Motor Rebuild – (hot-to-trot)

[Doc Fizzix]

Costas

I am using Arias pistons. My tech wanted us to go 0.05 mm over just so we could make sure all the cylinders are straignt and round, do you know if going with a large diameter changes the compression ratio?

Here are a couple of links for my new pistons (PS they are the same that Dave M shipped me and I have Dave's pistons sitting here for anyone who wants them)

http://www.atomicspeedware.com/newpistarias.htm

http://www.ariaspistons.com/

[Matt RI]

How much is Bean selling the gaskets sets for?

They told me they are $259!

[Doc Fizzix]

Ask for Darren, I am sure he told me around $145.00, I might be in for a surprise when I get the bill

I will let you know next week when my two set show up and I get the bill

[Doc Fizzix]

Costas

My tech wanted us to go 0.05 mm over just so we could make sure all the cylinders are straignt and round, do you know if going with a large diameter changes the compression ratio?

oops! I am going with 0.5 mm over, sorry for the misprint

[Doc Fizzix]

OK, here is the Isuzu head set.

Missing most of the gaskets for a head-job. A list of what you get for $83.13:

- 16 valve guide seals
- block to head seal
- intake to plume gasket
- intake to head gasket
- exhaust gasket
- valve cover gasket

The rest?? Not there

Other gaskets were added separately:
- camshaft seals

[Doc Fizzix]

Just got back from GTI Coatings. I picked up the nuts, bolts, and everything else I left to be electroplated. WOW!

All items look great!

Here is a picture of the exhaust studs, look at the before picture and then the after, unbelievable, what a difference

[Doc Fizzix]

Here is a picture of just a handful of bolts that were electroplated.

Look like new and boy do they shine

[Doc Fizzix]

I even had all of the black parts re-coated

NOT PAINT! Electroplating

[Doc Fizzix]

One last sample of more parts that were plated

[Costas]

All your parts are bling bling GJ!

I am very concerned for the engine block gasket.

Since you are gonna use larger turbo (or am I messed up with all those threads I read?), what Boost pressure you intend to use it at? The first thing that may damage your precious engine would be a weak engine block gasket...

As I said before, if you are gonna run 1.0 boost then all is fine even with the stock one but if you are gonna run 1.2+ then BE CAREFUL on the choise you ll make on this gusket.

Keep up the good job, surely inspires us all.

Costas

[Dico]

One last sample of more parts that were plated

They look great!
Just hope i can find a local UK place that can achieve the same.

[Doc Fizzix]

Lotus complete gasket set showed up today along with a bunch of parts (will take pictures latter)

The gasket set was $258.00 and NOT $145.00 as I had thought

The label on the outside of the gasket set says Lotus, then you open it up and the contents are all bagged in a Genuine Isuzu Parts plastic bag. Just as I thought, this is the complete Isuzu overhaul kit no longer available from Isuzu with the Lotus sticker slapped on the box. Dave Bean has 10 in ( -2 that I bought) and I would suggest to buy one before they are gone

Lets hope our Isuzu friends do not start buying up Lotus parts

[Eddie_Z]

Really nice article you have made.

Funny how there are some differences in the Impulse 4XE1T and Elan 4XE1T, not major, but more than I had thought. It's a good thing you guys got the nicer cams, on our Impulses, the 1.8 cam swap is often done, and our cars pull HARD with them.

One question though, what made you decide to rebuild this engine with only 1,400 miles? This engine is not even broken in yet! The gaskets and seals I understand.


And FWIW, the Lotus Elan shares alot of similarities with the 1989 Isuzu I-mark RS engine. The I-mark also has the same style of IAC, has hydrualic lifters, same throttlebody, and possibly even the camshafts too!

[Doc Fizzix]

Thanks Eddie

The motor had been sitting since 1996 so I wanted to check it out before I ever used it, plus, I wanted to find all of the difference between the two motors before I felt comfortable putting it in my car, lets just say I wanted to make sure it was 100% the same as the Lotus version

There is a long and strange story behind this motor but lets just shorten things up, this is the second time I have owned this motor and the first time I did nothing with it for three years. When I got it back this spring I really wanted to have some fun with it.

The 1989 Isuzu I-mark RS is a close match from what I have learned but the tappets are not the same as the version used in the Elan. The 1992-93 1.8L GEO storm gsi motor has the exact same head and the same tappets.

Here is an a picture I got from Robie that shows the differences in the tappets between a 1989 I-mark and the Lotus Elan (and GEO storm 1.8L gsi)

[Eddie_Z]

Wow, very interesting details. I've heard there are tappets that are designed for higher revving engines. I wonder if the tappets used in the Elan/I-mark are better to use since they both had 1.6 engines, and the I-mark I know revs to 8K with no problems of valve float.

Also, can you take close-up pictures of both (Impulse/Elan) cams, and cam gears. I'm actually curious to see which cam gears came with your Elan. Take a close up picture of where it's marked "I" on the intake gear and "E" on the exhaust gear. On the Impulse intake cam gear it should be marked "I-4" and "E" for the exhaust gear.

[Doc Fizzix]

Another difference between the Lotus and Isuzu motors has been found. The check valve of the Lotus head has a hole that is drilled through the center, this hole allows the head to pump oil through the oil ports to the hydraulic lifters so the lifters can fill with oil. The Isuzu motor has blank (not-drilled) check valve since the Isuzu turbo does not have hydraulic lifters. Bought a new check valve from Dave Bean.

[Doc Fizzix]

Also, can you take close-up pictures of both (Impulse/Elan) cams, and cam gears. I'm actually curious to see which cam gears came with your Elan. Take a close up picture of where it's marked "I" on the intake gear and "E" on the exhaust gear. On the Impulse intake cam gear it should be marked "I-4" and "E" for the exhaust gear.

Yes, my gears are stamped with a "I-4" and an "E". I can take a picture but they are the same as on the Elan.

[Doc Fizzix]

Just came back from the machine shop. The head was resurfaced, took off 0.003" Also, the ports are going to be cleaned and smoothed, there are some very rough and jagged edges inside of the stock casting, this should give a little smoother flow. We are not "porting" but just cleaning up a little.

[DeeAitch]

Hmmm, could this check valve be the cause of my noisy tappets on start up Looks easy enough to change during a cam belt job so might give it a shot.
Part number and price please
Nice project. Interesting that Lotus did a bit more than just import the motor from Isuzu. I too was wondering why you were doing this on a low mileage motor when you could just as easily worked your magic on mine after a straight swap but then I realised you are 'somewhere over there'

[Doc Fizzix]

Actually, from what I ahve been told, Lotus did not do the work to the motor, they ordered the motors from Isuzu ready to go and Isuzu did all the work. The differences between the motor are all still Isuzu parts, some of the parts apear in different or other Isuzu/GEO cars from the Isuzu Impulse to the GEO Storm.

(PICTURED) Here is the part number for the relief valve: A100E6192S (Lotus part number)

Here is the part number for the check valve: A100E6193S (Lotus part number)

PLEASE NOTE: The picture shows the relief valve, not the check valve, my error. I bought both and then mixed my terminology up. Expect to pay $36.00 US each you need both