Shaun_E

Electrical: I'd start with the coil - if it's the one bolted to the engine block then they get a hard life in a Caterham and I went through about 3 of them before going wasted spark with a remote coil pack. Otherwise the usual rotor arm, distributor cap, leads. Fuel: fuel pump is a possible culprit. I'd been chasing a similar issue for months - swapped all the ignition components out with no success but checked fuel pressure which was fine at idle but dropped rapidly under load. A new pump resolved the issue. TPS is also a possibility.

What thermostat are you using? Most Duratec cars use an 82 deg thermostat and if that's the case on yours, your fan would still be on when the thermostat is closed so definitely too low a range. I can't remember exactly what temp my fan comes on (it's controlled by the ECU) but it's mid/high 90s. My car, as with many Duratecs, is overcooled when ambient temps are low.

We have 2 crotch straps fitted adjusted to the two positions we need - just use the one you need and tuck the other one out of the way

Take a look here: https://www.jenvey.co.uk/throttle-bodies-and-components/fuel-injectors I have the Siemens 630cc/min which are not ideal as they flow way too much. They fit using the Jenvey fuel rail and come with a small spacer to enable that fit. I am thinking of swapping to the 440cc/min ones. I think you can probably use either of the Pico injectors as well - probably best to give Jenvey a call and they can advise. 330cc is probably fine for a stock 420 but do check. My engine is 260bhp and probably needs more flow than that but it's not an exact science!

You'll have the same issue with most aftermarket ECUs - the volumes are too small to warrant writing the code for Windows and Mac. As above, buying a cheap "garage laptop" will be the best answer in the long run. There are plenty of other rolling road tuners that can work with Emerald - try Troy at Northampton motorsport, Steve Greenald at Track and Road or Dave Gemzoe depending on where in the country you are.

A good point from 7 Wonders - if you have the injectors in the TB instead of the stock position, the Bosch green injectors don't fit with a flat filter backplate so you need to buy the shorter pico injectors.

I've got Raceline 48mm TBs on my 260bhp engine. If you aren't looking for more power then maybe 45mm would be fine but speak to them and they can advise. As James said above, you will need a remap.

If you have an update/addition to the bolt list then please email to itsupport@caterhamlotus7.club since the published email above is no longer live. I'll try to get the page updated with the correct address. I'll also try and get it moved to the club website as currently it's hosted on my storage 😮.

Top one is 11" (x 1/2" UNF) according to my bolt list but I don't have the details for the bottom one .

Hi Mike - I’ll have them please. Can come and collect them at some convenient time - no rush.

G4062 works well - I drop the tyre pressure down to 10 or 15 psi as much more than that and it gets messy!. I've seem some recommendations for a vacuum bleed kit but i think they are a lot more expensive.

Yes, flat top beams are OK for MOT:

There's even a drawing in the Competition section here

For the last 10 years I've had the Siemans 630cc/min injectors on my 260bhp Duratec 2.0L. They were chosen mainly because they physically fitted and were available! Every time it's been mapped, the mapper has complained that the engine is fiddly to map in that it doesn't respond nicely to injection map changes. I always put this down to the injectors being massively oversized (which technically they are). It was never a huge issue and the maps I ended up with were good (both Steve Greenald and Troy at Northampton motorsport have mapped the car at different times). The engine is out for a rebuild and I've been toying with the idea of getting some more appropriately sized injectors. A slightly lower capacity injector is now available: Siemans 440cc/min so what I'd like to know is if it is worth making the change? The usual fitment for similar engines is the Bosch "green" 412cc/min but these don't physically fit due to the backplate/air filter set-up I have. The existing injectors have been cleaned and checked recently and are well matched and working well. Thoughts please 😊

No, I used to have a heater and the plate is just blanking the hole🙂. The battery weighs half what a Banner does.