Caterham 7 Assembly Manual

ASSEMBLY GUIDE

EDITION 1.0

ASSEMBLY GUIDE

EDITION 1.0

Your feedback and comments are welcome: [email protected]

ASSEMBLY GUIDE

i

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.

ASSEMBLY GUIDE

ii

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 application form and a guide on how to complete it, is contained within an envelope of documents
provided with your kit and which is probably acting as a coaster for your g&t at the moment. Take this
moment to find it and remove it from the garage and place it somewhere safe (and memorable).

ASSEMBLY GUIDE

iii

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).

ASSEMBLY GUIDE

iv

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 oered 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
eort 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 oer 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.

As a guide, the Post Build Inspection through to registration can take around 6 weeks to complete.

v

ASSEMBLY GUIDE

That’s it, we’re ready to start assembly

ENJOY

ASSEMBLY GUIDE

vi

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!

1

HINTS & TIPS

When using a torque wrench, listen/feel the click
and then stop. It does not need to be any tighter
and you might actually weaken the fixing by
‘over‑torquing’ it. Always wind your torque wrench
setting back to free when you’ve finished with it.

John K

A ‘caphead bolt’ has a circular head with a hexagonal drive
inside it. It is tightened with an allen key or hex drive socket.
Capheads are useful where there is limited space around
the head for a spanner or socket. They look nice too!

Richard T

Generally, metric Nyloc nuts have a
blue nylon insert and imperial ones a
white nylon insert.

Grant P

You can tell if you have ‘wide track suspension’ car by looking at the front
dampers. Wide track has a 25mm long hexagonal spacer between the top
spring retainer and the mounting bush.

Matt T

A bolt size is described by its diameter (e.g. M10=10mm)
by the length not including the head (e.g. 65mm).

James A

A ‘spring washer’ has a split in it and squashes up
closed when a fixing is tightened. It is usually used
under a bolt head to help resist it coming undone.

John S

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.

Chris B

Thread lock is used to stop
something coming undone, but
it only needs a little drop on
the thread to be effective.

Jamie A

Teabag, boiling water, then the milk, in that order.

Simon L

Left and right are as viewed
from the driver’s seat.

Harrison P

1Nm of torque equals 0.736lbft.

Mick F

When using a spanner, always use the ring end wherever
possible. The open end is really only for those times that access
is too limited for a ring spanner or socket.

Mick A

ASSEMBLY GUIDE

ASSEMBLY GUIDE

2

KEY

SYMBOLS

Repeat on other side

Required torque (where applicable)

S3 / S5 chassis specific instructions

S Pack / R Pack
specific instructions

Fixing item

Item number

Advice from factory
professionals

Now is a good time to take
some photos

Reminder to apply for your IVA test

Refer to IVA Checklist Guide

AA

AJ

AM

S3

S5

Nm

1

FIXINGS

PART

NUMBER

QTYUSED ON

1AA

BM12X100

2

Lower wishbone

rear

2AB

BM12X65

2

Lower wishbone

front

3AC

BM10X65

2

Upper wishbone

rear

4AD

BM10X60

2

Upper wishbone

front

5AE

BM8X40

4

Anti-roll bar

mounting brackets

6AF

NMPH14

1

Temporary use to

help lock upper

wishbone ball joint

7AG

NMYF12

2

Lower wishbone

rear

8AH

NMYF10

4

Upper wishbone

9AJ

WPCM12

18

Lower wishbone

10 AK

WPHM8

4

Anti-roll bar

mounting brackets

11 AL

WPH3/8

2

Brake pipe

Drawings are for illustrative purposes only and are not to scale.

A

SERIAL
NUMBER

44

Pack

PACK NUMBER

30F015B

FRONT SUSPENSION DeDION CARS (METRIC)

This pack may include extra fasteners to cover different options

ITEM

BASIC

DESCRIPTION

ILLUSTRATION

Bolt M12 x 100

Grade 10.9

Bolt M12 x 65

Grade 10.9

Bolt M10 x 65

Grade 10.9

Bolt M10 x 60

Grade 10.9

Bolt M8 x 40

Grade 10.9

Plain Nut M14

x 1.5 thread

Nyloc Nut M12

Plain Washer

⅜" x ¾"

Heavy duty

Page 1 of 2

Nyloc Nut M10

Plain Washer

M12

Chamfered

Plain Washer

M8

Heavy duty

PART

NUMBER

QTYUSED ON

1AA

BM12X100

2

Lower wishbone

rear

A

SERIAL
NUMBER

44

Pack

PACK NUMBER

30F015B

FRONT SUSPENSION DeDION CARS (METRIC)

This pack may include extra fasteners to cover different options

ITEM

BASIC

DESCRIPTION

ILLUSTRATION

Bolt M12 x 100

Grade 10.9

x4 (Indicates number of each fixing required)

(Greyed out area indicates fixings are not
required for current step)

REPEAT

ASSEMBLY GUIDE

3

TOOLS

KEY

Spanner

Scissors

Grease

Latex gloves

Junior hacksaw

Long nose pliers

Pop rivet gun

Muscle

Pozidrive
screwdriver

Power adhesive

Flat head
screwdriver

Thread lock /
LocTite

LOCTITE

LOCTITE

Tape

Torx

Tape measure

Trolley jack

Torque wrench

WD40

Ruler

Side cutters

Silicon gun

Silicon

Socket wrench

Spray adhesive

Spray lube

Socket wrench
(allen)

Stanley knife

Spirit level

Drill bit

Axle stand

Combination
spanner

Allen key

Engine hoist

Copper grease

Drill

Cable tie

Assistance

+

ASSEMBLY GUIDE

4

LET’S GET READY

PAR TS

FIXINGS

TOOLS

TIPS

x3

When deciding how high your axle stands
should be (the higher the better for working
on), don’t forget that a complete car will
need to come down off them, so make sure
your trolley jack can reach and lift the
height you set them too!

Mick F

Some tape or foam on the
top of the axle stands will
stop them scratching the
chassis.

Matt T

ASSEMBLY GUIDE

5

LET’S GET READY

ASSEMBLY GUIDE

6

START WITH THE SUSPENSION WISHBONES

PAR TS

FIXINGS

TOOLS

TIPS

PART

NUMBER

QTYUSED ON

1AA

BM12X100

2

Lower wishbone

rear

2AB

BM12X65

2

Lower wishbone

front

3AC

BM10X65

2

Upper wishbone

rear

4AD

BM10X60

2

Upper wishbone

front

5AE

BM8X40

4

Anti-roll bar

mounting brackets

6AF

NMPH14

1

Temporary use to

help lock upper

wishbone ball joint

7AG

NMYF12

2

Lower wishbone

rear

8AH

NMYF10

4

Upper wishbone

9AJ

WPCM12

18

Lower wishbone

10 AK

WPHM8

4

Anti-roll bar

mounting brackets

11 AL

WPH3/8

2

Brake pipe

Drawings are for illustrative purposes only and are not to scale.

A

SERIAL

NUMBER

44

Pack

PACK NUMBER

30F015B

FRONT SUSPENSION DeDION CARS (METRIC)

This pack may include extra fasteners to cover different options

ITEM

BASIC

DESCRIPTION

ILLUSTRATION

Bolt M12 x 100

Grade 10.9

Bolt M12 x 65

Grade 10.9

Bolt M10 x 65

Grade 10.9

Bolt M10 x 60

Grade 10.9

Bolt M8 x 40

Grade 10.9

Plain Nut M14

x 1.5 thread

Nyloc Nut M12

Plain Washer

⅜" x ¾"

Heavy duty

Page 1 of 2

Nyloc Nut M10

Plain Washer

M12

Chamfered

Plain Washer

M8

Heavy duty

94

PART

NUMBER

QTYUSED ON

12 AM

WSHM12

2

Lower wishbone

front

13 AN

WSHM8

6

Anti-roll bar

mounting brackets &

upper damper

mount

14 AP

WSS3/8

2 Brake pipe

15 AR

NFYH1/2

2Wing stay

16 AS

NFYF1/2

2

Front brake, upright
mounting (std track

ONLY)

Drawings are for illustrative purposes only and are not to scale.

A

SERIAL
NUMBER

44

Pack

PACK NUMBER

30F015B

FRONT SUSPENSION DeDION CARS (METRIC)

This pack may include extra fasteners to cover different options

ITEM

BASIC

DESCRIPTION

ILLUSTRATION

Spring Washer

M12

Nyloc Nut ½"

Full height

Page 2 of 2

Spring Washer

M8

Washer ⅜"
Shake-proof

Nyloc Nut ½"

Half height

x2

x2

x2

x2

x2

x4

x14

x2

17mm
19mm

Lower wishbone

Wishbone bush sleeve

Upper wishbone

17mm
19mm

1

3

2

For now, only tighten the nuts/bolts lightly and then
torque them up when the car is finished and on the
ground. This sets the bushes correctly and ensures
the best handling.

Harrison P

The big washers are chamfered and
the chamfered side should be towards
the wishbone.

Alex H

Leave bolt AD
loose for now,
as we have to
take it back out
again to put
the headlight
bracket on later.

John K

ASSEMBLY GUIDE

7

START WITH THE SUSPENSION WISHBONES

81Nm

AB

AJ

AM

1

2

3

AJ

81Nm

AA

AJ

AG

47Nm

47Nm

AD

AH

AC

AH

REPEAT

ASSEMBLY GUIDE

8

NOW FOR THE STEERING RACK

PAR TS

FIXINGS

TOOLS

TIPS

PART

NUMBER

QTYUSED ON

1BA

BMCH6X70

4Rack clamps

2BB

BF1/4X1.1/2

2Column clam p

3BC

BM8X35

2

Column to rack
universal joint

4BD

NFYH1/2

1Steering wheel boss

5BE

NFPF1/2

2Track rod lock nut

6BF

NFPFH7/16

1

Column clamp

grubscrew locknut

7BG

NMYF8

2

Column to rack
universal joint

8BH

NMYF6

4

Steering rack

clamps

9BJ

WPH1/2

1

Steering wheel boss

10 BK

WPH1/4

6

Rack clamps and

column clamp

11 BL

WSH1/4

2

Column clamp

Drawings are for illustrative purposes only and are not to scale.

B

SERIAL

NUMBER

55

Pack

PACK NUMBER

30S003B

STEERING DeDION CARS (METRIC)

This pack may include extra fasteners to cover different options

ITEM

BASIC

DESCRIPTION

ILLUSTRATION

Caphead Bolt

M6 x 70

DIN 912

Bolt ¼" x 1½"

Bolt M8 x 35

Grade 8.8

Nyloc Nut ½"

Half height

Plain Nut ½"

Plain Nut ⁷⁄₁₆"

Half height

Nyloc Nut M8

Spring Washer ¼

Heavy duty

Page 1 of 1

Nyloc Nut M6

Plain Washer

½" x 1⅛"

Chamfered

Plain Washer

¼"

Heavy duty

x4

x2

x2

x2

x4

x4

10mm
13mm

Steering rack

Column universal joint

Rack clamps

IVA cover

Track rod end

5mm

13mm
22mm
¾"

1

3

2

5

4

Finding the right IVA cover isn’t
obvious because it is effectively
a long cap. To use it, you cut the
closed end off.

Jamie A

The trackrod end needs to screw on
about 12 turns (it will be properly set
later when the tracking is done).

Matthew H

ASSEMBLY GUIDE

9

NOW FOR THE STEERING RACK

11Nm

BE

3

5

20Nm

BC

BG

BH

BK

BA

2

1

4

ASSEMBLY GUIDE

10

PART

NUMBER

QTYUSED ON

1AA

BM12X100

2

Lower wishbone

rear

2AB

BM12X65

2

Lower wishbone

front

3AC

BM10X65

2

Upper wishbone

rear

4AD

BM10X60

2

Upper wishbone

front

5AE

BM8X40

4

Anti-roll bar

mounting brackets

6AF

NMPH14

1

Temporary use to

help lock upper

wishbone ball joint

7AG

NMYF12

2

Lower wishbone

rear

8AH

NMYF10

4

Upper wishbone

9AJ

WPCM12

18

Lower wishbone

10 AK

WPHM8

4

Anti-roll bar

mounting brackets

11 AL

WPH3/8

2

Brake pipe

Drawings are for illustrative purposes only and are not to scale.

A

SERIAL

NUMBER

44

Pack

PACK NUMBER

30F015B

FRONT SUSPENSION DeDION CARS (METRIC)

This pack may include extra fasteners to cover different options

ITEM

BASIC

DESCRIPTION

ILLUSTRATION

Bolt M12 x 100

Grade 10.9

Bolt M12 x 65

Grade 10.9

Bolt M10 x 65

Grade 10.9

Bolt M10 x 60

Grade 10.9

Bolt M8 x 40

Grade 10.9

Plain Nut M14

x 1.5 thread

Nyloc Nut M12

Plain Washer

⅜" x ¾"

Heavy duty

Page 1 of 2

Nyloc Nut M10

Plain Washer

M12

Chamfered

Plain Washer

M8

Heavy duty

94

PART

NUMBER

QTYUSED ON

12 AM

WSHM12

2

Lower wishbone

front

13 AN

WSHM8

6

Anti-roll bar

mounting brackets &

upper damper

mount

14 AP

WSS3/8

2 Brake pipe

15 AR

NFYH1/2

2Wing stay

16 AS

NFYF1/2

2

Front brake, upright
mounting (std track

ONLY)

Drawings are for illustrative purposes only and are not to scale.

A

SERIAL
NUMBER

44

Pack

PACK NUMBER

30F015B

FRONT SUSPENSION DeDION CARS (METRIC)

This pack may include extra fasteners to cover different options

ITEM

BASIC

DESCRIPTION

ILLUSTRATION

Spring Washer

M12

Nyloc Nut ½"

Full height

Page 2 of 2

Spring Washer

M8

Washer ⅜"
Shake-proof

Nyloc Nut ½"

Half height

AND THEN THE DAMPERS

PAR TS

FIXINGS

TOOLS

TIPS

6mm

Spring / damper

Upper damper eyelet

Lower damper eyelet

6mm

6mm

1

3

2

Put the top of the damper on first
and be careful not to let it swing into
the side of the chassis.

Grant P

The bottom can be a tight fit!

Mick F

x2

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

ASSEMBLY GUIDE

11

AND THEN THE DAMPERS

25Nm

1

2

3

25Nm

AN

ASSEMBLY GUIDE

12

PART

NUMBER

QTYUSED ON

1AA

BM12X100

2

Lower wishbone

rear

2AB

BM12X65

2

Lower wishbone

front

3AC

BM10X65

2

Upper wishbone

rear

4AD

BM10X60

2

Upper wishbone

front

5AE

BM8X40

4

Anti-roll bar

mounting brackets

6AF

NMPH14

1

Temporary use to

help lock upper

wishbone ball joint

7AG

NMYF12

2

Lower wishbone

rear

8AH

NMYF10

4

Upper wishbone

9AJ

WPCM12

18

Lower wishbone

10 AK

WPHM8

4

Anti-roll bar

mounting brackets

11 AL

WPH3/8

2

Brake pipe

Drawings are for illustrative purposes only and are not to scale.

A

SERIAL

NUMBER

44

Pack

PACK NUMBER

30F015B

FRONT SUSPENSION DeDION CARS (METRIC)

This pack may include extra fasteners to cover different options

ITEM

BASIC

DESCRIPTION

ILLUSTRATION

Bolt M12 x 100

Grade 10.9

Bolt M12 x 65

Grade 10.9

Bolt M10 x 65

Grade 10.9

Bolt M10 x 60

Grade 10.9

Bolt M8 x 40

Grade 10.9

Plain Nut M14

x 1.5 thread

Nyloc Nut M12

Plain Washer

⅜" x ¾"

Heavy duty

Page 1 of 2

Nyloc Nut M10

Plain Washer

M12

Chamfered

Plain Washer

M8

Heavy duty

94

PART

NUMBER

QTYUSED ON

12 AM

WSHM12

2

Lower wishbone

front

13 AN

WSHM8

6

Anti-roll bar

mounting brackets &

upper damper

mount

14 AP

WSS3/8

2 Brake pipe

15 AR

NFYH1/2

2Wing stay

16 AS

NFYF1/2

2

Front brake, upright
mounting (std track

ONLY)

Drawings are for illustrative purposes only and are not to scale.

A

SERIAL
NUMBER

44

Pack

PACK NUMBER

30F015B

FRONT SUSPENSION DeDION CARS (METRIC)

This pack may include extra fasteners to cover different options

ITEM

BASIC

DESCRIPTION

ILLUSTRATION

Spring Washer

M12

Nyloc Nut ½"

Full height

Page 2 of 2

Spring Washer

M8

Washer ⅜"
Shake-proof

Nyloc Nut ½"

Half height

IT’S TIME FOR THE WINGSTAYS

PAR TS

FIXINGS

TOOLS

TIPS

19mm
22mm
¾"

22mm

Wingstay

Front brake & upright assembly

x2

x2

1

2

Some of the fixings
required and shown
on the drawings,
such as the ball
joint nut, are already
on the part and not
in the fixing pack.

Anthony L

Use the plain
nut to pull the
top ball joint
home before
using a nyloc,
otherwise the
thread will spin.

Chris N

The drilled hole is for the side repeater earth that we’ll fit later. It’s easier to
drill from the top and down through both sides of the tube, rather than through
one side from the bottom (where the earth will be fixed).

Tiago O

Put the ‘upright’ into the lower
wishbone joint then attach
the steering before tightening
the bottom nut. This stops it
all swinging around hitting the
side of the chassis.

John S

"

13

ASSEMBLY GUIDE

1 x ⅛

IT’S TIME FOR THE WINGSTAYS

WIDE
TRACK

54Nm

81Nm

61Nm

AS

AR

STANDARD TRACK

1

2

REPEAT

54Nm

ASSEMBLY GUIDE

14

Now is a good time to take some photos

15

Have you applied for your IVA yet?

ASSEMBLY GUIDE

ASSEMBLY GUIDE

16

LET THERE BE LIGHTS

PAR TS

FIXINGS

TOOLS

TIPS

PART

NUMBER

QTYUSED ON

1CA

71080

6

Indictor assembly to

indicator pod

2CB

71077

2

Side repeater earth

on wingstay

3CC

71079

4

Rear light cluster

upper fixing

4CD

71078

4

Rear light cluster

lower fixing

5CE

NMYF6

2

Horn bracket to

steering rack

platform

(160/270/310)

6CF

WPH1/4

2

Horn bracket to

steering rack

platform

(160/270/310)

7CG

BM8X50

1

Through steering

rack platform &

spacer

(420)

8CH

WPH5/16

2Bolt head/nut

9CI

NMYF8

1Horn bolt

Drawings are for illustrative purposes only and are not to scale.

BASIC

DESCRIPTION

ILLUSTRATION

Screw 10 x ¾

"

Black Supaflange

Page 1 of 1

Screw 12 x 1"

Self tapping

Screw 8 x ½"

Black Supaflange

Screw 12 x 1½

"

Self tapping

LIGHTING & HORNS

ITEM

Pack

45

SERIAL
NUMBER

PACK NUMBER

30L002B

C

Nyloc Nut M6

Plain Washer

¼"

Heavy duty

Bolt M8 x 5

Grade 8.8

Plain Washer

5/16"

Nyloc Nut

M8

x6

Headlight assembly

Indicator assembly

Indicator pod

17mm
24mm

17mm

1

3

2

The wiring for the headlights is attached to the chassis when
you receive your kit. The wires go through the hole in the end
of the headlight bracket and out of the other hole in order to
go up into the headlight and over to the indicator.

Jamie A

Headlight bracket

4

ASSEMBLY GUIDE

17

LET THERE BE LIGHTS

7

7

1

2

3

4

CA

REPEAT

ASSEMBLY GUIDE

18

PART

NUMBER

QTYUSED ON

1AA

BM12X100

2

Lower wishbone

rear

2AB

BM12X65

2

Lower wishbone

front

3AC

BM10X65

2

Upper wishbone

rear

4AD

BM10X60

2

Upper wishbone

front

5AE

BM8X40

4

Anti-roll bar

mounting brackets

6AF

NMPH14

1

Temporary use to

help lock upper

wishbone ball joint

7AG

NMYF12

2

Lower wishbone

rear

8AH

NMYF10

4

Upper wishbone

9AJ

WPCM12

18

Lower wishbone

10 AK

WPHM8

4

Anti-roll bar

mounting brackets

11 AL

WPH3/8

2

Brake pipe

Drawings are for illustrative purposes only and are not to scale.

A

SERIAL

NUMBER

44

Pack

PACK NUMBER

30F015B

FRONT SUSPENSION DeDION CARS (METRIC)

This pack may include extra fasteners to cover different options

ITEM

BASIC

DESCRIPTION

ILLUSTRATION

Bolt M12 x 100

Grade 10.9

Bolt M12 x 65

Grade 10.9

Bolt M10 x 65

Grade 10.9

Bolt M10 x 60

Grade 10.9

Bolt M8 x 40

Grade 10.9

Plain Nut M14

x 1.5 thread

Nyloc Nut M12

Plain Washer

⅜" x ¾"

Heavy duty

Page 1 of 2

Nyloc Nut M10

Plain Washer

M12

Chamfered

Plain Washer

M8

Heavy duty

94

PART

NUMBER

QTYUSED ON

12 AM

WSHM12

2

Lower wishbone

front

13 AN

WSHM8

6

Anti-roll bar

mounting brackets &

upper damper

mount

14 AP

WSS3/8

2 Brake pipe

15 AR

NFYH1/2

2Wing stay

16 AS

NFYF1/2

2

Front brake, upright
mounting (std track

ONLY)

Drawings are for illustrative purposes only and are not to scale.

A

SERIAL
NUMBER

44

Pack

PACK NUMBER

30F015B

FRONT SUSPENSION DeDION CARS (METRIC)

This pack may include extra fasteners to cover different options

ITEM

BASIC

DESCRIPTION

ILLUSTRATION

Spring Washer

M12

Nyloc Nut ½"

Full height

Page 2 of 2

Spring Washer

M8

Washer ⅜"
Shake-proof

Nyloc Nut ½"

Half height

LAST PART OF THE FRONT SUSPENSION: CONNECTING THE TWO SIDES TOGETHER

PAR TS

FIXINGS

TOOLS

TIPS

x4

x4

13mm

Anti-roll bar

Anti-roll bar rubber

Anti-roll bar bracket

Anti-roll bar dust cover

Anti-roll bar ball

x4

LOCTITE

LOCTITE

1

3

2

5

4

Getting the assembled anti‑roll
bar fully into both cups on the
upper wishbone can be a bit of a
fight. It’s made of springy stuff,
so don’t worry that you are
bending it.

Jamie A

Use four small cable
ties to secure the
dust cover.

Mick F

Grease the balls and cups generously.

Matt T

Check that the colour of the
mounting rubbers matches the
colour spot on the bar.

John K

ASSEMBLY GUIDE

19

LAST PART OF THE FRONT SUSPENSION: CONNECTING THE TWO SIDES TOGETHER

1

2

3

4

5

AE

AK

AN

20Nm

LOCTI TE

LOCTI TE

REPEAT

ASSEMBLY GUIDE

20

PART

NUMBER

QTYUSED ON

1AA

BM12X100

2

Lower wishbone

rear

2AB

BM12X65

2

Lower wishbone

front

3AC

BM10X65

2

Upper wishbone

rear

4AD

BM10X60

2

Upper wishbone

front

5AE

BM8X40

4

Anti-roll bar

mounting brackets

6AF

NMPH14

1

Temporary use to

help lock upper

wishbone ball joint

7AG

NMYF12

2

Lower wishbone

rear

8AH

NMYF10

4

Upper wishbone

9AJ

WPCM12

18

Lower wishbone

10 AK

WPHM8

4

Anti-roll bar

mounting brackets

11 AL

WPH3/8

2

Brake pipe

Drawings are for illustrative purposes only and are not to scale.

A

SERIAL

NUMBER

44

Pack

PACK NUMBER

30F015B

FRONT SUSPENSION DeDION CARS (METRIC)

This pack may include extra fasteners to cover different options

ITEM

BASIC

DESCRIPTION

ILLUSTRATION

Bolt M12 x 100

Grade 10.9

Bolt M12 x 65

Grade 10.9

Bolt M10 x 65

Grade 10.9

Bolt M10 x 60

Grade 10.9

Bolt M8 x 40

Grade 10.9

Plain Nut M14

x 1.5 thread

Nyloc Nut M12

Plain Washer

⅜" x ¾"

Heavy duty

Page 1 of 2

Nyloc Nut M10

Plain Washer

M12

Chamfered

Plain Washer

M8

Heavy duty

94

PART

NUMBER

QTYUSED ON

12 AM

WSHM12

2

Lower wishbone

front

13 AN

WSHM8

6

Anti-roll bar

mounting brackets &

upper damper

mount

14 AP

WSS3/8

2 Brake pipe

15 AR

NFYH1/2

2Wing stay

16 AS

NFYF1/2

2

Front brake, upright
mounting (std track

ONLY)

Drawings are for illustrative purposes only and are not to scale.

A

SERIAL
NUMBER

44

Pack

PACK NUMBER

30F015B

FRONT SUSPENSION DeDION CARS (METRIC)

This pack may include extra fasteners to cover different options

ITEM

BASIC

DESCRIPTION

ILLUSTRATION

Spring Washer

M12

Nyloc Nut ½"

Full height

Page 2 of 2

Spring Washer

M8

Washer ⅜"
Shake-proof

Nyloc Nut ½"

Half height

PAR TS

FIXINGS

TOOLS

TIPS

Brake hose

1

FITTING THE BRAKE HOSES

13mm (x2)
⁄"

The hose will want to curve once fitted.
Make sure the curve points towards
the front of the car.

Khalfani D

Brake hoses come in
packs of 3: 2 front, 1 back.

Anthony L

x2

x2

ASSEMBLY GUIDE

21

FITTING THE BRAKE HOSES

1

ASSEMBLY GUIDE

22

PAR TS

FIXINGS

TOOLS

TIPS

10mm

Horn kit (x2)

Bolt for spacer

Spacer (miscellaneous box)

13mm

6mm

1

3

2

LET'S MAKE SOME NOISE

Miscellaneous box

ASSEMBLY GUIDE

23

1 x 8mm

LET'S MAKE SOME NOISE

270/310/360 420

1

3

1

1 x 8mm

2

ASSEMBLY GUIDE

24

PAR TS

FIXINGS

TOOLS

TIPS

PART

NUMBER

QTYUSED ON

1DA

BM8X50 1

Expansion tank

bracket to chassis

2DB

SF1/4X3/4

1

Expansion tank to

bracket

3DC

SM6X20

4 SV radiator bracket

4DD

30Z1072A

4Fan brackets to fan

5DE

SPHM6X16

4

Fan to radiator

cowling - SV only

6DF

NMYF6

8

x4 Fan to radiator
x4 SV radiator
bracket

7DG

NMPF8

8

Radiator bobbin

8DH

NFYF1/4

1

Expansion tank

bracket

9DI

WPH1/4

13

8 x SV rad bracket
4 x Fan fixings
1 x Expansion tank
braket

10 DJ

WPH5/16

4

Radiator bobbin

back

11 DK

WPH5/17X7/8

4

Radiator bobbin

front

Drawings are for illustrative purposes only and are not to scale.Page 1 of 2

Bolt M8 X 50

Grade 8.8

Plain Washer

5/16

"

Heavy duty

Nyloc Nut 1/4"

Plain Washer

1/4"

Heavy duty

Plain Washer

5/16" X 7/8"
Heavy duty

Setscrew M6X16

Panhead Pozi

Nyloc Nut M6

Plain Nut M8

Setscrew M8X20

Grade 8.8

COOLING SIGMA

This pack may include extra fasteners to cover different options

ITEM

BASIC

DESCRIPTION

ILLUSTRATION

Bolt M6 X 16 with

square section

Setscrew 1/4"

X 3/4"

D

SERIAL
NUMBER

44

Pack

PACK NUMBER

30C047B

PART

NUMBER

QTYUSED ON

12 DL

WPH1/4X7/8

1

Expansion tank

bracket

13 DM

WSH5/17

9

8 x Radiator bobbin
1 x Expansion tank

14 DN

SGT25-40

6

2 x U shape hose to
water rail
2 x Top radiator hose
2 x Bottom radiator hose

15 DO

SGT23-35

2

1 x Engine outlet to
big T piece
1 x Engine outlet to
heater inlet

16 DP

SGT16-25

18

6 x Heater inlet/outlet
3 x Big T-piece
1 x Expansion tank
2 x Modine
4 x Dry Sump
2 x Submarine

17 DQ

SGT8-16

6

Expansion tank

small T-piece

18 DR

1610-01015

12

Cowling flap

Drawings are for illustrative purposes only and are not to scale.Page 1 of 2

Plain Washer

1/4

" X 7/8"

Heavy duty

Page 1 of 2

Rivet - Black

5/32" X 0.47"

Hose Clip

17 - 25mm

Hose Clip

8 - 16mm

Hose Clip

30 - 40mm

Hose Clip

23 - 35mm

COOLING SIGMA

This pack may include extra fasteners to cover different options

ITEM

BASIC

DESCRIPTION

ILLUSTRATION

Spring Washer

5/16"

Heavy duty

D

SERIAL
NUMBER

44

Pack

PACK NUMBER

30C047B

x4

x4

x8

x4

x4

x4

13mm
10mm

Radiator

Fan

Fan brackets (x2)

Radiator bobbins (x4)

13mm

x8

1

3

2

4

FITTING THE RADIATOR ON THE STANDARD CHASSIS

The fan may have four
plastic legs or feet
that slot into it.

Vincent M

The fan may have a
'flat' section on the
rim. This should be
at the top.

James S

Be careful to tighten
the fan on gently
and just with a nip.

Lloyd D

ASSEMBLY GUIDE

25

FITTING THE RADIATOR ON THE STANDARD CHASSIS

DD

42

1

DJ

3

DF

DI

DG

DM

DK

270/310/360

STANDARD CHASSIS

26

PART

NUMBER

QTYUSED ON

1DA

BM8X50 1

Expansion tank

bracket to chassis

2DB

SF1/4X3/4

1

Expansion tank to

bracket

3DC

SM6X20

4 SV radiator bracket

4DD

30Z1072A

4Fan brackets to fan

5DE

SPHM6X16

4

Fan to radiator

cowling - SV only

6DF

NMYF6

8

x4 Fan to radiator
x4 SV radiator
bracket

7DG

NMPF8

8

Radiator bobbin

8DH

NFYF1/4

1

Expansion tank

bracket

9DI

WPH1/4

13

8 x SV rad bracket
4 x Fan fixings
1 x Expansion tank
braket

10 DJ

WPH5/16

4

Radiator bobbin

back

11 DK

WPH5/17X7/8

4

Radiator bobbin

front

Drawings are for illustrative purposes only and are not to scale.Page 1 of 2

Bolt M8 X 50

Grade 8.8

Plain Washer

5/16

"

Heavy duty

Nyloc Nut 1/4"

Plain Washer

1/4"

Heavy duty

Plain Washer

5/16" X 7/8"
Heavy duty

Setscrew M6X16

Panhead Pozi

Nyloc Nut M6

Plain Nut M8

Setscrew M8X20

Grade 8.8

COOLING SIGMA

This pack may include extra fasteners to cover different options

ITEM

BASIC

DESCRIPTION

ILLUSTRATION

Bolt M6 X 16 with

square section

Setscrew 1/4"

X 3/4"

D

SERIAL
NUMBER

44

Pack

PACK NUMBER

30C047B

PART

NUMBER

QTYUSED ON

12 DL

WPH1/4X7/8

1

Expansion tank

bracket

13 DM

WSH5/17

9

8 x Radiator bobbin
1 x Expansion tank

14 DN

SGT25-40

6

2 x U shape hose to
water rail
2 x Top radiator hose
2 x Bottom radiator hose

15 DO

SGT23-35

2

1 x Engine outlet to
big T piece
1 x Engine outlet to
heater inlet

16 DP

SGT16-25

18

6 x Heater inlet/outlet
3 x Big T-piece
1 x Expansion tank
2 x Modine
4 x Dry Sump
2 x Submarine

17 DQ

SGT8-16

6

Expansion tank

small T-piece

18 DR

1610-01015

12

Cowling flap

Drawings are for illustrative purposes only and are not to scale.Page 1 of 2

Plain Washer

1/4

" X 7/8"

Heavy duty

Page 1 of 2

Rivet - Black

5/32" X 0.47"

Hose Clip

17 - 25mm

Hose Clip

8 - 16mm

Hose Clip

30 - 40mm

Hose Clip

23 - 35mm

COOLING SIGMA

This pack may include extra fasteners to cover different options

ITEM

BASIC

DESCRIPTION

ILLUSTRATION

Spring Washer

5/16"

Heavy duty

D

SERIAL
NUMBER

44

Pack

PACK NUMBER

30C047B

ASSEMBLY GUIDE  

PAR TS

FIXINGS

TOOLS

TIPS

x4

x4

x8

Brackets

1

3

2

5

4

THE RADIATOR MOUNTING FOR THE WIDE-BODIED CHASSIS IS SLIGHTLY DIFFERENT

Radiator

Fan

Fan brackets (x2)

Radiator bobbins (x4)

13mm
10mm

10mm
13mm

27

ASSEMBLY GUIDE

THE RADIATOR MOUNTING FOR THE WIDE-BODIED CHASSIS IS SLIGHTLY DIFFERENT

270/310/360

WIDE CHASSIS

5

1

DG

DM

DK

DD

4

2

DF

DI

3

DJ

DC

DI

DF

PART

NUMBER

QTYUSED ON

1DA

BM8X50 1

Expansion tank

bracket to chassis

2DB

SF1/4X3/4

1

Expansion tank to

bracket

3DC

SM6X20

4 SV radiator bracket

4DD

30Z1072A

4Fan brackets to fan

5DE

SPHM6X16

4

Fan to radiator

cowling - SV only

6DF

NMYF6

8

x4 Fan to radiator
x4 SV radiator
bracket

7DG

NMPF8

8

Radiator bobbin

8DH

NFYF1/4

1

Expansion tank

bracket

9DI

WPH1/4

13

8 x SV rad bracket
4 x Fan fixings
1 x Expansion tank
braket

10 DJ

WPH5/16

4

Radiator bobbin

back

11 DK

WPH5/17X7/8

4

Radiator bobbin

front

Drawings are for illustrative purposes only and are not to scale.Page 1 of 2

Bolt M8 X 50

Grade 8.8

Plain Washer

5/16

"

Heavy duty

Nyloc Nut 1/4"

Plain Washer

1/4"

Heavy duty

Plain Washer

5/16" X 7/8"
Heavy duty

Setscrew M6X16

Panhead Pozi

Nyloc Nut M6

Plain Nut M8

Setscrew M8X20

Grade 8.8

COOLING SIGMA

This pack may include extra fasteners to cover different options

ITEM

BASIC

DESCRIPTION

ILLUSTRATION

Bolt M6 X 16 with

square section

Setscrew 1/4"

X 3/4"

D

SERIAL
NUMBER

44

Pack

PACK NUMBER

30C047B

PART

NUMBER

QTYUSED ON

12 DL

WPH1/4X7/8

1

Expansion tank

bracket

13 DM

WSH5/17

9

8 x Radiator bobbin
1 x Expansion tank

14 DN

SGT25-40

6

2 x U shape hose to
water rail
2 x Top radiator hose
2 x Bottom radiator hose

15 DO

SGT23-35

2

1 x Engine outlet to
big T piece
1 x Engine outlet to
heater inlet

16 DP

SGT16-25

18

6 x Heater inlet/outlet
3 x Big T-piece
1 x Expansion tank
2 x Modine
4 x Dry Sump
2 x Submarine

17 DQ

SGT8-16

6

Expansion tank

small T-piece

18 DR

1610-01015

12

Cowling flap

Drawings are for illustrative purposes only and are not to scale.Page 1 of 2

Plain Washer

1/4

" X 7/8"

Heavy duty

Page 1 of 2

Rivet - Black

5/32" X 0.47"

Hose Clip

17 - 25mm

Hose Clip

8 - 16mm

Hose Clip

30 - 40mm

Hose Clip

23 - 35mm

COOLING SIGMA

This pack may include extra fasteners to cover different options

ITEM

BASIC

DESCRIPTION

ILLUSTRATION

Spring Washer

5/16"

Heavy duty

D

SERIAL
NUMBER

44

Pack

PACK NUMBER

30C047B

28

Lower hose 110mm (cut from long length)

4

PAR TS

FIXINGS

TOOLS

TIPS

x2

10mm
7mm

19mm

Heater

Heater cable

Valve

Upper hose 120mm (cut from long length)

x4

1

3

2

5

THINGS ARE HEATING UP

Remember to remove bungs
from heater.

Jamie A

It’s worth re‑tightening after a couple
of uses of car.

John S

Use 7mm for jubilee clips but not
too tight!

Chris B

ASSEMBLY GUIDE

29

THINGS ARE HEATING UP

3

1

DP

44

DE

2

5

ASSEMBLY GUIDE

ASSEMBLY GUIDE

30

KEEPING THE AIR CLEAN

PAR TS

FIXINGS

TOOLS

TIPS

Air box

Rubber mounts

Air filter

Trim

8mm

1

3

2

4

Bobbins are screwed into
the car by hand.

John K

Unmarked bag:

• M5 (x6)

• Spring (x6)

• Flats (x6)

• Nylocs M5 (x3)

• ⁄ washers (x3)

• ¾ washers (x3)

• Screws (x20)

ASSEMBLY GUIDE

31

KEEPING THE AIR CLEAN

2

1

4

3

ASSEMBLY GUIDE

32

GETTING READY TO PUT THE ENGINE IN

PAR TS

FIXINGS

TOOLS

TIPS

6mm
8mm

Engine mount

Bellhousing

Starter motor

1

3

2

You will need to remove the engine
mounts and starter motor but
don’t throw away the bolts – keep
them safe!

Chris N

ASSEMBLY GUIDE

33

GETTING READY TO PUT THE ENGINE IN

3

2

1

ASSEMBLY GUIDE

34

ATTACH THE GEARBOX TO THE BELLHOUSING

PAR TS

FIXINGS

TOOLS

TIPS

PART

NUMBER

QTYUSED ON

1EA

3EZ1137A 2

AV Mount

2EB

30Z1076A

4 AV Mount

3EC

3EZ1142A

4Gearbox

4ED

BMCH10X60

4

1 x Bellhousing
3 x Starter Motor

5EE

BMCH10X55

3Bellhousing

6EF

BMCH10X40

3Bellhousing

7EG

BMCH10X35

2

Engine Mount

RHS Top

8EH

BMCH8X25

2

Engine Mount

1 x LHS Top

1 x LHS Bottom

9EI

BMCH8X30

1

Engine Mount

LHS Bottom

10 EJ

BMCH8X35

2

Engine Mount

RHS Bottom

11 EK

BMCH6X25

3

ClutchSlave

Cylinder

Drawings are for illustrative purposes only and are not to scale.

E

SERIAL
NUMBER

66

Pack

PACK NUMBER

3EZ1105F

SIGMA GEARBOX 5 SPEED

This pack may include extra fasteners to cover different options

ITEM

BASIC

DESCRIPTION

ILLUSTRATION

Bolt M14 X 40

Grade 12.9

Caphead Bolt

M8 X 40

Grade 12.9

Caphead Bolt

M12 X 50
Grade 12.9

Coarse Thread

Caphead Bolt

M10 X 60
Grade 12.9

Caphead Bolt

M10 X 55
Grade 12.9

Caphead Bolt

M10 X 40
Grade 12.9

Caphead Bolt

M10 X 35
Grade 12.9

Caphead Bolt

M6 X 25

Grade 12.9

Page 1 of 2

Caphead Bolt M8

X 25 Grade

12.9

Caphead Bolt M8

X 30 Grade

12.9

Caphead Bolt M8

X 35 Grade

12.9

PART

NUMBER

QTYUSED ON

12 EL

3GZ1163A 3

Gear Lever

13 EM

WPH14

2 AV Mount

14 EN

30Z2031A

4Gearbox

15 EO

WPHM6

3Gear Lever

16 EP

WPH5/16

8 AV Mount

17 EQ

WSHM12

4Gearbox

18 ER

WSHM10

10

x 7 Bellhousing x
3 Engine Mount

19 ES

WSHM10

3

Starter Motor

20 ET

WSHM8

5

Engine Mount

21 EU

WSHM6

3

Clutch Slave

Cylinder

22 EV

NMYF8

4

AV Mount

23 EW

30Z2030A

2

AV Mount

Drawings are for illustrative purposes only and are not to scale.

E

SERIAL
NUMBER

66

Pack

PACK NUMBER

3EZ1105F

SIGMA GEARBOX 5 SPEED

This pack may include extra fasteners to cover different options

ITEM

BASIC

DESCRIPTION

ILLUSTRATION

Buttonhead Bolt

M6 X 10

Grade 10.9

Internal Hex

Plain Washer

M12

Spring Washer

M10

Wire Spring

Washer M10

Plain Washer

M14

Plain Washer M6

Plain Washer

5/16"

Spring Washer

M14

Page 2 of 2

Spring Washer

M12

Spring Washer

M8

Spring Washer

M6

Myloc Nut

M8

x4

10mm

Gearbox

Bell housing

x4

x4

1

2

ASSEMBLY GUIDE

35

ATTACH THE GEARBOX TO THE BELLHOUSING

EC

EN

EQ

2

1

68Nm

36

PART

NUMBER

QTYUSED ON

1EA

3EZ1137A 2

AV Mount

2EB

30Z1076A

4 AV Mount

3EC

3EZ1142A

4Gearbox

4ED

BMCH10X60

4

1 x Bellhousing
3 x Starter Motor

5EE

BMCH10X55

3Bellhousing

6EF

BMCH10X40

3Bellhousing

7EG

BMCH10X35

2

Engine Mount

RHS Top

8EH

BMCH8X25

2

Engine Mount

1 x LHS Top

1 x LHS Bottom

9EI

BMCH8X30

1

Engine Mount

LHS Bottom

10 EJ

BMCH8X35

2

Engine Mount

RHS Bottom

11 EK

BMCH6X25

3

ClutchSlave

Cylinder

Drawings are for illustrative purposes only and are not to scale.

E

SERIAL
NUMBER

66

Pack

PACK NUMBER

3EZ1105F

SIGMA GEARBOX 5 SPEED

This pack may include extra fasteners to cover different options

ITEM

BASIC

DESCRIPTION

ILLUSTRATION

Bolt M14 X 40

Grade 12.9

Caphead Bolt

M8 X 40

Grade 12.9

Caphead Bolt

M12 X 50
Grade 12.9

Coarse Thread

Caphead Bolt

M10 X 60
Grade 12.9

Caphead Bolt

M10 X 55
Grade 12.9

Caphead Bolt

M10 X 40
Grade 12.9

Caphead Bolt

M10 X 35
Grade 12.9

Caphead Bolt

M6 X 25

Grade 12.9

Page 1 of 2

Caphead Bolt M8

X 25 Grade

12.9

Caphead Bolt M8

X 30 Grade

12.9

Caphead Bolt M8

X 35 Grade

12.9

PART

NUMBER

QTYUSED ON

12 EL

3GZ1163A 3

Gear Lever

13 EM

WPH14

2 AV Mount

14 EN

30Z2031A

4Gearbox

15 EO

WPHM6

3Gear Lever

16 EP

WPH5/16

8 AV Mount

17 EQ

WSHM12

4Gearbox

18 ER

WSHM10

10

x 7 Bellhousing x
3 Engine Mount

19 ES

WSHM10

3

Starter Motor

20 ET

WSHM8

5

Engine Mount

21 EU

WSHM6

3

Clutch Slave

Cylinder

22 EV

NMYF8

4

AV Mount

23 EW

30Z2030A

2

AV Mount

Drawings are for illustrative purposes only and are not to scale.

E

SERIAL
NUMBER

66

Pack

PACK NUMBER

3EZ1105F

SIGMA GEARBOX 5 SPEED

This pack may include extra fasteners to cover different options

ITEM

BASIC

DESCRIPTION

ILLUSTRATION

Buttonhead Bolt

M6 X 10

Grade 10.9

Internal Hex

Plain Washer

M12

Spring Washer

M10

Wire Spring

Washer M10

Plain Washer

M14

Plain Washer M6

Plain Washer

5/16"

Spring Washer

M14

Page 2 of 2

Spring Washer

M12

Spring Washer

M8

Spring Washer

M6

Myloc Nut

M8

ASSEMBLY GUIDE

AND THEN THE GEARBOX TO THE ENGINE

PAR TS

FIXINGS

TOOLS

TIPS

x1

x3

x3

8mm

x7

ASSEMBLY GUIDE

37

AND THEN THE GEARBOX TO THE ENGINE

ED

ES

ED

EE

EF

ER

54Nm

54Nm

38

AT LAST, THE ENGINE IS GOING IN

PAR TS

FIXINGS

TOOLS

TIPS

Engine mounts

Engine rubbers

6mm
8mm
⅜”

13mm

13mm
15mm

1

2

Protect the chassis
with soft stuff such
as cardboard or folded
towels/blankets. Just
not your fingers.

Tiago O

It's 54Nm for the
bolts tightened with
the 8mm hex socket
& 30Nm for the 6mm
hex socket.

Grant P

It will fit – keep at it!

Rich T

Removing the
tensioner will make
things much easier.

James A

When fitting the engine rubbers and mounts,
do them as loosely as possible so you can
wiggle things to get bolts in. Tighten it all up
gradually once all the bolts are in.

Jamie A

+

Tensioner

3

ASSEMBLY GUIDE  

39

AT LAST, THE ENGINE IS GOING IN

1

2

3

ASSEMBLY GUIDE  

ASSEMBLY GUIDE

40

AND THE GEARBOX IS FIXED IN PLACE

PAR TS

FIXINGS

TOOLS

TIPS

Once the engine is in, the
wiring can be connected to the
car's loom. It should be self
explanatory.

Chris B

6mm 6mm

13mm
22mm

13mm
19mm

13mm

5 Speed 6 Speed

ASSEMBLY GUIDE

41

AND THE GEARBOX IS FIXED IN PLACE

6 SPEED5 SPEED

ASSEMBLY GUIDE

42

PAR TS

FIXINGS

TOOLS

TIPS

Engine oil SW-30

Gear oil GL4

FILLING THE ENGINE AND GEARBOX WITH OIL

ASSEMBLY GUIDE

43

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

ASSEMBLY GUIDE

44

PART

NUMBER

QTYUSED ON

1DA

BM8X50 1

Expansion tank

bracket to chassis

2DB

SF1/4X3/4

1

Expansion tank to

bracket

3DC

SM6X20

4 SV radiator bracket

4DD

30Z1072A

4Fan brackets to fan

5DE

SPHM6X16

4

Fan to radiator

cowling - SV only

6DF

NMYF6

8

x4 Fan to radiator
x4 SV radiator
bracket

7DG

NMPF8

8

Radiator bobbin

8DH

NFYF1/4

1

Expansion tank

bracket

9DI

WPH1/4

13

8 x SV rad bracket
4 x Fan fixings
1 x Expansion tank
braket

10 DJ

WPH5/16

4

Radiator bobbin

back

11 DK

WPH5/17X7/8

4

Radiator bobbin

front

Drawings are for illustrative purposes only and are not to scale.Page 1 of 2

Bolt M8 X 50

Grade 8.8

Plain Washer

5/16

"

Heavy duty

Nyloc Nut 1/4"

Plain Washer

1/4"

Heavy duty

Plain Washer

5/16" X 7/8"
Heavy duty

Setscrew M6X16

Panhead Pozi

Nyloc Nut M6

Plain Nut M8

Setscrew M8X20

Grade 8.8

COOLING SIGMA

This pack may include extra fasteners to cover different options

ITEM

BASIC

DESCRIPTION

ILLUSTRATION

Bolt M6 X 16 with

square section

Setscrew 1/4"

X 3/4"

D

SERIAL
NUMBER

44

Pack

PACK NUMBER

30C047B

PART

NUMBER

QTYUSED ON

12 DL

WPH1/4X7/8

1

Expansion tank

bracket

13 DM

WSH5/17

9

8 x Radiator bobbin
1 x Expansion tank

14 DN

SGT25-40

6

2 x U shape hose to
water rail
2 x Top radiator hose
2 x Bottom radiator hose

15 DO

SGT23-35

2

1 x Engine outlet to
big T piece
1 x Engine outlet to
heater inlet

16 DP

SGT16-25

18

6 x Heater inlet/outlet
3 x Big T-piece
1 x Expansion tank
2 x Modine
4 x Dry Sump
2 x Submarine

17 DQ

SGT8-16

6

Expansion tank

small T-piece

18 DR

1610-01015

12

Cowling flap

Drawings are for illustrative purposes only and are not to scale.Page 1 of 2

Plain Washer

1/4

" X 7/8"

Heavy duty

Page 1 of 2

Rivet - Black

5/32" X 0.47"

Hose Clip

17 - 25mm

Hose Clip

8 - 16mm

Hose Clip

30 - 40mm

Hose Clip

23 - 35mm

COOLING SIGMA

This pack may include extra fasteners to cover different options

ITEM

BASIC

DESCRIPTION

ILLUSTRATION

Spring Washer

5/16"

Heavy duty

D

SERIAL
NUMBER

44

Pack

PACK NUMBER

30C047B

START PLUMBING

PAR TS

FIXINGS

TOOLS

TIPS

Lower radiator hose

7mm

x2

1

Reminder for later on: nip up the
clips once the car has been run.

Grant P

Fit the hose to the larger
outlet on the engine.

Mick F

ASSEMBLY GUIDE

45

START PLUMBING

DN

1

ASSEMBLY GUIDE

46

PART

NUMBER

QTYUSED ON

1DA

BM8X50 1

Expansion tank

bracket to chassis

2DB

SF1/4X3/4

1

Expansion tank to

bracket

3DC

SM6X20

4 SV radiator bracket

4DD

30Z1072A

4Fan brackets to fan

5DE

SPHM6X16

4

Fan to radiator

cowling - SV only

6DF

NMYF6

8

x4 Fan to radiator
x4 SV radiator
bracket

7DG

NMPF8

8

Radiator bobbin

8DH

NFYF1/4

1

Expansion tank

bracket

9DI

WPH1/4

13

8 x SV rad bracket
4 x Fan fixings
1 x Expansion tank
braket

10 DJ

WPH5/16

4

Radiator bobbin

back

11 DK

WPH5/17X7/8

4

Radiator bobbin

front

Drawings are for illustrative purposes only and are not to scale.Page 1 of 2

Bolt M8 X 50

Grade 8.8

Plain Washer

5/16

"

Heavy duty

Nyloc Nut 1/4"

Plain Washer

1/4"

Heavy duty

Plain Washer

5/16" X 7/8"
Heavy duty

Setscrew M6X16

Panhead Pozi

Nyloc Nut M6

Plain Nut M8

Setscrew M8X20

Grade 8.8

COOLING SIGMA

This pack may include extra fasteners to cover different options

ITEM

BASIC

DESCRIPTION

ILLUSTRATION

Bolt M6 X 16 with

square section

Setscrew 1/4"

X 3/4"

D

SERIAL
NUMBER

44

Pack

PACK NUMBER

30C047B

PART

NUMBER

QTYUSED ON

12 DL

WPH1/4X7/8

1

Expansion tank

bracket

13 DM

WSH5/17

9

8 x Radiator bobbin
1 x Expansion tank

14 DN

SGT25-40

6

2 x U shape hose to
water rail
2 x Top radiator hose
2 x Bottom radiator hose

15 DO

SGT23-35

2

1 x Engine outlet to
big T piece
1 x Engine outlet to
heater inlet

16 DP

SGT16-25

18

6 x Heater inlet/outlet
3 x Big T-piece
1 x Expansion tank
2 x Modine
4 x Dry Sump
2 x Submarine

17 DQ

SGT8-16

6

Expansion tank

small T-piece

18 DR

1610-01015

12

Cowling flap

Drawings are for illustrative purposes only and are not to scale.Page 1 of 2

Plain Washer

1/4

" X 7/8"

Heavy duty

Page 1 of 2

Rivet - Black

5/32" X 0.47"

Hose Clip

17 - 25mm

Hose Clip

8 - 16mm

Hose Clip

30 - 40mm

Hose Clip

23 - 35mm

COOLING SIGMA

This pack may include extra fasteners to cover different options

ITEM

BASIC

DESCRIPTION

ILLUSTRATION

Spring Washer

5/16"

Heavy duty

D

SERIAL
NUMBER

44

Pack

PACK NUMBER

30C047B

PAR TS

FIXINGS

TOOLS

TIPS

Upper radiator hose

1

x2

7mm

AND KEEP PLUMBING

Reminder for later on: nip up the
clips once the car has been run.

James A

ASSEMBLY GUIDE

47

AND KEEP PLUMBING

1

DN

ASSEMBLY GUIDE

48

Now is a good time to take some photos

ASSEMBLY GUIDE

49

Have you applied for your IVA yet?

ASSEMBLY GUIDE

50

A BIT OF SUB-ASSEMBLY – SOME HOSES NEED MODIFYING

PAR TS TOOLS

TIPS

Silicone hoses

1

Don't throw away the long
piece of hose after cutting.

Rich T

FIXINGS

ASSEMBLY GUIDE

51



A BIT OF SUB-ASSEMBLY – SOME HOSES NEED MODIFYING

1

1

ASSEMBLY GUIDE

52

PART

NUMBER

QTYUSED ON

1DA

BM8X50 1

Expansion tank

bracket to chassis

2DB

SF1/4X3/4

1

Expansion tank to

bracket

3DC

SM6X20

4 SV radiator bracket

4DD

30Z1072A

4Fan brackets to fan

5DE

SPHM6X16

4

Fan to radiator

cowling - SV only

6DF

NMYF6

8

x4 Fan to radiator
x4 SV radiator
bracket

7DG

NMPF8

8

Radiator bobbin

8DH

NFYF1/4

1

Expansion tank

bracket

9DI

WPH1/4

13

8 x SV rad bracket
4 x Fan fixings
1 x Expansion tank
braket

10 DJ

WPH5/16

4

Radiator bobbin

back

11 DK

WPH5/17X7/8

4

Radiator bobbin

front

Drawings are for illustrative purposes only and are not to scale.Page 1 of 2

Bolt M8 X 50

Grade 8.8

Plain Washer

5/16

"

Heavy duty

Nyloc Nut 1/4"

Plain Washer

1/4"

Heavy duty

Plain Washer

5/16" X 7/8"
Heavy duty

Setscrew M6X16

Panhead Pozi

Nyloc Nut M6

Plain Nut M8

Setscrew M8X20

Grade 8.8

COOLING SIGMA

This pack may include extra fasteners to cover different options

ITEM

BASIC

DESCRIPTION

ILLUSTRATION

Bolt M6 X 16 with

square section

Setscrew 1/4"

X 3/4"

D

SERIAL
NUMBER

44

Pack

PACK NUMBER

30C047B

PART

NUMBER

QTYUSED ON

12 DL

WPH1/4X7/8

1

Expansion tank

bracket

13 DM

WSH5/17

9

8 x Radiator bobbin
1 x Expansion tank

14 DN

SGT25-40

6

2 x U shape hose to
water rail
2 x Top radiator hose
2 x Bottom radiator hose

15 DO

SGT23-35

2

1 x Engine outlet to
big T piece
1 x Engine outlet to
heater inlet

16 DP

SGT16-25

18

6 x Heater inlet/outlet
3 x Big T-piece
1 x Expansion tank
2 x Modine
4 x Dry Sump
2 x Submarine

17 DQ

SGT8-16

6

Expansion tank

small T-piece

18 DR

1610-01015

12

Cowling flap

Drawings are for illustrative purposes only and are not to scale.Page 1 of 2

Plain Washer

1/4

" X 7/8"

Heavy duty

Page 1 of 2

Rivet - Black

5/32" X 0.47"

Hose Clip

17 - 25mm

Hose Clip

8 - 16mm

Hose Clip

30 - 40mm

Hose Clip

23 - 35mm

COOLING SIGMA

This pack may include extra fasteners to cover different options

ITEM

BASIC

DESCRIPTION

ILLUSTRATION

Spring Washer

5/16"

Heavy duty

D

SERIAL
NUMBER

44

Pack

PACK NUMBER

30C047B

SUB-ASSEMBLY – TEMPERATURE SENSOR

PAR TS TOOLS

TIPS

Temperature sender

Cooling submarine

Earth tag

7mm

13mm
10mm

1

3

2

Use a drop of Locktite on the sender.

Tiago O

Be careful not to over‑tighten
the sender.

Jamie A

LOCTITE

LOCTITE

FIXINGS

x2

ASSEMBLY GUIDE

53

SUB-ASSEMBLY – TEMPERATURE SENSOR

1

3

2

DP

ASSEMBLY GUIDE

54

PART

NUMBER

QTYUSED ON

1DA

BM8X50 1

Expansion tank

bracket to chassis

2DB

SF1/4X3/4

1

Expansion tank to

bracket

3DC

SM6X20

4 SV radiator bracket

4DD

30Z1072A

4Fan brackets to fan

5DE

SPHM6X16

4

Fan to radiator

cowling - SV only

6DF

NMYF6

8

x4 Fan to radiator
x4 SV radiator
bracket

7DG

NMPF8

8

Radiator bobbin

8DH

NFYF1/4

1

Expansion tank

bracket

9DI

WPH1/4

13

8 x SV rad bracket
4 x Fan fixings
1 x Expansion tank
braket

10 DJ

WPH5/16

4

Radiator bobbin

back

11 DK

WPH5/17X7/8

4

Radiator bobbin

front

Drawings are for illustrative purposes only and are not to scale.Page 1 of 2

Bolt M8 X 50

Grade 8.8

Plain Washer

5/16

"

Heavy duty

Nyloc Nut 1/4"

Plain Washer

1/4"

Heavy duty

Plain Washer

5/16" X 7/8"
Heavy duty

Setscrew M6X16

Panhead Pozi

Nyloc Nut M6

Plain Nut M8

Setscrew M8X20

Grade 8.8

COOLING SIGMA

This pack may include extra fasteners to cover different options

ITEM

BASIC

DESCRIPTION

ILLUSTRATION

Bolt M6 X 16 with

square section

Setscrew 1/4"

X 3/4"

D

SERIAL
NUMBER

44

Pack

PACK NUMBER

30C047B

PART

NUMBER

QTYUSED ON

12 DL

WPH1/4X7/8

1

Expansion tank

bracket

13 DM

WSH5/17

9

8 x Radiator bobbin
1 x Expansion tank

14 DN

SGT25-40

6

2 x U shape hose to
water rail
2 x Top radiator hose
2 x Bottom radiator hose

15 DO

SGT23-35

2

1 x Engine outlet to
big T piece
1 x Engine outlet to
heater inlet

16 DP

SGT16-25

18

6 x Heater inlet/outlet
3 x Big T-piece
1 x Expansion tank
2 x Modine
4 x Dry Sump
2 x Submarine

17 DQ

SGT8-16

6

Expansion tank

small T-piece

18 DR

1610-01015

12

Cowling flap

Drawings are for illustrative purposes only and are not to scale.Page 1 of 2

Plain Washer

1/4

" X 7/8"

Heavy duty

Page 1 of 2

Rivet - Black

5/32" X 0.47"

Hose Clip

17 - 25mm

Hose Clip

8 - 16mm

Hose Clip

30 - 40mm

Hose Clip

23 - 35mm

COOLING SIGMA

This pack may include extra fasteners to cover different options

ITEM

BASIC

DESCRIPTION

ILLUSTRATION

Spring Washer

5/16"

Heavy duty

D

SERIAL
NUMBER

44

Pack

PACK NUMBER

30C047B

BACK TO THE PLUMBING

PAR TS

FIXINGS

TOOLS

TIPS

Submarine assembly

7mm

x1

1

ASSEMBLY GUIDE

55

BACK TO THE PLUMBING

1

ASSEMBLY GUIDE

56

PART

NUMBER

QTYUSED ON

1DA

BM8X50 1

Expansion tank

bracket to chassis

2DB

SF1/4X3/4

1

Expansion tank to

bracket

3DC

SM6X20

4 SV radiator bracket

4DD

30Z1072A

4Fan brackets to fan

5DE

SPHM6X16

4

Fan to radiator

cowling - SV only

6DF

NMYF6

8

x4 Fan to radiator
x4 SV radiator
bracket

7DG

NMPF8

8

Radiator bobbin

8DH

NFYF1/4

1

Expansion tank

bracket

9DI

WPH1/4

13

8 x SV rad bracket
4 x Fan fixings
1 x Expansion tank
braket

10 DJ

WPH5/16

4

Radiator bobbin

back

11 DK

WPH5/17X7/8

4

Radiator bobbin

front

Drawings are for illustrative purposes only and are not to scale.Page 1 of 2

Bolt M8 X 50

Grade 8.8

Plain Washer

5/16

"

Heavy duty

Nyloc Nut 1/4"

Plain Washer

1/4"

Heavy duty

Plain Washer

5/16" X 7/8"
Heavy duty

Setscrew M6X16

Panhead Pozi

Nyloc Nut M6

Plain Nut M8

Setscrew M8X20

Grade 8.8

COOLING SIGMA

This pack may include extra fasteners to cover different options

ITEM

BASIC

DESCRIPTION

ILLUSTRATION

Bolt M6 X 16 with

square section

Setscrew 1/4"

X 3/4"

D

SERIAL
NUMBER

44

Pack

PACK NUMBER

30C047B

PART

NUMBER

QTYUSED ON

12 DL

WPH1/4X7/8

1

Expansion tank

bracket

13 DM

WSH5/17

9

8 x Radiator bobbin
1 x Expansion tank

14 DN

SGT25-40

6

2 x U shape hose to
water rail
2 x Top radiator hose
2 x Bottom radiator hose

15 DO

SGT23-35

2

1 x Engine outlet to
big T piece
1 x Engine outlet to
heater inlet

16 DP

SGT16-25

18

6 x Heater inlet/outlet
3 x Big T-piece
1 x Expansion tank
2 x Modine
4 x Dry Sump
2 x Submarine

17 DQ

SGT8-16

6

Expansion tank

small T-piece

18 DR

1610-01015

12

Cowling flap

Drawings are for illustrative purposes only and are not to scale.Page 1 of 2

Plain Washer

1/4

" X 7/8"

Heavy duty

Page 1 of 2

Rivet - Black

5/32" X 0.47"

Hose Clip

17 - 25mm

Hose Clip

8 - 16mm

Hose Clip

30 - 40mm

Hose Clip

23 - 35mm

COOLING SIGMA

This pack may include extra fasteners to cover different options

ITEM

BASIC

DESCRIPTION

ILLUSTRATION

Spring Washer

5/16"

Heavy duty

D

SERIAL
NUMBER

44

Pack

PACK NUMBER

30C047B

MORE PLUMBING

PAR TS

FIXINGS

TOOLS

TIPS

x1

ASSEMBLY GUIDE

57

MORE PLUMBING

DP

ASSEMBLY GUIDE

58

PART

NUMBER

QTYUSED ON

1DA

BM8X50 1

Expansion tank

bracket to chassis

2DB

SF1/4X3/4

1

Expansion tank to

bracket

3DC

SM6X20

4 SV radiator bracket

4DD

30Z1072A

4Fan brackets to fan

5DE

SPHM6X16

4

Fan to radiator

cowling - SV only

6DF

NMYF6

8

x4 Fan to radiator
x4 SV radiator
bracket

7DG

NMPF8

8

Radiator bobbin

8DH

NFYF1/4

1

Expansion tank

bracket

9DI

WPH1/4

13

8 x SV rad bracket
4 x Fan fixings
1 x Expansion tank
braket

10 DJ

WPH5/16

4

Radiator bobbin

back

11 DK

WPH5/17X7/8

4

Radiator bobbin

front

Drawings are for illustrative purposes only and are not to scale.Page 1 of 2

Bolt M8 X 50

Grade 8.8

Plain Washer

5/16

"

Heavy duty

Nyloc Nut 1/4"

Plain Washer

1/4"

Heavy duty

Plain Washer

5/16" X 7/8"
Heavy duty

Setscrew M6X16

Panhead Pozi

Nyloc Nut M6

Plain Nut M8

Setscrew M8X20

Grade 8.8

COOLING SIGMA

This pack may include extra fasteners to cover different options

ITEM

BASIC

DESCRIPTION

ILLUSTRATION

Bolt M6 X 16 with

square section

Setscrew 1/4"

X 3/4"

D

SERIAL
NUMBER

44

Pack

PACK NUMBER

30C047B

PART

NUMBER

QTYUSED ON

12 DL

WPH1/4X7/8

1

Expansion tank

bracket

13 DM

WSH5/17

9

8 x Radiator bobbin
1 x Expansion tank

14 DN

SGT25-40

6

2 x U shape hose to
water rail
2 x Top radiator hose
2 x Bottom radiator hose

15 DO

SGT23-35

2

1 x Engine outlet to
big T piece
1 x Engine outlet to
heater inlet

16 DP

SGT16-25

18

6 x Heater inlet/outlet
3 x Big T-piece
1 x Expansion tank
2 x Modine
4 x Dry Sump
2 x Submarine

17 DQ

SGT8-16

6

Expansion tank

small T-piece

18 DR

1610-01015

12

Cowling flap

Drawings are for illustrative purposes only and are not to scale.Page 1 of 2

Plain Washer

1/4

" X 7/8"

Heavy duty

Page 1 of 2

Rivet - Black

5/32" X 0.47"

Hose Clip

17 - 25mm

Hose Clip

8 - 16mm

Hose Clip

30 - 40mm

Hose Clip

23 - 35mm

COOLING SIGMA

This pack may include extra fasteners to cover different options

ITEM

BASIC

DESCRIPTION

ILLUSTRATION

Spring Washer

5/16"

Heavy duty

D

SERIAL
NUMBER

44

Pack

PACK NUMBER

30C047B

STILL MORE PLUMBING

PAR TS

FIXINGS

TOOLS

TIPS

U shape hose

x2

1

7mm

ASSEMBLY GUIDE

59

STILL MORE PLUMBING

DN

120mm

120mm

1

ASSEMBLY GUIDE

60

PART

NUMBER

QTYUSED ON

1DA

BM8X50 1

Expansion tank

bracket to chassis

2DB

SF1/4X3/4

1

Expansion tank to

bracket

3DC

SM6X20

4 SV radiator bracket

4DD

30Z1072A

4Fan brackets to fan

5DE

SPHM6X16

4

Fan to radiator

cowling - SV only

6DF

NMYF6

8

x4 Fan to radiator
x4 SV radiator
bracket

7DG

NMPF8

8

Radiator bobbin

8DH

NFYF1/4

1

Expansion tank

bracket

9DI

WPH1/4

13

8 x SV rad bracket
4 x Fan fixings
1 x Expansion tank
braket

10 DJ

WPH5/16

4

Radiator bobbin

back

11 DK

WPH5/17X7/8

4

Radiator bobbin

front

Drawings are for illustrative purposes only and are not to scale.Page 1 of 2

Bolt M8 X 50

Grade 8.8

Plain Washer

5/16

"

Heavy duty

Nyloc Nut 1/4"

Plain Washer

1/4"

Heavy duty

Plain Washer

5/16" X 7/8"
Heavy duty

Setscrew M6X16

Panhead Pozi

Nyloc Nut M6

Plain Nut M8

Setscrew M8X20

Grade 8.8

COOLING SIGMA

This pack may include extra fasteners to cover different options

ITEM

BASIC

DESCRIPTION

ILLUSTRATION

Bolt M6 X 16 with

square section

Setscrew 1/4"

X 3/4"

D

SERIAL
NUMBER

44

Pack

PACK NUMBER

30C047B

PART

NUMBER

QTYUSED ON

12 DL

WPH1/4X7/8

1

Expansion tank

bracket

13 DM

WSH5/17

9

8 x Radiator bobbin
1 x Expansion tank

14 DN

SGT25-40

6

2 x U shape hose to
water rail
2 x Top radiator hose
2 x Bottom radiator hose

15 DO

SGT23-35

2

1 x Engine outlet to
big T piece
1 x Engine outlet to
heater inlet

16 DP

SGT16-25

18

6 x Heater inlet/outlet
3 x Big T-piece
1 x Expansion tank
2 x Modine
4 x Dry Sump
2 x Submarine

17 DQ

SGT8-16

6

Expansion tank

small T-piece

18 DR

1610-01015

12

Cowling flap

Drawings are for illustrative purposes only and are not to scale.Page 1 of 2

Plain Washer

1/4

" X 7/8"

Heavy duty

Page 1 of 2

Rivet - Black

5/32" X 0.47"

Hose Clip

17 - 25mm

Hose Clip

8 - 16mm

Hose Clip

30 - 40mm

Hose Clip

23 - 35mm

COOLING SIGMA

This pack may include extra fasteners to cover different options

ITEM

BASIC

DESCRIPTION

ILLUSTRATION

Spring Washer

5/16"

Heavy duty

D

SERIAL
NUMBER

44

Pack

PACK NUMBER

30C047B

A BREAK FROM PLUMBING TO FIT THE EXPANSION BOTTLE

PAR TS

FIXINGS

TOOLS

TIPS

x1

x1

x1

x1

x1

13mm
11mm

Expansion bottle

Expansion bottle bracket

Expansion bottle cap

11mm

x1

1

3

2

Throw away the red cap that
came on the expansion bottle.

Grant P

ASSEMBLY GUIDE

61

A BREAK FROM PLUMBING TO FIT THE EXPANSION BOTTLE

DH

DI

DB

DL

1 2

3

DA

DM

ASSEMBLY GUIDE

62

PART

NUMBER

QTYUSED ON

1DA

BM8X50 1

Expansion tank

bracket to chassis

2DB

SF1/4X3/4

1

Expansion tank to

bracket

3DC

SM6X20

4 SV radiator bracket

4DD

30Z1072A

4Fan brackets to fan

5DE

SPHM6X16

4

Fan to radiator

cowling - SV only

6DF

NMYF6

8

x4 Fan to radiator
x4 SV radiator
bracket

7DG

NMPF8

8

Radiator bobbin

8DH

NFYF1/4

1

Expansion tank

bracket

9DI

WPH1/4

13

8 x SV rad bracket
4 x Fan fixings
1 x Expansion tank
braket

10 DJ

WPH5/16

4

Radiator bobbin

back

11 DK

WPH5/17X7/8

4

Radiator bobbin

front

Drawings are for illustrative purposes only and are not to scale.Page 1 of 2

Bolt M8 X 50

Grade 8.8

Plain Washer

5/16

"

Heavy duty

Nyloc Nut 1/4"

Plain Washer

1/4"

Heavy duty

Plain Washer

5/16" X 7/8"
Heavy duty

Setscrew M6X16

Panhead Pozi

Nyloc Nut M6

Plain Nut M8

Setscrew M8X20

Grade 8.8

COOLING SIGMA

This pack may include extra fasteners to cover different options

ITEM

BASIC

DESCRIPTION

ILLUSTRATION

Bolt M6 X 16 with

square section

Setscrew 1/4"

X 3/4"

D

SERIAL
NUMBER

44

Pack

PACK NUMBER

30C047B

PART

NUMBER

QTYUSED ON

12 DL

WPH1/4X7/8

1

Expansion tank

bracket

13 DM

WSH5/17

9

8 x Radiator bobbin
1 x Expansion tank

14 DN

SGT25-40

6

2 x U shape hose to
water rail
2 x Top radiator hose
2 x Bottom radiator hose

15 DO

SGT23-35

2

1 x Engine outlet to
big T piece
1 x Engine outlet to
heater inlet

16 DP

SGT16-25

18

6 x Heater inlet/outlet
3 x Big T-piece
1 x Expansion tank
2 x Modine
4 x Dry Sump
2 x Submarine

17 DQ

SGT8-16

6

Expansion tank

small T-piece

18 DR

1610-01015

12

Cowling flap

Drawings are for illustrative purposes only and are not to scale.Page 1 of 2

Plain Washer

1/4

" X 7/8"

Heavy duty

Page 1 of 2

Rivet - Black

5/32" X 0.47"

Hose Clip

17 - 25mm

Hose Clip

8 - 16mm

Hose Clip

30 - 40mm

Hose Clip

23 - 35mm

COOLING SIGMA

This pack may include extra fasteners to cover different options

ITEM

BASIC

DESCRIPTION

ILLUSTRATION

Spring Washer

5/16"

Heavy duty

D

SERIAL
NUMBER

44

Pack

PACK NUMBER

30C047B

SOME MORE HOSE MODIFICATION

PAR TS

FIXINGS

TOOLS

TIPS

T-Piece

x3

1

7mm

The short 'L' shaped hose is pre‑formed.

John S

ASSEMBLY GUIDE

63

SOME MORE HOSE MODIFICATION

DP

1

ASSEMBLY GUIDE

64

PART

NUMBER

QTYUSED ON

1DA

BM8X50 1

Expansion tank

bracket to chassis

2DB

SF1/4X3/4

1

Expansion tank to

bracket

3DC

SM6X20

4 SV radiator bracket

4DD

30Z1072A

4Fan brackets to fan

5DE

SPHM6X16

4

Fan to radiator

cowling - SV only

6DF

NMYF6

8

x4 Fan to radiator
x4 SV radiator
bracket

7DG

NMPF8

8

Radiator bobbin

8DH

NFYF1/4

1

Expansion tank

bracket

9DI

WPH1/4

13

8 x SV rad bracket
4 x Fan fixings
1 x Expansion tank
braket

10 DJ

WPH5/16

4

Radiator bobbin

back

11 DK

WPH5/17X7/8

4

Radiator bobbin

front

Drawings are for illustrative purposes only and are not to scale.Page 1 of 2

Bolt M8 X 50

Grade 8.8

Plain Washer

5/16

"

Heavy duty

Nyloc Nut 1/4"

Plain Washer

1/4"

Heavy duty

Plain Washer

5/16" X 7/8"
Heavy duty

Setscrew M6X16

Panhead Pozi

Nyloc Nut M6

Plain Nut M8

Setscrew M8X20

Grade 8.8

COOLING SIGMA

This pack may include extra fasteners to cover different options

ITEM

BASIC

DESCRIPTION

ILLUSTRATION

Bolt M6 X 16 with

square section

Setscrew 1/4"

X 3/4"

D

SERIAL
NUMBER

44

Pack

PACK NUMBER

30C047B

PART

NUMBER

QTYUSED ON

12 DL

WPH1/4X7/8

1

Expansion tank

bracket

13 DM

WSH5/17

9

8 x Radiator bobbin
1 x Expansion tank

14 DN

SGT25-40

6

2 x U shape hose to
water rail
2 x Top radiator hose
2 x Bottom radiator hose

15 DO

SGT23-35

2

1 x Engine outlet to
big T piece
1 x Engine outlet to
heater inlet

16 DP

SGT16-25

18

6 x Heater inlet/outlet
3 x Big T-piece
1 x Expansion tank
2 x Modine
4 x Dry Sump
2 x Submarine

17 DQ

SGT8-16

6

Expansion tank

small T-piece

18 DR

1610-01015

12

Cowling flap

Drawings are for illustrative purposes only and are not to scale.Page 1 of 2

Plain Washer

1/4

" X 7/8"

Heavy duty

Page 1 of 2

Rivet - Black

5/32" X 0.47"

Hose Clip

17 - 25mm

Hose Clip

8 - 16mm

Hose Clip

30 - 40mm

Hose Clip

23 - 35mm

COOLING SIGMA

This pack may include extra fasteners to cover different options

ITEM

BASIC

DESCRIPTION

ILLUSTRATION

Spring Washer

5/16"

Heavy duty

D

SERIAL
NUMBER

44

Pack

PACK NUMBER

30C047B

AND BACK TO PLUMBING

PAR TS

FIXINGS

TOOLS

TIPS

x1

7mm

T-Piece assembly

1

ASSEMBLY GUIDE

65

AND BACK TO PLUMBING

DP

1

ASSEMBLY GUIDE

66

PART

NUMBER

QTYUSED ON

1DA

BM8X50 1

Expansion tank

bracket to chassis

2DB

SF1/4X3/4

1

Expansion tank to

bracket

3DC

SM6X20

4 SV radiator bracket

4DD

30Z1072A

4Fan brackets to fan

5DE

SPHM6X16

4

Fan to radiator

cowling - SV only

6DF

NMYF6

8

x4 Fan to radiator
x4 SV radiator
bracket

7DG

NMPF8

8

Radiator bobbin

8DH

NFYF1/4

1

Expansion tank

bracket

9DI

WPH1/4

13

8 x SV rad bracket
4 x Fan fixings
1 x Expansion tank
braket

10 DJ

WPH5/16

4

Radiator bobbin

back

11 DK

WPH5/17X7/8

4

Radiator bobbin

front

Drawings are for illustrative purposes only and are not to scale.Page 1 of 2

Bolt M8 X 50

Grade 8.8

Plain Washer

5/16

"

Heavy duty

Nyloc Nut 1/4"

Plain Washer

1/4"

Heavy duty

Plain Washer

5/16" X 7/8"
Heavy duty

Setscrew M6X16

Panhead Pozi

Nyloc Nut M6

Plain Nut M8

Setscrew M8X20

Grade 8.8

COOLING SIGMA

This pack may include extra fasteners to cover different options

ITEM

BASIC

DESCRIPTION

ILLUSTRATION

Bolt M6 X 16 with

square section

Setscrew 1/4"

X 3/4"

D

SERIAL
NUMBER

44

Pack

PACK NUMBER

30C047B

PART

NUMBER

QTYUSED ON

12 DL

WPH1/4X7/8

1

Expansion tank

bracket

13 DM

WSH5/17

9

8 x Radiator bobbin
1 x Expansion tank

14 DN

SGT25-40

6

2 x U shape hose to
water rail
2 x Top radiator hose
2 x Bottom radiator hose

15 DO

SGT23-35

2

1 x Engine outlet to
big T piece
1 x Engine outlet to
heater inlet

16 DP

SGT16-25

18

6 x Heater inlet/outlet
3 x Big T-piece
1 x Expansion tank
2 x Modine
4 x Dry Sump
2 x Submarine

17 DQ

SGT8-16

6

Expansion tank

small T-piece

18 DR

1610-01015

12

Cowling flap

Drawings are for illustrative purposes only and are not to scale.Page 1 of 2

Plain Washer

1/4

" X 7/8"

Heavy duty

Page 1 of 2

Rivet - Black

5/32" X 0.47"

Hose Clip

17 - 25mm

Hose Clip

8 - 16mm

Hose Clip

30 - 40mm

Hose Clip

23 - 35mm

COOLING SIGMA

This pack may include extra fasteners to cover different options

ITEM

BASIC

DESCRIPTION

ILLUSTRATION

Spring Washer

5/16"

Heavy duty

D

SERIAL
NUMBER

44

Pack

PACK NUMBER

30C047B

LAST BIT OF PLUMBING

PAR TS

FIXINGS

TOOLS

TIPS

⅝ Hose

x2

1

7mm

ASSEMBLY GUIDE

67

LAST BIT OF PLUMBING

DQ

1

ASSEMBLY GUIDE

68

CONNECTING THE FUEL LINE

PAR TS

FIXINGS

TOOLS

TIPS

ASSEMBLY GUIDE

69

CONNECTING THE FUEL LINE

ASSEMBLY GUIDE

70

PAR TS

FIXINGS

TOOLS

TIPS

Throttle cable

1

FIT THROTTLE CABLE

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.

Rich T

ASSEMBLY GUIDE

71

FIT THROTTLE CABLE

1

ASSEMBLY GUIDE

72

PROTECTING & ATTACHING THE CLUTCH HOSE

PAR TS

FIXINGS

TOOLS

TIPS

14mm

8mm water hose

1

Nip up the banjo bolt.

John K

The hose is used to stop chaffing.

James A

ASSEMBLY GUIDE

73

PROTECTING & ATTACHING THE CLUTCH HOSE

1

ASSEMBLY GUIDE

74

PAR TS

FIXINGS

TOOLS

TIPS

CONNECTING THE BATTERY (POSITIVE / RED FIRST)

10mm (x2)

Always connect live side of battery first
(red wire).

Chris B

Be careful to ensure that the red leads go to
the + side and the black wires to the – side.

Dan D

Make the battery the
last thing you connect.

Jamie A

ASSEMBLY GUIDE

75

CONNECTING THE BATTERY (POSITIVE / RED FIRST)

ASSEMBLY GUIDE

76

IT LIVES!

PAR TS

FIXINGS

TOOLS

TIPS

ASSEMBLY GUIDE

77

IT LIVES!

ASSEMBLY GUIDE

78

PART

NUMBER

QTYUSED ON

1DA

BM8X50 1

Expansion tank

bracket to chassis

2DB

SF1/4X3/4

1

Expansion tank to

bracket

3DC

SM6X20

4 SV radiator bracket

4DD

30Z1072A

4Fan brackets to fan

5DE

SPHM6X16

4

Fan to radiator

cowling - SV only

6DF

NMYF6

8

x4 Fan to radiator
x4 SV radiator
bracket

7DG

NMPF8

8

Radiator bobbin

8DH

NFYF1/4

1

Expansion tank

bracket

9DI

WPH1/4

13

8 x SV rad bracket
4 x Fan fixings
1 x Expansion tank
braket

10 DJ

WPH5/16

4

Radiator bobbin

back

11 DK

WPH5/17X7/8

4

Radiator bobbin

front

Drawings are for illustrative purposes only and are not to scale.Page 1 of 2

Bolt M8 X 50

Grade 8.8

Plain Washer

5/16

"

Heavy duty

Nyloc Nut 1/4"

Plain Washer

1/4"

Heavy duty

Plain Washer

5/16" X 7/8"
Heavy duty

Setscrew M6X16

Panhead Pozi

Nyloc Nut M6

Plain Nut M8

Setscrew M8X20

Grade 8.8

COOLING SIGMA

This pack may include extra fasteners to cover different options

ITEM

BASIC

DESCRIPTION

ILLUSTRATION

Bolt M6 X 16 with

square section

Setscrew 1/4"

X 3/4"

D

SERIAL
NUMBER

44

Pack

PACK NUMBER

30C047B

PART

NUMBER

QTYUSED ON

12 DL

WPH1/4X7/8

1

Expansion tank

bracket

13 DM

WSH5/17

9

8 x Radiator bobbin
1 x Expansion tank

14 DN

SGT25-40

6

2 x U shape hose to
water rail
2 x Top radiator hose
2 x Bottom radiator hose

15 DO

SGT23-35

2

1 x Engine outlet to
big T piece
1 x Engine outlet to
heater inlet

16 DP

SGT16-25

18

6 x Heater inlet/outlet
3 x Big T-piece
1 x Expansion tank
2 x Modine
4 x Dry Sump
2 x Submarine

17 DQ

SGT8-16

6

Expansion tank

small T-piece

18 DR

1610-01015

12

Cowling flap

Drawings are for illustrative purposes only and are not to scale.Page 1 of 2

Plain Washer

1/4

" X 7/8"

Heavy duty

Page 1 of 2

Rivet - Black

5/32" X 0.47"

Hose Clip

17 - 25mm

Hose Clip

8 - 16mm

Hose Clip

30 - 40mm

Hose Clip

23 - 35mm

COOLING SIGMA

This pack may include extra fasteners to cover different options

ITEM

BASIC

DESCRIPTION

ILLUSTRATION

Spring Washer

5/16"

Heavy duty

D

SERIAL
NUMBER

44

Pack

PACK NUMBER

30C047B

ONE LAST BIT OF PLUMBING…

PAR TS

FIXINGS

TOOLS

TIPS

Hose

1

7mm

x1

Cut off hook and trim if required.

Grant P

ASSEMBLY GUIDE

79

ONE LAST BIT OF PLUMBING…

1

ASSEMBLY GUIDE

80

PART

NUMBER

QTYUSED ON

1DA

BM8X50 1

Expansion tank

bracket to chassis

2DB

SF1/4X3/4

1

Expansion tank to

bracket

3DC

SM6X20

4 SV radiator bracket

4DD

30Z1072A

4Fan brackets to fan

5DE

SPHM6X16

4

Fan to radiator

cowling - SV only

6DF

NMYF6

8

x4 Fan to radiator
x4 SV radiator
bracket

7DG

NMPF8

8

Radiator bobbin

8DH

NFYF1/4

1

Expansion tank

bracket

9DI

WPH1/4

13

8 x SV rad bracket
4 x Fan fixings
1 x Expansion tank
braket

10 DJ

WPH5/16

4

Radiator bobbin

back

11 DK

WPH5/17X7/8

4

Radiator bobbin

front

Drawings are for illustrative purposes only and are not to scale.Page 1 of 2

Bolt M8 X 50

Grade 8.8

Plain Washer

5/16

"

Heavy duty

Nyloc Nut 1/4"

Plain Washer

1/4"

Heavy duty

Plain Washer

5/16" X 7/8"
Heavy duty

Setscrew M6X16

Panhead Pozi

Nyloc Nut M6

Plain Nut M8

Setscrew M8X20

Grade 8.8

COOLING SIGMA

This pack may include extra fasteners to cover different options

ITEM

BASIC

DESCRIPTION

ILLUSTRATION

Bolt M6 X 16 with

square section

Setscrew 1/4"

X 3/4"

D

SERIAL
NUMBER

44

Pack

PACK NUMBER

30C047B

PART

NUMBER

QTYUSED ON

12 DL

WPH1/4X7/8

1

Expansion tank

bracket

13 DM

WSH5/17

9

8 x Radiator bobbin
1 x Expansion tank

14 DN

SGT25-40

6

2 x U shape hose to
water rail
2 x Top radiator hose
2 x Bottom radiator hose

15 DO

SGT23-35

2

1 x Engine outlet to
big T piece
1 x Engine outlet to
heater inlet

16 DP

SGT16-25

18

6 x Heater inlet/outlet
3 x Big T-piece
1 x Expansion tank
2 x Modine
4 x Dry Sump
2 x Submarine

17 DQ

SGT8-16

6

Expansion tank

small T-piece

18 DR

1610-01015

12

Cowling flap

Drawings are for illustrative purposes only and are not to scale.Page 1 of 2

Plain Washer

1/4

" X 7/8"

Heavy duty

Page 1 of 2

Rivet - Black

5/32" X 0.47"

Hose Clip

17 - 25mm

Hose Clip

8 - 16mm

Hose Clip

30 - 40mm

Hose Clip

23 - 35mm

COOLING SIGMA

This pack may include extra fasteners to cover different options

ITEM

BASIC

DESCRIPTION

ILLUSTRATION

Spring Washer

5/16"

Heavy duty

D

SERIAL
NUMBER

44

Pack

PACK NUMBER

30C047B

…TO CONNECT THE HEATER

PAR TS

FIXINGS

TOOLS

TIPS

7mm

x1

The coolant concentrate should
be diluted 50/50 with water. It
does not need to be exact!

Anthony L

ASSEMBLY GUIDE

81

…TO CONNECT THE HEATER

ASSEMBLY GUIDE

82

PAR TS

FIXINGS

TOOLS

TIPS

Coolant concentrate

FILL WITH COOLANT

ASSEMBLY GUIDE

83

FILL WITH COOLANT

Fill expansion bottle to max mark

ASSEMBLY GUIDE

84

CONNECT THE AIRBOX TO THE ENGINE

PAR TS

FIXINGS

TOOLS

TIPS

7mm

Airbox hose

Hose clip

Insert set

1

3

2

All fixings for this step should be in the supplied airbox box

To help push insert in
use the work bench.

Rich T

Spray brake cleaner in the
hose and on the insert.

John K

ASSEMBLY GUIDE

85

CONNECT THE AIRBOX TO THE ENGINE

2

3

1

ASSEMBLY GUIDE

86

PART

NUMBER

QTYUSED ON

1BA

BMCH6X70

4Rack clamps

2BB

BF1/4X1.1/2

2Column clam p

3BC

BM8X35

2

Column to rack
universal joint

4BD

NFYH1/2

1Steering wheel boss

5BE

NFPF1/2

2Track rod lock nut

6BF

NFPFH7/16

1

Column clamp

grubscrew locknut

7BG

NMYF8

2

Column to rack
universal joint

8BH

NMYF6

4

Steering rack

clamps

9BJ

WPH1/2

1

Steering wheel boss

10 BK

WPH1/4

6

Rack clamps and

column clamp

11 BL

WSH1/4

2

Column clamp

Drawings are for illustrative purposes only and are not to scale.

B

SERIAL

NUMBER

55

Pack

PACK NUMBER

30S003B

STEERING DeDION CARS (METRIC)

This pack may include extra fasteners to cover different options

ITEM

BASIC

DESCRIPTION

ILLUSTRATION

Caphead Bolt

M6 x 70

DIN 912

Bolt ¼" x 1½"

Bolt M8 x 35

Grade 8.8

Nyloc Nut ½"

Half height

Plain Nut ½"

Plain Nut ⁷⁄₁₆"

Half height

Nyloc Nut M8

Spring Washer ¼

Heavy duty

Page 1 of 1

Nyloc Nut M6

Plain Washer

½" x 1⅛"

Chamfered

Plain Washer

¼"

Heavy duty

PAR TS

FIXINGS

TOOLS

TIPS

x2

x1

x2

x1

⁄"

11mm

Lower steering column

Steering column clamp

Steering column bush

Upper steering column

Grub screw

Steering column clamp plate

⁄"

⁄"

1

3

6

2

5

4

GIVING IT SOME DIRECTION

Put the clamp in the middle of column recess.

Jamie A

Grease the steering bushes.

Lee A

Fit the clamp bolts first,
then grubscrew & finish
with the locking nut.

Tiago O

ASSEMBLY GUIDE

87

7

GIVING IT SOME DIRECTION

BF

5

4

1

BC

BG

20Nm

14Nm

3

20Nm

BC

BG

2

BD

BJ

6

BB

BK

BL

ASSEMBLY GUIDE

88

PAR TS TOOLS

FIXINGS TIPS

8mm Extension

Exhaust manifold gasket

Cat / Collector

Exhaust primary pipes

Exhaust collector springs

8mm

17mm
(

270

&

310

only)

1

3

2

4

THIS IS EXHAUSTING

Use cable ties to compress
exhaust spring.

Mick F

Put masking tape round exhaust
hole to prevent scratches.

Chris B

A pair of pliers are best to help hook over.

James A

Fixings are supplied loosely attached to the engine in place

to follow

ASSEMBLY GUIDE

89

THIS IS EXHAUSTING

2

3

4

1

47Nm

ASSEMBLY GUIDE

90

FITTING THE HANDBRAKE

PAR TS

FIXINGS

TOOLS

TIPS

13mm (x2)

Handbrake assembly

Handbrake clevis

Handbrake cable

Handbrake pulley

Handbrake clevis pin

Pulley clevis pin

1

3

6

2

5

4

Miscellaneous pack

• Setscrew 8 (x25)

• Washer M8

• Washer M6

Remember to put a loop in
inner cable around pulley.

Grant P

Cable tie adjuster
end of cable to diff.

Dan D

ASSEMBLY GUIDE

91

FITTING THE HANDBRAKE

1

3

4 2

5

6

ASSEMBLY GUIDE

92

SLIDE IN THE PROPSHAFT

PAR TS

FIXINGS

TOOLS

TIPS

Propshaft

1

Line the splines in the
propshaft to the gearbox.

Anthony L

Grease prop if necessary,
it will have a grease nipple.

John S