How to replace '88 NA exhaust manifold

[Choppa]

I got the SJ manifold to fit OK eventually on mine but it did need a bit of persuasion.  It's been fine for the last 18 months. I seem to remember that SJs did also offer a new cast manifold for about £200 more than their stainless one, I wonder if they still have them.

Also last year at the Classic Car Show, LotusBits were showing  an Excel engine and chassis on their stand with their  stainless manifold fitted. The manifold looked very good, certainly better that the SJ one, and the guy I was chatting to said  they offered a similar  manifold for an N/A Esprit as well. 

As you are only up the road from me in Sandhurst I could bring mine over so you can see how the SJ one fits and sounds if you like.

[brianc]

Thanks Choppa, can you PM me your details as I'd like to take you up on the offer of a look at the SJ manifold?

Brian

[bob janek]

On 9/7/2017 at 07:14, brianc said:

So after a fab day out at The Lotus Festival on Saturday, i got home and noticed that there was an 'exhaust blowing' sound coming from my NA Esprit.  Closer inspection and a feel around (and a couple of burnt fingers - ouch) shows that the exhaust manifold has developed a bit of a blow near cylinder number 4.

At the risk of sounding stupid, can anybody confirm if I can replace the manifold without taking the engine out and does anybody have any useful tips covering the process?  I'm particularly worried that the nuts / studs will be seized solid making the job even more difficult.

TIA

Hi i'm just new here i'm just restoring my lotus and the sad news is yes the engine has to come out some of the nuts are really hard to get to the cast iron do have cracking problems so i got S j Sorts ltd to make me up some stainless steel free flow not a bad price i must say then replace the studs with stainless steel studs and yes words i said that i never new i had lots off f and c words but thats the fun off  owning a lotus i love my girl so over the last 2 years i've been rebuilding her i do have the full work shop manual my lotus esprit is a 1988 912 engine 

 

Edited September 10, 2017 by bob janek
spelling

[Sparky]

Welcome!  But I disagree.  I've replaced plenty of Esprit manifolds without removing the engine.  It all depends on the extent of corrosion.

[mdw]

The SJ 4 into 1 manifold  did not fit to my 88 n/a in anyway. So they took it back and refunded.   Alunox made 2 n/a systems about 4 years ago one of which went on my old n/a.  They didn't make any more  as far as I know.  It was a lovely piece of kit and the whole system cost £1600 ish.   

I took my manifold off with the engine insitu................................ and then took the engine out 2 months later !!!

I do have the old uncracked ( from what I can see) cast manifold hanging from the celling in the garage if you want to make me an offer, can send pics.

 

 

[brianc]

Malcolm,  Your replacement system looks great but the rest of my exhaust is in pretty good shape so not sure it's worth replacing the whole lot.

I would be interested in what was wrong with the SJ manifold with regards to fitting.  

Could well be interested in your old one if I cannot sort out something new so if you can PM me a couple of pictures that would be great and I can make an offer as necessary.

[DaKa]

Not sure if you will gain anything from seeing this done with the engine out, but I did enjoy the episode anyway.

https://m.youtube.com/watch?v=eD6jann-znI

It's covered in the first 10 minutes - seized studs seem to be the danger?

 

[brianc]

On 9/8/2017 at 20:55, Jacques said:

Brian, do you have a Picture of the na exhaust manifold?

Cheers,

Jacques.

Sorry for the delay, busy weekend with family commitments etc. I managed to get a look last night from underneath using a mirror.  Looks like it's actually a small hole near one of the mounts on the rear cylinder and not an actual crack.  Couldn't get in to take a picture of the actual problem area but managed to get one taken of most of the manifold from underneath (attached).

[Jacques]

very different from the turbo version. You could ask alunox if they will make another one.

Cheers,

Jacques.

[brianc]

Managed to make a temporary repair using some high temperature JB Weld putty until I can get down to Malcolm and pick up his 2nd hand manifold.

Not given her the full beans yet but it's held up for the last 30 miles or so of 'normal' driving.

[DaKa]

Read somewhere in this section about an exhaust manifold stud missing/working itself out - apparently one of mine has done the same following an inspection.

Can they be bought from a standard supplier (size/threading) or, specialist supplier only?

P.S. How does one get hold of the magician 'Sparky' - he's clearly highly regarded and keen to help enthusiast keep Lotus rolling.

[eeyoreish]

15 minutes ago, DaKa said:

How does one get hold of the magician 'Sparky' - he's clearly highly regarded and keen to help enthusiast keep Lotus rolling.

Beam the Lotus emblem up onto the night sky..?

[DaKa]

Knowing my luck, if a masked caped crusader turned up at my door it would be Dick Turpin to empty my pockets!!

[Dan E]

Damian, it’s very like getting hold of The A Team. “If no one else can help you and if you can find him, ..........” 

[Bibs]

5 hours ago, DaKa said:

P.S. How does one get hold of the magician 'Sparky' - he's clearly highly regarded and keen to help enthusiast keep Lotus rolling.

@Sparky

[Dan E]

Or you can do that ?

[Bibs]

I think Sparky is top right

[Sparky]

I look much the same nowadays, but I've dumped the wig.

[andydclements]

On 12/09/2017 at 21:36, Jacques said:

very different from the turbo version. You could ask alunox if they will make another one.

Cheers,

Jacques.

I think that the NA Esprit manifold is the same as the (later- post 87ish) Excel manifold. Excels have two versions, one with the single bolt upper-most (pig to get to), one for the HC engine (and later LCs) with the single bolt lower-most. On that basis you may locate a decent secondhand Excel manifold (Lotusbits, Dave in Enfeild who sells parts via eBay, etc), as long as you check compatibility such as comparing part numbers.

[brianc]

Thanks for the tip on the Excel manifolds. I'll check the part numbers against the one for my Esprit but I have a nasty feeling that they are slightly different. 

[andydclements]

Just checked SJ site.

Excel standard compression (Low) is 907E0601   Esprit S3 907E0601

Excel High compression not listed, so cannot compare and don't have my parts lists to hand but the fact that the low compression manifolds were the same, makes me susect that Lotus would continue to use parts common to both after the change.