BOX 16 - Kits 61-62-63-64

Kit 61 - Assembly and mounting of the reinforcement arches for the engine compartment

61A Arch support
61B Front reinforcement arch
61C Service box
61D Electrical box
61E Left reinforcement arch
61F Right reinforcement arch

61G Fuel line
61H Clip (x 2)
Screw ACP M 1.4 x 3 mm (x 5)
Screw EP M 2.0 x 5 mm (x 3)
Screw DP M 2.0 x 4 x 5 mm (x 2)
Screw MP M 1.2 x 3 mm (x 3)

Step 1

Position the arch support link (61A) and the electrical box (61D) on the front reinforcement arch (61B), then secure them with two ACP screws. Position the left and right reinforcement arches (61E&61F) on the arch support (61A) and the electrical box (61D) respectively, then secure them with two ACP screws.

Step 2

The engine compartment reinforcement arch is now pre-assembled.

Step 3

Position the pre-assembled engine compartment reinforcement arch on the cabin floor (52A) by means of the arch support (61A) and the electrical box (61D), then secure it with a DP screw and an EP screw respectively.

Step 4

Position the service box (61C) on the cabin floor (52A) and secure it with an EP screw (see illustration opposite).

Step 5

Position the two clips (61H) on the cabin floor (52A) and secure them with two MP screws.

Step 6

Pass the fuel line (61G) through the two brackets (61H) - red arrows.

ASSEMBLY DIAGRAM

GENERAL VIEW

Kit 62 - Assembly and mounting of the steering column housing. Mounting of the electrical cables.

62A Housing lower steering column
62B Housing upper steering column
62C Control turn signal
62D Control windscreen wiper

62E Clamp
62F Ignition switch
Screw AP M 1.7 x 4 mm (x 8)

Step 1

Position the ball joints at the ends of the respective turn signal (62C) and windscreen wiper (62D) switches in their respective housings on the lower steering column (62A), then position the upper steering column housing (62B) and secure with an AP screw. Position the ignition switch (62F) in the recess provided on the lower comodo housing (62A).

Step 2

Carefully remove the reading light (3P) from the dashboard (3A) and put it aside for future use. Position the upper steering column housing (62B) in the recess provided on the dashboard (3A), then secure it from behind with an AP screw (see illustrations above).

Step 3

Lift the cabin floor (52A) and remove cables G / green - white (47I), F / green - white (47H) and C / grey - white (47E) for future use. Remove cable A / red - black (47C) and pass it through the oval opening in the cabin floor (52A) (blue arrow). Turn the dashboard (3A) over and put it on the front seats.

Step 4

Position the A / red - black cable switch (47C) on the clip (62E). Position the switch button for cable A (47C) in the ignition switch (62F) (blue arrow), then align the openings in the clip (62E) with those on the dashboard (3A) (green arrow).

Step 5

Secure the clamp (62E) to the dashboard (3A) using two AP screws.

Step 6

Flip the dashboard (3A) over.

Step 7

Pass the cable wire C (48C) - with the green PCB - through the oval opening in the cabin floor (52A) (blue arrow) and align the openings in the PCB with those in the dashboard (3A).

Step 8

Attach the cable C PCB (48C) to the dashboard (3A) using two AP screws.

ASSEMBLY DIAGRAM

GENERAL VIEW

Kit 63 - Fitting the dashboard and passenger compartment panels to the chassis. Assembly of electrical cables

63A Left side panel
63B Right side panel
63C Passenger compartment lighting (x 2)
63D Clamp
63E Adhesive tape (x 2)

Screw MP M 1.2 x 3 mm (x 5)
Screw IP M 2.3 x 6 mm (x 5)
Screw AP M 1.7 x 4 mm (x 4)
Screw EP M 2.0 x 5 mm (x 5)

Step 1

Position the passenger compartment lights (63C) on the right and left side panels (63B&63A), then secure each with two MP screws. Position the F-cable switches (48B) on the right and left side panels (63B&63A) - longest wire as specified by the red arrow - and secure them with two IP screws.

Step 2

Position the right and left side panels (63B&63A) on the dashboard (3A), then fasten them with two AP screws. Position the LED lights from cable G (48A) in the outer sockets on the right and left side panels (63B&63A) - longest wire. Group the five cables together, then secure them to the dashboard (3A) using the clamp (63D) and an AP screw.

Step 3

Pass the F and G cables (48B&48A) through the oval opening in the cabin floor (52A).

Step 4

Position the dashboard (3A) on the cabin floor (52A) and secure with two IP screws.

Step 5

Connect the G cables (48A&47I), the F cables (48B&47H) and the C cables (48C&47E) in accordance with their respective colours. Arrange cable C (48C) and its plugs on the side of the fuel tank (red arrow) to conceal it later under the left-hand reinforcement arch (61E).

Step 6

Group all the cables together, except cable C (48C), then pass them underneath the steering column (53A) and tape them together (63E) - illustrations above.

Step 7

Start fitting the cabin floor (52A) to the chassis floor (39A) by engaging the steering column (53A) into the square opening located on the cabin floor (52A) - green and blue arrows.