free hit
counters
S4s engine and nearside fuel tank removal - mike_sekinger's Esprit Blog - The Lotus Forums Jump to content
  • entries
    11
  • comments
    76
  • views
    21,501

S4s engine and nearside fuel tank removal

Sign in to follow this  
mike_sekinger

874 views

Hi Folks,

The weather was really quite warm today so I decided it was a good day to remove the S4s engine.

The time consuming part is the preparation to disconnect everything - the actual lift is easily a one man job with a little care

A/C was non-functional, so left the pump attached
[img]http://img37.imagefra.me/i51g/sekinger/grq4_2a1_u6qlh.jpg[/img]

Limited clearance on front body
[img]http://img40.imagefra.me/i51g/sekinger/grq4_b69_u6qlh.jpg[/img]

Ready to roll the chassis clear
[img]http://img37.imagefra.me/i51g/sekinger/grq4_f20_u6qlh.jpg[/img]

Papas little helper :innocent:
[img]http://img40.imagefra.me/i51g/sekinger/grq4_6d6_u6qlh.jpg[/img]

Manifold nuts removed
[img]http://img37.imagefra.me/i51g/sekinger/grq4_ec8_u6qlh.jpg[/img]

Twin cracks in the old manifold
[img]http://img37.imagefra.me/i51g/sekinger/grq4_410_u6qlh.jpg[/img]

Nearside tank ready for removal
[img]http://img40.imagefra.me/i51g/sekinger/grq4_9e9_u6qlh.jpg[/img]

Underside of nearside tank badly corroded
[img]http://img40.imagefra.me/i51g/sekinger/grq4_3c2_u6qlh.jpg[/img]

Empty engine bay
[img]http://img40.imagefra.me/i51g/sekinger/grq4_9ea_u6qlh.jpg[/img]

Not a bad days work :thumbsup:

Cheers,
Mike S
Sign in to follow this  


23 Comments


Recommended Comments

Some more progress.

Turbo back from being overhauled - unfortunately it has to go back, as the threads are not correct for the water connections
[img]http://img37.imagefra.me/i51s/sekinger/grq4_aa3_u6qlh.jpg[/img]

Got the replacement tank through from Lotus After Sales. Looks as though they have had the supplier do something about the coating :thumbsup:
[img]http://img40.imagefra.me/i51s/sekinger/grq4_e10_u6qlh.jpg[/img]

Needed to remove the broken manifold stud - closest to the turbo. Ended up having to Heliocoil it...
[img]http://img40.imagefra.me/i51s/sekinger/grq4_58c_u6qlh.jpg[/img]
[img]http://img40.imagefra.me/i51s/sekinger/grq4_d8c_u6qlh.jpg[/img]
[img]http://img40.imagefra.me/i51s/sekinger/grq4_901_u6qlh.jpg[/img]

New manifold test fitted ready for the weekend
[img]http://img40.imagefra.me/i51s/sekinger/grq4_daa_u6qlh.jpg[/img]

More progress planned over the weekend.

Cheers,
Mike S

Share this comment


Link to comment
Final update for this week.... it was very cold in the workshop so not as much progress as I would have liked..... :wallbash:

Exhaust manifold nuts and locking plates
[img]http://img40.imagefra.me/i51u/sekinger/grq4_11b_u6qlh.jpg[/img]

New gearbox mounts
[img]http://img37.imagefra.me/i51u/sekinger/grq4_057_u6qlh.jpg[/img]

New engine mounts - blue dot on RH side, pink on LH side
[img]http://img40.imagefra.me/i51u/sekinger/grq4_1ba_u6qlh.jpg[/img]

Fresh LH fuel tank installed and plumbed
[img]http://img37.imagefra.me/i51u/sekinger/grq4_cc0_u6qlh.jpg[/img]
[img]http://img37.imagefra.me/i51u/sekinger/grq4_995_u6qlh.jpg[/img]
[img]http://img40.imagefra.me/i51u/sekinger/grq4_815_u6qlh.jpg[/img]

Hopefully, the turbo will be back for next weekend, so I can finally get the engine ready for re-installation.

Cheers,
Mike S

Share this comment


Link to comment
Hi BIbs,

Not sure that there will be any noticeable engine performance improvement, but it will certainly help with heat management in the engine compartment and provide some environmental protection for the manifold.

I´ll report back on how the coating is performing once the engine has been running for a few months.

Cheers,
Mike S

Share this comment


Link to comment
Why did you not use copper nuts on the manifold? They will never seize and if they do, you can put some force on them to break the thread. Clean up the studs and you're ready

Share this comment


Link to comment
Following advise from a respected 4-cylinder specialist, I´m using stainless studs and nuts.

With the exception of the one broken stud closest to the turbo, all other nuts came away without problems after 15 years.

Cheers,
Mike S

Share this comment


Link to comment
A day of frustration and annoyance.... the intention had been to install the turbo and prepare the engine for re-installed in the car.

The turbo was unpacked but when giving a cursory inspection and check on the shaft play, I found that there was way too much - almost 0.50mm play. There is an audible clonk as the impellor makes contact with the compressor housing...... not impressed. The turbo has gone back again to be rebuilt properly. :wallbash:

[img]http://img40.imagefra.me/i524/sekinger/grq4_3d8_u6qlh.jpg[/img]
[img]http://img40.imagefra.me/i524/sekinger/grq4_911_u6qlh.jpg[/img]

In the absense of being able to install the turbo, I overhauled the chargecooler pump.

Undo from the oil pump housing and withdraw
[img]http://img37.imagefra.me/i524/sekinger/grq4_7ad_u6qlh.jpg[/img]
[img]http://img37.imagefra.me/i524/sekinger/grq4_053_u6qlh.jpg[/img]

Remove the pump cover and found a couple of the impellor fins missing
[img]http://img40.imagefra.me/i524/sekinger/grq4_659_u6qlh.jpg[/img]
[img]http://img37.imagefra.me/i524/sekinger/grq4_f01_u6qlh.jpg[/img]

Rebuilt and installed
[img]http://img40.imagefra.me/i524/sekinger/grq4_696_u6qlh.jpg[/img]
[img]http://img37.imagefra.me/i524/sekinger/grq4_318_u6qlh.jpg[/img]

Hopefully, there will be more progress next weekend.

Cheers,
Mike S

Share this comment


Link to comment
Hiya Freek,

Actually designed and built by a clever chappy at Lotus. Comes with bolts drilled to accept different diameter drills when opening out the stud. :detective:

Cheers,
Mike S

Share this comment


Link to comment
Hi Mike,

many thanks for the info, especially the bit about the different bolts. If I ever need the tool I know now how to make one.

Again many thanks

Freek

Share this comment


Link to comment
Progress made on the S4s this last weekend.

While the engine was out we tackled the usual suspects in addition to the exhaust manifold:

Water pump was replaced with a fresh pump
[img]http://img37.imagefra.me/i52e/sekinger/grq4_96a_u6qlh.jpg[/img]
[img]http://img40.imagefra.me/i52e/sekinger/grq4_093_u6qlh.jpg[/img]

Cam boxes resealed and cam oil seals replaced
[img]http://img40.imagefra.me/i52e/sekinger/grq4_ebc_u6qlh.jpg[/img]
[img]http://img37.imagefra.me/i52e/sekinger/grq4_458_u6qlh.jpg[/img]
[img]http://img40.imagefra.me/i52e/sekinger/grq4_508_u6qlh.jpg[/img]
[img]http://img40.imagefra.me/i52e/sekinger/grq4_ded_u6qlh.jpg[/img]
[img]http://img37.imagefra.me/i52e/sekinger/grq4_377_u6qlh.jpg[/img]

Moved to 104deg inlet timing for improved response
[img]http://img37.imagefra.me/i52e/sekinger/grq4_d16_u6qlh.jpg[/img]
[img]http://img37.imagefra.me/i52e/sekinger/grq4_870_u6qlh.jpg[/img]

Rebuilt T3-60 trim turbo installed. Utilising a new bearing housing with metric threads for water - so deployed banjo fixings
[img]http://img40.imagefra.me/i52e/sekinger/grq4_56b_u6qlh.jpg[/img]

Engine was finally now ready for re-installation
[img]http://img40.imagefra.me/i52e/sekinger/grq4_6a7_u6qlh.jpg[/img]
[img]http://img40.imagefra.me/i52e/sekinger/grq4_80b_u6qlh.jpg[/img]

Gearbox oil seals refreshed and driveshafts installed
[img]http://img40.imagefra.me/i52e/sekinger/grq4_2d0_u6qlh.jpg[/img]
[img]http://img37.imagefra.me/i52e/sekinger/grq4_4b0_u6qlh.jpg[/img]

Chassis tube protected with heat wrap
[img]http://img37.imagefra.me/i52e/sekinger/grq4_1bc_u6qlh.jpg[/img]

Need at least another full day to complete the reconnection of the engine in the car...... but a good weekends work ! :thumbsup:

Cheers,
Mike S

Share this comment


Link to comment
Good job Mate, nice to see someone sharing the fun of owning a Lotus. I might do this when I eventually get my brakes from PNM, seems to be taaking ages. 6 pots for hte front and 4 for the back, should stop now.

Dave

Share this comment


Link to comment
Thank you Holger - a worthy comment.

Engine plumbed in and ready for fluids
[img]http://img37.imagefra.me/i52k/sekinger/grq4_8ea_u6qlh.jpg[/img]
[img]http://img37.imagefra.me/i52k/sekinger/grq4_c04_u6qlh.jpg[/img]
[img]http://img37.imagefra.me/i52k/sekinger/grq4_52d_u6qlh.jpg[/img]

Gear change mechanism and exhaust hanger
[img]http://img40.imagefra.me/i52k/sekinger/grq4_550_u6qlh.jpg[/img]
[img]http://img37.imagefra.me/i52k/sekinger/grq4_299_u6qlh.jpg[/img]

Now a question for the 4-cylinder gurus.
The vaccuum pump has two ports - one smaller than the other. I only have one connection for the vaccuum pump - a small diameter flexible rubber one. The small diameter plastic hard-pipe for the heater is already tee´d off earlier in the hose run.
What connects to the smaller diameter port on the vaccuum pump?
[img]http://img40.imagefra.me/i52k/sekinger/grq4_c8a_u6qlh.jpg[/img]

Fluids tomorrow !

Cheers,
Mike S

Share this comment


Link to comment
Hi Mike,

Good progress on your 4 banger. I can't help you with the vacuum pump as I have a mechanical one in my car (S4 parts list shows only one used connection, the one closest to the mounting bracket and also mentions a connector sleeve unequal bore).
I have one question however, can you give me some information about the heat insulation you used on the chassis tubes ?? I was thinking of fabricating solid stainless steel ones but your solution looks far more easy and is probably much more effective.

Many thanks in advance,
Freek

Share this comment


Link to comment
[quote name='mike_sekinger' date='20 February 2011 - 11:43 AM']


Now a question for the 4-cylinder gurus.
The vaccuum pump has two ports - one smaller than the other. I only have one connection for the vaccuum pump - a small diameter flexible rubber one. The small diameter plastic hard-pipe for the heater is already tee´d off earlier in the hose run.
What connects to the smaller diameter port on the vaccuum pump?
[img]http://img40.imagefra.me/i52k/sekinger/grq4_c8a_u6qlh.jpg[/img]

Fluids tomorrow !

Cheers,
Mike S
[/quote]


Looks like the small black port that the hose is connected to. The other white port is probably the air outlet to ambient.

Share this comment


Link to comment
Thanks Travis.

I got some help from Sparky and connected up to that port at the weekend.

Can´t start the car yet, as the main coolant pipe is leaking from a split in the de-gas port. It was repaired with ´chemical metal´, but it is not holding water. New pipe on the way.......

@Freek: The chassis tube is protected by a simple wrap of high quality heat shield material. It is held in place by jubilee clips. It is very easy to remove and inspect the tube beneath.

Cheers,
Mike S

Share this comment


Link to comment
What a day....... it was like Christmas this morning. I got my AP clutch back for the V8 and the main coolant pipe for the S4s.

As I was flying back to Dusseldorf in the afternoon, I had a rushed morning on the cars.

Out with the pipe with the damaged degas stub
[img]http://img40.imagefra.me/i538/sekinger/grq4_0a9_u6qlh.jpg[/img]

In with the new.....
[img]http://img40.imagefra.me/i538/sekinger/grq4_123_u6qlh.jpg[/img]

Compression union fitted due to seized PAS pipe fitting
[img]http://img37.imagefra.me/i538/sekinger/grq4_053_u6qlh.jpg[/img]

Everything is looking good for a start-up at the weekend :thumbsup:

Cheers,
Mike S

Share this comment


Link to comment
Hi Christopher,

The 4-cyl is pretty nice to work on, but the jobs weren´t too challenging. Wish I had known about the Torx bolts in the cam boxes [i]before[/i] starting the removal work :getmecoat:

I have a huge respect for the likes of Sparky/Wookie who perform maintenance tasks with the engine in situ, by the side of the road. I´m not sure that I would have been having so much fun under those circumstance :unworthy:

This weekend coming is going to be pretty exciting in the sense that both the S4s and the V8 are scheduled for their respective start-up and road tests. Hoping for a positive result there.

How are you with your plans to pull and rebuild your engine?

Cheers,
Mike S

PS: I´ve been watching the Twinkie/Butterfinger thread with some level of envy - loved bulk-buying those things from the 7-11 when in Orlando..... found them addictive :thumbup:

Share this comment


Link to comment

Create an account or sign in to comment

You need to be a member in order to leave a comment

Create an account

Sign up for a new account in our community. It's easy!

Register a new account

Sign in

Already have an account? Sign in here.

Sign In Now

×