S3 Duratec exhaust primaries removal

[Doc007]

I'm trying to take the whole system off my S3 Duratec with the 420 style dry sump triangular oil reservoir. The (old) assembly guide suggests during assembly the order is 4 (outside-in) 3 (outside-in) 2 (inside-out) 1 (inside-out), with the No.1 cylinder being at the front.

But I can't for the life of me wangle the first one out. I know it will be easier from there on and what's most frustrating is that I did it a few years ago but cannot remember how!

Don't suppose there are any simple videos/how to guides/tips?

[Alan Reeves]

call me if stuck and can pop up

[Doc007]

Managed it! 

What a ballache.

Technique seemed to be to remove all the bolts, freeing up all 4 primaries and the wiggle and jiggle until you deliver No.1 vertically past the cam cover between No.3&4.

 

[John Vine]

Well done!  I was just about to post the following:

 

I did this job recently when I needed to refurbish the gearbox, and wrote up a guide.  See Section D6.

As you say, #1 is the awkward fella.  Instead of reversing the sequence in the various Assembly Guides, I removed mine in this order: #1 inwards, #3 #2 #4 outwards.  It's just possible to do all this with the steering column in place.  Removing the breather hose will provide a bit more room.

JV

[ChrisC]

It's easy without the dry sump tank.  It's also easy to damage the side skins (like i did with my 360) https://caterham420detailedbuildblog.co.uk/2019/12/24/exhaust-primaries/

 

[John Vine]

Amazing photos, Chris.  What camera do you use?

JV