Dismantling the engine

A parcel arrived from EliseParts. Fantastic service, only 5 days to get here from the UK. In the package were a new radiator and a socket for the head bolts. The radiator is all aluminium, and will replace the standard one which has plastic end caps that are prone to popping off. Also included was a new "ladder" into which the head bolts screw. The new one is thicker, therefore stronger and helps prevent warping of the head and block. Important in an engine prone to blowing head gaskets!

With the new socket I was able to undo the head bolts and pull the head off. The pistons have a little carbon on the tops but are otherwise in good condition. There was a little surface rust on the bores due to water from cleaning getting in through the slightly open valves.

As the pistons run in liners which can move, I have clamped them in place while I clean the tops using makeshift clamps from the old head bolts, some tubing and washers.

Cleaning and dismantling

With the engine out, I had to remove the clutch and flywheel and the gearbox. With that done i could mount it on the engine stand. I also cleaned the engine, and removed the cam belt cover, the rear of which had a hole in it, which looks like it was both worn and melted. Something else to replace.

Hole in the cam belt cover. Not sure what has caused it but there's no other damage.

I removed the cam cover and the condition of the camshafts is excellent. Seems a shame to take it all apart when it is such good condition. :-( I took off the cam belt, tensioner and cam pulleys, but can't go much further. I have ordered the correct socket to remove the cylinder head bolts, so won't do much more work on the engine until it arrives.

I started on the new upgraded tie rods, fitting the strengthening pieces to the rear subframe and the upright.

Above is the new bracket loosely fitted to the upright (it's the black bit at the bottom!). Below is the strengthening plate on the rear subframe.

The Engine is Out

I put in a couple of warm hours (at least it wasn't as hot as it has been) in the garage last night and removed the driveshafts, gear cables and engine mounts. It seems the way to remove the driveshafts from the gearbox is with brute force!

I set up The engine hoist that Marty lent me and attached it on to the inlet and exhaust manifold studs. After about 20 minutes of careful lifting of the engine and lowering of the chassis, the engine was out!

It's now on the ground waiting for the gearbox to be removed so it can be put on the engine stand. I may try and do that tonight.

The engine and gearbox are a little dirtier than I expected but not bad for an engine that is almost 16 years old. There is obviously at least one small oil leak but whether it's enough to worry about I hope to find out soon. I expect the engine and box the clean up nicely as the engine bay is protected by the under tray and so there's not much dirt around, just oil.

The empty engine bay:

The engine out and waiting to be cleaned separated from the gearbox and fitted to the stand.

The rebuild begins - taking it apart

The garage has been cleared out, the bike is now in its new home outside under the bike port, so despite today's 37 degree heat (98f) I decided to start the process of stripping the car.

It's now up on stands and the wheel arch liners are out.

I bought some "magic" sponges after recommendations on the Lotus forum and had a quick test of their ability to clean the aluminium of the chassis and under tray. They work well with just a little soapy water, but wear out quickly so I'll need some more.

Rear clam removed showing the aluminium chassis

The rear clam. I managed to remove it without any assistance!

The boot panel has been removed. Next task is to start disconnecting the driveshafts, exhaust manifold and various pipes and wiring loom from the engine so it can be removed.