Work on manifold

[s29ttc]

Well following on from last post my lambda sensor seemed to kick the bucket. The sensor seemed to weld itself to the manifold and by taking it out striped the threads down. Ali kindly supplied a spare manifold lying about which had 2 broken studs and 2 jamed in the downpipe flange. The boss where the sensor was connected had been badly striped with taking out the previous sensor.

In work with lots of WD40 and some bashing and pulling we managed to get two of the studs out from the downpipe flange. The other two wouldnt budge so we drilled and retaped the holes. I have replaced these with stronger studs so hopefully the same problem won't occur.



The boss was very badly damaged so we retaped it first but the sensor seemed a very loose fit due to taking out the other sensor it must have striped a good bit of material. To combat this we drilled out the threads and machined a stainless sleeve which was put it. We then welding this in place and drilled and retaped the boss to the required size leaving a nice clean thread for the new sensor.



We put up both the head face and downpipe flange on the grinder to clean up the faces. Securing the job was quite hard and we only took a couple of thou off as I didnt want to strip too much material. The face doesnt look too good but I am hope the new gasket will seal the edges. I just didnt want to remove too much material from the top.



I got the sensor from eliseparts and hope this one lasts a bit longer than two months. I was just a bit worried of the open wires whether I should use a heat sheilding on them or I would get away with cable tying them away from the manifold to prevent them melting.



Anyways I ordered the gaskets and should hopefully arrive tomorrow and get it swaped over, hopefully the task won't be too hard and the old manifold comes out ok.



I shall keep you updated

[mac]

Just push the cable outer down once installed - it's heat resistant.


Mac

[s29ttc]

Thanks Mac going to give it a bash tomorrow if the gasket arrives should be fun lol

[CSK_423]

I don't envy you having to remove the Fanimold

Good luck hope it goes well

ps welcome to Elise ownership, how many things have went wrong in the 2 weeks you've had it ?

[hiscot]

a lot of effort for a load of junk, but top marks on finnished job
you should of just got a six stud manifold and pipe as the four stud version is quite badly restricted
as std the lambda comes with a heat cover that slides over the whole lot

[thinfourth]

What exactly do you do to have access to all these machining tools?

And i know it certainly ain't a photographer

[s29ttc]

I thought that, well purchased that one from eliseparts and thats what came so I prosume that would be the best one for an elise since they stock it and its not exactly cheap when they bump on VAT and EU tax its like £76. Not much at all went wrong with it, just a wee problem that hasnt been fully sorted which was misfire. I beleive the lambda sensor was playing a part in the whole thing breaking down while it was happening. The misfire looked to be sorted at Ali's but he noticed the sensor wires smoking away when it was up on ramp so that will need to be replaced. Once this is done tonight it should be all good I am hoping

[s29ttc]

What exactly do you do to have access to all these machining tools?

And i know it certainly ain't a photographer

I work as a mechanical engineer. Currently do design work but know everyone on the shop floor so speak nice to them haha!

[hiscot]

when you buy the lambda it does not come with the heat cover if yours had smoking sensor wires and no heat cover, is it not possable that the insulation on your old lambda had melted and shorted ? do you know why yours had failed ?
i would not fit a new lambda without the right silver heat proof cover whilst the black outer will slide down it wont seal the exposed sensor wires enough it gets very hot in that area and without much airflow either

[s29ttc]

The heat sheild was round the wire in the old sensor but not right at the top. The top wires where exposed and melted away. Im not sure if it was the sensor that caused this or the wires lying against the manifold as it happened at Ali's and he just pulled it out. The wires where on floor all burnt at the top and the sensor was done in with the cermanic tip missing. I will try and get heat sheilding then as I said on my first post on this thread

"I was just a bit worried of the open wires whether I should use a heat sheilding on them or I would get away with cable tying them away from the manifold to prevent them melting."

Wont do any harm to cover it up

[Rich H]

Wrapped the porker wires in fiberglass tape...

[s29ttc]

I have some heatproff sheilding from work and some special heat proof tape so hopefully that should do the job

[s29ttc]

Also.........Meant to ask but are there any hints and tips with removal of the old manifold as I have heard this is a bit of a job? Soaking the nuts and studs in WD40 or such like........?

[2F45T4U]

ye pretty much. if you can get a windygun with a wirebrush on it to get as much rust and muck off the studs as you can first, then use decent HEX drive sockest (not multihex ones that only grab..erm..round the corners of the nut)

other than that best of luck, and dont get ANY WD40 on the new lambda as the silicon in it will poison it almost instantly.


Fraser

[s29ttc]

Ahhhhhh so good idea to wash the manifold as there was cutting compound used to cut the threads