Caterham 7 Assembly Manual
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Caterham 7 Assembly Manual

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ASSEMBL Y GUIDE
EDITION 1.0

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  • Page 1 ASSEMBL Y GUIDE EDITION 1.0...
  • Page 2 ASSEMBL Y GUIDE EDITION 1.0 Your feedback and comments are welcome: assemblyguide@caterham.com...
  • Page 3 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;...
  • Page 4 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 5 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’.
  • Page 6 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.
  • Page 7 That’s it, we’re ready to start assembly ENJOY ASSEMBL Y GUIDE...
  • Page 8 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! ASSEMBL Y GUIDE...
  • Page 9 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 they should not be repeatedly re‑used. When using a torque wrench, listen/feel the click and then stop.
  • Page 10 S Y M B O L S F I X I N G S SERIAL Pack NUMBER PACK NUMBER SERIAL Item number Pack NUMBER 30F015B 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 This pack may include extra fasteners to cover different options BASIC...
  • Page 11 T O O L S Flat head Allen key Ruler Spray adhesive WD40 screwdriver Assistance Grease Scissors Spray lube Axle stand Junior hacksaw Side cutters Stanley knife Cable tie Latex gloves Silicon Tape Combination Long nose pliers Silicon gun Tape measure spanner Thread lock / Copper grease...
  • Page 12 LET’S GET READY P A R T S T O O L S 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...
  • Page 13 LET’S GET READY ASSEMBL Y GUIDE...
  • Page 14 START WITH THE SUSPENSION WISHBONES P A R T S T O O L S Lower wishbone 17mm 19mm Upper wishbone 17mm Wishbone bush sleeve 19mm F I X I N G S T I P S SERIAL SERIAL Pack Pack NUMBER NUMBER...
  • Page 15 START WITH THE SUSPENSION WISHBONES 47Nm 47Nm 81Nm 81Nm REPEAT ASSEMBL Y GUIDE...
  • Page 16 NOW FOR THE STEERING RACK P A R T S T O O L S Steering rack 10mm 13mm Rack clamps Column universal joint Track rod end 13mm 22mm IVA cover ¾" F I X I N G S T I P S SERIAL Pack NUMBER...
  • Page 17 NOW FOR THE STEERING RACK 20Nm 11Nm ASSEMBL Y GUIDE...
  • Page 18 AND THEN THE DAMPERS P A R T S T O O L S Spring / damper Lower damper eyelet Upper damper eyelet F I X I N G S T I P S SERIAL SERIAL Pack Pack NUMBER NUMBER Put the top of the damper on first The bottom can be a tight fit! PACK NUMBER...
  • Page 19 AND THEN THE DAMPERS 25Nm 25Nm ASSEMBL Y GUIDE...
  • Page 20 IT’S TIME FOR THE WINGSTAYS P A R T S T O O L S Wingstay 19mm 22mm 22mm ¾" Front brake & upright assembly ⅛" F I X I N G S T I P S SERIAL SERIAL The drilled hole is for the side repeater earth that we’ll fit later. It’s easier to Pack Pack NUMBER...
  • Page 21 IT’S TIME FOR THE WINGSTAYS 1 x ⅛" 61Nm 81Nm 54Nm WIDE STANDARD TRACK 54Nm TRACK REPEAT ASSEMBL Y GUIDE...
  • Page 22 Now is a good time to take some photos ASSEMBL Y GUIDE...
  • Page 23 Have you applied for your IVA yet? ASSEMBL Y GUIDE...
  • Page 24 LET THERE BE LIGHTS P A R T S T O O L S Headlight assembly Indicator pod 17mm Indicator assembly 24mm Headlight bracket 17mm F I X I N G S T I P S SERIAL Pack NUMBER The wiring for the headlights is attached to the chassis when PACK NUMBER 30L002B you receive your kit.
  • Page 25 LET THERE BE LIGHTS REPEAT ASSEMBL Y GUIDE...
  • Page 26 LAST PART OF THE FRONT SUSPENSION: CONNECTING THE TWO SIDES TOGETHER P A R T S T O O L S Anti-roll bar 13mm Anti-roll bar bracket Anti-roll bar rubber Anti-roll bar ball Anti-roll bar dust cover F I X I N G S T I P S SERIAL SERIAL...
  • Page 27 LAST PART OF THE FRONT SUSPENSION: CONNECTING THE TWO SIDES TOGETHER 20Nm REPEAT ASSEMBL Y GUIDE...
  • Page 28 FITTING THE BRAKE HOSES P A R T S T O O L S Brake hose 13mm (x2) ⁹⁄ ₁ ₆" F I X I N G S T I P S SERIAL SERIAL Pack Pack NUMBER NUMBER The hose will want to curve once fitted. Brake hoses come in PACK NUMBER PACK NUMBER...
  • Page 29 FITTING THE BRAKE HOSES ASSEMBL Y GUIDE...
  • Page 30 LET'S MAKE SOME NOISE P A R T S T O O L S Horn kit (x2) 10mm Spacer (miscellaneous box) Bolt for spacer 13mm F I X I N G S T I P S Miscellaneous box ASSEMBL Y GUIDE...
  • Page 31 LET'S MAKE SOME NOISE 270/310/360 1 x 8mm 1 x 8mm ASSEMBL Y GUIDE...
  • Page 32 DESCRIPTION NUMBER DESCRIPTION NUMBER Plain Washer Bolt M8 X 50 Expansion tank Expansion tank at the top. BM8X50 " X 7/8" WPH1/4X7/8 Grade 8.8 bracket to chassis bracket Vincent M Lloyd D Heavy duty Spring Washer Expansion tank to 8 x Radiator bobbin Setscrew 1/4"...
  • Page 33 FITTING THE RADIATOR ON THE STANDARD CHASSIS 270/310/360 STANDARD CHASSIS ASSEMBL Y GUIDE...
  • Page 34 USED ON ILLUSTRATION DESCRIPTION NUMBER DESCRIPTION NUMBER Plain Washer Bolt M8 X 50 Expansion tank Expansion tank BM8X50 " X 7/8" WPH1/4X7/8 Grade 8.8 bracket to chassis bracket Heavy duty Spring Washer Expansion tank to 8 x Radiator bobbin Setscrew 1/4"...
  • Page 35 THE RADIATOR MOUNTING FOR THE WIDE-BODIED CHASSIS IS SLIGHTLY DIFFERENT 270/310/360 WIDE CHASSIS ASSEMBL Y GUIDE...
  • Page 36 NUMBER DESCRIPTION NUMBER Jamie A Chris B Plain Washer Bolt M8 X 50 Expansion tank Expansion tank BM8X50 " X 7/8" WPH1/4X7/8 Grade 8.8 bracket to chassis bracket Heavy duty Spring Washer Expansion tank to 8 x Radiator bobbin Setscrew 1/4"...
  • Page 37 THINGS ARE HEATING UP ASSEMBL Y GUIDE...
  • Page 38 KEEPING THE AIR CLEAN P A R T S T O O L S Air box Air filter Rubber mounts Trim F I X I N G S T I P S Unmarked bag: Bobbins are screwed into • M5 (x6) the car by hand.
  • Page 39 KEEPING THE AIR CLEAN ASSEMBL Y GUIDE...
  • Page 40 GETTING READY TO PUT THE ENGINE IN P A R T S T O O L S Engine mount Starter motor Bellhousing F I X I N G S T I P S You will need to remove the engine mounts and starter motor but don’t throw away the bolts –...
  • Page 41 GETTING READY TO PUT THE ENGINE IN ASSEMBL Y GUIDE...
  • Page 42 BMCH10X55 Bellhousing Grade 12.9 Spring Washer Gearbox WSHM12 Caphead Bolt M10 X 40 BMCH10X40 Bellhousing Grade 12.9 x 7 Bellhousing Spring Washer WSHM10 3 Engine Mount Caphead Bolt Engine Mount M10 X 35 BMCH10X35 RHS Top Grade 12.9 Wire Spring...
  • Page 43 ATTACH THE GEARBOX TO THE BELLHOUSING 68Nm ASSEMBL Y GUIDE...
  • Page 44 BMCH10X55 Bellhousing Grade 12.9 Spring Washer Gearbox WSHM12 Caphead Bolt M10 X 40 BMCH10X40 Bellhousing Grade 12.9 x 7 Bellhousing Spring Washer WSHM10 3 Engine Mount Caphead Bolt Engine Mount M10 X 35 BMCH10X35 RHS Top Grade 12.9 Wire Spring...
  • Page 45 AND THEN THE GEARBOX TO THE ENGINE 54Nm 54Nm ASSEMBL Y GUIDE...
  • Page 46 AT LAST, THE ENGINE IS GOING IN P A R T S T O O L S Engine mounts Engine rubbers Tensioner ⅜” 13mm 13mm 15mm F I X I N G S T I P S When fitting the engine rubbers and mounts, It's 54Nm for the do them as loosely as possible so you can bolts tightened with...
  • Page 47 AT LAST, THE ENGINE IS GOING IN ASSEMBL Y GUIDE  ...
  • Page 48 AND THE GEARBOX IS FIXED IN PLACE P A R T S T O O L S 5 Speed 6 Speed 13mm 13mm 22mm 19mm 13mm F I X I N G S T I P S Once the engine is in, the wiring can be connected to the car's loom.
  • Page 49 AND THE GEARBOX IS FIXED IN PLACE 5 SPEED 6 SPEED ASSEMBL Y GUIDE...
  • Page 50 FILLING THE ENGINE AND GEARBOX WITH OIL P A R T S T O O L S Engine oil SW-30 Gear oil GL4 F I X I N G S T I P S ASSEMBL Y GUIDE...
  • Page 51 FILLING THE ENGINE AND GEARBOX WITH OIL Ford 1.6L Engine = 3.8 Litres 5 Speed Gearbox = (Pre-Filled) 6 Speed Gearbox =  Fill to level of filling point on the side of gearbox ASSEMBL Y GUIDE...
  • Page 52 NUMBER DESCRIPTION NUMBER Grant P Mick F Plain Washer Bolt M8 X 50 Expansion tank Expansion tank BM8X50 " X 7/8" WPH1/4X7/8 Grade 8.8 bracket to chassis bracket Heavy duty Spring Washer Expansion tank to 8 x Radiator bobbin Setscrew 1/4"...
  • Page 53 START PLUMBING ASSEMBL Y GUIDE...
  • Page 54 DESCRIPTION NUMBER DESCRIPTION NUMBER James A Plain Washer Bolt M8 X 50 Expansion tank Expansion tank BM8X50 " X 7/8" WPH1/4X7/8 Grade 8.8 bracket to chassis bracket Heavy duty Spring Washer Expansion tank to 8 x Radiator bobbin Setscrew 1/4"...
  • Page 55 AND KEEP PLUMBING ASSEMBL Y GUIDE...
  • Page 56 Now is a good time to take some photos ASSEMBL Y GUIDE...
  • Page 57 Have you applied for your IVA yet? ASSEMBL Y GUIDE...
  • Page 58 A BIT OF SUB-ASSEMBLY – SOME HOSES NEED MODIFYING P A R T S T O O L S Silicone hoses F I X I N G S T I P S Don't throw away the long piece of hose after cutting. Rich T ASSEMBL Y GUIDE...
  • Page 59 A BIT OF SUB-ASSEMBLY – SOME HOSES NEED MODIFYING ASSEMBL Y GUIDE...
  • Page 60 DESCRIPTION NUMBER DESCRIPTION NUMBER Jamie A Plain Washer Bolt M8 X 50 Expansion tank Expansion tank BM8X50 " X 7/8" WPH1/4X7/8 Grade 8.8 bracket to chassis bracket Heavy duty Spring Washer Expansion tank to 8 x Radiator bobbin Setscrew 1/4"...
  • Page 61 SUB-ASSEMBLY – TEMPERATURE SENSOR ASSEMBL Y GUIDE...
  • Page 62 USED ON ILLUSTRATION DESCRIPTION NUMBER DESCRIPTION NUMBER Plain Washer Bolt M8 X 50 Expansion tank Expansion tank BM8X50 " X 7/8" WPH1/4X7/8 Grade 8.8 bracket to chassis bracket Heavy duty Spring Washer Expansion tank to 8 x Radiator bobbin Setscrew 1/4"...
  • Page 63 BACK TO THE PLUMBING ASSEMBL Y GUIDE...
  • Page 64 USED ON ILLUSTRATION DESCRIPTION NUMBER DESCRIPTION NUMBER Plain Washer Bolt M8 X 50 Expansion tank Expansion tank BM8X50 " X 7/8" WPH1/4X7/8 Grade 8.8 bracket to chassis bracket Heavy duty Spring Washer Expansion tank to 8 x Radiator bobbin Setscrew 1/4"...
  • Page 65 MORE PLUMBING ASSEMBL Y GUIDE...
  • Page 66 USED ON ILLUSTRATION DESCRIPTION NUMBER DESCRIPTION NUMBER Plain Washer Bolt M8 X 50 Expansion tank Expansion tank BM8X50 " X 7/8" WPH1/4X7/8 Grade 8.8 bracket to chassis bracket Heavy duty Spring Washer Expansion tank to 8 x Radiator bobbin Setscrew 1/4"...
  • Page 67 STILL MORE PLUMBING 120mm 120mm ASSEMBL Y GUIDE...
  • Page 68 DESCRIPTION NUMBER DESCRIPTION NUMBER Grant P Plain Washer Bolt M8 X 50 Expansion tank Expansion tank BM8X50 " X 7/8" WPH1/4X7/8 Grade 8.8 bracket to chassis bracket Heavy duty Spring Washer Expansion tank to 8 x Radiator bobbin Setscrew 1/4"...
  • Page 69 A BREAK FROM PLUMBING TO FIT THE EXPANSION BOTTLE ASSEMBL Y GUIDE...
  • Page 70 USED ON ILLUSTRATION DESCRIPTION NUMBER DESCRIPTION NUMBER Plain Washer Bolt M8 X 50 Expansion tank Expansion tank BM8X50 " X 7/8" WPH1/4X7/8 Grade 8.8 bracket to chassis bracket Heavy duty Spring Washer Expansion tank to 8 x Radiator bobbin Setscrew 1/4"...
  • Page 71 SOME MORE HOSE MODIFICATION ASSEMBL Y GUIDE...
  • Page 72 USED ON ILLUSTRATION DESCRIPTION NUMBER DESCRIPTION NUMBER Plain Washer Bolt M8 X 50 Expansion tank Expansion tank BM8X50 " X 7/8" WPH1/4X7/8 Grade 8.8 bracket to chassis bracket Heavy duty Spring Washer Expansion tank to 8 x Radiator bobbin Setscrew 1/4"...
  • Page 73 AND BACK TO PLUMBING ASSEMBL Y GUIDE...
  • Page 74 USED ON ILLUSTRATION DESCRIPTION NUMBER DESCRIPTION NUMBER Plain Washer Bolt M8 X 50 Expansion tank Expansion tank BM8X50 " X 7/8" WPH1/4X7/8 Grade 8.8 bracket to chassis bracket Heavy duty Spring Washer Expansion tank to 8 x Radiator bobbin Setscrew 1/4"...
  • Page 75 LAST BIT OF PLUMBING ASSEMBL Y GUIDE...
  • Page 76 CONNECTING THE FUEL LINE P A R T S T O O L S F I X I N G S T I P S ASSEMBL Y GUIDE...
  • Page 77 CONNECTING THE FUEL LINE ASSEMBL Y GUIDE...
  • Page 78 FIT THROTTLE CABLE P A R T S T O O L S Throttle cable F I X I N G S T I P S Fixings are supplied loosely attached to the engine in place The silicone goes in the top of the pedal to prevent the cable coming out.
  • Page 79 FIT THROTTLE CABLE ASSEMBL Y GUIDE...
  • Page 80 PROTECTING & ATTACHING THE CLUTCH HOSE P A R T S T O O L S 8mm water hose 14mm F I X I N G S T I P S Nip up the banjo bolt. The hose is used to stop chaffing. John K James A ASSEMBL Y GUIDE...
  • Page 81 PROTECTING & ATTACHING THE CLUTCH HOSE ASSEMBL Y GUIDE...
  • Page 82 CONNECTING THE BATTERY (POSITIVE / RED FIRST) P A R T S T O O L S 10mm (x2) F I X I N G S T I P S Always connect live side of battery first Make the battery the (red wire).
  • Page 83 CONNECTING THE BATTERY (POSITIVE / RED FIRST) ASSEMBL Y GUIDE...
  • Page 84 IT LIVES! P A R T S T O O L S F I X I N G S T I P S ASSEMBL Y GUIDE...
  • Page 85 IT LIVES! ASSEMBL Y GUIDE...
  • Page 86 USED ON ILLUSTRATION DESCRIPTION NUMBER DESCRIPTION NUMBER Plain Washer Bolt M8 X 50 Expansion tank Expansion tank BM8X50 " X 7/8" WPH1/4X7/8 Grade 8.8 bracket to chassis bracket Heavy duty Spring Washer Expansion tank to 8 x Radiator bobbin Setscrew 1/4"...
  • Page 87 ONE LAST BIT OF PLUMBING… ASSEMBL Y GUIDE...
  • Page 88 ILLUSTRATION DESCRIPTION NUMBER DESCRIPTION NUMBER Plain Washer Bolt M8 X 50 Expansion tank Expansion tank BM8X50 " X 7/8" WPH1/4X7/8 Grade 8.8 bracket to chassis bracket Anthony L Heavy duty Spring Washer Expansion tank to 8 x Radiator bobbin Setscrew 1/4"...
  • Page 89 …TO CONNECT THE HEATER ASSEMBL Y GUIDE...
  • Page 90 FILL WITH COOLANT P A R T S T O O L S Coolant concentrate F I X I N G S T I P S ASSEMBL Y GUIDE...
  • Page 91 FILL WITH COOLANT Fill expansion bottle to max mark ASSEMBL Y GUIDE...
  • Page 92 CONNECT THE AIRBOX TO THE ENGINE P A R T S T O O L S Airbox hose Insert set Hose clip F I X I N G S T I P S All fixings for this step should be in the supplied airbox box To help push insert in Spray brake cleaner in the use the work bench.
  • Page 93 CONNECT THE AIRBOX TO THE ENGINE ASSEMBL Y GUIDE...
  • Page 94 GIVING IT SOME DIRECTION P A R T S T O O L S Lower steering column ⁷⁄ ₁ ₆" Upper steering column Steering column clamp 11mm Steering column clamp plate ⁷⁄ ₃ ₂" Grub screw Steering column bush ¹¹⁄ ₁ ₆" F I X I N G S T I P S SERIAL...
  • Page 95 GIVING IT SOME DIRECTION 14Nm 20Nm 20Nm ASSEMBL Y GUIDE...
  • Page 96 THIS IS EXHAUSTING P A R T S T O O L S Exhaust manifold gasket to follow Extension Exhaust primary pipes Cat / Collector Exhaust collector springs 17mm & only) F I X I N G S T I P S 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.
  • Page 97 THIS IS EXHAUSTING 47Nm ASSEMBL Y GUIDE...
  • Page 98 FITTING THE HANDBRAKE P A R T S T O O L S Handbrake assembly 13mm (x2) Handbrake pulley Handbrake clevis Pulley clevis pin Handbrake clevis pin Handbrake cable F I X I N G S T I P S Miscellaneous pack Remember to put a loop in Cable tie adjuster...
  • Page 99 FITTING THE HANDBRAKE ASSEMBL Y GUIDE...
  • Page 100 SLIDE IN THE PROPSHAFT P A R T S T O O L S Propshaft F I X I N G S T I P S Line the splines in the Grease prop if necessary, propshaft to the gearbox. it will have a grease nipple. Anthony L John S ASSEMBL Y GUIDE...
  • Page 101 SLIDE IN THE PROPSHAFT ASSEMBL Y GUIDE...
  • Page 102 NUMBER Chris B Bolt 1/2" X 11" Upper diff mounting Plain washer 1/2" Fine tuning diff BF1/2X11 WPT1/2X7/8 bolt X 7/8" Thin setup Caphead Bolt Lower diff mounting Plain washer 1/2" M12 X 65 BMCH12X55 79017 Free play on diff bolt X 3/4"...
  • Page 103 HEAVY STUFF: FITTING THE DIFF 61Nm 47Nm 47Nm ASSEMBL Y GUIDE...
  • Page 104 FILL THE DIFFERENTIAL WITH OIL P A R T S T O O L S Differential oil F I X I N G S T I P S ASSEMBL Y GUIDE...
  • Page 105 FILL THE DIFFERENTIAL WITH OIL Differential = 0.8L ASSEMBL Y GUIDE...
  • Page 106 Bolt 1/2" X 11" Upper diff mounting Plain washer 1/2" Fine tuning diff BM12X100 BF1/2X11 WPT1/2X7/8 Grade 10.9 mountings bolt X 7/8" Thin setup John K Caphead Bolt Caphead Bolt Front radius arm Lower diff mounting Plain washer 1/2" BMCH10X65...
  • Page 107 PREPARING THE DEDION TUBE 5 x ⅛" ASSEMBL Y GUIDE...
  • Page 108 AND FITTING IT IN PLACE P A R T S T O O L S F I X I N G S T I P S ASSEMBL Y GUIDE...
  • Page 109 AND FITTING IT IN PLACE ASSEMBL Y GUIDE...
  • Page 110 2 Lower Rear Bolt Plain Washer Damper Front Radius Arm 1/2" X 2.1/2" BF1/2X2.1/2 WPH3/8X7/8 3/8" X 7/8" Grade 10.9 2 Rear Radius Arm Rear Anti Roll Bar Rear Anti Roll Bar Bolt M6 X 80 Plain Washer BM6X80 WPHM6 Grade 10.9...
  • Page 111 ATTACHING THE REAR DAMPERS 47Nm 81Nm ASSEMBL Y GUIDE...
  • Page 112 2 Lower Rear Bolt Plain Washer Damper Front Radius Arm 1/2" X 2.1/2" BF1/2X2.1/2 WPH3/8X7/8 3/8" X 7/8" Grade 10.9 2 Rear Radius Arm Rear Anti Roll Bar Rear Anti Roll Bar Bolt M6 X 80 Plain Washer BM6X80 WPHM6 Grade 10.9...
  • Page 113 THEN THE RADIUS ARM 81Nm 34Nm ASSEMBL Y GUIDE...
  • Page 114 2 Lower Rear Bolt Plain Washer Damper Front Radius Arm 1/2" X 2.1/2" BF1/2X2.1/2 WPH3/8X7/8 3/8" X 7/8" Grade 10.9 2 Rear Radius Arm Rear Anti Roll Bar Rear Anti Roll Bar Bolt M6 X 80 Plain Washer BM6X80 WPHM6 Torque up as before on axle stands.
  • Page 115 AND NOW THE (CAREFULLY SPACED) A-FRAME 81Nm 81Nm ASSEMBL Y GUIDE...
  • Page 116 2 Lower Rear Bolt Plain Washer Damper Front Radius Arm 1/2" X 2.1/2" BF1/2X2.1/2 WPH3/8X7/8 3/8" X 7/8" Grade 10.9 2 Rear Radius Arm Rear Anti Roll Bar Rear Anti Roll Bar Bolt M6 X 80 Plain Washer BM6X80 WPHM6 Grade 10.9...
  • Page 117 IF YOU HAVE THE OPTIONAL REAR ANTI-ROLL BAR, IT GOES ON LIKE THIS ASSEMBL Y GUIDE...
  • Page 118 INSERT THE DRIVESHAFTS P A R T S T O O L S Driveshaft Driveshaft nut F I X I N G S T I P S Driveshafts are handed, and so are the nuts, the left hand nut tightens anti‑clockwise. James A ASSEMBL Y GUIDE...
  • Page 119 INSERT THE DRIVESHAFTS ASSEMBL Y GUIDE...
  • Page 120 NUMBER Chris B Bolt 1/2" X 11" Upper diff mounting Plain washer 1/2" Fine tuning diff BF1/2X11 WPT1/2X7/8 bolt X 7/8" Thin setup Caphead Bolt Lower diff mounting Plain washer 1/2" M12 X 65 BMCH12X55 79017 Free play on diff bolt X 3/4"...
  • Page 121 FITTING THE REAR HUB 47Nm 47Nm 47Nm 47Nm ASSEMBL Y GUIDE...
  • Page 122 AND SPEED SENSOR (ONE SIDE ONLY) P A R T S T O O L S Speed sensor F I X I N G S T I P S ASSEMBL Y GUIDE...
  • Page 123 AND SPEED SENSOR (ONE SIDE ONLY) 1 x ⁄ " 30mm ASSEMBL Y GUIDE...
  • Page 124 Now is a good time to take some photos ASSEMBL Y GUIDE...
  • Page 125 Have you applied for your IVA yet? ASSEMBL Y GUIDE...
  • Page 126 JUST WING IT P A R T S T O O L S Cycle wing Wheel Wheel nuts F I X I N G S T I P S You may need to bend the arms of Key the wing & wingstay before using adhesive.
  • Page 127 JUST WING IT ASSEMBL Y GUIDE...
  • Page 128 SOME EXTRA ADHESIVE UNDERNEATH P A R T S T O O L S F I X I N G S T I P S The WD40 will help spread the adhesive. Mick F ASSEMBL Y GUIDE...
  • Page 129 JUST WING IT ASSEMBL Y GUIDE...
  • Page 130 TAPE IN PLACE FOR 24 HOURS P A R T S T O O L S F I X I N G S T I P S ASSEMBL Y GUIDE...
  • Page 131 TAPE IN PLACE FOR 24 HOURS ASSEMBL Y GUIDE...
  • Page 132 FINISH WITH TRIM P A R T S T O O L S F I X I N G S T I P S ASSEMBL Y GUIDE...
  • Page 133 FINISH WITH TRIM ASSEMBL Y GUIDE...
  • Page 134 FITTING THE REAR WINGS P A R T S T O O L S Rear wing to follow Sanding Drum F I X I N G S T I P S SERIAL Pack NUMBER Cut the supplied piping in half and it Don’t forget the fuel tank PACK NUMBER ZFG12...
  • Page 135 FITTING THE REAR WINGS ASSEMBL Y GUIDE...
  • Page 136 AND THE WING PROTECTORS P A R T S T O O L S Wing protector ⅛" F I X I N G S T I P S For stainless steel protectors For carbon fibre protectors When drilling through protector start Carbon fibre protectors will not SERIAL SERIAL...
  • Page 137 AND THE WING PROTECTORS ASSEMBL Y GUIDE...
  • Page 138 FITTING THE LIGHTS P A R T S T O O L S Side repeater Rear light Numberplate lamp F I X I N G S T I P S SERIAL Pack NUMBER Use a cradle clip & cable tie to keep PACK NUMBER 30L002B the rear light loom out of the way.
  • Page 139 FITTING THE LIGHTS ASSEMBL Y GUIDE...
  • Page 140 FUSE BOX COVER & KNEE TRIM PADS P A R T S T O O L S ⁵⁄ ₃ ₂" F I X I N G S T I P S Chassis fastener pack ZCH01 supplied loose: • Screw ¾" x 10 • Rivet 5⁄...
  • Page 141 FUSE BOX COVER & KNEE TRIM PADS 7 x ⁵⁄ ₃ ₂" ASSEMBL Y GUIDE...
  • Page 142 FIT THE TUNNEL CARPET P A R T S T O O L S F I X I N G S T I P S Spray on both tunnel Allow the adhesive to panel and carpet. go tacky before fitting. John K Harry P ASSEMBL Y GUIDE...
  • Page 143 FIT THE TUNNEL CARPET ASSEMBL Y GUIDE...
  • Page 144 AND THE BOOT CARPET P A R T S T O O L S F I X I N G S T I P 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.
  • Page 145 AND THE BOOT CARPET ASSEMBL Y GUIDE...
  • Page 146 THIS IS A COVER UP P A R T S T O O L S Fuel filler cove Tunnel closing panel ⁵⁄ ₃ ₂" F I X I N G S T I P S Supplied loose: The fuel filler cover just screws to the boot floor. • Rivets Drill two holes and use self tapping screws.
  • Page 147 THIS IS A COVER UP ASSEMBL Y GUIDE...
  • Page 148 NOW FIT THE TUNNEL TOP P A R T S T O O L S ⅛" F I X I N G S T I P S The hole can be seen if you flip the tunnel top over. Mick F ASSEMBL Y GUIDE...
  • Page 149 NOW FIT THE TUNNEL TOP ASSEMBL Y GUIDE...
  • Page 150 BELT UP P A R T S T O O L S F I X I N G S T I P S Supplied with seat belts These will be loosely fitted already – you'll need to tighten & torque. Chris N ASSEMBL Y GUIDE...
  • Page 151 BELT UP 47Nm 47Nm ASSEMBL Y GUIDE...
  • Page 152 FITTING THE FOUR-POINT HARNESS P A R T S T O O L S 17mm F I X I N G S T I P S All fixings supplied with the harnesses The buckle is attached to a lap strap and this should be fitted to the tunnel side.
  • Page 153 FITTING THE FOUR-POINT HARNESS 47Nm ASSEMBL Y GUIDE...
  • Page 154 FITTING THE SIX-POINT HARNESS P A R T S T O O L S 7⁄ 1 6" 16mm 17mm 16mm 17mm F I X I N G S T I P S All fixings supplied with the harnesses The buckle is attached to a lap strap and this should be fitted to the tunnel side.
  • Page 155 FITTING THE SIX-POINT HARNESS 47Nm 47Nm ASSEMBL Y GUIDE...
  • Page 156 FITTING CLOTH OR LEATHER SEATS P A R T S T O O L S Seat 13mm Seat base Headrest F I X I N G S T I P S SERIAL Pack NUMBER Loosely fit the rear bolts to help Nip up all bolts once fitted.
  • Page 157 FITTING CLOTH OR LEATHER SEATS ASSEMBL Y GUIDE...
  • Page 158 OR FITTING THE RACE SEATS P A R T S T O O L S Seat 13mm Adjustable runner Fixed seat spacer F I X I N G S T I P S For fixed seats For adjustable seats Put a bit of Loctite on bolts that go Runners / seat spacers SERIAL SERIAL...
  • Page 159 OR FITTING THE RACE SEATS ASSEMBL Y GUIDE...
  • Page 160 FITTING THE ROLL OVER BAR P A R T S T O O L S Roll over bar 13mm 17mm 17mm F I X I N G S T I P S SERIAL Pack NUMBER If you've fitted the rear dampers they'll PACK NUMBER 30P010A need to come off again to do this properly.
  • Page 161 FITTING THE ROLL OVER BAR 25Nm 47Nm 47Nm ASSEMBL Y GUIDE...
  • Page 162 OR THE ROLL CAGE FOR ACADEMY CARS P A R T S T O O L S 17mm 17mm F I X I N G S T I P S SERIAL Pack NUMBER Mask up the paintwork before fitting to avoid scratches. PACK NUMBER 30P017A ROLL CAGE SERIES 3 METRIC...
  • Page 163 OR THE ROLL CAGE FOR ACADEMY CARS 47Nm 47Nm 47Nm ASSEMBL Y GUIDE...
  • Page 164 USED ON ILLUSTRATION DESCRIPTION NUMBER Bolt M12 X 120 BM12X120 A-frame Grade 10.9 Caphead Bolt Boss on top of BFCH7/16X1.5 7/16" X 1 1/2" chassis Set screw Front cage bracket X 25 Grade SM10X25 10.9 Plain Washer Front cage bracket WPHM10...
  • Page 165 AND THE SIDE IMPACT BAR 47Nm 47Nm ASSEMBL Y GUIDE...
  • Page 166 EVEN MORE EXHAUSTING P A R T S T O O L S Silencer 10mm 13mm Exhaust clamp Lambda sensor ⅞" Cat guard 19mm Clip Silencer mounting bracket Exhaust mounting bobbin F I X I N G S T I P S SERIAL Pack NUMBER...
  • Page 167 EVEN MORE EXHAUSTING ASSEMBL Y GUIDE...
  • Page 168 THE NOSE CONE BADGE P A R T S T O O L S Nose cone Bonnet Badge F I X I N G S T I P S The nose cone goes on Stick the supplied foam around the edge before the bonnet.
  • Page 169 THE NOSE CONE BADGE ASSEMBL Y GUIDE...
  • Page 170 FITTING THE WIPERS P A R T S T O O L S Wiper arm Wiper blade F I X I N G S T I P S Ensure wipers are in paused position Now would be a good time to fill before fitting the wiper arms.
  • Page 171 FITTING THE WIPERS ASSEMBL Y GUIDE...
  • Page 172 AND FINALLY, AT LAST, THE WING MIRRORS P A R T S T O O L S Mirror head Mirror mount Mirror mount stud 25mm Grub screw Fibre washer F I X I N G S T I P S Wing mirror bag You may have to unclick the glass out to tighten up.
  • Page 173 AND FINALLY, AT LAST, THE WING MIRRORS ASSEMBL Y GUIDE...
  • Page 174 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 and 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).
  • Page 175 Using the 10mm spanner, ‘crack off’ the nipple about half of a turn. Ask your assistant to pump the pedal a few times. You should see bubbly fluid flowing through the 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.
  • Page 176 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.
  • Page 177 Torque the wheel nuts to 65lbft (about 85Nm). v. 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! ASSEMBL Y GUIDE...
  • Page 178 Caterham Cars Limited, 2–3 Kennet Road, Dartford, Kent, DA1 4QN +44 (0) 1322 625800 /CaterhamCars @caterhamcars Content is subject to change without notice. © Caterham 2017 Edition 1.0 12/17 Images are for illustrative purposes only.

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