Today was the day I planned to take on a relatively small task -- installing the Everest chip that came in the mail a few days ago. So, here's how it went, and how that relatively small task turned into a full day of cursing and swearing, broken up by 3 trips to the parts store for tools I needed.
First, I headed out to the car with removal/installation instructions in hand. I sat beside the driver's side (as instructed) and reached in to locate the ECU. The first thing I found was a pallet of relays just floating around loosely. Of course, as I tried to investigate that, two of the relays fell to the floor. Dammit! Now there's no doubt that I'm going to have to get back into the Lotus position and finally get serious about finding the two nuts that secure the knee bolster, and take the bolster off so I can figure out what's up with that bunch of relays. Trouble light. Mirror. Contorsions. Finally....I found one of the nuts behind/next to the relay pallet (this must be why the relays weren't secured. The previous owner, who installed the Superchip, didn't have the patience to put it all back together correctly.). After contorting and fighting and cussing for a while, I had to make the first trip to the parts store to get a deep-well, 10mm socket. (I bought a set of six metric deep-wells just in case) Finally, I got that nut off. Now to find the other. It took a lot of looking, squirming, contorting, and swearing, but it finally paid off. The damn thing hides behind a white-ish plastic thing labeled "Fed Logic Unit." Take the connector off that, then remove the screw holding the upper end of it in place (requiring removal of three harness brackets), then get the deep-well socket onto it. Crap! I need one of those omni-directional adapters for the ratchet handle. Another trip to the store (I have one for my big 3/8 drive ratchet, but not for the small 1/4 inch one). Ok, that did it. The bolster's off. Now the work on the ECU and the relays will be easy. There's a single screw that holds the relay bracket in place, and it's missing. Thank you again, Mr. Previous Owner. I got lucky, and found a screw that fit perfectly on the first try.
Now to the ECU and the new chip.
I took the ECU out (no problem), then following the instructions, I opened it up, took out the chip, and then it got confusing. The original OEM chip, which I had in the box the Superchip came in, had to go back in, then install the Everest. The trouble is, the OEM chip still sat piggy-back on it's adapter (that connects it to the circuit board), but the Superchip came off, leaving it's adapter (which is soldered to the board) behind. This means that when the OEM chip is put in place, it stands 50% taller than it should, based on the pictures, and the blue plastic cover isn't tall enough to clip back in place at that end of the board. After dicking around with it for a few minutes, I decided "F@$k it," and just put it on with the blue cover only clipped at one end of the board. Well, short story long, it all went together (with that one exception) as advertised.
ECU back in the car. Relay board back in place, with the suicidal relays returned to their homes, and now the real fun begins.
First, since I had to take the bolster all the way off (it had been hanging down a bit since I worked on the speedo cluster a while back, and I was leaving it that way until I figured out a permanent fix for the inaccurate speedo), this was the best time to go ahead with painting the cluster's trim with the gun metal to match the rest of the trim I've been working on. Out comes the cluster. I won't go into detail about the painting. When it comes time to put it back in, I decided to fiddle with the speedo a bit. I pulled out the little stop that the needle rests against at a stand still, and pulled the speedo needle off. I put the needle back on pointing to where about minus-10 mph would be, then held it above where the stop goes, and reinstalled the stop. I did that because at a stand still, the needle didn't actually rest on the stop, and I thought that could have something to do with the speedo always reading 15-20 mph faster than the GPS indicates. As it turns out, I was right. After putting everything back together, when I went for a test drive to test the Everest, I noticed the speedo is now reading only 5-10 mph fast. Unfortunately, I put everything all the way back together before I discovered that, and there's no way in Hell I'm taking it back out to move the needle again. That will have to wait until something else requires it.
The last bit of work was to remove the MBC. That was a piece of cake.
Test drive results: Perfect! Although I must admit, I don't notice a huge difference in the performance (I had the MBC adjusted to allow about .8 bar boost), I think it's smoother, and I know it is better for the engine to have the system mapped for the higher boost, instead of just cranking it up and defeating the fuel cut-off with a Supershit. It went right to .9 bar consistently (and I have a totally stock exhaust system), although I did once exceed that to about 1.0 briefly. I can live with that. I don't normally drive that way anyhow, and all I have to do if I see that is back off a bit.
I did discover what must be one of the biggest, if not the biggest, pain in the arse job in an Elan. That damn knee bolster. The front of it is held in place by two tiny, tiny clips that have to fit onto a little metal shelf. You have to push it up into place, then push it forward to engage the clips. The trouble is, you can't see them, and you can't feel anything. All you can do is bang on it hard with your fist to
hopefully get them engaged, and then relax to see if the thing drops or not. If it doesn't drop, you've
probably got them engaged. Then you put those two nuts on, which are impossible to see, and nearly impossible to reach, and will have you ready to take a torch to the car by the time you're done!

What's worse, as the nuts tighten, because of the length of the studs (which is actually a bit more than the depth of a standard deep-well socket), you tend to be pushing out on the bolster a bit, and those clips, being as frakking tiny as they are, tend to disengage from the shelf, and you have to start all over!

frakkin'
Anyway, all's well now. I'll post a pic or two of the cluster, trimmed in gun metal, tomorrow.
BTW, if anybody wants a Superchip for an Elan, I've got one dirt cheap.