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MD355

Serious trouble V8

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A-grade is closest to the size specification that CP Carrillo used for their piston, but the difference in size tolerances is small.

In the end the builder will measure the liners to ensure the appropriate clearance with the CP piston.


1996 Esprit V8, 1998 Esprit V8 GT, 1999 Esprit S350 #002 (Esprit GT1 replica project), 1996 Esprit V8 GT1 (chassis 114-001), 1992 Lotus Omega (927E), 1999 Esprit V8SE, 1999 Esprit S350 #032, 1995 Esprit S4s, 1999 Esprit V8 GT (ex-5th Gear project), 1999 Esprit V8SE ('02 rear)

1999 S350 #002 Esprit GT1 replica

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Wouldn't the pistons rings be sufficient to fill any little difference? As far as I understand the rings should be cut to the right length so they are well adjusted, but I have no experience at rebuilding an engine so I am just wondering ^^

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Ring gap and piston/cylinder clearance are different.  If you take the wide-end of the bore size for OEM liners and work back with the size of the CP piston, then you could end up with greater wall clearance that desired - CP spec sheets stated 0.084mm.. 

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1996 Esprit V8, 1998 Esprit V8 GT, 1999 Esprit S350 #002 (Esprit GT1 replica project), 1996 Esprit V8 GT1 (chassis 114-001), 1992 Lotus Omega (927E), 1999 Esprit V8SE, 1999 Esprit S350 #032, 1995 Esprit S4s, 1999 Esprit V8 GT (ex-5th Gear project), 1999 Esprit V8SE ('02 rear)

1999 S350 #002 Esprit GT1 replica

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Great explanation, Mike !!!

Now what about conrods ? Do I keep stock conrods ?

Any chance the forged pistons will be too loud during warm-up due to the bigger tolerances ?

Could this be a problem (oil consumption/ vibrations etc) ?

Thanks !!!

Edited by MD355

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Unless you have a genuine desire for a much higher power engine, stock rods should be fine.  They are also fine with the forged pistons.

You should not observe any audible difference or issues with higher oil consumption over stock pistons.

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1996 Esprit V8, 1998 Esprit V8 GT, 1999 Esprit S350 #002 (Esprit GT1 replica project), 1996 Esprit V8 GT1 (chassis 114-001), 1992 Lotus Omega (927E), 1999 Esprit V8SE, 1999 Esprit S350 #032, 1995 Esprit S4s, 1999 Esprit V8 GT (ex-5th Gear project), 1999 Esprit V8SE ('02 rear)

1999 S350 #002 Esprit GT1 replica

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Today's update !!

Forged pistons, all bearings, all oil pump new parts, all gaskets ordered !!!

Fortunately the machinist fixed the crankshaft requiring only +0.25mm bearings , which are available !!!

So now we wait for the parts to arrive to start the build !!

In the meantime, what do you guys think about intercooler / chargecooler on the V8 ?

Has anyone done it, reliably and cost effectively ? Thanks !!!

 

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Also, I think I am going to need an upgraded radiator !!

I currently have the stock one, and installed a switch to turn on manually the fans on the radiator !!

This systems seemed to work ok, for now !!

Any suggestions for upgraded radiator for the V8 ?

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ProAlloy (the same company that produced that sweet chargecooler system) also produce the main coolant radiator.

I would recommend them or C&R in the USA, who have also provided me with very high quality items in the past.

Or you can get your existing radiator re-cored with a bigger more efficient set-up.  That might save a fair chunk of money.

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1996 Esprit V8, 1998 Esprit V8 GT, 1999 Esprit S350 #002 (Esprit GT1 replica project), 1996 Esprit V8 GT1 (chassis 114-001), 1992 Lotus Omega (927E), 1999 Esprit V8SE, 1999 Esprit S350 #032, 1995 Esprit S4s, 1999 Esprit V8 GT (ex-5th Gear project), 1999 Esprit V8SE ('02 rear)

1999 S350 #002 Esprit GT1 replica

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Today’s update !!!

I received my Carrillo forged piston !!

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4E1A012B-644F-4EF0-8A7F-DDFF86A8B55A.jpeg

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I came across this :

 

I asked for price and if they still make it !! I am seriously tempted !!!

Maybe I need to install upgraded radiator and chargecooler in conjuction !!

 

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Well, of course you are free to install what you think is cool but I suspect it won't enhance the reliability you were looking for in the first place %)

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2 hours ago, Giniw said:

Well, of course you are free to install what you think is cool but I suspect it won't enhance the reliability you were looking for in the first place %)

While we are at the subject of reliability, I am replacing everything that can be broken on the engine : new oil pump, new bearings, new water pump, new top end (fixed already), etc. One part I wanted to replace but is no longer available is the chain that gives drive to the timing belts. I found the “tensioners” of the chain and I am replacing them, but the chain itself I cannot find. Any ideas?

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14 hours ago, MD355 said:

While we are at the subject of reliability, I am replacing everything that can be broken on the engine 

What's the lifespan of the primary drive shaft bearings, I know the outer bearing on Porsche engines is famous for failing & wrecking the engine?


Cheers,

John W

http://jonwatkins.co.uk

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1 hour ago, jonwat said:

What's the lifespan of the primary drive shaft bearings, I know the outer bearing on Porsche engines is famous for failing & wrecking the engine?

This would make good sense if you have the front cover off for oil pump component replacement.  Both roller bearings are available directly from SKF suppliers.

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1996 Esprit V8, 1998 Esprit V8 GT, 1999 Esprit S350 #002 (Esprit GT1 replica project), 1996 Esprit V8 GT1 (chassis 114-001), 1992 Lotus Omega (927E), 1999 Esprit V8SE, 1999 Esprit S350 #032, 1995 Esprit S4s, 1999 Esprit V8 GT (ex-5th Gear project), 1999 Esprit V8SE ('02 rear)

1999 S350 #002 Esprit GT1 replica

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1 hour ago, jonwat said:

What's the lifespan of the primary drive shaft bearings, I know the outer bearing on Porsche engines is famous for failing & wrecking the engine?

I don't think there is a fixed time / miles interval for replacement, I believe that the lifespan of the bearings is relevant to the preventive maintenance of the car : frequent Oil changes, normal warmup of engine, etc etc.

 

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18 minutes ago, MD355 said:

I don't think there is a fixed time / miles interval for replacement, I believe that the lifespan of the bearings is relevant to the preventive maintenance of the car : frequent Oil changes, normal warmup of engine, etc etc.

 

The problem is being sealed for life roller bearings preventative maintenance has no effect on them & when they fail the engine dies. On the Porsche the inner bearing is an oil fed bush & there are kits to replace the outer bearing with the same.


Cheers,

John W

http://jonwatkins.co.uk

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1 hour ago, jonwat said:

What's the lifespan of the primary drive shaft bearings

The early V8s had an issue with premature intermediate shaft bearing wear, at some point during 97 the front bearing was changed from ball to roller type, the front cover bearing housing was also altered to accommodate the smaller 50mm O/D roller bearing.

With an overhung shaft driving two cambelts it's critical not to overload the bearing by over tensioning the belts. 

As far as bearing life goes, my early V8 engine @43k is out for its second replacement set of IS bearings.

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My car amassed over 100k miles on original I. S.  Bearings... 

It was a 99 model year, so I guess the revised Bearings

 

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15 minutes ago, steve930 said:

My car amassed over 100k miles on original I. S.  Bearings... 

Hi Steve, are you sure that they were not replaced as part of the Ed Winter rebuild?


1996 Esprit V8, 1998 Esprit V8 GT, 1999 Esprit S350 #002 (Esprit GT1 replica project), 1996 Esprit V8 GT1 (chassis 114-001), 1992 Lotus Omega (927E), 1999 Esprit V8SE, 1999 Esprit S350 #032, 1995 Esprit S4s, 1999 Esprit V8 GT (ex-5th Gear project), 1999 Esprit V8SE ('02 rear)

1999 S350 #002 Esprit GT1 replica

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2 minutes ago, mike_sekinger said:

Hi Steve, are you sure that they were not replaced as part of the Ed Winter rebuild?

The engine achieved over 100k (miles) before the rebuild.. (original Bearings) Then as you suggest they were replaced.... During the rebuild

 

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More updates !!

I measured the weight of the Carrillo forged pistons and voila : 315 grams

Once I get my original pistons back I will weigh them for comparison !!

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23 hours ago, MD355 said:

I came across this :

 

I asked for price and if they still make it !! I am seriously tempted !!!

Maybe I need to install upgraded radiator and chargecooler in conjuction !!

 

I'd be interested to know how much they want for a kit. I've looked at building something from off the shelf parts in the past.

cheers

-Chris

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Some ideas for Intercooling the V8 !!!!!

While I am waiting for the rest of the parts to arrive for my car, I was doing some research and I came across a Lotus Esprit V8 that is for sale with 500 bhp.

I looked at the ad and found this picture. It appears that this guy has built some sort of custom Air-to-air Intercooler !!

If you look closely, the blue pipes of the intake (which are covered with insulating material) must have warm air exiting the compressor side of the turbo, going to the sides of the car (there must be intercooler there) and coming back to the intake plenum...

Cool and simple idea !!! I will call the guy to find out more details !!

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