Maintenance

Adding VVC to an EU3 K Series Engine Wiring Loom

Adding VVC to an EU3 K Series Engine Wiring Loom

By Andrew Revill. With thanks to Alan Archer.

Assembly Guide

This is the assembly guide from around 2001 and covers a lot of K-series cars.

Assembly Guide

Assembly guide 2014

This is the assembly guide from 2014 and covers Sigma engined cars. 

Assembly Guide 2014

Caterham Service Schedule

Regular maintenance tasks as per the Caterham service schedule

Caterham Service Schedule - Duratec specific

Thanks to Marcus for this service schedule adapted to take account of the differences for the Duratec engine.

Change CRB Without Removing Engine

Stephen Grant/ Martin Woodham (with Top tip from Gareth Harrold) checklist for replacing Clutch Release Bearing without taking the engine out of the car.

Changing a radiator fan control switch to an ECU controlled fan with a manual over ride switch.

Thanks to ben7 for creating this document and to Paul Deslandes and Jonathan Kay for their valuable input.

Check the oil level on a K-series engine

Oil Capacities

Standard Wet Sump:5 litres

Standard Wet Sump with Oil / Air separator:7.5 litres

Dry Sump (tank in Bellhousing) :4.5 litres

Clutch Release Bearing pre-load article

Having trouble with your clutch release bearing? Wondering what those squealing noises are? ​John Vine describes his CRB problems, unearths a likely cause, and sets out his solution.

Corner Weights / Flat Floor Set-Up

One of the important items that should be checked when trying to optimise the handling characteristics of your Seven are the corner weights in order to ensure that each tyre is carrying its proper share of the overall weight of the car.

Equipment for loan register

Here's a list of equipment owned by members that they are willing to lend to other members.

Fitting a Battery Master Switch

A master switch kit has been produced by Caterham Cars to enable the fitment of an Autolec battery master switch, primarily for competition purposes, but also for security. This contains the following components:

 

1 x Autolec Battery Master Switch with fixing bolts

Fitting a Track Day Rollover bar

The April 2016 edition of Lowflying contained an article covering the fitting of a trackday rollover bar to a Caterham Seven.

How to adjust throttle bodies

Close the TBs completely and then adjust the balance mechanism so that both start to open at *exactly* the same time. open the throttle fully to make sure that all 4 plates are at the same angle when fully open to confirm they are in balance, it's often easier to see discrepancies when the throttle is fully open.

Installing a 3rd brake light

Heres how to fit a 3rd high level brake light to your Caterham. With thanks to Oli Wright for the instructions and pictures.

Click here for full document

Jacking up a Seven

Using a Scissor or Bottle Jack (eg to change a wheel)

 

Removing K-series engine

I'm about to remove the engine/gearbox from my car for some work on the engine/clutch - I've a few questions below but any other useful tips greatly received:

Replace the A-Frame bush

Q
As the bolt heads are recessed at both sides where it attaches to the de dion tube and a fairly tight fit for a socket, I didn't seem to be able to find any of my metric sockets that would fit.

Stop rear light corrosion

Rear Light Corrosion

Caterham rear lights always corrode on the inside as they cannot effectively be sealed. This is because they are trailer/caravan rear lights, but mounted upside down. As the drain holes are now at the top water gets in, especially if the car is used all year round.

Stop the gauges from misting up

Question

I get a build up of condensation on the inside of the faces of the fuel and temperature guages when I run my car. How can I prevent this?

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