Small steps

While waiting for the tools for cam timing to arrive (dial gauge and cam locking tool) I've been tinkering away. I fitted the flywheel, which required taking the engine off the stand, which meant taking the engine hoist out, putting it together then lifting the engine, fitting the flywheel and putting the engine back on the stand. It's a lightweight flywheel which should make the engine rev more freely. I used brand new flywheel bolts - we don't want it coming off at 7000 rpm and cutting its way through the car!

Having the flywheel on makes it easy to stop the crank moving, so I fitted the new cam belt and tensioner.

I gave the gearbox a quick clean and fitted the new driveshaft oil seals, which were easy to fit.

Before stopping to have a beer I gave my mountain bike a quick bit of maintenance ready for a short ride. It's been over I year since I last rode it so I'll do a short ride to get my backside used to being in the saddle again.

Head fitted

I fitted the new head, using the new oil ladder and head bolts.
I found out that the new oil ladder requires higher torque for the head bolts, so I will have to retighten them. My manual says 20Nm, the new bolts should be tightened to 30Nm. Edit: Done!
I also fitted the rear cam belt cover that came off the spare engine, and has no hole in it, plus, there's a heatshield to prevent it happening again. Presumably it is heat from the exhaust that melts the plastic.

The new cam cover got a bit of a clean and was plonked on the new head to see how it might look. I may highlight the lettering and Lotus logo later.

A whole lotta spares

Thanks to Shane, a fellow Elise owner, who delivered his old engine to me today. It's from a 2004 series 2, had head gasket failure and was replaced with a more powerful VVC engine.
I now have a source of spares, especially the rear cam belt cover, plus newer alternator and starter.
There are also a few upgrades that come with a later engine, such as a better heat shield for the exhaust, and one to stop the cam belt cover melting!

I will also fit the later cam cover which says "Lotus Performance", old one has "Elise" but the "16 Valve" lettering is facing in the opposite direction.

Comparing the heads and removing the radiator

Temperatures were a little cooler today so I managed to get some work done. First, a few photos of the old and new heads.
The new valves are a couple of millimetres larger than the old, plus the inlet and exhaust ports are also larger and smoother.

Old head (above) New head (below)

Old vs new heads. Note safety footwear.

To replace the radiator with an all-aluminium version meant that the front clam had to come off. I. haven't attempted this before (I have removed the rear clam before) but it was very straightforward. The hardest part is getting the inner wheel arch liners out. They are plastic but quite stiff so take a fair bit of tugging to get out, once all the screws are undone.

Next step was to remove the radiator surround, the rear screws were difficult to get to but mole grips helped. I may replace them with Allen-head bolts to make them easier to replace and remove.

Front crash structure cleaned up.

I drilled out the fan brackets and reprinted them even though they are hidden under the radiator and won't be seen. I will have to rivet them onto the new radiator, might have to buy a few rivets.

New radiator with welded on aluminium ends. The original has plastic end caps which are prone to leaking.  The fan will be mounted underneath.