A4 Assembly Guide DURATEC Edition 2.3

ASSEMBLY GUIDE
DURATEC – EDITION 2.3

ASSEMBLY GUIDE
DURATEC – EDITION 2.3
Your feedback and comments are welcome: assemblyguide@caterham.com
For help and build support enquiries contact: buildsupport@caterham.com
For help and support with IVA and registrations contact: ivaapplications@caterham.com
Welcome to your new Caterham kit
Building your own Caterham is immensely rewarding and satisfying. Of course, it should be remembered
that you are building a high performance sports car, not a flat-pack wardrobe, so it will be a little challenging
from time to time; but we’ve set out to make it as easy as possible for anyone, whatever their skill level and
help is just a phone call away.
But before you do anything else, pop the kettle on or pour yourself a G&T with a slice; and
READ THE NEXT THREE PAGES – THEY ARE REALLY IMPORTANT

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

setting back to free when you’ve finished with it.
John K
When using a spanner, always use the ring end wherever

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

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

A bolt size is described by its diameter (e.g. M10=10mm)
closed when a fixing is tightened. It is usually used
by the length not including the head (e.g. 65mm).
under a bolt head to help resist it coming undone.
James A
John S
1
2
F#©K!
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!
B?LL#
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#©K!
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%!
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#¢*$!
L
B?L
Speak to an expert
buildsupport@caterham.com
F#©K!
$H@%
!
B?LL#
¢*$!
3
KEY
S Y M B O L S F I X I N G S
A
SERIAL
44
Pack
NUMBER
A
PACK NUMBER
1
SERIAL
44
Item number Pack 30F015B
NUMBER
Advice from factory PACK NUMBER

30F015B
FRONT SUSPENSION DeDION CARS (METRIC)
professionals FRONT SUSPENSION DeDION CARS (METRIC)
This pack may include extra fasteners to cover different options
AA
BASIC PART
ITEM
BASIC PART
QTY USED ON ILLUSTRATION ITEM QTY USED ON ILLUSTRATION
DESCRIPTION NUMBER DESCRIPTION NUMBER
AJ
Lower wishbone
Fixing item
Bolt M12 x 100
1 AA Grade 10.9
BM12X100 2
rear Bolt M12 x 100 Lower wishbone
1 AA BM12X100 2
Grade 10.9 rear
AM
Bolt M12 x 65 Lower wishbone
2 AB BM12X65 2
Grade 10.9 front
Now is a good time to take 2 AB

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

3 AC
Bolt M10 x 65
Grade 10.9
BM10X65 2
Upper wishbone
rear
specific instructions
4 AD BM10X60 2
Grade 10.9 front
x4 (Indicates number
front of each fixing required)
Bolt M8 x 40 Anti-roll bar Bolt M10 x 60 Upper wishbone
5 AE Grade 10.9
BM8X40 4
mounting brackets
4 AD Grade 10.92 BM10X60
35 Nm Required torque (where applicable) Temporary use to

mm 6 AF
Plain Nut M14
x 1.5 thread
NMPH14 1 help lock upper
Bolt M8 x 40 Anti-roll bar
wishbone ball joint 5 AE BM8X40 4
Grade 10.9 mounting brackets
Reminder to apply for your IVA test 7 AG Nyloc Nut M12 NMYF12 2
Lower wishbone
rear
Temporary use to
S3 6 AF
Plain Nut M14
x 1.5 thread
S3 / S5 chassis specific instructions 8 AH Nyloc Nut M10 NMYF10 4 Upper wishbone

wishbone ball joint
S5 Plain Washer
7 AG Nyloc Nut M12 NMYF12 2
Lower wishbone
9 AJ M12 WPCM12 18 Lower wishbone rear
Chamfered
Repeat on other side

Plain Washer
Refer to IVA Checklist Guide

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

10 AK M8 WPHM8 4
REPEAT Heavy duty mounting brackets 8 AH Nyloc Nut M10 Upper wishbone
NMYF10
11 AL
Plain Washer
⅜" x ¾"
Heavy duty
WPH3/8 2 Brake pipe required for current step)
Plain Washer
9 AJ M12 WPCM12 18 Lower wishbone
Drawings are for illustrative purposes only and are not to scale. Page 1 of 2 Chamfered
Plain Washer
Anti-roll bar
10 AK M8 WPHM8 4
Heavy duty mounting brackets
Plain Washer
11 AL ⅜" x ¾" WPH3/8 2 Brake pipe
Heavy duty
Drawings are for illustrative purposes only and are not to scale. Page 1 of 2
4
KEY
T O O L S
Adjustable
Engine hoist Power adhesive Spanner Torque wrench
spanner
Flat head Pozidrive

Allen key Spirit level Torx
screwdriver screwdriver
+ Assistance Grease Ruler Spray adhesive Trolley jack
Axle stand Junior hacksaw Scissors Spray lube WD40
Cable tie Latex gloves Side cutters Stanley knife
Combination
Long nose pliers Silicon Super glue
spanner
Copper grease Marker Pen Silicon gun Tape
Drill Muscle Socket wrench Tape measure
Socket wrench Thread lock /
LO
Drill bit
CT
Pop rivet gun
IT
E
(allen) LocTite
5
LET’S GET READY
P A R T S T O O L S
x3
F I X I N G S T I P S
When deciding how high your axle stands Some tape or foam on the
should be (the higher the better for working top of the axle stands will
on), don’t forget that a complete car will stop them scratching the
need to come down off them, so make sure chassis.
your trolley jack can reach and lift the Matt T
height you set them too!
Mick F
6
LET’S GET READY
7
START WITH THE SUSPENSION WISHBONES
P A R T S T O O L S
1 Lower wishbone
17mm
19mm
2 Upper wishbone
17mm
3 Wishbone bush sleeve
19mm
94
A A
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER
PACK NUMBER
30F015B
PACK NUMBER
30F015B For now, only tighten the nuts/bolts lightly and then Leave bolt AD
This pack may include extra fasteners to cover different options torque them up when the car is finished and on the loose for now,
ground. This sets the bushes correctly and ensures as we have to
BASIC PART BASIC PART
ITEM QTY USED ON ILLUSTRATION ITEM QTY USED ON ILLUSTRATION
Bolt M12 x 100 Lower wishbone

x2 Spring Washer Lower wishbone
x2
the best handling. take it back out
1 AA BM12X100 2 12 AM WSHM12 2
Grade 10.9 rear M12 front
Anti-roll bar
2 AB
Bolt M12 x 65
Grade 10.9
BM12X65 2
Lower wishbone
front x2 13 AN
Spring Washer
M8
WSHM8 6
mounting brackets &
upper damper
mount Harrison P again to put
3 AC
Bolt M10 x 65
Grade 10.9
BM10X65 2
Upper wishbone
rear x2 14 AP
Washer ⅜"
Shake-proof
WSS3/8 2 Brake pipe
the headlight
4 AD
Bolt M10 x 60
Grade 10.9
BM10X60 2
Upper wishbone
front x2 15 AR Nyloc Nut ½"
Half height
NFYH1/2 2 Wing stay
bracket on later.
5 AE
Bolt M8 x 40
Grade 10.9
BM8X40 4
Anti-roll bar
mounting brackets
16 AS Nyloc Nut ½"
Full height
NFYF1/2 2
Front brake, upright
mounting (std track
ONLY)
The big washers are chamfered and John K
6 AF
Plain Nut M14
x 1.5 thread
NMPH14 1
Temporary use to
help lock upper
wishbone ball joint
the chamfered side should be towards
Lower wishbone
rear x2
the wishbone.
Alex H
8 AH Nyloc Nut M10 NMYF10 4 Upper wishbone
x4
x14
Plain Washer
Chamfered
Plain Washer
Anti-roll bar
10 AK M8 WPHM8 4
Plain Washer
Heavy duty
8
START WITH THE SUSPENSION WISHBONES
35
AC35
mm mm
47Nm
AH
AD
35
mm
35
mm
47Nm 3
AH
AA
35
mm
AJ
35
mm
81Nm
AG
AJ
1
AB
35 81Nm AJ
mm
AM
REPEAT
9
NOW FOR THE STEERING RACK
P A R T S T O O L S
1 Steering rack
13mm
2 Rack clamps
3 Column universal joint 5mm
4 Track rod end

10mm
13mm
5 IVA cover 22mm
¾"
B
SERIAL
55
Pack
NUMBER
PACK NUMBER
3ACZ0021
RELEASED NOV-19
Finding the right IVA cover isn’t The trackrod end needs to screw on
STEERING DeDION CARS (METRIC)
This pack may include extra fasteners to cover different options obvious because it is effectively about 12 turns (it will be properly set
a long cap. To use it, you cut the later when the tracking is done).
BASIC PART
ITEM QTY USED ON ILLUSTRATION
DESCRIPTION NUMBER
x4
Caphead Bolt
closed end off.

1 BA M6 x 70 BMCH6X70 4 Rack clamps
DIN 912
Matthew H
2 BB Bolt ¼" x 1½" BF1/4X1.1/2 2 Column clamp
Jamie A
x2
Bolt M8 x 40 Column to rack
3 BC BM8X40 2
Grade 10.9 universal joint
Nyloc Nut ½"

4 BD Half height
NFYH1/2 1 Steering wheel boss
5 BE Plain Nut ½" NFPF1/2 2 Track rod lock nut

x2 Don't fully
6 BF
Plain Nut ⁷⁄₁₆"
Half height
NFPFH7/16 1
Column clamp
grubscrew locknut tighten steering
7 BG Nyloc Nut M8 NMYF8 2
Column to rack
universal joint x2 rack for now.
8 BH Nyloc Nut M6 NMYF6 4 Steering rack clamps
x4 Dan D
Plain Washer
9 BJ ½" x 1⅛" WPH1/2 1 Steering wheel boss
Chamfered
x4
Plain Washer
Rack clamps and
10 BK ¼" WPH1/4 6
Heavy duty column clamp
Spring Washer ¼
11 BL Heavy duty
WSH1/4 2 Column clamp
10
NOW FOR THE STEERING RACK
BC
35 32Nm
mm
BG
3
BA
35 11Nm
BH
mm
BK 1
5
2
4
BE
11
AND THEN THE DAMPERS
P A R T S T O O L S
1 Spring / damper
6mm
2 Lower damper sleeve
3 Upper damper sleeve 6mm
6mm
94
A A
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER
PACK NUMBER
30F015B
PACK NUMBER
30F015B Put the top of the damper on first The bottom can be a tight fit!
This pack may include extra fasteners to cover different options and be careful not to let it swing into Mick F
the side of the chassis.
Bolt M12 x 100 Lower wishbone Spring Washer Lower wishbone

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

4 AD BM10X60 2 15 AR NFYH1/2 2 Wing stay
Grade 10.9 front Half height

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

Lower wishbone
Fixings not contained in the pack will be
supplied loosely fitted to the chassis and
rear

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

30F015B 30F015B

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

x2
top ball joint
ONLY)
Temporary use to
6 AF
Plain Nut M14
x 1.5 thread
wishbone ball joint x1 home before
Lower wishbone
rear
using a nyloc,
Remove and discard the washer that comes on the back of otherwise the
9 AJ
Plain Washer
M12
Chamfered
WPCM12 18 Lower wishbone the assembly before fitting the wingstay; it's not needed. thread will spin.
10 AK
Plain Washer
M8 WPHM8 4
Anti-roll bar
mounting brackets
Rich T Chris N
Heavy duty
Plain Washer
Heavy duty
14
IT’S TIME FOR THE WINGSTAYS
1 x ⅛"
35 35 61Nm
mm mm
35 35
mm mm
81Nm AR 2
35 35
AS 54Nm
mm mm
WIDE
35
TRACK
mm
35
mm
54Nm STANDARD TRACK REPEAT
15
Now is a good time to take some photos
16
Have you applied for your IVA yet?
17
LET THERE BE LIGHTS
P A R T S T O O L S
1 Headlight assembly
17mm
2 Indicator pod
17mm
3 Indicator assembly 17mm
24mm
4 Headlight bracket
5 IVA trim
T I P S
It's very important to read the IVA Guide This is the trickiest
before starting this job to ensure grommets job on the car, so once
and sheathing are in the right place. It's very done you can breathe a
F I X I N G S difficult to add them once fitted! sigh of relief!
John S Tiago A
C
SERIAL
45
Pack
NUMBER
PACK NUMBER
30L002B
LIGHTING & HORNS
BASIC PART
DESCRIPTION NUMBER
x6
Screw 10 x ¾" Indictor assembly to
The wiring for the headlights is attached to the chassis when you receive your
1 CA 71080 6
Black Supaflange indicator pod
kit. The wires go through the hole in the end of the headlight bracket and out of
Screw 8 x ½" Side repeater earth
2 CB 71077 2
Black Supaflange on wingstay
the other hole in order to go up into the headlight and over to the indicator.
Screw 12 x 1½" Rear light cluster
3 CC 71079 4
Self tapping upper fixing
Screw 12 x 1" Rear light cluster

4 CD Self tapping
71078 4
lower fixing Jamie A
Horn bracket to
steering rack
5 CE Nyloc Nut M6 NMYF6 2
platform
(160/270/310)
Horn bracket to
Plain Washer
steering rack
6 CF ¼" WPH1/4 2
Heavy duty platform
(160/270/310)
7 CG
Bolt M8 x 5
Grade 8.8
BM8X50 1
Through steering
rack platform &
spacer
(420)
The tab on the headlight bracket 4 hooks
8 CH
Plain Washer
5/16"
WPH5/16 2 Bolt head/nut Glue IVA trim all around the under the wishbone bracket on the chassis.
9 CI
Nyloc Nut
M8
NMYF8 1 Horn bolt
edge of the pod before fitting. Harrison P
Chris B
18
LET THERE BE LIGHTS
CA 5
7
4
REPEAT
19
LAST PART OF THE FRONT SUSPENSION: CONNECTING THE TWO SIDES TOGETHER
P A R T S T O O L S
1 Anti-roll bar
13mm
2 Anti-roll bar bracket
3 Anti-roll bar rubber
4 Anti-roll bar ball
LO
CT
IT
E
5 Anti-roll bar dust cover
94
A A
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER
PACK NUMBER
30F015B
PACK NUMBER
30F015B Use four small cable ties to Grease the balls and cups generously.
BASIC
BASIC
This pack may include extra fasteners to cover different options secure the dust cover. Matt T
PART PART
Mick F
1 AA BM12X100 2 12 AM WSHM12 2
Anti-roll bar
2 AB
Bolt M12 x 65
2
Lower wishbone
13 AN
Spring Washer
6
mounting brackets &
x4
Getting the assembled
BM12X65 WSHM8
mount
3 AC
Bolt M10 x 65
Grade 10.9
BM10X65 2
Upper wishbone
rear
14 AP
Washer ⅜"
Shake-proof
WSS3/8 2 Brake pipe
Check that the colour of the mounting anti-roll bar fully into
4 AD
Bolt M10 x 60
Grade 10.9
BM10X60 2
Upper wishbone
front
15 AR Nyloc Nut ½"
Half height
NFYH1/2 2 Wing stay
rubbers matches the colour spot on the bar. both cups on the upper
John K wishbone can be a bit
5 AE
Bolt M8 x 40
Grade 10.9
BM8X40 4
Anti-roll bar
mounting brackets x4 16 AS Nyloc Nut ½"
Full height
NFYF1/2 2 mounting (std track
ONLY)
of a fight. It’s made of

Temporary use to
Plain Nut M14
6 AF x 1.5 thread
wishbone ball joint

Lower wishbone
rear
springy stuff, so don’t
8 AH Nyloc Nut M10 NMYF10 4 Upper wishbone Use the thread lock on the thread of the worry that you are
9 AJ
Plain Washer
M12 WPCM12 18 Lower wishbone
anti-roll bar, not in the thread of the ball. bending it.
Chamfered
Dan D Jamie A
x4
Plain Washer
Anti-roll bar
10 AK M8 WPHM8 4
Plain Washer
Heavy duty
20
LAST PART OF THE FRONT SUSPENSION: CONNECTING THE TWO SIDES TOGETHER
AE
35 35 20Nm
mm AK
mm
AN
LO
CT
IT
E
3
REPEAT
21
FITTING THE BRAKE HOSES
P A R T S T O O L S
1 Brake hose
13mm (x2)
⁹⁄₁₆"
2 Copper washer
94
A A
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER
The hose will want to curve once fitted. Brake hoses come in
30F015B 30F015B
BASIC
BASIC
This pack may include extra fasteners to cover different options Make sure the curve points towards packs of 3: 2 front, 1 back.
the front of the car.
PART PART
Anthony L
1 AA BM12X100 2 12 AM WSHM12 2
Anti-roll bar
Khalfani D
2 AB BM12X65 2 13 AN WSHM8 6
mount
3 AC
Bolt M10 x 65
Grade 10.9
BM10X65 2
Upper wishbone
rear
14 AP
Washer ⅜"
Shake-proof
WSS3/8 2 Brake pipe
x2

ONLY)
Temporary use to
The copper washer should

Plain Nut M14
6 AF x 1.5 thread
wishbone ball joint

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

10mm
2 Spacer (miscellaneous box)
3 Bolt for spacer 13mm
6mm
Miscellaneous box
24
LET'S MAKE SOME NOISE
270/310/360 420
11xx8mm
8mm
2
1
25
WET SUMP FITTING THE RADIATOR
P A R T S T O O L S
1 Radiator
13mm
10mm
2 Blanking plate
3 Fan 5mm
4 Radiator bobbins
D D
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER
PACK NUMBER
30C047B
PACK NUMBER
30C047B Be careful to tighten the The fan should have a ‘flat’ section on the
COOLING SIGMA
COOLING SIGMA
This pack may include extra fasteners to cover different options fan gently and with just rim. This should be at the top.
a nip.
Grant P
Plain Washer
Bolt M8 X 50 Expansion tank Expansion tank
1 DA BM8X50 1 12 DL 1/4" X 7/8" WPH1/4X7/8 1
Grade 8.8 bracket to chassis bracket
Dan P
Heavy duty
Spring Washer
Setscrew 1/4" Expansion tank to 8 x Radiator bobbin
2 DB X 3/4"
SF1/4X3/4 1 13 DM 5/16" WSH5/17 9
bracket Heavy duty 1 x Expansion tank
2 x U shape hose to
Setscrew M8X20 Hose Clip water rail
3 DC Grade 8.8
SM6X20 4 SV radiator bracket 14 DN 30 - 40mm
SGT25-40 6 2 x Top radiator hose
2 x Bottom radiator hose
1 x Engine outlet to
Bolt M6 X 16 with Hose Clip big T piece
4 DD square section
30Z1072A 4 Fan brackets to fan 15 DO SGT23-35 2
23 - 35mm 1 x Engine outlet to
heater inlet
6 x Heater inlet/outlet
3 x Big T-piece
Setscrew M6X16 Fan to radiator Hose Clip 1 x Expansion tank
The blanking plate is fitted using two

5 DE SPHM6X16 4 16 DP SGT16-25 18
Panhead Pozi cowling - SV only 17 - 25mm 2 x Modine
4 x Dry Sump
2 x Submarine
x4 Fan to radiator
6 DF Nyloc Nut M6 NMYF6 8 x4 SV radiator
bracket x4 17 DQ
Hose Clip
8 - 16mm
SGT8-16 6
Expansion tank
small T-piece
M8X16 bolts, they should be in the box.
7 DG Plain Nut M8 NMPF8 8 Radiator bobbin
x4 18 DR Rivet - Black
5/32" X 0.47"
1610-01015 12 Cowling flap
James A
Expansion tank
8 DH Nyloc Nut 1/4" NFYF1/4 1
bracket
8 x SV rad bracket
Plain Washer 1/4" 4 x Fan fixings
9 DI WPH1/4 13
Heavy duty 1 x Expansion tank
braket
Plain Washer
x4
Radiator bobbin
10 DJ 5/16" WPH5/16 4
Heavy duty back
Plain Washer
Radiator bobbin
11 DK 4
x4
5/16" X 7/8" WPH5/17X7/8
Heavy duty front
26
W
WET SUMP FITTING THE RADIATOR
ET
SU
M
P
1
3
DG
DJ
DK
DF
2
27
DRY SUMP FITTING THE RADIATOR
P A R T S T O O L S
1 Radiator
13mm
10mm
2 Blanking plate
3 Fan 5mm
4 Radiator bobbins
D D
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER
PACK NUMBER
30C047B
PACK NUMBER
30C047B Be careful to tighten the The fan should have a ‘flat’ section on the
COOLING SIGMA
COOLING SIGMA
This pack may include extra fasteners to cover different options fan gently and with just rim. This should be at the top.
a nip.
Grant P
Plain Washer
1 DA BM8X50 1 12 DL 1/4" X 7/8" WPH1/4X7/8 1
Dan P
Heavy duty
Spring Washer
2 DB X 3/4"
SF1/4X3/4 1 13 DM 5/16" WSH5/17 9
2 x U shape hose to
3 DC Grade 8.8
4 DD square section
heater inlet
3 x Big T-piece
5 DE SPHM6X16 4 16 DP SGT16-25 18
4 x Dry Sump
2 x Submarine
x4 Fan to radiator
bracket x4 17 DQ
Hose Clip
8 - 16mm
SGT8-16 6
Expansion tank
small T-piece
7 DG Plain Nut M8 NMPF8 8 Radiator bobbin

x4 18 DR Rivet - Black
5/32" X 0.47"
Expansion tank
bracket
8 x SV rad bracket
9 DI WPH1/4 13
braket
Plain Washer
x4
Radiator bobbin
10 DJ 5/16" WPH5/16 4
Heavy duty back
Plain Washer
Radiator bobbin
11 DK 4
x4
5/16" X 7/8" WPH5/17X7/8
Heavy duty front
28
D
DRY SUMP FITTING THE RADIATOR
RY
SU
M
P
1
3
DG
DJ
DK
DF
2
29
THINGS ARE HEATING UP
P A R T S T O O L S
1 Heater
10mm
7mm
2 Valve
3 Heater cable 19mm
4 Lower hose 110mm (cut from long length)
5 Upper hose 120mm (cut from long length)
6 Grommet
D D
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER
PACK NUMBER
30C047B
PACK NUMBER
30C047B Remember to remove bungs Use 7mm for jubilee clips but not
COOLING SIGMA
COOLING SIGMA
This pack may include extra fasteners to cover different options from heater. too tight!
Jamie A Chris B
Plain Washer
1 DA BM8X50 1 12 DL 1/4" X 7/8" WPH1/4X7/8 1
Grade 8.8 bracket to chassis Heavy duty bracket
Spring Washer
2 DB X 3/4"
SF1/4X3/4 1 13 DM 5/16" WSH5/17 9
2 x U shape hose to
3 DC Grade 8.8
It’s worth re-tightening the jubilee

4 DD square section
heater inlet
clips after a couple of uses of car.

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

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

5/32" X 0.47"
Expansion tank
bracket
8 x SV rad bracket
9 DI WPH1/4 13
braket
Plain Washer
Radiator bobbin
10 DJ 5/16" WPH5/16 4
Heavy duty back
Plain Washer
Radiator bobbin
11 DK 5/16" X 7/8" WPH5/17X7/8 4
Heavy duty front
30
THINGS ARE HEATING UP
DE 6
DP
31
WET / DRY SUMP REMOVE ENGINE PARTS
P A R T S T O O L S
1 Engine mounts
2 Starter motor
3 Bellhousing
Remove the engine mounts, Remember where the bolts go.

starter motor and bellhousing. John S
Mick F
32
33
P A R T S T O O L S
1 Altenator
15mm
2 Altenator Belt
3 Plenum
Remove altenator, altenator belt and plenum. Use a 15mm spanner

Richard T and turn anti-clockwise
to remove altenator.
Harrison P
Remember where the bolts go.

John S
34
35
WET / DRY SUMP ATTACH GEARBOX TO BELLHOUSING
P A R T S T O O L S
1 Gearbox
10mm
2 Bellhousing
F F
SERIAL
66
SERIAL
66
Pack Pack
NUMBER NUMBER
3EZ2029B 3EZ2029B
DURATEC GEARBOX 5 SPEED DURATEC GEARBOX 5 SPEED

This pack may include extra fasteners to cover different options This pack may include extra fasteners to cover different options
Bolt
1 FA M14 X 30 X 1.5 30Z2032A 2 AV Mount 12 FL Plain Washer M6 WPHM6 3 Gear Lever
Grade 12.9
x4
Caphead
Spring Washer
2 FB M12 X 40 X 1.75 BMCH12X40 4 Bellhousing 13 FM M14
30Z2030A 2 AV Mount
Grade 12.9
x4
Caphead Bolt
Spring Washer
3 FC M10 X 90 BMCH10X90 1 Bellhousing 14 FN M12
WSHM12 4 Gearbox
Grade 12.9
Caphead Bolt
Spring Washer x 2 Starter Motor x
4 FD M10 X 55 BMCH10X55 3 Bellhousing 15 FO M10
WSHM10 4
Grade 12.9 2 Front Bellhousing
Caphead Bolt
x 5 Bellhousing x Spring Washer Clutch Slave
5 FE M10 X 45 BMCH10X45 7 16 FP M6
WSHM6 3
Grade 12.9 2 Starter Motor Cylinder
Caphead Bolt
6 FF M8 X 40 30Z1076A 4 AV Mount
Grade 12.9
Caphead Bolt
Clutch Release
7 FG M6 X 25 BMCH6X25 3
Grade 12.9 Bearing
Buttonhead Bolt
M6 X 10
8 FH Grade 10.9
3GZ1163A 3 Gear Lever
Internal Hex
Nyloc Nut
9 FI M8
NMYF8 4 AV Mount
Plain Washer
10 FJ M14
WPH14 2 AV Mount
x4
Plain Washer
11 FK M12
30Z2031A 4 Bellhousing
36
WET / DRY SUMP ATTACH GEARBOX TO BELLHOUSING
FB
35 68Nm FK
mm
FN
37
WET / DRY SUMP AND THEN GEARBOX TO ENGINE
T O O L S
8mm
Refit bellhousing and gearbox to engine.

Harrison P
38
WET / DRY SUMP AND THEN GEARBOX TO ENGINE
35 35 47Nm
mm mm
DRY SUMP
39
FILLING THE ENGINE AND GEARBOX WITH OIL
P A R T S T O O L S
Engine oil SW-30
Gear oil GL4
40
FILLING THE ENGINE AND GEARBOX WITH OIL
Ford 2.0L Engine

Wet Sump = 4.5 Litres
Dry Sump = 6 .0 Litres (3 Litres in Engine,
3 Litres in Tank, top up if required)
5 Speed Gearbox = (Pre-Filled)
Before Installation. You can double check the oil
level by removing the plug on the side. The oil
should be to this level.
41
WET / DRY SUMP AT LAST THE ENGINE IS GOING IN
P A R T S T O O L S
1 Engine mounts
+
2 Engine rubbers
6mm
8mm
⅜
13mm
13mm
15mm
When fitting engine rubbers Tighten gradually once all bolts are in.
and mounts, fit as loosely Chris N
as possible so you can wiggle
things to get bolts in.
James A
Protect the chassis with soft stuff

such as cardboard or a folded
towels / blankets.
Harry P
42
WET / DRY SUMP AT LAST THE ENGINE IS GOING IN
2
1
43
WET / DRY SUMP AND THE GEARBOX IS FIXED IN PLACE
P A R T S T O O L S
13mm
22mm
6mm
Once the engine is in, the See IVA guide – how to secure a loom.
wiring can be connected to the Grant P
car's loom. It should be self
explanatory.
Chris B
44
WET / DRY SUMP AND THE GEARBOX IS FIXED IN PLACE
45
WET / DRY SUMP REFIT ALTENATOR, BELT & STARTER MOTOR
P A R T S T O O L S
1 Altenator belt
8mm
2 Altenator
3 Starter motor 15mm
Refit altenator, altenator

belt and starter motor.
Lee A
46
WET / DRY SUMP REFIT ALTENATOR, BELT & STARTER MOTOR
3
2
47
WET SUMP LOWER RADIATOR HOSE
P A R T S T O O L S
1 Lower radiator hose

7mm
D D
SERIAL
44 SERIAL
44
Pack Pack Reminder for later on – nip Support hose by cable tying to
NUMBER NUMBER

30C047B 30C047B
COOLING SIGMA
COOLING SIGMA
up once the car has been run. chassis rails. Make sure they are clear
of the steering rack.
Mick F
Plain Washer
1 DA BM8X50 1 12 DL 1/4" X 7/8" WPH1/4X7/8 1
bracket to chassis bracket
Grant P
Grade 8.8
Heavy duty
Spring Washer
2 DB X 3/4"
SF1/4X3/4 1 13 DM 5/16" WSH5/17 9
2 x U shape hose to
3 DC
Setscrew M8X20
Grade 8.8
SM6X20 4 SV radiator bracket 14 DN
Hose Clip
30 - 40mm
SGT25-40 6
water rail
2 x Top radiator hose
x2
Fit the hose to the larger outlet on the engine.

4 DD square section
heater inlet
3 x Big T-piece
5 DE 4
Dan D
SPHM6X16 16 DP SGT16-25 18
4 x Dry Sump
2 x Submarine
x4 Fan to radiator
6 DF Nyloc Nut M6 NMYF6 8 x4 SV radiator Hose Clip Expansion tank
17 DQ SGT8-16 6
bracket

5/32" X 0.47"
Expansion tank
bracket
8 x SV rad bracket
9 DI WPH1/4 13
braket
Plain Washer
Radiator bobbin
10 DJ 5/16" WPH5/16 4
Heavy duty back
Plain Washer
Radiator bobbin
11 DK 5/16" X 7/8" WPH5/17X7/8 4
Heavy duty front
48
W
WET SUMP LOWER RADIATOR HOSE
ET
SU
M
P
1
DN
49
WET SUMP UPPER RADIATOR HOSE
P A R T S T O O L S
1 Upper radiator hose

7mm
D D
SERIAL
44 SERIAL
44
Pack Pack Reminder for later on – nip
NUMBER NUMBER

30C047B 30C047B
COOLING SIGMA
COOLING SIGMA
up once the car has been run.
Mick F
Plain Washer
1 DA BM8X50 1 12 DL 1/4" X 7/8" WPH1/4X7/8 1
Spring Washer
2 DB X 3/4"
SF1/4X3/4 1 13 DM 5/16" WSH5/17 9
2 x U shape hose to
3 DC
Setscrew M8X20
Grade 8.8
Hose Clip
30 - 40mm
SGT25-40 6
water rail
x2
4 DD square section
heater inlet
3 x Big T-piece
5 DE SPHM6X16 4 16 DP SGT16-25 18
4 x Dry Sump
2 x Submarine
x4 Fan to radiator
17 DQ SGT8-16 6
bracket

5/32" X 0.47"
Expansion tank
bracket
8 x SV rad bracket
9 DI WPH1/4 13
braket
Plain Washer
Radiator bobbin
10 DJ 5/16" WPH5/16 4
Heavy duty back
Plain Washer
Radiator bobbin
11 DK 5/16" X 7/8" WPH5/17X7/8 4
Heavy duty front
50
W
WET SUMP UPPER RADIATOR HOSE
ET
SU
M
P
DN
51
WET SUMP EXPANSION BOTTLE
P A R T S T O O L S
1 Expansion bottle
13mm
11mm
2 Expansion bottle cap
3 Expansion bottle bracket 11mm
D D
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER
PACK NUMBER
30C047B
PACK NUMBER
30C047B Throw away the red cap that
COOLING SIGMA
COOLING SIGMA
This pack may include extra fasteners to cover different options came on the expansion bottle.
Lloyd D
x1 x1
Plain Washer
1 DA BM8X50 1 12 DL 1/4" X 7/8" WPH1/4X7/8 1
x1 x1
Spring Washer
2 DB X 3/4"
SF1/4X3/4 1 13 DM 5/16" WSH5/17 9
2 x U shape hose to
3 DC Grade 8.8
4 DD square section
heater inlet
3 x Big T-piece
5 DE SPHM6X16 4 16 DP SGT16-25 18
4 x Dry Sump
2 x Submarine
x4 Fan to radiator
17 DQ SGT8-16 6
bracket

5/32" X 0.47"
x1
Expansion tank
bracket
8 x SV rad bracket
x1
9 DI WPH1/4 13
braket
Plain Washer
Radiator bobbin
10 DJ 5/16" WPH5/16 4
Heavy duty back
Plain Washer
Radiator bobbin
11 DK 5/16" X 7/8" WPH5/17X7/8 4
Heavy duty front
52
W
WET SUMP EXPANSION BOTTLE
ET
SU
1
M
P
2
DB
DL
DH
DI
DA
DM
53
WET SUMP HOSES
P A R T S T O O L S
1 T-piece
7mm
2 Hose roll
3 Reducer hose
D D
44 44
The hose that comes
SERIAL SERIAL
Pack Pack
NUMBER NUMBER
PACK NUMBER
30C047B
PACK NUMBER
30C047B You will need to cut hoses to size.
COOLING SIGMA
COOLING SIGMA
This pack may include extra fasteners to cover different options John S from the engine reduces in
ITEM
BASIC
DESCRIPTION
PART
NUMBER
BASIC
DESCRIPTION
PART
NUMBER
diameter to the T-piece.
Plain Washer
1 DA 12 DL 1
Chris N
BM8X50 1 1/4" X 7/8" WPH1/4X7/8
Spring Washer
2 DB X 3/4"
SF1/4X3/4 1 13 DM 5/16" WSH5/17 9
2 x U shape hose to
3 DC Grade 8.8
4 DD
Bolt M6 X 16 with
square section
30Z1072A 4 Fan brackets to fan 15 DO
Hose Clip
23 - 35mm
SGT23-35 2
big T piece
heater inlet
x1
x7
3 x Big T-piece
5 DE SPHM6X16 4 16 DP SGT16-25 18
4 x Dry Sump
2 x Submarine
x4 Fan to radiator
17 DQ SGT8-16 6
bracket

5/32" X 0.47"
Expansion tank
bracket
8 x SV rad bracket
9 DI WPH1/4 13
braket
Plain Washer
Radiator bobbin
10 DJ 5/16" WPH5/16 4
Heavy duty back
Plain Washer
Radiator bobbin
11 DK 5/16" X 7/8" WPH5/17X7/8 4
Heavy duty front
54
W
WET SUMP HOSES
ET
SU
M
P
DP
DP DO
3
2
1
55
DRY SUMP FIXING THE TANK
P A R T S T O O L S
1 Dry sump tank

10mm
2 Temperature sender
3 P-clips 5mm
Unmarked bag:
• M8 x 20 caphead The M8 caphead fits the tab The bottom P-clips fix on
• M8 spring and plain head washer on the tank to the chassis. to the lower chassis rails.
• M6 x 20 bolts (x2) John K Grant P
• M6 Nyloc (x2)
• ¼" washers (x2)
Put PTFE tape in the

The tab on the tank may need to temperature sensor.
be spaced out. Use M8 washers. Chris N
Jamie A
56
D
DRY SUMP FIXING THE TANK
RY
SU
M
P
2
57
DRY SUMP FITTING THE EXPANSION BOTTLE
P A R T S T O O L S
1 Expansion bottle
13mm
11mm
2 Expansion bottle cap
3 Expansion bottle bracket 11mm
4 Expansion bottle plate
⁵⁄₃₂
D D
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER
PACK NUMBER
30C047B
PACK NUMBER
30C047B Lay the plate over the top of the chassis Throw away the red cap that
COOLING SIGMA
COOLING SIGMA
This pack may include extra fasteners to cover different options until the hole sits in the middle of the came on the expansion bottle.
tube; mark and drill.
Lloyd D
x1 x1
Plain Washer
1 DA BM8X50 1 12 DL 1/4" X 7/8" WPH1/4X7/8 1
Vincent M
Heavy duty
x1 x1
Spring Washer
2 DB X 3/4"
SF1/4X3/4 1 13 DM 5/16" WSH5/17 9
2 x U shape hose to
3 DC Grade 8.8
4 DD square section
heater inlet
3 x Big T-piece
5 DE SPHM6X16 4 16 DP SGT16-25 18
4 x Dry Sump
2 x Submarine
x4 Fan to radiator
17 DQ SGT8-16 6
bracket

5/32" X 0.47"
x4
x1
Expansion tank
bracket
8 x SV rad bracket
x1
9 DI WPH1/4 13
braket
Plain Washer
Radiator bobbin
10 DJ 5/16" WPH5/16 4
Heavy duty back
Plain Washer
Radiator bobbin
11 DK 5/16" X 7/8" WPH5/17X7/8 4
Heavy duty front
58
D
DRY SUMP FITTING THE EXPANSION BOTTLE
RY
SU
M
P
2
1
DB
DL
DH
DI
3
DA
DM
4
59
DRY SUMP LOWER RADIATOR HOSE
P A R T S T O O L S
1 Lower radiator hose

7mm
D D
SERIAL
44 SERIAL
44
Pack Pack Reminder for later on – nip Support hose by cable tying to
NUMBER NUMBER

30C047B 30C047B
COOLING SIGMA
COOLING SIGMA
up once the car has been run. chassis rails. Make sure they are clear
of the steering rack.
Mick F
Plain Washer
1 DA BM8X50 1 12 DL 1/4" X 7/8" WPH1/4X7/8 1
Grant P
Grade 8.8
Heavy duty
Spring Washer
2 DB X 3/4"
SF1/4X3/4 1 13 DM 5/16" WSH5/17 9
2 x U shape hose to
3 DC
Setscrew M8X20
Grade 8.8
Hose Clip
30 - 40mm
SGT25-40 6
water rail
x2
Fit the hose to the larger outlet on the engine.

4 DD square section
heater inlet
3 x Big T-piece
5 DE 4
Dan D
SPHM6X16 16 DP SGT16-25 18
4 x Dry Sump
2 x Submarine
x4 Fan to radiator
17 DQ SGT8-16 6
bracket

5/32" X 0.47"
Expansion tank
bracket
8 x SV rad bracket
9 DI WPH1/4 13
braket
Plain Washer
Radiator bobbin
10 DJ 5/16" WPH5/16 4
Heavy duty back
Plain Washer
Radiator bobbin
11 DK 5/16" X 7/8" WPH5/17X7/8 4
Heavy duty front
60
D
DRY SUMP LOWER RADIATOR HOSE
RY
SU
M
P
1
DN
61
DRY SUMP UPPER RADIATOR HOSE
P A R T S T O O L S
1 Upper radiator hose

7mm
D D
SERIAL
44 SERIAL
44
Pack Pack Reminder for later on – nip
NUMBER NUMBER

30C047B 30C047B
COOLING SIGMA
COOLING SIGMA
up once the car has been run.
Mick F
Plain Washer
1 DA BM8X50 1 12 DL 1/4" X 7/8" WPH1/4X7/8 1
Spring Washer
2 DB X 3/4"
SF1/4X3/4 1 13 DM 5/16" WSH5/17 9
2 x U shape hose to
3 DC
Setscrew M8X20
Grade 8.8
Hose Clip
30 - 40mm
SGT25-40 6
water rail
x2
4 DD square section
heater inlet
3 x Big T-piece
5 DE SPHM6X16 4 16 DP SGT16-25 18
4 x Dry Sump
2 x Submarine
x4 Fan to radiator
17 DQ SGT8-16 6
bracket

5/32" X 0.47"
Expansion tank
bracket
8 x SV rad bracket
9 DI WPH1/4 13
braket
Plain Washer
Radiator bobbin
10 DJ 5/16" WPH5/16 4
Heavy duty back
Plain Washer
Radiator bobbin
11 DK 5/16" X 7/8" WPH5/17X7/8 4
Heavy duty front
62
D
DRY SUMP UPPER RADIATOR HOSE
RY
SU
M
P
DN
63
DRY SUMP HOSES
P A R T S T O O L S
1 T-piece
7mm
2 Hose roll
3 Reducer hose
D D
44 44
The hose that comes
SERIAL SERIAL
Pack Pack
NUMBER NUMBER
PACK NUMBER
30C047B
PACK NUMBER
30C047B You will need to cut hoses to size.
COOLING SIGMA
COOLING SIGMA
This pack may include extra fasteners to cover different options John S from the engine reduces in
ITEM
BASIC
DESCRIPTION
PART
NUMBER
BASIC
DESCRIPTION
PART
NUMBER
diameter to the T-piece.
Plain Washer
1 DA 12 DL 1
Chris N
BM8X50 1 1/4" X 7/8" WPH1/4X7/8
Spring Washer
2 DB X 3/4"
SF1/4X3/4 1 13 DM 5/16" WSH5/17 9
2 x U shape hose to
3 DC Grade 8.8
4 DD
Bolt M6 X 16 with
square section
Hose Clip
23 - 35mm
SGT23-35 2
big T piece
heater inlet
x1
x7
3 x Big T-piece
5 DE SPHM6X16 4 16 DP SGT16-25 18
4 x Dry Sump
2 x Submarine
x4 Fan to radiator
17 DQ SGT8-16 6
bracket

5/32" X 0.47"
Expansion tank
bracket
8 x SV rad bracket
9 DI WPH1/4 13
braket
Plain Washer
Radiator bobbin
10 DJ 5/16" WPH5/16 4
Heavy duty back
Plain Washer
Radiator bobbin
11 DK 5/16" X 7/8" WPH5/17X7/8 4
Heavy duty front
64
D
DRY SUMP HOSES
RY
SU
M
P
DP
DP
DO
3
2
1
65
DRY SUMP CATCH TANK
P A R T S T O O L S
1 Silicone hose 90°

7mm
D D
SERIAL
44 SERIAL
44
Pack Pack The silicone hose you are The hose itself should have a grey lining.
NUMBER NUMBER

30C047B 30C047B
COOLING SIGMA
COOLING SIGMA
looking for has a 90º one end James S
ITEM
BASIC
DESCRIPTION
PART
NUMBER
BASIC
DESCRIPTION
PART
NUMBER
and then a long piece.
Plain Washer
1 DA BM8X50 1 12 DL 1/4" X 7/8" WPH1/4X7/8 1
Chris B
Grade 8.8
Heavy duty
Put hose through P-Clip

Spring Washer
2 DB X 3/4"
SF1/4X3/4 1 13 DM 5/16" WSH5/17 9
and attach to tank.

2 x U shape hose to
3 DC Grade 8.8
Grant P
4 DD square section
heater inlet
x3 Use the excess to run

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

x4 Fan to radiator
x4 SV radiator
bracket
17 DQ
Hose Clip
8 - 16mm
SGT8-16 6
Expansion tank
small T-piece from tank to D-Bottle.
5/32" X 0.47"
1610-01015 12 Cowling flap Vincent M
Expansion tank
bracket
8 x SV rad bracket
9 DI WPH1/4 13
braket
Plain Washer
Radiator bobbin
10 DJ 5/16" WPH5/16 4
Heavy duty back
Plain Washer
Radiator bobbin
11 DK 5/16" X 7/8" WPH5/17X7/8 4
Heavy duty front
66
D
DRY SUMP CATCH TANK
RY
SU
M
P

67
DRY SUMP OIL PIPE – 1 OF 3
P A R T S T O O L S
1 Oil pipe – 39C059
The pipe will fit both ways but you Put copper slip on the threads.
don’t want any kinks in the pipe itself Rich T
– one way will fit better.
Tiago O
Take care not to cross thread.

Tighten by hand slowly
Anthony L
and give a small ‘nip’ up.
Chris B
68
D
RY
SU
M
P
1
69
P A R T S T O O L S
1 Oil pipe – 39C060
Tiago O

Anthony L
Chris B
70
D
RY
SU
M
P
1
71
P A R T S T O O L S
1 Oil pipe –
Tiago O

Anthony L
Chris B
72
D
RY
SU
M
P
1
73
WET / DRY SUMP – A BIT OF SUB-ASSEMBLY (SOME HOSES NEED MODIFYING)
P A R T S T O O L S
1 Silicone hoses
Don't throw away the long

piece of hose after cutting.
Rich T
74
WET / DRY SUMP – A BIT OF SUB-ASSEMBLY (SOME HOSES NEED MODIFYING)
75
WET / DRY SUMP SUB-ASSEMBLY – TEMPERATURE SENSOR
P A R T S T O O L S
1 Temperature sender
2 Earth tag
7mm
3 Cooling submarine
8mm
13mm
LO
CT
IT
E
D D
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER
PACK NUMBER
30C047B
PACK NUMBER
30C047B Use a drop of LocTite on the sender. Be careful not to over-tighten
COOLING SIGMA COOLING SIGMA
ITEM
BASIC
PART
BASIC
PART
Tiago O the sender.
Bolt M8 X 50 Expansion tank Plain Washer

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

5/32" X 0.47"
Expansion tank
bracket
8 x SV rad bracket
9 DI WPH1/4 13
braket
Plain Washer
Radiator bobbin
10 DJ 5/16" WPH5/16 4
Heavy duty back
Plain Washer
Radiator bobbin
11 DK 5/16" X 7/8" WPH5/17X7/8 4
Heavy duty front
76
WET / DRY SUMP SUB-ASSEMBLY – TEMPERATURE SENSOR
2
DP
77
WET / DRY SUMP SUBMARINE
P A R T S T O O L S
1 Submarine assembly
7mm
D D
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER

30C047B 30C047B

Plain Washer
1 DA BM8X50 1 12 DL 1/4" X 7/8" WPH1/4X7/8 1
Spring Washer
2 DB X 3/4"
SF1/4X3/4 1 13 DM 5/16" WSH5/17 9
2 x U shape hose to
3 DC Grade 8.8
4 DD
Bolt M6 X 16 with
square section
Hose Clip
23 - 35mm
SGT23-35 2
big T piece
heater inlet
x1
x1
3 x Big T-piece
5 DE SPHM6X16 4 16 DP SGT16-25 18
4 x Dry Sump
2 x Submarine
x4 Fan to radiator
17 DQ SGT8-16 6
bracket

5/32" X 0.47"
Expansion tank
bracket
8 x SV rad bracket
9 DI WPH1/4 13
braket
Plain Washer
Radiator bobbin
10 DJ 5/16" WPH5/16 4
Heavy duty back
Plain Washer
Radiator bobbin
11 DK 5/16" X 7/8" WPH5/17X7/8 4
Heavy duty front
78
WET / DRY SUMP SUBMARINE
DO
DP
79
WET SUMP LAST BIT OF PLUMBING
P A R T S T O O L S
1 ⁵⁄₁₆" hose
7mm
D D
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER
PACK NUMBER
30C047B
PACK NUMBER
30C047B Run hose through spare P-Clip. Cut hose to length.
This pack may include extra fasteners to cover different options This pack may include extra fasteners to cover different options Dan P Lee A
Plain Washer
1 DA BM8X50 1 12 DL 1/4" X 7/8" WPH1/4X7/8 1
Spring Washer
2 DB X 3/4"
SF1/4X3/4 1 13 DM 5/16" WSH5/17 9
2 x U shape hose to
3 DC Grade 8.8
4 DD square section
heater inlet
3 x Big T-piece
5 DE SPHM6X16 4 16 DP SGT16-25 18
4 x Dry Sump
2 x Submarine
x4 Fan to radiator
bracket
17 DQ
Hose Clip
8 - 16mm
SGT8-16 6
Expansion tank
small T-piece x2
5/32" X 0.47"
Expansion tank
bracket
8 x SV rad bracket
9 DI WPH1/4 13
braket
Plain Washer
Radiator bobbin
10 DJ 5/16" WPH5/16 4
Heavy duty back
Plain Washer
Radiator bobbin
11 DK 5/16" X 7/8" WPH5/17X7/8 4
Heavy duty front
80
W
WET SUMP LAST BIT OF PLUMBING
ET
SU
M
P
1
DQ
81
DRY SUMP LAST BIT OF PLUMBING
P A R T S T O O L S
1 ⁵⁄₁₆” hose
7mm
D D
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER

30C047B 30C047B

Plain Washer
1 DA BM8X50 1 12 DL 1/4" X 7/8" WPH1/4X7/8 1
Spring Washer
2 DB X 3/4"
SF1/4X3/4 1 13 DM 5/16" WSH5/17 9
2 x U shape hose to
3 DC Grade 8.8
4 DD square section
heater inlet
3 x Big T-piece
5 DE SPHM6X16 4 16 DP SGT16-25 18
4 x Dry Sump
2 x Submarine
x4 Fan to radiator
bracket
17 DQ
Hose Clip
8 - 16mm
SGT8-16 6
Expansion tank
small T-piece x2
5/32" X 0.47"
Expansion tank
bracket
8 x SV rad bracket
9 DI WPH1/4 13
braket
Plain Washer
Radiator bobbin
10 DJ 5/16" WPH5/16 4
Heavy duty back
Plain Washer
Radiator bobbin
11 DK 5/16" X 7/8" WPH5/17X7/8 4
Heavy duty front
82
D
DRY SUMP LAST BIT OF PLUMBING
RY
SU
M
P
DQ
83
WET / DRY SUMP PLENUM
P A R T S T O O L S
1 Plenum
5mm
Those removed earlier
Refit the plenum.
Dan P
84
WET / DRY SUMP PLENUM
85
WET / DRY SUMP AIR BOX HOSE
P A R T S T O O L S
1 Airbox hose
7mm
2 Hose clip
All the fixings for this step should be supplied in the airbox.
86
WET / DRY SUMP AIR BOX HOSE
1
2
87
CONNECTING THE FUEL LINE
P A R T S T O O L S
88
CONNECTING THE FUEL LINE
89
PROTECTING & ATTACHING THE CLUTCH HOSE
P A R T S T O O L S
1 8mm water hose

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

John K James A
90
PROTECTING & ATTACHING THE CLUTCH HOSE
91
CONNECTING THE BATTERY (POSITIVE / RED FIRST)
P A R T S T O O L S
10mm (x2)
Always connect live side of battery first Make the battery the
(red wire). last thing you connect.
Chris B Jamie A
Be careful to ensure that the red leads go to

the + side and the black wires to the – side.
Dan D
92
CONNECTING THE BATTERY (POSITIVE / RED FIRST)
93
IT LIVES!
P A R T S T O O L S
Add a plain M8 or 5⁄16 washer

underneath the earth lead to chassis.
Dan P
94
IT LIVES!
95
ONE LAST BIT OF PLUMBING…
P A R T S T O O L S
1 Hose
7mm
D D
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER
PACK NUMBER
30C047B
PACK NUMBER
30C047B Cut off hook and trim if required.
This pack may include extra fasteners to cover different options This pack may include extra fasteners to cover different options Grant P
Plain Washer
1 DA BM8X50 1 12 DL 1/4" X 7/8" WPH1/4X7/8 1
Spring Washer
2 DB X 3/4"
SF1/4X3/4 1 13 DM 5/16" WSH5/17 9
2 x U shape hose to
3 DC Grade 8.8
4 DD square section
heater inlet
3 x Big T-piece
x1
5 DE SPHM6X16 4 16 DP SGT16-25 18
4 x Dry Sump
2 x Submarine
x4 Fan to radiator
17 DQ SGT8-16 6
bracket

5/32" X 0.47"
Expansion tank
bracket
8 x SV rad bracket
9 DI WPH1/4 13
braket
Plain Washer
Radiator bobbin
10 DJ 5/16" WPH5/16 4
Heavy duty back
Plain Washer
Radiator bobbin
11 DK 5/16" X 7/8" WPH5/17X7/8 4
Heavy duty front
96
ONE LAST BIT OF PLUMBING…
97
…TO CONNECT THE HEATER
P A R T S T O O L S
7mm
D D
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER
PACK NUMBER
30C047B
PACK NUMBER
30C047B The coolant concentrate should
COOLING SIGMA
COOLING SIGMA
This pack may include extra fasteners to cover different options be diluted 50/50 with water. It
does not need to be exact!
Plain Washer
1 DA BM8X50 1 12 DL 1/4" X 7/8" WPH1/4X7/8 1
Anthony L
Heavy duty
Spring Washer
2 DB X 3/4"
SF1/4X3/4 1 13 DM 5/16" WSH5/17 9
2 x U shape hose to
3 DC Grade 8.8
4 DD square section
heater inlet
x1
3 x Big T-piece
5 DE SPHM6X16 4 16 DP SGT16-25 18
4 x Dry Sump
2 x Submarine
x4 Fan to radiator
17 DQ SGT8-16 6
bracket

5/32" X 0.47"
Expansion tank
bracket
8 x SV rad bracket
9 DI WPH1/4 13
braket
Plain Washer
Radiator bobbin
10 DJ 5/16" WPH5/16 4
Heavy duty back
Plain Washer
Radiator bobbin
11 DK 5/16" X 7/8" WPH5/17X7/8 4
Heavy duty front
98
…TO CONNECT THE HEATER
99
WET / DRY SUMP THROTTLE CABLE
P A R T S T O O L S
1 Throttle cable
The silicone goes in the top of the Cable tie the throttle cable
pedal to prevent the cable coming out. to engine hoist eyelet.
Rich T Anthony L
100
WET / DRY SUMP THROTTLE CABLE
101
FILL WITH COOLANT
P A R T S T O O L S
Coolant concentrate
102
FILL WITH COOLANT
Fill expansion bottle to max mark
103
GIVING IT SOME DIRECTION
P A R T S T O O L S
1 Lower steering column

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

⁷⁄₃₂"
5 Grub screw 13mm
6 Steering column bush

¹¹⁄₁₆"
B
SERIAL
55
Pack
NUMBER
PACK NUMBER
3ACZ0021
RELEASED NOV-19
Check clearance between Put the clamp in the middle of column with Grease the steering bushes.
STEERING DeDION CARS (METRIC)
This pack may include extra fasteners to cover different options steering column & Aux the grooved face of the clamp plate 4 Lee A
belt tensioner once engine against the column.
BASIC PART
DESCRIPTION NUMBER
Caphead Bolt
is installed. If necessary,
1 BA M6 x 70 BMCH6X70 4 Rack clamps
DIN 912
Jamie A
2 BB 2 Column clamp
rotate steering rack.
Bolt ¼" x 1½" BF1/4X1.1/2
3 BC
Bolt M8 x 40
Grade 10.9
BM8X40 2
Column to rack
universal joint x2 Dan P
4 BD
Nyloc Nut ½"
Half height
NFYH1/2 1 Steering wheel boss
x1 Fit the clamp bolts first,
5 BE Plain Nut ½" NFPF1/2 2 Track rod lock nut
then grubscrew & finish
6 BF
Plain Nut ⁷⁄₁₆"
Half height
NFPFH7/16 1
Column clamp
grubscrew locknut Steering rack to be rotated to fit column – with the locking nut.
7 BG Nyloc Nut M8 NMYF8 2
Column to rack
universal joint x2 don't forget to tighten rack brackets!. Tiago O
8 BH Nyloc Nut M6 NMYF6 4 Steering rack clamps

Harrison P
x1
Plain Washer
9 BJ ½" x 1⅛" WPH1/2 1 Steering wheel boss
Chamfered
Plain Washer
Rack clamps and
10 BK ¼" WPH1/4 6
Spring Washer ¼
11 BL Heavy duty
104
GIVING IT SOME DIRECTION
4
BF 6 BD
BJ
5
35 35 14Nm
mm mm
1 BB
BK
BL
35
BC
mm
32Nm
BG
35
BC
mm
32Nm
BG
7 7
7 7
105
THIS IS EXHAUSTING
P A R T S T O O L S
1 Exhaust manifold gasket

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

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

exhaust hole to prevent
scratches.
Work out which primary pipe goes where, Chris B
individually then put all four in plane, starting
with the front one & working back. Take care
with the hooks on your paintwork.
Chris N
106
THIS IS EXHAUSTING
35 35 47Nm
mm mm
107
FITTING THE HANDBRAKE
P A R T S T O O L S
1 Handbrake assembly
13mm (x2)
2 Handbrake pulley
3 Handbrake clevis
4 Pulley clevis pin
5 Handbrake clevis pin
6 Handbrake cable
Miscellaneous pack
• Setscrew 8 (x25) Remember to Cable tie adjuster end of cable to diff.
• Washer M8 put a loop in Dan D
• Washer M6 inner cable
around pulley.
Grant P Use pliers to bend the legs of the split-pins
once in place, which then holds them loosely
in the clevis pins.
Chris B
Handbrake wire connector

goes to top of terminal &
After plugging in connector, cable
ties up.
tie and secure any excess wiring.
Jamie A
Dan P
108
FITTING THE HANDBRAKE
STANDARD CHASSIS
CROSS CABLES AS
SHOWN
WIDE BODY CHASSIS
DO NOT CROSS
CABLES
1 4 2 6
109
SLIDE IN THE PROPSHAFT
P A R T S T O O L S
1 Propshaft
Line the splines in the Grease prop if necessary,

propshaft to the gearbox. it will have a grease nipple.
Anthony L John S
110
SLIDE IN THE PROPSHAFT
111
HEAVY STUFF: FITTING THE DIFF
P A R T S T O O L S
1 Differential
LO
19mm
CT
IT
E
19mm
10mm
to follow Extension
8mm
I I
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER
PACK NUMBER
30Z1067B
PACK NUMBER
30Z1067B Start at bottom right with Make sure propshaft is in first!
BASIC PART
AXLE DEDION METRIC
BASIC
AXLE DEDION METRIC
PART
spanner & work your way around. Harry P
Chris B
1 IA
Bolt 1/2" X 11"
UNF
BF1/2X11 1
Upper diff mounting
bolt x1 12 IL
Plain washer 1/2"
X 7/8" Thin
WPT1/2X7/8 16
Fine tuning diff
setup
x2 *
Caphead Bolt
Lower diff mounting Plain washer 1/2"
2 IB M12 X 65 BMCH12X55 2 13 IM X 3/4" Thin
79017 8 Free play on diff
Grade 10.9 bolt
Plain washer 1/2"

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

Hub
bolts
Through rear of ear

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

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

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

11 IK X 7/8"
WPH3/8X7/8 2 Brake pipe
* Use as required for spacing
112
HEAVY STUFF: FITTING THE DIFF
35 35 61Nm
mm mm
IM
IA
IQ
IH
IQ
IB
IQ
35 35 47Nm IF
LO
CT
mm
IT
mm
E
35 35 81Nm
mm mm
113
FILL THE DIFFERENTIAL WITH OIL
P A R T S T O O L S
Differential oil
114
FILL THE DIFFERENTIAL WITH OIL
Differential = 0.8L
115
PREPARING THE DEDION TUBE
P A R T S T O O L S
1 DeDion tube
2 LHS brake pipe
3 RHS brake pipe ⅛"
4 3 way union
5 Brake hose
11mm
13mm
14mm
H I I
SERIAL
53 SERIAL
44 SERIAL
44
Pack Pack Pack
NUMBER NUMBER NUMBER
PACK NUMBER
30R011D
PACK NUMBER
30Z1067B
PACK NUMBER
30Z1067B The upper brake hose fittings will
BASIC
REAR SUSPENSION DEDION METRIC
BASIC
AXLE DEDION METRIC
BASIC
AXLE DEDION METRIC
This pack may include extra fasteners to cover different options become self explanatory on the rear
damper installation page.
PART PART PART
ITEM QTY USED ON ILLUSTRATION ITEM QTY USED ON ILLUSTRATION ITEM QTY USED ON ILLUSTRATION
DESCRIPTION NUMBER DESCRIPTION NUMBER DESCRIPTION NUMBER
Bolt M12 X 100 A-frame fromt Bolt 1/2" X 11" Upper diff mounting Plain washer 1/2" Fine tuning diff
1 HA Grade 10.9
BM12X100 2 1 IA UNF
BF1/2X11 1 12 IL X 7/8" Thin
WPT1/2X7/8 16
mountings bolt setup
John K
Caphead Bolt
Caphead Bolt Front radius arm Lower diff mounting Plain washer 1/2"
2 HB M10 X 65
BMCH10X65 2 2 IB M12 X 65 BMCH12X55 2 13 IM X 3/4" Thin
(through cockpit) Grade 10.9 bolt
Bolt x 2 Lower Rear Plain washer 1/2"

3 HC 1/2" X 2.1/2" BF1/2X2.1/2 4 Damper x 3 IC Grade 10.9
Grade 10.9 ear to front DeDion Thick
2 Rear Radius Arm
x 4 Front hub
Rear DeDion
Bolt M6 X 80 Rear Anti Roll Bar Bolt M10 X 55 through ear Washer
4 HD Grade 10.9
BM6X80 4 4 ID Grade 10.9
BM10X55 8 15 IO M10
Mounting Blocks x 4 Caliper carrier
Hub
bolts
Tighten the braided pipe 5 into the

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

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

11 HK Nyloc Nut 1/4" NFYF1/4 1
3 - way union on
DeDion tube x1 11 IK
Plain washer 3/8"
X 7/8"
x2 the hose
Drawings are for illustrative purposes only and are not to scale. Page 1 of 2 Drawings are for illustrative purposes only and are not to scale. Page 1 of 2
116
PREPARING THE DEDION TUBE
IK
5
IR
IS
IT
5 xx⅛"
5 1.8mm
3
1
HK
117
AND FITTING IT IN PLACE
P A R T S T O O L S
118
AND FITTING IT IN PLACE
119
ATTACHING THE REAR DAMPERS
P A R T S T O O L S
1 Rear damper assembly

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

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

7 HG M12
NMYF12 2
mounts
Nyloc Nut Front radius arm

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

9 HI M8
NMYH8 2
Drop Link
Nyloc Nut Rear Anti Roll Bar

10 HJ M6
NMYF6 4
Mounting Blocks
3 - way union on
DeDion tube
120
ATTACHING THE REAR DAMPERS
35 35 47Nm
mm mm
HC
35 35 81Nm HM
mm mm
HP
121
THEN THE RADIUS ARM
P A R T S T O O L S
1 Radius arm
19mm
8mm
17mm
19mm
H H
SERIAL
53 SERIAL
53
Pack Pack
NUMBER NUMBER
PACK NUMBER
30R011D
PACK NUMBER
30R011D Before torquing up these bolts, reposition the
BASIC
BASIC
This pack may include extra fasteners to cover different options axle stands to under the DeDion tube (to hold up
the suspension). Make sure front has two axle
PART PART
stands so it is steady when jacking up the rear!

1 HA Grade 10.9
mountings
x 2 Lower Damper
2 HB
Caphead Bolt
M10 X 65
BMCH10X65 2
Front radius arm
(through cockpit) x2 13 HM
Plain Washer
1/2" Chamferred
WPH1/2 20
x 10 A-frame
washers
4 Radius Arm
x x4 Mick F
x 2 Lower Rear
x2 x2
Bolt
Plain Washer
4 HD Grade 10.9
BM6X80 4 15 HO M6
WPHM6 4
Mounting Blocks Mounting Block
Bolt 1/2" X 2.3/4" Schnorr Washer

5 HE Grade 10.9
BF1/2X2.3/4 1 A-frame to DeDion 16 HP M12
x2
x 2 Rear Radius
Half Nyloc
6 HF 1/2" UNF
NFYH1/2 3 Arm x
1 A-frame to DeDion

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

10 HJ M6
NMYF6 4
Mounting Blocks
3 - way union on
DeDion tube
122
THEN THE RADIUS ARM
HB
HF
HM
HC
HH HM
HN
35 35 81Nm
mm mm
35 35 34Nm
mm mm
123
AND NOW THE (CAREFULLY SPACED) A-FRAME
P A R T S T O O L S
1 A-frame
19mm
2 White nylon anti-squeak washers
19mm (x2)
H H
SERIAL
53 SERIAL
53
Pack Pack
NUMBER NUMBER
PACK NUMBER
30R011D
PACK NUMBER
30R011D Make sure the DeDion tube Use as many HM washers as
BASIC PART
BASIC
PART
is equal on both sides. required to space A-frame.
Tiago O John K
1 HA
Bolt M12 X 100
Grade 10.9
BM12X100 2
A-frame fromt
mountings x2 12 HL Washer 79029 10 Differential Isolation
*
x 2 Lower Damper
Caphead Bolt Front radius arm Plain Washer x 10 A-frame
2 HB M10 X 65
BMCH10X65 2 13 HM 1/2" Chamferred
WPH1/2 20
(through cockpit) washers x
4 Radius Arm
Bolt x 2 Lower Rear

Plain Washer
Take care to use the correct nuts as there is a

4 HD BM6X80 4 15 HO WPHM6 4
The A-frame has

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

a 'way up'. The

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

Half Nyloc
6 HF 1/2" UNF
NFYH1/2 3 Arm x
1 A-frame to DeDion
x2 offset downwards
7 HG M12
NMYF12 2
mounts
8 HH
Nyloc Nut
M10
NMYF10 2
Front radius arm
(through cockpit) in relation to the
9 HI
Half Nyloc
M8
NMYH8 2
Rear Anti Roll Bar
Drop Link front bushes. Torque up as before on axle stands.
10 HJ
Nyloc Nut
M6
NMYF6 4
Rear Anti Roll Bar
Mounting Blocks
Chris N Rich T
3 - way union on
DeDion tube
* Use as required for spacing
124
AND NOW THE (CAREFULLY SPACED) A-FRAME
35 35
HA 81Nm
mm mm
HE
= =
HF
35 35 81Nm
mm mm
HM
1
HG
IF REQUIRED
125
IF YOU HAVE THE OPTIONAL REAR ANTI-ROLL BAR, IT GOES ON LIKE THIS
P A R T S T O O L S
1 Rear anti roll bar
2 Anti roll bar rubber
3 Rear anti roll bar clamp
10mm
10mm
H H
SERIAL
53 SERIAL
53
Pack Pack
NUMBER NUMBER
PACK NUMBER
30R011D
PACK NUMBER
30R011D Be careful not to slip with the screwdriver!
REAR SUSPENSION DEDION METRIC REAR SUSPENSION DEDION METRIC
This pack may include extra fasteners to cover different options This pack may include extra fasteners to cover different options John S

1 HA Grade 10.9
mountings
x 2 Lower Damper
2 HB M10 X 65
BMCH10X65 2 13 HM 1/2" Chamferred
WPH1/2 20
(through cockpit) washers x
4 Radius Arm
Bolt x 2 Lower Rear

Plain Washer
4 HD
Bolt M6 X 80
Grade 10.9
BM6X80 4
Rear Anti Roll Bar
Mounting Blocks x4 15 HO
Plain Washer
M6
WPHM6 4
Rear Anti Roll Bar
Mounting Block x8
5 HE Grade 10.9
x 2 Rear Radius
Half Nyloc
6 HF 1/2" UNF
NFYH1/2 3 Arm x
1 A-frame to DeDion

7 HG M12
NMYF12 2
mounts

8 HH M10
NMYF10 2
(through cockpit)

9 HI M8
NMYH8 2
Drop Link
10 HJ
Nyloc Nut
M6
NMYF6 4
Rear Anti Roll Bar
Mounting Blocks x4
3 - way union on
DeDion tube
126
IF YOU HAVE THE OPTIONAL REAR ANTI-ROLL BAR, IT GOES ON LIKE THIS
2
HJ
HO
HD
HO
127
INSERT THE DRIVESHAFTS
P A R T S T O O L S
1 Driveshaft
2 Driveshaft nut
Driveshafts are handed, and so are the nuts,

the left hand nut tightens anti-clockwise.
James A
128
INSERT THE DRIVESHAFTS
129
FITTING THE REAR HUB
P A R T S T O O L S
1 Rear brake disc / flange assembly 8 Brake pads
2 Rear hub 9 Driveshaft nut
3 DeDion ear 10 Driveshaft washer
4 Anti roll bar bracket

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

bolts
Through rear of ear

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

Caphead Bolt
Schnorr washer Behind bolt heads
6 IF M10 X 20 BMCH10X20 4 Propshaft bolts 17 IQ M12 4
Grade 12.9 on diff
Caphead Bolt
Dan D
Rich T
Shakeproof
7 IG M12 X 25 BMCH12X25 2 Diff cage 18 IR washer 3/8"
Grade 8.8
Half Nyloc Rivet P-clips on DeDion

8 IH 1/2" "T" Type
NFYH1/2 1 Upper diff bolt 19 IS 1/8" X 0.51"
1661-0414 5
for brake pipe
9 II
Nyloc Nut
M10
NMYF10 8
Hub through ear to
DeDion x8 20 IT P-Clip NX1 5
Brake pipe on
DeDion
10 IJ
1/2" Nyloc Nut
M8
NMYH8 4
Rear anti roll bar
droplink x4
Plain washer 3/8"
11 IK X 7/8"
130
FITTING THE REAR HUB
ID
8
35
mm
IO
35
mm
47Nm
IP
IE
IJ
35 35
IO 47Nm
mm mm
IC IP
35 35 47Nm
mm mm
II
10 9
4 3 2 35
mm
35
mm 270Nm
ID
35
mm
35
mm
47Nm IO
5 II 1
131
AND SPEED SENSOR (ONE SIDE ONLY)
P A R T S T O O L S
1 Speed sensor
Ensure there is enough slack in the Adjust sensor gap to

wire to allow for suspension travel. approx. 0.8–0.9mm.
Tiago O Lloyd D
132
AND SPEED SENSOR (ONE SIDE ONLY)
1 x 5⁄32"
30mm
133
Now is a good time to take some photos
134
Have you applied for your IVA yet?
135
JUST WING IT
P A R T S T O O L S
1 Cycle wing
2 Wheel
3 Wheel nuts
Key the wing & wingstay You may need to bend the arms of
before using adhesive. the wingstay to make the wing level.
John S Anthony L
The 1⁄8" hole you drilled earlier is for the indicator earth.
Harry P
Do a 'dry run' first to make

The distance from the front edge of the sure the wings are level
wing to the wingstay should be 80mm. before using power adhesive.
Lee A Chris N
136
JUST WING IT
137
TAPE IN PLACE FOR 24 HOURS
P A R T S T O O L S
138
TAPE IN PLACE FOR 24 HOURS
139
SOME EXTRA ADHESIVE UNDERNEATH
P A R T S T O O L S
The WD40 will help spread the adhesive.

Mick F
140
SOME EXTRA ADHESIVE UNDERNEATH
141
FINISH WITH TRIM
P A R T S T O O L S
142
FINISH WITH TRIM
143
FITTING THE REAR WINGS
P A R T S T O O L S
1 Rear wing
to follow Sanding Drum
8mm
8mm
Q
SERIAL
31
Pack
NUMBER
PACK NUMBER
ZFG12 Cut the supplied piping in half and it Don’t forget the fuel tank
BASIC
REAR WINGS
This pack may include extra fasteners to cover different options will be enough for both wings. earth strap gets bolted to
the RH wing bolt.
PART
DESCRIPTION NUMBER
Rich T
x20
Set Screw
1 QA M5 X 20
SM5X20 20 Rear Wings
Tiago O
x10
Nyloc Nut Rear wings through
2 QB M5
NMYF5 10
boot
x30
Plain Washer
3 QC 3/16" X 3/4"
WP3/16X3/4 30 Wing washers
x4
Wing Piping Between wing and
4 QD 1/4" X 1"
76902 4m
body
144
FITTING THE REAR WINGS
1
7
7
7
QB
QC
7
QA
QD QC
145
AND THE WING PROTECTORS
P A R T S T O O L S
1 Wing protector
⅛"
For stainless steel protectors For carbon fibre protectors
When drilling through protector start Carbon fibre protectors will not
O P
SERIAL SERIAL
Pack Pack
NUMBER NUMBER
PACK NUMBER
ZWS01
PACK NUMBER
ZWS02 on the closest edge to the body. This have the protective film shown.
WING PROTECTORS STAINLESS STEEL
WING PROTECTORS CARBON FIBRE
This pack may include extra fasteners to cover different options will help the protector fit correctly. Anthony L
Chris B
Rivet Wing protector to Rivet Black Wing protector to
1 OA 1/8" X 0.51"
1661-0414 30 1 PA 1/8" X 0.51"
1610-01049 30
wing wing
Between wing Between wing

2 OB Wing Piping 76901 2m 2 PB Wing Piping 76901 2m
protector and wing protector and wing
146
AND THE WING PROTECTORS
x12 x1
x1
147
FITTING THE LIGHTS
P A R T S T O O L S
1 Side repeater
8mm
2 Rear light
3 Numberplate lamp
C
SERIAL
45
Pack
NUMBER
Use a cradle clip & cable tie to keep

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

DESCRIPTION NUMBER
John S
Screw 10 x ¾" Indictor assembly to
1 CA 71080 6
Black Supaflange indicator pod
Side repeater earth

Jamie A
Screw 8 x ½"
2 CB 71077 2
3 CC Screw 12 x 1½"
Self tapping
71079 4
Rear light cluster
upper fixing x4
4 CD Screw 12 x 1"
Self tapping
71078 4
Rear light cluster
lower fixing x4
Indicator repeater wires
go through the wingstay.
Chris B
148
FITTING THE LIGHTS
CC
CD

7 149
FUSE BOX COVER & KNEE TRIM PADS
P A R T S T O O L S
⁵⁄₃₂"
Chassis fastener pack ZCH01 supplied loose:
• Screw ¾" x 10 Building an Academy Car? If so you'll need to leave the
• Rivet 5⁄32 x 0.47" riveting-in of the side panels until after you've fitted the
roll cage (p154–155) as the front legs go behind the
panel, not over the top of it.
John S
150
FUSE BOX COVER & KNEE TRIM PADS
7 x ⁵⁄₃₂"
151
FIT THE TUNNEL CARPET
P A R T S T O O L S
Spray on both tunnel Allow the adhesive to

panel and carpet. go tacky before fitting.
John K Harry P
152
FIT THE TUNNEL CARPET
153
AND THE BOOT CARPET
P A R T S T O O L S
S-Pack cars have a fully carpeted boot. It's

something of a jigsaw pattern, but the parts
are simply glued in place like the bigger bits.
John S
154
AND THE BOOT CARPET
155
THIS IS A COVER UP
P A R T S T O O L S
1 Fuel filler cove
2 Tunnel closing panel
⁵⁄₃₂"
Supplied loose:
• Rivets The fuel filler cover just screws to the boot floor.
• Screws Drill two holes and use self tapping screws.
Rich T
156
THIS IS A COVER UP
157
NOW FIT THE TUNNEL TOP
P A R T S T O O L S
⅛"
The hole can be seen if you

flip the tunnel top over.
Mick F
158
NOW FIT THE TUNNEL TOP
159
BELT UP
P A R T S T O O L S
Supplied with seat belts
These will be loosely fitted already –
you'll need to tighten & torque.
Chris N
160
BELT UP
35 35 47Nm
mm mm
35 35 47Nm
mm mm
161
FITTING THE FOUR-POINT HARNESS
P A R T S T O O L S
17mm
All fixings supplied with the harnesses
The buckle is attached to a lap strap and
this should be fitted to the tunnel side.
Chris N
For Academy cars with Schroth

Harnesses see Page 148.
Dan P
162
FITTING THE FOUR-POINT HARNESS
IMPORTANT
For Academy cars with 35
mm
35
mm
47Nm
Schroth Harnesses see
page 148
163
SHOULDER STRAP MOUNTING ORIENTATION WAIST STRAP MOUNTING ORIENTATION
SL 65 S 156
35 35 40Nm Harness mounting plate Swivelling insert Spacer washer
mm mm
SG 96 7⁄16 x 52mm bolt 30Z2042A

7⁄16 x 30 thin head
Loctite Threadlock
Harness mounting plate
35 35
mm
40Nm Chassis
mm
S 65L swivelling insert
S 156 spacer washer
Chassis
Loctite
Threadlock
164
CRUTCH STRAP MOUNTING ORIENTATION
NFYF 7⁄16 nyloc
WPH 7⁄16 washer

Chassis
30P065A spacer
Harness mounting plate

S65L swivelling insert
S 156 spacer washer
Chassis
WPH 7⁄16 washer
SF 7⁄16 x2 bolt
35 35 40Nm
mm mm
165
FITTING THE SIX-POINT HARNESS
P A R T S T O O L S
7⁄16"
16mm
17mm
16mm
17mm
All fixings supplied with the harnesses
The buckle is attached to a lap strap and
this should be fitted to the tunnel side.
Lee A
166
FITTING THE SIX-POINT HARNESS
35 35 47Nm
mm mm
35 35 47Nm
mm mm
167
FITTING CLOTH OR LEATHER SEATS
P A R T S T O O L S
1 Seat
13mm
2 Seat base
3 Headrest 6mm
L
SERIAL
62
Pack
NUMBER
Loosely fit the rear bolts to help Nip up all bolts once fitted.
PACK NUMBER
30Z1058B
BASIC
CLOTH/LEATHER SEATS ALL CARS
PART
locate the front. Anthony L
DESCRIPTION NUMBER
Dan D
x4
Caphead Bolt
Through seat runner
1 LA M8 X 20 SMCH8X20 4
Grade 12.9 & floor
x4
Nyloc Nut
2 LB M8
NMYF8 4 Under floor
x4
Plain Washer
3 LC M8 X 30
WPH8X30 4 Under floor
168
FITTING CLOTH OR LEATHER SEATS
2 1
LA
LB
LC
169
OR FITTING THE RACE SEATS
P A R T S T O O L S
1 Seat
13mm
2 Adjustable runner
3 Fixed seat spacer 6mm
LO
CT
IT
E
+
For fixed seats For adjustable seats
Put a bit of LocTite on bolts that go Runners / seat spacers
M N
SERIAL
63 SERIAL
64
Pack Pack
NUMBER NUMBER
PACK NUMBER
30Z1062A
PACK NUMBER
30Z1063A into the seat on the runner version. can be fitted to seat
SEATS FIXED TILLETT RACING
SEATS ADJUSTABLE TILLETT RACING
This pack may include extra fasteners to cover different options Chris B before putting in car.
Mick F
x4 x4
Caphead Bolt Spacer box section Caphead Bolt
1 MA M8 X 25
BMCH8X25 4 1 NA M8 X 25
BMCH8X25 4 Runner to seat
to seat
2 MB
Caphead Bolt
M8 X 20
SMCH8X20 4
Floor to rivnut in
spacer box section x4 2 NB
Caphead Bolt
M8 X 20
SMCH8X20 4 Runner to floor
x4 Loosely fit the rear bolts
3 MC
Spring Washer
5/16"
WSH5/16 8 Bolt heads
x8 3 NC
Washer
5/16" X 1 1/4"
WP5/16X1.1/4 4 Under floor
x4 to help locate the front.
x4 Harry P
x4
Washer Nyloc Nut
4 MD 5/16" X 1 1/4"
WP5/16X1.1/4 4 Under floor 4 ND NMYF8 4 Under floor
M8
5 ME
Washer
M8 X 18
WPM8X18X1 4
Spacer box section
to seat x4 5 NE
Spacer Black
Plastic
TW2 3 Seat spacer
x3
7 MF
Spacer Black
Plastic
TW2 3 Seat spacer
x3 The fixed position seat is for the passenger side!
6 NF
Spacer Black
Plastic
TW3 5 Seat spacer
x5
Chris N
x5
Spacer Black Drawings are for illustrative purposes only and are not to scale. Page 1 of 1
8 MG Plastic
TW3 5 Seat spacer
170
OR FITTING THE RACE SEATS
NE
NF MF
NF MF
NF MG
MF
2 3
NB
NA MA
MB
NC MC MC
ND ME MD
171
FITTING THE ROLL OVER BAR
P A R T S T O O L S
1 Roll over bar

13mm
17mm
8mm
17mm
J
SERIAL
47
Pack
NUMBER
PACK NUMBER
30P010A If you've fitted the rear dampers they'll
BASIC
ROLL OVER & TRACK DAY BAR SERIES 3 METRIC
PART
need to come off again to do this properly.
DESCRIPTION NUMBER
Chris B
x2
Rear diagonals of
Bolt M10 X 60
1 JA Grade 8.8
BM10X60 2 roll over bar to
mounting brackets
x2
Setscrew
Roll over bar bracket
2 JB M8 X 20 SM8X20 2
Grade 8.8 to chassis
3 JC
Caphead Bolt
M10 X 20
BMCH10X20 2 Roll over bar boss
x2
x2
Rear diagonals of
Nyloc Nut
4 JD M10
NMYF10 2 roll over bar to
mounting brackets
5 JE
Plain Washer
M8
WPHM8 2
to chassis x2
6 JF
Spring Washer
M8
WSHM8 2
to chassis x2
x4
Rear diagonals of
Plain Washer
7 JG M10
WPHM10 4 roll over bar to
mounting brackets
172
FITTING THE ROLL OVER BAR
JB
35 35 25Nm JE
mm mm
JF
35 35 47Nm
JA
mm mm
JD
JG
JC
35 35 47Nm
mm mm
JC
173
EVEN MORE EXHAUSTING
P A R T S T O O L S
1 Silencer 7mm
10mm
13mm
2 Exhaust clamp
3 Lambda sensor ⅞"
4 Cat guard
5 Clip
6 Silencer mounting bracket
7 Exhaust mounting bobbin
G
SERIAL
56
Pack
NUMBER
PACK NUMBER
30X020B Cable tie the Lambda sensor lead neatly out of the way.
EXHAUST
This pack may include extra fasteners to cover different options Lee A
BASIC PART
DESCRIPTION NUMBER
x1
Setscrew
Exhaust Mounting
1 GA M8 X 25 SM8X25 1
Grade 8.8 Bracket
x2
Plain Nut
2 GB M8
NFPF8 2 Exhaust Bobbin
x 1 Exhaust
3 GC
Spring Washer
M8
WSHM8 3 Mounting Bracket x
2 Exhaust Bobbin x3
174
EVEN MORE EXHAUSTING
GB
GC
GD
GA
GC
4
GD
7 6
5
GB
GC
GD
1
3
2
175
THE NOSE CONE BADGE
P A R T S T O O L S
1 Nose cone
2 Bonnet
3 Badge
The nose cone goes on Stick the supplied foam around the edge
before the bonnet. of the nose and scuttle where the bonnet
Anthony L will sit (if you've not done already).
Harry P
176
THE NOSE CONE BADGE
1 2
177
FITTING THE WIPERS
P A R T S T O O L S
1 Wiper arm
2 Wiper blade
Ensure wipers are in paused position Now would be a good time to fill
before fitting the wiper arms. the washer bottle with fluid and
John S test the washers and wipers.
Chris B
178
FITTING THE WIPERS
1 2
179
AND FINALLY, AT LAST, THE WING MIRRORS
P A R T S T O O L S
1 Mirror head
2 Mirror mount
3 Mirror mount stud 2.5mm
4 Grub screw
T20
5 Fibre washer
Wing mirror bag
You may have to unclick the
glass out to tighten up.
Mick F
180
AND FINALLY, AT LAST, THE WING MIRRORS
4 3
181
WIRING THE STARTER MOTOR
P A R T S T O O L S
1 Starter motor
Cable from altenator

2 (brown wire with black sheath)
Cable from battery

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

4 (2 brown wires joined)
Cable from engine loom

5 (white wire with red stripe)
182
WIRING THE STARTER MOTOR
183
THE LAST FEW STEPS…
Your car is almost complete, but before you can drive triumphantly out of the garage (and legally, as far as
the end of your driveway) there are a few important things that need to be done. These are, bleeding the
brakes, preparing the engine for the its first grand firing-up ceremony (it will feel like that, even if you are
doing it on your own) and lastly torquing up the suspension.
So, on with bleeding the brakes which cannot be explained with a simple diagram unfortunately:
1 ssemble the things you’ll need: Brake fluid, both a 10mm and an 11mm spanner, a length of washer
A
hose (or similar clear plastic hose) and a waster fluid receptacle (some form of used bottle is ideal;
you won’t want to use it again after this)
2 ind a volunteer. They need to be able to reach and press the brake pedal, plus respond to your
F
instructions, so whilst a child is fine for this job, someone’s might be more inclined to listen to you.
3 ill the brake master cylinder with fresh brake fluid and leave the cap off. BE CAREFUL NOT TO
F
SPILL ANY ONTO THE PAINTWORK; if you do, wipe it off immediately. Brake fluid will react with the
paintwork causing it to blister and peel.
4 tarting at the left rear corner, locate the bleed nipple on the caliper. It will have a rubber cap on it.
S
Remove the cap, remember where you put it, and attach the washer hose to the nipple and put the
other end in the waste bottle. This sometimes needs the hose warming up in a cup of hot water to
allow it to stretch over the nipple.
184
5 Using the 10mm spanner, ‘crack off’ the nipple about half of a turn.
6 sk your assistant to pump the pedal a few times. You should see bubbly fluid flowing through the
A
pipe. When the bubbles die down, ask them to hold the pedal down, then tighten the nipple back up.
Check and top of the fluid level in the reservoir as necessary.
7 Ask them to lift off, then pump it a couple of times, then press the pedal down and hold it down.
8 rack off the nipple again and let the fluid and bubbles flow. It will stop flowing as soon as your
C
assistant has run out of brake pedal travel. Tighten the nipple.
9 epeat steps 8 and 9 until you get 100% bubble free fluid passing through the pipe, remembering to
R
check and top up the reservoir. You will waste quite a lot of brake fluid during this process.
10 nce you are satisfied that there are no more bubbles (no more air in the caliper), then you can
O
remove the washer hose and refit the dust cover.
11 epeat steps 5 to 10 for the remaining brakes in this order, right rear next, then right front and lastly
R
left front. The front brake nipples use an 11mm spanner.
12 lthough tedious, getting all the air out of the braking system is important and will give you a good,
A
firm brake pedal, which is what you need; not a soft spongy one like you have in a regular car. You
may need to repeat the whole process after the first drive or two (or even after the car has had a ride
on a trailer); air in the braking system is very good at hiding.
185
Brakes bled and we are ready to fire up the engine. Again, it’s easier to explain in writing than draw a
diagram. The only thing you’ll need for this job is to ensure that you have put some fuel in the car. The
shape of the Caterham fuel tank does not lend itself to making use of every last drop, so we recommend
an absolute minimum of 10 litres in the tank before trying to start the car. With the tank filled, we are ready
for initialisation.
But before anything else:

YOU DID REMEMBER TO PUT OIL IN THE ENGINE AND GEARBOX, RIGHT?
1 Reassure yourself the engine is full of oil.
2 Disconnect the inertia switch; it’s the black thing attached to the engine bay bulkhead under the
windscreen that has rubber cap on top and a plug with two wires connecting from underneath. By
disconnecting the inertia switch, the fuel pump will not work, so intentionally, the engine will not fire.
3 Ensure the gearbox is in neutral, then turn the ignition key and press and hold the start button.
4 As the engine cranks over, watch the oil pressure gauge. Keep cranking until the needle starts to
climb, then steadies out.
5 We now have oil pressure circulating in the engine, which means the engine is ready to be started.
6 Reconnect the inertia switch.
7 Take a deep breath, mutter 'this is it', cross your fingers and brace yourself.
8 Turn the ignition key, press and hold the start button. It will take a few moments for the fuel to get
through, so do not expect an instant start.
9 All things willing, the engine will start. Hooray! If it stops straight away, don’t worry. Try again and once
it starts give it a little rev.
186
That’s it. Your car is complete! Well done – you have built a car; a real live car; not many people can say
that. If you remembered to put in gearbox and differential oil, and fill the system with coolant, then a
tentative edge out onto the driveway is in order. You’ll need to pop the wheels on and lower it from the
axle stands and just tighten the suspension first.
Let’s just run through that quickly:

i. Put a wheel on and do the nuts up a few turns by hand (to ensure they do not cross-thread).
ii. Tighten them up the best you can with the wheels off the ground.
iii. Lower the car from the axle stands, front first; taking care that it doesn’t lean back on the axle
stands at the back (a helper might be handy).
iv. Torque the wheel nuts to 65lbft (about 85Nm).
v. Flick back to the pages where we put the wishbones on and torque as shown
vi. That’s it, you’re ready to go!
Take care and good luck with the IVA and registration process.
You will soon be experiencing the sheer pleasure of being a Caterham driver. Once again, enjoy!
187
APPENDIX
189
FIXING PACKS
94
A A
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER

30F015B 30F015B
FRONT SUSPENSION DeDION CARS (METRIC) FRONT SUSPENSION DeDION CARS (METRIC)

1 AA BM12X100 2 12 AM WSHM12 2
Anti-roll bar
2 AB BM12X65 2 13 AN WSHM8 6
mount
Bolt M10 x 65 Upper wishbone Washer ⅜"

3 AC BM10X65 2 14 AP WSS3/8 2 Brake pipe
Grade 10.9 rear Shake-proof


ONLY)
Temporary use to
Plain Nut M14
6 AF x 1.5 thread
wishbone ball joint
Lower wishbone
rear
Plain Washer
Chamfered
Plain Washer
Anti-roll bar
10 AK M8 WPHM8 4
Plain Washer
Heavy duty
190
FIXING PACKS
B C
SERIAL
55 SERIAL
45
Pack Pack
NUMBER NUMBER

3ACZ0021 30L002B
RELEASED NOV-19
STEERING DeDION CARS (METRIC) LIGHTING & HORNS

Caphead Bolt
1 BA M6 x 70 BMCH6X70 4 Rack clamps Screw 10 x ¾" Indictor assembly to
1 CA 71080 6
DIN 912 Black Supaflange indicator pod
2 BB Bolt ¼" x 1½" BF1/4X1.1/2 2 Column clamp Screw 8 x ½" Side repeater earth
2 CB 71077 2
Bolt M8 x 40 Column to rack

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

4 BD NFYH1/2 1 Steering wheel boss Screw 12 x 1" Rear light cluster
Half height 4 CD 71078 4
Self tapping lower fixing
Horn bracket to
5 BE Plain Nut ½" NFPF1/2 2 Track rod lock nut steering rack
5 CE Nyloc Nut M6 NMYF6 2
platform
(160/270/310)
Plain Nut ⁷⁄₁₆" Column clamp Horn bracket to
6 BF NFPFH7/16 1 Plain Washer
Half height grubscrew locknut steering rack
6 CF ¼" WPH1/4 2
Heavy duty platform
(160/270/310)
Column to rack Through steering
7 BG Nyloc Nut M8 NMYF8 2 Bolt M8 x 5 rack platform &
universal joint 7 CG BM8X50 1
Grade 8.8 spacer
(420)
8 BH Nyloc Nut M6 NMYF6 4 Steering rack clamps Plain Washer

8 CH 5/16"
WPH5/16 2 Bolt head/nut
Plain Washer
9 BJ ½" x 1⅛" WPH1/2 1 Steering wheel boss Nyloc Nut
Chamfered 9 CI M8
NMYF8 1 Horn bolt
Plain Washer Drawings are for illustrative purposes only and are not to scale. Page 1 of 1
Rack clamps and
10 BK ¼" WPH1/4 6
Spring Washer ¼
11 BL Heavy duty
191
FIXING PACKS
D D
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER

30C047B 30C047B

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

5/32" X 0.47"
Expansion tank
bracket
8 x SV rad bracket
9 DI WPH1/4 13
braket
Plain Washer
Radiator bobbin
10 DJ 5/16" WPH5/16 4
Heavy duty back
Plain Washer
Radiator bobbin
11 DK 5/16" X 7/8" WPH5/17X7/8 4
Heavy duty front
192
FIXING PACKS
E E
SERIAL
66
SERIAL
66
Pack Pack
NUMBER
NUMBER
PACK NUMBER
PACK NUMBER
3EZ1105F
3EZ1105F
SIGMA GEARBOX 5 SPEED

SIGMA GEARBOX 5 SPEED
BASIC PART
BASIC PART DESCRIPTION NUMBER
DESCRIPTION NUMBER
Buttonhead Bolt
M6 X 10
12 EL Grade 10.9
Bolt M14 X 40
1 EA Grade 12.9
3EZ1137A 2 AV Mount Internal Hex
Plain Washer
Caphead Bolt
13 EM M14
WPH14 2 AV Mount
2 EB M8 X 40 30Z1076A 4 AV Mount
Grade 12.9
Plain Washer
Caphead Bolt 14 EN M12
30Z2031A 4 Gearbox
M12 X 50
3 EC Grade 12.9
3EZ1142A 4 Gearbox
Coarse Thread
15 EO Plain Washer M6 WPHM6 3 Gear Lever

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

8 EH X 25 Grade BMCH8X25 2 1 x LHS Top
12.9 Spring Washer
1 x LHS Bottom 20 ET M8
WSHM8 5 Engine Mount
Caphead Bolt M8
Engine Mount
9 EI X 30 Grade BMCH8X30 1 Clutch Slave
12.9 LHS Bottom 21 EU
Spring Washer
WSHM6 3
M6 Cylinder
Caphead Bolt M8
Engine Mount
10 EJ X 35 Grade BMCH8X35 2 Myloc Nut
12.9 RHS Bottom 22 EV M8
NMYF8 4 AV Mount
Caphead Bolt
Clutch Slave Spring Washer
11 EK M6 X 25 BMCH6X25 3 23 EW 30Z2030A 2 AV Mount
Grade 12.9 Cylinder M14
193
FIXING PACKS
F F
SERIAL
66
SERIAL
66
Pack Pack
NUMBER NUMBER
3EZ2029B 3EZ2029B
DURATEC GEARBOX 5 SPEED DURATEC GEARBOX 5 SPEED

Bolt
1 FA M14 X 30 X 1.5 30Z2032A 2 AV Mount 12 FL Plain Washer M6 WPHM6 3 Gear Lever
Grade 12.9
Caphead
Spring Washer
2 FB M12 X 40 X 1.75 BMCH12X40 4 Bellhousing 13 FM M14
30Z2030A 2 AV Mount
Grade 12.9
Caphead Bolt
Spring Washer
3 FC M10 X 90 BMCH10X90 1 Bellhousing 14 FN M12
WSHM12 4 Gearbox
Grade 12.9
Caphead Bolt
Spring Washer x 2 Starter Motor x
4 FD M10 X 55 BMCH10X55 3 Bellhousing 15 FO M10
WSHM10 4
Grade 12.9 2 Front Bellhousing
Caphead Bolt
x 5 Bellhousing x Spring Washer Clutch Slave
5 FE M10 X 45 BMCH10X45 7 16 FP M6
WSHM6 3
Grade 12.9 2 Starter Motor Cylinder
Caphead Bolt
6 FF M8 X 40 30Z1076A 4 AV Mount
Grade 12.9
Caphead Bolt
Clutch Release
7 FG M6 X 25 BMCH6X25 3
Grade 12.9 Bearing
Buttonhead Bolt
M6 X 10
8 FH Grade 10.9
Internal Hex
Nyloc Nut
9 FI M8
NMYF8 4 AV Mount
Plain Washer
10 FJ M14
WPH14 2 AV Mount
Plain Washer
11 FK M12
30Z2031A 4 Bellhousing
194
FIXING PACKS
G
SERIAL
56
Pack
NUMBER
PACK NUMBER
30X020B
EXHAUST
BASIC PART
DESCRIPTION NUMBER
Setscrew
Exhaust Mounting
1 GA M8 X 25 SM8X25 1
Grade 8.8 Bracket
Plain Nut
2 GB M8
NFPF8 2 Exhaust Bobbin
x 1 Exhaust
Spring Washer
3 GC M8
WSHM8 3 Mounting Bracket x
2 Exhaust Bobbin
195
FIXING PACKS
H H
SERIAL
53
SERIAL
53
Pack Pack
NUMBER NUMBER
30R011D 30R011D
REAR SUSPENSION DEDION METRIC REAR SUSPENSION DEDION METRIC


1 HA Grade 10.9
mountings
x 2 Lower Damper
2 HB BMCH10X65 2 13 HM 1/2" Chamferred
WPH1/2 20
M10 X 65 (through cockpit) washers x
4 Radius Arm
Bolt x 2 Lower Rear Plain Washer

4 HD BM6X80 4 15 HO M6
WPHM6 4
Grade 10.9 Mounting Blocks Mounting Block

5 HE Grade 10.9
x 2 Rear Radius
Half Nyloc
6 HF 1/2" UNF
NFYH1/2 3 Arm x
1 A-frame to DeDion

7 HG M12
NMYF12 2
mounts

8 HH M10
NMYF10 2
(through cockpit)

9 HI M8
NMYH8 2
Drop Link

10 HJ M6
NMYF6 4
Mounting Blocks
3 - way union on
DeDion tube
196
FIXING PACKS
J O
SERIAL
47 SERIAL
Pack Pack
NUMBER NUMBER

30P010A ZWS01
ROLL OVER & TRACK DAY BAR SERIES 3 METRIC WING PROTECTORS STAINLESS STEEL
Rear diagonals of
Bolt M10 X 60 Rivet Wing protector to
1 JA Grade 8.8
BM10X60 2 roll over bar to 1 OA 1/8" X 0.51"
1661-0414 30
wing
mounting brackets
Setscrew
Roll over bar bracket Between wing
2 JB M8 X 20 SM8X20 2 2 OB Wing Piping 76901 2m
Grade 8.8 to chassis protector and wing
Caphead Bolt
3 JC M10 X 20
BMCH10X20 2 Roll over bar boss
Rear diagonals of
Nyloc Nut
4 JD M10
NMYF10 2 roll over bar to
mounting brackets
Plain Washer Roll over bar bracket

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

6 JF M8
WSHM8 2
to chassis
Rear diagonals of
Plain Washer
7 JG M10
WPHM10 4 roll over bar to
mounting brackets
197
FIXING PACKS
P Q
SERIAL SERIAL
31
Pack Pack
NUMBER NUMBER

ZWS02 ZFG12
WING PROTECTORS CARBON FIBRE REAR WINGS

Rivet Black Wing protector to Set Screw

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

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

4 QD 1/4" X 1"
76902 4m
body
198
Caterham Cars Limited, 2–3 Kennet Road, Dartford, Kent, DA1 4QN
+44 (0) 1322 625800
/CaterhamCars @caterhamcars
Content is subject to change without notice.

© Caterham 2021
Edition 2.1D 03/21
Images are for illustrative purposes only.

A4 Assembly Guide DURATEC Edition 2.3

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A4 Assembly Guide DURATEC Edition 2.3

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ASSEMBLY GUIDE

DURATEC – EDITION 2.3

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

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

READ THE NEXT THREE PAGES – THEY ARE REALLY IMPORTANT

Book IVA Test

Take plenty of photos

Arrange post build check

This was more fun than I ever expected!

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

When using a spanner, always use the ring end wherever

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

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

Advice from factory PACK NUMBER

Now is a good time to take 2 AB

S Pack / R Pack Bolt M10 x 60 Upper wishbone

35 Nm Required torque (where applicable) Temporary use to

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

Repeat on other side

Refer to IVA Checklist Guide

(Greyed out4 area indicates fixings are not

Flat head Pozidrive

+ Assistance Grease Ruler Spray adhesive Trolley jack

Axle stand Junior hacksaw Scissors Spray lube WD40

Cable tie Latex gloves Side cutters Stanley knife

Copper grease Marker Pen Silicon gun Tape

Drill Muscle Socket wrench Tape measure

Socket wrench Thread lock /

Bolt M12 x 100 Lower wishbone

3 Column universal joint 5mm

4 Track rod end

closed end off.

Nyloc Nut ½"

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

2 Lower damper sleeve

3 Upper damper sleeve 6mm

Bolt M12 x 100 Lower wishbone Spring Washer Lower wishbone

Bolt M10 x 60 Upper wishbone Nyloc Nut ½"

Front brake, upright

7 AG Nyloc Nut M12 NMYF12 2

8 AH Nyloc Nut M10 NMYF10 4 Upper wishbone

PACK NUMBER PACK NUMBER

FRONT SUSPENSION DeDION CARS (METRIC)

Front brake, upright John S Anthony L

LIGHTING & HORNS

Screw 12 x 1" Rear light cluster

2 Anti-roll bar bracket

3 Anti-roll bar rubber

4 Anti-roll bar ball

of a fight. It’s made of

7 AG Nyloc Nut M12 NMYF12 2

Front brake, upright

The copper washer should

7 AG Nyloc Nut M12 NMYF12 2

1 Horn kit (x2)

2 Spacer (miscellaneous box)

3 Bolt for spacer 13mm

The blanking plate is fitted using two

7 DG Plain Nut M8 NMPF8 8 Radiator bobbin

3 Heater cable 19mm

4 Lower hose 110mm (cut from long length)

5 Upper hose 120mm (cut from long length)

It’s worth re-tightening the jubilee

clips after a couple of uses of car.