S1 Elise 2.0 Duratec Conversion
Discussion
I've done a little more work so I figure an update is warranted.
My water manifold is now with a local performance garage Wallace Performance who said that they could handle the relocation and blanking off of the required ports (Thanks to Mark Bideleux on SELOC for his input on this). I have a feeling that I'll get it back some time next week.
In the mean time the engine has been relocated to my friends triple garage where we'll perform the conversion. We also began to bolt a few bits onto the engine.
First things to go on were the throttle bodies. At first we thought this would be a simple job but on examining the bolting locations we found that one of the bolt holes was slightly too big and had no thread. It appears to have come like this from the factory so must not be used by a standard Ford inlet manifold kit.
Only one solution really a Helicoil, something that neither of us have never used before. Still, in for a penny in for a pound.
So, one 9mm Helicoil kit later we.
Drilled out the mounting hole in the head.
Taped the hole
Installed the coil.
And Bingo! A 9mm threaded hole.
Which allowed us to mount the AT Power direct to head Duratec throttle bodies.
Looks pretty good I think.
We also fitted a new horizontal oil filter housing, tensioner pulley for the new alternator arrangement and the gearbox adapter plate. I'll get some photos of this little lot up on my next update.
My water manifold is now with a local performance garage Wallace Performance who said that they could handle the relocation and blanking off of the required ports (Thanks to Mark Bideleux on SELOC for his input on this). I have a feeling that I'll get it back some time next week.
In the mean time the engine has been relocated to my friends triple garage where we'll perform the conversion. We also began to bolt a few bits onto the engine.
First things to go on were the throttle bodies. At first we thought this would be a simple job but on examining the bolting locations we found that one of the bolt holes was slightly too big and had no thread. It appears to have come like this from the factory so must not be used by a standard Ford inlet manifold kit.
Only one solution really a Helicoil, something that neither of us have never used before. Still, in for a penny in for a pound.
So, one 9mm Helicoil kit later we.
Drilled out the mounting hole in the head.
Taped the hole
Installed the coil.
And Bingo! A 9mm threaded hole.
Which allowed us to mount the AT Power direct to head Duratec throttle bodies.
Looks pretty good I think.
We also fitted a new horizontal oil filter housing, tensioner pulley for the new alternator arrangement and the gearbox adapter plate. I'll get some photos of this little lot up on my next update.
As promised a few more picks of work so far.
The secret sauce that is the gearbox adapter plate.
A new top tentioner pully has been fitted. The conversion kit uses the alternator from my existing engine and it will be fitted, with the aid of custom mounts, below and to the right of the water pump.
Finally the new oil filter housing. This is much more compact than the Ford item and ditches the cooler plate. It will proved clearance between the bulkhead of the lotus and the filter itself.
Oh, and another of the throttle bodies. Just for luck.
I'm almost at a natural hold point now but I have a few more things I can do before I really have to pause and wait for the car to come off the road.
- I've still to recieve back my modified water manifold.
- I need to purchase some ARP flywheel bolts so I can fit the flywheel to the engine.
- I need to purchase a clutch; I'll be going for an uprated AP item.
- I need to mount an air temperture sensor in the backplate of the throttle bodies.
Once all this is done I'll have to pause and wait till the end of October till the car comes off the road.
The secret sauce that is the gearbox adapter plate.
A new top tentioner pully has been fitted. The conversion kit uses the alternator from my existing engine and it will be fitted, with the aid of custom mounts, below and to the right of the water pump.
Finally the new oil filter housing. This is much more compact than the Ford item and ditches the cooler plate. It will proved clearance between the bulkhead of the lotus and the filter itself.
Oh, and another of the throttle bodies. Just for luck.
I'm almost at a natural hold point now but I have a few more things I can do before I really have to pause and wait for the car to come off the road.
- I've still to recieve back my modified water manifold.
- I need to purchase some ARP flywheel bolts so I can fit the flywheel to the engine.
- I need to purchase a clutch; I'll be going for an uprated AP item.
- I need to mount an air temperture sensor in the backplate of the throttle bodies.
Once all this is done I'll have to pause and wait till the end of October till the car comes off the road.
Edited by GregorFuk on Friday 9th September 13:44
[quote=GregorFuk]As promised a few more picks of work so far.
The secret sauce that is the gearbox adapter plate.
Those two black marks on the wall made by an E30 M3 Evolution III Sport! Have not got the heart to paint over them!
Due to the extreme weather I think the end of the car season has been brought forward!
The secret sauce that is the gearbox adapter plate.
Those two black marks on the wall made by an E30 M3 Evolution III Sport! Have not got the heart to paint over them!
Due to the extreme weather I think the end of the car season has been brought forward!
As requested Nigel 
Okay, I took the car for an MOT earlier in the week which it passed without too much trouble. Emissions were very tight which could cause me problem on the other side of the conversion, we will have to wait and see.
So today was the day we started things properly.
First things first, we got the car up on stands. Not too much of a problem there though the front end was very light, occasionally lifting off the ramps, hence the cargo straps.
Then, arch liners out.
Then after an hour or two of spannering with the odd Dremel intervention the rear clam was off.
Fluids Drained
And now everything is unhooked and the engine + gearbox are ready to be lifted out.
We did a power of work today and it went a lot quicker than I expected, but I guess dismantling is the easy part, it's putting it all back together that will be to real test. There is a part of me asking myself what have I done? Especially when I look at the wiring loom. I'm sure if we tackle things in a methodical manner it will all come together....Fingers crossed...
So, next step is to get an engine crane on site to lift the engine and box clear. Then I'll give the engine bay and its surrounds a good clean and tidy up. I'll also need to order a clutch and the ARP flywheel bolts.
I've pulled the injectors from the inlet manifold and will send them away for cleaning and a service this week.
Okay, I took the car for an MOT earlier in the week which it passed without too much trouble. Emissions were very tight which could cause me problem on the other side of the conversion, we will have to wait and see.
So today was the day we started things properly.
First things first, we got the car up on stands. Not too much of a problem there though the front end was very light, occasionally lifting off the ramps, hence the cargo straps.
Then, arch liners out.
Then after an hour or two of spannering with the odd Dremel intervention the rear clam was off.
Fluids Drained
And now everything is unhooked and the engine + gearbox are ready to be lifted out.
We did a power of work today and it went a lot quicker than I expected, but I guess dismantling is the easy part, it's putting it all back together that will be to real test. There is a part of me asking myself what have I done? Especially when I look at the wiring loom. I'm sure if we tackle things in a methodical manner it will all come together....Fingers crossed...
So, next step is to get an engine crane on site to lift the engine and box clear. Then I'll give the engine bay and its surrounds a good clean and tidy up. I'll also need to order a clutch and the ARP flywheel bolts.
I've pulled the injectors from the inlet manifold and will send them away for cleaning and a service this week.
A little bit more work was performed last night and the car is now K free!
We were very kindly lent an engine crane which made easy meat of lifting the engine and gearbox clear of the chassis.
A few pics of the process.
Strops on.
And lift!
And separate!
Duratec goes here.
The K is feeling a little unloved I'm sure
We were very kindly lent an engine crane which made easy meat of lifting the engine and gearbox clear of the chassis.
A few pics of the process.
Strops on.
And lift!
And separate!
Duratec goes here.
The K is feeling a little unloved I'm sure
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