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Callaway

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  1. Freek, Thanks for the timely reply! With this down I should be cruisin' tomorrow. Can't wait, thanks again my friend! -Erik E. 1994 Esprit S4
  2. My 1994 Esprit S4 is just about ready to roll for the first time in over a year and the body shop is trying to figure out where exactly this wire connects. They shot me over this picture on email to see if I recognized it. This is on the drivers side by the brake fluid unit, headlight, etc. I do have the factory tech manual on CD but I wanted to see if anyone of you guys could spot this off the top of your head. Thanks in advance fellas, looking forward to getting behind the wheel again! -Erik E. 1994 Esprit S4
  3. Hey guys, Sorry I am so late getting back to this thread, I've been swamped lately and just now got around to pulling the downpipe off. There is alot of oil in the exhaust side of the turbo. I could see where oil had leaked around the exhaust manifold even before I pulled the downpipe off. All I have left to do is pull the four bolts off of the manifold and out she comes! Anyone know a good place here in the US to have my turbo rebuilt at? Thanks! Best Regards, -Erik E. 1994 Esprit S4
  4. Hey guys, Thanks for all the help! Unfortunately I've been busy and haven't been able to pursue this matter any further. I did want to add that when I said major loss of power I really mean MAJOR loss of power, as in the car BARELY accelerates. Lets just say you couldn't reasonably drive it anywhere! With the car in neutral it revs fine, and the engine sounds fine. Very little (sometimes none) smoke at idle, but a fair amount of white smoke when revved in neutral and quite a bit more if you put in gear and try to drive it. My brother was telling me that on the way to the house after this happened he could go WOT (or at any throttle position for that matter) and the car just barely accelerated, he describes it as "the car felt like it had only 50 horse power and could barely move itself". He said that everything was still smooth (no bucking or missing), just no power. Stefan, I'll definitely check that out. Did you experience a loss of power to the extent that I described in my last post? Thanks for your help! -Erik E. 1994 Esprit S4 Dave, No I haven't checked these but I will make sure to do so, sometimes it can be simple things so it never hurts! Thanks for your input! Craig, Haven't checked the coolant level yet, will add that to my list! I'm definitely trying to keep it positive lol! Mark, Thanks for the info, that's not good! I was hoping that since it was only a gallon 87 I had mostly burned it off, but you never know. Very little smoke at idle (with periods of no smoke at all). Boost gauge shows no vacuum whatsoever and the car won't boost at all (in fact the boost gauge stays pegged to the left and never moves at all now). Idle sounds like usual. Let me know what you think and thanks for your help! Andy, I'll definitely have to do a compression test, i'll report back when I find out more! Thanks for your help! -Erik E. 1994 Esprit S4
  5. Artie, I haven't checked the couplers yet. I just went into the garage and cranked her up and its not throwing a check engine light. My first worry was that it hit some bad gas. A few days ago I wasn't paying attention and accidentally filled her up with 1.9 gallons of 87 octane (out of habit from filling up my Tahoe all of the time). I quickly realized I had made a mistake, and went ahead and finished filling up with about 13 gallons of 92 octane. I proceeded to drive a good 50-60 miles before hitting any real boost, just to make sure to burn a good bit of that lower octane gas up. I'm really hoping some of that lower octane gas didn't cause any knock, however the engine still idles and revs fine without and odd noises so I think I may be safe (crossing my fingers). I'm assuming the ECU would have retarded the timing had it started knocking too bad. I had also hit full boost a few times today before the incident without any problems. Thanks for the quick reply! -Erik E. 1994 Esprit S4
  6. Hey guys, Well no sooner do I get her back together does she go down once again. My brother was driving the car back home for me today and he was running it through the rev range at WOT. He heard a loud pop and then the sound of rushing air. The car is now blowing white smoke when you rev it up, however, it still idles and revs smoothly. I backed it out of the garage and anytime you place load on the engine it starts to really billow out white smoke. My guess at this point is that the head gasket is blown, do these symptoms seem to indicate this to anyone else? My brother mentioned that after the incident the car had little power and struggled to get up to speed. He also mentioned that the boost gauge was sitting flat (all the way to the left) while cruising instead of at zero like it normally does. I plan on running a compression test on it this weekend and draining the oil to check for coolant mixing, but I figured I would throw up a post and see if anyone had any input they could give me. Thanks! Best Regards, Erik E. 1994 Esprit S4
  7. Todd, I have been using Freeze 12 in my 1994 S4 with good results for over a year. It blows pretty cold, however, I suspect a true R12 drop in may blow just a tad bit colder. Either way, it has worked well for me! Let me know if I can be of any other help! -Erik E. 1994 Esprit S4
  8. Hey guys, I need to know which cable goes closest to the gear box. One of the cables has a yellow sticker on it, and in the picture included I just had it set up like this; but I am not sure if this is correct. This is on a 1994 S4. Also, I've tried the cables in both positions and in both orientations I have not been able to get into Reverse gear. What is the best way to go about adjusting the linkage? -Thanks! -Erik E. 1994 Esprit S4
  9. Jon, I had the exact same symptoms! White smoke plumes coming off the exhaust manifold for a few minutes after the car heated up, with a burning rubber smell. It was the top camshaft tower o-ring (or camshaft end cap o-ring). I ordered the top and bottom o-rings (wanted to replace both while I had access to both end caps), removed the heat shield, popped off the end caps and replaced the o-rings on them, problem solved! Altogether a really painless procedure! -Erik E. 1994 Esprit S4
  10. Anyone who is familiar with the renault tranny know if it would be actually possible to fill the tranny with oil through the reverse light switch port, once the reverse gear has been selected? I can feel that something is in the way when putting my pinky finger down into the hole while the car is in neutral. I'm still working on getting the linkage right so that I can shift into reverse and see if it slides out of the way. I have the exact amount of fluid that the tranny takes, so overfilling would not be a concern. Thanks! -Erik E. 1994 Esprit S4
  11. Well over fathers day my dad handed me that bolt remover set from sears, still no dice. To make matters worse the damn transmission mount is right in the way of me getting it on there straight, and it makes it hard to work around. Is it possible to fill up the case with oil any other way? I have the exact amount of oil that goes in, so overfilling it would not be an issue. Someone suggested trying the reverse selector switch port, however I unscrewed it and there is something blocking the hole. I'm not sure if this is moved out of the way when reverse is selected, I tried to select reverse however the linkage needs adjusting, so I am not able to find reverse at the moment. Anyone got any other ideas? I'm really trying to avoid having to pull the damn tranny again, I just got it all back together! Thanks for the responses everyone! -Erik E. 1994 Esprit S4
  12. Hey Guys, Well I have been working getting the car finished today, and OF COURSE, I cannot finish this SOB without one more problem popping up. I managed to strip the shoddy tranny fill plug, so I attempted to get at it with a set of vice grips. Now it is just a mangled, semi-rounded mess. Anyone have any ideas of how I can get this stupid plug out? I did a quick search and someone mentioned welding a larger nut to the remaining bit, however, I do not have any welding equipment, so i am not sure how viable that option is at this point. I keep trying to tell myself I love this car, but its really starting to chap my ass lately! Any ideas would be greatly appreciated! -Erik E. 1994 Esprit S4
  13. I finally managed to get the roll pins, tranny, AND bolt stud out today! Thanks Travis and everyone else who contributed! Now its just a reverse process and I should be good to go. I need to send out a special thanks to Jim Knowles (lotus4s) for all of his help, wisdom, and support. I had the pleasure of speaking to Jim on the phone the other night and I can't say enough good things about him ! I really appreciate it Jim, it was good to chat with you! -Erik E. 1994 Esprit S4
  14. Travis, I'll give that a whirl, hopefully it will come free here soon. Do you know the size of your punches by any chance? Thanks! -Erik E. 1994 Esprit S4
  15. Anyone know the exact size of punches I should buy? I bought two, each fitting the circumference of the separate roll pins, and now I've got the first (smaller) punch jammed in there. I didn't think about the fact that the roll pins actually compress when put in. Now I need to figure out how I can pull the damn punch out. Its only about 3/4 inch pushed in, but its stuck pretty good. I've been pulling on it with a pair of pliers for the last 8 minutes and it hasn't come free yet. Did I mention that I wish I would have just seen the right torque specs so I could have avoided this hassle!?! *FRUSTRATED* -Erik E. 1994 Esprit S4
  16. LoL! That is definately true, God how I wish I had just looked at the right torque pressures for those bolts now! I could be out driving right now instead of stressing over it. Live and learn I suppose! I think I'll try to be as gentle as possible while driving the roll pins out. Since I will not be removing the seals or o-rings unless they are damaged, will I still need to drain the tranny before taking the pins out? I'm assuming it only needs to be drained if you are going to replace the seals, but I want to double check before I make a mess of the garage floor (and waste good tranny oil, just replaced it only 3000 miles ago). -Erik E. 1994 Esprit S4
  17. Travis, Great guide, thanks for the link. Will it be completely necessary to remove the seals and o-rings if they are not leaking, or can I just knock out the roll pins to release the driveshafts from the tranny so that I can lift it out of the car? From looking at your guide it looks like I could pull this off, but I could be missing something. -Erik E. 1994 Esprit S4
  18. After pulling the driveshafts will it be necessary to replace the seals? The reason I ask is because mine have never leaked so I assume they are in good shape. On top of that I already ordered the new flywheel bolts from JAE earlier today and had them overnighted, so if I were going to get some new seals I should have included them in that shipment! Anyone have any helpful insight into removing the driveshafts? Anything I should be aware of before I begin? Thanks again everyone, this is a great community and I can't thank you guys enough for all of the help and support you have given me! -Erik E. 1994 Esprit S4
  19. DOH! Jim, you were right! I went back and looked at my manual where I found the torque specs, sure enough it says V8; tighten two of the bolts, then apply loctite to the remaining bolts and tighten to 81 ft lbs. This one is on me! I must have been in a hurry, I never even noticed it said V8, GOD I wish I had double checked now! Thanks for the replies, I still need to get the driveshafts off and obtain a cherry picker to lift the tranny out. Its unfortunate because thats what I was trying to avoid the whole time! Anyone know if it might be possible to get the stub out with the tranny still behind it? Depending on the size of the drill needed, I might be able to slide one in there and get it lined up. I have about a 4-5 inch gap and the the space inside the front of the tranny to work with. Thanks! -Erik E. 1994 Esprit S4
  20. Steve, Thanks for reply! Just got the flywheel back off and the stud is about a little less than a 1/4 inch below the crank flange. Guess I'll have a go with an reverse out, in the meantime I will definitely be ordering a whole new set of bolts on Monday! -Erik E. 1994 Esprit S4
  21. Well this week just became a damn nightmare. While I was tightening one of the flywheel bolts to 81 ft lbs, it managed to snap. So I am left with about 3/4 inch or a little more of a bolt stuck in my crank. Anyone think an easy out will get this one out? Any suggestions would be greatly appreciated! In the meantime, I think I am going to go lie down for a bit, i'm steamed..... -Erik E. 1994 Esprit S4
  22. Thanks for the great replies, I did manage to get the flywheel off (used the screwdriver through the clutch cover hole suggestion combined w/ a cheater bar, worked perfect!), I'm about to run by a shop and have her ground here shortly! My question regarding the flywheel alignment has to do with all of the marks with various numbers and the "TDC" mark, which I assume means Top Dead Center. I noticed that the caption on a picture of the flywheel on Travis's site said that he used a honda alignment tool (here is the link: http://www.lotuscolorado.com/vulcangrey/ga...ission/P4100179 ). I just want to make sure that I'm not supposed to align one of those marks a certain way once the flywheel is back on before I reassemble everything and start her up. -Erik E. 1994 Esprit S4
  23. Hey guys! With the help of Marcus's instructions and Travis's pictures (thanks again guys!) I managed to get my transmission slid back enough to have access to the clutch/flywheel. I am currently down to the flywheel and have a couple of questions: 1. What is the best way to loosen/remove the flywheel bolts? I am unable to break them free without the flywheel rotating on me. I managed to get the clutch cover bolts off with a cheater bar and applying spurts of pressure to break them free. This does not seem to be working on the flywheel bolts, unfortunately. I went ahead and sprayed them liberally with some liquid wrench in the meantime in hopes that it will help loosen them up. Also, are the flywheel bolts 18mm? Thats what I have been using but it doesn't seem really snug. I tried 17mm and it seems to be too small, it will not slip onto the bolts completely. 2. When I take the flywheel to have it skimmed, do I need to tell them to do anything else besides to be sure and step it? 3. After I reassemble the flywheel and clutch, will it be necessary for me to realign the flywheel in a certain way now that it has spun a good bit from loosening the clutch/flywheel bolts? Any help is appreciated! -Erik E. 1994 Esprit S4
  24. Travis, Thanks for the link, it has been very helpful while removing various parts! I have a question about removing the flywheel that I will be posting a new thread about, I hope to hear from you on said thread. Thanks again! Marcus, You are the man, the steps worked out perfectly! Thanks for the helpful instruction! -Erik E. 1994 Esprit S4
  25. Hey guys! I am planning to begin the clutch job today on my 1994 S4, as the clutch started slipping here recently. I have already removed the trunk, now I just need to get started on removing the other various bits and bobs. I ran a search on the topic, and came across a thread where Marcus said that the job can be done without having to remove the drive shafts or the exhaust bracket. Marcus, if you could give any other pointers on this process it would be greatly appreciated! I have seen the pictures on Lotus Esprit World and it looks like they did the job this way. One of my main questions is this: directly behind the end of the tranny there looks to only be about a two inch clearance. The body looks like it would block the transmission from coming back any further, however, it almost looks to be removable. Is this a separate panel from the body that I can remove? I am trying to see exactly how I will be able to slide the tranny back enough to get sufficient clearance to pull the clutch out. I have heard that the chassis needs to be supported before taking off the cross brace. I'm guessing that the spot to jack from would be the rear chassis jacking point, and to leave it supported while the cross brace is off? If anyone has any suggestions I'd love to hear them! I will be documenting the process with pictures and a write up, in order to assist anyone desiring to do their own clutch job in the future. Thanks! -Erik E. 1994 Esprit S4
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