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My 1996 1 of 3 S4 - Got it back to U.K all the way from Asia! - Esprit 'Project & Restoration' Room - The Lotus Forums Jump to content
UPAUTO

My 1996 1 of 3 S4 - Got it back to U.K all the way from Asia!

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Hi everyone

I am just a newer on this forum, I joined member since May this year after when I got my 96 S4 in U.K. Since it - I have been working on it. The story is…………………….

Early this year (2012), I have travelled to Taiwan for 10 days holiday, during the holiday - I have purchased a 1996 Lotus Esprit S4 which was for sale in Taiwan, this is only 1 of 3 Lotus Esprit S4 which been made in 1996 and those three are all in Taiwan. This Lotus esprit S4 only has done 12096km (7560miles) during last 12 years, 1 ownership; however it has not been used for few years, due to some leaking problems. I will be showing all the process from when the car was in Taiwan to U.K, faults finding and finally fully recondition back to 90's supercar showroom condition.

23/02/2012 Lotus Esprit S4 was on the way to the port, ready for shipping from Taiwan.

IMG_0074.JPG

03/04/2012 Lotus Esprit S4 has fianlly arrived to Southampton U.K in the container.

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With only (12096 km) 7560 miles on the clock and nearly half tank of fuel.

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Off loaded from the container and waiting for delivery to Nottingham next week.

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11/04/12 after many weeks waiting, Lotus Esprit S4 has finally arrived to Nottingham.

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Due to lack of care & use, engine bay is covered with all the dirts, oils and carbons.

SAM_0632.JPG

14/04/2012 Fuel leaking problem found - fuel breath pipe has cracked in few sections.

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Removed the boot carpet and panel for close inspection, degrease and clean.

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Fully dgreased, washed and cleaned the gearbox and rear top chassis.

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16/04/12 Removed intake pipes, manifold, fuel rail and throttle body.

160412c.JPG

All the removed parts are waiting for degrease and clean.

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Faulty intake manifold core plug has caused rust and coolant leak.

160412a.JPG

Removed air condition pump and alternator pump.

160412b.JPG

18/04/12 Chargecooler, intake manifold and throttle body have all been cleaned.

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20/04/12 Fully degreased, washed and cleaned the engine.

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Carbon fibre vinyl wrapped on the starter motor.

200412a.JPG

22/04/12 Fully degreased, washed and cleaned underneath of rear chassis (Left).

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Fully degreased, washed and cleaned underneath of rear chassis (Right).

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02/05/12 Cleaned and de gasketed for intake manifold flange.

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Cleaned and de gasketed for intake manifold throttle body flange.

020512a.JPG

Cleaned and removed the old rusty core plug.

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New 1st core plug has inserted with sealant.

020512c.JPG

New 2nd core plug has inserted with sealant.

021512d.JPG

De gasketed on the intake flange and moved the wiring loom, ready for more cleaning.

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03/05/12 Carbon fibre vinyl wrapped on the charcoal canister.

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21/05/12 Got back from Matla break, removed engine covers and clean all the rubber tubes.

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22/05/2012 The ECU wiring harness before clean.

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After cleaned and re taped.

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23/05/12 Air con pump, starter motort and rear strut bar re fitted.

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Cleaning and degreasing the engine covers.

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24/05/12 After many many weeks waiting, the C&E 386 form has arrived.

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27/05/12 Alternator, new oil filter and cable convoluted conduit fitted.

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29/05/12 New fuel breath pipe has arrived.

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Proper fuel pipe rather than original plastic pipe.

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Near side new fuel breath pipe fitted.

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Off side new fuel breath pipe fitted.

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Near side trim panel re fitted.

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Off side trim panel re fitted.

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31/05/12 Coil pack and air con pipes re fitted. Cleaned and waxed the engine panels.

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Rear window fabric trim re fitted.

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07/06/2012 Removed 4 x spark plugs, it has been running rich, due to lack of use.

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Degreased again for touch up chips of the paint on the surface and custom made the gasket.

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08/06/2012 Re assembled the intake system.

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09/06/2012 New engine covers, intake manifold gasket and O rings arrived.

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10/06/12 Cleaned the old dirty spark plugs for now, will fit new set in the future.

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Cleaned the lower engine head surface and applied with gasket sealant.

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The gasket fitted on the lower engine head surface.

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Cleaned the lower engine cover surface and applied with gasket sealant.

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Finally bolted the lower engine cover to the engine.

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Sorted out all the coolant pipes, re fitted the charcoal canister, spark plugs & HT leads.

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15/06/12 Re fitted air box, engine cover and chargecooler.

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Check Garrett turbo - it is in nearly new condition, no play and no oil leak.

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New 10w60 racing oil and Anti freeze coolant.

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1.5 liter's oil ready to put into engine.

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Fresh oil pouring in to engine.

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Re fitted vacuum pump, coolant header tank and induction pipe. Engine re started!

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That is it!! so far.... I haven't been working on it for last few months. I have deicded to save fund and leave till next spring to do more work - hopefully by next summer and car will be on the road with number plate. Tony

Sorry about the last few pictutes are only showing links rather than pictures, I have used my all picture usages. Tony

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Upgrade today to remove Google ads and support TLF.

 :-) great..my one is just for look for now....haha

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Says on that import form that your S4 is a 2.0. That right?

Cool pics by the way! Lovely looking car.

Edited by esprit s2

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yep 250BHP model, Left hand side drive as well :0) thanks

Edited by ramjet

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Many thanks, still a lot of works to do - but need fund to do it.....sleep.pngsmile.png

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wink.png thanks - just tart it up a bit....

I washed and cleaned during the weekend smile.png

269832_502171256468560_1750573414_n.jpg

I even cleaned the other Toy too p.gif

409221_502171089801910_1669935999_n.jpg

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Wooooo...lovely racing green!

Big thank you - will do smile.png Tony

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I know Louts Esprit manifold always have a bit of problems after many years…..  I checked my S4 during the weekend – wowow after 16 years.  The nuts and studs are still in zinc plated condition and manifold just like new. WOW :D

 

manifold.JPG

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Today I spent some time to clean wheels and suspensions from my Esprit, checked the brake & suspensions too - every things are ok so far.....  On the brake discs surface - the brown stuffs are very light grease to stop disc rust up.  As my Lotus still no ready on the road yet.

 

 

Near side front

 

lotusnsfwheel.JPG

 

Near side rear

 

lotusnsrwheel.JPG

 

 

Off side front

 

lotusosfwheel.JPG

 

 

Off side rear

 

lotusosrwheel.JPG

Edited by UPAUTO

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I seem to remember the manual saying not to remove the manifold from the back plate as the air flow has been very accurately set at the factory???

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Really interesting to see this progress! I didn't know that the last S4's were 2.0 engines.  It'll be great to have another S4 back on the road!

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Thanks Guys.... I am trying.......err...... ;)


I seem to remember the manual saying not to remove the manifold from the back plate as the air flow has been very accurately set at the factory???

I don't know about this......  too??


The 2ltr engine was a tax dodge in a few countries!

Car looks nice!

Indeed.... especially for Italian market.....

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After few months wet weather, I decided to clean up under the bonnet.

 

CAM00218.jpg

 

And then I discovered there is water in NS headlight pod buckets.

 

SAM_3852.JPG

 

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Not sure about OS, therefore I removed all the lamps to exam.  OS is in good condition and luckily I discovered earlier - NS rust is re workable.

 

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After good cleaned the head lamps - they all in great condition, not bad for 18years old :turned:

 

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SAM_3862.JPG

Edited by UPAUTO

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