Steel Radiator bypass pipe

[MarkP]

Thanks Sinan,
I confirmed with SJSportscars this morning that they are still not available. They have considered making a batch but to date demand has not been there. They would also need a good one to copy. As you say, the need is to get the end where the o ring goes right, the rest is just pipe. Did you have good photos and measurements for the o ring end?
I wont know what mine looks like until I pull it out and for the time being my leak is not sufficient to need doing urgently. So for me I am putting it on hold for a bit.

Mark.

[MarkP]

To close this off from my point of view, in the end the leak needed something to be done. I bought a replacement pipe from a breaker via eBay on an exchange basis. What I got looked very solid and has done the job.

[Neil D.]

Dear all,
I have the dreaded "O Ring" leak at the end of the radiator bypass tube.
Can it be removed, without removing the Turbo, of exhaust manifold ?
The clamp the holds the tube to the block looks like 14mm, I will make an extra long swan neck spanner to get access
Any tips are greatly appreciated.

Thank you
Neil

[TorqueHorse]

Sorry to hear that connection is leaking. You can take the pipe off without removing the turbo. I think you can even do it without without removing the flexible oil return pipe at the bottom of the turbo. I've done that pipe twice now and the first time took hours, but the second time just "worked". If I remember correctly, I think the trick is to keep spinning the pipe as you are either pulling it out, or putting it back in. And I think you have to also do it in stages where you might pull out a bit; spin; push back in a bit at a different angle; spin; and then pull out again, etc.

[Neil D.]

Thanks for that, I dread removing the turbo and having to re-tap all the holes

https://www.flickr.com/photos/195781657 ... F515432z5/

Does this bolt support the bypass pipe bracket ?

Pain to access. I have made a tool, but it is dead tight

Thanks for any advice,

Neil

[Tuga2112]

just posting image directly to help

[TorqueHorse]

That looks like it to me. Also, I had the prongeron off when I did mine. I don't know if you have to, but it makes things easier in terms of access.

[Neil D.]

Well, managed to get the tube out of the car, not a pleasant job.

Removed the Prongeron to gain more space, section EMJ, Who has a copy please ???? as I have not found it in my collection of manuals
The tube appears to have a small crack, So I will need to repair this.
https://www.flickr.com/photos/195781657@N08/52861734553/in/dateposted/
https://www.flickr.com/photos/195781657@N08/52860712952/in/dateposted/
The most difficult/painful part was to remove the bolt that secures the tube to the engine block. 14mm, M10 to hold the tube in place !!!
O ring ID is 19.8 mm (in Izuzu catalogue) Lotus Turbo appears to be bigger diameter
O ring chord measured at 2.6 mm
O ring groove measured at 20.2mm

More as I move forwards

Neil

[Fredjohn]

Neil
Section EMJ is in the Manuals tab above. Visible when logged in.

[Neil D.]

Hummm, I must be hitting the wrong buttons

Do you have a direct link?, I cannot see EMJ, EMK or EML

Thanks

Neil

[donsladek]

EMJ is the tab named "Closed loop Manual" - Closed loop & Catalytic Converter

EMK is the tab named "Engine Management Manual" - no cat or closed loop

EML is the Normally Aspirated (NA) Engine Management Manual, available here:
www.lotusm100.com/manuals/D100T0327J-Section%20EML.pdf

[Fredjohn]

Hummm, I must be hitting the wrong buttons

Do you have a direct link?, I cannot see EMJ, EMK or EML

Thanks

Neil

In Manuals tab, at top, EMJ is titled Closed Loo... and EMK is titled Engine Man.

[Neil D.]

Thank you both for your advice in finding the correct manuals
I must be a numpty, still have not found the section about removing the prongeron.
I would need to torque settings fro the rebuild
Thank you very much once again
Neil

[Fredjohn]

Thank you both for your advice in finding the correct manuals
I must be a numpty, still have not found the section about removing the prongeron.
I would need to torque settings fro the rebuild
Thank you very much once again
Neil

To remove the prongeron, just undo all its bolts. But you need to support the suspension and the car separately. See wikilec under Sump Removal.

Torque settings (all) are in Section TDH of the main workshop manual pages 6, 7 and 8.

[Neil D.]

Thanks for those references,
Inspection under microscope, then I will have the crack(s) brazed today, and hopefully back in the car soon.
Neil

[Tuga2112]

To remove the prongeron, just undo all its bolts. But you need to support the suspension and the car separately. See wikilec under Sump Removal.

and watch my video