Heads up for owners @30K - LotusTalk

QuadCamSix · 11-07-2009, 01:53 PM

I had a VERY bad misfire at 6K and a slight loss of power under WOT on the low cam. This appeared very suddenly after the car had been sitting for about a week. Fearing the worst and assuming that it was time to check the cam lobes anyway (my Elise is an 05), I decided to pull the valve cover. All is fixed now but I want to share and remind you guys to pull your coils and take a look for leaks or moisture damage. This may explain some of the stalling & other issues some people mention.

Anyway, here is what I found:

The harness for the coil packs had been rubbing though and was about to short out.

The valve cover gasket was obviously leaking on one of the plugs.

One of the plugs was full of water. This may have been due to parking on a steep hill. Regardless the coil pack, plug tube and spark plug were covered in rust.

VisualEchos · 11-07-2009, 09:52 PM

Thanks for the heads up man!

QuadCamSix · 11-08-2009, 08:25 AM

No problem. The wire harness was of the most concern. Since it was rubbing and the car is unmodified I suspect many others have worn through parts of the harness. You can clearly see that the harness was working on rubbing through over cyl #3 as well. Another 10K and this would clearly have caused a problem.

fonzi337 · 11-09-2009, 09:04 PM

Thanks for posting this. Will keep an eye out for it.

And please remind me: we want to park our cars facing downhill when it's raining to help avoid problems like this? I think that's what I remember reading, but it never made much sense to me (wouldn't you want to park it facing uphill? I'm probably missing something)...

QuadCamSix · 11-09-2009, 09:38 PM

I think the issue is when we park on a hill tilted toward the passenger side. I wouldn't be overly concerned about how I park but I think its something that should be checked every other oil change. BTW went to toyota today and you CANNOT order replacement boots for the coil packs. You have to order the entire coil. $90+ USD

RoadDad · 11-09-2009, 10:01 PM

RoadDad · 11-09-2009, 10:06 PM

Quote:

Originally Posted by fonzi337

Thanks for posting this. Will keep an eye out for it.

And please remind me: we want to park our cars facing downhill when it's raining to help avoid problems like this? I think that's what I remember reading, but it never made much sense to me (wouldn't you want to park it facing uphill? I'm probably missing something)...

Open your boot lid and look at the location of the drain holes (they are really more like slots) in the channel around the opening to the boot. That will show you which end of the car to face downhill when washing/raining/etc.

Keeper · 11-10-2009, 02:36 AM

Curious to hear if anyone else sees this type of wear after inspecting their car.

Post up!

RENDERMAN · 11-10-2009, 07:34 PM

I just discovered the same thing on that same last plug hole in your image a few days ago, with oil all over the inside of the port. I changed the spark plug and it improved but is there any permanent damage to the engine? the plug was soaked in oil!!

tomorrow I will re-examine the plug to see if it's dry...

tesprit · 11-10-2009, 08:57 PM

Quote:

Originally Posted by RENDERMAN

I just discovered the same thing on that same last plug hole in your image a few days ago, with oil all over the inside of the port. I changed the spark plug and it improved but is there any permanent damage to the engine? the plug was soaked in oil!!

tomorrow I will re-examine the plug to see if it's dry...

It won't stay dry for long. You need to replace the failed spark plug tube seal in the valve cover. Just remove the valve cover, press the bad seal out of it, clean up all the crud in the area of the seal as well as the inside of the spark plug tube, spark plug and coil, then press in the new seal and replace the valve cover.

QuadCamSix · 11-10-2009, 10:55 PM

Yea just replace the O-rings. I got the entire valve cover set for something like $17. And no, no permanent damage to the engine. Its just a misfire and a small oil leak.

On the bright side, the cams, rockers and entire cyl head looks friggin new inside! The synthetic oil really does make a huge difference.

RENDERMAN · 11-11-2009, 08:46 AM

Thanks guys I'll do the work today and post the result :heart:

OTB · 11-11-2009, 09:42 AM

I had to replace the wiring to one coilpack around 16k miles. the wiring isn't as protected as it should have been from the factory.

RENDERMAN · 11-11-2009, 05:57 PM

Finished earlier today and Here's what I got, not too bad after all and thanks God for synthetic oil (Actually Mobil 1) you can eat off my engine. Again thanks a million guys for your help, I appreciate it

QuadCamSix · 11-11-2009, 10:52 PM

Renderman, #4 looks a little rusty or oily.

FYI when re-installing the new O-rings find a socket that is the same size as the outer portion of the O-ring. Then use a small hammer to tap/press it in. Works perfect!

Cheers.

RENDERMAN · 11-12-2009, 05:25 AM

Yeah, it had some surface rust, this picture was taking before I cleaned it. BTW the picture looks worst that it actually is. Thanks for the head's up!!

11-07-2009, 01:53 PM	#1 (permalink)
QuadCamSix Testing your next engine! Join Date: May 2006 Location: Asheville North Carolina Posts: 193	Heads up for owners @30K I had a VERY bad misfire at 6K and a slight loss of power under WOT on the low cam. This appeared very suddenly after the car had been sitting for about a week. Fearing the worst and assuming that it was time to check the cam lobes anyway (my Elise is an 05), I decided to pull the valve cover. All is fixed now but I want to share and remind you guys to pull your coils and take a look for leaks or moisture damage. This may explain some of the stalling & other issues some people mention. Anyway, here is what I found: The harness for the coil packs had been rubbing though and was about to short out. The valve cover gasket was obviously leaking on one of the plugs. One of the plugs was full of water. This may have been due to parking on a steep hill. Regardless the coil pack, plug tube and spark plug were covered in rust. __________________ The Lotus Elise is not a very practical car, but it could probably be considered the most practical motorcycle ever made!

11-07-2009, 09:52 PM	#2 (permalink)
VisualEchos Registered User Join Date: Aug 2006 Location: Missouri Posts: 1,015 Images: 3	Thanks for the heads up man! __________________ My Car

11-08-2009, 08:25 AM	#3 (permalink)
QuadCamSix Testing your next engine! Join Date: May 2006 Location: Asheville North Carolina Posts: 193	No problem. The wire harness was of the most concern. Since it was rubbing and the car is unmodified I suspect many others have worn through parts of the harness. You can clearly see that the harness was working on rubbing through over cyl #3 as well. Another 10K and this would clearly have caused a problem. __________________ The Lotus Elise is not a very practical car, but it could probably be considered the most practical motorcycle ever made!

11-09-2009, 09:38 PM	#5 (permalink)
QuadCamSix Testing your next engine! Join Date: May 2006 Location: Asheville North Carolina Posts: 193	I think the issue is when we park on a hill tilted toward the passenger side. I wouldn't be overly concerned about how I park but I think its something that should be checked every other oil change. BTW went to toyota today and you CANNOT order replacement boots for the coil packs. You have to order the entire coil. $90+ USD __________________ The Lotus Elise is not a very practical car, but it could probably be considered the most practical motorcycle ever made!

11-09-2009, 10:01 PM	#6 (permalink)
RoadDad perfututum futūtor Join Date: Dec 2006 Posts: 6,019	__________________ "Really, you want to maintain a semblance of professionalism since you represent Lotus. Me... I don't need to. Bite me." -Randy

11-09-2009, 09:04 PM	#4 (permalink)
fonzi337 Registered User Join Date: Apr 2009 Posts: 30	Thanks for posting this. Will keep an eye out for it. And please remind me: we want to park our cars facing downhill when it's raining to help avoid problems like this? I think that's what I remember reading, but it never made much sense to me (wouldn't you want to park it facing uphill? I'm probably missing something)...

11-10-2009, 02:36 AM	#8 (permalink)
Keeper Probably Lurking Join Date: Nov 2003 Location: North of Boston Posts: 2,285	Curious to hear if anyone else sees this type of wear after inspecting their car. Post up! __________________ -Shawn (2005 Lotus Econoxotic) Uberpost -- things owners should know - common problems/fixes - rattles, squeaks, noises - read the manual - good ideas? - maintenance - mods - reference - abbreviations

11-10-2009, 07:34 PM	#9 (permalink)
RENDERMAN Registered User Join Date: Jun 2007 Location: Miami 305 Posts: 904 Images: 6	I just discovered the same thing on that same last plug hole in your image a few days ago, with oil all over the inside of the port. I changed the spark plug and it improved but is there any permanent damage to the engine? the plug was soaked in oil!! tomorrow I will re-examine the plug to see if it's dry... __________________ WILL.I.AM 2005 Saffron yellow Custom Elise…. Adobe Photoshop CS4 Certified Instructor Check out my work, Site under construction... http://www.wilsart.com/

11-10-2009, 10:55 PM	#11 (permalink)
QuadCamSix Testing your next engine! Join Date: May 2006 Location: Asheville North Carolina Posts: 193	Yea just replace the O-rings. I got the entire valve cover set for something like $17. And no, no permanent damage to the engine. Its just a misfire and a small oil leak. On the bright side, the cams, rockers and entire cyl head looks friggin new inside! The synthetic oil really does make a huge difference. __________________ The Lotus Elise is not a very practical car, but it could probably be considered the most practical motorcycle ever made!

11-11-2009, 08:46 AM	#12 (permalink)
RENDERMAN Registered User Join Date: Jun 2007 Location: Miami 305 Posts: 904 Images: 6	Thanks guys I'll do the work today and post the result :heart: __________________ WILL.I.AM 2005 Saffron yellow Custom Elise…. Adobe Photoshop CS4 Certified Instructor Check out my work, Site under construction... http://www.wilsart.com/

11-11-2009, 09:42 AM	#13 (permalink)
OTB Registered User Join Date: Aug 2007 Posts: 106	Ignition wiring failures here too. I had to replace the wiring to one coilpack around 16k miles. the wiring isn't as protected as it should have been from the factory. __________________ Eli Don't rub the lamp unless you want the genie to come out!

11-11-2009, 05:57 PM	#14 (permalink)
RENDERMAN Registered User Join Date: Jun 2007 Location: Miami 305 Posts: 904 Images: 6	Finished earlier today and Here's what I got, not too bad after all and thanks God for synthetic oil (Actually Mobil 1) you can eat off my engine. Again thanks a million guys for your help, I appreciate it __________________ WILL.I.AM 2005 Saffron yellow Custom Elise…. Adobe Photoshop CS4 Certified Instructor Check out my work, Site under construction... http://www.wilsart.com/

11-11-2009, 10:52 PM	#15 (permalink)
QuadCamSix Testing your next engine! Join Date: May 2006 Location: Asheville North Carolina Posts: 193	Renderman, #4 looks a little rusty or oily. FYI when re-installing the new O-rings find a socket that is the same size as the outer portion of the O-ring. Then use a small hammer to tap/press it in. Works perfect! Cheers. __________________ The Lotus Elise is not a very practical car, but it could probably be considered the most practical motorcycle ever made!

11-12-2009, 05:25 AM	#16 (permalink)
RENDERMAN Registered User Join Date: Jun 2007 Location: Miami 305 Posts: 904 Images: 6	Yeah, it had some surface rust, this picture was taking before I cleaned it. BTW the picture looks worst that it actually is. Thanks for the head's up!! __________________ WILL.I.AM 2005 Saffron yellow Custom Elise…. Adobe Photoshop CS4 Certified Instructor Check out my work, Site under construction... http://www.wilsart.com/

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