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We removed the plenum chamber and throttle body to help with the engine installation and plumbing (in fact I think it is impossible to route all the coolant pipes with it in place).

Refitting is very simple, just a matter of bolting it back on. A couple of the bolts are difficult to access but a combination of socket extensions and wobble bars did the job.

We also installed the airbox and air filter which simply mounts on three rubber bobbins just in front of the scuttle on the passenger side. A piece of rubber edge seal needs to be fitted to the airbox intake, the rubber flange will form a seal against the bonnet intake.

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The throttle cable ‘plugs’ into the pedal box and arcs around the front of the engine to loop back and terminate in the throttle body. The nipple on the pedal box end slots into the throttle pedal. The throttle pedal slot required a little adjustment and deburring with a Dremel until I was happy that the cable was secure but would not chafe during use (it may be worth purchasing a spare throttle cable and keeping it in the boot as a precaution).

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The throttle pedal and throttle stop need adjusting to ensure a full range of movement on the throttle body. This involved bending the upper part of the throttle pedal backwards and lowering the pedal stop (apparently this is entirely normal). I managed to get a full range of movement and the final act was to put a blob of silicone sealant in the top of the pedal to stop the cable from jumping out before refitting the pedal box cover. I had also read that some IVA inspectors like to see the ‘plug’ secured where it attaches to the pedal box – I drilled and tapped a small hole to accept a 4mm cap-head screw as a retainer.

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UPDATE: Caterham supply a Banner lead-acid starting battery as standard. Nothing wrong with this except there are lighter options out there these days.

Once all the electrics are sorted I will swap the Banner unit out with a Lithium Ion Phosphate battery from Jack Webber Motorsport. The cost of these batteries has fallen dramatically in the last couple of years and they bring several advantages, the most obvious is the weight saving. The new JWM battery is about a quarter of the weight of the lead acid battery.

I had to fabricate a simple mount using two pieces of aluminium bar and nylon spacers. The test fit worked fine, I’ll rearrange the wiring later.

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