This guide is based on myTechTalk thread "Duratec R400: removing/repairing/replacing wet sump" (April 2016).
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.
Although this guide is aimed at pre-2015 Duratecs, it may also apply to most Sigma models, and probably the 160 too.
Adding VVC to an EU3 K Series Engine Wiring Loom
By Andrew Revill. With thanks to Alan Archer.
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.
Thanks to ben7 for creating this document and to Paul Deslandes and Jonathan Kay for their valuable input.
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.
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.
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:
This is the assembly guide from 2014 and covers Sigma engined cars.
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.
Stephen Grant/ Martin Woodham (with Top tip from Gareth Harrold) checklist for replacing Clutch Release Bearing without taking the engine out of the car.
Heres how to fit a 3rd high level brake light to your Caterham. With thanks to Oli Wright for the instructions and pictures.