Porting the wastegate

Still under development by Geoff

One of the first jobs is to remove the heatshields from around the manifold and pre-cat housing.

Top heatshield removal

On the majority of SE's, there is no Oxygen (Lambda) sensor and the top heatshield can be removed by removing the three retaining bolts (M4x10mm) using a 10mm spanner.

On S2, Fed, some ROW Elans and a handful of SE's, there is a sensor, which can sometimes be difficult to remove even after frequent dousing in penetrating oil, heat and using the correct lambda socket. The top heatshield can be removed without removing the sensor however. First remove the three retaining bolts and raise the heatshield as high as it will go.

Gently raise the RHS of the heatshield and the gap will widen (shown by the red arrows) as the heatshield bends on the PAS mounting bolt (shown by the blue arrow).

Eventually, it should be possible to pop the heatshield over the top of the sensor and the heatshield will spring back to its original shape.

Now simply unplug the sensor connector and release it from the bodywork by sliding to the side. The heatshield can then be removed completely.

Exhaust manifold heatshield removal

GS: WIP

GS Notes

Remove the top turbo pipe completely - banjo on top of turbo, retaining clip on right of manifold and banjo on back of engine.

Remove the three studs from the exhaust flange and remove the gasket.

Remove the three wastegate capsule retaining bolts, C clip on bottom of wastegate actuator and all pipes then remove the wastegate capsule complete. This aid removal and helps avoid scratching the paintwork.

Loosen the EGR pipe clamp on the side of the thermostat housing, pull back the EGR pipe and remove gasket (if EGR is fitted of course).

Check that everything is clear and that there is a suitable place to put the manifold/precat/turbo as it is very heavy.

Remove the last exhaust manifold nut, gently pull the whole assembly forwards until it is clear of the studs. The left hand stud may not be clear and the manifold may be fouling the PAS bracket nut - in which case gently lever the whole assembly to the right using the PAS bracket as the fulcrum and it will be released as the hole is open to the left hand side.

Remove ...........................