BOX 23 - Kits 89-90-91-92

Part 89 - ROLL CAGE (2)

Parts of number 089

  • 89A Rear roll bar tube 
  • 89B Right roll bar cage 
  • 89C Left front roll bar bracket (driver side) 
  • 89D Right front roll bar bracket (co-driver side) 
  • 89E Passenger’s reading light 
  • 89F Reading light arm 
  • 89G Reading light base 
  • 89H Clamp (x 2) 
  • Screw AM M 1.7 x 4 mm (x 8) 
Step 1
Position the right cage of the roll bar (89B) on the right floor panel (67B), taking care to match the three openings of the roll bar upright (89B) with those located on the dashboard panel (80A), as well as with the one located at the end of the upper bar of the roll cage (88B) (yellow circles). 

Then fix the cage with three AM screws as shown in the photos. 

Turn the assembly over and secure the right cage of the roll bar (89B) on the right floor panel (67B) with an AM screw from below.

Step 2

Place the rear roll bar tube (89A) on the left (88A) and right (89B) roll bar cages, then secure it with two AM screws as indicated by the yellow circles.

Step 3

Place the left front roll bar bracket (89C) in front of the driver’s seat as indicated, then insert it into the openings on the left roll bar cage (88A) and the left floor panel (67A). Then place the right front roll bar bracket (89D) in front of the passenger’s seat, additionally insert it into the openings on the right roll bar cage (89B) and the right floor panel (67B).

Step 4

Assemble elements 89E, 89F and 89G - forming together the passenger’s reading light - as indicated by the yellow arrows. Check that the curved part of the arm (89F) is correctly placed towards the light (89E).

Step 5

Place the two clamps (89H) on the right roll bar cage (89B) – do not tighten them. Position the passenger’s reading light (89F) as shown and tighten the two clamps. Then cut the excess lengths of the clamps (89H) with a scissor.

GENERAL VIEW

Part 90 - REAR BULKHEAD

Parts of number 90

  • 90A Rear bulkhead 
  • 90B Bulkhead support (x 4) 
  • Screw BM M 1.7 x 5 mm (x 3) 
  • Screw SM M 1.7 x 3 mm (x 10) 
Step 1

Place the four supports (90B) on the rear bulkhead (90A) and secure each of them with an SM screw as per detailed photo (right).

Step 2

Retrieve the hooks provided in steps 72, 73, 77 and 78. Insert two hooks (72B&73B) into the openings on the upper edge of the rear bulkhead (90A) ensuring their correct orientation see photos. 

Then insert  two other hooks (77B&78B) into the openings on the lower edge of the rear bulkhead (90A). Ensure their correct orientation as shown in the photo: external hooks facing outwards (yellow circles) and internal hooks facing inwards (red circles).

Step 3

Position the rear bulkhead (90A) by inserting the four bulkhead supports (90B) on the left and right floor panel (67A&67B). Insert the tubes of the roll bar cages (88A&89B) into the side openings (blue circles) and those of the rear roll bar pipe (89A) into the upper openings (red circles) of the bulkhead. 

Turn the assembly over and secure the bulkhead (90A) with four SM screws. 

Then secure the bulkhead (90A) to the base of the left and right roll bar cage (88A&89B) with two BM screws.

Step 4

Please use a tweezer for the next step;  Attach the seat belt hook (73C) to the lower hook (73B)

and the upper seat belt attachment hooks (72C&76C) to the upper hooks (72B&76B) of the rear bulkhead (90A) as shown in the pictures. 

Then attach the seat belt attachment hooks (77C&73C) to the hooks (77B&73B). Finish by attaching the seat belt attachment hooks (77C) to the hook (77B).

GENERAL VIEW

Part 91 - REAR WINDOW

Parts of number 91

  • 91A Rear panel 
  • 91B Rear window 
  • 91C Support plate 
  • Screw AP P 1.7 x 4 mm (x 2) 
  • Screw ACP P 1.4 x 3 mm (x 6) 
  • Screw AM M 1.7 x 4 mm (x 4) 
Step 1

Place the rear window (91B) on the rear panel (91A) and secure with five ACP screws.

Step 2

Turn the rear panel (91A) over and secure the support plate (91C) with one AP screw as shown in the photo. 

Step 3

Position the rear panel (91A) on the rear bulkhead (90A). Flip the assembly over, align the openings and secure the rear panel (91A) with three AM screws.

GENERAL VIEW

Part 92 - UPPER REINFORCEMENT BAR OF THE ROLL BAR SAFETY CAGE

Parts of number 92

  • 92A Left rear upper reinforcement bar 
  • 92B Right rear upper reinforcement bar 
  • 92C Tank support 
  • 92D Cap 
  • 92E Tank 
  • 92F Adhesive tape (x 3) 
  • 92G Clamp 
  • Screw ADM M 1.7 x 8 mm (x 2) 
  • Flat head screw AIM M 2 x 3 x 6 mm (x 8) 
  • Screw SM M 1.7 x 3 mm (x 3) 
  • Screw AP P 1.7 x 4 mm (x 5) 
Step 1

Position the rounded end (yellow circle) of the left rear upper reinforcement bar (92A) on the rear panel (91A) and secure it with an AP screw.

Step 2

Place the right rear upper reinforcement bar (92B) with the rounded end (yellow circle) to the left. Position the tank support (92C) as shown in the photo and secure it with an SM screw.

Step 3

Place the cap (92D) on the tank (92E) and secure it from below with an AP screw. 

Position the tank (92E) on the rear panel (91A) and on the tank support (92C) (placed on the right rear reinforcement bar 92B), then secure it with an SM screw onto the support and with an AP screw on the rear panel.

Step 4

Turn the chassis over. Remove the two screws (yellow circles) securing the front joint (67D), then remove the joint as shown. Keep these items in a safe place as these will be used in a later stage.

Step 5

Connect the headlight cables (18D) to the C2 socket on the PCB (18C). Locate the headlight cables (18D) with the three LEDs labeled C2-2. 

Pass the C2-2 LEDs, one at a time, through the openings in the left floor panel (67A) see blue circle. Insert the LEDs into the openings provided on the dashboard panels (80A, 84B and 85D), see blue circles. Turn the chassis over and secure the cables with the two adhesive tapes (92F).

Step 6

Reposition the front joint (67D) -  previously removed - and secure it with its two CM screws.

Step 7

Take the front frame assembly made in stage 86 and align it with the seating unit. Tilt the lower frame (5A) (as indicated by the red arrow) and place the left and right floorboards (67A & 67B) on top (yellow arrows). 

Ensure that the clutch pedal (20B) is in front of the left front roll bar bracket (89C), as indicated by the blue circle and arrow.

Turn the steering wheel (86A) so that its two arms are perfectly horizontal (yellow line) and check the correct positioning of the ABARTH name and logo (blue circles), in order to keep the front wheels straight. Place the new intermediate shaft (86H) on the steering column (86F) and secure it with an ADM screw.

Step 8

Flip over the front frame and the seating unit that is held together, and secure these with six AIM screws. 

Position the headlight cables (18D) on the diagonal bar of the lower frame (5A) and secure these by using the clamp (92G) and tightening it (yellow arrow). 

Then cut the excess lengths of the clamps (92H) with a scissor as indicated by the red dotted line.

GENERAL VIEW