1995 S4 Turbo & Exhaust Upgrade - LotusTalk - The Lotus Cars Community
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post #1 of 41 (permalink) Old 11-17-2018, 04:46 PM Thread Starter
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1995 S4 Turbo & Exhaust Upgrade

I'm embarking on a project to upgrade my '95 S4 turbo & Exhaust.

From discussions here and in other places, I've decided on the following configuration as an initial design:

- Replace manifold with Alunox headers
- Upgrade turbo to GT3071R (build & configured by Aaron at ATS)
- Upgrade fuel pump to higher flow (per Aaron)
- Keep original primary injectors, upgrade to 800cc secondaries
- 3" cat-less dual exhaust also from Alunox
- ECU map from either Aaron or PUK Racing # 6 (likely Aaron's config).

Aaron has reported getting >400 rwhp in this configuration.

My engine has about 40k miles on it, so I'm hoping that it's fresh enough to survive the upgrade. Has good compression/oil usage history.

I thought I'd start a thread to document how it's going and share the results.
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post #2 of 41 (permalink) Old 11-21-2018, 08:29 AM Thread Starter
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The new headers and exhaust system from Allunox arrived.

I like the engineering quality. Also the flex joint between the turbo and cat will hopefully reduce some of the vibration and wear/tear on the studs that we experience.
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post #3 of 41 (permalink) Old 11-21-2018, 08:31 AM Thread Starter
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The old iron header is off. Pics of the old vs new, including the broken stud that we're discussing in the other thread.
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post #4 of 41 (permalink) Old 11-21-2018, 08:33 AM Thread Starter
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Another new surprise in this project -- one of the engine mount screws is missing and the mount appears to be slightly out of alignment. Next up will be removing the mount and inspecting the threads.
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post #5 of 41 (permalink) Old 11-24-2018, 01:12 PM
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This is going to be great. That is a lot of HP!

I wonder if it would be worthwhile to upgrade the primary injectors to a more modern style with a superior spray pattern? I was reading about the benefits on John Welch's site.

94 Esprit S4 - Silver
Previous - lots of hot rod Air Cooled 911s
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post #6 of 41 (permalink) Old 12-02-2018, 09:49 AM Thread Starter
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@Eric I did ask about that to both PUK and ATS and they thought that only the secondaries needed replacing and the original's in the '95 would be ok.
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post #7 of 41 (permalink) Old 12-02-2018, 09:53 AM Thread Starter
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It looks like the engine mount screw is just missing -- the original threaded hole looks great and a bolt tightens in there solid.

However, I notice now the left engine mount is loose at the rubber mount -- either the rubber has compressed or it just needs tightening.

Is this typically just a tighten - or should the rubber mount be replaced?
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post #8 of 41 (permalink) Old 12-02-2018, 09:56 AM Thread Starter
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I also found that the cause of the "wet manifold syndrome" was the rear cam seals. I replaced both of those and the oil leak stopped.

I definitely recommend replacing those if you ever take the turbo off - the original rubber material seems to go very hard. The new ones were a different type of rubber from what I can tell.
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post #9 of 41 (permalink) Old 12-02-2018, 10:01 AM
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Good to know (about the injectors)!

So better exhaust flow, better better turbo, more power! ......

More heat - you have to order the monster Charge Cooler that Alunox or ATS sell :-)

Its like an addiction for me....i just need a little more and then I will be satisfied - I think these businesses have me figured out, always adding one more piece that I just have to have!

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Previous - lots of hot rod Air Cooled 911s
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Last edited by Erik L; 12-03-2018 at 02:31 AM.
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post #10 of 41 (permalink) Old 12-03-2018, 08:11 AM
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Quote:
Originally Posted by rjmcdougall View Post
I'm embarking on a project to upgrade my '95 S4 turbo & Exhaust.

From discussions here and in other places, I've decided on the following configuration as an initial design:

- Replace manifold with Alunox headers
- Upgrade turbo to GT3071R (build & configured by Aaron at ATS)
- Upgrade fuel pump to higher flow (per Aaron)
- Keep original primary injectors, upgrade to 800cc secondaries
- 3" cat-less dual exhaust also from Alunox

- ECU map from either Aaron or PUK Racing # 6 (likely Aaron's config).

PUK chips do not address a need for fueling map corrections, and couple of other issues.

You need to talk to John Welch before you buy any PUK chips.
John knows it best!
Many years ago, John cracked the ECU code and for a long time was the "go-to man" who manipulated it tailoring performance of the Lotus Team racing cars (X180R).
John started it ALL.

John can flush your chip customizing the code/maps to your bespoke modifications parameters, much better than a "cookie cutter" made chip.
Cheaper and better way to do it, IMNSHO!
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Last edited by MRDANGERUS; 12-03-2018 at 07:16 PM.
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post #11 of 41 (permalink) Old 12-22-2018, 05:52 PM Thread Starter
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I took the old engine mount out and found it was sagging compared to the new replacement.

I also wonder if the sagging mount added to the pressure being put onto the old manifold, possibly contributing to the stud issues (which are now resolved!).

Next step: fuel pump.
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post #12 of 41 (permalink) Old 12-22-2018, 08:25 PM Thread Starter
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ATS's recommendation to match the turbo was to upgrade the fuel pump to a walbro 255lph:

"The stock fuel pump runs out about 270whp, plus they are just plain old. These pumps have been tested to over 500whp (on Toyota MR2 applications, I haven't pushed an Esprit that far yet)"

I found the specs here: https://walbrofuelpumps.com/walbro-gss-fuel-pumps

Also, the new pump hits 16 amps, which is higher than the current 10 amp fuse, relay and wiring, so ATS provided an additional relay/fuse to handle the upgraded current.

Picture shows the new pump fitted to the tank feed ready for wiring and install.
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post #13 of 41 (permalink) Old 12-23-2018, 04:15 AM
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I read somewhere that the pulsation dampeners can get old and start to allow the pressure to bleed off between the pump and injectors.

Looks like you are going to keep it. Did you consider deleting?

I dont know the pros/cons of deleting and I am curious.
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post #14 of 41 (permalink) Old 12-23-2018, 10:22 AM Thread Starter
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i didn't have any guidance on that so i left it in; lets figure out what the right thing to do is and i will reconfigure it.
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post #15 of 41 (permalink) Old 12-23-2018, 10:28 AM Thread Starter
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On ATS's page: "Also hose to eliminate the fuel pressure dampner is included. Elimination of fuel dampner is optional"
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post #16 of 41 (permalink) Old 12-23-2018, 10:32 AM
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Oh you beat me to it

Esprit 255lph Fuel Pump - ATS Racing

Aaron says he includes the hose to delete the dampener, I assume that he is in favor of deleting. Maybe he will chime in and explain the benefits.

I think pulsation dampeners were important on CIS cars because pulsing from the pump could cause the flapper that moved up and down to regulate fuel flow to the injectors to move a little causing things like unsteady idle. I would not think on an EFI controlled system it would have any effect? Maybe left over from the CIS cars?

Just guessing, I need to do some research.

94 Esprit S4 - Silver
Previous - lots of hot rod Air Cooled 911s
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Last edited by Erik L; 12-23-2018 at 11:40 AM.
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post #17 of 41 (permalink) Old 12-23-2018, 11:57 AM Thread Starter
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Headers are installed.

I had to ezout one broken stud and replace 3 others.

I found it hard to get the new headers to align - for the first 2 hours I tried various attempts at aligning but couldn't get all the ports on at the same time.

The final solution was to to use the old manifold as a guide - by bolting the new header to the old manifold I was able to force all of the tubes into position, allowing an easy fit onto the exhaust studs.

I went through the feedback on the studs thread and decided to use the new captive net set from Alunox, but re-use the lock-plates that were on the original manifold. That way I can lock the nuts in place. I also used neverseize on the studs and nuts.
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post #18 of 41 (permalink) Old 12-23-2018, 02:51 PM
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Wow, that would be impressive. Stock 300hp/290tq for the '95 S4. 400+hp rwhp would be something like 440 at the crank. 300hp to 440hp, still out of a 2.2L engine is quite remarkable.

I wonder what kind of torque is expected?
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post #19 of 41 (permalink) Old 12-24-2018, 04:31 AM
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I have a question , with 400hp to the rear wheels did you upgrade the tranny???
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post #20 of 41 (permalink) Old 12-24-2018, 04:47 AM
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Alunox exhaust

Alunox does an awesome job on the headers. Not so much on the exhaust system on G car Federal cars. The Stevens body may not be an issue. I would hook up the turbo/ manifold pipe in place and make sure you do not have a clearance issue with the wheel well. I had to cut some of the body away to clear the next piece of pipe that goes up over the shock support. I do not know if this problem exist on the later cars. Alunox treated me like I was a dumb girl that didn't know what I was doing. They used a ROW car which believe it of not has a different lower tub. A lad over in UK sent me pictures of his wheel arch with tire removed. Yup it was completely different. I was left alone on my problem. The muffler supplied was also wrong and almost twice the size. I still need to address the muffler. A friend here has a guy that cam give me some more throaty sound. I still an leaning on replacing the muffler completely. I still think they have a very nice header. Good luck!
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