Time to shorten my To Do list ... quick additions:

[HJ2]

Agreed to everything.

I intend to use new over used anytime, (CU RIngs tend to harden, i have experience with these al lot, that can not be said about the paper / metal to metal seals). The one on the cilinderhead is some sort of lead sandwich?

All standard seals is no problem, but an exhaust to cilinderhead gasket is not the thing i can buy around here... hence my questions

Now let's reassemble all the parts i have stripped!

[ovi]

Agreed to everything.

All standard seals is no problem, but an exhaust to cilinderhead gasket is not the thing i can buy around here... hence my questions

Now let's reassemble all the parts i have stripped!

I never reuse old and exhaust gasket and would not recommend Henk!

[muley]

HJ2

Good posts and excellent photos.

As I have a/c I also left the dipstick tube in situ and just bent it forward. For the life of me I simply could not get the original clip back on to the oil drain - the access is almost impossible with the a/c pump installed and the fact I have rheumatic fingers doesn't help! . Eventually I installed a jubilee clip which I can just about get a long screwdriver in to tighten it up.

Cheers

Jim aka muley

[HJ2]

Thanks Jim,

Do you have any pictures of your Jubilee clip install?
I was already wondering how to get the hose back I never noticed it was there until i removed the lot. Ah... so this was the resistance i was feeling ...
(hence all clips in place of my first picture as i just removed it....)

I'm most afraid however of refitting all the heat shield-parts... What parts can be 'on' when i place the lump back in the engine compartment?
What are your experiences with re-using the exhaust gasket?

@ Dapinky: How many exhaust manifolds did you successful re-fit while using the old gasket? (Taken that only one failed as you described earlier)
If it fails, is it easy to slip the new gasket in place with the bolts undone, but everything else in situ?

I just received a call that my recored radiator is ready to pick up!

Regards,
Henk-Jan

[dapinky]

Henk,

I haven't actually had one fail - but used a new one as it was part of a gasket set, so i had it spare!.

I have done 5 on my own cars, (1 HGF, 1 engine swap, 2 turbo ports, 1 manifold replacement), and the same sort of number on other peoples cars. (some re-used, some replaced as part of a gasket set).

Has anyone had a failure of the part? When i spoke to a guy at the factory a couple of years ago, they said the reason they still had a few in aftersales stock was because no-one ever bought them, always using one as part of the head set, or if just disturbing the manifold, re-using the old one. If it is good enough for Lotus, It's good enough for me (but I'm not an expert, so if someone can convince me that it is necessary to use a new one, I'll concede).

[HJ2]

Ha!

Usualy 'Van Sten Engineering' a Lotus specialist in Den Hoorn (just around the corner) has not so much M100 parts in stock. Just my luck that he had actually 2 pc. in store!
So i'll play it safe and install en fresh one, just in case.

To be continued, again!

[muley]

Thanks Jim,

Do you have any pictures of your Jubilee clip install?
I was already wondering how to get the hose back I never noticed it was there until i removed the lot. Ah... so this was the resistance i was feeling ...
(hence all clips in place of my first picture as i just removed it....)

I'm most afraid however of refitting all the heat shield-parts... What parts can be 'on' when i place the lump back in the engine compartment?
What are your experiences with re-using the exhaust gasket?

@ Dapinky: How many exhaust manifolds did you successful re-fit while using the old gasket? (Taken that only one failed as you described earlier)
If it fails, is it easy to slip the new gasket in place with the bolts undone, but everything else in situ?

I just received a call that my recored radiator is ready to pick up!

Regards,
Henk-Jan

No pics I'm afraid - there was only a tiny amount of room to work in. The problem was that the feed pipe was in the way and I couldn't work the clip that you fit with your fingers into position. I did had the pipe in place at that point (after a long struggle!) so I undid the jubilee clip so I could put it round the pipe without removing the pipe before holding it back together then tightening it using a long screwdriver -it was a difficult struggle. I reused all the gaskets because they seemed to be in good shape - the one between the turbo and precat seems to be a piece of metal. I just smeared them with a little grease - I'll probably get flamed but that's the way I've been doing it for nigh on 45 years...

I put the lump back into place without the larger heat shields. In practice I found I could not get one of the bolts in as there was no access when I put the heat shields on. It's still not fitted.

HTH


Jim

[HJ2]

Thanks again.

Today was a good day!

After i picked up the new gasket i assembled all parts back on the lump. This included all heatshields besides the top one (with TURBO written on it) The wastegate was still off. The oil return pipe was also on, including the spring clip on the turbo side. The other springclip i placed over the pipe on the block. I smeared a little vaseline on the inside of the tube. Then i could lower the complete assembly into place, including the heatshields! Presto. instant happiness
This saves me quite a lot of time actually. After that i plugged the hose onto the pipe and was able to slip the springclip back into position without any trouble! Who would have thought that ?

I am now in the progress of getting everyything connected again. Pictures to follow soon!

[muley]

Thanks again.

After that i plugged the hose onto the pipe and was able to slip the springclip back into position without any trouble! Who would have thought that ? NOT ME !

I am now in the progress of getting everyything connected again. Pictures to follow soon!

[CJ101KT]

We are currently in the process of removing the original precat from the manifold to fit the new Piper PCE but they are not wanting to shift. They are being soaked over the weekend but don't think they will budge without snapping in the process. This will mean removing the manifold and turbo and therefore will be required to fit a new gasket (assume). This will leave me in a position to get the wastegate ported by someone local so it's not all bad news. Can someone confirm if this is the correct gasket which is required and if there are any others which will be needed/advised to be replaced in the process of all this? Thanks, and good pictures too, very helpful.

GASKET, EXHAUST MANIFOLD to HEAD: A100E6097S

[HJ2]

Yup!

It's the same as i obtained yesterday
To make assembly easier, i left the most left stud in the block and modified the gasket a little so it would slide into place:



I placed it after i slid the whole contraption back in it's position. That way it would not damage while maneuvering around with the heavy lump with sharp edges . When it was time to tighten the nuts, just slide into position and then insert a manifold stud somewhere on the right so it stays in position.

Before that you have cleaned the surfaces of manifold and block of course

I can tell you about the other seals in a day or so. I re-used the old ones besides the exhaust manifold. I have to build the radiator back before i can test

Tough luck they don't come out! If it is possible, drive the car so pre cat & turbo will HOT when you remove the stud (wear proper gloves) It is worth a go before you do as i did... Then again, if you need the wastegate ported... Bite it and proceed

[dapinky]

Chris,

If you have aircon, you will have the same obstacles as Henk did (and Muley!), but if not, then it is a bit more straightforward.

See the wiki

[CJ101KT]

Chris,

If you have aircon, you will have the same obstacles as Henk did (and Muley!), but if not, then it is a bit more straightforward.

See the wiki

Thanks Dave. It's a non air con S2 and I'm not looking to rebuild the turbo, just remove the necessary to port the wastegate whilst fitting the new PCE and exhaust system. Can the other gaskets be re-used then, just need to get the one I stated?

[dapinky]

Chris,

The wiki covers the whole job, not just the re-build, so may help (or not).

Personally, as per my earlier posts, I re-use all the gaskets unless they show signs of damage. The Main one should be used dry, and due to its construction, is re-usable. it only needs changing if it has been contaminated with sealant, leaking oil or any other signs of damage. (According to Lotus!)

[HJ2]

Well,

Worked like a pig today
Refitting the turbo was easy as i was almost done.
The rad took me ages of fiddling until i got the hang of it. After that: Check, recheck and check the recheck, reconnect battery, lower car and start the engine!

It started instantly and runs idle as usual. After letting the copaslip smoke for a while and checks for leaks i thought it was safe to take her for a spin.

The car seemed to be running fine. Unfortunately however, as soon as the turbo kicks in and i see some response @ the boost-gage, the car starts running like crap and vibrates violently. 2 out of 10 tries is seems to run OK under boost, but the other 8/10 ... like Parkinson disease

I saw a yellow light briefly so Monday i will run Elanscan to see if this helps me.
Meantime: All hints and tips are wanted here! as i would like to use the turbo now and then So isf anyone got any clues what could be the problem

I:
ported the wastegate
installed new plug leads
replaced CAS and CAM seals
Cleaned the engine thoroughly.

It:
Runs fine when no boost.
Without boost (say 30% throttle) it goes up till the red line with no problems whatsoever
If i step on it... judder and vibrating, hesitates accelerating etc.

[Paul.P]

Henk-Jan, are you sure the wastegates free ?

[HJ2]

It was absolutely free before i reassembled the lot It's the first thing i will check when i'm back @ the car!
I sure hope it's something as simple as that, but i am not sure a sticky wastegate will result in heavy stuttering?

[Specky]

With Mr P...freedom of the wastegate

Vacum pipe reconnected?

Is the diaphragm OK?

TTFN

[HJ2]

Concerning the post count of the both of you, i will DEFINITELY check the wastegate first (after i checked if the turbo is spinning freely
I'll keep you posted! (let's hope this is not the start of another dreaded 'project creep'

[HJ2]

just a thought:

If the wastegate is sticky or no vacuum connected, would that not leave the turbo running fine, but 1: give idiot boost or 2: just a little boost as the wastefate would be permanently open or closed? How could the heavy judder effect be explained?