The Ultimate Forced Induction
tuning option for Rover K–Series engines
As fitted to: Lotus Elise, MGF
and Landrover Freelander
300
bhp turbo conversion (K300T) Engine statistics in
a nutshell
BBR.-GTi modified "K" Series Rover 1800cc
4 cylinder 16 valve
Bore = 78 mm
Stroke = 89 mm
SV/cyl = 425.27 cc
Total SV = 1,701.09 cc
CR = 8.5:1
Turbocharged
Max power output = 305 bhp at 6,800 rpm
Max torque = 285 lbs ft at 4,250 rpm
Torque spread min 235lbs ft at 3,500rpm
to 6,800rpm
Max engine speed = 7,200rpm
Max boost = 1.3 bar (2.3 bar abs.)
Schedule of engine
improvements and chassis installation modifications
Part One, BBR
new engine parts and alterations
- Forged, nitrided steel counterbalanced
crankshaft.
- Stronger, heavy-duty cylinder liners.
- Forged aluminium alloy pistons with
changed compression height, larger diameter gudgeon
pins and lightweight rings.
- Cylinder block machined for new liners.
- Ladder frame doweled to cylinder
block at all main bearing shuts.
- New forged HT steel connecting rods
- larger gudgeon pin diameter, new length to suit pistons.
- Steel crankcase strengthening base-plate
machined to accommodate bigger diameter crankcase studs
and drilled with special oil galleries to attach piston
oil spray plumbing.
- Specially manufactured larger crankcase-to-cylinder
head HT steel studs.
- Specially manufactured HT steel cylinder
head and crankcase nuts.
- Oil spray piston cooling system plumbed
to steel base plate and attached to the cylinder block.
- Cylinder head machined and fitted
with larger inlet and exhaust seats.
- Larger tuftrided nickel-steel inlet
and exhaust valves.
- Cylinder head gas-flowed.
- Cylinder head machined for stronger
gasket arrangement and to fit new exhaust manifold.
- Stronger cylinder head gasket.
- New inlet manifold, plenum chamber
and throttle elbow - designed to maximise mass airflow
with pulse tuned induction length and calculated optimum
plenum-chamber volume. Design uses a larger butterfly
assembly with attached throttle angle sensor. Castings
are black anodized aluminium alloy but magnesium castings
are available at extra cost.
- Larger fuel injectors.
- Fuel rail assembly fitted with manifold
pressure adjustable fuel pressure relief valve.
- Fabricated stainless steel exhaust
manifold plumbed underneath the engine to attach to
turbocharger on inlet side.
- BBR built and balanced hybrid Garrett
T3 turbocharger fitted with BBR 360¡ heavy duty
thrust bearing.
- Specially manufactured heavy-duty
single plate clutch, organic linings. (no space in bell
housing for twin plates)
- Dyno tested engine. Software written
for both fuel and ignition to suit all situations; e.g.
[Photo
Gallery]
Part two, in chassis
- Strengthened gearbox - new
closer ratio gears; long first gear (70mph; 112kph)
- BBR LSD – new limited
slip differential.
- BBR /Johnson Matthey metallic
substrate sports cat’.
- Stainless steel exhaust system,
straight through silencer.
- Water to air charge cooler
to control induction temperatures. Accommodated to the
rear of the car but plumbed to a water radiator mounted
in front of the main coolant radiator, coolant being
circulated by an electric pump, activated by inlet air
temperature/boost level.
- Special in-car plumbing for
turbo pipework (including oil feed and drain).
- New engine management control
computer and loom, connected to original sensors, except
throttle angle sensor, attached to the new throttle
body.
- Fuel system incorporates new
pumps, swirl pot and plumbing.
- Engine breather system.
- Modified engine-cooling system
incorporating swirl pot and expansion tank.
- Remote oil cooler and oil filter
unit
NB: Dry sump kit,
optional – see below.
[Photo
Gallery]
K300T
Parts List at a glance
1 off Forged billet steel crankshaft
4 off Forged steel connecting rods
4 off Heavy duty cylinder liner
4 off Forged lightweight aluminium alloy heavy-duty performance
pistons
4 off Lightweight, high performance, piston ring pack
8 off Oversize inlet valves
8 off Oversize exhaust valves
16 off Oversize valve seats
1 off Cast BBR high performance turbo inlet camshaft
1 off Ditto exhaust camshaft
16 off High performance valve springs
1 off Steel cylinder block strengthening base plate
10 off Crankcase/cylinder head fixing studs
10 off Cylinder head nuts
1 off Heavy duty clutch assembly, organic plate
1 off Cast aluminium alloy inlet manifold
1 off Cast aluminium alloy plenum chamber
1 off Cast aluminium alloy throttle elbow
1 off Throttle assembly
4 off Solenoid higher flow fuel injectors
1 off Fuel rail
1 off Fuel pressure relief valve
1 off Stainless steel exhaust manifold
1 off Stainless steel downpipe (to turbo)
1 off Turbocharger Garrett/BBR T3 hybrid
1 off Stainless steel exhaust pipe, turbo to catalyst
1 off High performance catalyst
1 off Catalyst to silencer link pipe (s.st)
1 off Stainless steel silencer
1 off Polished stainless steel tailpipe assembly
1 off Turbocharger compressor to intercooler pipework
1 off Intercooler – water to air type
1 off Intercooler water cooling radiator
1 off Small bore water pump – intercooler circulation
1 off Intercooler to throttle assembly pipework and intercooler
water-cooling plumbing
1 off Airbox
1 off Highflow air filter
1 off Airbox to turbocharger inlet pipework
1 off Engine management computer
1 off Engine management wiring loom and connector
1 off MAP manifold sensor
1 off Water temperature sensor
1 off Lambda sensor
1 off Throttle angle sensor
1 off Air temperature sensor
1 off Engine speed sensor
1 off Camshaft/engine position sensor
1 off Catalytic converter – stainless steel substrate,
heavy loaded Platinum/Rhodium coating
Click
here for Price List
Optional
– recommended for track use
BBR.-GTi dry sump kit, comprising:
Dry sump (modified
from original and including twin scavenge pick-ups and
strainers)
Dry sump pump – twin scavenge
Dry sump pulleys, brackets and belt
Dry sump oil tank
Dry sump pipework
Lotus
Elise – Manufacturer’s specifications, for comparison
only.
Engine: Cylinders 4 in line, mid mounted,
transversely
Capacity: 1,796cc
Construction: Aluminium engine block with
aluminium cylinder head
Power: 88Kw (118bhp) at 5500rpm
Torque: 165Nm (122 lb.ft) at 3000rpm
Bore/Stroke: 80mm/ 3.1"/89.3mm / 3.5"
Valve actuation: Double overhead camshaft
with hydraulic tappets
Fuelling: Fuel injected
Alternator: 85A
Ignition: Motorola electronic ignition
system
Transmission: Manual 5-speed transaxle
driving rear wheels, hydraulic clutch.
Ratios: First: 3.167, Second: 1.842, Third:
1.308, Fourth: 1.033, Fifth: 0.765
Reverse: 3.000, Final drive: 3.938
Body: Composite body panels with detachable
front and rear clamshells; integral fixed headlamps.
Chassis: Lotus-designed spaceframe structure
of epoxy-bonded sections of aluminium extrusions (built
by Hydro Aluminium) incorporating integral roll over hoop.
Suspension: Double wishbones with single
coil springs over monotube dampers all round. Lotus-patented
uprights of extruded aluminium, made by Alusuisse.
Steering: Rack and pinion, non power assisted
Wheels: Unique Lotus-designed 5-spoke,
by Alloy Wheels International.
Front: 5¸J15
Rear: 7J16
Tyres: Pirelli P Zero
Front: 185/55 R15
Rear: 205/50 R16
Brakes: 282mm-diameter aluminium/metal
matrix ventilated discs made by Lanxide, mounted outboard.
Non-servo split hydraulic system, including unique Lotus/AP
Racing opposed piston front calipers.
Performance: Maximum speed 202km/h 100km/h
5.9s 160 km/h 18.0s
Fuel Consumption: (l/100km) Urban9.6 Extra
urban 5.7 Combined 7.1
Dimensions: Wheel base 2300mm/ 90.6 Front
track 1440mm/ 56.7
Rear track 1453mm/ 57.2
Overall length 3726mm/146.7
Overall width 1701mm/ 67.0 (excluding mirrors)
Overall height 1202mm/ 47.3
Ground clearance 160mm/ 6.3
Fuel tank capacity 40l / 8.8gal
Fuel grade 95 RON minimum
Unladen weight: 690kg
Weight distribution: 39/61 (% front/rear)
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