DIY Engine Swap

paulW · Post by **paulW** » Sun Mar 29, 2009 7:05 pm

Heatshielding installed successfully...(wood at the bottom is temporaty, while sealant cures.)

P1010375.JPG

Clutch changed...(had to make a custom alignment tool, 22mm plastic water pipe was a perfect fit.)

P1010380.JPG

Changed Differential seals..piece of cake, popped out and in without any hassle.

Unlike the thermostat, which was a nightmare to get access to, even with the engine out...(how you can ever hope to reach the upper thermostat housing bolt with engine in.)

So all jobs done, and engine ready to drop in next weekend.

robin · Post by **robin** » Mon Mar 30, 2009 12:22 am

Mostly people remove the intake manifold to change the 'stat - though removing the manifold is also not easy!! I plan on sticking in a PRT when I next have the engine removed - cba doing it before then - I value the skin on my arms more than the alloy in my cylinder head

Cheers,
Robin

Rich H · Post by **Rich H** » Mon Mar 30, 2009 6:35 am

Neat job on the heatshields

roadboy · Post by **roadboy** » Mon Mar 30, 2009 5:30 pm

robin wrote:I plan on sticking in a PRT when I next have the engine removed - cba doing it before then - I value the skin on my arms more than the alloy in my cylinder head

Indeed. Wise words!

Dan

paulW · Post by **paulW** » Mon Apr 06, 2009 8:16 pm

P1010390b.JPG

This weekend, engine went in, driveshafts in, cables etc, all attached.
Broke the blue temp sensor..so ordered up a new one....so hopefully almost ready to fill it up with coolant, flush, bleed and see if it will turn over.

Replaced gear linkage bushes...HUGE difference, can feel the selector clicking into place, can't get it into gear at the moment, clutch needs bleeding and I am hoping that the gear selectors haven't been bent as they were supporting the engine in transit.

Clutch fluid is bright blue, so will have to try and source some similar or flush the system.

So apart from the uncertain aspect of the gear selection altogether a successful weekend.

...think I have the gear cables connected the right way round...left and right on the gear stick translates to in and out on the gearbox, forward and back, rotates the shaft into the gearbox?

paulW · Post by **paulW** » Tue Apr 21, 2009 9:50 am

Engine is in and started first time, without even a hiccup.

Found a small pin prick coolant hose leak...in the hose that goes to the radiator\heater on the drivers side...looks a nightmare to replace so fixed it for now.

Ran up to temperature ok, seemed to need a quick blip of the throttle to open the thermostat and get warm water into the radiator.

Gear linkage cables were connected the wrong way round, so gear selection is now working.

Flushed the brakes and clutch, but currently having a bit of a nightmare trying to bleed the clutch...any advice\ideas?

So just need to get this clutch working and throw the rear clam on and I should be back on the road.

(it is so so quiet, with standard engine, cat and standard exhaust!!)

roadboy · Post by **roadboy** » Tue Apr 21, 2009 10:03 am

paulW wrote: Flushed the brakes and clutch, but currently having a bit of a nightmare trying to bleed the clutch...any advice\ideas?

Make sure you push the slave cylinder all te way back whilst blleding the system. Normally a two man job tbh.

HTH

Dan

philthy · Post by **philthy** » Tue Apr 21, 2009 2:45 pm

Good effort on getting it to start 1st time!

tut · Post by **tut** » Tue Apr 21, 2009 3:29 pm

Sounds like a job well done Paul, its always a good feeling when it starts straight away instead of having to start trouble shooting.

tut

paulW · Post by **paulW** » Thu Apr 23, 2009 12:41 am

Thanks guys, was a lot easier due to replacement engine having most of the ancilleries already attached, but still nice feeling all the same.

Thanks for tip Dan, will try and get it bled properly at the weekend.

paulW · Post by **paulW** » Sat Apr 25, 2009 3:56 pm

So near, but so far...took car out for first test drive to go get fuel, engine running well, slight juddering from brakes, but probably just the corrosion on the disks clearing.

Though on return, when stopped small coolant leak, so looks like my repair has failed.

paulW wrote:Found a small pin prick coolant hose leak...in the hose that goes to the radiator\heater on the drivers side...looks a nightmare to replace so fixed it for now.

So need to find a replacement hose, tempted with some of these Elise S1 silicon hose sets...though can't find anyone with details on what hoses are included and if they are suitable to the early "up and over" S1's.

Think this looks like it might be the hose I need...the one that runs into the driver's side chassis rail.

http://cgi.ebay.co.uk/LOTUS-ELISE-S1-WA ... 240%3A1318

robin · Post by **robin** » Sat Apr 25, 2009 5:26 pm

I don't think that is the correct part.

I seem to have mislaid my parts manual (and they changed all the part numbers anyway, I think). Easiest way to get the correct part is to phone the parts department of a Lotus dealer, give them your chassis number and tell them which bit you want. It's fairly easily described as the rubber pipe that connects to the drivers side chassis coolant rails.

Cheers
Robin

roadboy · Post by **roadboy** » Sat Apr 25, 2009 5:38 pm

Pretty sure that is the pipe that connects to the chassis rail ali pipe but don't know if they are different on the early, up and over pipework cars.

Will dig out my parts manual.

Dan

paulW · Post by **paulW** » Mon Apr 27, 2009 3:45 pm

Think part number i am after is C111K0002F, been quoted £170!!!!

http://www.bell-colvill.co.uk/LotusShop ... C111K0002F

tut · Post by **tut** » Mon Apr 27, 2009 5:23 pm

£195, bloody joke. Can you get one copied or make one up with joins?

tut

Scottish Elises

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