oil leak from exhaust cam cover housing
Discussion
Hi,
Has anybody got the workshop manual procedure for removing / installing the exhaust cam cover housing from an '88 - '92 Esprit Turbo SE please? I have got an oil leak that is annoying me enough to take action over it now but I am missing the majority of the pages from the relevant section of chapter EB. I got the workshop manual from SJ Sportscare but there are a significant number of pages missing from various sections. I know that this problem is not uncommon because Gareth (igreenrover) got his manual from a different source and has the same problem. It would be a good idea for us to get together and provide each other with the pages that we are missing. Is it too much to expect that as we have paid full price we would like the the whole manual? FYI I have scanned my manuals in to pdf format as backup and working copies and have the 88 - 92 workshop manual,the additional electronic engine management (EMH) section and electrical sections.
Thank you in anticipation.
Danny '93 SE Highwing.
Has anybody got the workshop manual procedure for removing / installing the exhaust cam cover housing from an '88 - '92 Esprit Turbo SE please? I have got an oil leak that is annoying me enough to take action over it now but I am missing the majority of the pages from the relevant section of chapter EB. I got the workshop manual from SJ Sportscare but there are a significant number of pages missing from various sections. I know that this problem is not uncommon because Gareth (igreenrover) got his manual from a different source and has the same problem. It would be a good idea for us to get together and provide each other with the pages that we are missing. Is it too much to expect that as we have paid full price we would like the the whole manual? FYI I have scanned my manuals in to pdf format as backup and working copies and have the 88 - 92 workshop manual,the additional electronic engine management (EMH) section and electrical sections.
Thank you in anticipation.
Danny '93 SE Highwing.
Danny
Did you ever send me a list of what you are missing? I think you did and if so its on my machine in Manchester. I'll have a look when I get back later this week.
To be honest I've just never had chance to look through mine and see what was missing. Although I noticed a lot more missing as I was looking for sections I needed over the summer, but at the time had to muddle through.
As you said, I looked through a number of copies at Paul Matty and they were all the same! So there must be other people out there with the same problems.
Gareth
Did you ever send me a list of what you are missing? I think you did and if so its on my machine in Manchester. I'll have a look when I get back later this week.
To be honest I've just never had chance to look through mine and see what was missing. Although I noticed a lot more missing as I was looking for sections I needed over the summer, but at the time had to muddle through.
As you said, I looked through a number of copies at Paul Matty and they were all the same! So there must be other people out there with the same problems.
Gareth
danny tattersall said:
Hi,
Has anybody got the workshop manual procedure for removing / installing the exhaust cam cover housing from an '88 - '92 Esprit Turbo SE please?
If you're talking about the end cap at the rear of the housing (very common leak point) it's pretty simple, in fact I doubt it's in the Service Notes.
Remove the four nuts and washers holding the heat shield to the rear of both cam housings. Wriggle the outer shield free of the studs, being careful to note the location of all the large washers between it and the inner shield that will start falling off. It will seem impossible to remove at first, but it can be done. Do the same with the inner shield, noting the location of the various spacers and washers.
The end cap is pressed on with an o-ring in place to prevent leaks. Doubtless yours has hardened over time. There may be sealant on the cover as well. Using a thin scraper, knife, or similar instrument, carefully pry the end cap straight off. Replace the o-ring (part number A907E6027Z) and reverse the sequence to reassemble.
Cheers,
Sanj
>> Edited by sanj on Tuesday 14th September 14:59
Gareth & Sanj,
Thanks for the replies. My leak is from the rear end of the cam cover but i do not think that it is from the seal housing. Rather, I think that it is leaking between the mating surface below the cam cover housing itself. I was aware that the seal housing is a common problem but my leak is a couple of inches further forward and leaks directly on to the exhaust manifold.
Anyway, I think that it is still a good idea to see whether we could pool together and try and get a complete copy of the manual. I am a mechanical aircraft engineer by trade and am used to not having a procedure to follow (the most awkward jobs are never in the books) but at the end of the day I paid for a complete book!!
Thanks again.
Danny '93 SE Highwing.
Thanks for the replies. My leak is from the rear end of the cam cover but i do not think that it is from the seal housing. Rather, I think that it is leaking between the mating surface below the cam cover housing itself. I was aware that the seal housing is a common problem but my leak is a couple of inches further forward and leaks directly on to the exhaust manifold.
Anyway, I think that it is still a good idea to see whether we could pool together and try and get a complete copy of the manual. I am a mechanical aircraft engineer by trade and am used to not having a procedure to follow (the most awkward jobs are never in the books) but at the end of the day I paid for a complete book!!
Thanks again.
Danny '93 SE Highwing.
I got my manuals from www.lotus-books.com/
They are bound in three large books rather than as individual pages in a 3 ring binder, so I expect that they would be complete. I'll check for the missing sections tonight.
The prices on that site are extremely reasonable too. Much cheaper than any other I found. The only issue is shipping if you're in the US. The choices are sea mail (3 - a million weeks) or very expensive air mail.
They are bound in three large books rather than as individual pages in a 3 ring binder, so I expect that they would be complete. I'll check for the missing sections tonight.
The prices on that site are extremely reasonable too. Much cheaper than any other I found. The only issue is shipping if you're in the US. The choices are sea mail (3 - a million weeks) or very expensive air mail.
danny tattersall said:
My leak is from the rear end of the cam cover but i do not think that it is from the seal housing. Rather, I think that it is leaking between the mating surface below the cam cover housing itself. I was aware that the seal housing is a common problem but my leak is a couple of inches further forward and leaks directly on to the exhaust manifold.
Danny,
I'm not sure I follow your description. The cam "cover" is the relatively flat plate on top, painted, raised ribs and the word, "Lotus".
The cam carrier "housing" is the larger casting the cover sits upon. It includes the cam bearings, holds the cam and tappets, and bolts to the cylinder head.
The cam cover gasket is easy to change if that's what is leaking. One screw front and rear... remove them and the O-rings under them. Pry off the cover. Remove the gasket and any residue from both the cover and the housing. Clean all surfaces completely free of oil residue with brake cleaner applied to a rag.
If you get an OEM composition gasket, smear both sides with a light coat of Hylomar. Smear the mating surfaces of both the cover and housing with Hylomar.
If you get an aftermarket neoprene gasket, install it dry. Make sure the neoprene gasket and both metal faces are completely free of any oil residue and dry.
Replace the gasket and cover. Smear a little Hylomar on new O-rings and slide them over the bolts. Install the bolts and tighten them to about 6 lbs-ft. Firm wrist-tight. Don't over tighten.
If you are talking about a leak between the cam carrier housing the cylinder head proper, that's a much bigger job. It starts with removing the timing belt and escalates from there.
Since removing and replacing the cam carriers is most of the work involved in shimming the valves, it would be well worth your while to clearance the valves before re-assembling. Resealing the cam carrier to cylinder head joint requires all the same labor as clearancing the valves with the exception of actually measuring valve clearances & shim thickness and swapping shims. Also consider changing the timing belt while you are in there that deep.
Re-seal the cam carrier to cylinder head joint with Loctite 518 / Permatex Anaerobic Gasket Maker (51813... Loctite 518 private labeled). Make sure the mating surfaces are scrumptiously clean and oil free. Apply the 518. Install new O-rings around the front dowel pins/ oil passages. Install the appropriate shims on top of the valve stem/ spring assembly. Install the cam carrier and bolts. Torque to 16 lbs-ft. Replace the cam covers.
That's the nutshell version, but the devil is in the details. If you haven't been into a 9XX engine before, the latter task really isn't something you should wing without instructions to reference... preferably the Lotus manual. See about getting your missing pages before jumping into this job.
Regards,
Tim Engel
Lotus Owners Oftha North
Tim,
Thanks for the reply. My oil leak is definitely coming from the cam housing lower surface, where it mates with the upper surface of the cylinder head. The valve clearances were adjusted a few thousand miles ago but I agree that it is worthwhile re-checking them while I am there. I am familiar with doing this type of work but am still hoping to get hold of the pages that I am missing before commencing work.
All the best,
Danny.
'93 SE Highwing.
Thanks for the reply. My oil leak is definitely coming from the cam housing lower surface, where it mates with the upper surface of the cylinder head. The valve clearances were adjusted a few thousand miles ago but I agree that it is worthwhile re-checking them while I am there. I am familiar with doing this type of work but am still hoping to get hold of the pages that I am missing before commencing work.
All the best,
Danny.
'93 SE Highwing.
danny tattersall said:
I am familiar with doing this type of work but am still hoping to get hold of the pages that I am missing before commencing work.
Danny,
I've had several Lotus manuals arrive missing pages. But LCU has always been very good about promptly sending the missing pages at no additional charge. But then, I bought from US vendors.
Since you purchased off-shore from SJ, LCU might prefer that you take your problems back to SJ. Or, you don't have to mention where you bought the manuals. Just ask for the missing pages.
If you can't get the missing pages, I can photocopy them for you. They won't be on the coated paper, in the A4 size, or 4-hole punched... but you'll have the pages. Contact me off-list if you wish to go down that road.
Also, stay in touch when you get into the project. I've been there quite a few times and can probably answer questions.
Regards & Good luck,
Tim Engel
Lotus Owners Oftha North
Minnesota, USA
Tim,
Thank you for the offer of supplying the pages that I need. I just might take you up on it but I will try in the UK first. I would like to get replacements for all the pages that I am missing. It would be no exaggeration for me to say that I am missing well over 50 pages from the service notes from various chapters! There are some pages that have been duplicated two or three times and others that simply are not there.
Thank you for also offering to advise on the procedure for sorting the leak out - once I get the pages that I need I will e-mail you off-line.
Best Regards,
Danny '93 SE Highwing.
Thank you for the offer of supplying the pages that I need. I just might take you up on it but I will try in the UK first. I would like to get replacements for all the pages that I am missing. It would be no exaggeration for me to say that I am missing well over 50 pages from the service notes from various chapters! There are some pages that have been duplicated two or three times and others that simply are not there.
Thank you for also offering to advise on the procedure for sorting the leak out - once I get the pages that I need I will e-mail you off-line.
Best Regards,
Danny '93 SE Highwing.
I know exactly the leak here... My car is an 88' turbo and it has a little leak from this same area. It must be a common issue as I know of 3 other cars with this same little leak... fixing it until it gets bad seemed like a job (and from the above it is)...
As far as I can tell, the only real issue hear (other than not allowing the oil to get low)is an annoying leak that drips onto the hot exaust...?
Drive topless!!!
Cameron
As far as I can tell, the only real issue hear (other than not allowing the oil to get low)is an annoying leak that drips onto the hot exaust...?
Drive topless!!!
Cameron
I have the same leak.though it's just a drip (for now).
Only sometimes is there oil on the manifold when the car is standing,and when it is there it is literally just a drop (as big as a small coin). When it's being burned off though it is amazing the smoke and smell such a small drop creates - albeit for a few seconds.
I pulled up at a mates house last week,as i walked away from my car he said "jesus,whats that!!!" as a small puff of smoke whisped its way out the engine lid...
"a Lotus" I replied
Only sometimes is there oil on the manifold when the car is standing,and when it is there it is literally just a drop (as big as a small coin). When it's being burned off though it is amazing the smoke and smell such a small drop creates - albeit for a few seconds.
I pulled up at a mates house last week,as i walked away from my car he said "jesus,whats that!!!" as a small puff of smoke whisped its way out the engine lid...
"a Lotus" I replied
Hi Danny
I had the same problem which we corrected during restoration. The screw inserts seem to be the problem. If the insert is in bad shape and the hole it fits in is wallowed out then you will not be able to torque down the bolt. You will need to drill the hole to a larger diameter and fit a new insert.
Follow Tim's instructions to the letter.
louis
83 Turbo
I had the same problem which we corrected during restoration. The screw inserts seem to be the problem. If the insert is in bad shape and the hole it fits in is wallowed out then you will not be able to torque down the bolt. You will need to drill the hole to a larger diameter and fit a new insert.
Follow Tim's instructions to the letter.
louis
83 Turbo
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