Section 2
Page 5 Issue 1
8 The consumables detailed in Table 4 and
recommended lubricants detailed in Table 5 are
required during the build process.
TABLE 4 CONSUMABLES
Item Type Remarks
Rubber
lubricant
To ease assembly and
operation of rubber bushes
and grommets.
Coppaslip Anti seize compound
where lubrication is not
required to ensure ease of
future disassembly.
Threadlock Loctite Used where the application
prevents the use of nyloc
nuts or spring washers.
Silicon
sealant
To achieve a watertight
seal. It should be applied
sparingly.
Masking
tape
Protection of body.
Adhesive Contact Carpet/trim.
TABLE 5 RECOMMENDED LUBRICANTS
Item Type Remarks
Engine oil Comma Syner-Z
synthetic OW-40
Road usage
Caterham
Motorsport oil
5W-50
Performance/
Track driving
Gearbox
oil (5 and 6
speed)
Caterham
gearbox oil GL4
grade
Under no
circumstances
use GL5 grade oil
Differential
(standard
and LSD)
Caterham
differential oil
EP90
Brake fluid Comma DOT4
Engine
coolant
Comma
Xstream Red
OAT
9 It is recommended that a sturdy
workbench and a good vice are made available
for both holding items stable and lightly pressing
parts into position.
10 The application of undue force should not
be necessary if assembly is carried out in the
correct sequence.
NUTS, BOLTS AND WASHERS
11 As a general rule the fasteners used in
the chassis are of Imperial dimensions and the
drive train fasteners are of Metric dimensions.
12 Always assume that bolts and fasteners
are not properly tightened until they have been
specifically checked.
13 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.
14 Ensure that the correct tightening torque
is applied. Where torque figures are not
specified use the figures detailed in Table 6.
Particular care must be taken when using the
torque wrench to tighten fastenings into
aluminium.
TABLE 6 GENERAL TORQUE FIGURES
Thread Socket
size
Torque
(lbft)
Torque
(Nm)
1/4" UNF/UNC 7/16" A/F 5 7
5/16" UNF/UNC 1/2" A/F 15 20
3/8" UNF/UNC 9/16" A/F 25 34
7/16" UNF 5/8" or
11/16" A/F
35 48
1/2" UNF 3/4" A/F 45 61
5 mm 10 mm 4 6
6 mm 11 mm 5 7
8 mm 13 mm 15 20
10 mm 17 mm 35 48
12 mm 19 mm 45 61
15 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 toque.
16 Overtightening can often cause more
problems than undertightening, such as sheared
bolts and studs and incorrect stresses.
