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613
607
633
615
611
610
609
616
397
115
632
10
632
1
10
612
397
623
13
10
622
13
10
56
617
618
600
608
609
498
614
470
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1.1 The assembly instruction
On the left side you find the illustrations of the assembly groups in-
cluding the part lists indicating the necessary components. On the
right side, marked by the corresponding number of illustration, the in-
structions for the proper assembly.
1.2 Screws and other small parts
M3 nuts are generally not provided with an identification number. As
a help easier to find out screws and small parts, please see ill. 1
which is showing you the most important components at original size.
1.3 Cutting threads
Threads have to be cut into eleven of the screw holes on the front
panel (see ill. 2 on the right-hand top side), as well as into the four
lateral screw holes on the underside of the roof, and into both screw
holes on the side panels. Before you start the proper assembly, use
those two self-tapping screws 111 supplied with this kit to cut these
threads. You should lubricate the screw and the screw holes (using a
little petroleum jelly, for instance) before doing so and afterwards use
a soft cloth to remove excess lubricant.
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2.1 Assembly of the doors
Into the inner cover of the left door lay one door lock 610 and two
door hinges 615. Press the mirror support 470, the door shield 613 as
well as the door lock bushing 614 into the corresponding openings of
the left door 607. Then insert the door handle 611 from inside into
the corresponding opening of the door and screw up the inner door
cover with the proper door using two screws 397 and one screw 115.
From the enclosed plastic tube cut off a piece of 27mm length. The
bushing you have thereby made is indicated in the illustration by 633.
From underneath press then the pin for door hinge 616 into the
proper door hinge. First slide the bushing 633 and afterwards one of
the door hinge bushings 612 between both door hinges onto the door
hinge pin and press now the door hinge pin into the upper door
hinge. Slide now the second door hinge bushing 612 onto the bottom
part of the hinge pin.
Prepare now the right door 608 by the same way.
2.2 Assembling radiator, front panel, steering wheel, doors
Use two screws 397 to fix the radiator grille 617 as well as the grille
frame 618 onto the front panel 600 and press the front screen 623
into the front panel. For this purpose lay the screen into the opening
on the left inner side of the front panel and bend it on its centre point
backwards until the screen may laid as well into the right side. Press
then the screen frontwards onto the front panel. The screen should
now be fixed.
With screw 1 add now the dashboard switch 498 as well as the steer-
ing wheel 56 onto the dashboard 622. Slide the door hinge pins with
the pre-mounted doors into the bushings lateral of the dashboard.
With screws 10 and washers 13 fix then the proper dashboard with
the doors onto the front panel. Screw the door hinge pins with the at-
tached bushings 612, with hinge supports 632 and screws 10 onto
the front panel. Adjust the doors until they lay - when closed - in
parallel to the front panel and to the roof. For this purpose lightly
bend the aluminium door hinges as follows: squeeze the upper
hinges a bit together, and push a bit the bottom hinges apart.
57-e.DOC / K-MAN
Page 2
Assembly group of the front section ill. 2
Screws and other small parts at 1:1 ill. 1
Tapping screw 2.2 x 6.5
Part no. 397
Tapping screw 2.2 x 4.5
Part no. 21
Countersunk tapping screw 2.2 x 4.5
Part no. 564
Nut M4
Part no. 19
Nut M3
---
Nut M2
Part no. 109
Square nut M3
Part no. 12
Knurled nut M5
Part no. 210
M3 x 8
Part no. 2
M3 x 6
Part no. 1
Self-cutting screw M3 x 8
Part no. 111
Self-cutting screw M3 x 6
Part no. 10
M2 x 8
Part no. 115
M2 x 6
Part no. 114
Stud bolt M3 x 18
Part no. 16
M4 x 25
Part no. 18
M4 x 8
Part no. 17
M3 x 25
Part no. 6
M3 x 20
Part no. 5
M3 x 16
Part no. 4
M3 x 12
Part no. 3
M3 x 10
Part no. 57
Shim 5 x 10 x 1
Part no. 391
Washer 4.3
Part no. 20
Washer 3.2
Part no. 13
Washer 2.2
Part no. 24
Spring washer 3.2
Part no. 14
Serrated washer 3.2
Part no. 15
Retaining washer 3.2
Part no. 25
B-57-1
B-57-8
Qty.
No. Assembly part
2
611 Door handle, MAN
4
612 Hinge bushing, door
2
613 Door shield, MAN
2
614 Door lock bushing
4
615 Door hinge, MAN
2
616 Pin for door hinge
∅
1.5 x 43.5
1
617 Radiator grille, MAN
1
618 Frame radiator grille
1
622 Dashboard MAN
1
623 Windscreen MAN
4
632 Hinge support
2
633 Bushing 27mm
(to be cut off the
plastic tube 70mm)
Qty.
No. Assembly part
1
1 Screw M3 x 6
6
10 Self-cutting screw M3 x 6
2
13 Washer 3.2
1
56 Steering wheel
2
111 Self-cutting screw M3 x 8
(for threading)
2
115 Screw M2 x 8
6
397 Tapping screw 2.2 x 6.5
2
470 Mirror hinge, bottom
1
498 Switch dashboard
1
600 Front panel MAN
1
607 Door -lh-, MAN
1
608 Door -rh-, MAN
2
609 Door inner cover, MAN
2
610 Door lock, MAN
