Caterham Seven Bedienungsanleitung

Page | 1 ASSEMBLY GUIDE ALL CATERHAM SEVEN MODELS Version 02.2014

Page | 9 17.8.2) Light and wiring connections ...216 17.8.3) Stack dash spe

Page | 99 electrical contact is made. Pass bolt (3), plain washer (12) downwards through the rear hole of the engine mounting block, through the

Page | 100 36G006A Item 4) and one M8 x 30 mm bolt (5), do not fully tighten the bolts. Attach the RH engine mounting using the two M8 x 35 mm bol

Page | 101 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 tra

Page | 102 important). Fit the grommet into the hole and ensure that the harness will not foul the steering column or pedals. Figure 71: Brake lig

Page | 103 Once fitted the pipe cannot be removed without a special tool. Ensure that the pipe is kink free and routed away from possible snags or

Page | 104 7.2.6) Exhaust system The standard exhaust system consists of four primary pipes, a collector assembly which also incorporates the cata

Page | 105 For SV use the same procedure to fit the primary, the sequence to fit the primary is 4,3,2,1. 58X0011A is for #1(front) cylinder. 58X00

Page | 106 Figure 77: Lambda probe connection Undo the large worm drive clips and feed them through the channels on the inside of the collector/c

Page | 107 engine. It enables the engine oil to be cooled by circulating coolant around the oil-filled modine cooler. Figure 79: Location of modin

Page | 108 radiator onto the rubber radiator mountings ensuring that the hose connections face towards the engine. Secure the upper mounting using

Page | 10 List of Tables TABLE 1: SUGGESTED BUILD SEQUENCE ...

Page | 109 7.2.7.1) Water bleed hoses The smaller of the two inlets on the coolant expansion bottle connects to the 5/16” bore hose that must conn

Page | 110 a long ‘L’ shape (to connect the ‘T’ piece to heater outlet). Measure the relevant distances carefully prior to cutting the hose. The l

Page | 111 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

Page | 112 Figure 88: Heater control cable 1. Scuttle panel 2. Heater control cable 3. Locknut Figure 89: Heater control cable attachment 1. He

Page | 113 cable outer to adjust the throttle pedal position, refer toFigure91. Figure 90: Throttle cable linkage 1. Throttle cable 2. Throttle c

Page | 114 Figure 91: Breather pipe 1. Oil breather hose 2. ‘P’ clip 3. Breather bottle 4. Breather elbow 5. Cam cover

Page | 115 Figure 92: Duratec engine bay overview 1. Engine 12. Air filter 2. Exhaust primary pipe 13.ECU 3. Oil breather hose 14. ‘L’ water rail ho

Page | 116 7.3) Duratec – Superlight R400 7.3.1) Preparation Table 19: Special tools required for Superlight R400 engine Item Description Engine hois

Page | 117 Figure 93: Water outlet and 'L' shape hose 1. Engine connection 2. Long ‘L’ hose Remove and retain the gearbox filler plug.

Page | 118 Drill an 8mm hole into the steering rack platform so that the horns can be bolted to the plate. The horns are fixed beneath the steerin

Page | 11 List of Figures FIGURE 1: EXHAUST ...

Page | 119 Attach the RH engine mounting using the two M8 x 35 mm bolts (6) and one M10 x 40 mm bolt (2). Do not finally tighten the engine mounti

Page | 120 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 tra

Page | 121 important). Fit the grommet into the hole and ensure that the harness will not foul the steering column or pedals. Figure 97: Brake lig

Page | 122 Once fitted the pipe cannot be removed without a special tool. Ensure that the pipe is kink free and routed away from possible snags or

Page | 123 Bolt the exhaust mounting bracket (polythene bag marked 'exhaust') to the RH side of the car forward of the rear wheel, using

Page | 124 58X0013A is for #3 cylinder 58X0014A is for #4 (rear) cylinder When the primary pipes are in place, fit the remaining fasteners but do

Page | 125 NOTES 1. For a neater appearance position the clips with the drive screw towards the ground so that the clip ‘tail’ is out of sight ben

Page | 126 nuts. Position a hose clip on the flexible bottom radiator hose, apply rubber lubricant and fit the hose to the larger of the two outle

Page | 127 connections face towards the engine. Secure the upper mounting using nuts, plain washers and spring washers. Align the oil cooler brack

Page | 128 Figure 110: SV radiator arrangement Position hose clips on the forward ends of the flexible top and bottom radiator hoses; apply rubbe

Page | 12 FIGURE 39: SPEEDO DRIVE PLUG ...

Page | 129 to the top radiator hose using cable ties refer to Figure 121. 7.3.7.3) Heater and associated hoses Remove and retain the four screws,

Page | 130 heater inlet and outlet to the heater valve, refer to figure 115. The larger of the two inlets on the coolant expansion bottle must co

Page | 131 Figure 113: Water outlets cylinder head 1. ‘J’ hose 2. Hose to expansion tank 3. Large bore ‘L’ hose to water rail 4. Water outlets on

Page | 132 Figure 116: Heater control cable 1. Scuttle panel 2. Heater control cable 3. Locknut Figure 117: Heater control cable attachment 1. H

Page | 133 cable outer to adjust the throttle pedal position, refer to Figure119. Figure 118: Throttle cable linkage 1. Throttle cable 2. Throttl

Page | 134 Figure 119: Breather pipe 1. Oil breather hose 2. ‘P’ clip 3. Breather bottle 4. Breather elbow 5. Cam cover

Page | 135 Figure 120: Duratec engine bay overview 1 Engine 8 Clutch hose 15 Plenum chamber 2 Exhaust primary pipe 9 ‘J’ hose heater inlet 16

Page | 136 8.0) Preparation and installation of the differential The Caterham differential is attached to the chassis via a carrier that comes with t

Page | 137 Use a jack to lift the differential up from under the vehicle. This may be easier with additional help. Hang the differential from the

Page | 138 Attach the Propshaft to the differential pinion drive flange with 4 of M10x20 supplied in the Z-Pack and torque to 60Nm. NOTE For check

Page | 13 FIGURE 79: LOCATION OF MODINE ...

Page | 139 9.0) Rear suspension The following section covers the rear suspension assembly of your Caterham. 9.1) General The special tools identif

Page | 140 Figure 124: Di Dion tube RH brake pipe fitting 1. Brake pipe (RH) 4. Brake pipe (LH) 2. ‘P’ clip 5. Di Dion ear (RH) 3. Three way unio

Page | 141 Figure 125: LH brake pipe fitting 1. P-clip 2. Brake pipe LH 3. Three way connector 9.5) Assembly of the rear suspension Warnings 1.

Page | 142 9.7) Radius arms If Watts link has been specified refer to next section (Watts link assembly). Fit the radius arms to the lower chassis

Page | 143 9.8.3) Link arms to chassis With the De Dion tube in place attach the forward link arm to the upper mounting bush on the chassis using

Page | 144 blades and onto the round section of the rear anti-roll bar. Feed the rear anti-roll bar across the top of the lower chassis tubes and

Page | 145 Attach the forward ends of the 'A' frame to the mounting provided on the chassis, refer to Fig 131, using bolts (fastener pac

Page | 146 2. The holes in the ears are not symmetrical and therefore will ensure correct orientation. Figure 131: De Dion tube end (LH) 1. Brake

Page | 147 Figure 132: Anti-roll bar bracket and speed sensor 1. De Dion ear 2. ARB bracket 3. Anti-roll bar 4. Drive shaft 5. Speed sensor In t

Page | 148 and washer to pull the flange finally home). Place the thrust washer over the driveshaft and secure using the 41mmnyloc nut (LH plain

Page | 14 FIGURE 119: THROTTLE CABLE LINKAGE ...

Page | 149 The position of the droplinks in the anti-roll bar determines the degree of the anti-roll given. Positioning the droplinks closer to t

Page | 150 Figure 136: SV Handbrake cable arrangement 1. Pulley S3 Handbrake cable arrangement Locate the fixed nylon boss on the outer cable i

Page | 151 cover (interior trim) has been fitted as the handbrake lever is required to be in the vertical position during fitment of the trim. . F

Page | 152 Handbook for a complete list of recommended lubricants. NOTE This operation is made easier if the boot floor has been removed to allow

Page | 153 10.0) Interior and trim The following section details the interior trim of your Caterham including transmission tunnel top and carpetin

Page | 154 The carpet must fit flat at the transmission tunnel. If necessary, small cuts should be made in the area of the corners to allow the t

Page | 155 Stick masking tape to the underside of the carpet in the approximate position of the floor mounted poppers and lay the carpet into posi

Page | 156 on the sill protector and drill (5/32”) through the existing holes in the trim panel, through the sill protector and through the existi

Page | 157 Figure 141: Trim fixings 1. Piping 4. Chassis tube 2. Sill protector (optional) 5. Side panel 3. Body skin 6. Rivet Fit the piping an

Page | 158 the bolt into the harness mounting point, refer to Figure 144. Figure 143: Shoulder strap with track day roll over bar 1. Bolt 4. Bush

Page | 15 FIGURE 159: HOODSTICK SPACING ...

Page | 159 The six-point harness is fitted in the same way as the four point, with the exception that the crutch straps are bolted to the chassis

Page | 160 through the rear mountings and secure using plain washer (3) and nyloc nut (2). Tighten the fastenings. 10.11.2) Composite seats 10.11

Page | 161 If the car has a honeycomb floor, bolt (1) is passed through the runner, through spacer (6) and secured using plain washer (5) and nylo

Page | 162 If a track day roll over bar and Petty strut is installed, the seat can reclined slightly by replacing the front fixing with bolt (1) a

Page | 163 Figure 150: Completed interior 1. Rear bulkhead carpet 2. Footwell carpet 3. Tunnel carpet 4. Tunnel top NOTE Items may differ from t

Page | 164 11.0) Fibreglass The following section details the fibreglass components of your kit including cycle wings, rear wing protectors and re

Page | 165 mm drill. Ensure that the drill cannot contact the tyre. Drill an additional hole in the underside of the front wingstay near the open

Page | 166 NOTE To comply with SVA requirements the green repeater wire must be covered with heat shrink sleeving. Figure 151: Indicator repeater

Page | 167 the protector tight up against the inboard side of the wing (the side of the wing that bolts to the car). NOTES 1. The protectors are s

Page | 168 passed through the body from inside the boot. Loosely fit all fasteners. Wing piping (6) is provided to fit between the rear wing and

Page | 16 FIGURE 199: WIRE ROUTING THROUGH LIGHT UNIT ...

Page | 169 12.0) Lighting The lighting kit includes all the parts needed to make the car comply with the lighting requirements of IVA. It is impe

Page | 170 Figure 156: Headlight and indicator LH 1. Indicator cone 3. Headlight bracket 2. Headlight unit 4. Indicator cone Pass the black indi

Page | 171 Once the indicator repeaters have been fitted and all the connections have been located into the plug fit the yellow insert into the fr

Page | 172 Do not over tighten. Replace the bulbs and lens cover ensuring correct orientation of the lens cover (indicator to the outside). Conne

Page | 173 In the event that there are problems check that the bulbs have not been damaged during transit and replace as necessary. If the proble

Page | 174 13.0) Weather equipment This section explains how to perform the initial fitment of the weather equipment, the tool identified in Table

Page | 175 Figure 158: Hoodstick spacing Drill two 7/64” holes into the upper chassis tube, one either side, on the inside rear edge of the boot,

Page | 176 hoodstick as this will ensure that it is correctly adjusted. The front popper base for the side of the hood can now be fitted. To do t

Page | 177 This is covered with the vinyl which continues away from the frame giving a soft flexible area of about 35 mm around the outside. The

Page | 178 Figure 162: Sidescreen straps 1. Sidescreen 2. Vinyl strap NOTE Optional arm restraints are available. If these have been specified

Page | 17 0.0) Preliminary information 0.1) General warnings & cautions The following warnings and cautions indicate general and environmenta

Page | 179 165. Fit a fibre washer and the mirror stalk over the adaptor and tighten the grubscrew to secure the stalk (ensure that the large rece

Page | 180 13.6) Boot cover When correctly fitted, the boot cover should be as shown in Figure 167. Figure 166: Boot cover The boot cover is desi

Page | 181 establish locations for the remaining fasteners (boot cover fastens to the hood fastenings on the body). Fit the popper bases (3) and

Page | 182 to Fig 170. Mark the position of the fastener bases and fit the six fasteners (4) and buttons (5) across the back. It is important th

Page | 183 stretch the tonneau away from the vehicle centreline, towards the windscreen stanchion just sufficient to prevent bagginess in front of

Page | 184 14.0) Wheel fitment Warning Re-tighten wheel nuts after 200 mile. Some Caterham supplied alloy wheels are fitted with steel inserts ena

Page | 185 Figure 172: Spare wheel mounting items 1. Mounting wishbone 2. Wheel nuts 3. Fibre washer 4. Spare wheel bolt 5. Spacer NOTE 13"

Page | 186 15.0) Start up procedure and final checks This section details the operations, adjustments and checks that should be carried out prior

Page | 187 Tighten bleed screw and remove flexible hose. Replace dust cap. Carry out the procedure in the following sequence. RH rear calliper,

Page | 188 15.2) Clutch system – filling and bleeding Prior to filling the clutch master cylinder, check all connections to ensure that they

Page | 18 The electric radiator fan is controlled by a thermostatic switch which operates when the ignition is in the 'on' position. Wh

Page | 189 Mop up any spilled fluid, check for clutch ‘feel’ and correct operation (repeat the bleeding procedure if necessary); finally, hold dow

Page | 190 4. Use appropriate barrier creams. Remove the gearbox oil filler plug (if not removed earlier) using the cut down 3/8” Allen key. Add a

Page | 191 NOTE It may be necessary to turn the engine over for 30-40 seconds to achieve oil pressure. Once oil pressure has been achieved, switch

Page | 192 NOTE Should the temperature exceed 92C without the cooling fan cutting in, switch OFF the engine immediately to avoid damage. Contact

Page | 193 with a point on the rear tyres ~ 50 mm in from the outside edge, with the steering wheel centred. This approximate setting will not ca

Page | 194 Table 30: Torque figures for final checks and start up procedure Location Washers Torque Nm Front lower wishbone front Spring and plain 81

Page | 195 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 Spri

Page | 196 16.0) Individual vehicle approval and registration All Caterham cars will have to be inspected under the IVA regulations in order to be re

Page | 197  Noise  Exhaust Emissions  Speedometers The examiner will conduct an engineering assessment rather than the more thorough test th

Page | 198  The vehicle presenter does not remain with the car to operate controls etc. as requested 16.4) Inspection data 16.4.1) Design weight

Page | 1 Contents Contents ...

Page | 19 1.0) Introduction It is recommended that the entire assembly guide and IVA requirements are read before commencing building of the car.

Page | 199 altogether, as this improves both visibility and access. 16.5.5) Noise Tailpipe noise will be tested. Though the silencer is brand new

Page | 200 Figure 174: IVA bag contents 1. Scuttle trim 7. Bolt head covers 2. Foam tape 8. Nut covers 3. Edge trim 9. IVA mirror stalks and fitt

Page | 201 Figure 176: Bonnet catches 1. Rear bonnet catch cover 2. Front bonnet catch cover 3. Edge trim (indicator cone) 4. Edge trim (cycle wi

Page | 202 The sharp edge of each side screen hinges should be protected as shown in Fig 180. The protectors are made by cutting grommets in half

Page | 203 application for registration form (currently V55/5), insurance certificate and your certificate of newness (with full CKD De Dion kits

Page | 204 Shrewsbury Unit 6 Levens Drive Harlescott Shrewsbury SY3 7EG 01743 462621 Southampton (Northam): Unit R, Centurian Industrial Estat

Page | 205 17.0) Options These fitting instructions are supplied in addition to the normal assembly guide delivered with your kit. They are specific

Page | 206 17.3) Track day roll over bar Before fitting the Track day roll over bar it will be necessary to remove the rear spring damper units in

Page | 207 Pass the bolts through the plate on the Petty bar then rearwards through the fixing holes in the centre of the main hoop, secure with p

Page | 208 Figure 182: Front fixing boss location 1. Front hoop saddle bracket 2. Fixing bolt – in threaded bush 3. Chassis top tube - sill War

Page | 20 car. However, due to the sheer number of different components it is possible that some parts are omitted or duplicated. Kits should be

Page | 209 bushes located at each end of the seat back harness rail at the rear of the cockpit, refer to Figure 184. Figure 183: Rear hoop bucket

Page | 210 the threaded boss. Do not tighten at this stage. Repeat the above using bolts (2) and plain washers (5) passed through the outer legs o

Page | 211 Figure 184: Head restraint assembly 1. Adjusting bracket 2. Square head pad 3. Foam pad 4. Adjusting stud (head pad) 5. Plain nuts and

Page | 212 Pass the inner cable through the hole in the cable locater fitted to the extinguisher lower handle, then through the opposing hole in t

Page | 213 Figure 187: Filler cover and boot carpet removed Warning Wear appropriate eye protection whilst carrying out drilling operations. Remo

Page | 214 neck due to the O-ring and it must be pulled up evenly. The holes for the spacer are slotted to allow for correct alignment with the ho

Page | 215 17.8) High level brake light Figure 195: Kit contents for high level brake light 1. Wiring sub loom 2. Wiring to high level brake ligh

Page | 216 Figure 197: Alignment of bracket Using a spirit level, refer to Figure 199, adjust the bracket until the light platform is exactly par

Page | 217 filler neck cover, and remove it. From under the right and rear corner of the car, feed the terminated end of the supplied sub-loom up

Page | 218 Figure 203: Completed assembly 17.8.3) Stack dash speed sensor fitment Route the speed sensor loom through the hole on the tunnel top

Page | 21 requirement for UK markets only therefore the additional parts will not be supplied with overseas orders. 1.4) Disclaimer The Caterham

Page | 219 Figure 206: Wheel speed sensor 1. Calliper caphead bolts 2. Speed sensor 3. Speed sensor bracket 17.8.4) Rear brake calliper sub asse

Page | 220 Insert the brake pads into the Brake calliper assembly. Check for the correct alignment of the brake pads. Refer figure209. Now tighten

Page | 221 Insert M5 grub screw into threaded hole (right hand side of mount looking at Figure 210) until top of screw is just flush with surface

Page | 222 18.0) Wiring diagrams Figure 216: Main wiring harness for all standard instrumentation, Ford sigma variants

Page | 223 Figure 217: Engine harness (sigma)

Page | 224 Figure 218: R400 engine harness

Page | 225 Figure 219: R400 main chassis harness (standard dash)

Page | 226 Figure 220: R400 main chassis harness (stack dash)

Page | 22 1.5) Suggested Build Sequence Table 1: Suggested Build Sequence Work Area Detail Comment Front Steering Initial fit Steering rack IVA

Page | 23 Gearbox to engine Prep engine Oil pressure sender Normally fitted to the engine, if not please fit it before engine installation.

Page | 24 Gear stick Fuel pipe Primary exhaust pipes Collector box/ cat Lambda probe Head tank mounting Steering column Steering wh

Page | 25 Handbrake and cables Initial assembly Prop shaft Differential Rear suspension Brake pipes and flexi hose De-Dion tube Rear d

Page | 26 Four and six point harness lap and crutch straps Optional Carpets Seats Roll over bar/ cage as specified Head restraint Roll cag

Page | 27 2.0) Kit contents The following pages include pictures and tables to assist with part recognition and location. Due to the multiple pe

Page | 28 1. Exhaust silencer 2. Exhaust primary pipes 3. Cat/ collector 4. Cat guard 5. Polythene bag NOTE Items may differ from those il

Page | 2 2.1.8) Head light brackets ...37 2.1.9) Upright

Page | 29 Table 2: Polythene bag contents - exhaust, steering, suspension items, bell-housing and front wingstays Identifier Description Qty Gearb

Page | 30 Figure 2: Steering, large suspension items, bell-housing and front wingstays 1. Fastener pack ‘steering’ 10. Front anti-roll bar 2. F

Page | 31 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 a

Page | 32 2.1.3) Differential The differential is shown in Figure 4. 2.1.4) Driveshafts The driveshafts are shown in Figure 5. Figure 5: Drive

Page | 33 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: Sus

Page | 34 Table 4: Polythene bag contents - suspension Identifier Description Qty Front suspension Rubber cotton reel bushes Damper sleeves Anti-r

Page | 35 2.1.6) Cooling The cooling items are shown in Figure 7. 1. Expansion bottle hose 6. Cooling fan 2. Hose 7. Expansion bottle bracket 3.

Page | 36 2.1.7) Lighting The lighting items are shown in Figure 8. 1. Headlight 5. Indicator repeater x2 2. Fastener pack 30

Page | 37 2.1.8) Head light brackets The headlight brackets are shown in Figure 9. 1. LH headlight bracket 2. RH headlight bracket Figu

Page | 38 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

Page | 3 5.2) Lower wishbones ...64 5.3) Upper

Page | 39 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 conten

Page | 40 Figure 13: Rubber mats Figure 14: Transmission tunnel top

Page | 41 Table 5: Polythene bag contents - interior trim, cables and options Identifier Description Qty SVA Cable ties Track rod end sleeves Trac

Page | 42 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-spee

Page | 43 2.1.12) Chassis/body unit The chassis body unit comprises; chassis, body panels, pedals, master cylinder, instruments, switches, wiring

Page | 44 2.1.13) Weather gear (optional) The optional weather gear items are shown in Figure 18. Figure 18: Weather gear (optional) 1. Hoodstick

Page | 45 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

Page | 46 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

Page | 47 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

Page | 48 cable, clutch cable, rear wing protectors, steering wheel, spare wheel wishbone, seat belts and fixings, tonneau cover, seat runners, se

Page | 4 7.2.2) Installation of engine/gearbox into chassis ...99 7.2.3) Electrical connecti

Page | 49 Figure 21: Complete kit (less engine)

Page | 50 3.2) Basic definitions The text in the assembly guide refers to the Right Hand (RH) side or Left Hand (LH) side of the car. For all purpos

Page | 51 The engine hoist should only be required for a short time and can usually be sourced from a tool hire company. The 41 mm socket and tor

Page | 52 additive diff additive Brake fluid Comma DOT4 Comma DOT4 Engine coolant Comma Xstream red or ford super plus anti-freeze Comma Xstream

Page | 53 The majority of fastenings have washers inserted between the nut and or bolt head and the item being secured. Spring washers or lock wa

Page | 54  Bolt (fastener pack 30P017A Item 1) identifies the Bolt M8 x 50 mm from the fastener pack illustrated at Fig 23.  At a later poin

Page | 55 Figure 23: Fastener pack

Page | 56 3.5) General build information Caterham Seven builders should take care to observe basic safety precautions whilst assembling the kit si

Page | 57 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.

Page | 58 4.0) Steering The following section contains information on steering rack (standard and wide track), steering wheel fitments and other a

Page | 5 9.8) Watts link assembly (optional) ...142 9.8.1) Constructi

Page | 59 NOTES (1) The IVA covers will need to be trimmed on one end to fit over the tie rod ends (2) The IVA covers are secured using cable

Page | 60 NOTE Engine installation will be easier before the lower steering column is fitted. Figure 28: Steering rack to steering column 1. Nylo

Page | 61 To ease fitment lightly coat the upper steering bush with rubber lubricant. Figure 29: Upper steering column clamp 1. Locknut 4. Securi

Page | 62 4.3) Steering wheel fitment Two makes of steering wheel are available. Both the Motolita and the Momo wheel have a horn button mounted o

Page | 63 Table 12: Steering component torque figures Location Washers Nut Torque Steering rack clamps Plain under bolt head Nyloc 11 Nm Universal

Page | 64 5.0) Front suspension The following section covers the assembly and installation of all areas of the front suspension for your kit. 5.1)

Page | 65 Figure 32: Washer usage - lower wishbone (LH side) 1. Bolt 5. Nyloc nut 2. Spring washer 6. Rear chassis mount 3. Plain washer 7. Bolt

Page | 66 Ensure to fit a rubber grommet in the hole in the bracket before assembly. Since access to the upper and lower wishbone mountings are re

Page | 67 5.5.1) Standard The upright is located into the spherical joint on the lower wishbone and secured using the retained 1/2” nyloc nut. Ti

Page | 68 Figure 34: Front suspension 1. Cycle wingstay 4. Lower wishbone 2. Anti-roll bar 5. Spring damper unit 3. Inner radiator cowl 6. Uprig

Page | 6 10.11.1) Standard cloth or leather seats ...159 10.11.2) Composite seat

Page | 69 5.7) Front brake hoses Three stainless steel braided brake hoses are supplied, two of equal length for the front brakes and one of longe

Page | 70 Figure 37: Uprated calliper 1. Copper washer 3. Braided brake hose 2. Female union 4. Adaptor Located on the inside of the body are th

Page | 71 NOTE Lowering the platforms will decrease ride height, and raising the platforms will increase ride height. For the best results the rid

Page | 72 6.0) Fitment of gearbox to engine The following section details the assembly of the 5 and 6 speed gearbox. 6.1) Assembly of gearbox kit

Page | 73 NOTE Loosen gearbox filler plug. All Duratec models have the bellhousing pre-fitted to the engine, so fixing pack 36G006A is not req

Page | 74 Figure 40: Speedo shaft plug 1. Gearbox 2. Plug Bolt the metal/rubber/metal gearbox mounting, chamfered edge forward, refer to Fig 39,

Page | 75 Using the fixings supplied, connect the engine and gearbox; two bolts (2) and spring washers (10), pass forward from the top of the bell

Page | 76 7.0) Installation of engine and gearbox The following section details the installation of the engine and gearbox for your kit. The Sigma

Page | 77 7.1.1.2) Engine preparation The large diameter pre-formed 'U' hose should be fitted onto the aluminium water outlet located on

Page | 78 chassis/mounting to ensure that a good electrical contact is made. Pass bolt (3), plain washer (12) downwards through the rear hole of

Page | 7 13.6) Boot cover ...180 13.7) T

Page | 79 and propshaft have already been fitted, ensure that the propshaft locates into the gearbox tailshaft housing. Attach the LH engine mount

Page | 80 car may have additional wires and connectors that are not required on your vehicle. To help clarify this, a wiring diagram can be found

Page | 81 Figure 43: ECU and MAP unit 1.Fuel pipe connection 4. ECU 2. MAP unit 5. Air filter 3. Multi-pin plug The ECU and MAP unit are alread

Page | 82 The longest wire from the engine loom (terminating in a 4-pin plug) is the connection for the exhaust mounted lambda probe. This cannot

Page | 83 banjo bolt and pass the banjo bolt through the union at the end of the hose, refer to Fig 46. Fit the second copper washer to the banjo

Page | 84 Figure 48: Exhaust mounting 1. Angle bracket 4. Bobbin 2. Spring washer 5. Nut 3. Setscrew Remove the exhaust gasket and associated fa

Page | 85 Install the collector/catalyst over the assembled primary pipes with the threaded hole for the lambda probe faces towards the side panel

Page | 86 2. To reduce the risk of damage it is advisable to fit the silencer after the RH rear wing has been attached. 1. Silencer bracket 3.

Page | 87 to Fig 53. The hose passes forwards along the LH side of the engine bay before turning to pass along the top of the steering rack and tu

Page | 88 before attaching the rubber mountings and the radiator. Figure 56: SV radiator arrangement Position hose clips on the forward ends of t

Page | 8 16.5) Checking and preparing the car prior to inspection ...198 16.5.1) Wiper and washer syst

Page | 89 back of the cylinder head. Secure using hose clips (10). 7.1.7.2) Heater and associated hoses Remove and retain the four screws, nyloc n

Page | 90 The long ‘J’ hose connects the heater inlet to the water outlet at the rear of the cylinder head (next to the top hose ‘U’ bend). This h

Page | 91 Figure 59: Heater valve arrangement 1. Hose to large ‘T’ 4. Heater valve 2. Heater outlet 5. Hose to cylinder head 3. Heater inlet 6.Ho

Page | 92 Figure 62: Heater control cable attachment 1. Heater valve 2. Heater control cable Warning Due consideration should be given to the hi

Page | 93 Route the other end of the cable around the front of the cam cover; refer to Fig 64 and through the 22 mm hole in the front of the pedal

Page | 94 7.1.10) Air filter fitment Fit the Caterham air filter element to the throttle body housing and secure using the hose clip provided.

Page | 95 Figure 66: Sigma 125 engine bay overview 1. Engine 8. Heater outlet 15. Water rail 2. Exhaust 9. MAP unit 16. Top radiator hose 3. Thrott

Page | 96 Figure 67: Sigma 125 engine bay overview (rear) 1. Brake master cylinder 4. Heater control cable 2. Clutch master cylinder 5. Batte

Page | 97 7.2) Duratec - Roadsport 175/Superlight R300 engine 7.2.1) Preparation The special tools detailed in Table 17 will be required. Table 17: S

Page | 98 Apply rubber lubricant to the end of the water rail; pass the rail from the front of the engine, over the alternator, and under the curv