Caterham Seven User Manual Page 53
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additive
diff additive
Brake fluid
Comma DOT4
Comma
DOT4
Engine
coolant
Comma
Xstream red or
ford super plus
anti-freeze
Comma
Xstream red
or ford
super plus
anti-freeze
Comma
Xstream
red
It is recommended that a sturdy
workbench and a good vice are made
available for holding items stable.
The application of undue force should not
be necessary if assembly is carried out in
the correct sequence.
3.4) Nuts, bolts and washers
As a general rule the fasteners used are
RH thread and of Metric dimensions.
Some Imperial fasteners are still used,
particularly within the brakes and
suspension.
Always assume that bolts and fasteners
are not properly tightened until they have
been specifically checked.
All safety critical fastenings supplied by
Caterham Cars are high tensile
conforming to British Standards 1768
(Imperial) and 3692 (Metric). Customers
supplying their own fasteners should only
use fasteners with heads marked 10.9
and 12.9 particularly when attaching
suspension, steering, upright and axle
kits. Any unmarked bolt should not be
used.
Ensure that the correct tightening torque
is applied. Where torque figures are not
specified, use the figures detailed in Table
11. Particular care must be taken when
using the torque wrench to tighten
fastenings into aluminium.
Table 11: General torque figures
Thread
Socket size
Torque
(Nm)
1/4” UNF/UNC
7/16” A/F
7
5/16” UNF/UNC
1/2” A/F
20
3/8” UNF/UNC
9/16” A/F
34
7/16” UNF
5/8” or 11/16”
A/F
47
1/2” UNF
3/4” A/F
61
5mm
10mm
6
6mm
11mm
7
8mm
13mm
20
10mm
17mm
47
12mm
19mm
61
It is good practice to mark the bolt head or
nut with a spot of paint once it has been
finally tightened. This provides a good
visual means of checking that all fixings
have been set to the correct torque.
Over tightening can often cause more
problems than under tightening, such as
sheared bolts and studs and incorrect
stresses.
- ASSEMBLY GUIDE 1
- ALL CATERHAM SEVEN MODELS 1
- Version 02.2014 1
- Contents 2
- List of Tables 11
- List of Figures 12
- Page 13
- Page 14
- Page 15
- Page 16
- 1.0) Introduction 20
- 2.0) Kit contents 28
- Exhaust silencer 29
- Exhaust primary pipes 29
- Cat/ collector 29
- Cat guard 29
- Polythene bag 29
- 1. RH driveshaft 33
- 4. Nyloc nut (white insert) 33
- 2. Speed sensor ring 33
- 5. LH driveshaft assembly 33
- 3. Nyloc nut (green insert) 33
- 1. LH headlight bracket 38
- 2. RH headlight bracket 38
- 1. Upright assembly (RH) 39
- 2. Upright assembly (LH) 39
- 4.0) Steering 59
- 1. Steering wheel 63
- 4. Fixing screw 63
- 2. Steering column 63
- 5. Wheel centre 63
- 3. Mounting boss 63
- 5.0) Front suspension 65
- 1. Copper washer 71
- 3. Braided brake hose 71
- 2. Female union 71
- 4. Adaptor 71
- 1. Clutch release bearing 74
- 2. Hydraulic connection 74
- 1. Gearbox 74
- 2. Plug 74
- 3. Gearbox mounting 74
- SWL of 150 Kg 77
- 2. ‘U’ hose 78
- 3. Water rail 78
- 1. Fuel rail connection 83
- 2. Fuel pipe (from pump) 83
- 4. Bobbin 85
- 2. Spring washer 85
- 3. Setscrew 85
- 1. Primary pipe 86
- 1. Hose to ‘T’ piece 88
- 1. Cam cover 94
- 2. Breather pipe 94
- 3. Throttle body 94
- 1. Air intake 95
- 2. Trunking 95
- 1. Brake master cylinder 97
- 4. Heater control cable 97
- 2. Clutch master cylinder 97
- 5. Battery 97
- 3. Heater 97
- 1. Banjo bolt 104
- 3. Hose union 104
- 2. Copper washers 104
- 4. Clutch master 104
- 1. Angle bracket 105
- 2. Bobbin 105
- 1.Primary pipe 106
- 2.Collector/catalyst 106
- 1. Silencer bracket 107
- 3. Lambda probe 107
- 2. Band clamp 107
- 2. Bottom radiator hose 108
- 1. Cruciform 109
- 1. Scuttle panel 113
- 2. Heater control cable 113
- 3. Locknut 113
- 1. Heater valve 113
- 1. Throttle cable 114
- 2. Throttle cable adjuster 114
- 3. Throttle body linkage 114
- 4. Throttle cable nipple 114
- Description 117
- Engine hoist and sling 117
- SWL if 150 Kg (min) 117
- 1. Engine connection 118
- 2. Long ‘L’ hose 118
- 1. ‘T’ piece 131
- 3. Small straight hose 131
- 2. Hose to 131
- 4. Hose to heater outlet 131
- 1. Oil breather hose 135
- 2. ‘P’ clip 135
- 3. Breather bottle 135
- 4. Breather elbow 135
- 5. Cam cover 135
- 1. Cable bracket 137
- 9.0) Rear suspension 140
- 1. Brake pipe (RH) 141
- 4. Brake pipe (LH) 141
- 5. Di Dion ear (RH) 141
- 3. Three way union 141
- 1. P-clip 142
- 2. Brake pipe LH 142
- 3. Three way connector 142
- 1. Bell crank 143
- 2. Rod end 143
- 4. Link arm (forward) 143
- 5. Link arm (rearward) 143
- 1. De Dion tube RH end 144
- 2. Link arm (forward) 144
- 3. Bellcrank 144
- 4. Link arm (rearward) 144
- 5. Bellcrank spacer 144
- 1. Metalistic brush 145
- 4. Nylon washers 145
- 2. Bolt 145
- 5. Nyloc nut 145
- 3. ‘A’ frame 145
- 1. De Dion ear 148
- 2. ARB bracket 148
- 3. Anti-roll bar 148
- 4. Drive shaft 148
- 5. Speed sensor 148
- 1. Bolt 149
- 4. Drop link 149
- 2. Plain washer 149
- 5. Anti-roll bar 149
- 3. Extension piece 149
- 1. Pulley 151
- 10.0) Interior and trim 154
- 1. Knee trim panel 157
- 2. Roll cage (optional) 157
- 3. Piping 157
- 4. Self-tapping screws 157
- 1. Spacers 161
- 2. Adjusting handle 161
- 1. Composite seat 162
- 2. Six-point harness 162
- 3. Seat adjuster 162
- 1. Large recess 162
- 2. Spacer 162
- 1. Rear bulkhead carpet 164
- 2. Footwell carpet 164
- 3. Tunnel carpet 164
- 4. Tunnel top 164
- 11.0) Fibreglass 165
- 1. Rear wing fixings 168
- 2. Rear wings 168
- 3. Rectangular notches 169
- 1. Wing piping 169
- 2. ‘V’ Shaped notches 169
- 12.0) Lighting 170
- 13.0) Weather equipment 175
- 1. Screw 176
- 2. Washer (or popper base) 176
- 3. Hoodstrap 176
- 4. Rear body skin 176
- 5. Chassis tube 176
- 1. Hoodstick 177
- 2. Popper base 177
- 3. Rear wing 177
- 1. Windscreen stanchions 177
- 2. Sidescreen hinges 177
- 1. Sidescreen 179
- 2. Vinyl strap 179
- 1. Popper base 182
- 2. Boot cover 182
- 3. Fastener socket 182
- 1. Tonneau cover 183
- 1. Windscreen support 183
- 1. Punch 184
- 2. Dished base 184
- 14.0) Wheel fitment 185
- 1. Mounting wishbone 186
- 2. Wheel nuts 186
- 3. Fibre washer 186
- 4. Spare wheel bolt 186
- 5. Spacer 186
- 1. Pipe to master cylinder 189
- 2. Push-fit connector 189
- 3. Bleed key 189
- 1. Grommets 203
- Page 205
- 17.0) Options 206
- 1. Front hoop saddle bracket 209
- 3. Chassis top tube - sill 209
- 1. Bucket bush location 210
- 2. Roll cage rear hoop 210
- 3. Seat back harness rail 210
- 1. Speed sensor bracket 219
- 2. Lock nut 219
- 3. Speed sensor 219
- 18.0) Wiring diagrams 223
- Page 227
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