Maintenance

Duratec R400: how to remove and replace a wet sump

Introduction

This guide is based on myTechTalk thread "Duratec R400: removing/repairing/replacing wet sump"  (April 2016). 

How to pre-load the Clutch Release Bearing (CRB) -- for cars with cable clutches

Note: I've based this guide on an article I wrote for Low Flying (August 2004).  It applies to cars with cable-operated clutches, and specifically K-series from around 1997 on.  

oooOOOooo

 

Front Hub - Lack of lubrication

Especially applies to factory build & home build cars. Also any Seven more than four years old that has no record of lubrication maintenance on the front hubs

Rover K Series Sump Foam Baffle Change

ROVER K SERIES SUMP BAFFLE CHANGE

Re-calibrating the fuel gauge on pre-2015 Duratecs

Although this guide is aimed at pre-2015 Duratecs, it may also apply to most Sigma models, and probably the 160 too. 

NOTES:

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.

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.

Time Vernier Cams

Cam Timing (Non Standard Cams with Vernier Pulleys)

When turning the crankshaft to TDC, always turn it in such a way that the movement of the pistons is minimised.

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.

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.

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.

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:

Assembly guide 2014

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

Assembly Guide 2014

Tune Weber Carburettors

Selection and tuning of Weber DCOE carburettors

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.

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.

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

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.

Assembly Guide

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

Assembly Guide