lower wishbones ......................................................................................................64

5.3) Upper wishbones ......................................................................................................65

5.4) Spring damper units ..................................................................................................66

5.5) Upright attachment....................................................................................................66

5.5.1) Standard .............................................................................................................67

5.5.2) Wide track ..........................................................................................................67

5.6) Front anti-roll bar.......................................................................................................68

5.7) Front brake hoses .....................................................................................................69

5.8) Final tightening..........................................................................................................70

5.9) Cars fitted with adjustable damper platform ..............................................................70

6.1) Assembly of gearbox kit – 5 and 6-speed. ................................................................72

6.2) Fitting gearbox to engine ..........................................................................................74

6.3) Starter motor .............................................................................................................75

7.1) Sigma engine ............................................................................................................76

7.1.1) Preparation .........................................................................................................76

7.1.2) Installation of engine/gearbox into chassis .........................................................78

7.1.3) Electrical connections .........................................................................................80

7.1.4) Fuel system ........................................................................................................82

7.1.5) Clutch hydraulic hose .........................................................................................82

7.1.6) Exhaust systems ................................................................................................83

7.1.7) Cooling system ...................................................................................................86

7.1.8) Throttle cable fitment ..........................................................................................92

7.1.9) Breather pipe fitment ..........................................................................................93

7.1.10) Air filter fitment .................................................................................................94

7.1.11) Sigma 140 and Academy – air intake ...............................................................94

7.2) Duratec - Roadsport 175/Superlight R300 engine ....................................................97

7.2.1) Preparation .........................................................................................................97

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 7.2.2) Installation of engine/gearbox into chassis .........................................................99

7.2.3) Electrical connections .......................................................................................101

7.2.4) Fuel systems ....................................................................................................102

7.2.5) Clutch hydraulic hose .......................................................................................103

7.2.7) Cooling system .................................................................................................106

7.2.8) Throttle cable fitment ........................................................................................112

7.2.9) Breather pipe fitment ........................................................................................113

7.3) Duratec – Superlight R400 ......................................................................................116

7.3.1) Preparation .......................................................................................................116

7.3.2) Installation of engine/gearbox into chassis .......................................................118

7.3.3) Electrical connections .......................................................................................120

7.3.4) Fuel system ......................................................................................................121

7.3.5) Clutch hydraulic hose .......................................................................................122

7.3.6) Exhaust system ................................................................................................122

7.3.7) Cooling system and dry sump system ..............................................................125

7.3.8) Throttle cable fitment ........................................................................................132

7.3.9) Breather pipe fitment ........................................................................................133

8.0) Preparation and installation of the differential .............................................................136

8.1) Procedure ...............................................................................................................136

9.0) Rear suspension ........................................................................................................139

9.1) General ...................................................................................................................139

9.2) Preparation .............................................................................................................139

9.3) Fitting of rear brake pipes .......................................................................................139

9.4) Rear brake hose .....................................................................................................140

9.5) Assembly of the rear suspension ............................................................................141

9.6) Rear spring damper assemblies .............................................................................141

9.7) Radius arms ............................................................................................................142

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 9.8) Watts link assembly (optional) ................................................................................142

9.8.1) Construction of link arms ..................................................................................142

9.8.2) Link arms to bellcrank ......................................................................................142

9.8.3) Link arms to chassis .........................................................................................143

9.8.4) Bellcrank to Di Dion tube ..................................................................................143

9.9) Rear anti-roll bar (optional) .....................................................................................143

9.10) ‘A’ frame ................................................................................................................144

9.11) Assembly of De Dion tube ....................................................................................145

9.12) Anti-roll bar connection and adjustment ................................................................148

9.13) Handbrake mechanism .........................................................................................149

9.14) Handbrake adjustment ..........................................................................................151

9.15) Final adjustments ..................................................................................................151

9.16) Filling of differential ...............................................................................................151

10.0) Interior and trim ........................................................................................................153

10.1) General .................................................................................................................153

10.2) Seat back carpets .................................................................................................153

10.3) Transmission tunnel carpet ...................................................................................154

10.4) Transmission tunnel top ........................................................................................154

10.5) Rubber footwell mats ............................................................................................154

10.6) Boot carpet ...........................................................................................................155

10.7) Side and knee trim panels ....................................................................................155

10.8) Inertia reel seat belt ..............................................................................................157

10.9) Four point harness ................................................................................................157

10.10) Six point harness ................................................................................................158

10.10.1) Standard floor ...............................................................................................159

10.10.2) Lowered floor................................................................................................159

10.11) Seats...................................................................................................................159

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 10.11.1) Standard cloth or leather seats.....................................................................159

10.11.2) Composite seats ...........................................................................................160

10.12) Minor trim items ..................................................................................................162

10.12.1) Scuttle edge trim ..........................................................................................162

10.12.2) Nose badge ..................................................................................................162

10.12) Rear view mirror..................................................................................................162

11.0) Fibreglass .................................................................................................................164

11.1) Front cycle wings ..................................................................................................164

11.2) Rear wing protectors (Stone guards) ....................................................................166

11.3) Rear wings ............................................................................................................167

12.0) Lighting .....................................................................................................................169

12.1) Headlights and front indicators .............................................................................169

12.2) Front indicator repeaters .......................................................................................170

12.3) Front wiring electrical connections ........................................................................170

12.4) Rear lights .............................................................................................................171

12.5) Reversing light and fog light ..................................................................................172

12.6) Rear number plate light .........................................................................................172

12.7) Testing ..................................................................................................................172

12.8) Headlight beam setting .........................................................................................173

13.0) Weather equipment ..................................................................................................174

13.1) Fitting of hoodsticks and hoodstraps.....................................................................174

13.2) Hood fitting ............................................................................................................175

13.3) Sidescreen fitment ................................................................................................176

13.4) Arm rest bracket fitment (escutcheon bracket)......................................................178

13.5) Exterior mirrors .....................................................................................................178

13.5.1) Fitment to screen stanchion ...........................................................................178

13.5.2) Fitment to side screens ..................................................................................179

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 13.6) Boot cover .............................................................................................................180

13.7) Tonneau cover ......................................................................................................181

13.8) Correct usage of fastener fixing tool .....................................................................183

14.0) Wheel fitment ...........................................................................................................184

14.1) Spare wheel fitment ..............................................................................................184

15.0) Start up procedure and final checks .........................................................................186

15.1) Brake system – filling and bleeding.......................................................................186

15.1.1) Standard brakes .............................................................................................186

15.1.2) Uprated front brakes .......................................................................................187

15.2) Clutch system – filling and bleeding ......................................................................188

15.3) Coolant .................................................................................................................189

15.4) Fuel .......................................................................................................................189

15.5 Engine/gearbox fasteners ......................................................................................189

15.6) Gearbox oil ...........................................................................................................189

15.7) Engine oil ..............................................................................................................190

15.8) Cranking for oil pressure .......................................................................................190

15.9) Start up .................................................................................................................191

15.10) Front suspension and steering alignment ...........................................................192

15.11) Final checks ........................................................................................................193

16.0) Individual vehicle approval and registration ..............................................................196

16.1) Requirements........................................................................................................196

16.2) How to apply for the inspection .............................................................................197

16.3) Inspection refusal ..................................................................................................197

16.4) Inspection data......................................................................................................198

16.4.1) Design weight .................................................................................................198

16.4.2) Towing ............................................................................................................198

16.4.3) Speedometer ..................................................................................................198

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 16.5) Checking and preparing the car prior to inspection ...............................................198

16.5.1) Wiper and washer system ..............................................................................198

16.5.2) Radio interference suppression ......................................................................198

16.5.3) Lamps, reflectors and devices ........................................................................198

16.5.4) Rear view mirrors ...........................................................................................198

16.5.5) Noise ..............................................................................................................199

16.5.6) Emissions .......................................................................................................199

16.5.7) General construction ......................................................................................199

16.5.8) Protective steering ..........................................................................................199

16.5.9) Brakes ............................................................................................................199

16.5.10) Interior and exterior projections ....................................................................199

16.5.11) Race cars and IVA .......................................................................................202

16.6)Registration procedure after IVA inspection ...........................................................202

16.7) Location of vehicle inspection test stations where the IVA test can be carried out
.......................................................................................................................................203

17.0) Options .....................................................................................................................205

17.1) Battery master switch ............................................................................................205

17.2) Standard roll over bar ...........................................................................................205

17.3) Track day roll over bar ..........................................................................................206

17.4) Roll cage ...............................................................................................................207

17.4.1) Preparation .....................................................................................................207

17.4.2) Roll cage fitment.............................................................................................208

17.5) Head restraint (roll cage and roll over bar) ............................................................210

17.6) Fire extinguisher pull handle .................................................................................211

17.7) Aero fuel filler cap .................................................................................................212

17.8) High level brake light .............................................................................................215

17.8.1) Fitting the bracket ...........................................................................................215

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 17.8.2) Light and wiring connections ..........................................................................216

17.8.3) Stack dash speed sensor fitment ...................................................................218

17.8.4) Rear brake calliper sub assembly ..................................................................219

17.8.5) IVA mirror fitting instructions...........................................................................220

17.8.6) Front brake calliper sub assembly ..................................................................221

18.0) Wiring diagrams........................................................................................................222

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List of Tables

TABLE 1: SUGGESTED BUILD SEQUENCE ............................................................................................................... 22

TABLE 2: POLYTHENE BAG CONTENTS - EXHAUST, STEERING, SUSPENSION ITEMS, BELL-HOUSING AND FRONT
WINGSTAYS ................................................................................................................................................. 29
TABLE 3: POLYTHENE BAG CONTENTS - REAR AXLE ................................................................................................ 31
TABLE 4: POLYTHENE BAG CONTENTS - SUSPENSION ............................................................................................. 34
TABLE 5: POLYTHENE BAG CONTENTS - INTERIOR TRIM, CABLES AND OPTIONS ........................................................ 41
TABLE 6: PACKAGE CONTENTS ............................................................................................................................. 47
TABLE 7: TOOLS REQUIRED .................................................................................................................................. 50
TABLE 8: ADDITIONAL TOOLS AND EQUIPMENT ....................................................................................................... 50
TABLE 9: CONSUMABLES ...................................................................................................................................... 51
TABLE 10: RECOMMENDED LUBRICANTS................................................................................................................ 51
TABLE 11: GENERAL TORQUE FIGURES ................................................................................................................. 52
TABLE 12: STEERING COMPONENT TORQUE FIGURES ............................................................................................. 63
TABLE 13: FRONT SUSPENSION TORQUE FIGURES ................................................................................................. 70
TABLE 14: GEARBOX TORQUE FIGURES ................................................................................................................. 75
TABLE 15: SPECIAL TOOLS REQUIRED FOR SIGMA ENGINE ...................................................................................... 76
TABLE 16: GEARBOX INSTALLATION TORQUE FIGURES FOR SIGMA ENGINE .............................................................. 79
TABLE 17: SPECIAL TOOLS REQUIRED FOR DURATEC – ROADSPORT 175/ SUPERLIGHT R300 ENGINE ..................... 97
TABLE 18: GEARBOX TORQUE FIGURES FOR DURATECROADSPORT 175/ SUPERLIGHT R300 ENGINE ..................... 100
TABLE 19: SPECIAL TOOLS REQUIRED FOR SUPERLIGHT R400 ENGINE ................................................................. 116
TABLE 20: TORQUE FIGURES FOR DURATEC SUPERLIGHT R400 ENGINE ............................................................... 119
TABLE 21: SPECIAL TOOLS REQUIRED FOR REAR SUSPENSION.............................................................................. 139
TABLE 22: TORQUE FIGURES FOR REAR SUSPENSION........................................................................................... 152
TABLE 23: SPECIAL TOOLS REQUIRED FOR INTERIOR AND TRIM ............................................................................. 153
TABLE 24: FRONT LIGHTING WIRING CONNECTIONS .............................................................................................. 170
TABLE 25: REAR LIGHTING WIRING CONNECTIONS ................................................................................................ 172
TABLE 26: ADDITIONAL TOOLS REQUIRED FOR WEATHER EQUIPMENT .................................................................... 174
TABLE 27: ENGINE OIL INITIAL FILL ...................................................................................................................... 190
TABLE 28: RECOMMENDED SUSPENSION ALIGNMENT - ROAD USE STANDARD AND WIDE TRACK ............................... 192
TABLE 29: TYRE PRESSURES .............................................................................................................................. 193
TABLE 30: TORQUE FIGURES FOR FINAL CHECKS AND START UP PROCEDURE ........................................................ 194
TABLE 31: TRACK DAY ROLL OVER BAR MOUNTING BOLT TORQUE FIGURES ............................................................ 207
TABLE 32: ROLL CAGE MOUNTING BOLT TORQUE FIGURES .................................................................................... 210
TABLE 33: HEAD RESTRAINT FIXING TORQUE FIGURES.......................................................................................... 211

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List of Figures

FIGURE 1: EXHAUST ............................................................................................................................................. 28

FIGURE 2: STEERING, LARGE SUSPENSION ITEMS, BELL-HOUSING AND FRONT WINGSTAYS ....................................... 30
FIGURE 3: REAR AXLE ITEMS ................................................................................................................................ 31
FIGURE 4: DIFFERENTIAL ...................................................................................................................................... 32
FIGURE 5: DRIVESHAFTS ...................................................................................................................................... 32
FIGURE 6: SUSPENSION ITEMS .............................................................................................................................. 33
FIGURE 7: COOLING ITEMS ................................................................................................................................... 35
FIGURE 8: LIGHTING ITEMS ................................................................................................................................... 36
FIGURE 9: HEADLIGHT BRACKETS ......................................................................................................................... 37
FIGURE 10: UPRIGHTS ......................................................................................................................................... 38
FIGURE 11: BOOT CARPET.................................................................................................................................... 39
FIGURE 12: BULKHEAD CARPET ............................................................................................................................ 39
FIGURE 13: RUBBER MATS ................................................................................................................................... 40
FIGURE 14: TRANSMISSION TUNNEL TOP ............................................................................................................... 40
FIGURE 15: 5-SPEED GEARBOX ............................................................................................................................. 42
FIGURE 16: 6-SPEED GEARBOX (OPTIONAL) ........................................................................................................... 42
FIGURE 17: ITEMS LOOSE IN CHASSIS .................................................................................................................... 43
FIGURE 18: W EATHER GEAR (OPTIONAL) ............................................................................................................... 44
FIGURE 19: 1.6 SIGMA ENGINE .............................................................................................................................. 45
FIGURE 20: HEATER ASSEMBLY ............................................................................................................................ 45
FIGURE 21: COMPLETE KIT (LESS ENGINE)............................................................................................................. 49
FIGURE 22: CUT ALLEN KEY ................................................................................................................................. 51
FIGURE 23: FASTENER PACK ................................................................................................................................ 55
FIGURE 24: FRONT AXLE STANDS .......................................................................................................................... 56
FIGURE 25: REAR AXLE STANDS ............................................................................................................................ 57
FIGURE 26: STEERING RACK ASSEMBLY ................................................................................................................ 58
FIGURE 27: PEDAL BOX ........................................................................................................................................ 59
FIGURE 28: STEERING RACK TO STEERING COLUMN ............................................................................................... 60
FIGURE 29: UPPER STEERING COLUMN CLAMP....................................................................................................... 61
FIGURE 30: STEERING W HEEL - MOTOLITA............................................................................................................ 62
FIGURE 31: BODYWORK PROTECTION ................................................................................................................... 64
FIGURE 32: W ASHER USAGE - LOWER WISHBONE (LH SIDE) ................................................................................... 65
FIGURE 33: UPPER WISHBONE SECURING .............................................................................................................. 65
FIGURE 34: FRONT SUSPENSION ........................................................................................................................... 68
FIGURE 35: BRAKE PIPE UNION ............................................................................................................................. 69
FIGURE 36: STANDARD CALLIPER.......................................................................................................................... 69
FIGURE 37: UPRATED CALLIPER ............................................................................................................................ 70
FIGURE 38: CLUTCH ACTUATION MECHANISM......................................................................................................... 73

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FIGURE 39: SPEEDO DRIVE PLUG .......................................................................................................................... 73
FIGURE 40: SPEEDO SHAFT PLUG ......................................................................................................................... 74
FIGURE 41: W ATER RAIL AND 'U' HOSE .................................................................................................................. 77
FIGURE 42: HORN LOCATION ................................................................................................................................ 78
FIGURE 43: ECU AND MAP UNIT .......................................................................................................................... 81
FIGURE 44: BRAKE LIGHT SWITCH HARNESS .......................................................................................................... 81
FIGURE 45: FUEL PIPE CONNECTION ..................................................................................................................... 82
FIGURE 46: CLUTCH MASTER CYLINDER HOSE UNION ............................................................................................. 83
FIGURE 47: CLUTCH HYDRAULIC HOSE .................................................................................................................. 83
FIGURE 48: EXHAUST MOUNTING .......................................................................................................................... 84
FIGURE 49: PRIMARY PIPES AND COLLECTOR/CATALYST ........................................................................................ 85
FIGURE 50: LAMBDA PROBE CONNECTION ............................................................................................................. 85
FIGURE 51: EXHAUST ARRANGEMENT ................................................................................................................... 86
FIGURE 52: COOLANT HOSES ............................................................................................................................... 86
FIGURE 53: BOTTOM HOSE ENGINE CONNECTION (VIEWED FROM BELLOW) .............................................................. 87
FIGURE 54: RADIATOR/FAN PRIOR TO FITTING ........................................................................................................ 87
FIGURE 55: STANDARD RADIATOR ARRANGEMENT ................................................................................................. 87
FIGURE 56: SV RADIATOR ARRANGEMENT ............................................................................................................. 88
FIGURE 57: COOLANT EXPANSION BOTTLE MOUNTING BRACKET ............................................................................. 88
FIGURE 58: HEATER INSTALLATION ....................................................................................................................... 89
FIGURE 59: HEATER VALVE ARRANGEMENT ........................................................................................................... 91
FIGURE 60: HEATER CONTROL LOCATION .............................................................................................................. 91
FIGURE 61: HEATER CONTROL CABLE ................................................................................................................... 91
FIGURE 62: HEATER CONTROL CABLE ATTACHMENT ............................................................................................... 92
FIGURE 63: THROTTLE CABLE TO THROTTLE BODY ................................................................................................. 92
FIGURE 64: BREATHER PIPE ................................................................................................................................. 93
FIGURE 65: AIR INTAKE AND TRUNKING ................................................................................................................. 94
FIGURE 66: SIGMA 125 ENGINE BAY OVERVIEW ..................................................................................................... 95
FIGURE 67: SIGMA 125 ENGINE BAY OVERVIEW (REAR) .......................................................................................... 96
FIGURE 68: W ATER OUTLET AND 'L' SHAPE HOSE ................................................................................................... 98
FIGURE 69: HORN LOCATION ................................................................................................................................ 99
FIGURE 70: ECU ............................................................................................................................................... 101
FIGURE 71: BRAKE LIGHT SWITCH HARNESS ........................................................................................................ 102
FIGURE 72: FUEL PIPE CONNECTION ................................................................................................................... 102
FIGURE 73: CLUTCH MASTER CYLINDER HOSE UNION ........................................................................................... 103
FIGURE 74: CLUTCH HYDRAULIC HOSE ................................................................................................................ 103
FIGURE 75: EXHAUST MOUNTING ........................................................................................................................ 104
FIGURE 76: PRIMARY PIPES AND COLLECTOR/CATALYST ...................................................................................... 105
FIGURE 77: LAMBDA PROBE CONNECTION ........................................................................................................... 106
FIGURE 78: EXHAUST ARRANGEMENT ................................................................................................................. 106

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FIGURE 79: LOCATION OF MODINE ...................................................................................................................... 107
FIGURE 80: BREATHER BOTTLE MOUNTING BRACKET ........................................................................................... 107
FIGURE 81: BOTTOM RADIATOR HOSE ENGINE CONNECTION (VIEW FROM TOP) ...................................................... 107
FIGURE 82: SV RADIATOR ARRANGEMENT ........................................................................................................... 108
FIGURE 83: COOLANT EXPANSION BOTTLE MOUNTING BRACKET ........................................................................... 108
FIGURE 84: HEATER INSTALLATION ..................................................................................................................... 109
FIGURE 85: COOLANT HOSES ............................................................................................................................. 110
FIGURE 86: HEATER VALVE .............................................................................. ERROR! BOOKMARK NOT DEFINED.
FIGURE 86 TEMP SENDER SUBMARINE ................................................................................................................. 111
FIGURE 88: HEATER CONTROL LOCATION ............................................................................................................ 111
FIGURE 89: HEATER CONTROL CABLE ................................................................................................................. 112
FIGURE 90: HEATER CONTROL CABLE ATTACHMENT ............................................................................................. 112
FIGURE 91: THROTTLE CABLE LINKAGE ............................................................................................................... 113
FIGURE 92: BREATHER PIPE ............................................................................................................................... 114
FIGURE 93: DURATEC ENGINE BAY OVERVIEW ..................................................................................................... 115
FIGURE 94: W ATER OUTLET AND 'L' SHAPE HOSE ................................................................................................. 117
FIGURE 95: HORN LOCATION .............................................................................................................................. 118
FIGURE 96: HORN LOCATION (TOP DOWN) ........................................................................................................... 118
FIGURE 97: ECU ............................................................................................................................................... 120
FIGURE 98: BRAKE LIGHT SWITCH HARNESS ........................................................................................................ 121
FIGURE 99: FUEL PIPE CONNECTION ................................................................................................................... 121
FIGURE 100: CLUTCH MASTER CYLINDER HOSE UNION ......................................................................................... 122
FIGURE 101: CLUTCH HYDRAULIC HOSE .............................................................................................................. 122
FIGURE 102: EXHAUST MOUNTING ...................................................................................................................... 123
FIGURE 103: PRIMARY PIPES AND COLLECTOR/CATALYST .................................................................................... 124
FIGURE 104: LAMBDA PROBE CONNECTION ......................................................................................................... 124
FIGURE 105: EXHAUST ARRANGEMENT ............................................................................................................... 125
FIGURE 106: FITMENT OF DRY SUMP OIL TANK ..................................................................................................... 125
FIGURE 107: BOTTOM RADIATOR HOSE ENGINE CONNECTION (VIEWED FROM TOP) ................................................ 126
FIGURE 108: RADIATOR COWL FLAPS .................................................................................................................. 126
FIGURE 109: RADIATOR ARRANGEMENT .............................................................................................................. 127
FIGURE 110: ROUTING OF THE OIL PIPES ............................................................................................................. 127
FIGURE 111: SV RADIATOR ARRANGEMENT ......................................................................................................... 128
FIGURE 112: HEATER INSTALLATION ................................................................................................................... 129
FIGURE 113: COOLANT HOSES ........................................................................................................................... 130
FIGURE 114: W ATER OUTLETS CYLINDER HEAD ................................................................................................... 131
FIGURE 115: HEATER VALVE ARRANGEMENT ....................................................................................................... 131
FIGURE 116: HEATER CONTROL LOCATION .......................................................................................................... 131
FIGURE 117: HEATER CONTROL CABLE ............................................................................................................... 132
FIGURE 118: HEATER CONTROL CABLE ATTACHMENT ........................................................................................... 132

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FIGURE 119: THROTTLE CABLE LINKAGE ............................................................................................................. 133
FIGURE 120: BREATHER PIPE ............................................................................................................................. 134
FIGURE 121: DURATEC ENGINE BAY OVERVIEW ................................................................................................... 135
FIGURE 122: CATERHAM DIFFERENTIAL INSTALLATION (CAD IMAGE) .................................................................... 136
FIGURE 123: HANDBRAKE CABLE LOCATION ........................................................................................................ 136
FIGURE 124: DIFFERENTIAL INSTALLATION AND LHS............................................................................................ 137
FIGURE 125: DI DION TUBE RH BRAKE PIPE FITTING ............................................................................................ 140
FIGURE 126: LH BRAKE PIPE FITTING .................................................................................................................. 141
FIGURE 127: W ATTS LINK - RH SIDE ................................................................................................................... 142
FIGURE 128: W ATTS LINK - RH TOP VIEW ............................................................................................................ 143
FIGURE 129: REAR ANTI-ROLL BAR MOUNTING ..................................................................................................... 144
FIGURE 130: METALISTIC BRUSH - DE DION TUBE ................................................................................................ 144
FIGURE 131: FORWARD 'A' FRAME MOUNTING ..................................................................................................... 145
FIGURE 132: DE DION TUBE END (LH) ................................................................................................................ 146
FIGURE 133: ANTI-ROLL BAR BRACKET AND SPEED SENSOR ................................................................................. 147
FIGURE 134: SPEED SENSOR.............................................................................................................................. 147
FIGURE 135: ANTI-ROLL BAR CONNECTIONS ........................................................................................................ 148
FIGURE 136: HANDBRAKE ASSEMBLY .................................................................................................................. 149
FIGURE 137: SV HANDBRAKE CABLE ARRANGEMENT ........................................................................................... 150
FIGURE 138: HANDBRAKE CABLE ROUTING S3 (NON-ADJUSTABLE SIDE)................................................................ 150
FIGURE 139: REAR SUSPENSION ARRANGEMENT ................................................................................................. 151
FIGURE 140: CARPETS ....................................................................................................................................... 153
FIGURE 141: SIDE PANEL DETAIL ........................................................................................................................ 156
FIGURE 142: TRIM FIXINGS ................................................................................................................................. 157
FIGURE 143: MOUNTING HOLES FOUR-POINT HARNESS UPPER ............................................................................. 157
FIGURE 144: SHOULDER STRAP WITH TRACK DAY ROLL OVER BAR ........................................................................ 158
FIGURE 145: OUTBOARD LAP STRAP ................................................................................................................... 158
FIGURE 146: LAP STRAPS................................................................................................................................... 158
FIGURE 147: CRUTCH STRAP SPACER LOCATION ................................................................................................. 159
FIGURE 148: ADJUSTABLE SEAT ......................................................................................................................... 160
FIGURE 149: COMPOSITE SEAT AND SIX-POINT HARNESS ..................................................................................... 161
FIGURE 150: FIXED SEAT.................................................................................................................................... 161
FIGURE 151: COMPLETED INTERIOR .................................................................................................................... 163
FIGURE 152: INDICATOR REPEATER WIRING ......................................................................................................... 166
FIGURE 153: REAR WING PROTECTOR PIPING ...................................................................................................... 166
FIGURE 154: REAR WING FITMENT ...................................................................................................................... 167
FIGURE 155: W ING PIPING .................................................................................................................................. 168
FIGURE 156: REAR WING.................................................................................................................................... 168
FIGURE 157: HEADLIGHT AND INDICATOR LH ....................................................................................................... 170
FIGURE 158: W EATHER EQUIPMENT .................................................................................................................... 174

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FIGURE 159: HOODSTICK SPACING ..................................................................................................................... 175
FIGURE 160: HOODSTRAP FIXING........................................................................................................................ 175
FIGURE 161: HOOD SIDE FASTENERS .................................................................................................................. 176
FIGURE 162: HINGE AND SIDE SCREEN FITTING .................................................................................................... 176
FIGURE 163: SIDESCREEN STRAPS ..................................................................................................................... 178
FIGURE 164: ARM REST BRACKET ....................................................................................................................... 178
FIGURE 165: IVA MIRROR STALK ADAPTOR .......................................................................................................... 179
FIGURE 166: MIRROR FITTED TO SIDE SCREEN .................................................................................................... 179
FIGURE 167: BOOT COVER ................................................................................................................................. 180
FIGURE 168: FORWARD FASTENER BOOT COVER ................................................................................................. 181
FIGURE 169: TONNEAU COVER ........................................................................................................................... 181
FIGURE 170: TONNEAUCOVER POSITIONING ........................................................................................................ 182
FIGURE 171: TONNEAU COVER FASTENERS (FRONT) ............................................................................................ 182
FIGURE 172: DURABLE DOT FASTENER TOOL ...................................................................................................... 183
FIGURE 173: SPARE WHEEL MOUNTING ITEMS ..................................................................................................... 185
FIGURE 174: CLUTCH HYDRAULIC CONNECTIONS ................................................................................................. 188
FIGURE 175: IVA BAG CONTENTS ....................................................................................................................... 200
FIGURE 176: IVA SCUTTLE TRIM AND BATTERY MASTER SWITCH ........................................................................... 200
FIGURE 177: BONNET CATCHES .......................................................................................................................... 201
FIGURE 178: FRONT SUSPENSION....................................................................................................................... 201
FIGURE 179: EXHAUST MOUNTING ...................................................................................................................... 201
FIGURE 180: SIDE SCREEN HINGES ..................................................................................................................... 202
FIGURE 181: STANDARD ROLL OVER BAR ............................................................................................................ 205
FIGURE 182: TRACK ROLL OVER BAR .................................................................................................................. 206
FIGURE 183: FRONT FIXING BOSS LOCATION........................................................................................................ 208
FIGURE 184: REAR HOOP BUCKET BUSHES.......................................................................................................... 209
FIGURE 185: HEAD RESTRAINT ASSEMBLY........................................................................................................... 211
FIGURE 186: FIRE EXTINGUISHER PULL HANDLE ................................................................................................... 211
FIGURE 187: FIRE EXTINGUISHER INNER CABLE LOCATION.................................................................................... 212
FIGURE 188: FILLER COVER AND BOOT CARPET REMOVED.................................................................................... 213
FIGURE 189: DRILL OUT THE SIX RIVETS .............................................................................................................. 213
FIGURE 190: OLD FILLER BOSS REMOVED ........................................................................................................... 213
FIGURE 191: GASKET POSITIONED ON BACK PANEL .............................................................................................. 213
FIGURE 192: CAREFULLY DRILL NEW HOLES ........................................................................................................ 213
FIGURE 193: SPACER FITTED TO FILLER NECK ..................................................................................................... 214
FIGURE 194: FIT FLANGE .................................................................................................................................... 214
FIGURE 195: JOB COMPLETE .............................................................................................................................. 214
FIGURE 196: KIT CONTENTS FOR HIGH LEVEL BRAKE LIGHT .................................................................................. 215
FIGURE 197: DRILLING CENTRAL POPPER ON SV ................................................................................................. 215
FIGURE 198: ALIGNMENT OF BRACKET ................................................................................................................ 216

Page | 15
FIGURE 199: W IRE ROUTING THROUGH LIGHT UNIT .............................................................................................. 216
FIGURE 200: DRILLED HOLE ABOVE SPARE WHEEL BOSS ...................................................................................... 216
FIGURE 201: VIEW FROM UNDER RHS REAR CORNER .......................................................................................... 217
FIGURE 202: EXPLODED VIEW OF ASSEMBLY ....................................................................................................... 217
FIGURE 203: W IRES FROM SUPPORT TUBE ENTERING BOOT ................................................................................. 217
FIGURE 204: COMPLETED ASSEMBLY .................................................................................................................. 218
FIGURE 205: W HEEL SPEED SENSOR PLUG.......................................................................................................... 218
FIGURE 206: W HEEL SPEED SENSOR BRACKET .................................................................................................... 218
FIGURE 207: W HEEL SPEED SENSOR .................................................................................................................. 219
FIGURE 208: BRAKE CALLIPER ASSEMBLY ........................................................................................................... 219
FIGURE 209: BRAKE PAD ASSEMBLY ................................................................................................................... 219
FIGURE 210: KIT CONTENTS FOR MIRROR FITTING................................................................................................ 220
FIGURE 211: DISMANTLED MIRROR ..................................................................................................................... 220
FIGURE 212: ASSEMBLED MIRROR ...................................................................................................................... 220
FIGURE 213: STUD LOCATED ON STANCHION ....................................................................................................... 221
FIGURE 214: FINAL FITTED ASSEMBLY ................................................................................................................. 221
FIGURE 215: FRONT BRAKE CALLIPER ASSEMBLY................................................................................................. 221
FIGURE 216: FRONT BRAKE PADS ASSEMBLY ....................................................................................................... 221
FIGURE 217: MAIN WIRING HARNESS FOR ALL STANDARD INSTRUMENTATION, FORD SIGMA VARIANTS .................... 222
FIGURE 218: ENGINE HARNESS (SIGMA) .............................................................................................................. 223
FIGURE 219: R400 ENGINE HARNESS.................................................................................................................. 224
FIGURE 220: R400 MAIN CHASSIS HARNESS (STANDARD DASH) ............................................................................ 225
FIGURE 221: R400 MAIN CHASSIS HARNESS (STACK DASH) .................................................................................. 226

Page | 16
0.0) Preliminary information Hydraulic fluid (brake fluid) is corrosive to
paintwork, powder coat and plastic
0.1) General warnings & cautions components. Care should be taken to
The following warnings and cautions avoid spillage at any times.
indicate general and environmental
Cautions
hazards present during the building
process: Protect the environment. It is illegal to
pollute drains, water course and soil.
Warnings
Authorised waste collection facilities
Due consideration should be given to the include civic amenity sites and garages
highly flammable nature of petroleum or which provide facilities for the disposal of
alcohol based products and their vapours. oil and used oil filters. If in doubt ask the
Serious burns can result from incorrect local authority for advice.
use.
0.2) Specific warnings & cautions
Oils – prolonged and repeated contact The following warnings and cautions
may cause serious skin disorders. indicate specific hazards relating to the

Avoid contact with the skin as far as Caterham build process:

possible and wash thoroughly after any Warnings

contact.
Never work underneath a car without
Keep out of reach of children. supporting it on axle stands or equivalent.

First aid treatment should be obtained for Do not rely on a jack alone.

open cuts and wounds. Use appropriate eye protection whilst

Use appropriate barrier creams. carrying out drilling operations.

Hydraulic fluid (brake fluid) is poisonous. Use appropriate eye protection whilst

Wash affected areas immediately in case working under the car.

of skin contact and seek medical Cars fitted with electronic ignition systems
assistance if swallowed. have increased voltages compared with

Hydraulic fluid (brake fluid) is hydroscopic. conventional systems. Ensure system is

Ensure only clean fresh fluid is used. switched off prior to carrying out any work.

Page | 17
The electric radiator fan is controlled by a Cautions
thermostatic switch which operates when
All brake connections must be kept
the ignition is in the 'on' position. Whilst
spotlessly clean and contamination with
working on a hot engine ensure that the
oil, water and petrol should be avoided.
ignition is switched off.
When drilling fibreglass use tape on the
Do not remove coolant expansion bottle
surface over the drill holes to prevent
cap whilst coolant is hot. Take
damage to the gel coat or painted finish.
precautions to prevent scalds.
Slow drill speeds must be used.
Correct use of fixings is required in order
Do not over-tighten thermostatic fan
to ensure full engagement of the nyloc
switch.
nut.

Both imperial and metric threads are used

on the de dion brake pipes. The threads
on the three way union are imperial whilst
those on the brake callipers are metric.
To aid recognition a small notch is
machined into the hexagon of the metric
unions.

Retighten wheel nuts after 200 miles.

Ensure adhesive is applied in a well-

ventilated area. Follow instructions on
adhesive packaging. Care must be taken
whilst working in a confined area, for
instance the footwell.

Use a suitable face mask to prevent

inhalation of dust when drilling fibreglass
or carbon fibre.

Page | 18
1.0) Introduction For all service, repairs, warranty and
upgrade enquiries, contact the aftersales
It is recommended that the entire team located at all three of our sites:
assembly guide and IVA requirements are
read before commencing building of the Caterham Dartford (Kent)

car. This will allow planning ahead for the T: +44 (0)1322 625804
procurement of tools, consumables and
E:Aftersales@caterham.com
equipment required during the build
process.
Caterham Midlands (Leicester)
Whilst it is possible for many of the build
T: +44 (0)1455 841616
processes to be undertaken
simultaneously there are some areas E: MidlandService@caterham.com

where the correct build sequence is

critical. A suggested build sequence is 1.1.3) Caterham Parts
included at the end of this section.
For parts enquiries please contact
1.1) Contact information Caterham Dartford +44 (0)1322 625801

1.1.1) Customer Liaison 1.1.4) Technical Assistance

For all enquiries between point of order Caterham Cars will happily provide
and delivery please contact our sales technical assistance when requires. When
departments at Caterham South on 01883 in doubt, ask. Our technical team can be
333700 or Caterham Midlands on 01455 contacted on +44 (0)1322 625800
841616
Do ensure that you make a note of your
1.1.2) Caterham Aftersales sales order number (top of invoice) and
To maximise the enjoyment of your your customer number as these are the
Seven, the safety and integrity of the car references by which we know you and
must be maintained by careful adherence your kit and will ensure that, no matter
to the maintenance schedules. Further how long you take to assemble your car,
information on when servicing is required subsequent packages will be compatible.
can be found in the Owners Handbook
supplied with your car.
The kit provided by Caterham Cars
includes all the items required to build the

Page | 19
car. However, due to the sheer number of The Post Build Check therefore includes:
different components it is possible that
 Inspection of all safety related
some parts are omitted or duplicated. Kits
items.
should be checked to ensure all
 Inspection of all operating systems
components (including contents of
(Clutch, Gearbox, Axle etc.).
fastener packs) are present prior to
 A written report on any matters
starting construction. If there are any
causing concern or requiring
shortages or build enquiries contact Derek
attention.
Howlett at Caterham Dartford on +44
 Completion of any agreed warranty
(0)1322 625827.
work.
1.2) Post build check  Post Build Inspection Certificate
When your Caterham Seven is finally when the car has passed
completed and ready for the road it is inspection.
strongly recommended that you make use  Check to ensure compliance to IVA
of our Post Build Check facility. All requirements (if required).
customers are sent a free voucher
The inspection will take approximately
covering the first three hours of the Post
three hours and we suggest that you give
Build Check (this is ample time to check a
at least two weeks’ notice when booking
completed kit, which can be carried out at
your car in. If additional work is required
Caterham Dartford, at Caterham Midlands
please notify the Service Manager at the
or at one of our approved services
time of booking to ensure that sufficient
agents). The Seven even in its lowest
time can be made available. Any
state of tune possesses acceleration and
additional work will be charged on an
cornering abilities far in excess of most
hourly basis.
road going cars and it is therefore
extremely important that it is assembled 1.3) Individual Vehicle Approval
and set up correctly. The requirements for Individual Vehicle

We are also keen to ensure that our Approval (IVA) are detailed in the IVA and

customers do not suffer disappointment registration section. To pass the IVA YOU

as a result of sub-standard performance MUST TAKE PHOTOS OF YOURSELF

or premature component failure resulting BUILDING THE CAR. For advice or

from incorrect assembly. assistance on IVA matters contact the

Aftersales Department. IVA is a

Page | 20
requirement for UK markets only therefore Sound engineering principles must always
the additional parts will not be supplied be followed.
with overseas orders.
A free post build check is available from
1.4) Disclaimer Caterham Dartford or from one of

The Caterham Seven is supplied in kit Caterham Cars agents.

form and is supplied for amateur NOTE

construction.
In the UK, the assembled kit cannot
The builder must assume that all nuts, legally be driven to the post build
bolts and fasteners may be loose and inspection (prior to successful completion
takes the responsibility to ensure road of an IVA test).
worthiness.

Page | 21
1.5) Suggested Build Sequence

Table 1: Suggested Build Sequence

Work Area Detail Comment

Front

Steering Initial fit

Steering rack

IVA sleeves

Track rod ends

Front suspension

Lower wishbones

Upper wishbones

Headlight brackets and headlight

assembly

Damper units

Uprights

Wingstays

On R400 back radiator cowling

Anti-roll bar
should be fitted before anti roll bar

Front flexible brake hoses

Engine & Gearbox

Speedo drive plugs (large & small)

6 speed only

Gearbox rubber mounting

Gearbox to bell housing

Clutch release mechanism

Page | 22
 Gearbox to engine

Prep engine

Normally fitted to the engine, if not

Oil pressure sender please fit it before engine
installation.

Starter motor

Wiring loom (starter to alternator)

‘J’ hose

Intermediate top house (‘U’ hose)

Gearbox filler plug Loosen

Gearbox tail shaft plug Remove

Engine Bay

Engine mount blocks Fit to chassis

Earth lead

Wiper reservoir

Alternate header tank mounting

Optional fitment
plate

Horns

Install engine/ gearbox

Engine mounts Fit to engine

Earth lead

Engine/ chassis loom connections

Starter/ battery leads

ECU

MAP unit

Reverse light switch

Page | 23
 Gear stick

Fuel pipe

Primary exhaust pipes

Collector box/ cat

Lambda probe

Head tank mounting

Steering column

Steering wheel

Bottom hose

Top hose

Radiator bobbins

Fan and inner cowl Cowling is only on R400

Anti-roll bar Front suspension section

Fan switch

Radiator

Outer cowl Cowling is only on R400

Heater Maybe fitted before engine

Heater hoses

Heater valve

Heater control cable

Header tank

Expansion hoses

Cycle wings and indicator

repeaters

Rear chassis

Prep and install diff

Page | 24
 Handbrake and cables Initial assembly

Prop shaft

Differential

Rear suspension

Brake pipes and flexi hose

De-Dion tube

Only if standard roll over bar

Rear dampers
specified

Radius arms Or optional watts linkage

‘A’ frame

Drive shafts

Rear anti –roll bar Optional

De-Dion ears

Hub carriers

Including anti-roll bar spacer if

Speed sensor
specified

Hubs/ discs

Callipers

Attach handbrake cables Adjusted after brakes are bled

Cockpit & Boot

Transmission tunnel trim

Gear knob

Scuttle edge trim

Sill protectors Optional

Knee trim panels and interior panel Depends on roll over protection
piping specified

Page | 25
 Four and six point harness lap and
Optional
crutch straps

Carpets

Seats

Roll over bar/ cage as specified

Head restraint Roll cage option only

If track day roll over bar or roll

Rear dampers
cage specified

Fuel filler shroud

Bodywork and Hood

Front wings and indicator repeater Maybe fitted immediately after

lights fitting front anti-roll bar

Rear wing protectors

Rear wings

Exhaust pipe bracket

Exhaust silencer

Heat shields Silencer and collectors/ cat

Hood sticks

Hood fasteners

Side screens

IVA

Page | 26
2.0) Kit contents

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

2.1) Packages

The complete kit is supplied as follows:

 Chassis/Body unit (CBU).

 Composite panels (nosecone, rear wings and front wings).
 Engine assembly.
 Gearbox assembly.
 Boxes of parts (approximately 10).
 Wheel/tyre assemblies.
 Seats.
 Exhaust silencer.
 Heater (in own box).

IMPORTANT NOTE

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

2.1.1) Exhaust, steering, large suspension items, bell-housing and front wing stays

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

Page | 27
 Figure 1: Exhaust

3
1

2
5

1. Exhaust silencer 2. Exhaust primary pipes

3. Cat/ collector 4. Cat guard
5. Polythene bag

NOTE

Items may differ from those illustrated

Page | 28
Table 2: Polythene bag contents - exhaust, steering, suspension items, bell-housing
and front wingstays
Identifier Description Qty
Gearbox Gearbox mounting rubber 1
Gear knob 1
Speedo drive cover 1
Reverse light switch 1
Speedo blanking plug 1
Steering Track rod ends 2
Universal joint 1
Aluminium steering rack clamps 2 pairs
Steering column bush 1
Grub screw 1
Steering column clamp 1
Steering column plate 1
Exhaust Jubilee clips 5
Exhaust clamp 1
Exhaust mounting bracket 1
Mounting bobbins 1
Exhaust springs 2
Lambda sensor 1
Wheels Wheel nuts 16 or 18
Wheel nut washers 16 or 18
Centre caps 4 or 5
Centre cap badges 4 or 5

Page | 29
Figure 2: Steering, large suspension items, bell-housing and front wingstays

1. Fastener pack ‘steering’ 10. Front anti-roll bar

2. Front wingstay 11. ‘A’ frame
3. Polythene bag ‘steering’ 12. De Dion tube
4. Bell housing 13. Brake pipe (short)
5. Polythene bag ‘steering’ 14. Brake pipe (long)
6. Polythene bag ‘wheels’ 15. Propshaft
7. Fastener pack ‘gearbox’ 16. Upper steering column and QR boss (optional)
8. Steering rack 17. Lower steering column
9. Rear anti-roll bar

Page | 30
2.1.2) Rear axle

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

Figure 3: Rear axle items

1. De Dion ears 4. Hub/bearing assembly (2)

2. Brake calliper (2, LH and RH) 5. Polythene bag ‘rear axle’
3. Brake disc 6. Fastener pack 30R011A

Table 3: Polythene bag contents - rear axle

Identifier Description Qty
Rear Axle Cable ties -
Aluminium brake calliper spacers 4
Drive shaft washer 2
3-way brake union 1
Race washers 2

Rear brake pads 4

Page | 31
2.1.3) Differential

The differential is shown in Figure 4.

Figure 4: Differential

2.1.4) Driveshafts

The driveshafts are shown in Figure 5.

Figure 5: Driveshafts

1. RH driveshaft 4. Nyloc nut (white insert)

2. Speed sensor ring 5. LH driveshaft assembly
3. Nyloc nut (green insert)

Page | 32
2.1.5) Suspension

The suspension items are shown in Figure 6. The contents of the polythene bags are
detailed in Table 3.

Figure 6: Suspension items

1 Fastener pack 30R012A 8 Watts link (rear) radius arm

2 Fastener pack 30R011A 9 Watts link (front) radius arm
3 Lower wishbone (RH) 10 Polythene bag ‘rear suspension’
4 Spring damper unit (front) 11 Fastener pack 30F015A
5 Spring damper unit (rear) 12 Lower wishbone (LH)
6 Upper wishbone (RH) 13 Upper wishbone (LH)
7 Polythene bag ‘front suspension’

Page | 33
Table 4: Polythene bag contents - suspension
Identifier Description Qty
Front suspension Rubber cotton reel bushes 2
Damper sleeves 4
Anti-roll bar rubber cover 2
Anti-roll bar ball ends 2
Cables ties -
Anti-roll bars mounting clamps 2
Wishbone sleeves 2
Special stepped nyloc nut (widetrack/SV) 2
Rear suspension Rubber cotton reel bushes 2
(including rear anti-roll Aluminium mounting blocks 2 pairs
bar option) Bellcrank (Watts link) 2
Bellcrank spacer 2
Rod end (Watts link) 4
ARB mounting boss 2
Anti-roll bar extension 1
Thrust washer 2

Page | 34
2.1.6) Cooling

The cooling items are shown in Figure 7.

Figure 7: Cooling items

1 3 4

5
2

1
6 7 8 9

1. Expansion bottle hose 6. Cooling fan

2. Hose 7. Expansion bottle bracket
3. Fastener pack ‘cooling’ 8. Expansion bottle cap
4. Polythene bag ‘cooling’ 9. Expansion bottle
5. Bottom radiator hose 10. Radiator

NOTES

(1) A thermostatic fan switch may be supplied in lieu of a blanking plug (if supplied, the
switch must not be connected to the vehicle wiring harness).

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

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

Page | 35
2.1.7) Lighting

The lighting items are shown in Figure 8.

Figure 8: Lighting items

1 1

8
3 5
6
6

4
7 4

1. Headlight 5. Indicator repeater x2

2. Fastener pack 30L002A 6. Rear light cluster
3. Indicator cones (l/h and r/h) 7. Cable ties
4. Indicator (front) 8. Number plate light

Page | 36
2.1.8) Head light brackets

The headlight brackets are shown in Figure 9.

Figure 9: Headlight brackets

1 2

1. LH headlight bracket 2. RH headlight bracket

Page | 37
2.1.9) Uprights

The uprights are shown in Figure 10.

Figure 10: Uprights

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

NOTE

It is possible that the callipers may be supplied loose and not attached to the upright
assembly. If this is the case, the callipers need to be attached with the two bolts and shim
washers torqued to 58Nm.

Page | 38
2.1.10) Interior trim, cables and options

The interior trim, cables and options items are shown in Figures 11, 12, 13 and 14. The
contents of the polythene bags are detailed in Table 4.

Figure 11: Boot carpet

Figure 12: Bulkhead carpet

Page | 39
Figure 13: Rubber mats

Figure 14: Transmission tunnel top

Page | 40
Table 5: Polythene bag contents - interior trim, cables and options
Identifier Description Qty
SVA Cable ties -
Track rod end sleeves 2
Track rod end bottom cap 2
Wing mirror pack 1
Sticky back foam (roll) 1
Edge trim (roll) 1
Large flat bolt head covers 6
Small domed caps 12
Long bonnet catch rubbers 2
Short bonnet catch rubbers 2
Large domed caps 2
Medium domed caps 4
Spare Wheel Wheel nuts 2
Spare wheel bolt 1
Spacer 1
Mounting wishbone 1

Page | 41
2.1.11) Gearbox

The standard 5-speed gearbox is shown in Figure15, the optional 6-speed gearbox is
shown in Figure 16.

Figure 15: 5-speed gearbox

Figure 16: 6-speed gearbox (optional)

Page | 42
2.1.12) Chassis/body unit

The chassis body unit comprises; chassis, body panels, pedals, master cylinder,
instruments, switches, wiring loom, windscreen, fuel tank, fuel pump, fuel lines, ECU.
Additional items placed loose in the chassis are shown in Figure 17.

Figure 17: Items loose in chassis

1. Fastener pack ZCH 6. IVA trim

2. Fastener pack ZWE 7. Transmission tunnel cover
3. Fastener pack 30P016A 8. Wiper blades
4. Side screen mirrors 9. Wiper arms
5. Velcro strips 10. Fuel filler cover

NOTE

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

Page | 43
2.1.13) Weather gear (optional)

The optional weather gear items are shown in Figure 18.

Figure 18: Weather gear (optional)

1. Hoodsticks 5. Mirrors
2. Hood 6. Mirror plate (not required)
3. Side screens 7. Hood straps
4. Fastener pack ‘weather’ 8. Hinges

Page | 44
2.1.14) Engine

The engine, Fig 19, is supplied on a frame complete with engine mountings and lifting eyes.
Once the engine is fitted the lifting eyes must be removed. The engine is supplied
complete with wiring loom. The starter motor is not fitted as it is secured to the bell-
housing.

Figure 19: 1.6 sigma engine

2.1.15) Heater assembly

The heater assembly, Figure 20, is packed into an unmarked cardboard box.

Figure 20: Heater assembly

Page | 45
2.1.16) Wheels

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

2.1.17) Seat

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

2.1.18) Wings

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

2.1.19) Nosecone

The nosecone is supplied in protective bubble wrap. It is recommended that it is left

protected until required for fitment.

2.1.20) Roll over bar

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

Page | 46
3.0) Pre-assembly information

This section has been included to aid recognition of parts and to give a basic idea as to
where they might be found. Due to the complexity of the range of options available and
subsequent variations on packages it is impossible to list every permutation; however Table
5 (below) and Annex A (at the end of this section) show the normal location of parts in a
standard CKD kit.

3.1) Package contents

Kits supplied from Caterham Cars arrive as shown in Fig 21. Due to packaging constraints
some items may be located in different packages.

Table 6: Package contents

Box Package Contents

Box 1 Steering, exhaust, Steering rack, rack clamps, upper and lower steering columns,
gearbox assembly, column bush, column clamp, track rod ends. Grub screws,
drive shafts silencer assembly (standard system). Primary pipes (4), collector
or catalyst collector, silencer (competition system), catalyst heat
guard, mounting brackets and bobbins, wheel nuts, centre caps,
badges, bell-housing, clutch release mechanism, speed sensor
and threaded adapter, reverse light switch, mounting rubber,
gearknob, front and rear anti-roll bars and fixings, cycle
wingstays, 'A' frame, differential driveshafts and nuts, De Dion
Tube, brake pipes, propshaft
Box 2 Axle (De Dion) Disc pads and callipers, drive flanges, De Dion ears, hub,
bearings
Box 3 Differential Differential assembly
Box 4 Front suspension, Spring damper units, upper and lower wishbones, spring damper
rear suspension units, radius arms/Watts linkage
Box 5 Cooling Coolant hoses, water rail, cooling fan, heater (option on
Superlight), bobbins, expansion bottle and cap, radiator cowling
Box 6 Lighting Headlamp units, headlamp brackets, indicator pods, indicators,
number plate light, reversing light, fog light, side repeaters, horns
Box 8 Interior trim Covered tunnel top, tunnel side carpets, footwell mats, seat back
carpets, hood, hood sticks, boot cover, pulley and cables, throttle

Page | 47
 cable, clutch cable, rear wing protectors, steering wheel, spare
wheel wishbone, seat belts and fixings, tonneau cover, seat
runners, seat spacers, assembly guide, arm restraint, hardware
packs, IVA packs.
Box 9 Weather Hood straps, exterior mirrors, fuel filler cover, hinges
equipment (sidescreen), sill protectors, wiper arms, wiper blades, hardware
pack, mirrors
Box 10 Airbox/air intake Airbox and fixings
system
Own box Uprights Front uprights assemblies inc brakes on uprated uprights
Pallet Engine Complete engine and clutch, engine loom, engine mounting
brackets
Loose Sidescreens
Own box Gear box
Own box Radiator
Loose Exhaust silencer
Loose Wheels and tyres Alloy wheels and tyre assemblies
Loose Seats
Own box Roll over bar
On Chassis/body unit Chassis, battery, body panels, pedals, master cylinder,
Chassis instruments, switches, wiring loom, fuel tank, fuel pump, fuel
lines, ignition module/ECU. Rear wings, front wings, nosecone,
battery, battery clamp/tray, knee trim panels, scuttle trim,
econoseal plugs, steering column plate, grilles (Mesh 7), int panel
trim, keys (ignition, fuel cap, battery master switch), aluminium
tonneau cover, paint touch bottles

Page | 48
Figure 21: Complete kit (less engine)

Page | 49
3.2) Basic definitions Goggles Eye protection
Twist drill bits Metric and imperial
The text in the assembly guide refers to
Crimp pliers
the Right Hand (RH) side or Left Hand
Drill Preferably
(LH) side of the car. For all purposes the
rechargeable
RH side of the car is taken to be the
Axle stand Qty 4
driver’s side of a RH drive car.
Jug/small funnel
Also mentioned in the assembly guide are
the terms inboard (pointing towards the
The tools detailed in Table 8 are not
centre line of the car) and outboard
generally to hand in the amateur
(pointing away from the centre line of the
workshop. These will be required during
car).
the build process.
3.3) Tools and equipment
Table 8: Additional tools and
All kits supplied by Caterham Cars are equipment
specifically designed for the amateur car Item Remarks
builder with basic facilities. Table 7 Engine hoist SWL of 150 kg
details the general purpose tools that will Socket 41mm
be required during the build process. Torque wrench Up to 275 Nm
Cut down allen key Gearbox oil filler plug
Table 7: Tools required
3/8” for 6 speed
Item Remarks 10 mm for 5 speed
Socket set Metric and imperial Durable Dot fastening 76068 – supplied with
Spanner set Metric and imperial tool chassis kit
Screwdriver Flat point (various)
Screwdriver Phillips/posidrive
(various)
Soft faced hammer Rubber/plastic/
copper/hide
Circlip pliers
Torque wrench 0-80 Nm
Allen Keys Metric
Measuring tape
Hacksaw
Rivet gun

Page | 50
The engine hoist should only be required disassembly
for a short time and can usually be Threadlock Loctite Used where the

sourced from a tool hire company. The 41 threadlock application

mm socket and torque wrench will be 242 or 243 prevents the use
of nyloc nuts or
required to tighten the rear hubs to the
spring washers
drive shafts and the cut down Allen key is
Silicone Clear To achieve a
required to tighten the gearbox oil filler
sealant watertight seal.
plug, due to the restricted access in the
It should be
transmission tunnel. The key can be applied sparingly
modified as shown in Fig 22. Masking Duct tape Protection of
tape body
Figure 22: Cut Allen key
Adhesive Contact Carpet/trim

Table 10: Recommended lubricants

Item Ford Sigma Duratec Rover
Engine oil Ford engine oil Caterham
formula E-5W- motorsport
The consumables detailed in Table 9 and 30 oil 5W-50

recommended lubricants detailed in Table Caterham Caterham

motorsport oil motorsport
10 are required during the build process.
5W-50 oil 5W-50

Table 9: Consumables Comma X- Comma X-

TEC 5W-30 TEC 5W-30
Item Type Remarks
semi synthetic semi
Rubber Holts RL2R To ease synthetic
lubricant assembly and Gearbox oil Caterham Caterham Caterham
operation of (5 and 6 gearbox oil EP gearbox oil gearbox oil
rubber bushes speed) 80 grade EP 80grade EP 80
and grommets grade

Copper Comma Anti-seize

grease Copper compound where Item Ford Sigma Duratec Rover
Differential Caterham Caterham
ease lubrication is not
(All) differential oil differential
required to
EP90 oil EP90
ensure ease of
LSD – Lubeguard Lubeguard
future
additive limited slip diff limited slip

Page | 51
 additive diff additive kits. Any unmarked bolt should not be
Brake fluid Comma DOT4 Comma used.
DOT4
Engine Comma Comma Comma Ensure that the correct tightening torque
coolant Xstream red or Xstream red Xstream is applied. Where torque figures are not
ford super plus or ford red
specified, use the figures detailed in Table
anti-freeze super plus
11. Particular care must be taken when
anti-freeze
using the torque wrench to tighten
fastenings into aluminium.
It is recommended that a sturdy
workbench and a good vice are made Table 11: General torque figures

available for holding items stable. Torque

Thread Socket size
(Nm)
The application of undue force should not 1/4” UNF/UNC 7/16” A/F 7
be necessary if assembly is carried out in 5/16” UNF/UNC 1/2” A/F 20
the correct sequence. 3/8” UNF/UNC 9/16” A/F 34
7/16” UNF 5/8” or 11/16”
3.4) Nuts, bolts and washers 47
A/F
As a general rule the fasteners used are 1/2” UNF 3/4” A/F 61
RH thread and of Metric dimensions. 5mm 10mm 6
Some Imperial fasteners are still used, 6mm 11mm 7
particularly within the brakes and 8mm 13mm 20
suspension. 10mm 17mm 47
12mm 19mm 61
Always assume that bolts and fasteners
are not properly tightened until they have
been specifically checked. It is good practice to mark the bolt head or
nut with a spot of paint once it has been
All safety critical fastenings supplied by
finally tightened. This provides a good
Caterham Cars are high tensile
visual means of checking that all fixings
conforming to British Standards 1768
have been set to the correct torque.
(Imperial) and 3692 (Metric). Customers
supplying their own fasteners should only Over tightening can often cause more
use fasteners with heads marked 10.9 problems than under tightening, such as
and 12.9 particularly when attaching sheared bolts and studs and incorrect
suspension, steering, upright and axle stresses.

Page | 52
The majority of fastenings have washers  To prevent migration (sideways
inserted between the nut and or bolt head movement) of rubber bushes.
and the item being secured. Spring  The large plain chamfered washers
washers or lock washers are usually are often used in conjunction with
placed next to the bolt head or nut then the metalistic suspension bushes.
the plain washer. As a general rule the Where this is the case the
following washers are used as detailed: chamfered edge must be fitted
towards the bush to prevent
Plain washer
contact with the outer metal part of
 To protect the surface and spread the bush.
a load when attaching to a soft
Particular care should be taken to ensure
material such as glass fibre or
that the correct fastening is being used,
aluminium.
since it is possible to use an overlong bolt
 To adjust the spacing of one
only to find that it is apparently missing
component to another use plain
when the only remaining bolts are too
washers of appropriate thickness
short.
and external diameter.
 To present a uniform surface on The majority of fasteners supplied by
which to tighten a fastening onto a Caterham are in polythene bags with an
rough or irregular surface. A4 sheet on a card insert, refer to Fig 23.
The A4 sheet can be used to confirm that
Spring washer
the contents are correct. Each pack has a
 To lock a thread where there is a unique number, located at the top RH
possibility of the nut or bolt working corner and each item within the pack can
loose. Not used with a nyloc nut. be identified by a number at the bottom
LH corner of the part number box. Where
fasteners are specified in the text, the
Large diameter, thin plain washer unique pack number will be stated the first
time it is required along with the
 To spread a load onto very thin
description and the Item Identification
material.
number in brackets. The next time an
Large diameter plain washer item from that pack is required it will be
identified by description and the Item
Identification number only, for example:
Page | 53
  Bolt (fastener pack 30P017A
Item 1) identifies the Bolt M8 x 50
mm from the fastener pack
illustrated at Fig 23.
 At a later point in the same section
of text ‘nut (4)’ identifies the M8 nut
from the same fastener pack.

NOTE

Imperial and metric fasteners are supplied

together in some packs. Ensure that the
correct threadform is identified before use.

Page | 54
Figure 23: Fastener pack

Page | 55
3.5) General build information working on the car at different build

Caterham Seven builders should take levels.

care to observe basic safety precautions It is recommended that the chassis is

whilst assembling the kit since tools, parts supported on 4 axle stands which will give
and materials handled incorrectly may stability for both safe working and ready
result in injury. access. Placing of the axle stands is

Due to circumstances beyond the control made easier if assistance is available. Lift

of Caterham Cars, occasionally it is the front of the car and place the axle

necessary to change suppliers and/or to stands at the outer ends of the second

make minor changes to the car or kit chassis cross tube adjacent to the rear

specification. mounting of the lower front wishbone

mounting, refer to Fig 24. If the car is
If it is intended to build the car over a raised using a jack, ensure that it is
short period (up to 4 weeks) it is positioned under the front cruciform and
recommended that an application for the that the powder coat finish is protected.
IVA inspection is submitted as soon as
possible. There is usually a wait of 2-3 Figure 24: Front axle stands

weeks, minimum. In addition it will take up

to a week for the Vehicle Inspectorate to
process the application. Full details about
applying for the IVA inspection can be
found in the IVA section or at
www.directgov.co.uk.

Warning

Never work underneath a car without

supporting it on axle stands or
equivalent. Do not rely on a jack alone.

For IVA inspection you will need

photographic evidence of the car build.
Caterham recommends that you
should take some photos of yourself

Page | 56
The rear axle stands should be positioned
at either end of the chassis tube that
supports the front of the fuel tank, refer to
Fig 25. If the car is raised using a jack,
ensure that it is positioned centrally and
the powder coat finish on the chassis tube
is protected.

Figure 25: rear axle stands

Page | 57
4.0) Steering Figure 26: Steering rack assembly

The following section contains information

on steering rack (standard and wide
track), steering wheel fitments and other
associated tasks.

4.1) Steering rack (standard and wide

rack)

The steering rack should be fitted before

the front suspension. Before fitting the 1. Securing bolt 6. Track rod end
2. Steering rack 7. Securing nut
steering rack it is advisable to protect the 3. Rack clamps 8. Steering arm
4. Nyloc nut 9. IVA cover
outside of the aluminium side panels
5. Locknut 10. Steering rack gaiter
around the circular cut-outs through which
the rack protrudes. Masking tape is
Clamp the rack loosely into place using
sufficient for this purpose.
bolt (fastener pack 30S003A Item 1),
Warning nyloc nuts (8) and rack clamps (3).
Ensure a washer is placed between the
Never work underneath a car without
rack clamp and the nyloc nut. The rack
supporting it on axle stands or
will be tightened later when the steering
equivalent. Do not rely on a jack alone.
column is correctly positioned.
Carefully pass the steering rack through
Fit the IVA cover (polythene bag marked
the circular cut-outs in the side panels
'IVA' to the end of the steering rack arm,
until the machined areas of the rack line
ensure that the larger diameter is
up with the holes in the rack platform.
outboard. Screw the locknut (Figure 26
Ensure that the rack pinion exits the rack
item 5) onto the steering rack arm then fit
on the driver's side of the vehicle.
the track rod end. This should be
The steering rack is held in place by two screwed on 11 full turns (S3) or 13 (SV) to
piece aluminium rack clamps (polythene give an approximate track setting. Do not
bag marked 'steering'). The rack clamps tighten the locknuts.
are matched pairs and clamp the steering
rack into position as they are bolted into
place, refer to Figure 26.

Page | 58
NOTES The front of the pedal box is sealed using
a grommet inserted into the hole through
(1) The IVA covers will need to be
which the steering column passes, refer to
trimmed on one end to fit over the tie rod
Fig 27. The inside of the rubber grommet
ends
should be smeared with rubber lubricant
(2) The IVA covers are secured using to prevent wear.
cable ties. However this should not be
Position the ‘cheese wedge’ (refer to
done at this stage as final adjustment to
Figure 27) on the pedal box, aligned with
the tracking will be required.
the hole for the steering column (it may be
(3) Tracking is adjusted during final necessary to trim the top edge of the
checks. cheese wedge to avoid fouling the clutch
master cylinder). Mark the three hole
4.2) Steering column
positions using the holes in the cheese
The steering column should not be fitted
wedge as a guide. Drill the holes using
until after the engine and gearbox have
1/8” drill bit (it may be necessary to
been installed.
remove the clutch master cylinder for

Remove the lid of the pedal box, refer to access). Apply silicone sealant to the

Figure 27. seating edges of the cheese wedge and

secure the cheese wedge with rivets. Seal
Figure 27: Pedal box
the edges with sealant. Fit the grommet to
the large hole at the rear of the cheese
wedge. Coat the grommet with rubber
lubricant.

It is possible that the cheese wedge has

already been fitted to the chassis.

The lower steering column is inserted,

splined end first, through the dashboard
1 Lower steering column 3Grommet under the brake master cylinder, through
2 Cheese wedge 4 Grommet
sealing box 5 Pedal box the rubber grommet in the 'cheese
wedge', through the pedal box and finally
(Clutch master cylinder and brake pipes
omitted for clarity) through the rubber grommet in the pedal
box sealing plate.

Page | 59
NOTE vertical/horizontal when the steering
wheel is in the straight ahead position.
Engine installation will be easier before
the lower steering column is fitted. Fit the lower end of the universal joint onto
the rack, again clamping with the bolt and
Figure 28: Steering rack to steering
column nyloc nut and tighten both bolts to 11 Nm.
The universal joint should be run as
straight as possible, continuing along the
same angle as the column, the steering
rack can be turned in its blocks to achieve
this.

The upper steering column can now be

fitted.

NOTE
1. Nyloc nut 5. Nyloc nut
2. Bolt 6. Bolt When fitting an optional, quick release
3. Universal joint 7. Lower steering
column the upper steering column bush
4. Steering rack column
can be fitted prior to inserting the upper
steering column into the steering column
Position the front wheels (or uprights) in lock tube.
an approximate ‘straight ahead’ position
The lower column bush will have been
and attach the universal joint (polythene
fitted by Caterham, but care must be
bag marked 'steering') using bolt (3) and
taken when sliding the upper steering
nyloc nut (7) noting how the bolt locates
column down through the dashboard.
into the machined groove in the splined
Ensure that the lowest portion of upper
end of the lower steering column.
steering column is liberally coated with
NOTE grease and minimum force is exerted.
Telescope the upper steering column over
If insertion is difficult the universal joint
the lower steering column.
can be opened up by inserting a flat blade
screwdriver into the split and twisting. To Slide the upper steering bush onto the
ensure linearity of response it is column and into the dash tube. Note how
recommended that the yoke of the the raised rubber locators on the bush fit
universal joint is positioned with the cross in the holes in the dash tube.

Page | 60
To ease fitment lightly coat the upper NOTE
steering bush with rubber lubricant.
Before tightening the clamp:
Figure 29: Upper steering column
clamp Fit the steering wheel boss onto its spline
to ensure that the steering wheel boss
does not foul the dashboard. Slide the
steering column/steering wheel boss away
from the dashboard to achieve clearance.

Check that the lower steering column

does not foul the drive belt tension
mechanism on the engine. If necessary
1. Locknut 4. Securing bolts
rotate the steering rack in its clamps to
2. Upper steering 5. Lower steering
provide clearance.
column column
3. Clamp 6. Grub screw Tighten the steering rack clamps
to 11 Nm. Ensure that the two bolts
securing the steering column lock tube to
the scuttle face are tight.
The two parts of the steering column are
clamped together using the locking clamp,
make sure the cut out faces the column,
refer to Fig 29. Insert the grub screw
loosely into the clamp. Secure the two
halves of the clamp using two bolts (2),
plain washers (10) and spring washers
(11). Torque to 14 Nm. Tighten the grub
screw with an Allen key to eliminate any
free play in the steering. Lock the grub
screw into place using locknut (6).

Page | 61
4.3) Steering wheel fitment 4.3.2) Momo

Two makes of steering wheel are Loosely fit the mounting boss to the
available. Both the Motolita and the Momo steering wheel using the 6 mm x 16 mm
wheel have a horn button mounted on the countersunk Allen bolts. Centre the road
dashboard. Each steering wheel has a wheels to establish the straight ahead
different type of mounting boss. It is position of the steering wheel. Place the
recommended that the fitting of the steering wheel and boss over the splines
steering wheel is left until the entire in the straight ahead position. Remove
interior trim, including seats, has been the wheel and secure the boss to the
completed. column using nyloc nut (4) and washer
(9). Finally re-secure the wheel to the
4.3.1) Motolita
boss using the fixing provided.
Figure 30: Steering Wheel - Motolita
4.3.3) Quick release column

The Quick Release (QR) column has a

keyway in the QR boss and the steering
wheel must be centred by removing the
upper bolt on the lower steering column
universal joint, withdrawing the column
1. Steering wheel 4. Fixing screw and then turning the steering wheel and
2. Steering column 5. Wheel centre column to the straight ahead position. Re-
3. Mounting boss engage the column to the universal joint,
re-insert the bolt and tighten the securing

(IVA pad omitted for clarity) nyloc nut to 20 Nm.

Release steering lock and centre the road Ensure that the steering wheel can be
wheels to establish the straight ahead rotated smoothly with no tight spots.
position. Fit the steering wheel over the Tighten the steering rack clamp bolts and
steering column splines. Fit the steering column universal joint
washer (9) and secure the steering wheel bolts/nylocs to the torque figures specified
to the steering column using nyloc nut (4) in Table 12.
and tighten.

Page | 62
Table 12: Steering component torque
figures
Location Washers Nut Torque
Steering rack Plain under Nyloc 11 Nm
clamps bolt head
Universal None Nyloc 20 Nm
joint
Column Spring and Bolt 14 Nm
clamp plain under
bolt head

4.4) Associated tasks

Whilst the pedal box lid is removed, fit the

brake light switch harness and the throttle
cable.

NOTE

Before refitting the pedal box lid, check

that the pedal positions are acceptable
and that the brake switch operates
correctly. Adjust as necessary.

Refit the pedal box lid ensuring that the

brake pipes are not trapped or kinked and
that the ‘P’ clips are secured under the
pedal box lid screws.

Page | 63
5.0) Front suspension Figure 31: Bodywork protection

The following section covers the assembly

and installation of all areas of the front
suspension for your kit.

5.1) Preparation

It is recommended that the front wings are

not fitted until the front suspension is
assembled and the engine installed. This
reduces the risk of damage to the wings
and maintains easy access to the engine
5.2) Lower wishbones
bay.
Warning
It is recommended that the steering rack
Never work underneath a car without
is fitted before assembling the front supporting it on axle stands or
suspension, refer to Section 3. equivalent. Do not rely on a jack alone.

When assembling the front suspension, The lower wishbones are assembled with

there is a risk that the aluminium body the longer leg forward and the bearing

skin can be damaged, especially when retaining circlip facing downward.

fitting the top mounting bolts and the NOTE

spring damper units. It is therefore
advisable, particularly with painted cars, to Ensure that the circlip is correctly located

protect the bodywork with 2 or 3 layers of in the retaining groove prior to assembling

masking tape in key areas. It is the lower wishbone.

recommended that the bodywork under Fit the rear leg of the lower wishbone
the front bonnet catches is protected through the slot in the bottom skin
using card and masking tape, refer to immediately behind the vertical chassis
Figure 31. member. Secure using bolt (Fastener

Apply a thin coat of copper grease to all pack 30F015A Item 1) and nut (7) and

fixings prior to fitment (avoid inserting two plain washers (9) either side

contaminating any threads where Loctite of the wishbone refer to Fig 32.

is to be used).

Page | 64
Figure 32: Washer usage - lower OD x 35 mm (polythene bag marked 'front
wishbone (LH side)
suspension'), must be inserted into the
rear bush. The rear leg of the upper
wishbone, refer to Figure 33, is secured to
the rear mount using bolts (3) inserted
from the front of the mounting. The
spacer bush must be coated with copper
slip. The bolt is secured with a nut (8).
Do not tighten fixings.

1. Bolt 5. Nyloc nut Figure 33: Upper wishbone securing

2. Spring washer 6. Rear chassis mount
3. Plain washer 7. Bolt
4. Front chassis 8. Lower wishbone
mount

The front leg of the lower wishbone is

secured to the front of the chassis using
bolt (2), with washer (9) and spring
washer (12) next to the bolt head. Two
washers (9) are inserted between the
wishbone and the chassis, refer to Figure 1. Headlight bracket 4. Upper wishbone
32. 2. Headlight bracket 5. Spring damper unit
mounting
On wide track models there should be no 3. Upper wishbone 6. Upper wishbone
washers between the front mount and the front mount rear mount
chassis and 4 washers between the
chassis tube and the rear mount of the
The front leg of the upper wishbone is
lower wishbone.
secured to the front mount using bolt (4).
5.3) Upper wishbones Prior to inserting the bolt the headlight
The upper wishbones are handed and are bracket must be inserted over the chassis
assembled with the longer leg facing the mount. Before fitting the headlight bracket
front of the car. Prior to locating the upper assemble the headlight assembly to the
wishbone a spacer bush 10 mm ID x 1/2" bracket see page 164.

Page | 65
Ensure to fit a rubber grommet in the hole An aluminium spacer 8 mm id x 1/2”
in the bracket before assembly. od x 32 mm must be coated in copper slip
and inserted into the lower mounting bush
Since access to the upper and lower
of the spring damper unit. The spring
wishbone mountings are restricted by
damper unit is secured using an M8
other components installed later in the
caphead bolt (supplied in wishbone) which
build process the mounting fasteners must
passes through the rear leg of the lower
be fully tightened at this point. Hold the
wishbone through the aluminium spacer
wishbones horizontal and tighten the
bush and into a captive thread on the front
upper wishbone mounting bolts/nuts to 34
leg. This bolt should be torqued to
Nm and the bottom wishbone to 81 Nm.
20 Nm.
NOTE
NOTE
Check that there is an equal amount of
Do not tighten any other fixings at this
exposed threads between the locknut and
stage
ball joint, this should be adjusted to eight
threads for normal road use 5.5) Upright attachment

5.4) Spring damper units Warning

An aluminium spacer bush 8 mm id x 1/2” Correct use of fixtures is required to

od x 32 mm (polythene bag marked ‘front ensure full engagement of the nyloc
suspension’) must be coated in copper nut.
slip and inserted into the top mounting
Remove and retain the upper wishbone
bush of the front spring damper unit. The
ball-joint nyloc nut and the nyloc nut from
spring damper is secured to the top
the bottom of the upright assembly. The
mounting by the M8 cap head bolt
upright assembly must be mounted with
supplied in the chassis with a spring
the steering arm facing forward. Mount
washer (13) under the bolt head. This bolt
the upright assembly as follows:
should be torqued to 20 Nm.
NOTE
NOTES
The upright assemblies are marked RHS
It is necessary to gently press the body
or LHS on the inside of the assembly.
panel inwards to allow sufficient clearance

for the bolt to be located.

Page | 66
5.5.1) Standard Pass the top wishbone ball-joint down
through the top of the upright and through
The upright is located into the spherical
the wingstay. To fully engage the tapers of
joint on the lower wishbone and secured
the wishbone and ball-joint, fit the M14
using the retained 1/2” nyloc nut. Tighten
plain nut (6) from the fastener pack, apply
the nyloc nut to 55 Nm.
pressure to the top of the ball-joint and
tighten the plain nut. Once the ball-joint is
Warning locked in place remove the plain nut and
replace it with the nyloc supplied on the
Correct use of fixings is required in
order to ensure full engagement of the ball-joint. Tighten the nyloc nut to 54 Nm.
nyloc nut.
5.5.2) Wide track Tighten the inner stub axle nut to 82 Nm
and ensure that the upright turns freely on
The upright is located into the spherical
the wishbones.
joint on the lower wishbone. Prior to
locating the upright, a spacer located in Remove and retain the nyloc nut from the
the polythene bag marked ‘front track rod end. Remove and discard the
suspension’) must be inserted onto the hard plastic boot protector from the track
bottom of the upright. The upright is rod end taper and pass the tapered shaft
secured using the special turned down down through the steering arm on the
nyloc nut supplied. Tighten the special upright, secure with the nyloc nut. Tighten
nyloc nut to 55 Nm. nyloc nut to 34 Nm.

The cycle wingstay locates on the upright. Your front suspension should now
Remove and discard the 1/2” UNF nyloc resemble that shown in Figure 34. (IVA
nut and plain washer fitted to the inner covers not shown)
end of the stub axle. Place cycle wingstay
over the stub axle and secure using the
1/2” UNF nyloc provided. Do not tighten.

NOTE

If uprated front brake callipers have been

specified ensure that the brake pads are
installed before fitting the cycle wingstays.

Page | 67
Figure 34: Front suspension and around so they will align with the
holes drilled in the front face of the
chassis tube.

The rubber boots should be slid over the

anti-roll bar, ensuring that the larger
diameter of the rubber boot is outboard.
Apply Loctite to the threads at each end of
the anti-roll bar and fit the plastic balls,
tighten using protected grips.
1. Cycle wingstay 4. Lower wishbone
Liberally coat the balls with bearing
2. Anti-roll bar 5. Spring damper unit
3. Inner radiator 6. Upright assembly
grease. Assemble the anti-roll bar onto

cowl the chassis by pushing the plastic balls,

one at a time, into the mounting cups in

5.6) Front anti-roll bar the upper wishbones. Fit the spring
washers (13) to the bolts (5) and pass
Notes
forward through the vertical chassis tubes
(1) On R400 the inner radiator cowl is located and into the captive nuts on the mounting

inboard of the anti-roll bar and must be fitted first,brackets. Tighten to 20 Nm.

refer to section 6. Sigma 125/140 does not have The rubber boots are slid over the
mounting cups and secured to the top
radiator cowling.
wishbone using cable ties which fit into
(2) Check that the colour of the bushes the grooves provided. A further cable tie
corresponds to the colour marked on the is used to hold the boot onto the anti-roll
front anti-roll bar. bar itself with the tails of the cable tie
being cut off underneath for neatness.
The anti-roll bar is attached to the front of
the chassis using the special mounting NOTE
brackets and cotton reel shaped bushes
All connections should initially be made
(supplied in the polythene bag marked
finger tight
‘front suspension’). Liberally coat the
bushes with rubber lubricant and fit the
bushes into the brackets. Slide the
brackets over the ends of the anti-roll bar

Page | 68
5.7) Front brake hoses large copper washer is placed next to the

Three stainless steel braided brake hoses bolt head and smaller copper washer

are supplied, two of equal length for the placed between the banjo union and the

front brakes and one of longer length for calliper, refer to Fig 36. Do not over

the rear brakes. tighten. Torque to 10 Nm.

Attach the inner, threaded end of each Figure 36: Standard calliper

brake hose through the hole in the

aluminium body. A plain washer (fastener
pack 30F015A item 11) should be fitted
directly next to the aluminium body on the
outside. Secure using the 3/8” nut and
shake proof washer (14). The shake
proof washer must be between the nut 1. Banjo bolt 4. Banjo union
and the inside panel. Do not tighten. 2. Large copper 5. Braided brake
washer hose
Figure 35: Brake pipe union
3. Small copper
washer

5.6.1.2) Uprated calliper

On the uprated brake calliper the braided
brake hose has a female union at the
calliper end, refer to Fig 37. The braided
hoses are supplied with an adaptor that
screws into a threaded drilling inboard of

1. Female pipe union 3. Shakeproof washer

the calliper body. The adaptor must be

2. Plain washer fitted with the tapered end outward, this

provides the seal between the adaptor
and the braided brake hose female union,
The outer end should be attached to the and a copper washer between the adaptor
brake calliper as follows: and the brake calliper. The female union

5.6.1.1) Standard calliper on the braided hose screws directly to the

The outer end is attached to the brake adaptor. Do not over tighten. Torque to

calliper using the banjo bolt provided. The 10 Nm.

Page | 69
Figure 37: Uprated calliper Table 13: Front suspension torque
Figures
Location Washer Torque
Sub axle 81Nm
Damper to lower N/A 20Nm
wishbone (lower
fixing)
Damper to N/A 20Nm
chassis (top
fixing)
1. Copper washer 3. Braided brake hose Front anti-roll bar Spring under 20Nm

2. Female union 4. Adaptor fixing head

Upright top ball- None 54Nm
joint
Located on the inside of the body are the Upright – bottom Spacer – wide 54Nm
track only
female unions, refer to Fig 35, on the end
Location Washer Torque
of the brake pipes from the brake master
Upper wishbone 34Nm
cylinder. Fix the female union to the
Lower wishbone Spring under 81Nm
braided brake hose connection and front head then plain
tighten to 10 Nm. Tighten the locknut to as shown in

10 Nm. Figure 2.
Lower wishbone Plain spacers as 81Nm
Turn the steering from lock to lock and rear shown in Figure

ensure that the braided brake hoses do 2.

not foul on the suspension. If fouling is

observed remove the braided brake hose
5.9) Cars fitted with adjustable damper
from the calliper and twist the hose platform
through 180. Refit the braided brake Cars fitted with adjustable damper
hose to the calliper and tighten unions to platforms need to be adjusted to achieve
10 Nm. the optimum ride height. This is done by
lowering or raising the height of the
5.8) Final tightening
platforms on the threaded sleeve. It is
All the remaining fixings should be
essential that this task is carried out on
tightened according to Table 13.
level ground.

Page | 70
NOTE

Lowering the platforms will decrease ride

height, and raising the platforms will
increase ride height. For the best results
the ride height should be set with the
driver in the car and fuel in the tank.

1. Start by adjusting the front dampers to

achieve a minimum distance of 150 mm
(this can be increased for road use to a
maximum of 190 mm) between the ground
and the bottom of the lower chassis rail,
where the rear leg of the front lower
wishbone exits the side of the car. This
measurement should be the same on both
sides with the car loaded.

2. Now adjust the rear dampers in the

same manner to achieve a height 15 mm
higher than the front, measured to the
underside of the lower chassis rail
immediately in front of the 'A' frame
mounting point.

NOTE

Adjusting the rear may have an effect on

the front therefore it is good practice to
check between front and rear several
times during adjustment

3. Once the desired ride heights have

been set ensure that the platforms are
locked together to avoid movement.

Page | 71
6.0) Fitment of gearbox to engine ring. Using the four cap-head bolts
(fastener pack 36G006A Item 9) and
The following section details the assembly
spring washers (12), bolt the bell-housing
of the 5 and 6 speed gearbox.
to the gearbox from the inside. Tighten the
6.1) Assembly of gearbox kit – 5 and 6- bolts to 47 Nm.
speed.
Duratec: Do not remove bell-housing,
Both the 5 and 6-speed gearboxes are
smear silicone sealant over the O ring and
interchangeable and utilise all the same
place around the selector rod. Using 4
ancillaries. Assembly is identical for both
M10x35 bolts with spring and plain
5 and 6-speed gearboxes with the
washers supplied in the gearbox pack bolt
exception of the sealing method for bell-
from the outside and torque to 35Nm.
housing to gearbox.

New 2014 5 speed Caterham gearbox.

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

5-Speed Sigma. Smear the gasket on

both sides with silicone sealant and
position on the bell-housing. Using the
four cap-head bolts (fastener pack
36G006A Item 9) and spring
washers (12), bolt the bell-housing to the
gearbox from the inside. Tighten the bolts
to 47 Nm.
Fit the clutch release bearing before the
Duratec: Remove the bell-housing from gearbox
the engine, smear the gasket with silicone
There are no gaskets on this gearbox
and position on the bell-housing. Using 4
either between the gearbox and bell-
M12x70 bolts supplied and 4 spring
housing or the bell-housing and engine.
washers from pack ZGB14 and bolt from
the inside and torque to 47Nm Bolt the gearbox to the bell-housing using
the 4M12x70 bolts with a plain washer
6-Speed. Apply a thin layer of silicone
from the inside. Tighten bolts to 47Nm
sealant to the front face of the gearbox
and to the 'O' ring around the selector rod.
Ensure sealant is applied to the entire 'O'

Page | 72
 Apply RTV silicone gasket sealant to the
speedo output shaft opening on the RH
side of the gearbox and insert the small
plug supplied, refer to Figure 40.

NOTE

Loosen gearbox filler plug. NOTE

All Duratec models have the bellhousing The plugs are a drive fit and are installed
pre-fitted to the engine, so fixing pack closed end first the plugs only apply to 6
36G006A is not required. speed gearboxes.

Place the clutch release mechanism in New 2014 5 speed Caterham gearbox.
position in the bell-housing and secure
The clutch slave cylinder is bolted on
using the three cap-head bolts (7) and
using 3 M6x25 with spring and plain
spring washers (13), refer to Figure 38.
washers, tighten to 10Nm. Make sure the
Figure 38: Clutch actuation mechanism braided steel clutch hose is fitted before
you bolt the bell-housing to engine.

Figure 39: Speedo drive plug

1. Clutch release bearing

2. Hydraulic connection

1. Gearbox
Apply silicone sealant to the speedo drive 2. Plug
opening on the LH side of the gearbox 3. Gearbox mounting
and insert the large plug supplied, refer to
Figure 39.

Page | 73
Figure 40: Speedo shaft plug

1. Gearbox
2. Plug
Bolt the metal/rubber/metal gearbox
mounting, chamfered edge forward, refer
to Fig 39, to the underside of the tailshaft
The gearbox mount can only be fitted
housing using one bolt (8) and spring
once the engine and gearbox are in the
washer (12). Tighten to 61 Nm.
car and before the engine mounts are

New 2014 5 speed Caterham gearbox. fitted. Using 2 M14x40 bolts with a plain
washer and thread lock bolt the mount to
the gearbox, with the cut out facing the
front, tighten to 40Nm,

Using 4 M8x40 caphead bolts with a plain

washers and nyloc bolt the mount to the
chassis, tighten to 20Nm, bolts can be
found in pack 3EZ1105

6.2) Fitting gearbox to engine

Slide the gearbox into place on the rear of

the engine. It may be necessary to rotate
the gearbox assembly in order to line up
the gearbox first motion shaft splines with
the splines of the clutch plate.

Page | 74
Using the fixings supplied, connect the Tighten all starter motor and bell-housing
engine and gearbox; two bolts (2) and the bolts to the torques specified in Table
spring washers (10), pass forward from 14.
the top of the bell-housing into the cylinder
New 2014 5 speed Caterham gearbox.
block, two more bolts (2) and spring
washers, pass forward from the bottom of Install the starter motor into the front of
the bell-housing into the sump. Two bolts the bell-housing and secure with 3
(1) and spring washers pass rearward M10x60 cap head bolts and spring
through the 'ears' on the engine assembly washers.
and into the bell-housing on the RH side,
Tighten all starter motor and bell-housing
one further bolt (1) and spring washer
the bolts to the torques specified in Table
passes forward from the LH side of the
14.
engine into the bell-housing.
Table 14: Gearbox torque figures
New 2014 5 speed Caterham gearbox.
Fixing Torque
Slide the gearbox into place on the rear of Bell housing to gearbox 47Nm
the engine. It may be necessary to rotate Gearbox rubber mounting to 61Nm
the gearbox assembly in order to line up tailshaft housing

the gearbox first motion shaft splines with Engine to bell-housing 47Nm

the splines of the clutch plate. Bell-housing to sump 20Nm

Starter motor 34Nm
To bolt the bell-housing to engine from the
front of the engine looking back from the
top right going clockwise M10x40,
M10x55,M10x55,M10x60, M10x45, M10
x55 and M10x40 all with spring washers.
Tighten to 35Nm

6.3) Starter motor

Install the starter motor into the front of

the bell-housing and secure with 3
M10x55 cap head bolts and thin spring
washers.

Page | 75
7.0) Installation of engine and plastic tubing in hot water to soften in

gearbox order to make fitting easier.

Route the clear washer tubing along the

The following section details the
wiring loom behind the dashboard and
installation of the engine and gearbox for
attach using cable ties, to prevent it falling
your kit. The Sigma, Duratec 175
down into view. Pass it down through the
(R300)and Duratec R400engines are
large grommet in the top of the
detailed separately. Please refer to the
transmission tunnel and along the engine
relevant section.
bay diagonal tube until in line with the
7.1) Sigma engine washer bottle. Trim the tube to length and
7.1.1) Preparation attach to the washer motor.

The special tools detailed in Table 15 Connect the washer motor to the wiring
bellow will be required for this section. loom via the two pin plug adjacent to the
washer bottle mounting. To ease fitment
Table 15: Special tools required for
sigma engine of the two pin plug the washer motor can
Item Description be removed from the washer bottle, the
Engine hoist and sling SWL of 150 Kg two pin plug fitted and the washer motor
(min) reinserted into the washer bottle.

The windscreen wipers must not be

fitted until the wiper motor has been
7.1.1.1) Screen wash/wipe
run and allowed to park in order to
NOTE
prevent damage to the paintwork. Fit the
The bracket for the washer bottle must be wiper arms so that they are horizontal
fixed to the front of the passenger side when parked. The wiper arms must move
foot box before the engine is installed. smoothly through their range of travel.

Remove the securing nut from the base of

the washer jet and pass the washer jet
NOTE
through the hole in the centre of the
scuttle and secure with the plastic A small amount of water splashed on the
securing nut. Fit the clear plastic tubing to windscreen will prevent the wiper blades
the washer jet. Dip the end of the clear from juddering during test and adjustment

Page | 76
7.1.1.2) Engine preparation 7.1.1.3) Chassis preparation
The large diameter pre-formed 'U' hose Protect the appearance of the engine bay
should be fitted onto the aluminium water chassis tubes and pedal box sides and
outlet located on the rear of the cylinder edges by covering with card and/or
head, and the rear aluminium water rail, masking tape.
you will need to cut this pipe to length,
Ensure that all wires and connector plugs
refer to Figure 41. Apply rubber lubricant
are secured and will not snag or catch the
to the ends of the hose and push over the
engine/gearbox as it is lowered.
outlets; Secure using a hose clip
(Fastener pack 'cooling' 30C047A). NOTE

Figure 41: Water rail and 'U' hose Before fitting engine mounting rubber
blocks ensure that the large threaded
(1/2" UNF) boss in the centre is clear of
rubber and that the bolt will thread in
cleanly.

Fit the engine mounting rubber block to

the RH side of the engine bay. The two
bolts (fastener pack 30P012A Item 3),
plain washer (12) are passed downwards
1. Engine connection through the mounting, through the chassis
2. ‘U’ hose
and are secured with nyloc nuts (9) and
3. Water rail
plain washers (12). Do not tighten.
Remove and retain the gearbox filler plug.
Removal of this plug is not essential; Fit the engine mounting rubber block to
however access is restricted within the the LH side of the engine bay, locate the
confines of the transmission tunnel. It is engine earth lead (a black earth lead
easier to fill the gearbox up before you put approximately 300 mm long supplied
it into the car. Remove the plastic plug loose in a box), pass bolt (2) and washer
from the gearbox tailshaft housing once (12) downwards through the lead, through
the engine and gearbox are in the the front hole of the engine mounting
chassis, the plug will hold the oil in the block, through the chassis and secure
gearbox while you fit it. with nyloc nut (9) and plain washer (12).
Remove a little paint from the

Page | 77
chassis/mounting to ensure that a good Tighten the 13 mm nut in the centre of
electrical contact is made. Pass bolt (3), each horn and connect the horns to the
plain washer (12) downwards through the electrical harness by the purple and
rear hole of the engine mounting block, yellow wires and connectors located
through the chassis and secure with above the horns on the front upper cross
nyloc (9) and plain washer (12). Do not member.
tighten. (Other end of the earth lead
7.1.2) Installation of engine/gearbox into
needs to be connected to engine through
chassis
engine mount after engine installation).
Warnings
Locate the twin electric horns on the two
studs near the rear edge of the steering 1. Never work underneath a car without

rack platform. Before fitting the horns, supporting it on axle stands or

loosen the 13 mm nut in the centre of equivalent. Do not rely on a jack alone.

each horn, this will allow rotation of the 2. Use appropriate eye protection
horns so that the electrical connections whilst working under the car.
are closer together.
3. Care should be taken while dropping
Secure the horns with the nyloc nuts the engine into the chassis to avoid
(fastener pack 30P012A item 10) and any damage to engine component or
ensure that it is not possible for the horns wiring.
to come into contact with each other, the
steering rack or other components in the Using the lifting hoist and sling detailed in

engine bay refer to Figure 42. Table 15, attach the engine/gearbox using
the lifting eyes provided on the engine,
Figure 42: Horn location lower the engine/gearbox assembly into
the engine bay at an angle of between 30-
40 (with the engine higher than the
gearbox). Insert the gearbox assembly
into the transmission tunnel.

Continue to slide the engine/gearbox

rearward until the holes in the gearbox
mounting line up with the holes in the
chassis cross member. If the differential

Page | 78
and propshaft have already been fitted, gearbox to contact the chassis under
ensure that the propshaft locates into the cornering.
gearbox tailshaft housing.
Bolt the gearbox mounting rubber to the
Attach the LH engine mounting using the chassis using bolts (fastener pack
two M8 x 25 mm bolts (fastener pack 30P012A Item 4) passed down through
36G006A Item 4) and one M8 x 30 mm the outer metal part of the rubber
bolt (5), use spring washer item (11) for mounting and then through the elongated
each bolts. Connect the other end of the holes in the chassis. Secure with a plain
earth lead through one of the engine washer (12) and nyloc nut (9) on each bolt
mount fixings. Do not tighten the bolts. and tighten to 20 Nm.

Attach the RH engine mounting using the Finally tighten the fixings detailed in
two M8 x 35 mm bolts (6) and two M10 x Table 16.
40 mm bolt (2),use spring washer item (10
Table 16: Gearbox installation torque
& 11 ) for each bolts, Do not fully tighten figures for sigma engine
the engine mounting retaining bolts until Fixing Torque
advised later in this section. Engine mounting to block 25Nm
Engine mounting to mounting 41Nm
Lower the engine onto the rubber engine
rubbers
mountings and pass the bolts (fastener
Engine mounting rubbers to 20Nm
pack 30P012A Item 1 (LHS) and 21
chassis
(RHS)) down through the tube on the
Gearbox mounting rubber to 20Nm
outer end of the engine mounting
chassis
brackets. Screw the bolts loosely into the
threaded bush in the centre of the rubber
engine mounting. It is recommended that
the engine is not removed from the hoist NOTES
until all the bolts have been tightened
(detailed later in this section). 1. It is now safe to remove the engine
hoist.
Adjust the gearbox on its slotted
mountings to achieve equal clearance 2.Wiring – Every effort is made to clearly

within the transmission tunnel. This must explain and identify all the electrical

be checked carefully as clearances are connections as you go through this

tight and poor alignment can cause the section; however the loom fitted to your

Page | 79
car may have additional wires and
connectors that are not required on your
vehicle. To help clarify this, a wiring
diagram can be found in the electrical
section.

Fit the gear lever to the top of gearbox

tailshaft housing and secure with three
setscrews (7). No washers are required;
tighten to a torque of 20 Nm.

Fit the reverse light switch (polythene bag)

into the side of the gearbox. This can be
accessed via the hole in the RH side of
the transmission tunnel. The switch
should be inserted finger tight and then
tightened a further quarter of a turn using
a suitable sized spanner. Connect the
The gear lever can only be inserted one
wiring loom to the reverse light switch.
way, make sure the lower bush is seated
From the cockpit, insert the large grommet
correctly and bolt down with 3 M6x12
(polythene bag) to cover the access hole
button head screws to 11NM, these can
in the transmission tunnel.
be found in 3EZ1105
New 2014 5 speed Caterham gearbox.
7.1.3) Electrical connections
The reverse light switch has already been
The engine wiring loom is already
fitted to the gearbox, just connect the two
attached to the engine and some
connectors to the connectors in the main
ancillaries, however it is necessary to link
wiring harness in the tunnel.
the engine wiring loom to the remaining
ancillaries and the vehicle wiring loom. All
the plastic connecting plugs are matched
pairs so it is not possible to connect them
incorrectly.

Page | 80
Figure 43: ECU and MAP unit The two, paired, black/yellow wires with
ring terminals in the engine loom are earth
connections. Attach both pairs to a
suitable earth point on the bulkhead.

The green, green/purple pair (with

grommet) in the engine loom is for the
brake light switch. The brake light switch
is inside the drivers pedal box and the
harness may be connected during
installation of the steering column. Pass
1.Fuel pipe connection 4. ECU
the brake light switch harness through the
2. MAP unit 5. Air filter
hole in the rear of the pedal box, refer to
3. Multi-pin plug
Fig 44 and push the two female
connectors onto the male connectors of
The ECU and MAP unit are already fitted. the brake light switch (orientation is not
important). Fit the grommet into the hole
Connect the green 3-pin plug on the
and ensure that the harness will not foul
engine loom to the connection on the
the steering column or pedals.
MAP unit. Connect the short pipe on the
MAP unit to the corresponding connection
on the throttle body using the rubber
Figure 44: Brake light switch harness
vacuum hose provided (125 only).

Connect the black wire from the vehicle

loom to pin 16 in the ECU plug (140 only)

The ECU for the Academy is already fitted

under the battery. The MAP unit is
positioned on the passenger footbox.

Connect the oil pressure switch from the

LH side of the engine block to the
connector from the main loom which can 1. Brake light switch 4. Sealant
2. Cheese wedge 5. Brake light
be found clipped to the outside of the
3. Grommet 6. Switch harness
passenger foot box.

Page | 81
The longest wire from the engine loom 7.1.4) Fuel system
(terminating in a 4-pin plug) is the The black, corrugated plastic, high
connection for the exhaust mounted pressure fuel pipe from the fuel pump
lambda probe. This cannot be connected emerges from the transmission tunnel and
until the exhaust primary pipes and is a push-fit on the white elbow connection
collector/catalyst is fitted. at the rear of the fuel rail, refer to Fig 45.

Remove the outermost Bell housing Note that there is no fuel return pipe with

securing bolt and spring washer. Pass this system

the Bell housing mounting bolt and Figure 45: Fuel pipe connection
attached spring washer through the black
battery earth lead and secure to the bell-
housing. Tighten to 34 Nm.

Connect the red lead from the starter

motor to the battery. Also connect the
black lead on the main vehicle loom to the
starter motor on the same terminal.

NOTE

If a battery master switch is fitted, there

will be two red leads; one goes to the
1. Fuel rail connection
battery, the other to the starter. The brown
2. Fuel pipe (from pump)
lead is already connected.
Once fitted the pipe cannot be removed

Connect the brown lead from the without a special tool. Ensure that the pipe

alternator to the starter. is kink free and routed away from possible
snags or chafe points. Remove the red
Connect the brown/red wire (covered with
protective cover and push the connection
black insulation) from the chassis loom to
on the pipe firmly onto the elbow and
the starter solenoid.
check that it is securely attached. Secure
NOTE the pipe with cable ties if necessary.

Make sure the leads are not touching to 7.1.5) Clutch hydraulic hose
any surrounding metal component. Remove all packaging from the clutch
hydraulic hose. Fit a copper washer to the
Page | 82
banjo bolt and pass the banjo bolt through Figure 47: Clutch hydraulic hose
the union at the end of the hose, refer to
Fig 46. Fit the second copper washer to
the banjo bolt and screw the banjo bolt
into the clutch master cylinder outlet port
(remove the port plug). Do not fully tighten
the banjo bolt.

Figure 46: Clutch master cylinder hose

union

7.1.6) Exhaust systems

The standard exhaust system consists of

four primary pipes, a collector assembly
which also incorporates the catalytic
converter and a one piece silencer and tail
pipe.
1. Banjo bolt 3. Hose union
2. Copper washers 4. Clutch master Bolt the exhaust mounting bracket
cylinder (polythene bag marked 'exhaust') to the
Route the hose down the side of the pedal RH side of the car forward of the rear
box, over the wiring loom (under the wheel, using setscrew (fastener pack
heater hose if fitted) and across the top of 30X020A Item 1) and spring washers (3),
the bell-housing, Refer to Figure 47. Push refer to Figure 48. Secure the bobbin to
the end of the hose into the connector in the angle bracket with a nut (2) and spring
the clutch release bearing assembly and washer (3).
ensure that the hose is firmly attached.
Secure the hose with cable ties if
necessary, to prevent chafing and tighten
the banjo bolt (the clutch system is filled
and bled during start-up/final checks.

Page | 83
Figure 48: Exhaust mounting 1. Pass the flanged end of # 4 pipe
inwards, attach the flange loosely to the
cylinder head and ensure that the pipe sits
in the bottom LH corner of the aperture
(viewed from outside).

2. Pass the flanged end of # 1 pipe

inwards, attach the flange loosely to the
cylinder head and ensure that the pipe sits
in the top RH corner of the aperture.

1. Angle bracket 4. Bobbin 3. Pass the plain end of # 3 pipe

2. Spring washer 5. Nut outwards, attach the flange loosely to the
3. Setscrew cylinder head and ensure that the pipe sits
Remove the exhaust gasket and in the bottom RH corner of the aperture.
associated fasteners from the RH side of
4. Pass the plain end of # 2 pipe
the cylinder head, remove any masking
outwards, attach the flange loosely to the
tape protecting the exhaust ports and
cylinder head and ensure that the pipe sits
clean off any adhesive residue.
in the top LH corner of the aperture.
The S3 exhaust primary pipes are marked
NOTE
with their part numbers:
For SV use the same procedure to fit the
36X014A is for # 1 (front) cylinder
primary, the sequence to fit the primary is
36X015A is for # 2 cylinder. 4,3,1,2.

36X016A is for # 3 cylinder. 56X005A is for #1(front) cylinder.

36X017A is for # 4 (rear) cylinder. 56X006A is for #2 cylinder.

Protect the area around the square 56X007A is for #3 cylinder.

aperture in the side panel with masking
56X008A is for #4 (rear) cylinder.
tape and card, place the exhaust gasket
over the remaining studs and fit the When the primary pipes are in place fit
primary pipes in the following sequence: any remaining fasteners but do not tighten
them.

Page | 84
Install the collector/catalyst over the NOTE
assembled primary pipes with the
The lambda probe wiring passes under
threaded hole for the lambda probe faces
the side of the car below the lower chassis
towards the side panel. Secure the
tube, it must not be routed through the
collector to the primary pipes with the two
primary pipe aperture in the side panel.
springs, refer to Figure 49. Support the
weight of the collector such that the Figure 50: Lambda probe connection
primary pipes are not in contact with the
sides of the aperture and tighten the
primary pipe/cylinder head fasteners to 34
Nm.

Figure 49: Primary pipes and

collector/catalyst

Undo the large worm drive clips and feed

them through the channels on the inside
of the collector/catalyst guard. Fit the
silencer guard to the silencer body with
1. Primary pipe the channels offset towards the rear of the
2. Collector/catalyst (guard fitted) silencer and tighten the clips, refer to
Figure 51. Ensure that the clip drives are
not at the bottom of the silencer where
Fit the Lambda probe into the threaded
they could contact the road. Attach the
hole in the collector/catalyst and connect
collector/catalyst guard in the same
the probe plug to the corresponding
manner.
socket from the engine wiring loom.
Secure the Lambda probe connection and NOTES
wiring to the chassis ensuring that it
1. For a neater appearance position the
cannot contact the hot exhaust or any
clips with the drive screw towards the
moving part, refer to Figure 50.
ground so that the clip ‘tail’ is out of sight
beneath the exhaust.

Page | 85
 2. To reduce the risk of damage it is outlet pipe. Locate the bracket at the rear
advisable to fit the silencer after the RH of the silence over the bobbin on the
rear wing has been attached. silencer mounting bracket and secure with
a nut and spring washer. Tighten the nut
Figure 51: Exhaust arrangement and band clamp. It may be necessary to
reposition the guards slightly.

7.1.7) Cooling system

1
Position a hose clip on the flexible top
radiator hose, apply rubber lubricant and
fit the hose to the end of the water rail
pipe emerging from the curve of the inlet
manifold, Refer to Fig 52. Do not tighten
the clip.
2
Figure 52: Coolant hoses

1. Top radiator hose 5. ‘T’ piece

2. Water rail 6. Hose to expansion
tank
3. Hose to heater outlet 7. Cable tie
4. Hose to cylinder
1. Silencer bracket 3. Lambda probe block
2. Band clamp

Position a hose clip on the flexible bottom

Loosely fit the single band clamp to the radiator hose, apply rubber lubricant and
front of the silencer and position the front fit the hose to the larger of the two outlets
of the silencer over the collector/catalyst on the LH side of the engine block, Refer

Page | 86
to Fig 53. The hose passes forwards using four nuts and washer provided in
along the LH side of the engine bay fastener pack (fastener pack 30C047A,
before turning to pass along the top of the Item 7,10 & 13).
steering rack and turns again to meet the
Figure 54: Radiator/fan prior to fitting
radiator connection. Do not tighten the
clip.

Figure 53: Bottom hose engine

connection (viewed from bellow)

1. Top hose connection 4. Fan power lead

2. Fan 5. Bottom hose connection
3. Fan legs

Figure 55: Standard radiator

arrangement
1. Hose to ‘T’ piece
2. Bottom radiator hose

Fit the four rubber radiator mountings to

the front of the chassis and secure using
nuts, plain washer and spring
washers provided in the cooling pack.

Fit the four fan legs (polythene bag

marked 'cooling') to the cooling fan.
Secure the fan complete with legs to the
brackets,( using bolt 11 and nut 6 in pack The radiator mounting arrangement on SV
30C047A) the fan can then be mounted to models differs considerably from that
the bobbins, ensuring that the fan shown. SV kits include LH and RH
electrical connector is located on the RH radiator mounting plates, refer to Figure
side, mount the radiator to the bobbins 56; these plates must be fixed to the body

Page | 87
before attaching the rubber mountings Fit the expansion bottle mounting bracket
and the radiator. on the top of the cruciform, immediately
behind the radiator, refer to Fig 57, and
Figure 56: SV radiator arrangement
secure using bolt, plain washer and spring
washer. Tighten to 11 Nm.

Figure 57: Coolant expansion bottle

mounting bracket

1. Cruciform
Position hose clips on the forward ends of 2. Expansion bottle mounting bracket

the flexible top and bottom radiator hoses;

apply rubber lubricant and fit the hoses
The round coolant expansion bottle sits on
over the connections on the radiator.
the mounting bracket and is secured using
Tighten the clips at both ends of both
a setscrew, plain washer and nylocnut,
hoses.
refer to Figure 66 for correct orientation of

NOTE the expansion tank hose connections.

The flexible radiator hoses may need to 7.1.7.1) Water bleed hoses

be trimmed to length. The smaller of the two inlets on the

coolant expansion bottle connects to the
Locate the two-pin plug containing the
rear RH side of the cylinder head, refer to
black/green and black wires situated on
Figure 66
the upper front diagonal chassis member.
Connect the two-pin plug to the cooling Route the 5/16” bore hose, along the top

fan electrical connector. Secure the cable radiator hose and fuel rail and around the

to the chassis members using cable ties.

Page | 88
back of the cylinder head. Secure using temp sender submarine and remember to
hose clips (10). bolt the earth tag on first.

7.1.7.2) Heater and associated hoses

Remove and retain the four screws, nyloc
nuts and washers and the two washer
plates securing the diffuser panel to the Figure 58: Heater installation
heater. Position the diffuser panel on the
inside surface of the scuttle with the air
vents facing down and insert the four
screws from the inside. Pass the heater
harness through the large hole in the
scuttle panel and locate the heater over
the screws, secure with the washer plates, 1. Washer plate 4. Heater inlet hose
nyloc nuts, washers and two additional 2. Heater 5. Heater control
screws from the fastener pack, refer to Fig 3. Heater outlet hose cable
58. Connect the heater harness connector
heater to the matching plug, located under
Heater hose is supplied as three pre-
the dashboard.
formed pieces; a short ‘L’ shape, a long ‘L’
NOTE shape and a long ‘J’ shape:

Cars not fitted with a heater will be The short ‘L’ connects the ‘T’ piece to the
supplied with a blanking plate. Apply a engine inlet next to the bottom radiator
small amount of silicon sealant around the hose.
edge of the plate to seal it.
The long ‘L’ shape must be cut in two to
Academy Cars. provide a long straight hose (to connect
the ‘T’ piece to the heater outlet) and a
From the T piece on the LH side of the
short ‘L’ shape (to connect the expansion
block route the hose to the front of the
tank to the ‘T’ piece). Measure the
Modine which is near the oil filter. From
relevant distances carefully before cutting
the rear of the Modine route the J hose up
the hose.
to the rear RH side of the engine. In this
pipe under the coil pack you need to fit the Before fitting any hoses remove the bungs
from the ends of the heater pipes.

Page | 89
The long ‘J’ hose connects the heater inlet refer to Fig 59. Connect the other side of
to the water outlet at the rear of the the heater valve upper (outlet) connection
cylinder head (next to the top hose ‘U’ to the straight connector at the top of the
bend). This hose must be trimmed to heater. Apply rubber lubricant where
length. Cut a 240 mm length of hose from necessary and secure using hose clips.
the straight leg and cut this into two 120 Ensure that the hose is routed to avoid
mm pieces. Use the 120 mm pieces to chafing, use cable ties as necessary.
connect the heater inlet and outlet to the
Trim to length and connect the long ‘J’
heater valve.
hose between the lower (inlet) connection
The larger of the two inlets on the coolant of the heater valve and the outlet at the
expansion bottle must connect to one end back of the cylinder head (next to the top
of the cross-bar of the large ‘T’ piece ‘U’ hose). Connect the curved pipe on the
(near the alternator) that also connects to heater valve to the lower (inlet) connection
the heater valve (outlet side) and to the on the heater using a short length of 5/8”
smaller of the two connections at the front bore hose, refer to Fig 59. Apply rubber
LH side of the engine block, refer to Fig lubricant where necessary and secure
52. Measure and cut the long, 5/8” bore, using hose clips. Ensure that the hose is
‘L’ shaped hose as described previously. routed to avoid chafing, use cable ties as
Apply rubber lubricant to the hose and fit necessary. Do not fully tighten the hose
to the coolant expansion bottle and ‘T’ clips at the heater end at this point.
piece securing with a hose clip at each
NOTE
end.
On cars where no heater is fitted the
Apply rubber lubricant and connect the
relevant connections at the rear of the
short ‘L’ shaped hose to the smaller of the
cylinder head and on the front LH side of
two connections at the LH front of the
the engine block must be joined by a
engine block, connect this hose to the
suitable length of hose.
stem of the large ‘T’ piece. Secure using
hose clips.

Use the cut length of 5/8” bore hose (from

the long ‘L’ hose) to connect the
remaining leg of the ‘T’ piece to the upper
(outlet) connection on the heater valve,

Page | 90
Figure 59: Heater valve arrangement Figure 61: Heater control cable

1. Hose to large ‘T’ 4. Heater valve 1. Scuttle panel

2. Heater outlet 5. Hose to cylinder head 2. Heater control cable
3. Heater inlet 6.Hose clip(s) 3. Locknut

Remove and retain the locknut and Connect the other end to the heater
washer from the heater control cable and control valve by sliding the eyelet on the
pass it from inside the cockpit, through the inner cable over the peg on the heater
hole in the front face of the scuttle, refer to valve operating arm then slide the outer
Figs 60 and 61. Secure the cable in place cable under the adjacent clamp and
using the locknut and washer provided. tighten the screw to secure in place, refer
to Figure 62. Ensure that the valve travels
Figure 60: Heater control location
through its full range when operated from
inside the car. This can be adjusted by
slackening the clamp that locates the
outer cable to the valve and sliding the
cable one way or another.

Page | 91
Figure 62: Heater control cable inlet hose with coolant solution. When the
attachment
hose is full refit it to the heater inlet and
secure with the hose clip. This procedure
should minimise the amount of bleeding
required once the engine is running for the
first time.

7.1.8) Throttle cable fitment

Attach the throttle cable to the linkage on

the throttle body by engaging the nipple in
the throttle operating lever and then
1. Heater valve
clipping its square shaped black plastic
2. Heater control cable
adjuster onto the adjacent bracket. This
adjuster can be threaded up and down the
Warning cable outer to adjust the throttle pedal
position, refer to Figure 63.
Due consideration should be given to
the highly flammable nature of Figure 63: Throttle cable to throttle
body
petroleum or alcohol based products
and their vapours. Serious burns can
result from incorrect use.

Fill the cooling system with a 50%

antifreeze solution (refer to Owner's
Handbook for Caterham recommended
coolant). Add the coolant solution to the
expansion bottle. Place paper or cloth on
the scuttle in the area below the heater
inlet/outlet hoses. Ensure that the heater
valve is in the fully open position (control 1. Throttle cable

knob pulled towards the driver) and 2. Throttle cable adjuster

3. Throttle body linkage
remove the heater inlet (top connector)
hose which was previously left loose.
Temporarily seal off the heater valve inlet
and at the same time back fill the heater

Page | 92
Route the other end of the cable around Ensure that the pipe is routed to avoid
the front of the cam cover; refer to Fig 64 chafing, use cable ties as necessary.
and through the 22 mm hole in the front of
On Sigma 140 the throttle body is blocked
the pedal box and clip the plastic seat into
off and the breather from the cam cover
place. The inner cable is fed into the slot
goes to a bottle located at the front LH
on the top of the pedal with the portion of
side of the chassis above the steering
cable protruding past the cable
rack, there is also another breather pipe
termination located through the hole. The
that is already fitted just below the inlet
top of the pedal should be gently
manifold that also goes to the breather
squeezed with a pair of pliers to capture
bottle.
the cable and prevent it escaping.
The academy is similar to the 140 except
NOTE
the breather bottle is mounted on the front
In order to obtain a preferred pedal height of the scuttle.
and achieve adequate cable tension it
Figure 64: Breather pipe
may be necessary to bend the top of the
pedal prior to locating the cable. This is
done by inserting a Phillips screwdriver
into the top of the pedal, bracing the
bottom of the pedal with a block of wood,
and gently bending the top of the pedal so
as to take up the slack in the cable. Use
the adjusting mechanism at the throttle
body end of the cable to remove any free
play. Once pedal has been manipulated 1. Cam cover
to desired position; ensure that no part 2. Breather pipe
of the pedal is in contact with the head 3. Throttle body
of the securing bolt.

7.1.9) Breather pipe fitment

Fit the breather pipe between the throttle

body and engine cam cover, refer to Fig
64. Apply rubber lubricant where
necessary and secure using hose clips.

Page | 93
 Check that the throttle operates smoothly
without sticking.

7.1.11) Sigma 140 and Academy – air

intake

Fit the airbox and trunking as shown

below. The airbox is mounted on three
rubber bobbins secured to the heater tray
panel.

Figure 65: Air intake and trunking

7.1.10) Air filter fitment

2 1
Fit the Caterham air filter element to the
throttle body housing and secure using
the hose clip provided. The hose clip 1. Air intake
should not be over tightened as it is 2. Trunking
possible to distort the throttle body and
prevent smooth operation of the throttle.

Page | 94
Figure 66: Sigma 125 engine bay overview

2 3 4

5
21

20

19

18
17 11 8
12
16 9
15 13
14 10

1. Engine 8. Heater outlet 15. Water rail

2. Exhaust 9. MAP unit 16. Top radiator hose
3. Throttle cable 10. ECU 17. Water bleed hose
4. Pedal box 11. Air filter 18. Small ‘T’ piece
5. Clutch hose 12. Heater outlet 19. Blanking plug
6. Heater inlet hose 13. Heater outlet hose 20. Expansion bottle
7. ‘U’ hose 14. Large ‘T’ piece 21. Radiator

Page | 95
Figure 67: Sigma 125 engine bay overview (rear)

1. Brake master cylinder 4. Heater control cable

2. Clutch master cylinder 5. Battery
3. Heater

Page | 96
7.2) Duratec - Roadsport 175/Superlight washer bottle. Trim the tube to length and
R300 engine
attach to the washer motor.
7.2.1) Preparation
Connect the washer motor to the wiring
The special tools detailed in Table 17 will loom via the two pin plug adjacent to the
be required. washer bottle mounting. To ease fitment

Table 17: Special tools required for of the two pin plug the washer motor can
Duratec – Roadsport 175/ Superlight be removed from the washer bottle, the
R300 engine
two pin plug fitted and the washer motor
Item Description
reinserted into the washer bottle.
Engine hoist and sling SWL if 150 Kg (min)

The windscreen wipers must not be

fitted until the wiper motor has been
7.2.1.1) Screen wash/wipe
run and allowed to park in order to
NOTE
prevent damage to the paintwork. Fit
The bracket for the washer bottle must be the wiper arms so that they are horizontal
fixed to the front of the passenger side when parked. The wiper arms must move
foot box before the engine is installed. smoothly through their range of travel.

Remove the securing nut from the base of NOTE

the washer jet and pass the washer jet
A small amount of water splashed on the
through the hole in the centre of the
windscreen will prevent the wiper blades
scuttle and secure with the plastic
from juddering during test and adjustment.
securing nut. Fit the clear plastic tubing to
the washer jet. Dip the end of the clear 7.2.1.2) Engine preparation
plastic tubing in hot water to soften in The large diameter short 'L' shape hose
order to make fitting easier. should be fitted onto the aluminium water
outlet located on the rear of the cylinder
Route the clear washer tubing along the
head, refer to Fig 68. Apply rubber
wiring loom behind the dashboard and
lubricant to the long end of the hose and
attach using cable ties, to prevent it falling
push over the outlet; rotate the hose until
down into view. Pass it down through the
the short end sits along the LH side of the
large grommet in the top of the
engine refer fig 68. Secure using a hose
transmission tunnel and along the engine
clip.
bay diagonal tube until in line with the

Page | 97
Apply rubber lubricant to the end of the 7.2.1.3) Chassis preparation
water rail; pass the rail from the front of Protect the appearance of the engine bay
the engine, over the alternator, and under chassis tubes and pedal box sides and
the curve of the plenum chamber. Insert edges by covering with card and/or
the pipe into the short end of the ‘L’ shape masking tape.
hose and secure using a hose clip. Align
Ensure that all wires and connector plugs
the water rail mountings with the lugs
are secured and will not snag or catch the
under the Plenum chamber and secure
engine/gearbox as it is lowered.
using screws, nuts and washers provided.
NOTE
NOTE
Before fitting engine mounting rubber
Water rail might have already been fitted
blocks ensure that the large threaded
to the engine.
(1/2" UNF) boss in the centre is clear of
rubber and that the bolt will thread in
cleanly.
Figure 68: Water outlet and 'L' shape
hose
Fit the engine mounting rubber block to
the RH side of the engine bay. The two
1
bolts (fastener pack 30P012A Item 3),
plain washer (12) are passed downwards
through the mounting, through the chassis
and are secured with nyloc nuts (9) and
plain washers (12). Do not tighten.

2
Fit the engine mounting rubber block to
the LH side of the engine bay, locate the
1. Engine connection engine earth lead (a black lead
2. Long ‘L’ hose approximately 300 mm long), pass bolt (2)
Remove and retain the gearbox filler plug. and washer (12) downwards through the
Remove the plastic plug from the gearbox lead, through the front hole of the engine
tailshaft housing. Removal of these plugs mounting block, through the chassis and
is not essential; however access is secure with nyloc nut (9) and plain washer
restricted within the confines of the (12). Remove a little paint from the
transmission tunnel. chassis/mounting to ensure that a good

Page | 98
electrical contact is made. Pass bolt (3), above the horns on the front upper cross
plain washer (12) downwards through the member.
rear hole of the engine mounting block,
7.2.2) Installation of engine/gearbox into
through the chassis and secure with
chassis
nyloc (9) and plain washer (12). Do not
tighten. Warnings

Locate the twin electric horns on the two 1. Never work underneath a car without

studs near the rear edge of the steering supporting it on axle stands or

rack platform. Before fitting the horns, equivalent. Do not rely on a jack alone.

loosen the 13 mm nut in the centre of 2. Use appropriate eye protection

each horn, this will allow rotation of the whilst working under the car.
horns so that the electrical connections
are closer together. 3. For Duratec engines, Alternator and
starter motor must be removed before
Secure the horns with the nyloc nuts engine installation.
provided and ensure that it is not possible
for the horns to come into contact with Using the lifting hoist and sling detailed in

each other, the steering rack or other Table 17, attach the engine/gearbox using

components in the engine bay refer to the lifting eyes provided on the engine,

Figure 69. lower the engine/gearbox assembly into

the engine bay at an angle of between 30-
Figure 69: Horn location
40 (with the engine higher than the
gearbox). Insert the gearbox assembly
into the transmission tunnel.

Continue to slide the engine/gearbox

rearward until the holes in the gearbox
mounting line up with the holes in the
chassis cross member. If the differential
and Propshaft have already been fitted,

Tighten the 13 mm nut in the centre of ensure that the Propshaft locates into the

each horn and connect the horns to the gearbox tailshaft housing.

electrical harness by the purple and Attach the LH engine mounting using the
yellow wires and connectors located two M8 x 25 mm bolts (fastener pack

Page | 99
36G006A Item 4) and one M8 x 30 mm washer (12) and nyloc nut (9) on each bolt
bolt (5), do not fully tighten the bolts. and tighten to 20 Nm.

Attach the RH engine mounting using the Finally tighten the fixings detailed in
two M8 x 35 mm bolts (6) and one M10 x Table 18.
40 mm bolt (2). Do not finally tighten the
Table 18: Gearbox torque figures for
engine mounting retaining bolts until DuratecRoadsport 175/ Superlight
advised later in this section. R300 engine

Fixing Torque
Lower the engine onto the rubber engine
Engine mounting to block 34Nm
mountings and pass the bolts (fastener
Engine mounting to mounting 41Nm
pack 30P012A Item 1) down through the
rubbers
tube on the outer end of the engine
Engine mounting rubbers to 20Nm
mounting brackets. Screw the bolts chassis
loosely into the threaded bush in the Gearbox mounting rubber to 20Nm
centre of the rubber engine mounting. It is chassis
recommended that the engine is not
removed from the hoist until all the bolts
NOTES
have been tightened (detailed later in this
section). 1. It is now safe to remove the engine
hoist.
Adjust the gearbox on its slotted
mountings to achieve equal clearance 2.Wiring – Every effort is made to clearly
within the transmission tunnel. This must explain and identify all the electrical
be checked carefully as clearances are connections as you go through this
tight and poor alignment can cause the section; however the loom fitted to your
gearbox to contact the chassis under car may have additional wires and
cornering. connectors that are not required on your
vehicle. To help clarify this, a wiring
Bolt the gearbox mounting rubber to the
diagram can be found in the electrical
chassis using bolts (fastener pack
system.
30P012A Item 4) passed down through
the outer metal part of the rubber Fit the gear lever to the top of gearbox
mounting and then through the elongated tailshaft housing and secure with three
holes in the chassis. Secure with a plain setscrews (7). No washers are required;
tighten to a torque of 20 Nm.
Page | 100
Fit the reverse light switch (polythene bag) Figure 70: ECU
into the side of the gearbox. This can be
accessed via the hole in the RH side of
the transmission tunnel. The switch
should be inserted finger tight and then
tightened a further quarter of a turn using
a suitable sized spanner. Connect the
wiring loom to the reverse light switch.
From the cockpit, insert the large grommet
(polythene bag) to cover the access hole
in the transmission tunnel. 1. Fuel pipe 3. ECU
connection 4. Air filter
7.2.3) Electrical connections 2. Multi-pin plug 5. Plenum chamber

The engine wiring loom is already

attached to the engine and some Connect the white/red/black wire plug
ancillaries, however it is necessary to link from the oil pressure sender on the LH
the engine wiring loom to the remaining side of the engine block to the plug on the
ancillaries and the vehicle wiring loom. All engine loom and route with cable ties
the plastic connecting plugs are matched (Might have already been connected).
pairs so it is not possible to connect them
incorrectly. The black wire with ring terminals in the
engine loom is earth connections. Attach
Attach the grey, multi-pin plug to the to a suitable earth point on the bulkhead.
respective socket on the Engine Control
Unit (ECU), which is located on the The green, green/purple pair (with

passenger side heater tray, forward of the grommet) in the engine loom is for the

battery. Make the connection and ensure brake light switch. The brake light switch

that the red retaining clip is pushed fully is inside the drivers pedal box and the

home, refer to Figure70. harness may be connected during

installation of the steering column. Pass
the brake light switch harness through the
hole in the rear of the pedal box, refer to
Fig 71 and push the two female
connectors onto the male connectors of
the brake light switch (orientation is not
Page | 101
important). Fit the grommet into the hole NOTE
and ensure that the harness will not foul
In case of battery master switch, connect
the steering column or pedals.
red leads from master switch to battery
Figure 71: Brake light switch harness and starter motor as marked.

Connect the brown lead from the

alternator to the starter.

Connect the brown/red wire from the

chassis loom to the starter solenoid.

7.2.4) Fuel systems

The black, corrugated plastic, high

pressure fuel pipe from the fuel pump
1. Brake light switch 4. Sealant emerges from the transmission tunnel and
2. Cheese wedge 5. Brake light switch is a push-fit on the connection at the rear
3. Grommet harness of the fuel rail, refer to Fig 72. Note that
there is no fuel return pipe with this

The longest wire from the engine loom system.

(terminating in a 4-pin plug) is the Figure 72: Fuel pipe connection

connection for the exhaust mounted
lambda probe. This cannot be connected
until the exhaust primary pipes and
collector/catalyst is fitted, refer to cooling
systems (section 7.1.7).

Remove the outermost Bell housing

securing bolt and spring washer. Pass
the Bell housing mounting bolt and
attached spring washer through the black
battery earth lead and secure to the Bell-
housing. Tighten to 34 Nm.

Connect the red lead from the starter 1. Fuel rail connection
2. Fuel pipe (from pump)
motor to the battery.

Page | 102
Once fitted the pipe cannot be removed 1. Banjo bolt 3. Hose union
without a special tool. Ensure that the pipe 2. Copper washers 4. Clutch master

is kink free and routed away from possible cylinder

snags or chafe points. Push the

connection on the pipe firmly onto the Route the hose down the side of the pedal
elbow and check that it is securely box, over the wiring loom (under the
attached. Secure the pipe with cable ties if heater hose if fitted) and across the top of
necessary. the bell-housing, Refer to Figure 74.

7.2.5) Clutch hydraulic hose Secure the hose with cable ties if
necessary, to prevent chafing and tighten
The clutch hydraulic hose is already
the banjo bolt (the clutch system is filled
connected to the clutch mechanism. Fit a
and bled during start-up/final checks.
copper washer to the banjo bolt and pass
the banjo bolt through the union at the end
of the hose, refer to Figure 73 (banjo bolt
and the washers can be found in a bag
attached to clutch hose) . Fit the second
copper washer to the banjo bolt and screw
Figure 74: Clutch hydraulic hose
the banjo bolt into the clutch master
cylinder outlet port (remove the port plug).

Do not fully tighten the banjo bolt.

Figure 73: Clutch master cylinder hose

union

Page | 103
7.2.6) Exhaust system Series 3.

The standard exhaust system consists of CSP903 is for # 1 (front) cylinder

four primary pipes, a collector assembly
CSP904 is for # 2 cylinder.
which also incorporates the catalytic
converter and a one piece silencer and tail CSP905 is for # 3 cylinder.
pipe.
CSP906 is for # 4 (rear) cylinder.
Bolt the exhaust mounting bracket
Protect the area around the square
(polythene bag marked 'exhaust') to the
aperture in the side panel with masking
RH side of the car forward of the rear
tape and card, place the exhaust gasket
wheel, using setscrew (fastener pack
over the remaining studs and fit the
30X020A Item 1) and spring washers (3),
primary pipes in the following sequence:
refer to Fig 75. Secure the bobbin to the
angle bracket with a nut (2) and spring 1. Pass the flanged end of # 4 pipe
washer (3). inwards, attach the flange loosely to the
cylinder head and ensure that the pipe sits
Figure 75: Exhaust mounting
in the top LH corner of the aperture
1 (viewed from outside).

2. Pass the flanged end of # 3 pipe

2
inwards, attach the flange loosely to the
cylinder head and ensure that the pipe sits
in the bottom LH corner of the aperture.

3. Pass the plain end of # 2 pipe

1. Angle bracket
outwards, attach the flange loosely to the
2. Bobbin
cylinder head and ensure that the pipe sits
Remove the exhaust gasket and
in the bottom RH corner of the aperture.
associated fasteners from the RH side of
the cylinder head, remove any masking 4. Pass the plain end of # 1 pipe
tape protecting the exhaust ports and outwards, attach the flange loosely to the
clean off any adhesive residue. cylinder head and ensure that the pipe sits
in the top RH corner of the aperture.
The exhaust primary pipes are marked
with their part numbers. NOTE

Page | 104
For SV use the same procedure to fit the Figure 76: Primary pipes and
collector/catalyst
primary, the sequence to fit the primary is
4,3,2,1.

58X0011A is for #1(front) cylinder. 1

58X0012A is for #2 cylinder.

58X0013A is for #3 cylinder

2
58X0014A is for #4 (rear) cylinder

When the primary pipes are in place, fit 1.Primary pipe

the remaining fasteners but do not tighten 2.Collector/catalyst

them.

Install the collector/catalyst over the Fit the Lambda probe into the threaded

assembled primary pipes with the hole in the collector/catalyst and connect

threaded hole for the lambda probe faces the probe plug to the corresponding

towards the side panel. Secure the socket from the engine wiring loom.

collector to the primary pipes with the two Secure the Lambda probe connection and

springs, refer to Fig 76. Support the wiring to the chassis ensuring that it

weight of the collector such that the cannot contact the hot exhaust or any

primary pipes are not in contact with the moving part, refer to Figure 77.

sides of the aperture and tighten the NOTE

primary pipe/cylinder head fasteners to 34
The lambda probe wiring passes under
Nm.
the side of the car below the lower chassis
tube, it must not be routed through the
primary pipe aperture in the side panel.

Page | 105
Figure 77: Lambda probe connection Figure 78: Exhaust arrangement

Undo the large worm drive clips and feed

them through the channels on the inside
of the collector/catalyst guard. Ensure that
the clip drives are not at the bottom of the
silencer where they could contact the
road.

NOTES

1. Silencer bracket 3. Lambda probe

1. For a neater appearance position the
2. Band clamp
clips with the drive screw towards the
ground so that the clip ‘tail’ is out of sight
beneath the exhaust. Loosely fit the single band clamp to the
front of the silencer and position the front
2. To reduce the risk of damage it is
of the silencer over the collector/catalyst
advisable to fit the silencer after the RH
outlet pipe. Locate the bracket at the rear
rear wing has been attached.
of the silence over the bobbin on the
silencer mounting bracket and secure with
a nut and spring washer. Tighten the nut
and band clamp. It may be necessary to
reposition the guards slightly.

7.2.7) Cooling system

All wet sump Duratec engines have an oil

cooler modine fitted to the RHS of the

Page | 106
engine. It enables the engine oil to be Position a hose clip on the flexible bottom
cooled by circulating coolant around the radiator hose, apply rubber lubricant and
oil-filled modine cooler. fit the hose to the larger of the two outlets
on the LH side of the engine block, Refer
Figure 79: Location of modine
to Fig 81. The hose passes forwards
along the LH side of the engine bay
before turning to pass along the top of the
steering rack and turns again to meet the
radiator connection. Do not tighten the
clip.

Figure 81: Bottom radiator hose engine

connection (view from top)

Position the breather bottle mounting

bracket on the chassis as shown in the
picture. Align the RHS hole on the bracket
with the RHS rivet on the chassis and
mark both hole. Drill the marked hole with
5/32” drill and fit the bracket in place using
5/32 rivets refer to fig 80. Push fit the
breather bottle on to the mounting
bracket. 1. Small straight hose to ‘T’ piece
2. Bottom radiator hose
Figure 80: Breather bottle mounting
bracket
Fit the four rubber radiator mountings to
the front of the chassis and secure using
nuts, plain washer and spring
washers provided in the cooling pack.

Warning

Do not over tighten the blanking plug.

The blanking plug is already fitted to the

radiator, make sure it is tight. Fit the

Page | 107
radiator onto the rubber radiator NOTE
mountings ensuring that the hose
The flexible radiator hoses may need to
connections face towards the engine.
be trimmed to length.
Secure the upper mounting using nuts,
plain washers and spring washers. Locate the two-pin plug containing the
black/green and black wires situated on
The radiator mounting arrangement on SV
the engine loom. Route the plug to the
models differs considerably from that
front and connect the two-pin plug to the
shown. SV kits include LH and RH
cooling fan electrical connector. Secure
radiator mounting plates, refer to Fig 82;
the cable to the chassis members using
these plates must be fixed to the body
cable ties.
before attaching the rubber mountings
and the radiator/inner cowl. Fit the expansion bottle mounting bracket
on the top of the cruciform, immediately
Figure 82: SV radiator arrangement
behind the radiator, refer to Fig 83, and
secure using bolt, plain washer and spring
washer. Tighten to 11 Nm.

Figure 83: Coolant expansion bottle

mounting bracket

1. Cruciform
2. Expansion bottle mounting bracket
Position hose clips on the forward ends of The round coolant expansion bottle sits on
the flexible top and bottom radiator hoses; the mounting bracket and is secured using
apply rubber lubricant and fit the hoses a setscrew, plain washer and nyloc nut;
over the connections on the radiator. refer to Fig 93 for correct orientation of the
Tighten the clips at both ends of both expansion tank hose connections.
hoses.

Page | 108
7.2.7.1) Water bleed hoses NOTE
The smaller of the two inlets on the
Cars not fitted with a heater are supplied
coolant expansion bottle connects to the
with a blanking plate. Apply a small
5/16” bore hose that must connect to the
amount of silicon sealant around the edge
small diameter connector at the rear RH
of the plate to seal it.
side of the cylinder head, refer to Fig
19/26. Figure 84: Heater installation

Route the 5/16” bore hose from the

expansion bottle along the top radiator
hose, water rail and under the plenum
chamber around the back of the cylinder
head. Cut piece of 5/16" hose to length,
apply rubber lubricant to each open end
and fit to the connections as described. 1. Washer plate 4. Heater outlet hose
2. Heater 5. Heater control
Secure using hose clips. Secure the hose
3. Heater inlet hose cable
to the top radiator hose using cable ties
refer to Fig 93.
NOTE
7.2.7.2) Heater and associated hoses
Remove and retain the four screws, nyloc There are two long ‘L’ shape hose in the
nuts and washers and the two washer cooling kit. One with large right angle is
plates securing the diffuser panel to the heater hose and the other with smaller
heater. Position the diffuser panel on the right angle is oil breather hose.
inside surface of the scuttle with the legs
Heater hose is supplied as three pre-
pointing downwards and insert the four
formed pieces; one short straight, one
screws from the inside. Pass the heater
long ‘L’ shape and one long ‘J’ shape
harness through the large hole in the
scuttle panel and locate the heater over The short straight hose connects the ‘T’
the screws, secure with the washer plates, piece to the engine inlet near to the
nyloc nuts, washers and two additional bottom radiator hose.
screws from the fastener pack, refer to Fig
The long ‘L’ shape hose must be cut in
84. Connect the heater harness connector
two to provide a short straight hose (to
heater to the matching plug, located under
connect expansion bottle to ‘T’ piece) and
the dashboard.

Page | 109
a long ‘L’ shape (to connect the ‘T’ piece Figure 85: Coolant hoses
to heater outlet). Measure the relevant
distances carefully prior to cutting the
hose.

The long ‘J’ hose connects the heater inlet

to the water outlet at the rear of the
cylinder head (near the large diameter ‘L’
shape hose connecting the water rail).
This hose must be trimmed to length. Cut
a 240 mm length of hose from the straight 1. ‘T’ piece 3. Small straight hose
leg and cut this into two 120 mm pieces. 2. Hose to 4. Hose to heater outlet
Use the 120 mm pieces to connect the expansion bottle or rear of engine if
heater inlet and outlet to the heater valve, heater isn’t fitted
ref fig 87 and 93.

Before fitting any hoses remove the bungs Apply rubber lubricant and connect the
from the ends of the heater pipes. short straight hose to the smaller of the
two connections at the LH front of the
The larger of the two inlets on the coolant
engine block, connect this hose to the
expansion bottle must connect to one end
stem of the large ‘T’ piece. Secure using
of the cross-bar of the large ‘T’ piece
hose clips. Refer fig 85.
(near the alternator) that also connects to
the smaller of the two connections at the Use the cut length of hose (from the long
front LH side of the engine block, refer to ‘L’ hose) to connect the remaining leg of
Fig 85. Measure and cut the long ‘L’ the ‘T’ piece to the heater valve inlet.
shaped hose as described previously. Connect the other side of the heater valve
Apply rubber lubricant to the hose and fit upper/lower connection to the straight
to the coolant expansion bottle and ‘T’ connectors on the heater using cut off
piece securing with a hose clip at each hose of 120 mm length, trim the hose
end. where necessary. Apply rubber lubricants
where necessary and secure using hose
clips. Ensure that the hose is routed to
avoid chafing, use cable ties as
necessary.

Page | 110
Trim to length and connect the long ‘J’ Figure 86: Temp sender submarine
hose between the lower (inlet) connection
of the heater valve and the outlet at the
back of the cylinder head, insert the temp
sender submarine into this pipe under the
coil pack. Apply rubber lubricant where
necessary and secure using hose clips.
Ensure that the hose is routed to avoid
chafing, use cable ties as necessary. Do
not fully tighten the hose clips at the
heater end at this point. Refer fig 86/87.

Figure 86: Heater valve arrangement Remove and retain the locknut and
washer from the heater control cable and
pass it from inside the cockpit, through the
hole in the front face of the scuttle, refer to
Figures 88 and 89. Secure the cable in
place using the locknut and washer
provided.

Figure 87: Heater control location

1. Hose to ‘T’ piece 5. ‘J’ hose to cylinder
2. Heater outlet head
3. Heater inlet 6. Hose clip
4. Heater valve
NOTE

On cars where no heater is fitted the

relevant connections at the rear of the
cylinder head and on the front LH side of
the engine block must be joined by a
suitable length of hose.

Page | 111
Figure 88: Heater control cable to Figure 90. Ensure that the valve travels
through its full range when operated from
inside the car. This can be adjusted by
slackening the clamp that locates the
outer cable to the valve and sliding the
cable one way or another.

Fill the cooling system with a 50%

antifreeze solution (refer to Owner's
Handbook for Caterham recommended

1. Scuttle panel coolant). Add the coolant solution to the

2. Heater control cable expansion bottle. Place paper or cloth on
3. Locknut the scuttle in the area below the heater
inlet/outlet hoses. Ensure that the heater
Figure 89: Heater control cable valve is in the fully open position (control
attachment knob pulled towards the driver) and
remove the heater inlet (top connector)
hose which was previously left loose.
Temporarily seal off the heater valve inlet
and at the same time back fill the heater
inlet hose with coolant solution. When the
hose is full refit it to the heater inlet and
secure with the hose clip. This procedure
should minimise the amount of bleeding
required once the engine is running for the
1. Heater valve
first time.
2. Heater control cable
7.2.8) Throttle cable fitment

Connect the other end to the heater Attach the throttle cable to the linkage on

control valve by sliding the eyelet on the the throttle body by engaging the nipple in

inner cable over the peg on the heater the throttle operating lever and then

valve operating arm then slide the outer clipping its square shaped black plastic

cable under the adjacent clamp and adjuster onto the adjacent bracket. This

tighten the screw to secure in place, refer adjuster can be threaded up and down the

Page | 112
cable outer to adjust the throttle pedal done by inserting a Phillips screwdriver
position, refer toFigure91. into the top of the pedal, bracing the
bottom of the pedal with a block of wood,
Figure 90: Throttle cable linkage
and gently bending the top of the pedal so
as to take up the slack in the cable.
Finally use the adjusting mechanism at
the throttle body end of the cable to
remove any free play.

7.2.9) Breather pipe fitment

The long ‘L’ hose with smaller right angle

is an oil Breather hose. Apply rubber
1. Throttle cable lubricant and connect the right angle end
2. Throttle cable adjuster of the hose to the top rear RH corner of
3. Throttle body linkage
the engine. Refer figure92. Drill 20mm
4. Throttle cable nipple
hole on the top of the breather bottle and
fit the breather elbow refer to figure93.
Route the other end of the cable around Route the breather hose along the RH
the front of the cam cover; refer to Fig 91 side of the engine to the front towards
and through the 22 mm hole in the front of breather bottle using ‘P’ clips provided
the pedal box and clip the plastic seat into and fit to the breather elbow. Apply rubber
place. The inner cable is fed into the slot lubricant where necessary. Ensure that
on the top of the pedal with the portion of the pipe is routed to avoid chafing, use
cable protruding past the cable cable ties as necessary.
termination located through the hole. The
top of the pedal should be gently
squeezed with a pair of pliers to capture
the cable and prevent it escaping.

NOTE

In order to obtain a preferred pedal height

and achieve adequate cable tension it
may be necessary to bend the top of the
pedal prior to locating the cable. This is

Page | 113
Figure 91: Breather pipe

1. Oil breather hose

2. ‘P’ clip
3. Breather bottle
4. Breather elbow
5. Cam cover

Page | 114
Figure 92: Duratec engine bay overview

2 3 4 5
6
22 1

21 7

10
20

11

19 12
18
17 16 15 14 13

1. Engine 12. Air filter

2. Exhaust primary pipe 13.ECU
3. Oil breather hose 14. ‘L’ water rail hose
4.Throttle cable 15. Plenum chamber
5. Pedal box 16. Dip stick
6. Brake master cylinder 17. Top radiator hose
7. Clutch master cylinder 18. Breather bottle
8. Clutch hose 19. Blanking plug
9. ‘J’ hose heater inlet 20. Expansion bottle
10. Heater 21. Radiator
11. Heater outlet 22. Water bleed hose

Page | 115
7.3) Duratec – Superlight R400 Connect the washer motor to the wiring

7.3.1) Preparation loom via the two pin plug adjacent to the
washer bottle mounting. To ease fitment
Table 19: Special tools required for
Superlight R400 engine of the two pin plug the washer motor can

Item Description
be removed from the washer bottle, the
Engine hoist and sling SWL if 150 Kg (min) two pin plug fitted and the washer motor
reinserted into the washer bottle.

7.3.1.1) Screen wash/wipe The windscreen wipers must not be fitted

NOTE until the wiper motor has been run and
allowed to park in order to prevent
The bracket for the washer bottle must be
damage to the paintwork. Fit the wiper
fixed to the front of the passenger side
arms so that they are horizontal when
foot box before the engine is installed.
parked. The wiper arms must move
Remove the securing nut from the base of smoothly through their range of travel.
the washer jet (polythene bag marked
NOTE
'miscellaneous') and pass the washer jet
through the hole in the centre of the A small amount of water splashed on the
scuttle and secure with the plastic windscreen will prevent the wiper blades
securing nut. Fit the clear plastic tubing to from juddering during test and adjustment.
the washer jet. Dip the end of the clear
7.3.1.2) Engine preparation
plastic tubing in hot water to soften in
The large diameter long shape ‘L’ hose
order to make fitting easier.
should be fitted onto the plastic water
Route the clear washer tubing along the outlet located on the rear of the cylinder
wiring loom behind the dashboard and head, refer to Figure94. Apply rubber
attach using cable ties, to prevent it falling lubricant to the long end of the hose and
down into view. Pass it down through the push over the outlet; rotate the hose until
large grommet in the top of the the short end sits along the LH side of the
transmission tunnel and along the engine engine refer figure94. Secure using a
bay diagonal tube until in line with the hose clip.
washer bottle. Trim the tube to length and
attach to the washer motor.

Page | 116
Figure 93: Water outlet and 'L' shape rubber and that the bolt will thread in
hose
cleanly.

1 Fit the engine mounting rubber block to

the RH side of the engine bay. The two
bolts (fastener pack 30P012A Item 3),
plain washer (12) are passed downwards
through the mounting, through the chassis
and are secured with nyloc nuts (9) and
2
plain washers (12). Do not tighten.

Fit the engine mounting rubber block to

1. Engine connection
the LH side of the engine bay, locate the
2. Long ‘L’ hose
engine earth lead (a black lead
approximately 300 mm long), pass bolt (2)
Remove and retain the gearbox filler plug. and washer (12) downwards through the
Remove the plastic plug from the gearbox lead, through the front hole of the engine
tailshaft housing. Removal of these plugs mounting block, through the chassis and
is not essential; however access is secure with nyloc nut (9) and plain washer
restricted within the confines of the (12). Remove a little paint from the
transmission tunnel. chassis/mounting to ensure that a good

7.3.1.3) Chassis preparation electrical contact is made. Pass bolt (3),

plain washer (12) downwards through the
Protect the appearance of the engine bay
rear hole of the engine mounting block,
chassis tubes and pedal box sides and
through the chassis and secure with
edges by covering with card and/or
nyloc (9) and plain washer (12). Do not
masking tape.
tighten.
Ensure that all wires and connector plugs
Locate the twin electric horns on the two
are secured and will not snag or catch the
studs near the rear edge of the steering
engine/gearbox as it is lowered.
rack platform. Before fitting the horns,
NOTE loosen the 13 mm nut in the centre of

Before fitting engine mounting rubber each horn, this will allow rotation of the

blocks ensure that the large threaded horns so that the electrical connections

(1/2" UNF) boss in the centre is clear of are closer together.

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Drill an 8mm hole into the steering rack 7.3.2) Installation of engine/gearbox into
platform so that the horns can be bolted to chassis
the plate. The horns are fixed beneath the Warnings
steering rack platform using a BMCH8x50
bolt dropped into the drilled hole with a 1. Never work underneath a car without

spring washer under the head. A 32mm supporting it on axle stands or

long aluminium spacer is then used to equivalent. Do not rely on a jack alone.

space the horns down, and the horns are 2. Use appropriate eye protection
attached to the bottom of the bolt with an whilst working under the car.
M8 nyloc nut and a plain washer.
3. For Duratec engines, Alternator and
Figure 94: Horn location starter motor must be removed before
engine installation.

Using the lifting hoist and sling detailed in

Table 19, attach the engine/gearbox using
the lifting eyes provided on the engine,
lower the engine/gearbox assembly into
the engine bay at an angle of between 30-
Figure 95: Horn location (top down)
40 (with the engine higher than the
gearbox). Insert the gearbox assembly
into the transmission tunnel.

Continue to slide the engine/gearbox

rearward until the holes in the gearbox
mounting line up with the holes in the
chassis cross member. If the differential
and Propshaft have already been fitted,
ensure that the Propshaft locates into the
Tighten the 13 mm nut in the centre of gearbox tailshaft housing.
each horn and connect the horns to the
Attach the LH engine mounting using the
electrical harness by the purple and
two M8 x 25 mm bolts (fastener pack
yellow wires and connectors located
36G006A Item 4) and one M8 x 30 mm
above the horns on the front upper cross
bolt (5), do not fully tighten the bolts.
member.

Page | 118
Attach the RH engine mounting using the Finally tighten the fixings detailed in
two M8 x 35 mm bolts (6) and one M10 x Table 20.
40 mm bolt (2). Do not finally tighten the
engine mounting retaining bolts until
Table 20: Torque figures for Duratec
advised later in this section.
Superlight R400 engine

Lower the engine onto the rubber engine Fixing Torque

mountings and pass the bolts (fastener Engine mounting to block 34Nm
pack 30P012A Item 1) down through the Engine mounting to mounting 41Nm
tube on the outer end of the engine rubbers

mounting brackets. Screw the bolts Engine mounting rubbers to 20Nm

loosely into the threaded bush in the chassis

Gearbox mounting rubber to 20Nm
centre of the rubber engine mounting. It is
chassis
recommended that the engine is not
removed from the hoist until all the bolts
have been tightened (detailed later in this NOTES
section).
1. It is now safe to remove the engine
Adjust the gearbox on its slotted hoist.
mountings to achieve equal clearance
2.Wiring – Every effort is made to clearly
within the transmission tunnel. This must
explain and identify all the electrical
be checked carefully as clearances are
connections as you go through this
tight and poor alignment can cause the
section; however the loom fitted to your
gearbox to contact the chassis under
car may have additional wires and
cornering.
connectors that are not required on your
Bolt the gearbox mounting rubber to the vehicle. To help clarify this, a wiring
chassis using bolts (fastener pack diagram can be found in the electrical
30P012A Item 4) passed down through system.
the outer metal part of the rubber
Fit the gear lever to the top of gearbox
mounting and then through the elongated
tailshaft housing and secure with three
holes in the chassis. Secure with a plain
setscrews (7). No washers are required;
washer (12) and nyloc nut (9) on each bolt
tighten to a torque of 20 Nm.
and tighten to 20 Nm.

Page | 119
Fit the reverse light switch (polythene bag) Figure 96: ECU
into the side of the gearbox. This can be
accessed via the hole in the RH side of
the transmission tunnel. The switch
should be inserted finger tight and then
tightened a further quarter of a turn using
a suitable sized spanner. Connect the
wiring loom to the reverse light switch.
From the cockpit, insert the large grommet
(polythene bag) to cover the access hole
in the transmission tunnel. 1. Fuel pipe 3. ECU
connection 4. Air filter
7.3.3) Electrical connections 2. Multi-pin plug 5. Plenum chamber

The engine wiring loom is already

attached to the engine and some Connect the white/red/black wire plug
ancillaries, however it is necessary to link from the oil pressure sender on the LH
the engine wiring loom to the remaining side of the engine block to the plug on the
ancillaries and the vehicle wiring loom. All engine loom and route with cable ties.
the plastic connecting plugs are matched (May have already been connected).
pairs so it is not possible to connect them
incorrectly. The black wire with ring terminals in the
engine loom is earth connections. Attach
Attach the grey, multi-pin plug to the to a suitable earth point on the bulkhead.
respective socket on the Engine Control
Unit (ECU), which is located on the The green, green/purple pair (with

passenger side heater tray, forward of the grommet) in the engine loom is for the

battery. Make the connection and ensure brake light switch. The brake light switch

that the red retaining clip is pushed fully is inside the drivers pedal box and the

home, refer to Figure97. harness may be connected during

installation of the steering column. Pass
the brake light switch harness through the
hole in the rear of the pedal box, refer to
Figure 98 and push the two female
connectors onto the male connectors of
the brake light switch (orientation is not
Page | 120
important). Fit the grommet into the hole NOTE
and ensure that the harness will not foul
In case of battery master switch, connect
the steering column or pedals.
red leads from master switch to battery
Figure 97: Brake light switch harness and starter motor as marked.

Connect the brown lead from the

alternator to the starter.

Connect the brown/red wire from the

chassis loom to the starter solenoid.

7.3.4) Fuel system

The black, corrugated plastic, high

pressure fuel pipe from the fuel pump
1. Brake light switch 4. Sealant emerges from the transmission tunnel and
2. Cheese wedge 5. Brake light switch is a push-fit on the connection at the rear
3. Grommet harness of the fuel rail, refer to Figure 99. Note
that there is no fuel return pipe with this

The longest wire from the engine loom system.

(terminating in a 4-pin plug) is the Figure 98: Fuel pipe connection

connection for the exhaust mounted
lambda probe. This cannot be connected
until the exhaust primary pipes and
collector/catalyst is fitted.

Remove the outermost Bell housing

securing bolt and spring washer. Pass
the Bell housing mounting bolt and
attached spring washer through the black
battery earth lead and secure to the Bell-
housing. Tighten to 34 Nm.

Connect the red lead from the starter

motor to the battery. 1. Fuel rail connection
2. Fuel pipe (from pump)

Page | 121
Once fitted the pipe cannot be removed 1. Banjo bolt 3. Hose union
without a special tool. Ensure that the pipe 2. Copper washers 4. Clutch master

is kink free and routed away from possible cylinder

snags or chafe points. Push the Route the hose down the side of the pedal

connection on the pipe firmly onto the box, over the wiring loom (under the

elbow and check that it is securely heater hose if fitted) and across the top of

attached. Secure the pipe with cable ties if the bell-housing, Refer to Figure 101.

necessary. Secure the hose with cable ties if

necessary, to prevent chafing and tighten
7.3.5) Clutch hydraulic hose the banjo bolt (the clutch system is filled
The clutch hydraulic hose is already and bled during start-up/final checks).
connected to the clutch mechanism. Fit a
Figure 100: Clutch hydraulic hose
copper washer to the banjo bolt and pass
the banjo bolt through the union at the end
of the hose, refer to Figure 100 (banjo bolt
and the washers can be found in a bag
attached to clutch hose) . Fit the second
copper washer to the banjo bolt and screw
the banjo bolt into the clutch master
cylinder outlet port (remove the port plug).
Do not fully tighten the banjo bolt.

Figure 99: Clutch master cylinder hose

union

7.3.6) Exhaust system

The standard exhaust system consists of

four primary pipes, a collector assembly
which also incorporates the catalytic
converter and a one piece silencer and tail
pipe.

Page | 122
Bolt the exhaust mounting bracket CSP906 is for # 4 (rear) cylinder
(polythene bag marked 'exhaust') to the
Protect the area around the square
RH side of the car forward of the rear
aperture in the side panel with masking
wheel, using setscrew (fastener pack
tape and card, place the exhaust gasket
30X020A Item 1) and spring washers (3),
over the remaining studs and fit the
refer to Fig 102. Secure the bobbin to the
primary pipes in the following sequence:
angle bracket with a nut (2) and spring
washer (3). 1. Pass the flanged end of # 4 pipe
inwards, attach the flange loosely to the
cylinder head and ensure that the pipe sits
Figure 101: Exhaust mounting in the top LH corner of the aperture
(viewed from outside).
1
2. Pass the flanged end of # 3 pipe
2 inwards, attach the flange loosely to the
cylinder head and ensure that the pipe sits
in the bottom LH corner of the aperture.

3. Pass the plain end of # 2 pipe

1. Angle bracket outwards, attach the flange loosely to the
2. Bobbin cylinder head and ensure that the pipe sits
Remove the exhaust gasket and in the bottom RH corner of the aperture.
associated fasteners from the RH side of
4. Pass the plain end of # 1 pipe
the cylinder head, remove any masking
outwards, attach the flange loosely to the
tape protecting the exhaust ports and
cylinder head and ensure that the pipe sits
clean off any adhesive residue.
in the top RH corner of the aperture.
The exhaust primary pipes are marked
NOTE
with their part numbers:
For SV use the same procedure to fit the
Series 3.
primary, the sequence to fit the primary is
CSP903 is for # 1 (front) cylinder 4,3,2,1.

CSP904 is for # 2 cylinder. 58X0011A is for #1(front) cylinder.

CSP905 is for # 3 cylinder. 58X0012A is for #2 cylinder.

Page | 123
58X0013A is for #3 cylinder cannot contact the hot exhaust or any
moving part, refer to Figure 104.
58X0014A is for #4 (rear) cylinder
NOTE
When the primary pipes are in place, fit
the remaining fasteners but do not tighten The lambda probe wiring passes under
them. the side of the car below the lower chassis
tube, it must not be routed through the
Install the collector/catalyst over the
primary pipe aperture in the side panel.
assembled primary pipes with the
threaded hole for the lambda probe faces Figure 103: Lambda probe connection
towards the side panel. Secure the
collector to the primary pipes with the two
springs, refer to Figure 103. Support the
weight of the collector such that the
primary pipes are not in contact with the
sides of the aperture and tighten the
primary pipe/cylinder head fasteners to 34
Nm.

Figure 102: Primary pipes and Undo the large worm drive clips and feed
collector/catalyst
them through the channels on the inside
of the silencer and collector/catalyst
guard. Fit the silencer guard to the
silencer body with the channels offset
towards the rear of the silencer and
tighten the clips, refer to Figure 105.
Ensure that the clip drives are not at the
bottom of the silencer where they could

Fit the Lambda probe into the threaded contact the road. Attach the

hole in the collector/catalyst and connect collector/catalyst guard in the same

the probe plug to the corresponding manner.

socket from the engine wiring loom.

Secure the Lambda probe connection and
wiring to the chassis ensuring that it

Page | 124
NOTES silencer mounting bracket and secure with
a nut and spring washer. Tighten the nut
1. For a neater appearance position the
and band clamp. It may be necessary to
clips with the drive screw towards the
reposition the guards slightly.
ground so that the clip ‘tail’ is out of sight
beneath the exhaust. 7.3.7) Cooling system and dry sump
system
2. To reduce the risk of damage it is
advisable to fit the silencer after the RH The oil tank should be fixed to the chassis

rear wing has been attached. rail intersection point with an M8x20 cap-
head bolt using an M8 spring washer and
Figure 104: Exhaust arrangement
an M8 plain washer. Position the breather
bottle mounting bracket on the chassis as
shown in the picture. Align the RHS hole
on the bracket with the RHS rivet on the
chassis and mark both hole. Drill the
marked hole with 5/32” drill and fit the
bracket in place using 5/32 rivets refer to
Figure106. Push fit the breather bottle on
to the mounting bracket.

Figure 105: Fitment of dry sump oil

tank

1. Silencer bracket 3. Lambda probe

2. Band clamp

Loosely fit the single band clamp to the

Two P-clips should then be placed around
front of the silencer and position the front
the bottom chassis rails and secured to
of the silencer over the collector/catalyst
the bottom of the oil tank with two M6x20
outlet pipe. Locate the bracket at the rear
bolts and two M6 nyloc nuts using ¼”
of the silence over the bobbin on the
plain washers under the bolt heads and

Page | 125
nuts. Position a hose clip on the flexible Secure the six rubber flaps (from polybag
bottom radiator hose, apply rubber ‘cooling’) to the engine bay side of the
lubricant and fit the hose to the larger of inner cowl using the 5/32” rivets provided
the two outlets on the LH side of the (two rivets per flap), refer to Figure 108.
engine block, Refer to Figure 107. The Fit the fan/cowl assembly to the rubber
hose passes forwards along the LH side radiator mountings, ensuring that the
of the engine bay before turning to pass cooling fan is closest to the engine bay,
along the top of the steering rack and refer to Figure 108.
turns again to meet the radiator
NOTES
connection. Do not tighten the clip.
1. The inner cowl must be fitted before the
Figure 106: Bottom radiator hose
engine connection (viewed from top) front anti-roll bar and the anti-roll bar must
be fitted before the radiator.

2. The four screws in the integral radiator

mounting brackets are not required; they
should be removed and discarded.

Figure 107: Radiator cowl flaps

1. Small straight hose to ‘T’ piece

2. Bottom radiator hose

Fit the four rubber radiator mountings to

the front of the chassis and secure using
nuts, plain washer and spring Warning
washers provided in the cooling pack.
Do not over tighten the blanking plug.
Secure the fan to the inner cowl, ensuring
The blanking plug is already fitted to the
that the fan electrical connector is located
radiator, make sure it is tight. Fit the
on the RH side, using four M6 screws and
radiator onto the rubber radiator
washers provided.
mountings ensuring that the hose

Page | 126
connections face towards the engine. Figure 109: Routing of the oil pipes
Secure the upper mounting using nuts,
plain washers and spring washers.

Align the oil cooler bracket bottom

mounting hole to the bottom rubber
radiator mounting and the Secure using
nuts, plain washers and spring washers
(do not tighten) refer the Figure 109.

Align the oil cooler bracket against  The bottom of the oil tank connects
radiator bracket and mark the other hole to the rear of the sump
on the oil cooler bracket. Drill the 8 mm  The RHS of the oil cooler connects
hole, refer the Figure109. Fit the oil cooler to the front of the sump
bracket using fixings provided in z pack.  The LHS of the oil cooler connects
to the top of the oil tank. The hose
Figure 108: Radiator arrangement
should run along the bottom of the
radiator

The radiator mounting arrangement on SV

models differs considerably from that
shown. SV kits include LH and RH
radiator mounting plates, refer to Figure
111; these plates must be fixed to the
body before attaching the rubber
mountings and the radiator/inner cowl.
1. Blanking plug 5. Oil cooler hose
2. Radiator bracket 6. Oil cooler hose
3. Oil cooler bracket 7. Radiator
4. Oil cooler 8. Radiator mount

Fit the oil cooler to the bracket using

fixings provided in z pack refer figure. 110.

The oil cooler and dry sump hoses need

to be fitted as shown in the schematic.

Page | 127
Figure 110: SV radiator arrangement 7.3.7.1) Relocation of expansion bottle
bracket
A measurement of 135mm should be
marked for the first riveting point, from the
centre of the cross-member intersection to
along the forward-most tube (RHS of the
engine bay).

Use the position of this measurement to

locate the other rivet positions for the
expansion tank plate. The rivets used
should be 5/32”. The orientation of the
expansion tank is dictated by the position
of the expansion tank bracket. This will
Position hose clips on the forward ends of position the expansion tank so that the
the flexible top and bottom radiator hoses; bottom outlet will face downward between
apply rubber lubricant and fit the hoses the two chassis rails.
over the connections on the radiator.
7.3.7.2) Water bleed hoses
Tighten the clips at both ends of both
The smaller of the two inlets on the
hoses.
coolant expansion bottle connects to the
NOTE 5/16” bore hose that must connect to the
small diameter connector at the rear RH
The flexible radiator hoses may need to
side of the cylinder head, refer to Figure
be trimmed to length.
86.
Locate the two-pin plug containing the
Route the 5/16” bore hose from the
black/green and black wires situated on
expansion bottle along the top radiator
the engine loom. Route the plug to the
hose, water rail and under the plenum
front and connect the two-pin plug to the
chamber around the back of the cylinder
cooling fan electrical connector. Secure
head. Cut piece of 5/16" hose to length,
the cable to the chassis members using
apply rubber lubricant to each open end
cable ties.
and fit to the connections as described.
Secure using hose clips. Secure the hose

Page | 128
to the top radiator hose using cable ties 1. Washer plate 4. Heater outlet hose
2. Heater 5. Heater control cable
refer to Figure 121.
3. Heater inlet hose
7.3.7.3) Heater and associated hoses
Remove and retain the four screws, nyloc
NOTE
nuts and washers and the two washer
plates securing the diffuser panel to the There are two long ‘L’ shape hose in the
heater. Position the diffuser panel on the cooling kit. One with large right angle is
inside surface of the scuttle and insert the heater hose and the other with smaller
four screws from the inside. Pass the right angle is oil breather hose.
heater harness through the large hole in
Heater hose is supplied as three pre-
the scuttle panel and locate the heater
formed pieces; one short straight, one
over the screws, secure with the washer
long ‘L’ shape and one long ‘J’ shape:
plates, nyloc nuts, washers and two
additional screws from the fastener pack, The short straight hose connects the ‘T’
refer to Figure 112. Connect the heater piece to the engine inlet near to the
harness connector heater to the matching bottom radiator hose.
plug, located under the dashboard.
The long ‘L’ shape hose must be cut in
NOTE two to provide a short straight hose (to
connect expansion bottle to ‘T’ piece) and
Cars not fitted with a heater will be
a long ‘L’ shape (to connect the ‘T’ piece
supplied with a blanking plate. Apply a
to heater outlet). Measure the relevant
small amount of silicon sealant around the
distances carefully before cutting the
edge of the plate to seal it.
hose.
Figure 111: Heater installation
The long ‘J’ hose connects the heater inlet
to the water outlet at the rear of the
cylinder head (near the large diameter ‘L’
shape hose connecting the water rail).
This hose must be trimmed to length. Cut
a 240 mm length of hose from the straight
leg and cut this into two 120 mm pieces.
Use the 120 mm pieces to connect the

Page | 129
heater inlet and outlet to the heater valve, stem of the large ‘T’ piece. Secure using
refer to figure 115. hose clips. Refer figure 114.

The larger of the two inlets on the coolant Use the cut length of hose (from the long
expansion bottle must connect to one end ‘L’ hose) to connect the remaining leg of
of the cross-bar of the large ‘T’ piece the ‘T’ piece to the heater valve inlet.
(near the alternator) that also connects to Connect the other side of the heater valve
the smaller of the two connections at the upper/lower connection to the straight
front LH side of the engine block, refer to connectors on the heater using cut off
Figure113. Measure and cut the long ‘L’ hose of 120 mm length as mention
shaped hose as described previously. previously, trim the hose where
Apply rubber lubricant to the hose and fit necessary. Apply rubber lubricants where
to the coolant expansion bottle and ‘T’ necessary and secure using hose clips.
piece securing with a hose clip at each Ensure that the hose is routed to avoid
end. chafing, use cable ties as necessary.

Figure 112: Coolant hoses Trim to length and connect the long ‘J’
hose between the lower (inlet) connection
of the heater valve and the outlet at the
back of the cylinder head. Apply rubber
lubricant where necessary and secure
using hose clips. Ensure that the hose is
routed to avoid chafing, use cable ties as
necessary. Do not fully tighten the hose
clips at the heater end at this point. Refer
figure 114/115.
1. ‘T’ piece 3. Small straight hose
2. Hose to 4. Hose to heater outlet
expansion bottle

Apply rubber lubricant and connect the

short straight hose to the smaller of the
two connections at the LH front of the
engine block, connect this hose to the

Page | 130
Figure 113: Water outlets cylinder head On cars where no heater is fitted the
relevant connections at the rear of the
cylinder head and on the front LH side of
the engine block must be joined by a
suitable length of hose.

Remove and retain the locknut and

washer from the heater control cable and
pass it from inside the cockpit, through the
hole in the front face of the scuttle, refer to

1. ‘J’ hose Figures 116 and 117. Secure the cable in

2. Hose to expansion tank place using the locknut and washer
3. Large bore ‘L’ hose to water rail provided.
4. Water outlets on engine cylinder head
Figure 115: Heater control location

Figure 114: Heater valve arrangement

1. Hose to ‘T’ piece 5. ‘J’ hose to cylinder

2. Heater outlet head
3. Heater inlet 6. Hose clip
4. Heater valve

NOTE

Page | 131
Figure 116: Heater control cable travels through its full range when
operated from inside the car. This can be
adjusted by slackening the clamp that
locates the outer cable to the valve and
sliding the cable one way or another.

Fill the cooling system with a 50%

antifreeze solution (refer to Owner's
Handbook for Caterham recommended
coolant). Add the coolant solution to the

1. Scuttle panel expansion bottle. Place paper or cloth on

2. Heater control cable the scuttle in the area below the heater
3. Locknut inlet/outlet hoses. Ensure that the heater
Figure 117: Heater control cable valve is in the fully open position (control
attachment
knob pulled towards the driver) and
remove the heater inlet (top connector)
hose which was previously left loose.
Temporarily seal off the heater valve inlet
and at the same time back fill the heater
inlet hose with coolant solution. When the
hose is full refit it to the heater inlet and
secure with the hose clip. This procedure
should minimise the amount of bleeding
required once the engine is running for the
1. Heater valve
first time.
2. Heater control cable

7.3.8) Throttle cable fitment

Connect the other end to the heater Attach the throttle cable to the linkage on
control valve by sliding the eyelet on the the throttle body by engaging the nipple in
inner cable over the peg on the heater the throttle operating lever and then
valve operating arm then slide the outer clipping its square shaped black plastic
cable under the adjacent clamp and adjuster onto the adjacent bracket. This
tighten the screw to secure in place, refer adjuster can be threaded up and down the
to Figure 118. Ensure that the valve

Page | 132
cable outer to adjust the throttle pedal done by inserting a Phillips screwdriver
position, refer to Figure119. into the top of the pedal, bracing the
bottom of the pedal with a block of wood,
Figure 118: Throttle cable linkage
and gently bending the top of the pedal so
as to take up the slack in the cable.
Finally use the adjusting mechanism at
the throttle body end of the cable to
remove any free play.

7.3.9) Breather pipe fitment

The long ‘L’ hose with smaller right angle

is an oil Breather hose. Apply rubber
1. Throttle cable lubricant and connect the right angle end
2. Throttle cable adjuster of the hose to the top rear RH corner of
3. Throttle body linkage
the engine. Refer figure 120. Drill 20mm
4. Throttle cable nipple
hole on the top of the breather bottle and
fit the breather elbow refer to figure 121.
Route the other end of the cable around Route the breather hose along the RH
the front of the cam cover; refer to Figure side of the engine to the front towards
119 and through the 22 mm hole in the breather bottle using ‘P’ clips provided
front of the pedal box and clip the plastic and fit to the breather elbow. Apply rubber
seat into place. The inner cable is fed into lubricant where necessary. Ensure that
the slot on the top of the pedal with the the pipe is routed to avoid chafing, use
portion of cable protruding past the cable cable ties as necessary.
termination located through the hole. The
top of the pedal should be gently
squeezed with a pair of pliers to capture
the cable and prevent it escaping.

NOTE

In order to obtain a preferred pedal height

and achieve adequate cable tension it
may be necessary to bend the top of the
pedal prior to locating the cable. This is

Page | 133
Figure 119: Breather pipe 1. Oil breather hose
2. ‘P’ clip
3. Breather bottle
4. Breather elbow
5. Cam cover

Page | 134
Figure 120: Duratec engine bay overview

1 Engine 8 Clutch hose 15 Plenum chamber

2 Exhaust primary pipe 9 ‘J’ hose heater inlet 16 Dipstick
3 Oil breather pipe 10 Heater 17 Top radiator hose
4 Throttle cable 11 Heater outlet 18 Breather bottle
5 Pedal box 12 Battery 19 Blanking plug
6 Brake master cylinder 13 Air filter 20 Radiator
7 Clutch master cylinder 14 ‘L’ water rail hose 21 Expansion bottle

Page | 135
 2. Check oil level inside the differential
8.0) Preparation and installation
(14mm allen key) – if the unit is a non-
of the differential
LSD variant it will have oil in it.

The Caterham differential is attached to NOTE

the chassis via a carrier that comes with
The oil should still be checked and topped
the differential. The differential until is
up if necessary with Caterham Differential
supplied with drive flanges – these can be
Oil. If the unit is a LSD then please use
discarded at a later stage in the
the additive supplied.
installation process.
3. Install the handbrake cable down the
Figure 121: Caterham differential
installation (CAD image) tunnel (you may attach your clevis/clevis
wheel to the handbrake at this stage). The
white adjuster is located on the RHS, the
chassis mounting for the yellow top hat on
the cable is utilised on the LHS.

NOTE

If building an SV vehicle there is a longer

clevis used on the handbrake (part
number 50P014A).
NOTE
Figure 122: Handbrake cable location
Install the handbrake mechanism and
cables (see rear suspension section)
before installing the differential and
propshaft. The handbrake cables are
connected to the rear brake callipers and
are adjusted later.

8.1) Procedure

1. Install the Propshaft into the chassis

tunnel. 1. Cable bracket
2. ½ x 11” bolt with schnorr washer (25)
3. Cable adjuster on RHS of vehicle

Page | 136
Use a jack to lift the differential up from Measure from either side of the differential
under the vehicle. This may be easier with carrier to the outboard side of the chassis
additional help. Hang the differential from (outboard of rear ARB mount – 1” BOX) to
the top mount with a thin/long screwdriver centralise. During this process there will
or tube/rod. be a need to pull the bottom bolts out and
use shim washers (item 21 in pack
Warnings
30Z1067A) inserted in between the
1. Never work underneath a car without metalastic bush and carrier as necessary.
supporting it on axle stands or
You may now use the ½ x 11” top bolt
equivalent. Do not rely on a jack alone.
(schnorr washer under the head). It is
2. Use appropriate eye protection optional to grind a chamfer on the end of
whilst working under the car. the bolt (threaded part 45 degrees x ½”)
as this makes it easier to slide and locate
Attach the front end of the differential at
the top bolt. Ensure there is plenty of
the lower mounts; use the M12x55
copper slip used on the bolt. You will also
capheads from the Z-Pack 30Z1067A
need to space the upper bolt between the
(copper slip the shank). Take care to use
carrier and the metalastic with shim
M12 Schnorr washers underneath the
washers. Use a ½” nyloc nut and schnorr
head of the bolt. Attach the bolts loosely
washer to fasten the bolt.
as you will need to centralise the
differential in the next stage. Torque the top and bottom bolts to 60Nm.

Figure 123: Differential installation and The driveshaft flanges can now be
LHS
removed into the differential. This is done
by using a bar and levering them out of
the main case.

The driveshafts can now be inserted into

the differential and the suspension fitted.

Please ensure that the handbrake cable

on the LHS does not sag down to the
1. ½” nyloc nut with schnorr washer driveshaft. Utilise the holes on the side of
2. Cable tie and handbrake cable the diff carrier and cable tie in place.
3. M12 x 55 with schnorr washer

Page | 137
Attach the Propshaft to the differential
pinion drive flange with 4 of M10x20
supplied in the Z-Pack and torque to
60Nm.

NOTE

For checking purposes the torque settings

of the carrier bracket to differential
fasteners are as follows:

x2 M10 plain on rear – 47Nm

x2 M12 caphead on either side – 81Nm

Page | 138
9.0) Rear suspension temporarily fitted to ensure correct
alignment and routing of the brake pipe.
The following section covers the rear
suspension assembly of your Caterham. NOTE

9.1) General Please check section options section for

Brake calliper sub assembly.
The special tools identified in Table 10 will
be required to tighten the rear hub nuts. Warning

Table 21: Special tools required for Both imperial and metric threads are
rear suspension
used on the de Dion brake pipes. The
Item Description threads on the three way union are
Socket 41mm imperial whilst those on the brake
Torque wrench 274Nm
callipers are metric. To aid recognition
a small notch is machined into the

Copper grease should be applied to all hexagon of the metric unions on the

fixings prior to assembly (excluding brake pipes.

pipe nuts and items secured with Loctite).

With the fixing boss offset towards the RH

9.2) Preparation side of the tube fit the three way union
(polythene bag marked 'rear axle') to the
It is recommended that the lower chassis
threaded stud situated towards the RH
tubes that will be under the De Dion tube
end of the De Dion tube, refer to Figure
are protected. Several layers of masking
125, and secure using a nyloc nut
tape or a thin card taped to the tubes is
(fastener pack 30R011A Item 11). Ensure
sufficient.
that the three-way union is located with
9.3) Fitting of rear brake pipes the input uppermost.
Place the De Dion tube on the work bench
with the outer flange facing forward and
the buttress facing downwards.

Fit the aluminium De Dion ears and brake

calliper to the De Dion tube, refer to
assembly of De Dion tube. Do not use
lock washers or Loctite at this stage as
the ears and brake callipers are
Page | 139
Figure 124: Di Dion tube RH brake pipe NOTE
fitting
The existing holes may require cleaning
with a 1/8” drill bit to remove paint but
under no circumstances should additional
holes be drilled.

9.4) Rear brake hose

NOTE
1. Brake pipe (RH) 4. Brake pipe (LH)
All connections should initially be made
2. ‘P’ clip 5. Di Dion ear (RH)
finger tight.
3. Three way union

The rear braided hose can now be fitted.

Thread the locknut onto the male union on
Fit the RH short brake pipe loosely to the
one end of the hose then attach the
three way union and secure the brake
braided hose to the three way union on
pipe to the top of the De Dion tube using
the De Dion tube and tighten to 10 Nm.
'P' clips (fastener pack 30Z1067A Item 23)
Lock into place using the locknut. The
and rivet (22). The De Dion tube is
locknut supplied should not restrict the
predrilled with the correct spacing.
union from tightening fully.
NOTE
Place a plain washer over the male union
The existing holes may require cleaning on the other end of the braided hose then
with a 1/8” drill bit to remove paint but pass the union forwards through the
under no circumstances should additional vertical aluminium panel, apply a further
holes be drilled. plain washer then the shake proof washer
and secure in place with the locknut
Fit the LH longer brake pipe loosely to the
provided. Finally, attach the rigid brake
three way union as shown in Fig 126.
pipe from the transmission tunnel.
Ensure that the brake pipe runs along the
centre of the top of the De Dion tube. NOTES
Secure the brake pipe using the 'P' clips
1. The rigid brake pipe may need slight
(23) and rivets (22). Remove the brake
realignment.
callipers and De Dion ears.
2. Sharp kinks must not be created.

Page | 140
Figure 125: LH brake pipe fitting 2.If the track day roll over bar or roll cage
is to be installed do not install the spring
damper units yet.

Insert a sleeve into the top bush of the

damper unit (close coils of spring are at
the top), align the top bush with the top
mounting and insert the top mounting bolt
1. P-clip (2) through the access holes provided in
2. Brake pipe LH
the seat back panel. Tighten to 54 Nm
3. Three way connector
once the spring damper unit has been
attached to the De Dion tube.
9.5) Assembly of the rear suspension
NOTE
Warnings
Sometime it may be a tight interference
1. Never work underneath a car without
while fitting sleeve into the damper and
supporting it on axle stands or
might need pressing using a bench vice.
equivalent. Do not rely on a jack alone.
The lower spring damper mounting is
2. Use appropriate eye protection
secured to the threaded boss welded to
whilst working under the car.
the underside of the De Dion tube. Pass
Place the De Dion tube into the chassis bolt (3) through spring washer (16), plain
from the RH side ensuring that the central washer (13), the spring damper unit and
buttress faces downwards and that the plain washer and secure to the De Dion
flanges face forward. Care must be taken tube. Tighten to 54 Nm.
to prevent damage to the brake pipes.
NOTE
9.6) Rear spring damper assemblies
Because the suspension is not under
NOTES
load, the bottom bush of the damper unit
1. The rear spring damper units are only and the mounting on the De Dion tube will
fitted at this point if the standard roll over not be in alignment. Take great care not to
bar is to be installed. cross-thread the bottom mounting bolt. If
necessary remove the mounting bolt from
the rear of the ‘A’ frame to allow more
movement of the De Dion tube.

Page | 141
9.7) Radius arms into the four linkage arms. Adjust the

If Watts link has been specified refer to length of the link arms as shown in Figure

next section (Watts link assembly). 127. Tighten locknuts.

Fit the radius arms to the lower chassis Figure 126: Watts link - RH side

bush with the waisted section facing

outboard, to provide maximum clearance
to the brake calliper. The arms are fitted
using M10 x 65 mm cap head bolts
(fastener pack 30R011A Item 2) passed
from the inside of the cockpit through the
1. Bell crank
radius arm and secured with nyloc nut (8)
2. Rod end
and plain washer (14). The bolts should
3. Locknut
be tightened to 34 Nm with the arms
4. Link arm (forward)
parallel to the ground. This preloads the
5. Link arm (rearward)
bushes in the correct position for when the
9.8.2) Link arms to bellcrank
suspension is properly loaded.
Fit the short rearward link arm (waisted
Fit the rear end of the radius arm between
section inboard) to the larger offset
the brackets on the top of the De Dion
mounting on the bellcrank using bolt (3)
tube using bolt (3) passed inboard and
passing from inboard to outboard and
secure using a nyloc nut (6). Do not fully
secure with nyloc nut (6). Ensure that the
tighten.
larger offset of the bellcrank faces
9.8) Watts link assembly (optional) downwards and the links are inset
towards the vehicle centre line.
The Watts link replaces the conventional
single radius arm location of the De Dion Fit the long forward link arm to the upper
tube by employing two links, one facing mounting on the bellcrank using bolt (3)
forward and one facing rearward passing from inboard to outboard and
connected via a bellcrank. secure with nyloc nut (6). Ensure that the
waisted sections in the forward link arm
9.8.1) Construction of link arms
are facing outboard.
Thread the rod ends (polythene bag
marked 'rear suspension') with nut
(fastener pack 30R012C Item 5) and fit

Page | 142
9.8.3) Link arms to chassis order to pass the load to the flanges
rather than the bellcrank spacers.
With the De Dion tube in place attach the
forward link arm to the upper mounting Figure 127: Watts link - RH top view
bush on the chassis using caphead bolt
(fastener pack 30R011A Item 2) pass
from inside the cockpit, through the link
arm. Secure using nyloc nut (8) and plain
washer (14).

The rear link arm attaches to the rear of

the wheel arch into a plain boss. Secure
the rear link arm to the boss using bolt
(fastener pack 30R012C Item 2) nyloc nut
(4) and plain washer (7). Hold link arms 1. De Dion tube RH end

horizontally and tighten to 34 Nm. 2. Link arm (forward)

3. Bellcrank
9.8.4) Bellcrank to Di Dion tube 4. Link arm (rearward)

Drop the bellcrank into the vertical flanges 5. Bellcrank spacer

on top of the De Dion tube. It should be

noted that the bellcrank is secured using 9.9) Rear anti-roll bar (optional)
an M10 bolt but the vertical flanges have a
Warnings
1/2" hole for traditional radius arm fitment.
Two bellcrank spacers are used on the 1. Never work underneath a car without
inner sides of the flanges to centre the supporting it on axle stands or
bolt in the hole, refer to Figure 128. equivalent. Do not rely on a jack alone.
Assemble the bellcrank into the vertical
2. Use appropriate eye protection
flanges ensuring that the two bellcrank
whilst working under the car.
spacers are correctly located; pass bolt
(1) and plain washer (7) inboard through Ensure that the colour of the rubber
the vertical flanges. Secure with nyloc nut 'cotton reel' bushes (polythene bag
(4) and plain washer (7). Tighten to 34 marked 'rear suspension') corresponds to
Nm. It is essential that plain washers are the colour dot on the rear anti-roll bar.
used on the outside of both flanges in Apply rubber lubricant to the centre of the
bushes and slide them down over the flat

Page | 143
blades and onto the round section of the point for the 'A' frame, refer to Figure 130.
rear anti-roll bar. Place the 'A' frame under the car with the
forward mountings offset upwards.
Feed the rear anti-roll bar across the top
of the lower chassis tubes and below the Figure 129: Metalistic brush - De Dion
tube
differential. The rear anti-roll bar is
clamped to the chassis by the aluminium
anti-roll bar mounting block and secured
using bolt (fastener pack 30R011A Item 4)
and plain washer (15). The bolt is passed
vertically up through the chassis tube,
through the thin mounting block. Secure
using plain washer (15) and nyloc
nut (10), refer to Figure 129. Tighten to 1. Metalistic brush 4. Nylon washers
2. Bolt 5. Nyloc nut
14 Nm.
3. ‘A’ frame
Figure 128: Rear anti-roll bar mounting

Attach the 'A' frame to the De Dion tube

using bolt (18) passed through the 'A'
frame, through the metalistic bush, make
sure you put the nylon washers each side
of the metalistic bush, and back through
the 'A' frame. Secure using nyloc nut (6)
but do not fully tighten unless the spring

1. Cotton reel brush 4. Anti-roll bar damper assemblies have been installed
2. Clamp (upper thick) 5. Plain washer (spring damper installation depends on
3. Clamp (lower thin) 6. Nut roll over bar/cage specified).

NOTE
9.10) ‘A’ frame
Nylon 'Race' washers are provided in
The De Dion tube is located laterally using
some applications and if supplied should
an 'A' frame which has bushes fitted to the
be fitted over the centre part of the bush
forward ends. The De Dion tube has a
between the De Dion tube and the 'A'
metalistic bush fitted to the attachment
frame, refer to Figure 130.

Page | 144
Attach the forward ends of the 'A' frame to
the mounting provided on the chassis,
refer to Fig 131, using bolts (fastener pack
30R011A Item 1), passed inboard, with
large diameter plain washers (14), you
need to space the A frame with the
washers, there will be 4 one side and 3 on
the other side between the A frame and
the chassis, then put 1 washer (14) on the
other side and then put on the nyloc nuts
(7). Do not tighten the 'A' frame fixings. Insert the unthreaded end of the
driveshaft into the differential taking care
Check that the De Dion tube is centralised
not to damage the seals in the differential.
in the chassis. Measure the gaps
The longer driveshaft is fitted to the RH
between the De Dion tube end plates and
side. The shorter driveshaft is fitted to the
the outer edge of the chassis tube; these
LH side. To aid insertion, lightly grease
should be identical 2 mm. If adjustment
the splines of the driveshaft and if
is required move one of the washers (14)
necessary gently tap the outer end of the
between the chassis and 'A' frame until
driveshaft with a soft faced hammer.
the required position is achieved. You will
Ensure that the driveshaft is held as
normally have 3 washers one side and 4
straight as possible to prevent damage to
the other.
the boot.
Figure 130: Forward 'A' frame
mounting 9.11) Assembly of De Dion tube

Position the aluminium ears over the

driveshaft and attach to the De Dion tube,
refer to Figure 132.

NOTES

1. The ears are not handed however the

calliper fixing lugs protruding from the ear
must be uppermost.

Page | 145
2. The holes in the ears are not rear holes of the hub, the centre holes in
symmetrical and therefore will ensure the ear and the front holes in the De Dion
correct orientation. tube and tighten into place with the
nylocnuts (7). No washers are required
Figure 131: De Dion tube end (LH)
on these bolts.

Secure the hub to the ear via the forward

holes passing the two bolts (4) through
the hub and ear then securing into place
with plain washers (16) and nyloc nut (7).

NOTES

All cars come with 2 rear ARB

1. Brake calliper 9. Bolt brackets.
2. Spacer 10. Hub carrier
Academy cars only come with the right
3. Nyloc nut 11. Bolt
4. Plain washer 12. Rear disc/flange hand one for the speed sensor

5. Spring washer assembly

The speed sensor also needs to be
6. Bolt 13. Thrust washer
mounted on the ARB bracket Refer figure
7. De Dion tube 14. Nyloc nut (41mm)
133.
8. De Dion ear 15. Driveshaft

Apply Loctite to the threads of bolt

(fastener pack 30Z1067A Item 6) and bolt
the ears into place using spring washers
(20) and plain washers (18) into the
threaded holes at the rear of the De Dion
tube.

Locate the rear hub carrier, with the

rounded edge of the flange uppermost.
Carefully slide the hub over the end of the
driveshaft taking care not to damage
bearings or seals. Bolt the hubs to the ear
by passing the two bolts (3) through the

Page | 146
Figure 132: Anti-roll bar bracket and the bracket. Adjust the two locknuts until
speed sensor
there is a 1 mm clearance between the
sensor and the serrated disc on the
driveshaft (this is only an approximate
clearance you may have to move the
sensor out to get a Speedo reading).
Tighten the locknuts without disturbing
this clearance. Refer figure 133 or 134 as
appropriate.

Connect the sensor plug to the 3-pin

connector on the chassis loom near the
‘A’ frame mounting boss. Secure the
assembled connector to the lower chassis
rail ensuring that there is sufficient free
play in the sensor lead to accommodate
1. De Dion ear
suspension movement.
2. ARB bracket
3. Anti-roll bar Figure 133: Speed sensor
4. Drive shaft
5. Speed sensor

In the case of cars fitted with a rear anti-

roll bar, coat the threads of bolt (fastener
pack 30R011A Item 17) with Loctite and
pass through the lower hole in the ARB
bracket, through a plain washer (fastener
pack 30Z1067A Item 16) and into the
hexagonal, threaded, extension piece.
Slide the rear disc/flange assembly over
Tighten all fixings to a torque of 47 Nm.
the splined end of the driveshaft and ease
Remove the outer locknut from the speed into position through the seal in the hub
sensor. Pass the speed sensor through until it is tight against the bearing. (It may
the bracket and replace the locknut be necessary to use the driveshaft nut
ensuring that the serrated face is against

Page | 147
and washer to pull the flange finally bolts to 47 Nm. Finally attach and tighten
home). Place the thrust washer over the the brake pipes.
driveshaft and secure using the
9.12) Anti-roll bar connection and
41mmnyloc nut (LH plain insert, RH green adjustment
insert) noting that the LH nyloc nut has a
Shorten the droplinks as much as possible
LH thread. These can initially be
ensuring the threaded ends face in the
tightened to 81 Nm. These nuts must be
same direction. Tighten locknuts.
finally torqued to 270 Nm. This is most
Remove the nuts from the ends and
easily achieved once the brakes have
discard, apply Loctite to the threaded arm
been bled and the foot brake is applied.
of the droplink and screw into the
Check that there is clearance between the extension piece using washer (15), refer
outboard rubber boot on the driveshaft to Fig 133. Pass the threaded portion of
and the lower damper mounting bolt. the lower droplink through the anti-roll bar
and secure with nyloc nut (fastener
Check that the outboard driveshaft CV
pack 30R011A Item 9).
joints do not foul the inner edges of the De
Dion ears. If contact occurs, slacken the Figure 134: Anti-roll bar connections
bolts holding the hub carrier to the ear and
adjust until there is sufficient clearance.
Re-tighten to the specified torque figures.

The brake callipers are handed and must

be fitted with the handbrake cable
abutments towards the front of the car. Fit
the correct brake pads fully into the
callipers ensuring that the range of
1. Bolt 4. Drop link
movement of the pads is not hindered by
2. Plain washer 5. Anti-roll bar
the calliper body. Slide the calliper over 3. Extension piece
the brake disc whilst separating the brake
pads. Secure using bolt (fastener pack
30Z1067A Item 4) with spring washer (18) NOTE

and plain washer (16). Pass through the Droplink assembly and connections,
De Dion ear, through the spacer (Fig 132 shown rotated through 180 for clarity.
item 2) and into the calliper. Tighten fixing

Page | 148
The position of the droplinks in the anti-roll Pull the two sections of outer cable to the
bar determines the degree of the anti-roll opposite ends of the inner cable with the
given. Positioning the droplinks closer to nylon adjuster nuts to the right. Place the
the pivot (at the cotton reel bushes) will inner cable; refer to Figure 136, around
give more roll resistance. The same the pulley (polythene bag). Install the
position must be set both LH and RH. pulley into the handbrake clevis and insert
The rearmost hole is the softest and the thin clevis pin through the handbrake
forward most hole is the stiffest position. clevis through the pulley and back into the
handbrake clevis. Secure the clevis pin in
9.13) Handbrake mechanism
place with split pin (fastener pack 30P12A
Warnings Item 14). On series 3 cars the inner cable

1. Never work underneath a car without should cross over before being inserted

supporting it on axle stands or into the pulley.

equivalent. Do not rely on a jack alone. Figure 135: Handbrake assembly

2. Use appropriate eye protection

whilst working under the car.

NOTES

1. Prior to installing the handbrake cable,

ensure that the adjustable boss is
1. Handbrake inner cable
slackened off to allow easier location.
2. Thin clevis pin and split pin
2. The grommet and short section of 3. Handbrake clevis
flexible tubing on each section of outer 4. Handbrake assembly

cable are not required in this application 5. Thick clevis pin and split pin
6. Pulley
and may be removed.

Install the handbrake mechanism and

Insert the handbrake cables into the
cables, before installing the differential
transmission tunnel with the nylon
and propshaft. The handbrake cables are
adjusting nuts to the RH side of the
connected to the rear brake callipers and
transmission tunnel; the cable routing is
adjusted later.
shown in Figure 137.

Page | 149
Figure 136: SV Handbrake cable Connect the electrical spade connector to
arrangement
the top switch on the handbrake.

The two ends of the handbrake cable

emerge from the rear of the transmission
tunnel rearwards. Each end of the
handbrake cable should be routed over
the respective driveshaft then turned
through 180 under the driveshaft and
1. Pulley secured to the chassis diagonals, using
cable ties, just outboard of the 'A' frame.

S3 Handbrake cable arrangement Finally the handbrake cable is turned back

on itself and attached to the calliper
through the abutments, refer to Figure
138.

NOTE

Ensure that cable cannot foul flexible

brake pipe during suspension movement.

Figure 137: Handbrake cable routing

S3 (non-adjustable side)
Locate the fixed nylon boss on the outer
cable into the LH bracket on the chassis
above the differential and locate the
adjuster on the outer cable into the RH
bracket on the differential.

Secure the handbrake assembly to the

chassis using the screws (fastener
pack 30P012A Item 4) and nyloc nuts (9).
There are two holes front hole in the
handbrake mechanism to allow
adjustment of the handbrake lever in the
'off' position. The handbrake cable should not be
adjusted until the transmission tunnel

Page | 150
cover (interior trim) has been fitted as the 1. Never work underneath a car without
handbrake lever is required to be in the supporting it on axle stands or
vertical position during fitment of the trim. equivalent. Do not rely on a jack alone.

. 2. Use appropriate eye protection

whilst working under the car.
Figure 138: Rear suspension
arrangement
If the damper units have been fitted, place
the axle stands under the De Dion tube so
that the weight of the car is taken up
through the spring damper units. Ensure
that all the suspension securing bolts are
tightened as detailed in Table 22.

9.16) Filling of differential

Warnings
1. Watts link rear arm 5. Anti-roll bar
2. Brake calliper 6. Handbrake cable Oils - prolonged and repeated contact

3. Hub assembly 7. Watts link front arm may cause serious skin disorders:
4. Drop link
1. Avoid contact with the skin as far as
possible and wash thoroughly after
9.14) Handbrake adjustment
any contact.
Adjust the handbrake by rotating the
2. Keep out of reach of children.
knurled nut that locates in the bracket
above the differential. The handbrake 3. First aid treatment should be
should be set to lock the rear wheels on obtained for open cuts and wounds.
three clicks of the ratchet mechanism.
4. Use appropriate barrier creams.
Ensure that the pads are not binding and
tighten the second knurled nut to lock the Once the driveshafts have been located
adjuster. the differential can be filled with oil if not
already done. It is recommended that the
differential is filled with EP90 gear oil
9.15) Final adjustments
(Including those fitted with a limited slip
Warnings differential). Refer to your Owner's

Page | 151
Handbook for a complete list of
recommended lubricants.

NOTE

This operation is made easier if the boot

floor has been removed to allow access.

Ensure the filler plug is to hand. Fill the

differential with approximately 1.1 litres of
EP90 gear oil until the oil runs out of the
filler hole. Screw the filler plug in and
tighten.

Secure the boot floor to the chassis.

Table 22: Torque figures for rear

suspension
Torque
Location
(Nm)
Watts link locknut 20
Bellcrank to link 14
Watts link rear mount 34
Bellcrank to De Dion 34
Watts link front mount 34
Radius arm 34
‘A’ frame 81
Rear damper bolts (all) 54
Hub nuts 270
Hub mountings 47
Brake calliper 47
Rear anti-roll bar clamp 14
De Dion ears 47

Page | 152
10.0) Interior and trim Figure 139: Carpets

The following section details the interior

trim of your Caterham including
transmission tunnel top and carpeting,
footwell and boot carpeting, seat belts/
harnesses, seating and mirrors.

10.1) General

Superlight models are not supplied with

any carpets unless otherwise specified.

Before fitting the carpets ensure that all

operations that require access under the
carpets have been completed.
10.2) Seat back carpets
The items specified in Table 23 will be Warning
required during procedures detailed in this
Ensure adhesive is applied in a well-
section.
ventilated area. Follow instructions on
Table 23: Special tools required for adhesive packaging. Care must be
interior and trim
taken whilst working in a confined area
Item Remarks
e.g. Thefootwell.
Adhesive Contact adhesive
Durable dot fastening Supplied in chassis The carpet that covers the seat back area
tool (Part No. 76068) pack has a vinyl strip along the upper edge.
Lay the carpet into place ensuring that the
carpet covers the aluminium seat back
It is recommended that a dry run is
right down to the floor. Apply adhesive to
completed before cutting or gluing the
the vinyl strip and stick to the square tube
carpets in the final position.
at the top of the seat back panel.

The seatback carpet will need to be cut to

allow the seat belt through it. Mark the
carpet where the inertia reel seat belt exits
the seat back and cut a slot.

Page | 153
The carpet must fit flat at the transmission 10.4) Transmission tunnel top
tunnel. If necessary, small cuts should be NOTE
made in the area of the corners to allow
the tabs on the carpet to hinge out against Do not attempt to fit the tunnel top until

the transmission tunnel. the tunnel carpet adhesive is completely

dry.
Once the carpet has been fitted around
the transmission tunnel apply adhesive to The transmission tunnel top incorporates

the carpet and press into position against a padded armrest, the gear lever gaiter

the seat back. It is only necessary to and the handbrake gaiter. On R300/R400

apply adhesive as far down as the top of models the two electrical plugs on the

the transmission tunnel as the remainder underside of the tunnel top must be

of the carpet is behind the seats. connected to the two plugs in the
transmission tunnel.
10.3) Transmission tunnel carpet
Pull the handbrake near vertical. Fit the
Attach the small aluminium transmission
transmission tunnel top, ensuring that the
tunnel cover on the rear of the
handbrake and gear lever locate in the
transmission tunnel top using the 5/32"
respective gaiter and press firmly into
rivets provided.
position over the sides of the transmission
Ensure that the reverse light switch and tunnel carpets.
associated blanking grommet have been
Screw the gear knob into position and lock
installed prior to fitting the transmission
with a grubscrew.
tunnel carpets. The transmission tunnel
carpets are handed so ensure that the 10.5) Rubber footwell mats
correct carpet is fitted to each side. Place the mats in the respective footwell

Coat the transmission tunnel with (mats are handed).

adhesive and stick the transmission tunnel They are secured into the footwell using
carpets to the transmission tunnel. the three poppers fitted at the rear of the
Ensure that good adhesive coverage is footwell.
maintained, particularly in the forward
Attach 3 popper bases (fastener pack
section of the transmission tunnel.
ZIT03 Item 2) to the rear of the front
footwell using rivets (1) through which
need to be drilled in the floor panel.

Page | 154
Stick masking tape to the underside of the Fit the fuel filler cover plate into position
carpet in the approximate position of the and drill through the cover plate into the
floor mounted poppers and lay the carpet boot board using a 2 mm drill. Attach the
into position. Press down firmly on the cover plate using self-tapping screws
carpet so that the bases make an (fastener pack ZCH01 Item 7). It may be
impression on the masking tape. Make necessary to relocate the fuel filler hose
appropriate holes in the carpet and rivet clips to fit the cover.
together the popper (3) and fastener
10.7) Side and knee trim panels
button (4), using the Durable Dot
fastening tool, refer to Table 1. Ensure NOTES

that the fastener button is uppermost on 1. If specified, the optional sill protectors
the carpet. and roll cage must be fitted before the

NOTE installation of the knee trim panels, side

panels and associated piping can be
For correct use of the popper fastener tool completed.
refer to weather equipment section.
2. If specified, optional Arm rest bracket
Fit the footwell mats into place and secure (escutcheon bracket) must be fitted with
using the poppers. side panel/sill protectors (sill protectors

10.6) Boot carpet are optional).

The boot carpet is laid into position and Not all of the rivets used to secure the
requires no adhesive. It will be necessary interior side panels into place will have
to cut the carpet to fit around the fuel filler been fitted. This is to allow fitting of sill
pipe. Tuck the edges of boot carpet down protectors and to provide access to the
the sides of the aluminium honeycomb front roll cage mountings, if required.
bootboard at the rear and the sides taking
Warning
care not to damage the aluminium body
panel. When drilling the sill protectors take
care not to drill through both sides of
The boot carpet also covers the boot
the chassis tube.
interior side and front panels. Apply
adhesive and secure the carpet shape If necessary, position the sill protector on
into the relevant space. the sill, with the long edge between the
chassis tube and trim panel, press down

Page | 155
on the sill protector and drill (5/32”) self-tapping screws (fastener pack ZCH01
through the existing holes in the trim Item 8).
panel, through the sill protector and
NOTE
through the existing holes in the chassis
tube. Position a length of trim piping with If the optional roll cage is to be fitted leave
the flat portion between the interior side the screws out of the rearmost two holes.
panel and the chassis tube and cut to
For optional arm rest bracket fitment, do
length. The piping should reach from the
not fit rivets into 3-4 central rivet holes.
front of the knee trim panel to just behind
(Please see arm rest bracket fitment
the point where the side panel meets the
section in the weather equipment section).
rear wheel arch panel, refer to Figure 141.
Ensure that the rounded edge of the Fit the sill protector between the piping
piping sits neatly along the top edge of the and the chassis rail and align the holes
side panel. drilled previously. Drill through the holes
again to pierce the flat portion of the
Figure 140: Side panel detail
piping and secure the sill protector, piping
and side panel using rivets (5), refer to
Figure 142.

NOTE

If the optional roll cage is to be fitted leave

the rivets out of the forward three holes in
the horizontal row and the top three holes
in the vertical row.
1. Knee trim panel
2. Roll cage (optional)
3. Piping
4. Self-tapping screws

Position the pre-bent and drilled knee trim

panel between the piping and the chassis
tube, secure the knee trim panel, piping
and side panel to the chassis tube using

Page | 156
Figure 141: Trim fixings 10.9) Four point harness

The harness should be fitted after the seat

back carpet, tunnel carpets and boot
cover has been fitted (if specified). Locate
the threaded mounting holes in the top of
the chassis, (refer to Fig 143), and
carefully cut away the material covering
the holes.

Figure 142: Mounting holes four-point

harness upper

1. Piping 4. Chassis tube

2. Sill protector (optional) 5. Side panel
3. Body skin 6. Rivet

Fit the piping and secure the curved

section of side panel in a similar manner.
Ensure that this section of piping overlays
1. Roll over bar mounting
the horizontal section. Cut a series of ‘V’
2. Roll over bar locating recess
shaped notches in the flat portion of the
3. Drivers harness mounting
piping so that it follows the curve of the
4. Passenger harness mounting
side panel neatly. 5. Chassis member
6. Inertia reel mounting
10.8) Inertia reel seat belt

If specified, the inertia reel seat belts will

have been positioned by Caterham, From the mounting kit supplied with the
however none of the visible chassis harness, assemble a 7/16" UNF x 1 3/4"
mountings will be tightened. The belts bolt, plain washer next to the bolt head,
should be tightened at the same time as and pass through the broad shoulder
the interior trim is fitted. The top and strap, crinkle washer and through the
bottom mountings should be tightened to bush. Ensure the smaller diameter of the
47 Nm. bush is closest to the bolt head. Screw

Page | 157
the bolt into the harness mounting point, Figure 144: Outboard lap strap
refer to Figure 144.

Figure 143: Shoulder strap with track

day roll over bar

1. Buckle
2. Outboard lap strap

To fit the inboard lap strap, assemble

a 7/16" UNF x 1" bolt, with a plain washer
next to the bolt head, pass through the

1. Bolt 4. Bush inboard lap strap, crinkle washer, and

2. Shoulder restraint 5. Plain washer through the bush. Ensure the smaller
3. Crinkle washer diameter of the bush is closest to the bolt
head. Insert the bolt into the threaded
boss and tighten to 47 Nm, refer to
To fit the outboard lap strap, assemble
Figure 146. Ensure lap strap buckle is
a 7/16" UNF x 1" bolt, with a plain washer
uppermost.
next to the bolt head, pass through the
outboard lap strap crinkle washer, and Figure 145: Lap straps
through the bush. Ensure the smaller
diameter of the bush is closest to the bolt
head. Insert the bolt in the threaded boss
and tighten to 48 Nm refer to Figure 145.
Ensure lap strap buckle is uppermost.

NOTE

Use of a longer bolt to secure the outer

lap strap will result in damage to outer 1. Outboard lap strap

body side panel. 2. Inboard lap strap

3. Buckle
10.10) Six point harness

Page | 158
The six-point harness is fitted in the same spacers detailed above. Secure in place
way as the four point, with the exception using the plain washers and nyloc nuts
that the crutch straps are bolted to the supplied. Tighten all fixings to 61 Nm.
chassis brackets protruding from the rear
Fit the shoulder and lap straps as detailed
lower crossmember behind the seat.
previously.
10.10.1) Standard floor
Figure 146: Crutch strap spacer
To fit the crutch strap drill an 11 mm hole location
through the two crutch strap mounting
points located at the rear of the cockpit
and through the floor of the cockpit.
Assemble an M10 x 25 bolt with a plain
washer next to the bolt head. Pass the
bolt through the hole in the crutch strap,
through the crinkle washer and top hat
spacer, down through the chassis
1. Lowered floor pan
mounting ensuring the strap is offset
2. Top hat spacer bush
downwards, and through the cockpit floor.
3. Crinkle washer
Secure the bolt in place using a plain 4. Fixing eyelet
washer and nyloc nut. Tighten to 47 Nm. 5. Aluminium Spacer
Ensure the crutch strap fixing plate has 6. Crutch strap fixing bracket
the bend facing the cockpit floor.

10.10.2) Lowered floor 10.11) Seats

Drill a 7/16” hole through the crutch strap- 10.11.1) Standard cloth or leather seats
fixing bracket then through the floor pan
The adjustable seats are supplied
directly below it.
attached to the seat runner. Place the

Lay out the crutch strap to assure the seat into position over the underseat

correct orientation and assemble the carpet (SV only) and secure the front

harness eyelets and spacers, refer to Fig mountings by passing setscrew (fastener

147. pack ZSE03 Item 1) down through the

mounting and securing using plain washer
Insert the long 7/16” x 3” bolt upwards
(3) and nyloc nut (2). Slide the seat fully
through the floor pan and assembled
forward and pass setscrew (1) down

Page | 159
through the rear mountings and secure is towards the seat base. Secure using
using plain washer (3) and nyloc nut (2). bolt (2), one thick spacer (8) and one thin
Tighten the fastenings. spacer (7) on each fixing ensuring they
are between the runner and the seat.
10.11.2) Composite seats
Torque all fixings
10.11.2.1) Adjustable seats to 14 Nm.
Fit the runner with the adjusting handle to
Ensure that the harness option specified
the RH side of the seat with the handle
has been installed prior to fitting the seat.
facing forwards and inboard of the runner.
Place the seat into position feeding the lap
Secure the front mounting using reduced
and shoulder straps through the apertures
head cap head bolt (fastener pack ZSE06
in the seat body and the crutch strap (if
Item 2) through the round hole then
specified) through the aperture in the seat
through two thick spacers (8) and into the
base, refer to Fig 149. Ensure that the
threaded seat base. Secure the rear with
harness straps are not twisted.
cap head bolt (2) through the square hole,
through 1 thick spacer (8) and 1 thin On low-floor cars the seat adjusting
spacer (7) and into the threaded seat handle must pass beneath the square
base, refer to Fig 148. chassis tube and through the aperture in
the vertical section of aluminium panel.
Figure 147: Adjustable seat
Secure the front mountings with bolt (2)
passed down through the runner and
secure under the floor using plain washer
(5) and nyloc nut (4).

Slide the seat fully forwards and pass a

bolt (2) down through the rear holes in the
runner and secure under the floor using
plain washer (5) and nyloc nut (4).

1. Spacers
2. Adjusting handle

NOTE
Fit the LH runner in the same way
ensuring that the outer part of the runner

Page | 160
If the car has a honeycomb floor, bolt (1) is fitted in the correct orientation. The cut-
is passed through the runner, through outs must face away from the seat base
spacer (6) and secured using plain allowing flush fitment to the floor. The
washer (5) and nyloc nut (4). large cut-out must be biased towards the
rear of the seat. Both tubes are identical
Figure 148: Composite seat and six-
point harness and are fitted in the same orientation,
refer to Fig 150.

Figure 149: Fixed seat

1. Large recess
2. Spacer

Position the square section aluminium

tubes on the seat base and pass bolt
(fastener pack ZSE05 Item 2) through the
large hole in the underside of the spacer
1. Composite seat
2. Six-point harness and into the small hole opposite, through
3. Seat adjuster one thick spacer (8) and into the threaded
seat base. Torque all fixings
10.11.2.1) Fixed seat
to 14 Nm.
The fixed seat is bolted to the floor via
two 25 mm square section, aluminium
tubes. This tube has a series of cut-outs
on one side and plain holes in the
opposite side. It is important that this tube NOTE

Page | 161
If a track day roll over bar and Petty strut adhesive but has two locating dowels.
is installed, the seat can reclined slightly Before removing the paper to reveal the
by replacing the front fixing with bolt (1) adhesive on the underside of the badge,
and additional thick plastic spacers (8) on carry out a trial fit to ensure the badge will
each side at the front, between the seat sit square. It may be necessary to
base and the aluminium tube. remove the paint from the pre-drilled holes
on the nose cone before fitting the badge.
Ensure that the harness option specified
has been installed prior to fitting the seat. 10.12) Rear view mirror
Place the seat into position feeding the lap The centre mounted mirror is a legal
and shoulder straps through the apertures requirement and must be fitted. The
in the seat body and the crutch strap (if mirror has a self-adhesive pad and should
specified) through the aperture in the seat be stuck as high as possible on the
base, refer to Fig 143. Ensure that the interior of the windscreen on the centre
harness straps are not twisted. line of the car. Prior to removing the
paper backing from the self-adhesive pad
Secure the seat with bolts (2) and plain
ensure the area where the mirror is to be
washers (5) passed upwards through the
placed has been thoroughly cleaned using
floor into the threaded bosses in the
an alcohol based degreaser. Note that
aluminium tubes.
the mirror can be inverted on its stalk to
10.12) Minor trim items minimise windscreen obstruction.
10.12.1) Scuttle edge trim
On Superlight models without a
This strip (chassis kit) is designed both to windscreen, the mirror must be secured to
finish off the scuttle around the dashboard the scuttle top on the centreline of the
tidily and to protect the occupants from vehicle. Ensure that the area where the
the hard aluminium edge. Cut the trim to mirror is to be placed has been thoroughly
length and secure by firmly pushing the cleaned using an alcohol based
trim into place by hand. The scuttle edge degreaser.
trim is an IVA requirement.

10.12.2) Nose badge

The circular nose badge (polythene bag

marked 'miscellaneous') is mounted on
the nose cone of the vehicle. It is self-

Page | 162
Figure 150: Completed interior

1. Rear bulkhead carpet

2. Footwell carpet
3. Tunnel carpet
4. Tunnel top

NOTE

Items may differ from those shown,

dependant on the chosen specification.

Page | 163
11.0) Fibreglass Drill through the cycle wing at the pre-
marked points using a 5 mm drill. Then
The following section details the fibreglass enlarge the centre hole to approximately
components of your kit including cycle 15 mm.
wings, rear wing protectors and rear
wings. Feed the repeater wire through the cycle
wing from the outside then secure the
11.1) Front cycle wings base using the nuts supplied.
The front cycle wings are not handed, but
The cycle wing will have been marked
they will be marked for the repeater
with the positions for the front two
position. The repeaters should be near the
mounting bolts for each wing. These
leading edge of the wing, on the outside.
should be drilled through using a 5 mm
Piping (polythene bag marked 'IVA') drill.
should be fitted around the edge of the
The front cycle wings bolt to the tubular
cycle wing. This is an IVA requirement,
wingstays which are rigidly mounted to the
refer to the IVA section.
front uprights.
It is easier to fit the front indicator
Fit the front wheels ensuring that the
repeaters to the cycle wings prior to fitting
steering rack is centred. Place the cycle
them to the cycle wingstay.
wing over the wingstay so that the bolt
Warnings holes are over the centre line of the
forward wingstay tube such that the wing
1) Use appropriate eye protection
overhangs evenly on either side of the
whilst carrying out drilling operations.
tyre. The wing can be held in position
2) Use a suitable face mask to prevent using masking tape. It is possible that the
inhalation of dust when drilling wingstay will need to be bent to allow the
fibreglass or carbon fibre. cycle wing to fit centrally over the tyre.
Mark the positions for the bolt holes onto
3) When drilling fibreglass use tape on
the wingstay.
the surface over the drill holes to
prevent damage to the gel coat or Remove the cycle wing and with the tyre
painted finish. Slow drill speeds must protected centre punch the wingstay. Drill
be used. the holes through the wingstay using a 6

Page | 164
mm drill. Ensure that the drill cannot Check alignment of the holes with the
contact the tyre. wingstays, adjusting if required, then drill
through from the top of the cycle wing with
Drill an additional hole in the underside of
a 5 mm drill.
the front wingstay near the open end
using a 5/32” drill. Remove all sharp Place a strip of self-adhesive foam
edges on the inside and outside of the (fastener pack ZFG12 Item 7) on the top
wingstay tube. of each cycle wingstay tube. Cut two
rubber grommets in half to provide four
Loosely fit the cycle wing to check the
rubber washers. Pass screw (5) through
alignment of the cycle wing and wingstays
the manufactured washers and down
relative to the tyre. The cycle wing should
through the cycle wing and wingstay.
be checked to ensure that it is centrally
Secure using washers (4) and nyloc nuts
located over the tyre. Remove the cycle
(2). Tighten until the rubber washer is
wing. Place a strip of masking tape
slightly larger than the screw head. The
across the tyre underneath the drilled
black wire from the indicator repeater is
wingstay. Using a ruler held at 90 to the
the earth lead and should be attached to
surface of the tyre, mark the lateral
the front wingstay using a pop-rivet in the
positions of the two holes. Rotate the
5/32” hole drilled at Para 10. Remove
wheel so that the masking tape is under
paint to ensure a good contact.
the rear tube of the wingstay and transfer
the bolt hole position to the wingstay tube. Route the green wire from the indicator
Centre punch and drill using a 6 mm drill repeater inside the wingstay until it
as for the front holes. emerges from the pre-drilled hole near the
wingstay brace. From the wingstay the
Refit the cycle wing, loosely bolting it at
wire must be routed along the rear of the
the front and aligning it over the tyre and
upper wishbone ball joint, and the upper
then carefully remove the wheel without
wishbone. Secure using small cable ties
disturbing the wing. Masking tape can be
at 50 mm intervals, refer to Fig 152.
used to hold the wing in place. Carefully
mark the underneath of the wing with the
bolt hole positions and then remove the
wing. Drill a small pilot hole from
underneath the cycle wing, taking care not
to damage the gel coat/painted surface.

Page | 165
NOTE chuck when drilling holes for the inner row
of rivets.
To comply with SVA requirements the
green repeater wire must be covered with The wing piping (fastener pack ZWS01 or
heat shrink sleeving. ZWS02 (option) Item 2) fits between the
rear wing protector and the rear wing. Cut
Figure 151: Indicator repeater wiring
the piping to length and fit around the top,
outer and lower edges of the wing
protector so the bead is against the edge
of the protector. 'V' shaped notches (refer
to Fig 153) should be cut to allow the
piping to smoothly follow the shape of the
protector. Position the piping under the
protector, ensure correct orientation of the
protector (refer to Fig 156) and drill
1. Upper wishbone through the existing holes into the piping
2. Front wingstay with a 1/8" drill.
3. Repeater wire
4. Wingstay brace
Figure 152: Rear wing protector piping

Once inside the aluminium body skin the

green wire should be fitted into the 6 pin
econoseal plug. It is recommended that
this connection is made at the same time
1. ‘V’ shaped notch
as the headlamp and indicator wiring.
2. Wing piping
11.2) Rear wing protectors (Stone 3. Holes
guards)

NOTE
The wing protector should be placed on
It is advisable to fit the wing protectors to the lower front of the rear wings. The
the wings before fitting the wings to the correct position can be obtained by
car. Once the wings are fitted there is very placing the lower angled edge
little clearance between bodywork and drill approximately 5 mm up from the lower
edge of the wing and the inboard side of

Page | 166
the protector tight up against the inboard holes for the suspension arms. To enable
side of the wing (the side of the wing that the wing to be fitted to the car you will
bolts to the car). need to trim out the fibreglass from the
larger holes to enable fitment over the
NOTES
radius arm or Watts link arms, refer to Fig
1. The protectors are supplied flat so will 154). The wings are supplied in this way
need to be gently shaped to follow the to maintain their strength prior to them
contour of the wing. being fitted to the car. An alternative fixing
method would be to remove the
2. The protective film on stainless steel
suspension arms then refit them once the
wing protectors should be removed from
wing is secured in place.
around the rivet heads before fitting. The
protected side faces outward. Figure 153: Rear wing fitment

Position the protector on the rear wing

and mark one of the corner holes. Ensure
correct spacing and orientation. Drill the
hole using a 1/8" drill. Fit the rear wing
piping into position under the protector
and rivet into position using rivet (1).

NOTE

Carbon fibre wing protector uses black 1. Rear wing fixings

rivets and the stainless steel wing 2. Rear wings
protector uses plain rivets.

Attach the wing protector working Offer the rear wing up to the side of the
outwards, one rivet at a time, from the car and bolt in place using a setscrew
corner ensuring that the wing piping is in (fastener pack ZFG12 Item 1) and plain
the correct position. Drill 1/8" holes and washers (3) into rivnuts at the front of the
attach using rivets (1). rear wing and bolts (1), plain washers (3)
through the rear of the wing and secured
11.3) Rear wings
using plain washers (3) and nyloc nuts (2).
The rear wings are provided pre-drilled
The setscrews used to secure the rear
with both the wing fixing holes and further
upper section of the wing should be

Page | 167
passed through the body from inside the Figure 155: Rear wing
boot. Loosely fit all fasteners.

Wing piping (6) is provided to fit between

the rear wing and the car body. The wing
piping should be positioned against the
rear wing and cut to length. The wing
piping has six ribs running longitudinally.
'V' shaped notches, refer to Figure 155,
should be cut to the sixth rib to allow the
piping to smoothly follow the curve of the
rear wing. Where the wing mounting bolts
occur, rectangular shapes should be cut
to the fifth rib to accommodate.

Figure 154: Wing piping

1. Piping between wing and panel
2. Piping on three sides of wing protector

1. Wing piping
2. ‘V’ Shaped notches
3. Rectangular notches

Secure the rear wing ensuring that the

bead of the wing piping is protruding. Do
not over tighten fixings, refer to Figure
156.

Page | 168
12.0) Lighting from the headlight bowl. Remove the plug
from the back of the headlight bulb and
The lighting kit includes all the parts remove the sidelight housing from the
needed to make the car comply with the reflector.
lighting requirements of IVA. It is
imperative that these instructions are Remove the securing nut and lock washer

adhered to in order to fulfil the legal from the headlight mounting stud and

requirements of the lighting. smear a thin layer of oil to the thread.

Insert the headlight harness and headlight
If fitted, remove the lead from the battery mounting stud through the indicator cone
negative terminal. and into the headlight bracket.

12.1) Headlights and front indicators Refit the headlight securing nut and lock
Fit a length of edge strip (polythene bag washer and tighten until the headlight unit
'IVA') to the underside edge of the cannot move freely, this will aid assembly
indicator cone. It is an IVA requirement however these nuts will need to be
that the edge strip covers the entire edge slackened off to allow the headlights to be
of the mounting cone, including the correctly adjusted, refer to Figure 157.
portion directly beneath the lens.
NOTE
Remove the lens from the front indicator.
Ensure that the locating tag on the
Ensure that the drainage hole on the
headlight shell engages with the recess in
indicator seal is at the bottom, line up the
the mounting stud.
holes in the indicator base with the holes
in the indicator cone and secure using
three setscrews (fastener pack 30L002A
Item 3) and nyloc nuts (6). Do not over
tighten. Replace the lens.

Tighten the two grub screws securing

each headlight bracket into the chassis.
Tighten to 7 Nm.

Remove the headlight rim by undoing the

clamping screw located on top of the
headlight bowl and unhooking the lens

Page | 169
Figure 156: Headlight and indicator LH 12.2) Front indicator repeaters

The front indicator repeaters are fitted at

the same time as the front cycle wings,
refer to cycle wing section within the
fibreglass chapter.

12.3) Front wiring electrical

connections

Locate the 2 loose econoseal plugs

supplied in the chassis pack (2 part black
1. Indicator cone 3. Headlight bracket plug and yellow insert). Take the six wires
2. Headlight unit 4. Indicator cone (the sixth wire is the indicator repeater
wire which may not be fitted at this point)
and push them into the back of the loose
Pass the black indicator earth wire
black plug ensuring that the connections
(terminated in a ring terminal) through the
click into place. If they do not locate
hollow headlight unit mounting stud and
correctly turn them through 180oand try
secure to the earth screw at the base of
again. Refer to Table 24 for the correct
the headlight unit. Pull excess wire into
terminal position within the connector.
headlight unit.
Table 24: Front lighting wiring
Refit the sidelight housing into the
connections
reflector and refit the plug to the headlight
Wiring loom Light unit
bulb. Hook the bottom of the headlight rim Function
colour wire colour
into the lip on the headlight bowl and
Earth Black Black
swing the headlight rim up into position. Headlight Blue/red Blue/red
Secure using the clamping screw. (dipped
beam)
Feed the headlight wiring and the green
Headlight Blue/white Blue/white
indicator wire through the hollow headlight
(main beam)
bracket so that it exits into the engine bay.
Indicator Green/white Green
The headlamp wires can be “shortened” to Repeater Green/white Green

equal lengths by gathering the excess Sidelight Red Red

wires into the headlamp bowl.

Page | 170
Once the indicator repeaters have been mm and this takes the wiring and the
fitted and all the connections have been econoseal plug. The innermost takes one
located into the plug fit the yellow insert of the retaining screws. Enlarge the
into the front of the plug. Connect the innermost hole using a 4 mm drill.
plug to the wiring loom and secure the
Remove the lenses from the rear light
cables to the chassis.
assemblies along with the bulbs noting
12.4) Rear lights that the indicator uses a single filament

The kit includes two identical rear light bulb and the brake light uses a double

assemblies which comprise of tail, brake filament bulb.

and indicator lights. They are mounted on NOTE

rubber blocks which ensure that the lights
are vertical when fitted and are secured The rear light assemblies are not
‘handed’. One of the metal baseplates
with four self-tapping screws. Turn one
light unit around on the rubber block and must be inverted to create a LH/RH pair
with the indicator fitting to the outside
ensure that the amber indicator lens is on
the outside. edge of each light.

Warnings Using the metal baseplate as a guide, drill

a 4 mmhole through the rubber block in
1) Use appropriate eye protection each corner. Ensure that the drill is kept
whilst carrying out drilling operations. at 90 to the baseplate.

2) Use a suitable face mask to prevent

Feed the electrical wiring and the
inhalation of dust when drilling
econoseal plug through the 30 mm hole
fibreglass or carbon fibre.
ensuring that the grommet is passed

3) When drilling fibreglass use tape on through the hole. Attach the rear light unit

the surface over the drill holes to at the lower inboard corner using screw

prevent damage to the gel coat or (2). Do not over tighten. Ensure that the

painted finish. Slow drill speeds must rear light unit is horizontal and drill

be used. through the rear light unit into the rear

wing. Remove the light unit. Clear away
The rear wings have been pre-drilled with
the swarf and refit the light unit using
two holes for the rear light assemblies.
screws (1) on the upper holes and screws
The outermost hole has been drilled to 30
(2) on the lower holes.

Page | 171
Do not over tighten. Replace the bulbs 12.6) Rear number plate light
and lens cover ensuring correct Remove and retain the cross-point screw
orientation of the lens cover (indicator to retaining the light cover and lens; remove
the outside). and retain the cover and lens. Remove

Connect the econoseal plug to the and retain the two nuts and spring

corresponding socket protruding from a washers from the metal baseplate.

hole inside the rear wing. Ensure that the Pass the wire from the chassis loom
plugs are correctly mated and push the through the RH upper hole of the light
plug inside the rear side panel. Fit the bracket on the chassis and through the
grommet to the hole in the body side back of baseplate. Fit the baseplate to the
panel. bracket and secure with the nuts and

For reference the rear electrical spring washers. Ensure that the baseplate

connections are detailed in Table 25. studs earth to the bracket through the nuts
(remove paint from the bracket as
Table 25: Rear lighting wiring necessary).
connections
Wiring loom Light unit NOTE
Function
colour wire colour
Cars that are not supplied with a spare
Rear light Red/white Red
wheel bracket will be pre-fitted with a
Brake Green/mauve Green
number plate light bracket located below
Left indicator Green/red Green
Right the lower chassis tubes.
Green/white Green
indicator
Remove and discard the two brass bullet
Earth Black Black
connectors supplied in the light. Shorten
the wire to a convenient length, strip back
Secure the wiring inside the body using sufficient insulation and attach (crimp) a
cable ties. male bullet connector. Insert the bullet
connector into the central terminal on the
12.5) Reversing light and fog light
light. Replace the lens, cover and cross-
The reversing light and the fog light are point screw.
fixed to the rear panel and the wiring
12.7) Testing
connections have been made at the
factory. Reconnect the battery negative lead.
Check all the lights for correct operation.

Page | 172
In the event that there are problems check same. When alignment is satisfactory, re-
that the bulbs have not been damaged check the vertical measurement and
during transit and replace as necessary. tighten the headlight securing nuts.
If the problem persists check every earth
3. The alignment will be tested and
point on the chassis both on the wiring
adjusted during the post build check. If the
loom and the battery earth lead. If the
car is not being submitted for a post build
problem is related to a particular system
check, we strongly advise kit builders to
or side, check the fuse box located under
get the headlights professionally adjusted.
the dashboard in the passenger side of
the cockpit further information on fuse
identification can be found in your
Owner's Handbook.

12.8) Headlight beam setting

If possible the headlight beam setting

should be carried out using professional
equipment; if such equipment is not
available, proceed as detailed below:

1. Position the car on a firm level

surface, 2 m from a vertical surface
(measured from the front edge of the
lower lip of the nose cone). Slacken the
headlight securing nuts and switch on the
lights (dipped). Adjust the lights until the
brightest spot of each light pool (at the
apex of the dip-beam cut-off) is 650 mm
above the ground.

2. Measure the distance between the

centres of the headlights on the car and
the distance between the centres of the
bright spots on the wall. Adjust the
headlights as necessary until the two
measurements are approximately the

Page | 173
13.0) Weather equipment 13.1) Fitting of hoodsticks and
hoodstraps
This section explains how to perform the NOTE
initial fitment of the weather equipment,
Whichever option of roll over protection
the tool identified in Table 26 will be
has been specified must be fitted before
required. However, if the specification for
the hoodsticks.
your car included hood fitment then
instructions on how to refit, remove and Remove the inner hoodstick from the
fold for storage can be found in your hoodstick assembly and feed the end loop
Owner's Handbook. of hoodstraps over the front hoodstick and
loop in the centre of the hoodstraps over
Table 26: Additional tools required for
weather equipment the rear hoodstick ensuring that the
Item Description adjusting buckle faces downwards when
Durable Dot fastening Part No. 76068 the hoodsticks are erect, refer to Figure
tool (supplied in fastener 159.
pack ZBC02)
Reassemble the hoodstick assembly and
attach to the triangular brackets on the
Correctly fitted weather equipment is chassis using the fixings provided.
shown in Figure 158. Ensure that one plain washer is fitted
under the head of the screw and the other
Figure 157: Weather equipment
between the fixing bracket and the
hoodstick.

Before fitting the hood you must first

secure the rearward part of the hoodstick
in the correct position. Measure distance
A from the top surface of the rear chassis
tube to the centre of the rear hoodstick to
obtain the correct positioning (standard
chassis 395 mm or
SV 420 mm), refer to Figure 159.

Page | 174
Figure 158: Hoodstick spacing Figure 159: Hoodstrap fixing

1. Screw
Drill two 7/64” holes into the upper chassis 2. Washer (or popper base)
tube, one either side, on the inside rear 3. Hoodstrap

edge of the boot, opposite the outermost 4. Rear body skin

5. Chassis tube
popper base (145 mm from the roll cage
mounting lug). Make a small hole in the
loose end of each hoodstrap and using 13.2) Hood fitting
the two self-tapping screws (fastener pack
With the hoodsticks in the upright position
ZWE05 Item 10) and washers, fix the
and the adjusting buckle fully slackened,
straps to the rear panel on the inside of
drape the hood over the car and attach it
the top chassis rail, refer to Figure 160.
to the windscreen with the pre-fitted
NOTES fasteners. Start with the two outer most
fasteners and ensure that the felt seal is
1. With the hoodstraps taut, check the
correctly located along the top face of the
position of the rear hoodstick, as this will
windscreen frame.
affect the tension of the hood when finally
adjusted. Move to the rear of the car and attach the
back of the hood again with the pre-fitted
2. For a neater appearance, popper bases
fasteners.
may be used with the self-tapping screws
used to secure the hoodstraps. Tension the hood by adjusting the
hoodstraps until the front hoodstick is in
line with the stitched darts in the hood.
Use the Velcro lined sleeve stitched to the
inside of the hood to capture the front

Page | 175
hoodstick as this will ensure that it is 1. Hoodstick
correctly adjusted. 2. Popper base
3. Rear wing
The front popper base for the side of the
hood can now be fitted. To do this pull the
side of the hood down and assess the 13.3) Sidescreen fitment

approximate position for the popper base. Using the setscrews (5) and nyloc
Apply several layers of masking tape to nuts (13) attach the sidescreen hinges to
this area. the outside of the windscreen stanchions
with the eyelet towards the rear of the car,
Pull the side of the hood down again and
refer to Fig 162. Fit the brass hinge
press on the fastener to create an imprint
pins (8) into the 4 remaining hinges. Now
in the masking tape. Drill a 3/32” hole
slide the hinges with the pins fitted into the
through the centre of the impression,
top of hinges attached to the car.
remove the tape and secure a popper
base using a self-tapping screw. NOTE

NOTE SV sidescreens hinges are now supplied

with pre-fitted hinge pins.
Care should be taken while drilling hole on
curve of the chassis tube. Figure 161: Hinge and side screen
fitting
Repeat the above procedure for the
remaining popper bases along the cockpit
and boot sides, refer to Figure 161.

Figure 160: Hood side fasteners

1. Windscreen stanchions
2. Sidescreen hinges

The sidescreen is constructed using a

steel frame around the window section.

Page | 176
This is covered with the vinyl which Remove the top part of the hinges from
continues away from the frame giving a the chassis and secure them to the
soft flexible area of about 35 mm around outside of the sidescreen, using setscrew
the outside. The correct position for the (5) and nyloc nut (13), with the pin
sidescreen is with the soft part at the top towards the front and pointing downwards.
tucked up between the two parts of the Fit IVA covers to the nuts on the inside of
hood that make up the seal along the top the sidescreen and fit IVA protectors to
of the door aperture and the soft area the non-chamfered ends of the hinge
towards the front tucked inside the halves, refer to Figure 164.
stanchion. The lower rear radius of the
Refit the sidescreen by sliding the pins
sidescreen should follow the lower edge
down into the hinges on the car. With the
of the hood and the metal frame at the top
sidescreen closed, tuck the top in
should be just below the top of the door
between the flap of the hood.
aperture.
Each sidescreen is held shut by two vinyl
With the hood still fitted and correctly
straps and fasteners. From inside the car,
tensioned, offer up the sidescreen into
pull the straps in over the top edge of the
position and mark the position of the four
chassis and mark the place for the
fixing holes. (For ease of marking it may
fastener base. Drill a 5/32" hole in line
help to run a strip of masking tape down
with the rivets holding the side panel in
the front edge of the sidescreen).
place. (You will be drilling into a round
Warning tube so care should be taken to avoid the
drill wandering as it hits the tube).
Use appropriate eye protection whilst
carrying out drilling operations.

Next remove the sidescreen and place it

on a solid surface and protect the window
from damage caused by swarf before
drilling the holes for the fixings. The metal
frame inside the sidescreen is very hard
so it is advisable to centre punch and drill
through with a 3 mm pilot hole then finally
with a 5 mm drill to enable fitment of the
hinge.

Page | 177
Figure 162: Sidescreen straps (it’s optional on S3). Stick the masking
tape on the interior panel in the middle
over the rivet holes. Hold the side screen
tight against the car and press mark the
arm rest popper position on the masking
tape. Normally the popper line up with one
of the rivet holes on the side panel. Push
fit the escutcheon bracket and line up the
marked position with the centre of the
1. Sidescreen
bracket (Bracket should fit over the inside
2. Vinyl strap
panel and rubber trim). Drill the marked
popper position through the bracket (5/32”
NOTE drill size). Refer to figure160.

Optional arm restraints are available. If Figure 163: Arm rest bracket
these have been specified on your car
then only the top strap is required to
locate the sidescreen.

Attach a popper base (2) using rivet (1).

Next pull the strap down over the popper
base and mark the centre to position the
fastener. Whilst doing this ensure the
sidescreen is pulled tight up against the
13.5) Exterior mirrors
body of the car to reduce draughts and
NOTE
water ingress. Fix a fastener to the
marked position on the strap using the After the IVA inspection, the mirrors may
durable dot tool, refer to figure 172. be fitted to the side screens but in order to
Repeat this process for all fixing straps. pass IVA inspection, the mirrors must be

13.4) Arm rest bracket fitment fitted to the windscreen stanchions.

(escutcheon bracket)
13.5.1) Fitment to screen stanchion
Optional arm rest bracket needs to be
Remove and retain the central, slot-head
fitted at this stage. SV/CSR cars comes
screw, in the screen stanchion and screw
with arm rest attached to the side screen
in the IVA mirror stalk adaptor, refer to Fig

Page | 178
165. Fit a fibre washer and the mirror stalk 13.5.2) Fitment to side screens
over the adaptor and tighten the Exterior mirrors are fitted to the
grubscrew to secure the stalk (ensure that sidescreens, towards the front, just below
the large recess in the stalk faces the clear window panel. Locate the holes
rearwards). pre-drilled in the metal frames

Figure 164: IVA mirror stalk adaptor (approximately 130 mm from front corner
and 104 mm apart) then drill through the
material with a sharp 5 mm drill. Attach
the mirrors to the hidden metal frame of
the sidescreen using the countersunk
screws (6), washers (14) and secure with
nyloc nuts (13).

Figure 165: Mirror fitted to side screen

1. IVA protector (1/2 grommet)

2. Mirror stalk adaptor 1. Mirror
3. Hinge 2. Hinges
3. Screen stanchion

Remove the mirror head from the original

stalk noting the relationship of all parts. Plastic M5 caps (polythene bag marked
Assemble the mirror head to the IVA stalk 'IVA') should be fitted to the nuts securing
and adjust as required (retain the remains the mirror to the sidescreen. These can
of the original mirror for use post-IVA). be secured in place using a little silicone
sealant.

Page | 179
13.6) Boot cover All boot covers have a metal insert along

When correctly fitted, the boot cover the forward edge, with pre-drilled holes to

should be as shown in Figure 167. locate the fastener bases. The forward
edge of the boot cover should align with
Figure 166: Boot cover the front edge of the seat bulkhead.
Ensure that the boot cover is centrally
located and mark the holes through the
forward edge of the boot cover. Drill a
7/64” hole through each marked location
and fit a popper base (fastener pack
ZBC02 Item 5) secured with a self-tapping
screw (6).

The boot cover is designed to attach If harness type seat belts are being fitted
permanently to the top of the bulkhead the metal insert in the boot cover must be
behind the seat and clip onto the same removed. Align the boot cover as
fasteners as those provided for the hood previously described and mark the
at the rear of the car. It is designed to fit location of the four threaded bosses.
over the hoodsticks when not in use Punch a hole in each of the marked
therefore it is essential that these are locations and fit the harness shoulder
fitted prior to fitting the boot cover. When strap securing bolts through the boot
the hood is erected, the boot cover is cover.
folded away and stored in the boot.
Additionally fit four fasteners (5) using
The boot cover is designed to fit around screws (6) in the following locations; one
the roll bar, since these vary according to fastener 1 1/4" either side of the car
specification, ensure the correct boot centreline and one fastener at the
cover has been supplied. There is a midpoint between each pair of shoulder
special boot cover designed for use with restrains. If a tonneau cover is to be
the roll cage. fitted, the position of the fasteners will
have to be adjusted accordingly.
NOTE
Stretch the boot cover over the luggage
For cars fitted with harness type seat belts
area. Secure around the rear stays of the
go to ‘Note’ in Boot cover section.
roll over bar using the Velcro and

Page | 180
establish locations for the remaining Figure 168: Tonneau cover
fasteners (boot cover fastens to the hood
fastenings on the body). Fit the popper
bases (3) and buttons (4) starting from the
rear centre working outwards and then
forwards.

If a tonneau cover is to be fitted then the

forward button on each side is substituted
by a popper base (fastener pack ZTC01 Before the tonneau cover can be fitted
Item 6), assembled as shown in Fig 167 both the boot cover and seat belts must
and fitted to the fastener socket (4) using be installed and the detachable head
the punch provided (for correct usage of restraints must be removed. The tonneau
fastener fixing tool refer to figure 172). cover should be fitted with the steering
wheel in place. However, if a Quick
Figure 167: Forward fastener boot
cover Release (QR) column has been specified
to function as an anti-theft device and is
intended to be removed when the car is
unattended then this should also be
removed prior to fitting the tonneau.

Carefully align the tonneau along the

centre line of the car and stretch it so that
1. Popper base
there is about 25 mm of tonneau ahead of
2. Boot cover
the fasteners fitted to the centre of the
3. Fastener socket
scuttle. Mark and fit two fasteners (4) and
buttons (5) in the tonneau to correspond
13.7) Tonneau cover with these fasteners.
When correctly fitted the tonneau cover
Carefully measure the positioning of the
should be as shown in Figure 169.
rear edge of the tonneau relative to the
fastener bases securing the front of the
boot cover ensuring that the rear edge of
the tonneau is exactly parallel to the seat
bulkhead and it is properly centred, refer

Page | 181
to Fig 170. Mark the position of the securing with a rivet (1). Fit a fastener (4)
fastener bases and fit the six fasteners (4) and button (5) in the tonneau to
and buttons (5) across the back. It is correspond.
important that these fasteners are located
Figure 170: Tonneau cover fasteners
correctly as these set the correct tension (front)
for the whole cover. It should not be
stretched so tight that it puts tension on
the fittings, bearing in mind it will not
stretch so well in cold weather, nor so
loose as to allow water to collect on it.

Figure 169: Tonneaucover positioning

1. Windscreen support

Mark and drill a 5/32" hole and fit a further

fastener (3) securing with rivet (1) 38 mm
below the rear lower edge of the scuttle,
19 mm rearward of the centreline of the
large scuttle securing rivet. Stretch the
1. Tonneau cover
tonneau and secure with a fastener (4)
2. Boot cover
and button (5).

Mark, drill a 5/32" hole and fit a further

Starting with the passenger side, mark
fastener (3) securing with rivet (1) 50 mm
and drill a 5/32" hole and fit a further
down from the top rear of the sill and 45
fastener (3) securing the rivet (1) on the
mm forward of the wheel arch. Pull down
scuttle 45 mm inward from the lower edge
the tonneau and secure with a fastener (4)
of the windscreen support where it joins
and button (5).
the triangular base, refer to Fig 171.
Stretch the tonneau carefully into position Unzip the tonneau when fitting the
taking care to pull the tonneau far enough fasteners to the driver's side, leaving the
forward to achieve a little clearance in rear fasteners in place along the seat
front of the rear wing, mark and drill a bulkhead. Repeat the fitting procedure as
5/32" hole and fit a further fastener (3) per the passenger's side taking care to

Page | 182
stretch the tonneau away from the vehicle Figure 171: Durable Dot fastener tool
centreline, towards the windscreen
stanchion just sufficient to prevent
bagginess in front of the steering wheel).

Fastening the zip will correctly tension the

tonneau.

NOTE 1. Punch
2. Dished base
If a roll cage is fitted, additional fasteners
must be fitted to the body to match the
tonneau cover fasteners on either side of
the Velcro-fastened splits for the roll cage
forward supports.

13.8) Correct usage of fastener fixing

tool

The fastener tool, Figure 172, consists of

two parts; the dished base part and the
punch.

 Place the base on a solid surface

dished side upwards
 Put the fastener button through the
material and rest it in the dished
part of the base
 Then place the fastener socket
over the tube part of the button so
that the cupped section is facing
upwards
 Place the punch on the end of the
tube and hit it with a hammer until
the tube has peened over gripping
the two parts together

Page | 183
14.0) Wheel fitment If specified for your kit, the spare wheel
carrier will have been fitted at the factory.
Warning
Locate the mounting wishbone, Figure
Re-tighten wheel nuts after 200 mile. 173 (1) (polythene bag marked 'spare

Some Caterham supplied alloy wheels are wheel') and secure to the spare wheel

fitted with steel inserts enabling secure using two wheel nuts (2). The wishbone

tightening of the wheel nuts. The wheel should be placed on the inboard side of

nuts can settle into the wheels over the the spare wheel.

first few hundred miles causing loss of Place the spare wheel in the spare wheel
torque so should be re-tightened to the carrier with the point of the mounting
correct torque after approximately 200 wishbone inboard of the wheel. Care
miles. must be taken to avoid damage to the

Many of the tyres supplied by Caterham paintwork whilst locating the spare wheel.

are directional. Check that the tyre Assemble the spare wheel bolt (4), fibre
orientation is correct before fitting the washer (3) (located in polythene bag
wheel to the car. marked 'miscellaneous') and spacer

Fit the wheel using the wheel nuts (polythene bag marked 'spare wheel') (5).

provided ensuring that the cone on each Secure the spare wheel to the car using

wheel nut is correctly located in the wheel. the assembled spare wheel bolt through

The wheel nuts should not be over the centre of the mounting wishbone.

tightened. It is recommended that they are Ensure wheel nuts and spare wheel

tightened whilst the car wheels are on the mounting bolt are tight.

ground. Tighten wheel nuts to 74 Nm.

Fit the wheel centre caps as follows:

13", 14" and 15" wheels. Placing wheel

centre cap into wheel and pushing fully
home ensuring correct seating.

14.1) Spare wheel fitment

NOTE

Page | 184
Figure 172: Spare wheel mounting
items

1. Mounting wishbone
2. Wheel nuts
3. Fibre washer
4. Spare wheel bolt
5. Spacer

NOTE

13" wheels fitted with low profile tyres are

secured to the spare wheel boss using a
single bolt and spacer located through
one of thewheel stud holes.

Page | 185
15.0) Start up procedure and final paintwork with clean cloths to prevent

checks possible fluid leakage from causing

damage to the paintwork.
This section details the operations,
Ensure all bleed nipples on the callipers
adjustments and checks that should be
are closed then fill the brake master
carried out prior to starting the car for the
cylinder with fresh brake fluid that
first time. Refer to your Owner's
complies with SA3J 1703F DOT 4
Handbook for recommended lubricants
specification. Replace the master cylinder
and capacities.
cap.
15.1) Brake system – filling and
bleeding 15.1.1) Standard brakes

Prior to filling the brake master cylinder Remove and retain the dust cap from the
recheck all brake connections, including LH rear brake calliper bleed screw. Place
factory fitted connections, from the brake a length of flexible hose over the bleed
master cylinder to each calliper and screw and place the other end of the tube
ensure that they are properly tightened. into a clean glass container and pour in
sufficient brake fluid to cover the end of
Warnings
the tube.
1. Brake fluid is poisonous; wash
Depress the brake pedal several times to
affected areas immediately in case of
build up pressure and maintain pressure
skin contact and seek medical
on the brake pedal.
assistance if fluid is swallowed or
enters the eyes. With pressure maintained on the brake
pedal unscrew the bleed screw and allow
2. Brake fluid is hygroscopic. Ensure
the compressed air and brake fluid to flow
that fluid comes from freshly opened
into the container. Tighten the bleed
container.
screw before the brake pedal is released
3. Brake fluid is corrosive to paintwork, repeat this process until no more air
powder coat and plastic components. bubbles can be seen in the brake fluid.
Care should be taken to avoid spillage
NOTE
at all times.
Ensure brake fluid level remains above
Remove the brake master cylinder cap
half full level in the brake master cylinder.
and protect the surrounding scuttle

Page | 186
Tighten bleed screw and remove flexible NOTE
hose. Replace dust cap. Carry out the
Ensure that the arrow on anti-rattle clip
procedure in the following sequence. RH
points in the direction of wheel rotation.
rear calliper, LH front calliper and finally
RH front calliper. Bleed the brake system observing the
same order as for the standard brakes.
As the rear callipers can be difficult to
bleed, it may help to gently tap the calliper The uprated front brakes have two bleed
body during the bleed process to release screws on each calliper. Remove the dust
trapped air pockets. cover from the inboard bleed screw on the
front LH calliper. Connect the flexible
It may be necessary to repeat the brake
tube to the bleed screw and operate the
bleed procedure several times before a
brake pedal several times. Whilst
firm high brake pedal is achieved.
mounting pressure on the brake pedal
15.1.2) Uprated front brakes open the bleed screw and allow
compressed air and brake fluid to flow into
The uprated front callipers are usually
the container. Tighten the bleed screw
supplied without the brake pads fitted.
before the pedal is released. Repeat the
Before bleeding the system fit the brake
procedure until no air bubbles are visible
pads into the calliper such that when
in the released brake fluid. Remove the
viewed from the rear of the calliper the
flexible tube and replace the dust cap.
curve of the brake pad follows the shape
Carry out the procedure for the outboard
of the disc.
bleed screw.
NOTE
As a final check on system integrity, apply
The front wingstays obstruct access to the pressure to the brake pedal and check all
uprated callipers. Ensure that the brake connections and bleed screws for any
pads are installed before fitting the sign of leakage.
wingstays.
Initially brake pedal travel may seem
Fit the anti-rattle clips behind the retaining excessive despite the system being fully
pin (between the pin and the pads/disc). bled. However, the system will improve
Rotate the disc and ensure that the anti- as the pads bed to the discs during the
rattle clip does not contact the disc at any first 500-1000 miles.
time.

Page | 187
15.2) Clutch system – filling and SA3J 1703F DOT 4 specification.
bleeding
Replace the master cylinder cap.
Prior to filling the clutch master cylinder,
Rotate the bleed key counter-clockwise
check all connections to ensure that they
until it stops and place a length of flexible
are properly tightened.
hose over the bleed screw and place the
Warnings other end of the tube into a clean glass
container and pour in sufficient brake fluid
1. Brake fluid is poisonous; wash
to cover the end of the tube.
affected areas immediately in case of
skin contact and seek medical Pump the clutch pedal until good pressure
assistance if fluid is swallowed or is felt and clear fluid, free of air bubbles,
enters the eyes. flows from the bleed nipple. Rotate the
bleed key fully clockwise, remove the pipe
2. Brake fluid is hygroscopic. Ensure
and replace the bleed nipple cover.
that fluid comes from freshly opened
container. Figure 173: Clutch hydraulic
connections
3. Brake fluid is corrosive to paintwork,
powder coat and plastic components.
Care should be taken to avoid spillage
at all times.

Remove the clutch master cylinder cap

and protect the surrounding scuttle
paintwork with clean cloths to prevent
possible fluid leakage from causing
damage to the paintwork.

Locate the bleed nipple/key on the

gearbox bell-housing (refer to Fig 174)
and remove the bleed nipple cover. 1. Pipe to master cylinder
Ensure that the bleed key is in the position 2. Push-fit connector
shown in Fig 174 (rotated fully clockwise) 3. Bleed key
and fill the clutch master cylinder reservoir
with fresh brake fluid that complies with

Page | 188
Mop up any spilled fluid, check for clutch 15.3) Coolant
‘feel’ and correct operation (repeat the Check all coolant hose securing clips are
bleeding procedure if necessary); finally, tight and that the coolant level is visible in
hold down the clutch pedal and check for the coolant expansion bottle.
leaks.
15.4) Fuel
NOTE
Warning
All sigma and Duratec cars are fitted with
Due consideration should be given to
throttle and clutch pedal stop.
the highly flammable nature of
For Duratec cars the clutch bleed nipple is petroleum or alcohol-based products
under the plate on top of the bellhousing. and their vapours. Serious burns can
result from incorrect use.
1. Throttle stop: The adjustment of the
stop is critical in order to obtain full throttle Check the security of the push-fit fuel pipe
at the throttle body end. Reaching down connection at the fuel rail.
into the footbox, press the throttle pedal
Remove the fuel filler cap and add 15
until the butterfly is fully open then adjust
litres of unleaded petrol to the fuel tank.
the throttle stop up to the back of the
pedal ball. This may take some time to get 15.5 Engine/gearbox fasteners
the correct adjustment. It is desired not to Check that all engine and gearbox mounts
have any cable stretching at full throttle and fasteners are tight.
(when butterfly is fully open and pedal
15.6) Gearbox oil
touches stop).
Warnings
2. Clutch pedal stop: the adjustment of
the Clutch stop is critical in order to obtain Oils - prolonged and repeated contact
full clutch operation. The clutch pedal is may cause serious skin disorders.
adjusted to the require length but it might
1. Avoid contact with the skin as far as
require fine tuning considering slight
possible and wash thoroughly after
variation on different cars. This may take
any contact.
some time to get the correct adjustment.
2. Keep out of reach of children.

3. First aid treatment should be

obtained for open cuts and wounds.

Page | 189
4. Use appropriate barrier creams. With all variants the engine oil should be
filled via the screw cap on the top of the
Remove the gearbox oil filler plug (if not
engine. Remove the cap from the cam
removed earlier) using the cut down 3/8”
cover and slowly pour in the oil allowing
Allen key.
time for the oil to run to the bottom of the
Add approximately 2 litres of gearbox oil engine. Replace the cap and tighten by
to the gearbox until it dribbles out of the hand only.
filler hole. Replace the filler plug.
Check around the engine area both under
Due to the restricted access it may help to the vehicle and within the engine
make a filling tube using a small funnel compartment for any visible leaks (oil or
and hose. coolant). Check all wiring and hoses to
ensure that they are correctly located
New 2014 5 speed Caterham gearbox.
particularly near any moving parts, for
You must use special oil for this gearbox example, alternator or cooling fan.

GL-4 or GL-5 and is SAE 75W-90. 15.8) Cranking for oil pressure

You need to put 1.6 litres of oil into the Before running the engine for the first time

gearbox via the filler plug on the top. it is recommended that the following

There is a level plug on the left hand side sequence is carried out. This will ensure

and 300ml into the gear lever hole. that the oil system is capable of delivering
lubricant throughout the engine.
15.7) Engine oil
 Apply handbrake and check that
The capacity of the engine oil system will
the gear lever is in the Neutral
vary dependent upon the specification of
position
the vehicle. Refer to Table 27 for an initial
 Disconnect the wires from the
fill quantity which is sufficient to start and
inertia switch, located on the
run the engine at idle before checking and
bulkhead above the ECU
topping up as detailed in your Owner's.
 Operate the ignition switch to crank
Table 27: Engine oil initial fill the engine over until oil pressure
Engine type Initial fill Qty registers on the gauge (oil pressure
Wet sump 4.5 litre will be low due to the speed of the
Dry sump 6 litre engine when turned by the starter
motor).

Page | 190
NOTE Turn ignition key to position II again and
the pump should now prime.
It may be necessary to turn the engine
over for 30-40 seconds to achieve oil Turn the ignition switch to position III so
pressure. Once oil pressure has been that the engine turns over until the engine
achieved, switch OFF ignition and starts. Some models are fitted with a
reconnect the inertia switch. Press down pushbutton starter switch. If this is the
on the rubber button on top of the inertia case on your vehicle turn the ignition
switch to ensure that it has been de- switch to position II (red ignition light ON)
activated. and depress the button to operate the
starter motor.
15.9) Start up

Apply handbrake and check that the gear Do not allow the engine to run for more

lever is in the Neutral position. than one minute without checking the oil
level. Using the dipstick as a level, top up
Warnings the oil system until oil is visible between

1. The electric radiator fan is controlled the 'Min' and 'Max' marks. This will

by a thermostatic switch which ensure enough oil is in the engine to

operates when the ignition is in the on perform the initial run and warm up. The

position. whilst working on a hot final check for the engine oil level will be

engine ensure that the ignition is performed later in this Section. Check

switched off. around and under the engine for any

visible signs of leaks.
2. Do not remove coolant expansion
bottle cap whilst coolant is hot. Take Once you have checked and topped up

precautions to prevent scalds. the oil level as required, restart the engine
and leave running until it is warm. Ensure
Check under the car to ensure that there
that the oil pressure gauge continues to
are no visible leaks. De-activate the
indicate 2 bar (29 psi) or above at idle.
immobiliser.
Allow the engine to run until the cooling
Turn the ignition key to position II and
fan cuts in (this should be at
listen for the fuel pump to prime. If no
approximately 92C). Switch off the
sound is heard, switch OFF the ignition
engine.
and reset the inertia switch by pressing
the rubber button on top until it clicks.

Page | 191
NOTE Table 28: Recommended suspension
alignment - road use standard and
Should the temperature exceed 92C wide track

without the cooling fan cutting in, switch Front Rear

OFF the engine immediately to avoid Tracking 0 20'  0 10' N/A

damage. Contact the Caterham technical Toe-In

helpline, as it is possible that there is an Camber 1 20'  0 15' 1 30'  0 15'

air lock in the cooling system. (Negative) (Negative)

Castor 4 00'  1 00' (0 20'
Check the car for visible leaks. Re-check variation left to right, front)
the hose clips for tightness as the rubber
hoses become softer when warm.
Increased negative camber will tend to
Finally check the engine oil as detailed in improve the car's turn in characteristics in
the Owner's Handbook ensuring the fast corners but at the expense of possible
instructions for the correct engine tramlining on uneven surfaces and
specification are followed. If in any doubt uneven tyre wear under normal
please contact Caterham cars. conditions. The factory settings should

15.10) Front suspension and steering therefore be adhered to except where the
alignment car is being prepared for motor sport.
The front suspension is adjustable for
The adjustment of castor is achieved by
both camber and castor angles. The top
moving the lower front wishbone
wishbones normally come from the factory
backwards or forwards in the chassis
pre-adjusted although you may wish to
using spacing washers, therefore altering
reset or change the basic settings.
the effective kingpin angle in side
Factory recommended settings are shown
elevation. Increasing the angle away from
in Table 28.
vertical will produce more pronounced
self-centring of the steering and hence a
greater feeling of stability, but at the
expense of heavier steering.

Initial toe-in settings (standard track) for

driving to a service agent for post build
checking can be set visually by ensuring
the outside edge of the front tyres lines up

Page | 192
with a point on the rear tyres ~ 50 mm in x 13
from the outside edge, with the steering 6J x 13 CR500 175/55
18 18
wheel centred. This approximate setting x 13

will not cause either dangerous handling 6J x 14 AVON 185/60

20 20
x 14
or unnecessary tyre wear for limited initial
6½J x 13 CR500 175/55
mileage. Initial tracking of wide track cars 18 -
x 13
can be set by visually aligning the outside
8½J x 13 CR500 205/55
edges of the front and rear wheels. - 20
x 13

It is recommended that distinctly different 6½J x 15 CR500 195/45

18 18
settings are used for race, hill climb or x 15

sprint applications. Caterham can provide

a range of anti-roll bars and a competition Some tyres supplied by Caterham are
parts brochure is available from the Parts directional. As a result any spare tyre
Department at the factory. supplied will only be treaded in the correct

15.11) Final checks direction for one side of the car. If the
spare tyre needs to be fitted to the side
Warning
where the rotation is incorrect this should
Re-tighten wheel nuts after 200 miles be done only as a means to get you home
and must be rectified before any further
The wheel/tyre combinations supplied by
use of the vehicle. Ensure that the tyres
Caterham, are pre-inflated to
are fitted with the correct orientation.
approximately 40 psi (2.8 bar) to ensure
that the tyre is correctly seated on the Ensure that no wires or brake hoses are in
wheel rim and must be reduced prior to such a position to chafe or to contact
driving. Tyre pressures should be moving or hot components. Particular
checked in accordance with Table 29. care should be taken with wires close to
the exhaust manifold.

Before the car is used, ensure that all

bolts securing suspension, steering and
Table 29: Tyre pressures brakes are properly tightened, refer to
Wheel Front Rear Table 30.
Tyre type/size
type (psi) (psi)
6J x 13 ACB10 6 x 20 18 18

Page | 193
Table 30: Torque figures for final checks and start up procedure
Location Washers Torque Nm
Front lower wishbone front Spring and plain 81
Front lower wishbone rear Plain spacer 81
Front upper wishbone front N/A 34
Front upper wishbone rear N/A 34
Front spring damper top Spring and plain 20
Front spring damper bottom Loctite 20
Upright top ball joint N/A 54
Upright bottom fixing Spacer (widetrack only) 54
Front anti-roll bar clamps N/A 20
Steering rack clamps Plain under bolt head 11
Steering column universal joint N/A 20
Steering column clamp plate Spring and plain under bolt head 14
Track rod end to upright N/A 34
Upper differential mounting Plain under bolt head and nut 54
Lower differential mounting Plain under bolt head 54
Propshaft N/A 74
Rear spring damper top N/A 54
Rear spring damper bottom 54
Watts link locknut 20
Bellcrank to link 14
Watts link rear mount 34
Watts link front mount 34
Bell crank to De Dion 34
Radius arms 34
‘A’ frame N/A 81
Hub nuts Thrust 270
Hub mounting N/A 47
Brake calliper Plain and spring 47
Rear anti-roll bar clamp Plain under bolt head and spring
14
under nut
De Dion ears Plain and spring 47
Gearbox to bell housing Spring under bolt head 47

Page | 194
Gearbox mount Spring under bolt head 61
Engine to bell housing Spring under bolt head 47
Bell housing to sump N/A 20
Starter motor Spring under bolt head 34
LH engine mounting bracket Spring under bolt head 34
RH engine mounting bracket Spring under bolt head 34
Engine mounting rubbers Plain between chassis and nut 20
Engine mounting to rubbers Spring under bolt head 41
Gearbox mount to chassis Plain between chassis and nut 20
Exhaust manifold N/A 34
Expansion tank bracket Plain under bolt head and nut 10
Gear-lever to tail housing N/A 20
Brake banjo bolt Copper washer each side of banjo 10
Brake unions N/A 10
Seat belt/harness bolts See assembly instructions 47
All roll over bar fixings See assembly instructions 20
Petty bar See assembly instructions 47
Wheel nuts (2 part nut and tapered washer) N/A 74

Page | 195
 to passing the IVA inspection may prevent
16.0) Individual vehicle approval
it from passing an MOT at a later date.
and registration
For example if a competition exhaust is
fitted the original catalyst equipped
All Caterham cars will have to be
system would need to be retained in order
inspected under the IVA regulations in
to meet MOT emission standards. The
order to be registered for road use.
MOT is an inspection of the vehicles
The inspectors have all been trained to condition and will be carried out in the
the same standard but may interpret same manner as for normal production
certain regulations differently. Each test cars. Items such as internal/external
station will have received a detailed projections, noise and fields of visibility
explanation of what a Caterham is and will not be inspected at an MOT.
what European regulations it complies
16.1) Requirements
with. The inspectors therefore should
have reasonable product knowledge and The following items are checked under the
have a contact number at Caterham if IVA inspection:
required.
 Anti-theft Devices
It is recommended that the car is  Defrosting and Demister System
presented in a clean condition as this will  Wiper and Washer System
greatly improve the inspector’s  Seats and their Anchorages
demeanour.  Seat Belts
 Seat Belt Anchorages
It is also advisable to take an emergency
kit with you to the test station. This should  Installation of Seat Belts

consist of a basic toolkit, cable ties, push  Interior Projections

on trim and a length of rubber hose. In  Radio Interference Suppression

the event of components needing  Glass and Glazing

tightening for adjustment or a non-  Lamp, Reflectors and Devices
compliance, the emergency kit may save  Rear View Mirrors
you taking the car away and having to  Tyres
re-present it at a later date.  Exterior Projections
 Protective Steering
You should remember that any
 Vehicle construction and design
modification made to the car subsequent
 Brakes

Page | 196
  Noise  Complete the form and return it
 Exhaust Emissions along with the test fee to:
 Speedometers
IVA section
The Vehicle and Operators
The examiner will conduct an engineering Services Agency
assessment rather than the more 91/92 The Strand
Swansea
thorough test that full European Type SA1 2DH
Approval entails. In some cases (brakes,
0870 6060 440
noise, emissions etc.) there will be a http://www.vosa.gov.uk
physical test either on a rolling road or
You will then receive confirmation of the
within the grounds of the test centre.
inspection which will give details of the
The inspection will not require any part of time and location. Where possible the
the car to be dismantled and will be inspection will be carried out at the
carried out at Vehicle Inspectorate test Vehicle Inspectorate test station you have
stations. selected.

The inspection is anticipated to take 16.3) Inspection refusal

approximately four hours and can be
The test station may refuse to inspect
booked between 0800-1700 Monday to
your car for the following reasons:
Thursday or 0800-1630 on Friday. There
is a fee payable for this service. An  You arrive at the test station later
additional fee will be charged if an than your appointment time
inspection is required outside these hours.  You have not paid your fee
 There is insufficient fuel or oil for
16.2) How to apply for the inspection
the test. You will be required to
The inspection has to be formally booked have a full tank of fuel
in advance therefore you must:  The car is presented in a

 Obtain an application form from dangerous or such a dirty condition

your local Vehicle Registration that the test is not feasible

Office (VRO) or Vehicle  A device designed to be readily

Inspectorate Office (HGV Station). opened cannot be opened (e.g.

bonnet padlocked)

Page | 197
  The vehicle presenter does not It is recommended that the checks and
remain with the car to operate operations detailed in the following
controls etc. as requested paragraphs are completed prior to taking
the car for the inspection.
16.4) Inspection data
16.5.1) Wiper and washer system
16.4.1) Design weight

You will be asked to specify the maximum Carry out a full system check prior to the

gross weights and maximum permitted inspection. Ensure the screen washer

axle weight during your application for a bottle is full, the wiper blades contact the

test date. This will then be checked by windscreen and the washer jets are

weighing the car without passengers and correctly adjusted. Ensure all hoses are

luggage (kerb weight) and then using a secure as the system will be checked

formula to calculate the theoretical gross under pressure.

weight. The following weights should be 16.5.2) Radio interference suppression

quoted for all models:
Caterham supplied ignition leads are
Maximum Gross Weight – 860Kgs suppressive. If you choose not to use the
Caterham supplied ignition leads and
Maximum Permitted Front Axle Weight –
have supplied your own leads, ensure
360Kgs
they are clearly marked as suppressive.
Maximum Permitted Rear Axle Weight –
16.5.3) Lamps, reflectors and devices
500Kgs
If you have built your car using the
16.4.2) Towing
components and information supplied, the
It is not recommended that the Seven is car will comply with IVA lighting
used for towing, therefore, when asked requirements. Ensure that repeater
the question; the answer is 'Not indicators are fitted to the front wings.
Applicable'.
16.5.4) Rear view mirrors
16.4.3) Speedometer
These should be set up for maximum
The speedometer is compatible with this visibility. Ensure that the windscreen
vehicle. mounted mirror and both screen stanchion
mirrors are in place. It is also worth
16.5) Checking and preparing the car
prior to inspection removing the hood, or arriving without it

Page | 198
altogether, as this improves both visibility pad must be in place during the
and access. inspection.

16.5.5) Noise 16.5.9) Brakes

Tailpipe noise will be tested. Though the The braking system will be subjected to a
silencer is brand new, the efficiency is thorough test (on brake rollers) so it is
increased when the internal packing has imperative that you take the time to bleed
expanded against the inner wall. It is the brakes correctly. The performance of
therefore recommended that you allow the the brakes often improves dramatically
car to idle as much as possible prior to after a small amount of use. Frequent
taking the car to the test centre. This will application of the brakes on the way to the
also allow a layer of soot to settle which test centre will help the brakes bed in.
will help deaden the 'ring' of the new
Ensure the handbrake is correctly
silencer.
adjusted and does actually lock the rear
16.5.6) Emissions wheels.

All Caterham cars are supplied with 16.5.10) Interior and exterior projections
catalytic converters and will meet the test
Supplied with the kit is a polythene bag
requirements.
marked 'IVA', refer to Figure 175. It is
16.5.7) General construction essential that these items are fitted prior
to presentation at the IVA Testing station.
This should be checked at the Post Build
Check stage, however if you are not using
that service ensure that chafing of brake
pipes and the wiring looms is not possible.
If you have followed the procedures
detailed in the Assembly Guide then you
should not have any problems at this
stage of the inspection.

16.5.8) Protective steering

All standard Caterham steering wheel

types have a removable pad fitted. This

Page | 199
Figure 174: IVA bag contents Apply the self-adhesive Velcro strips
around the sides and bottom of the fuse
box cover. Attach the other half of the
Velcro fastening to the Velcro already
attached to the fuse box cover. Locate
the cover over the fuse box sticking it in
place. (R400 only).

The edge trim should also be secured to

1. Scuttle trim 7. Bolt head covers the edges of the front cycle wings (Fig 177
2. Foam tape 8. Nut covers Item 4), the edge of the black plastic
3. Edge trim 9. IVA mirror stalks and housing around the rear fog and reverse
fittings
lights and the edges of the indicator
4. Cable ties 10. Rear bonnet catch
cones. Cars fitted with the detachable
cover
5. Track rod sleeve 11. Front bonnet catch wind deflector will also require edge trim
6. Flexible covers cover along the top edge of the deflector and
Ensure that the scuttle edge trim (Figure around the edges of the mirrors.
176 Item 1) is fitted to the edges of the
The caps (Figure 178 Item 3) should also
scuttle around the dashboard.
be fitted to the nut and bolt head of the top
Figure 175: IVA scuttle trim and battery wishbone front mounting.
master switch

1. Scuttle edge trim

2. Eyebrow edge trim
3. IVA cover
4. Battery master switch sheath
5. IVA cover (optional roll cage)

Page | 200
Figure 176: Bonnet catches Figure 177: Front suspension

1. Track rod sleeve

1. Rear bonnet catch cover
2. Stub axle cover
2. Front bonnet catch cover
3. Steering arm nut cover
3. Edge trim (indicator cone)
4. Track rod end nut cover
4. Edge trim (cycle wing)
Covers (Figure 178 Items 2, 3 and 4),
should be fitted over the inner stub axle
The bonnet catch covers (Figure 177 nuts, the steering arm nuts, the track rod
Items 1 and 2) should be pushed over the end nuts and the two wheel nuts that hold
respective bonnet catch. The covers the spare wheel to the spacer wishbone (if
(Figure 175 Item 7) should be fitted to the fitted). Covers (Figure 179 Item 1) should
shoulder strap mounting bolts (Only be fitted to the exposed nuts securing the
required if this 4 or 6-point harness option exhaust bobbin and the exhaust bracket
is specified). The sleeves (Figure 178 and an off-cut of scuttle edge trim should
Item 1) should have been fitted over the be fitted to the upper edge of the exhaust
track rodlocknuts during the front silencer bracket.
suspension build.
Figure 178: Exhaust mounting

Page | 201
The sharp edge of each side screen these parts will need to comply with the
hinges should be protected as shown in IVA criteria.
Fig 180. The protectors are made by
Fire Extinguisher. The 'T' handle that
cutting grommets in half and fixing them in
operates the fire extinguisher will need to
place with superglue.
be removed and the boss in the dash
NOTE covered.

The hinge halves fitted to the side screens Track day roll over bar/roll cage. All
must be protected in a similar manner. fixings will need to be covered. If the track
day roll over bar petty strut is supplied this
Road wheels are exempt from external
will need to be removed and the hole in
projections with the exception of the spare
the side panel must be covered.
wheel. Ensure the wheel is positioned
such that any balance weights are behind Battery Master Switch. The edges of the
the spare wheel carrier. master switch key will not pass IVA; a
rubber sheath for the key is included in
Figure 179: Side screen hinges
the IVA kit and this must be fitted for the
test. The eyebrow must be fitted with edge
trim and the fixing bolts will need
protective caps, refer to Figure 176.

16.6)Registration procedure after IVA

inspection

If your vehicle fails the IVA inspection for

any reason you will be allowed to take the
car away to rectify it.

1. Grommets Upon successful completion of the IVA

2. Rear view mirrors (IVA position)
inspection you will be issued with a
16.5.11) Race cars and IVA certificate to confirm that the car has
There are several parts that are passed to the standard required. This
mandatory on race cars which are not IVA certificate is officially called a Minister's
friendly. Ideally these parts should be Approval Certificate (MAC) and must be
fitted after the car has been submitted for retained. In order to register your car you
its IVA test but if this is not possible then must submit the MAC, a completed

Page | 202
application for registration form (currently DVLA to cover administration costs
V55/5), insurance certificate and your throughout the vehicle's life (sending out
certificate of newness (with full CKD De VED reminders etc.).
Dion kits only) along with your Vehicle
The car will be subjected to an MOT
Excise Duty (VED) fee for either six
inspection three years after it was first
months or twelve months to your local
registered.
Vehicle Registration Office (VRO). In
addition a registration fee will be levied by
16.7) Location of vehicle inspection test stations where the IVA test can be carried
out

Aberdeen Derby London–South (Mitcham)

Cloverhill Curzon Lane Redhouse Road
Bridge of Don Industrial Estate Alvaston Croydon
Aberdeen AB23 8EE Derby DE21 7AY Surrey CR0 3AQ
01224 702357 01332 571961 020 8684 1499

Beverley Exeter London–West (Yeading)

Oldbeck Road Grace Road Cygnet Way
Off Grovehill Road March Barton Trading Estate Willow Tree Lane
Beverley Exeter Yeading
East Yorkshire HU17 0JG Devon EX2 8PU Hayes
01482 881522 01392 278267 Middlesex UB4 9BS
020 8841 9205
Birmingham Gillingham
Garretts Green Industrial Estate Ambley Road Manchester–North (Chadderton)
Birmingham B33 0SS Gillingham Broadgate
0121 783 6560 Kent ME8 0SJ Broadway Business Park
01634 232541 Chadderton
Bristol (Avonmouth) Oldham OL9 9XA
Unit 10, I.O. Centre Glasgow (Bishopbriggs) 0161 947 1000
Poplar Way West Crosshill Road
Avonmouth Bishopbriggs Newcastle-upon-Tyne
Bristol BS11 0QL Glasgow G64 10A Sandy Lane
01179 381157 0141 772 6321 Gosforth
Newcastle-upon-Tyne NE3 5HB
Cardiff (Llantrisant) Leighton Buzzard: 0191 236 5011
School Road Stanbridge Road
Miskin Leighton Buzzard Norwich
Pontyclun Bedfordshire LU7 4QG Jupiter Road
Mid Glamorgan CF72 8YR 01525 373074 Hellesden
01443 224701 Norwich NR16 6SS
Liverpool (Speke): 01603 408128
Carlisle C/O South Liverpool Commercials
Brunthill Road Woodend Avenue Nottingham
Kingstown Industrial Estate Speke Main Road
Carlisle CA3 0EH Liverpool L24 9NB Watnall
01228 528106 0151 4860050 or 0151 5474445 Nottingham NG16
0115 938 2591
Chelmsford London–North (Edmonton)
Widford Industrial Estate Anthony Wharf
Chelmsford Lea Valley Trading Estate
Essex CM1 3DR Edmonton N18 3JR
01245 259341 020 8803 7733

Page | 203
Shrewsbury Southampton (Northam): Taunton
Unit 6 Levens Drive Unit R, Centurian Industrial Estate Taunton Trading Estate
Harlescott Bitterne Road West Norton Fitzwarren
Shrewsbury SY3 7EG Southampton SO18 1UB Taunton
01743 462621 02380 837397 Somerset TA2 6RX
01823 282525

Page | 204
 attached to the master switch connection
17.0) Options along with a double brown wire.

These fitting instructions are supplied in 17.2) Standard roll over bar
addition to the normal assembly guide Insert the bosses; on the underside of the
delivered with your kit. They are specific roll over bar main hoop into the bucket
to the additional equipment required when bushes located at each end of the seat
using your car for competition purposes. belt header rail towards the rear of the
This document is supplied with new kits cockpit, refer to Figure 181. Locate the
and as instructions to customers rear diagonals of the roll over bar into the
purchasing upgrades for an older car. IVA mounting brackets at the rear of the boot
notes have been included for customers compartment. Secure the roll over bar to
needing to register a new vehicle. the chassis using set screws (fastener
pack 30P010A Item 2), spring washers (6)
It is important that these instructions are
and washer (5).
read in conjunction with your assembly
guide in particular with regard to the The rear diagonals are secured to the
preliminary information that can be found brackets by bolt (1) and nyloc nuts (4) with
at the front of the guide. a plain washer (5) under the bolt head and
nyloc nut. Tighten all fastenings to 20
17.1) Battery master switch
Nm.
If specified the battery master switch will
have been fitted at the factory. Figure 180: Standard roll over bar

Locate the two thick red leads exiting the

transmission tunnel. Connect the lead
marked 'starter' to the starter solenoid
along with the large brown lead (with
black sleeve) from the alternator. Route
the lead marked 'battery' to the battery
positive terminal. Do not connect.

Check that the lead to the battery is 1. Standard roll over 3. Spring washer

attached to the single connection of the bar

2. Set screw 4. Plain washer
master switch and the lead to the starter is

Page | 205
17.3) Track day roll over bar 1. The Petty strut is not IVA compliant and

Before fitting the Track day roll over bar it therefore should be removed for normal

will be necessary to remove the rear road usage.

spring damper units in order to gain The forward end of the Petty strut is
access to the lower mounting points. secured to a mounting boss located within

The Track day roll over bar is fitted in the the chassis that is normally hidden behind

same manner as the standard roll over the interior trim panel. It can be found in

bar with the exception of additional fixings the passenger side of the cockpit

located in the ends of the main hoop. approximately one inch below the point at
which the dashboard tube is welded to the
Having placed the roll over bar into top of the chassis rail.
position, but before finally tightening the
fixings, pass from underneath bolt (3) If a 7/16" hole is not visible, drill out the

supplied with the roll over bar z pack, into six 5/32" rivets holding the top edge of the

the threaded holes in the ends the main trim panel surrounding this point and ease

hoop of the Track day roll over bar. Leave the trim panel away from the chassis until

these fasteners loose until all fixings are in the exact location of the mounting boss is

place. identified.

Figure 181: Track roll over bar Warning

Use appropriate eye protection whilst

carrying out drilling operations.

Drill a small pilot hole through the trim

panel taking great care not to touch the
outer side skin and enlarge such that a
7/16" bolt can be fitted through. Ensure
that the inner thread in the mounting boss
An additional, optional Petty strut can be is not damaged during this process.
added to the Track day bar for added Loosely fit bolt (fastener pack ZPS01 Item
strength. 2) and secure the trim panel with rivets.

Remove bolt (2). Secure the Petty strut to

the roll over bar, using bolts (1), with plain
washers (4), under the head of the bolts.

Page | 206
Pass the bolts through the plate on the 17.4) Roll cage
Petty bar then rearwards through the Warning
fixing holes in the centre of the main hoop,
secure with plain washers (4) and nyloc Never work underneath a car without

nuts (3). supporting it on axle stands or

equivalent. Do not rely on a jack alone.
Attach the forward end of the Petty strut to
the previously uncovered boss using bolt 17.4.1) Preparation

(2) passed through spring washer (6), Before fitting the roll cage it will be
plain washer (5) then the fixing plate at necessary to remove the rear spring
the forward end of the bar. It may be damper units in order to gain access to
necessary to use the additional plain the roll cage lower mounting points.
washer(s) (5) between the front fixing
NOTE
plate and the side of the chassis to
achieve the best fit. This roll cage is IVA-compliant however
protective covers will be required on the
Tighten additional roll over bar mounting
four bolt heads that attach the front hoop
bolts in accordance with Table 31.
to the chassis.
Table 31: Track day roll over bar
mounting bolt torque figures You will also be required to have IVA
compliant mirrors fitted to both the driver
Torque
Location and passenger sides of the car to ensure
Nm
Base of the bucket bushes 20 rear visibility is maintained.
Mounting flange 5/16” UNF 20
The lower ends of the hoop that forms the
Rear diagonals 5/16” UNF 20
front of the cage, attaches to two pre-fitted
Petty bar (all fixings) 47
threaded bushes. These bushes are
located, behind the side panels; one on
It is recommended that all parts of the roll each side of the car and approximately
over bar likely to be contacted by either one inch below the point at which the
the driver's or passenger's head to be dashboard tube is welded to the top of the
protected with approved roll bar padding. chassis rail, refer to Figure 183 before
Suitable FIA approved padding is attempting to fit the cage, these bushes
available from the Caterham parts will need to be uncovered.
counter.

Page | 207
Figure 182: Front fixing boss location centre line of the bush. Using a centre dot,
dot the outside of the side panel on the
witness mark and drill a 4 mm pilot hole,
then enlarge such to give clearance for a
7/16" bolt. Ensure that the inner thread in
the mounting boss is not damaged during
this process.

1. Front hoop saddle bracket Repeat this process on the other side of
2. Fixing bolt – in threaded bush the car then run a 7/16" UNF bolt into both
3. Chassis top tube - sill bosses to ensure the threads are clean
and undamaged.

Warning NOTES

Use appropriate eye protection whilst 1. Do not re-rivet the interior side panels
carrying out drilling operations. at this stage.

If a 7/16" hole is not visible in the side 2. If you intend to run sill protectors, you
panel, drill out the 5/32" rivets holding the will need to remove these prior to fitting
top edge of the trim panel surrounding this the cage. They will also require trimming
point and ease the trim panel away from at the forward end to enable them to be
the chassis until the exact location of the refitted around the cage.
mounting boss is identified. Drill a 4 mm
3. You are now ready to attach the roll
pilot hole through the trim panel then
cage to the chassis however due to the
enlarge to give clearance for a 7/16" bolt.
size and weight of this part it is strongly
Ensure that the inner thread in the
recommended that you obtain further
mounting boss is not damaged during this
assistance as an extra pair of hands to
process.
help guide the cage into position could
Take a 10 mm drill bit and pass it through prevent damage.
the threaded boss until the pointed end of
17.4.2) Roll cage fitment
the drill touches the inside of the outer
side panel. Gently tap the end of the drill Offer the cage up to the car and gently
bit until a small witness mark is visible on rest in place. Insert the bosses at the
the outside of the side panel along the bottom of the rear hoop into the bucket

Page | 208
bushes located at each end of the seat detailed below. Do not finally tighten any
back harness rail at the rear of the of the fixings until they are all in place.
cockpit, refer to Figure 184.
Locate the underside of the bucket
Figure 183: Rear hoop bucket bushes bushes and pass the reduced head bolts
(fastener pack 30P017A Item 3) up
through the bottom of the bush and into
the threaded boss on the roll cage. No
washers should be used on these bolts as
this will restrict damper clearance. Do not
tighten at this stage.

1. Bucket bush location Loosely fit bolt (2) through the interior side
2. Roll cage rear hoop panel, the roll cage and into the threaded
3. Seat back harness rail chassis boss. This will hold the side panel
in place whilst it is riveted back into place.
If you intend to run sill protectors then
Carefully lower the front of the cage until
these will need to be trimmed and re-fitted
the saddle brackets at the ends of the
at this stage. Run the piping between the
front hoop rest over the chassis top tube
interior side panel and the chassis side
(sill). When fitted, the inner leg of the
rivet into place through the pre drilled
saddle should be between the fixing boss
holes using rivets (fastener pack ZCH 01
and the interior side panel, refer to Figure
Item 5).
183.

NOTE
As the front of the cage is lowered into
place the rear legs will rise and locate If you are building a new kit, refer to the
themselves between the mounting plates assembly guide regarding fitment of knee
at the rear of the boot compartment. The trim panels as these are also best fitted at
bosses on the ends of the rear hoop will this time.
drop into the bucket bushes.
Remove the loosely fitted bolt (fastener
The cage can now be bolted into place pack 30P017A Item 2) and adding a plain
using the fixings provided. Align the holes washer (5) pass through the interior side
one by one and loosely fit all the fixings as panel, roll cage saddle bracket and into

Page | 209
the threaded boss. Do not tighten at this Table 32: Roll cage mounting bolt
torque figures
stage.
Location Torque
Repeat the above using bolts (2) and plain Nm
washers (5) passed through the outer legs Base of the bucket bushes 34
of the saddle bracket and into the Rear legs 20
threaded bush in the chassis. Ensure that Forward hoop saddle brackets 47
this bolt does not ‘bottom out’ on the bolt
inserted from inside the cockpit.
17.5) Head restraint (roll cage and roll
over bar)
NOTES
NOTE
1. If you intend to fit a rear wheel
protection bar then the outer fixing bolt on The head restraint is not IVA-compliant
the driver’s side of the car will need to be and should not be fitted prior to the IVA
removed again to allow fitment of this part. test.

2.The rear wheel protection bar is not The head restraint is supplied as two
IVA-compliant and should not be fitted parts, an adjusting bracket and a square
prior to the IVA test. head pad with a long adjusting stud.

The rear legs of the cage are secured to Attach the self-adhesive foam pad
the mounting plates at the rear of the boot (fastener pack 30P011A Item 5) to the
compartment using bolts (1) and nuts (4) front face of the square head pad.
passed through the plates and the holes
Attach the bracket to the cross section of
in the end of the legs. Plain washers (6)
the roll cage/bar so that the adjusting slot
must be fitted under both the head of the
is vertical to ground so that the longer
bolt and the nut (these bolts may appear
fixing leg attaches to the lower cross tube,
to be undersize but they are intended to
refer to Figure 185.
be only a loose fit in the respective holes).
Bolt in place using bolts (1) and nyloc
With all the fixings in place they can be
nuts (2) with plain washers (4) under both
finally tightened in accordance with Table
the head of the bolt and the nut.
32. See also note above.

Page | 210
Figure 184: Head restraint assembly When the car is complete and you have
obtained a comfortable driving position
this assembly can be adjusted up, down,
forwards and backwards to give the
optimum position in relation to your crash
helmet. Once this position has been set, it
is advisable to trim off any of the excess
studding.

17.6) Fire extinguisher pull handle

1. Adjusting bracket
2. Square head pad NOTE
3. Foam pad
The fire extinguisher handle is not
4. Adjusting stud (head pad)
IVA-compliant and therefore will not have
5. Plain nuts and washers (x2)
6. Bolts and washers (x2) been fitted at the factory, even though the

7. Nyloc nuts and washers (x2) rest of the extinguisher system may have
been. Do not fit prior to IVA test.

Screw one of the plain nuts (3) onto the Insert the inner cable through the hole in
head pad stud followed by one plain the centre of the boss that has been pre
washer (4), pass the stud rearwards fitted to your dashboard. Ensure that the
through the vertical slot in the adjusting handle is pushed fully home, refer to
bracket and fix into place with the Figure 186.
remaining plain washer (4) and plain nut
Figure 185: Fire extinguisher pull
(3). Finally tighten all fixings in handle
accordance with Table 33.

Table 33: Head restraint fixing torque

figures
Torque
Location
Nm
Bracket to roll cage/bar 34
Adjusting nuts (once adjusted) 34
1. Pull handle
2. Dash mounting boss

Page | 211
Pass the inner cable through the hole in 17.7) Aero fuel filler cap
the cable locater fitted to the extinguisher 3 2 1

lower handle, then through the opposing

hole in the top handle.

Secure the inner cable in place using the

solder-less nipple supplied, refer to Figure
5 4 6
187.

Trim off excess cable to approximately 30 1. Filler cap 5. M5 x 12 cap head

mm. 2. Gasket screws (x2)
3. Neck adapter 6. M5 x 16 CSK head
Apply a small piece of tape or heat shrink 4. Keys screws (x6)
to the trimmed inner cable to prevent
fraying.
Warning
NOTE
There is always a risk of fire or
It is advisable to allow approximately 5 explosion when working on fuel tanks.
mm of free play, as the scrutineer may Take the utmost care with
want to ensure that the cable is free whilst preparations.
scrutineering your car.
If the Aero filler cap is to be retro fitted,
Figure 186: Fire extinguisher inner the original cap must first be removed as
cable location
follows. Undo the two self-tapping screws
and remove the black filler neck cover
inside the boot. Remove the boot carpet
to prevent it getting dirty.

1. Outer cable 4. Top handle

2. Inner cable 5. Solder-less nipple
3. Cable locater

Page | 212
Figure 187: Filler cover and boot carpet Figure 189: Old filler boss removed
removed

Warning Take the gasket supplied with the kit and

carefully align the hole in the gasket with
Wear appropriate eye protection whilst
the hole in the back panel. Ensure two of
carrying out drilling operations.
the fixing holes are positioned at 3 o’clock
Remove the old cap with the the key and and 9 o’clock.
block the filler hole with tape or cloth.
Figure 190: Gasket positioned on back
Remove the two self-tapping screws that panel
retain the top of the filler neck to the filler
boss, the rubber hoses will then allow the
filler neck to be pulled out of the way.

Drill out the six rivets that retain the old

filler boss. This must be done very
carefully to avoid damage to the back Mark the new hole positions and carefully
panel. It is recommended this is done with centre punch the marks. Taking great
a hand or air drill to eliminate the sparks care, drill the holes (6 mm diameter).
caused by an electric drill.
Figure 191: Carefully drill new holes
Figure 188: Drill out the six rivets

Fit the black spacer to the filler neck using

The old filler boss can then be carefully the two M5 cap head screws supplied in
pulled away from the back panel. the kit. The spacer will be a tight fit on the

Page | 213
neck due to the O-ring and it must be Figure 193: Fit flange
pulled up evenly. The holes for the spacer
are slotted to allow for correct alignment
with the holes in the back panel. Tighten
the screws fully after the alignment has
been checked.

Figure 192: Spacer fitted to filler neck

Remove all drillings from the inside of the

boot and re-fit the boot carpet. Reposition
the filler neck cover and retain it using the
two self-tapping screws.

Figure 194: Job complete

Re-position the filler neck and gasket up

against the back panel. Push the filler
flange through the hole in the panel. Care
must be taken to ensure correct
orientation of the flange (One of the four
'scallops' has been enlarged to enable a All that remains is to remove the tape or
petrol pump nozzle to pass further into the cloth from the neck and fit the new cap.
neck. It is important that this larger
NOTE
scallop is orientated towards the top),
refer to Fig 195. Retain with the six M5 x Remember to fit the key to the new cap to
16 CSK head screws and pull these up your key ring.
evenly to ensure the flange locates
correctly on the O-ring.

Page | 214
17.8) High level brake light Warning

Figure 195: Kit contents for high level Wear eye protection when carrying out
brake light
drilling operations.

Centre mark a point 25 mm below the top

of the back panel, on the vehicle centre
line. Centre punch this, and drill a 5/32”
hole, taking care not to damage the back
panel. In the case of the SV, simply
remove the central hood/boot cover
popper using a 5/32" drill, as shown in
1. Wiring sub loom Figure 198.
2. Wiring to high level brake light
3. Rivets (x2) Figure 196: Drilling central popper on
SV
4. Male Lucar terminals and shrouds
5. Nut and plastic bolt from light kit
6. Replacement popper
7. Rubber grommet
8. Sticky pad
9. Cable ties
10. Larger spare wheel boss
Using masking tape to protect the
11. Cable insulation
paintwork from damage, position the
12. Light support bracket
bracket as shown in Fig 199, passing the
13. High level brake light
new, larger spare wheel boss through the
bracket and back panel, ensuring only one
17.8.1) Fitting the bracket large washer is used in between the back
If retro-fitting, the spare wheel must first panel and spare wheel support channel.
be removed from the car. Secure the boss using the 5/32” nut,
finger tight only.
Working from inside the boot, unscrew
the 5/8” nut which holds the spare wheel
boss to the back panel, and remove the
boss, taking care not to drop the large
washers.

Page | 215
Figure 197: Alignment of bracket plastic bolt from the underside, and
tighten nut to secure in place as shown in
Fig 200. Connect the terminals to the
male connectors on the metal strips on
the bulb holder.

Figure 198: Wire routing through light

unit

Using a spirit level, refer to Figure 199,

adjust the bracket until the light platform is Centre mark a point on the vehicle centre
exactly parallel to the top of the back line, 35 mm above the edge of the spare
panel, and mark from inside the boot wheel mounting boss. Centre punch, and
through the previously drilled hole, onto carefully drill a 1/4” hole, as shown in
the bracket. Figure 200. Masking tape can be used to

Remove the bracket, centre punch and protect the paintwork. Push the supplied

drill the hole using a 5/32” drill. Re-fit the rubber grommet into the hole.

bracket, and secure the upper mounting Figure 199: Drilled hole above spare
using the large black rivet, or for an SV wheel boss
the smaller countersunk rivet passed
through the replacement popper. Apply
threadlock, and tighten the 5/8” nut to 34
Nm.

17.8.2) Light and wiring connections

If painting of the light casing is required,

follow the instructions supplied with the Warning
light.
Disconnect the negative (-) terminal
Split the light and feed the terminated end from the battery before carrying out
of the supplied wires through both the electrical work.
hole in the base of the light unit, and the
Working from inside the boot, unscrew the
nut supplied with the light unit. Insert the
four retaining screws that secure the fuel

Page | 216
filler neck cover, and remove it. From Figure 201: Exploded view of assembly
under the right and rear corner of the car,
feed the terminated end of the supplied
sub-loom up into the boot area, through
the hole exposed by removing the filler
neck cover. Disconnect the wiring plugs
leading to the rear light cluster, and
connect the plugs from the sub loom in
between, as shown in Fig 201.
Cut the wires from the light unit to length
Figure 200: View from under RHS rear
so the connections can be concealed
corner
behind the filler neck cover, and terminate
with the male Lucar terminals and
shrouds. Connect these to the sub-loom;
grey/red to the green/purple, and grey to
the black wire. Use the cable ties
provided to tidy and secure the wiring, and
re-fit the filler neck cover.

Figure 202: Wires from support tube

Re-assemble the light unit, and feed the entering boot
cable insulation over the wires. Push
them through the hole in the sticky pad
and the hole in the platform on the
bracket, then use the sticky pad to fix the
light in place, shown in Fig 202. Feed the
wires down through the RH support tube
of the bracket, then through the rubber
grommet into the boot area, shown in Reconnect the battery, and with the aid of
Fig 203. an assistant, check to ensure that the
high-level brake light operates in
conjunction with the brake lights in the
rear clusters, and re-fit the spare wheel.
The completed assembly is shown in Fig
204.

Page | 217
Figure 203: Completed assembly (do not tighten). There are four bolts on
the brake disc, speed sensor should be
adjusted by aligning with one of the four
bolts. Select any of those bolt by rotating
the disc and Adjust the speed sensor front
edge so that the gap between the sensor
and the bolt on the disk is 2-3 mm. tighten
the lock nut on the sensor. Tighten the

17.8.3) Stack dash speed sensor fitment bolt on the calliper (50NM) and secured
the bracket in place. Refer figure 207.
Route the speed sensor loom through the
hole on the tunnel top along with main Figure 205: Wheel speed sensor
bracket
wiring loom to the front of the chassis near
LHS wheel. Use cable ties to route the
loom where necessary. Connect the
speed sensor plug to the plug on main
wiring marked as wheel sensor refer
figure 205.

Figure 204: Wheel speed sensor plug

1. Speed sensor bracket

2. Lock nut
3. Speed sensor

1. Plug on the wheel speed sensor loom

2. Plug on the main wiring loom

Insert the speed sensor in to the bracket

and secure with locknut (do not tighten).
Refer figure 206. Remove 2 caphead bolts
on the LHS brake calliper and fit the
bracket with speed sensor to the calliper

Page | 218
Figure 206: Wheel speed sensor Figure 207: Brake calliper assembly

1. Calliper caphead bolts

2. Speed sensor
1. Brake calliper
3. Speed sensor bracket
2. Calliper bracket
3. Shim

17.8.4) Rear brake calliper sub assembly

Insert the shim into the slot on the calliper Assemble calliper bracket and calliper
assembly. Make sure the shim has seated together using two bolts provided in the
properly. Please refer the fig. 208. brake pads box. Do not tighten the bolt at
this stage. Refer fig 208.

Figure 208: Brake pad assembly

1. Brake calliper
2. Calliper bracket
3. Brake pads

Page | 219
Insert the brake pads into the Brake Figure 210: Dismantled mirror
calliper assembly. Check for the correct
alignment of the brake pads. Refer
figure209. Now tighten the Calliper
bracket bolt to 20NM.

17.8.5) IVA mirror fitting instructions

Figure 209: Kit contents for mirror

fitting
1. Torx screw
2. Plastic cup
3. Mirror

Parts taken from the mirror (figure 211.)

now need to be assembled with the mirror

1. Mirror stalk mount. Place the plastic cup against hole

2. Fibre washer cut in mirror casing. Inside the mirror

3. M5 grub screw section there is a small swivelling arm this
4. Fixing stud is placed into the machined slot of the
mirror mount. The flat on the swivelling
arm faces towards the right (looking at
Side screen mirror (part number 291 0074
figure 210). The Torx screw should then
01) must first be dismantled from its
be inserted from the rear of the mount to
mounting arm using a T20 Torx bit.
secure the stalk and mirror together (see
Retaining the mirror section, Torx screw,
figure 212).
plastic cup and setting aside the arm (see
fig 211). Figure 211: Assembled mirror

Page | 220
Insert M5 grub screw into threaded hole on to the brake disc (callipers and uprights
(right hand side of mount looking at Figure are handed make sure for correct hand).
210) until top of screw is just flush with Fit the bolt and washers in correct
surface of mount. orientation. Torque the bolts to 58NM.

Figure 212: Stud located on stanchion Figure 214: Front brake calliper
assembly

If fitted remove the centre of three

windscreen-securing screws and replace
with supplied stud (shown in Fig 211)
using flat blade screwdriver. See Fig 213.

Place fibre washer over stud now located

in side screen. The previously assembled
mirror will now slide over the stud located
on the side screen. See Fig 214.

Figure 213: Final fitted assembly Pull out the locking clips (‘R’ clip) on
calliper and remove the brake pad Pins.
Slide the brake pads into the calliper and
fit the brake pad pins. Fit the locking clips
(‘R’ clips).

Figure 215: Front brake pads assembly

Adjust the mirror position to allow for

optimum vision and lock in place by
tightening M5 grub screw.

17.8.6) Front brake calliper sub assembly

Remove the bolts and washer from the

vertical link on upright. Slide the calliper
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18.0) Wiring diagrams

Figure 216: Main wiring harness for all standard instrumentation, Ford sigma variants

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Figure 217: Engine harness (sigma)

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Figure 218: R400 engine harness

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Figure 219: R400 main chassis harness (standard dash)

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Figure 220: R400 main chassis harness (stack dash)

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