Engine Rebuild and T-bird turbo

[kmckmc]

http://picasaweb.google.com.tw/m100s2/307RepairACUTUAL#

My S2 engine was in decent condition. I had driven about 5000miles in the past 3 years.
In this time period, I changed oil very often because there was some noise coming from the engine.
I decided to rebuild this engine because I had purchased a spare engine some time ago. Engine parts were no problems.
I show you all some pictures before the REBUILD.





Note: You can see a hole in the big end bearing shell. For a turbo conn rod's big end bearing shells, there should be plain bearing shells. I did consult other engine rebuilders and asked them whether it is forbidden to install that kind of bearing shell on this particular conn rod's big end. They all commented that it should not matter in this particular case.



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KMC Engine Rebuild Project:

Replace a new S2 steering rack : POW-A_RAK Installation done.



Recondition alternator: Recondition done.




Replace ball joints: Replacement done.




Recondition engine cylinder head: Recondition done.




Rebuild cylinder block:




Adopt T-bird turbo:



Port waste gate to 20mm: Ported.

New gear lever (shifter): installed. It's like shifting a new car!

Replace ASM water by-pass turbo PIPES (in stainless steel)

[kmckmc]

Porting wastegate to 20mm. The mechanic told me 21mm might be a bit too big.

The BEFORE picture:



The AFTER picture:

[kmckmc]

Conn Rod's big end bearings and Main bearing shells From an engine with 50K miles.

Conn Rod's big end bearings

Should I replace them?

UPDATE: I decided to keep them as they are within specification.

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Main bearing shells

Should I replace them?

UPDATE: I decided to keep them as they are within specification.

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Crankshaft condition.


I chose to use HASTINGS standard size piston rings for the rebuild.
Part number: 2C4647

[tigerdog]

I noticed the photo caption says "From Viking MS Purchase". Would this be Viking Motor Sports in Costa Mesa, California? I wonder what Elan the engine came from...

[kmckmc]

I purchased that engine about 3 years ago from Viking Motorsports. I think it was from a red M100.
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I would like to devote this post to T-bird / Thunderbird turbo unit upgrade.




I checked LEC's recent posts. Both Doc Fizzix and Nitroman did post some information about it in the ForSale section.
As I have purchased Doc's modified T-bird Turbo for M100, I take this opportunity to show some relevant pictures for LEC people who might be interested to take the same route.

Here, I paraphrase what I have gathered.

The T-bird turbo upgrade uses the compressor wheel from a Ford T-Bird (1987-1989). The turbos are both RHB5 units but the T-Bird had a larger compressor wheel and is capable of reaching boost levels up to 1.3-1.4 bar.

The T-bird compressor housing unit turbo will bolt right up to the current Elan IHI Turbo exhaust housing and will allow for increase in boost beyond 1.0 Bar up to 1.4 Bar. There should be no problem to attach the compressor housing to all those lines and M100's exhaust housing. The T-bird turbo upgrade should give M100 the most bolt-on horsepower one can get out of an IHI RHB5 turbocharger. It increases the flow rate to 388 CFM (from ~200CFM) if a suitable exhaust is installed.



Pictures of those annoying Turbo Unit Related nuts. I am still debating if I should use them.

[kmckmc]

Before this engine rebuilding procedure, I only see these engine parts on black and white print outs. Now, they are in color.

[kmckmc]

My S2's Engine Rebuilding process is going very well.

ENGINE OUT


ENGINE BACK IN

[Monty]

Nice work Micheal soon be back on the road

[kmckmc]

Thanks. It is almost ready. Now that T-bird turbo is installed and secured. Unfortunately, after my mechanic refilled coolant to the system, he detected a very small leakage from the radiator. There goes my money for Wurth 50% concentrate coolant. I am sure I can get my S2 back on the road by Thursday, the latest.

[kmckmc]

S2 #307 is home.
Radiator was refurbished.
Alignment done. local semi-annual MOT passed.

[Monty]

Be good to hear what you think off the Hybrid turbo, supprised you didn`t go for LGM turbo upgrade when it was available

[Doug]

nice project and thanks for the pics!

[kmckmc]

Thank you LEC community. Without your help, I could not have gone this far. My knowledge about cars has expanded.
I want to thank Doc's T-bird turbo and the hollow precat (from nitroman), both have improved my M100. As I already have 2.25" s/s exhaust pipe, I definitely can hear that my M100 is a lot louder. After a short drive this afternoon, I am debating whether I should put back the standard precat. If you recalled that I also have the helical LSD installed, I do not have the chance to feel the difference yet as I have not driven aggressively.
Ever since I have owned an Elan M100, it has consumed a great portion of my free time. I enjoy it very much though.