Julian H Posted February 6, 2016 Share Posted February 6, 2016 Spent a very enjoyable day [until I got to item 2] today fitting my next upgrade. Everything went very well but I have a few queries.1] Do I cut off and dispose of the IACV wires. I understand the Emerald does not need it. Is the other end of each wire no longer connected?2] The AutoTeknix airbox was a challenge to fit. I needed to remove the clutch cable and also had to shorten and put a lead on the tabs on the underside to make it fit. The airbox is only around 1mm from the top of the side engine bay and I will never be able to get the bonnet back on. Surely that is not right? The airfilter will not slide onto the end of the airbox, it fouls on the headlamp mounting bracket.Thanks Link to comment Share on other sites More sharing options...
Titanium7 Posted February 7, 2016 Share Posted February 7, 2016 It may be you have a different engine type or chassis than me but I had an EU3 engine in a metric chassis and the air box fitted perfectly. It was close to touching the bonnet but I stuck a short length of 3mm neoprene foam on the underside of the bonnet to stop any possible rubbing or vibration. The clutch cable issue was fiddly but not a problem that needed anything doing. The air filter fitted without interference as well. Link to comment Share on other sites More sharing options...
Julian H Posted February 7, 2016 Author Share Posted February 7, 2016 Mine is an imperial chassis with EU3 engine. It definitely is not right. I am not even going to try and fit the bonnet. I went to see a fellow members car last night [his is EU2 though] and the airbox is much smaller and much farther away from the chassis... A picture is worth a thousand words Link to comment Share on other sites More sharing options...
JNC Posted February 7, 2016 Share Posted February 7, 2016 Hello Julian , have you tried the airbox the other way round with the filter facing towards the scuttle ? Link to comment Share on other sites More sharing options...
oilyhands Posted February 7, 2016 Share Posted February 7, 2016 The air box won't fit the other way round.Part of the problem is that you have a larger airfilter than is normal when fitting that airborne kit, usually the stock Caterham filter is used which has a smaller diameter. This won't actually fit over the neck of the air box so a piece for plastic drainpipe as a sleeve, this makes the neck of the air box where the filter attaches around 6mm smaller and this doesn't interfere with the lamp mount bracket.Oily Link to comment Share on other sites More sharing options...
Area Representative Richard Price Posted February 7, 2016 Area Representative Share Posted February 7, 2016 Julian, Was your car originally either a VVC or Xpower 140? If so, its likely that you have a different RHS engine mount so that the ally plenum clears the bonnet. You can either replace the engine mount now the car is fitted with TBs or use a longer engine mount to rubber bolt and fit up to 15mm of spacer. Link to comment Share on other sites More sharing options...
Julian H Posted February 7, 2016 Author Share Posted February 7, 2016 Thanks Oily, that should solve the filter problem.Richard, please can you tell me more. I have an XPower which used to have the VVC plenum. I need to replace the engine mount or use a spacer to raise the engine by up to 15mm? How difficult is this job if I just get a spacer and where do I get one from. Also, if the engine rotates slightly, wont I have a problem with the exhaust not lining up with the hole through the bodywork on the opposite side? Link to comment Share on other sites More sharing options...
Area Representative Richard Price Posted February 7, 2016 Area Representative Share Posted February 7, 2016 'Not sure quite how much difference there is between the vvc and non vvc the engine mount , but I know of at least two cars that have had the wrong (standard) engine mount with a vvc plenum, that have then trashed the bonnet.I'd make a spacer out of suitable tube (5/8 diameter with 1.6mm or 16swg wall thickness should do) I'd guess it would need to be 12 to 15mm long. Then you'd need a longer engine mount to rubber mount bolt which is 1/2" UNF, that is longer by the same amount.You'll hardly notice any difference on the exhaustside, as the lhs engine mount is very close to the exhaust cut out and the engine will rotate about that point. Link to comment Share on other sites More sharing options...
Julian H Posted February 7, 2016 Author Share Posted February 7, 2016 Interestingly my bonnet only just cleared the plenum [XPower, not earlier style VVC]. In fact, it has left some evidence of fouling at the louvres over the years. Ill look into the spacers/engine mounts and report back. I hope you are right about the exhaust. I also realised it is going to make the alternator even closer to the chassis vertical member too, and that is only around 5mm away! Link to comment Share on other sites More sharing options...
Superwhite R283 Posted February 7, 2016 Share Posted February 7, 2016 Hi Julian Sorry to hear you're having problems with the install. I've just recently fitted an auto tek air box, EU3 in a metric S3, I didn't have any issues, happy to take any pictures if it would help. I didn't know you could get carbon ones, very nice, I want one :0) Cheers Darren Link to comment Share on other sites More sharing options...
Julian H Posted February 7, 2016 Author Share Posted February 7, 2016 HiThe CF was a special order. Other than that its a standard shape as far as I know. Was your engine originally an XPower or VVC? Photo would be great please. Link to comment Share on other sites More sharing options...
Superwhite R283 Posted February 7, 2016 Share Posted February 7, 2016 I'll have to keep my eye out for a second hand one (very unlikely) A few pitures:hereherehere Link to comment Share on other sites More sharing options...
Julian H Posted February 8, 2016 Author Share Posted February 8, 2016 Thanks for the photos. That's pretty much where my airbox is, perhaps a little farther to the offside and obviously lower down. My CF box was a special order from Bernard.Today I ordered a standard [non VVC] RH engine mount. Not from CC who were out of stock and quoted 4 weeks. Once I had overcome my coronary I phoned Mick Redline who popped one in the post to me this afternoon I cant imagine why I didn't phone them first! Hopefully that will solve my problem. Link to comment Share on other sites More sharing options...
JNC Posted February 9, 2016 Share Posted February 9, 2016 Julian, Are you changing one or both engine mounts ?. If only one will the engine tilt make any difference to the oil pick up ?. And oil level on the dipstick. Link to comment Share on other sites More sharing options...
revilla Posted February 9, 2016 Share Posted February 9, 2016 I'm fairly sure that it's only the RH engine that is different on the VVC, the LH remains the same as for the standard K Series. Link to comment Share on other sites More sharing options...
Mankee Posted February 9, 2016 Share Posted February 9, 2016 It'll make neglible difference to the level and oil pickup. Caterham only supply one sort of bracket for the left-hand side of the engine. Just the right-hand side one was lower for the big plenum clearance. Link to comment Share on other sites More sharing options...
Julian H Posted February 9, 2016 Author Share Posted February 9, 2016 Oil pickup should be ok then, phew. The new bracket arrived today which appears to raise the engine by 12-13mm on the RHS which will definitely allow the airbox to clear as intended Link to comment Share on other sites More sharing options...
JNC Posted February 10, 2016 Share Posted February 10, 2016 How are you getting on, is it going ok ? Link to comment Share on other sites More sharing options...
Alan Reeves Posted February 10, 2016 Share Posted February 10, 2016 Julian I hope your engine is as clean as those pictures...in the interest of lightness Link to comment Share on other sites More sharing options...
Julian H Posted February 10, 2016 Author Share Posted February 10, 2016 John, I am a wage slave and I dont have a garage [only a glorified car port] so weekday progress is non-existant. Alan, Dave did a very nice job cleaning the bits when he reassembled my engine so it is not too dissimilar to Superwhite R's [should we call him Daz or Percy L ] Link to comment Share on other sites More sharing options...
Superwhite R283 Posted February 11, 2016 Share Posted February 11, 2016 clever Link to comment Share on other sites More sharing options...
Alan Reeves Posted February 12, 2016 Share Posted February 12, 2016 you can use my garage at the weekend if you need one... Link to comment Share on other sites More sharing options...
Julian H Posted February 12, 2016 Author Share Posted February 12, 2016 That is so generous thankyou Alan, however someone else beat you to it so my little motor is being swept away in the morning... and will return with a bit more attitude. Link to comment Share on other sites More sharing options...
JNC Posted February 15, 2016 Share Posted February 15, 2016 Hello Julian, Did you manage to work on your car at the w/e and is it now under cover ?. I hope you are getting it sorted, Hopefully I will be picking mine up from CC tomorrow 16th fingers crossed, I feel like it's like my first night with a new girlfriend ( you know how it works but you know it will be different ) LOL . Link to comment Share on other sites More sharing options...
Julian H Posted February 16, 2016 Author Share Posted February 16, 2016 Have fun today John, it will be very special trip home. Appears like it will be a good day for you weatherwise too. Watch out for the speed camera just down the road from CC My engine is now stripped down awaiting some parts* to arrive. Really enjoying getting my hands dirty too *cams, belt, tensioner, injectors, air filter and other sundries Link to comment Share on other sites More sharing options...
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