davevr6car

I had a look at doing the same to my S4s, because the brakes were so crap. I then test drove a V8 with the later type ABS and I didn't think much of the brakes for such a high powered car. My work Ford Fucus car has better brakes. I stripped my entire brake system outand replaced it with: AP 4 pot calipers up front with larger S350 drilled discs 4 pot calipers mounted on s300 brackets with s350 rear drilled discs Kept the brembo calepers for the handbrake. I using a Nissan Patrol servo and master brake cylinder mounted on a custom made bracket which is connected to the original pedal box. I have remove the air con pump and in its place I'm using the earlier esprits vacumn pump. I made up a bracket for the pump to fit where the air con pump used to be and using the air con belt tensioner to tension the new vacumn pump belt. This supplies a constant vacumn to a audi A6 vacumn resevoir in the front comparment. I have a turbo bleed valve fitted with vacumn gauge before the resevoir and one way valves. This is then connected to the Nissan Patrol servo. What this mens is that I can adjust the amount of vacumn going to the servo which mens I can adjust the amount of servo assist from inside the car. The brakes are unbelievable now. When I first tried them I nearly went out thru the windscreen. I adjusted the vacumn to around -15psi which just gives me the right brake assist for the way I drive. All in I'd say the above conversion has cost me around £130, this is no9t including the calipers or disc's. Dave

Thanks for the info, I can still see the original honing marks and there is no evidence of lipping towards the top of the liner where the top ring would stop when at TDC. So Travis and Dave, do you reckon I just install my new piston rings on my original pistons and reasemble? I was thinking of getting my piston crowns ceramic coated. whats your opinion on this. Cheers for your help. Dave

Hi all, I'm starting to put my S4s engine back together are spinning a main bearing. While I had the engine apart I've decided to replace the piston rings as well. The question is hone the liners, in order to give the new rings a better chance of bedding in. Cheers Dave

Hi everyone, I'm currently rebuilding my S4s engine. I'm reassembling my oil pump with new seals, rotor and annulus. The rotor and annulus have a tiny notch / marked on one side of them. Can anyone tell me the orientation of the rotor towards the annulus. I have gone thru the service notes and it doesn't mention this only mentions if you reusing the same rotor and annulus. Both parts are brand new, so does it matter? Cheers for any info / help . Dave

Honda S2000 engine will give you 242bhp in standard trim and revs on to 9000rpm. Supercharge it for a reliable 350 - 360bhp. Gearbox is the problem Dave

Hi Gunter, The hole is that big you could fit your fist thru it and the plastic around the hole has deformed sligthly. Do you think this is repairable? Are you intrested in selling your spare bumper?

Bump

Hi Dave, You can put one down for me as well. I'd be mad after rebuilding the engine and not go for this option. The reason for the rebuild was, at high speed the oil cooler pipe to give way, emptying the oil all over the road. By the time I got the car into the hard shoulder I had sun a big end bearing. So a full rebuild was in order. Reground and polished crank, rehoned conrod. Balance crank flywheel and clutch housing. Ported and polished head. High lift inlet camshaft. Ported plenium. t3/4 cosworth upgraded turbo. Straight thru exhaust pipe with centre exit with porsche cayman exhaust tip. Custom air intake. Upgraded coil pack. 104' inlet and exhaust pullies. No.6 race chip. Arp head studs. New AC rad which I have plumbed into the charge cooler rad like the S300 to give more cooling capacity. Electric charge cooler pump. I have yet to choose fuel injectors. So I think the new exhaust manifold will compliment all my other ugrades? Other upgrades I have carried out: removed the delco abs brakes system. I now have a nissan patrol servo and master cylinder feeding AP racing front calipers and custom 4 piston rear calipers mounted on S300 brackets. These calipers are squeezing on S350 front and rear disc's mounted on alloy bells. The nissan servo is feed by an S3 vavuum pump fitted on a custom bracket where the AC pump used to be. The vacuum is feed into an Audi A6 vacuum resevoir with non return valves and then into a turbo bleed valve with gaiuge before entering into the servo. This means I can adjust the amount of vacuum assist I have and by having the gauge, makes it easier to adjust. The brakes are eye popping now. 1. Irg-machine - Interested 2. andyclements - yes 3. Geoff in OZ - yes 4. fsrowsell - yes 5. Jay Gallentine - Interested 6. Neil1607 - yes 7. snowrx - Interested 8. Whirlybird - yes 9. tjs98jetta - yes 10. turboesprit list yahoo - interested 11. turboesprit list yahoo - interested 12. turboesprit list yahoo - interested 13 turboesprit list yahoo - yes 14. turboesprit list yahoo - yes t 15. turboesprit list yahoo - yes 16. turboesprit list yahoo - yes 17. turboesprit list yahoo - yes 18. turboesprit list yahoo - yes 19. turboesprit list yahoo - yes 20. mdw -ye 21. dodge1979 - yes 22. Trevsked - yes 23. sparky - yes 24. sparky - yes 25. AlexGT3 - yes 26. Raging fool - yes 27. Kim.Poulsen - Yes 28. Davevr6car Cheers Dave

Hi Dave, I'm currently rebuilding my S4s engine at the moment with some upgrades. When would you expect to have these available? I'm would be interested in one, but depends on the above. Cheers Dave

On the bottom of page 37 in section EF of the Lotus service notes, it says the torque for the bolts for the bell housing to the sump is 41nm. Dave

Hi John, Kemp High Performane Engines, on ebay ebay is Gary Kemp as ment5ioned earlier. He doesn't have / can't get the 0.015" OD bearings. Dave

Yeap, the old guy said he recognised the crank, and said it was exactly the same as the old magnum cranks

Derek, Even by getting the caps and block machined, how is this going to make the bore smaller. It will reduce the vertical height of the bore, but not the width. I might have had some luck. I have located some bearing from different sites on the internet. Why would lotus sell individual shells/bearings. You would think that they would come in matched pairs / sets, up and lower. When I was getting the crank reground, the engineer smiled when I told him it was a lotus crank, he said you mean a crank out of a Bedford! According the 2.2 crank is identical to the ones in the old bedford!! Dave

I would have to replace the block and bottom end. If I got the main bearing housing casing skimmed and then the block and casing align bored to accept the standard outside dia bearings, would this not alter the stroke of the crank, ie would it not bring the piston closer to the head? Dave

Cheers lads for the help. Andy I tried Gary Kemp, but he doesn't stock them and the same with QED. 1 in 100 engines of this guise that lotus manufactured had to have the main bearing carrier honed out to correct themanufactoring errors. The mains are therefore oversized or made larger by 0.015" outside dia. I got my crank main bearings ground and polished so they are now smaller by 0.010" so I need "thicker" bearings by 0.010" or -0.010" internal dia. So my problem is, and which maybe a problem for a lot of people on here, is that if you want to rebuild the bottom end of your engine there are no main bearings in these sizes available. Dave cheers Dave

Hi, I'm rebuilding my S4s engine after a spun big end bearing. I had to get the crank reground to +0.010". So i need a full set of main bearings, 0.015"OD 0.010" ID. I have tried the usual dealers but they have none in stock and Lotus have none either and say they are obsolete. Does anybody know where I can get a set from. Cheers Dave

Cheers Travis for your in depth reply. The problem I have is that I want to replace the standard timing from 110' mop on the inlet and 100' mop exhaust to both 104' mop by using the oil pump pulley and another another 104' pulley i purchased from the internet, but the one from the internet does not match up with the oil pump 104' pulley. I'm working on rebuilding my S4s engine at the moment after it spun a big end bearing and was hoping to carry out this cam up grade as part of the rebuild. Would I be correct in saying that the green dot 104' pulley was used on the 2.0L turbo exhaust as well as the oil pump pulley on all 910 engines. The red dot 110' was for inlet on both 2L and 2.2L turbo inlet cams. The blue dot 100' for exhaust cam on the 2.2 turbo exhaust cam. I may check for the bumps on my cams that you mentioned above. Could I use the woodruff key slot in the cam pullies as a datum point, and measure from here to the dot/dimple in degrees, to figure out which cam is which? cheers Dave

Hi, does anybody know how to tell the difference between a 110' inlet, 100' exhaust and 104' cam pullies. The marks have worn off, ie Blue & red dots. cheers Dave

Hi Nigel, I have just uploaded a few photos onto my Gallery. http://www.thelotusforums.com/forums/gallery/album/237-s4s-turbo-diy-rebuild-amp-upgrade/ I have plenty more step by step photos if needed of the entire rebuild