My Pinion

Locost project ]

So, I decided it was time to change the gear lube in my 1988 Lotus Esprit Turbo with Citroen gearbox..

 

 When I removed the magnetic drain plug, I found a hitchhiker.. 

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the chip,  was scanned and enlarged by 400%.

 

 Once the gearbox was removed from the car, I opened up  the top, and found the chip was formerly a shift dog from 4th gear:

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Smaller version

 

Larger versions of the pinion photos...

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Smaller versions of the pinion photos

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Decided to go farther since the car was apart.... perform the pilot bearing upgrade, which means the crankshaft must come out

auxhousing.jpg (61834 bytes) The Auxiliary housing must be removed to access the nut holding the oil pick up tube.  A 6mm allen wrench is used on one fastener.

pickuptubenut.jpg (56608 bytes) If you look closely, you can see the "nut".  Jim Cummings from the turboesprit list says he used a 1/2" bolt with 2 nuts turned by a 3/4" wrench to remove it.  Thanks for the tip Jim! bottomend.jpg (69538 bytes) A look at my engine's "bottom end" before disassembly so that the pilot bearing recess can be machined to accept the better pilot bearing.  New bearings (STD) are ordered/

plastigauge1.jpg (59087 bytes) Put the crankshaft back in today, 10-29-05, but first double checked bearing clearances with Plastigauge.  Here is one main journal.

plastigauge2.jpg (41106 bytes) Here is another main.  Nicely within tolerance after the crank was polished!!

valveview.jpg (103692 bytes) View of the underside of the head after removing it from the block.  The valves were ground, 2 new exhaust valves, and all new exhaust valve guides were installed.  The underside of the head was massaged slightly (by about .003) to be sure it was flat.

pistonview.jpg (94307 bytes) The block, from above after the head was removed.

block.jpg (58850 bytes)The block from above after the head gasket was removed.  Even though I knew that there were cylinder liners, I was unprepared for how it looked!

enginebay2005.jpg (83470 bytes) The engine bay looks pretty roomy and lonely without the engine.  I've got some clean up work to do when I fit all new coolant hoses. 

 

engineblock200.jpg (94902 bytes) The engine block before I clean things up  to refit the head.  If you look at the floor, you can see parts that have been removed from the car.

bov.jpg (77479 bytes) Another thing I did while the car was apart was to add a Greddy Type RS Blow Off Valve.   Blow off valves supposedly help turbos last longer and give you better performance.  They also make that 'pssst' noise when you let off of the gas pedal.  Thought that might bug me, but I really enjoy it!  The unit cost right around $200. 

 

  To install it on my Bosch injected '88 required nothing extra other than the BOV and the gasket that came with it.... besides the holes drilled into the plenum.  I planned ahead on drilling and taping the holes for the BOV mounting bolts though as the plenum through bolts can be in the same area.  One of the BOV mounting bolts, I shortened by a bit.

Pray for me.... especially because:

I lost my job!

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Things are really tough right now.....

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