400 BHP Turbo Exige

The first stage of this conversion is to remove the bodywork from the rear of the car to enable removal of the engine and allow good access to the engine bay area for the complex runs of turbo air pipes and chargecooler water pipes. Due to the high power output of this particular conversion there will also be some additional engine bay installations such as fuel swirl pot and external high pressure fuel pump. There will also be a breathing system fitted which will automatically return oil vapour back to the crankcase.
With the bodywork removed the engine was then removed along with several other items which will no longer be used with this conversion. Bulkhead carpet is removed as the bulkhead becomes an importand area for mounting of tanks, chargecooling equipment and electronics. The rear suspension is also stripped down for reconditioning and strengthening and upgrade of rear toe links.

The 2ZZ engine for this application is to be built with an all steel bottm end including an EN40 steel crankshaft made from billet and a set of steel conrods. Forged alloy pistons will run in a precisely bored steel lined engine block. The engine block has it's original bores removed and then the block is rebored to accept custom made steel liners. The block is then fitted with a deck plate which simulates the cylinder head being in position and then the block is bored to specification.
The cylinder head is carefully machined to accept new racing valves made specially for ATF to a new valve size which after hours of testing we have found the perfect ratio. The cylinder head is ported to match the new valves and carefully matched to the inlet manifold and exhaust manifold. Valve seats are fussed over for hours until they are perfect and a port vacuum check is performed to insure that there is no leakage.