Lotus Esprit Series Workshop Manual

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Norwich, Norfolk, N ~ f 4 8 E Z .

England.

Telephone; Wymondha'm

602674

l o t u s

Table of Contents

Summary of Contents for Lotus Esprit Series

Page 1 Norwich, Norfolk, N ~ f 4 8 E Z . England. Telephone; Wymondha'm 602674 l o t u s...
Page 3 Page Workshop Manual i s produced primarily for Lotus Dealers to give repair and maintenance information on the Lotus Esprit car. I t i s divided into sections giving sub-assemblies comprehensive information i n some sections on the main and i n others cover.
Page 4 INTRODUCTION Page 2 VEHICLE IDENTIFICATION A l l cars are identified by a Chassis (Cor) Number, and this number w i l l be found on the Identification Plate which i s located in the front compartment on the rear bulk- head.
Page 5 TECHNICAL DATA Page CONTEN'TS Poge Description DIMENSIONS CAPACITIES ENGINE Generol Engine Belt Tensions linder Heod Valves inserts Seat Valve Guides Camshafts Cam Followers Auxiliary Shaft Crankshaft Flywheel Connecting Rod Gudgeon Pin Piston and Liner Lubrication System FUEL SYSTEM I G N I T I O N SYSTEM DISTRIBUTOR C O O L I N G SYSTEM CLUTCH...
Page 6 'age DIMENSIONS (96 ins) Wheel base (59.50 ins) Track Front (59.50 ins) Rear Overall Length (European Spec.) (165 ins) Overall Length (North American Spec.) (167.71 ins) Overall Width (73.25 ins) Overall Height (43.75 ins) (6 ins) Ground Clearance Turning Circle (Between Kerbs) (38 ft) Kerb Weight (European Spec.) CAPACITIES...
Page 7 TECHNICAL DATA Page 3 ENGINE GENERAL 907, Twin overhead camshafts Engine Type Number of cylinders 1-3-4-2 Firing order 1973 (120.4 cu ins) Capaci ty 69.2 (2.72 Stroke ins) 95.2 (3.75 Bore (nominal) ins) European Spec. North American Spec. Pressure (At sea level) European Spec.
Page 8 CYLINDER HEAD Material Aluminium alloy Gasket Steel asbestos Head depth (3.23 .O1 ins) Combustion chamber depth Max. permissible metal removal (To correct warping) Valve Timing European Spec. North American Spec. Exhaust opens Exhaust closes Valve M (Maximum European Spec. Inlet ~ O ~ . ~ ~ A . T . D . C . Exhaust 102.5' B .
Page 9 TECHNICAL DATA Page Valve Seat Inserts Bore i n head: ins) Standard Inlet ins) Exhaust (0.001 ins) lnlet ins) Exhaust (0.002 ins) lnlet ins) Exhaust +O. 127 (0.005 ins) lnlet Exhaust ins) Outside diameter seats 37.28 13/37.3507 1 .4695/1.4705 ins) Standard (1 .3535/1.3545 ins)
Page 10 'age Valve Guides (cont.) Exhaust Bore i n head Standard 0508 Outside diameter of guide 1 1.938/11.9507 Standard 0508 1 1.9888/12.0015 CAMSHAFTS End float Dimension Controlled by Selective thrust washers Running clearance C A M FOLLOWERS Bore i n camshaft housings Outside diameter SHAFT AUXILIARY...
Page 11 TECHNICAL DATA Page 7 CRANKSHAFT (cont.) Selective thrust washers on rear main bearing End f l w t Controlled b y Bearings (main) Number Steel backed, leaded bronze clearance* Static Max. undersize for regrind Bearing clearance measured with Plastigage. FLYWHEEL Max.
Page 12 TECHNICAL DAVA Page PISTON AND LINER (cont.) Identification 9.5: 1 European Dished top 8.4: 1 Federol Length 75.260 (2.963 in) Compression height Rings Cornpression O i l Control Diometer Grade 'B' Gudgeon pin bore offset 1.524 Piston clearance in cylinder liner ring gap Piston Second...
Page 13 TECHNICAL DATA Page LUBRICATION SYSTEM (cont.) N o t below 45 lbs/sq (3.16 kg cm sq) at 6.500 R.P.M. ond above Filter Type Eccentric rotor Toothed belt Drive (0.006 in) Mox. 028 1 mm ( .0005/. 001 5 in) Type of system Wet Sump FUEL SYSTEM AC-Delco (Paper Element)
Page 14 Page B.I.D.K. Needle Spring colour Blue Damper Oil Engine O i l Fast Idle Setting Between starter cam and screw head i n "off" position I G N I T I O N SYSTEM Coil and distributor Number 1 cylinder nearest to water pump Ignition advance control fully automatic...
Page 15 TECHNICAL DATA Page allow North American Specification Advance characteristic: Crankshoft degrees Crankshaft r.p.m. N o advance Below l000 2000 at 5000 6000 Clockwise Direction of rotation from drive end (all) Drive (all) offset dog Contact breaker gap (all) Firing angles Cam dwell angle Firing order Condenser capacity...
Page 16 Page CLUTCH Borg Beck, diaphra g m spring Make and type Single dry plate Operation Hydraulic 15.87 Master C linder bore diameter 22.22 Slave Cylinder bore diameter 21.59 (8.5 Drive plate diamet ; r number of springs Free play a t release lever TRANSMISSION Manual forward gears...
Page 17 TECHNICAL DATA Page FRONT SUSPENSION (cont.) Fedeml Front Spring Colour Code None Green Number of Effective Coils 10.5 Length, Free 35.30 cm 34.6 cm Coil Diameter 10.00 cm 10.00 cm Rate 55.14 k d 2 . 5 cm 63.63 kg/2. 5 cm STEERING Manual rack and pinion, with energy absorbing saginaw steering column Steering angles...
Page 18 Page BRAKES Girling hydraulic with type 28 supervac round. Eront brakes Disc diameter 250 m m (9.7 in) Disc thickness 12.7 m m (.50 in) Minimum thickness 11.7 m m Total disc run out 0.09 m m (.0035 in) TIR Lining area per brake 75 sq cm ( l l 630 sq cm (97.01 sq in)
Page 19 TECHNICAL DATA Page ELECTRICAL EQUIPMENT Battery Type Capacity amp hr hr Rating Negative Headlamps diameter units two in each hwdlamp pod. Headlamp RHD inner 50 (Main Sealed beam outer (Dip) 37.5 (Main) Sealed beam LHD inner Halogen outer North American inner Sealed Beam outer N o 2...
Page 20 Page TORQUE L O A D I N G FIGURES ENGINE Kg m Cylinder head (tighten cold) both pairs (front and rear) nuts 10.4 pairs (in middle) nuts 3.31-3.87 Sparking plugs 1.93-2.21 Camshaft housings 3.46 Camshaft sprockets M a i n bearing I F s i n g 1.93-2.21 8.02-8.29 11.61-11.89...
Page 21 TECHNICAL DATA Page Ibs ft Clutch 4.98 Clutch Housing Gearbox 1618 Clutch Assembly to Flywheel Gearbox Driveshaft Housing gearbox 7 Georbox mtg bracket to gearbox Top cover to gearbox Use avdelbond A 138 FRONT SUSPENSION Upper wishbone pivot chassis Upper ball joint to wishbone 22-24 Ball joint to vertical link, upper 5.93-6.53...
Page 22 TECHNICAL DATA Page STEERING Ibs f t Steering unit clamp screws 1.66 12-14 Upper column lower bolts 1.11-1.66 8-12 Intermediate column clamp bolts 2.21-2.76 16-20 Steering column lock retaining bolts Steering wheel retaining nut Tie-rod locknuts Ball joint to steering arm nuts 'Break-off' type REAR SUSPENSION Radius arm to rubber mounting...
Page 23 TECHNICAL DATA Page 19 HUBS 2.49 Front hub spindle nut 28-30 Front httb to brake disc Rear hub nut Wheel nttts Tighten nuts to this torque looding whilst rotating hub ensure bedding of toper rollers. Slacken nut bock 3 before inserting pin.
Page 24 Page DISTRIBUTOR North American Specification (Except Californio) The 'Lumenitiori' distributor (P907EWOOJ) i s basically a Lucas distributor with the contact breaker arid condenser replaced by an lnfra-red Sensor. Unit and o four bladed chopper fitted on the engine number. 1 O0 BTDC Static ignition timing BTDC A t idle speed...
Page 25 CHASSIS Page SECTION A Description Page GENERAL DESCRIPTION ACCIDENT DAMAGE FRONT SLJSPENSION FULCRUM P I N S ESPRIT Issue 04/78...
Page 26 Page ESPRIT...
Page 27 CHASSIS Page KEY TO FIG. Chassis Assembly Closing Plate/Mounting Bracket Bracing Strut Assembly, RH Bracing Strut Bracket, Tapping Plate Bracing Strut, Cross Beam, Rear Suspension, Assembl y Gear-box Mounting, Hole, 3" Bolt Tabwasher ESPRIT issue 04/78...
Page 28 CHASSIS Page GENERAL DESCRIPTION The chassis unit i s a prefabricated steel backbone type, linkin g the front and rear suspensions and having a centre box section. cross-member i s welded to the front of the chassis and this cariies the front suspen- sion arid steering mountings.
Page 29 BODY SECTION B Page Description BODY CARE DE-WAXING ACCIDENT REPAIRS SUPERFICIAL. DEFECT REPAIRS PAINT PROCEDURE BONNET (HOOD) B 22 DOORS B 38 WINDSCREEN (WINDSHIELD) HEADLAMPS INSTRUMENT BINNACLE SAFETY BELT S FRONT BUMPER B 50 EXTERNAL B/C POST FINISHER FRONT SEAT DOOR LOCK REAR QUARTER LIGHT B 54...
Page 30 Page FIG. Body Shell Door Assy, RH Sill, Outer LH S i l l , Outer RH Grille, Radiator Duct Headlamp Pod, LH Headlamp Pod, RH Finisher, Windscreen, Top Finisher, Windscreen, LH Finisher, Windscreen, RH Spoiler Pariel Rear Valance Front Bumper, Federal Rear Bumper, Dom/Eur Rear Bumper, Federal Plinth, Rear Bumper, Federal...
Page 31 BODY Body Components Fig. ESPRIT issue 04/78...
Page 32 Page GENERAL DESCRIPTION The body of the vehicle comprises a one-piece moulded glass fibre reinforced plastic shell which straddles a steel backbone chassis arid i s attached to i t a t various points. Whilst the chassis carries a l l the maior structural loads, the body i s used to carry or transfer the remainder, and when ttie body and chassis are mounted to g ether, each contributes to the strength and torsional stiffness of each other.
Page 33 BODY Page WINDSCREEN CLEANING When washing the windscreen, the wiper blade m y only be lifted awoy from the the blade acron the windscreen as this w i l l damage the mechanism. ROOF UPHOLSTERY A N D consists of an occasionol light wipe over with a cloth dampened i n a mild soap and water solution;...
Page 34 Page KEY TO FIG.2 Full Body Section, Mid-Nose, Section Body Section, Mid-Nose, RH Section - - - Full Full Body Section, Nose, Section Full Body Section, Nose, RH Section Full Body Section, Nose, LH Section Roof ESPRIT 04/78...
Page 35 BODY Page Front Body Sections S P RIT Issue 04/78...
Page 36 Page B8 KEY TO F I G . 3 Body Section, Short Rear, Full Section Body Section, Short Rear, RH Section Body Section, Short Rear, L H Section Body Section, Full Rear, Section Body Section, Full Rear, L H Section Bulkhead, Upper Bulkhead, Centre ESPRIT...
Page 37 BODY Page ESPRIT Fig. Bcdy Sections Rear 04/78...
Page 38 Page As a general rule there should be a bond wherever two ponels touch, or wherever they close on important points. I t i s usually possible to check these bonds both visually and physically for fractures or breaks. Ascertain the cause of damage and the direction of impact and examine a l l panels or bonds which may have been affected.
Page 39 Page rovings and resin, and whilst still wet, lay over o thin layer of chopped-strand mat and apply more resin hardener (1 oz weight). Allow to dry ond fully cure. Sand down and f i l l any imperfections with f i l l e r (Port N o . A036 dry.
Page 40 This can cause the resin to soften slightly and i n doing so give way to any inbuilt or associated stresses. I n a l l such cases technical advice should be sought from Lotus Cars Ltd. SPLIT BONDS ..
Page 41 BODY Page Before cutting away the damaged parts or ordering replacement sections, the proposed method of repair, positioning of joint lines, overlops etc. should be ascertained. Determine a method for the correct positioning of replacement sections and before cutting away damoged parts check on any prominent features from which measurements can be made and scribe these clearly on to the panels which are to be left intact.
Page 42 Page Bobbins Pulling O u t This could be caused by overloading e.g. accident damage. Where the bobbin and its surrounding area i s accessible from the rou g h side of the laminates either naturally or by cutting non-weakening access holes, the remedy i s to improvise o local mould i n wood or glass fibre of the body surrounding the finished side of the bobbin.
Page 43 BODY Page Fig. Body Mountings ESPRIT issue...
Page 44 Page U.N .C. t o f i t only bolts to them. Where the bolts ore porticulorly tight this may be due to resin within the threaded portion of the bobbin which can be remedied by tapping out. O n l y the correct length of the bolt should be used, i.e. those whose threod engages with the full depth of the bobbiri.
Page 45 BODY Page Remember that tensile applications are the most demanding and require continuity o f layup, that the above instructions be strictly adhered to, that the safety of the vehicle may be dependent upon the correctness of the application of these operations. MOUNTING POINTS BODY When mounting the body to chassis unit, o clearonce between the rearmost mounting...
Page 46 Page Spray door shuts and edges. Apply 2 cross coats of colour keeping wet, usirig thinner (Part N o . 368 6142) to give 23-24 seconds N o . 4 cup at 6 5 ' ~ ( 1 8 . 3 ~ ~ ) with 5 minutes flash between coats.
Page 47 BODY Page The point materiol used i s ICI P.40'7 two-pack polyurethone, which i s o synthetic resin requiring the addition of a catalyst or activator. not reflow with the original coat and so spot repairs or ponel blow-ins are not easily achieved.
Page 48 Page B20 The recommended methods for removing paint are as follows: Wash off with a slow thinner. Wet flot with an appropriate grade of paper deperident on the amount of "240" paint to be removed. Paper heavier than grade must not be used. BONNET (HOOD) REMOVE...
Page 49 BODY Page Front Fig. Compartment (Bohnet) ESPRIT...
Page 50 Page REPLACE Replacement i s a reversal of the removal procedure, takin g care that the hinge bracket bolts are refitted in the or.iginal positions. ADJUSTMENTS To adjust the front height of the bonnet to align with the front of the body, reposition the nuts securing the hinge bracket pivot bolts to the body.
Page 51 BODY Page Disconnect gas support struts, one on each side, from the ball assem- blies on the tailgate b y removing the retaining springs. Now, support the tailgate while the second operator removes both hinge bolts and the toilgate can be l i f t e d clear of the cnr. Fig.
Page 52 Page KEY TO Secondary Tailgate Seal Finisher, Top Finisher, Bottom Finisher, LH Finisher, Mounting Clips Hinge Blade, Bolt Bolt Plunger Housing, Tailgate L i f t Rubber Buffer, Tailgate L i f t Screw, Pozi Gas Strut Striker, Tailgate Lock Tapping Plate, Striker Grommet Cable, Tailgate Release...
Page 53 BODY Page Tai lga ESPRIT...
Page 54 Page KEY TO FIG.8 Door Beam Assy Hinge Bracket, Upper, LH Hinge Bracket, Lower Shim, Angled Shim, Upper Shim, Lower Tie Rod, Hinge Washer Bush, Hinge Pin Hinge Pin Check Strap Assy, LH Window Motor, LH Door Wipe Seal, Long Door Wipe Seal, Short, LH Window Frame, L H Silent Chonnel...
Page 55 BODY Page Fig. 8 -Door Components ESPRIT...
Page 56 Page B28 DOORS DOOR LOCK STRIKER ADJUSTMENT The door lock striker should only be adjusted when the car i s on its wheels on level I t i s not necessary to disturb this component other than to f i t a replacement, or to -make or1 adjustment.
Page 57 BODY Page B29 DOOR ADJUSTMENTS The Door Assembl following manner: the hinge. Loosen the two bolts securing the back end of the door assembly about the door lock. Move the door to the desired position and tighten up all bolts. Adjust the lock striker Fig.
Page 58 Page KEY TO FIG. 10 Door Hondle, Exterior, RH Bracket, tlandle Body Door Handle, Interior, RH Operating Flop Pivot Pin Door Lock, RH Striker Plate Rod, Interior Clip, RH Release to Rod, Lock Exterior Lock . . . Rod, Exterior to Lotch, RH 1 1 .
Page 59 BODY Page ESPRIT Fig. 1 0 Lock Door...
Page 60 Page B32 Vertical Adjustments the door assembly requires verticol adjustment, then loosen the two large clomping bolts securing to two hinge brockets just sufficient to allow up or down movement. Move the door assembly to the required position and tighten clamping bolts. DOOR PANEL REMOVAL Remove the trim inside the interior door handle, and loosen the three...
Page 61 BODY Page 833 Release the screws on the underside or lower part of the front and rear door shut edge securing the trim panel to the door. L i f t trim panel away from lower edge of door, push the panel up, un- hook from top of door, and remove panel.
Page 62 Page MOTOR W I N D O W OPERATING REMOVAL Remove the door time panel, and the PVC sheeting. Disconnect the cables from the motor. Check Strap Assy. Motor ~ s s y . Door Beam Fig. Window motor location Support the window with a suitable piece of wood, or top&...
Page 63 BODY WINDOW OPERATING MOTOR REPLACEMENT Reverse the removal instructions. STRAP DOOR CHECK REMOVAL Remove the door trim panel and the PVC sheeting. Release the bolt securing the check strap to the door hinge an3 the two bolts securing the strap to the door beam. Remove the assembly. DOOR CHECK STRAP REPLACEMENT Reverse the removal procedure.
Page 64 Page Fig. Side-capping rail/finisher Using a suitable thin blade, cut through the sealant between the body ing i t from the finisher. TO REPLACE Clean the body surface where the capping rail i s to be fitted ond apply sealant along the lower inner edge of the capping coil. Feed the capping rail under the finisher ond check alignment along the length and at both ends.
Page 65 BODY Page Drill new fixing holes 0.125 in (3.17 mm) diameter, taking care not to drill near or on existing holes, as this could weaken the fixing. rivet the copping rail to body and remove any excess sealant using a suitable solvent.
Page 66 WINDSCREEN (WINDSHIELD) REMOVE Remove the wiper arm/blade assembly. Remove sun visors, upper front headlining trim finisher and pull off trim. Remove the three finishers from the top and sides of the windscreen. These con only be removed by prising off, which w i l l damoge the finishers, therefore, new finishers w i l l be required w l ~ e n refitting.
Page 67 BODY 0.125 (3.17 Secure the clips with a mm) pop-rivet, then seal the head of the rivet with o smear of seolont. 0.75 mm) wide band of 'Solbit' primer round the periphery of the screen and the body aperture. Glass Section through windscreen and fixing clips Strip the ends of the 'Solbit' sealing/retaining medium to expose approximately...
Page 68 Page ends of the trim clips, and crossed at the end. Press into the surface of the 'Solbit' at re ular intervals the small spacers on which the glass w i l l rest. With the aid of a second operator, l i f t screen into position on the body, ensuring that the screen i s fitted so that i t i s resting on the spacers.
Page 69 Page the bottom of the motor can be turned by hand to raise the lamps i n an emergency or for maintenance. For maintenance purposes the headlam p s can be raised electrically. This i s achieved b y switchin g on the li g hts, waiting until pods are up, then raising the bonnet l i d (which operates a microswitch, turning off the power to the lamp bulbs).
Page 70 Page KEY TO FIG. Headlamp Motor Mountin g Bracket, ROW Headlamp ~ o t o r Mounting Bracket, Fed Headlamp Motor Assy Switch Plate Long Link, Headlamp Operation Short Link, Headlamp Operation End. !.Ink Shoulder Bush Cross shaft, LH Cross shaft, R H Cross shaft Coupling Bearing Bracket, Headlamp Support Stay, ROW Bearing Bracket, Headlamp Support Stay, Fed...
Page 71 BODY Single Fig. motor 04/78...
Page 72 Page Headlamp Motor Headlamp Motor Mounting Bracket Headlamp Motor Rotary Link Connecting Link Headlamp Actuation Bearing Housing, Glacier Bush Water Shield Hinge Pin, Pod and Bonnet Hinge Blade, Spring Clip Pod Outer Pivot Pin M 6 Jocknut 30 Screw ESPRIT...
Page 73 ESPRIT 04/78...
Page 74 Page HEADLAMP POD ADJUSTMENTS To adjust the 'up' positiori of the pod, the damper on the heodlomp jack spring ossembly, i n the front comportment, can be repositioned b y the nyloc nut on the jack spring shaft. Screwing i n the nut closes down the pod and screwing out the nut opens up the pod.
Page 75 BODY REPLACE Reverse the removal procedure. BELTS SAFETY The seat belt reel assemblies are located i n the engine compartment and are fitted to the back of the bulkhead, one on each side. TO REMOVE Prise off the small cover, near the bottom of the reel:assembly, gain access to the fixing bolt.
Page 76 Page Fig .20 Safety Be1 t fixings TESTING The reel w i l l lock when the car i s stopped sudderlly or accelerated hard. change of speed i n any direction, which iricludes turning, w i l l lack the reel. The reel should run free when the car i s stationary and when the car i s travelling a t a constant speed.
Page 77 BODY Page BUMPER FRONT REMOVE Remove both headlamp pod assemblies and disconnect the wires from both side/indicotor lamp assemblies. I t i s not necessary t o disconnect the side/indicator lamp assemblies on car with the Federal specification. From inside the headlamp pod accesses and front compartment, remove the bumper mounting bolts with their washers.
Page 78 Page REPLACE Reverse the renloval procedure, but first clean the surfaces on the body which come i n contact with bumper and apply sealant to the bumper before fitting. Refit trim panel i n the engine compartment. VALENCE TO REMOVE Unscrew the self tapping screws and bolts and washers.
Page 79 Page Rivets Fig.21 External Post Finisher FRQNT SEAT REMOVE Slide the seat fully bockward. From the front end of both seat runners, release the nuts with their flat washers from the runner mounting bolts. (The nuts are on the underside of the body.) Do not remove the bolts at this stage.
Page 80 Page Connect the seat sensor wires ( i f fitted). Apply underseal to the seat mounting bolts, nuts and washers, to prevent possible water entry. DOOR LOCK REMOVE Remove the door trim panel and PVC sheeting from the Remove the exterior door handle assembly Disconnect both remote control rods and F) from the lock assembly.
Page 81 BODY Page B53 FIG.22 Exterior Door Handle Door Lock Locking Rod to Exterior Hondle Releose Rod to Exterior Handle Locking Rod to lnterior Handle Release Rod t o lnterior Handle Adjustable Cocking Rod to Exterior Handle Clip Adjustable Release Rod to Exterior Handle Clip Adjustable Release Rod to lnterior Handle REPLACE Reverse the removal procedure, but before replacin g the PVC sheeting...
Page 82 Page REPLACE Check the rubber seal orourid the Reverse the removal procedure. opening for damage, replace necessary. DOOR WINDOW FRAME TO REMOVE Remove the door trim ponel, the window operating motor, the exterior door hor~dle ond the door lock assembly. Fig.23 Window Frorne fixing bolts Access to the bolts securirig the window frame i s through the access...
Page 83 BODY Page Door Shell fixing bolts REPLACE Reverse the removal procedure, fine adjustment of the position of the window frame can be achieved using the movement i n the door beam slots. Ensure that the door, window motor and locks are functioning DOOR SHELL Remove the door window frame.
Page 84 Page FRONT QUARTER LIGHT GLASS (DOOR) 7 ' 0 REMOVE Remove the door window frame and place i t on a felt covered bench. To remove the glass from the window frame, soak the 'Solbit' sealing/retainer medium i n "Solbit- Primer ' for approximately one hour and remove the glass, or the glass cannot be...
Page 85 BODY Page Apply 'Solbit-Primer' to the quarter light channel i n the window frame. Strip ends o f 'Solbit' to expose approximately inch of internal copper wire. Connect the ends to a variable transformer or a battery, and apply volts to the Disconnect the power source and position the 'Solbit' on the primed edge of the glass.
Page 86 Page DOOR WINDOW FINISHERS INTERNAL REMOVE FINISHER Remove the door trim panel to which the intern01 finisher i s fitted. East off the finisher from the door trim panel. REPLACE Apply sealant along the edge of the door. trim pariel and press on finisher arld refit door trim panel.
Page 87 BODY Page An oir scoop i s fitted to the rear of each rear quarter light, one feeds air into the engine cover and the other to the airbox, via the engine compartment. The side ~ a n e l s i n the engine compartment are sealed with vents into the engine compartment.
Page 88 Page Engine Boost fan fitted only Cover to Federal vehicles and those operating in high ambient climates RH Air Scoop scoop LEATHER UPHOLSTERY available i n many colours for the model To clean, wipe over occasionall with o cloth damped i n warm soopy water. important that the soap used i s a mild, non-caustic scap, such as roiier soap.
Page 89 Page If a new glass i s to be fitted for any reason a complete kit, Part N o . A07586158J-1 will be required for each screen. REMOVE For a windscreen remove the wiper arin/blade assembly, sun visors, upper front heodlining trim finisher and pull off trim. For the tailgate glass remove the electrical connections to the tailgate glass heater.
Page 90 Page Clean lan~iriated edges of gloss using a sharp knife. With the special paper frorn the repair k i t cut i n two, cleon with one half soaked i n Wipe Clean N o . the perimeter of the glass to the depth of the primer applicator. Also Using the other half of the s...
Page 91 BODY Page Sealant Application Nozzle Instructions for Cutting N o z z l e Cut the nozzle length to the 73mm dimension. Cut into the centre line of the nozzle at the 66mm dimension and then cut down centre line from the 73mm dimension. Check the dimension to the inside face of the material not, enlar g e opening by cutting away more material until 5mm i s reached.
Page 92 Page lication of Betaseal with Hand G u n Fig. assembly, therefore reducing the amount of moterial squeezed out of the Position the rubber spacer blocks on each corner of the screen as snown Part fig. Spacer block N o . off, size Sealant Typical Block Position...
Page 93 BODY Page NOTE: This operation can be made easier by using rubber suction pads. Press gently all round the edge of the windscreen in order to ensure perfect adhesion of the sealant to the body. Support the glass-at the top using tank tape and the lower edge with blocks 1 1 .
Page 95 FRONT SUSPENSION Page SECTION Description GENERAL DESCRIPTION SUSPENSION A N D gEERING GEOMETRY ANTI-ROLL BAR LOWER LINK COIL SPRING DAMPER UPPER WISHBONE FRONT HUB 04/78...
Page 96 FRONT SUSPENSIGN Page C2 ESPRIT...
Page 97 FRONT SUSPENSION Page KEY TO FIG.l Front Domper Front Spring Rubber Seat, Front Spring Front Brake Disc Dust Shield, Front Brake, R.H. Vertical Link, R.H. Front Hub Bearing K i t Steering Arm R.H. Upper Wishbone, R.H. Pivot Bolt, Upper Wishbone Washer, lnner Wosher, lnner Washer, Outer...
Page 98 GENERAL DESCRIPTION The front suspension of the fully independent type with twin upper wishbones, single lower links (track control arms) and on onti-roll bar giving locotion for the road springs are used. The upper end of the dampers are attached to the chassis, and the lower ends to the single lower llnks.
Page 99 FRONT SUSPENSION Page Remove the bolts securing each end of the anti-roll bar and l i f t oway the anti- roll bar complete with the rubber mountings. To Replace Check the bushes i n the lower links for wear, replace worn badly.
Page 100 to the chassis ond withdrow lower link. To Replace Reverse the renioval procedure and before tightenin g the bolts/nuts ensure the suspension i s under normal lood conditions (upper wishbone and lower link horizontal). This w i l l ensure that the damper bushes i n the front suspension are i n an almost torsionless state, when the front suspension i s i n the TECHNICAL DATA.
Page 101 FRONT SUSPENSION Page Rubber Bush Damper Top Mounting To Replace Place the seating washer and lower mounting rubber on the damper spindle. Offer the damper up throu g h the lower link arm and locate the damper spindle in the top mounting hole. Fit moulded rubber bush, metal cup washer, nut and locknut, and tighten to the instructions given in the TECHNICAL DATA (Top stem mounting).
Page 102 Remove the carpet i n the footwell which covers the access hole to the pivot bolt. Remove the rtut securing the pivot bolt and withdraw the pivot bolt through the hole in the bulkhead. Reverse the removal procedure taking care to ensure the washers are fitted i n the correct order.
Page 103 REAR SUSPENSION Page SECTION D Page Description GENERAL DESCRIPTION BEARING HOUSING & DRIVESHAFT ASSEMBLY RADIUS ARM MOUNTING REAR WHEEL TOE-IN LOWER LINK WHEEL BEARINGS DAMPER & SPRING ASSEMBLY ESPRIT 04/78...
Page 104 REAR Page ESPRIT...
Page 105 REAR SUSPENSION Page KEY TO FIG. l Rear Damper Study, Lower Damper Mounting Penny Washer, M i l d Steel Penny Washer, Hard Steel Rear Spring Rear Spring Insulator Radius Arm Assy, LH Rubber Mounting, Radius Arm Plate Reinforcing, Radius Arm Mounting Shaft, Outboard Joint, Universal Shaft, Intermediate...
Page 106 WEAR SBdSPElcllS18M Page GENERAL DESCRIPTION The rear suspension i s a fully independent diogorial trailing arm system. Radius arms (trailing orms) are attached to the chassis by o flexible mounting ot the front end arld to the bearing housing at the rear. The bearing housings i n turn are attached to the chassis a t the rear by lower lateral links;...
Page 107 REAR SUSPENSION Unscrew the radius arm assembly from the bearing housing and allow the radius arm to swing downward clear of the bearing housing. Withdraw radius arm, taking core not to lose the washers and nut. To Replace Reverse the removal procedure, ensuring a l l bolts/nuts are tightened to the torques specified i n TECHNICAL DATA.
Page 108 REAR %BISPENSIC)%II Page To Replace Reverse the removal procedure, tighten all bolts/r~uts to the torques specified i n the TECHNICAL DATA. REAR WHEEL TOE-IN To Adjust The correct rear wheel toe-in data given i n the TECHNICAL DATA section. the side to be adjusted) and add or delete spacers between the arm and the mounting to achieve the correct toe-in.
Page 109 REAR SUSPENSION Page Lower link inner ottachment Fig. To Replace Reverse the removal procedure, taking care to f i t washers i n correct order (see illustration) and ti g hten a l l bolts/nuts to the torques specified i n the TECHNICAL DATA.
Page 110 REAR SUSPEWSlOell Page D8 BEARINGS To Remove Remove bearing housing and drive shaft assembly as previously described. Remove the hub as described i n Section W i t h the bearing tlousing/driveshaft assernbly on the bed of press, press out the driveshaft assembly from the outside (hub side) of the housing. Remove both o i l seals and the circlip securing the bearing.
Page 111 REAR SUSPENSlOSl To Replace Before fitting the new beoring i n the housing, pre-heot the hub casting to minutes. A convenient method of doing this immerse the costing for minutes in boiling water. Press in new bearing from the hub side of the housing, until the bearing i s of the bearing only.
Page 112 Page El SECTION E Poge Description GENERAL DESCRIPTION LUBRICATION ENGINE TUNE COMPRESSION CHECK CAMSHAFT COVERS CAMSHAFTS VALVE CLEARANCES CAMSHAFT DRIVING BELT (TOOTHED BELT) D RIVIN G B E LT T E ~ ~ O N E R DECARBONISING CYLINDER HEAD & PISTONS VALVE SEAT INSERTS VALVE GUIDES CRANKSHAFT 'V' BELT PULLEY...
Page 113 GENERAL DESCRIPTION The engine, which i s inclined at to the vertical from the centre-line of the crankshaft, i s a die-cast all-alloy, four c linder with cast iron wet liners, i n line, twin overhead camshaft unit operating on the four-stroke cycle with cross-flow cylinder head.
Page 114 ENGINE Page E3 valve opens, o i l i s passed back into the inlet side of pump. From the pump the pressurised o i l flows through the full- flow filter to the o i l gallery. The o i l gallery passes along the right-hand side of the engine, from where oil i s taken t o feed the crankshaft main bearings and through drillings i n the webs of the crankshaft to the big-end bearings.
Page 115 Page ENGINE TUNE Pull off the sparking plug leads and rerrlove the plugs. TECHNICAL DATA, or i f the electrodes are badly burnt, f i t new plugs and re-connect the leads. Remove the ignition distributor cop and examine the contact-breaker points. Replace the points badly eroded, or excessive metal transfer i s evident.
Page 116 Page centre-plug ond replace securely. Refit carburetters to engine using new ond top up domper Reconnect the fuel pipes ot the corburetters. Check and adjust the valve and volve timing. Check tension of the toothed timing belt and odjl~st i f necessary. Check the ignition timing, adjusting necessary.
Page 117 Page torque loading. Replace the throttle cable bracket, breather pipe, and where applicable the air rail NOTE: When replacing the exhaust cover, first insert the two bolts i n the rear end. To Remove Remove the camshaft covers as previously described. which require adiustmerlt.
Page 119 Page securing the sprocket to the camshaft. ond pull off the camshaft sprocket. Shims ESPRIT...
Page 120 ENGINE Page Fig.3 Cornshoft sprocket held in vice Fig.4 ring...
Page 121 Page El0 W i t h the oid of o two-legged puller, attached to the rear of the camshaft housing, screw in the centre bolt to push out the camshaft towards the front of housing, to g ether with its oil seal. Fig.
Page 122 ENGINE Page ~ l l To Replace Smear a l i t t l e graphite grease on the bearing of the camshaft housing, insert camshaft into its housing from the front G & ' f i t a new front oil seal. Ensure o i l seal i s flush with outer face of houking, and fitted up to the shoulder on the inside of the housing, as the o i l drain hole w i l l be blocked.
Page 123 Page use mognets when refitting Seol between the cylinder head and cam housing with loctite gosket eliminator and on ring fitted over the roll pin dowel. Before applyin g new gasket eliminator ensure a l l old gosket eliminator i s removed from the mating surfoces of the cylinder heod and cam housing.
Page 124 Page E13 Fig.9 Checking cam follower clearances To Adjust NOTE: If valve clearances are to be verified with no gasket eliminator between the mating surfaces of cylinder head ond cam housing, then add 0.0015in to each valve clearance. Remove the camshafts intact i n their housings. Remove each adjusting shim where the clearance requires adjustment.
Page 125 CAMSHAFT DRIVING BELT (TOOTHED BELT) The camshaft driving belt i s fitted with an automatic belt terlsioner assembly (early vehicles are fitted with manual adjusters). Check the adiustrnent of the driving belt at service intewals and i f the belt i s removed or a new belt i s fitted. Fig.
Page 126 ENGINE Page Release handle with a rapid action. slow release w i l l result i n a high reading, which i s caused by a small amount of internal friction stopping the hook returning fully. Read off the tension i n pounds indicated by the pointer Rotate the engine crankshaft by hand approximately 120°...
Page 127 Page adjusters remove the alternotor odjusting strap, together with the nut ond bolt. Swing the olternotor up ond secure i n the'up' position to ... -.g the olternator completel y removed..Slacken off locknut and release adjusting screw by turning counter-clockwise (0.5 until the adjusting screw i s protruding a maximum of in) from the...
Page 128 ENGINE Page MUST The locking pin be fitted to the tensioner housing every time WARNING: the toothed belt removed or slackened off. Do not under ony circumstances attempt to remove the locking pin from the tensioner unless the unit fitted to the engine with the belt i n position.
Page 129 Page TENSIONER DRIVING BELT To Remove Set engine i n the timing position with number one piston at T.D.C. A l i g n the timing marks on the crar~kshaft pulley or flywheel with timing 12). pointer (figure Loosen the alternator fixing bolts and remove drive belt and crankshaft pulley.
Page 130 ENGINE Page ESPRIT...
Page 131 Page CAMSHAFTS. Remove both cornshaft corrier housing previously described i n Release the exhaust downpipe from the exhaust manifold and remove monifold (see Section S). PUMP Remove the water pump (see WATER Loosen the cylinder head nuts evenly, starting with the outer rluh and work inward diagonally.
Page 132 ENGINE Page Fig. Using Tool to retain cylinder liners F i t the cylinder head assembly, plain washers and nuts. Tighten a l l nuts to the specified torque looding workin g outward from the centre (see figure Using new gaskets, refit the exhaust manifold and the exhaust down pipe (see Section Replace the water pump.
Page 133 Page E22 Check for. oil and coolar~t leaks while engine i s running. Refit the air cleaner element, the air box cover and the air trunking. Re-adjust the idle speed and mixture i f necessary. VALVES To Remove Remove the cylinder head. Using a suitable valve spring compressor, compress the valve springs and extract the split collets.
Page 134 ENGINE Page should be l e f t oround the periphery of each piston crown. The of the cylinder liners should be touched. Clean each valve thoroughly and carefully examine for pitting. Valves i n a pitted condition should be refaced with a suitable grinder or new valves should be fitted.
Page 135 Page after milling to assist the removal by inserting a suitable drift through the appropriate port and gently tapping the seat frorn its recess. Ensure that the FREE OF FOREIGN recess i n the cylinder head i s ENTIRELY MATTER, otherwise the new insert w i l l seat fully i n the recess.
Page 136 Page Heat the whole cylinder head to a temperature EXCEEDING 200°C and freeze the insert with dry ice to a temperott~re LESS THAN minus W i t h the aid of Special Tool (05A or 06A), press the insert into place, ensuring that the seat FACES TOWARDS the combustion chamber.
Page 137 CRANKSHAFT BELT PULLEY To Remove Remove all the belts. Remove the set screw, spring washer and plain washer from the centre of the pulley. Pull off pulley, using a proprietary puller necessary. To Reploce Reverse the removal procedure. Check all belt tensions after replacing, and tighten bolts to the torques specified in TECHNICAL DATA.
Page 138 ENGINE Page E27 FRONT COVER OIL SEAL To Remove Set the engine i n the timing position. Remove the crankshaft belt pvlley. Remove the camshafts driving belt (toothed belt). Remove the cranksliaft sprocket. Remove the camshafts drivebelt automatic tensioner and the alternator adjusting bracket.
Page 139 Page Re p lace the remainder of the removed parts by reversing the removal procedure. PUMP WATER To Remove Drain the cooling system. Remove the belts. Release the clips and remove a l l hoses from the water pump housing. Release the bolts and remove bolts arid washers together with the water pump housing and gasket.
Page 140 ENGINE Page E29 Water pump assembly FILTER To Remove Drain the oil rump. To remove the filter, turn i n an anti-clockwise (towards the cylinder block) direction. Discord the filter. To Replace ESPRIT'...
Page 141 (su p plied with filter), which i s in contact with the o i l pump body, locate HAND f i l t e r on its adaptor ond screw on by i n a clockwise direction. When the filter 'seats' continue turning the filter for a further two-thirds to three- quarters of a turn to ensure on oil tight joint.
Page 142 ENGINE Page distributor cannot be irlcorrectly fitted. Before fitting the distributor, set the contact breaker gap to the specified clearance (see TECHNICAL DATA), then turn bock the rotor arm until the points are about to open. Fit distributor into its location and secure the clamp. D O OVERTIGHTEN.
Page 144 ENGINE Page Ex3 this operotion. Discard the oil pump body gosket. Remove the spring from the o i l pump end of the auxiliary shaft. Remove the circlip securing the inner rotor of the oil pump to the shaft. Remove the circlip from the forword end of the shaft.
Page 145 Page INLET MANIFOLD To Remove Drain the cooling system. Remove the airbox outer cover. Disconnect the water hoses from the manifold. Disconnect the breather pipe from the flame trap at the rear end of the air- box backplate. Disconnect the throttle and choke cobles, and the vacuum pipes.
Page 146 ENGINE Page Use o new gosket ond Tighten setscrews and nuts to the specified torque loading (see TECHNICAL DATA). Refill the engine with the recommended o i l . CONNECTING ROD (BIG-END) BEARINGS To Remove Remove the sump. Commencing with N o . (from radiator end) connecting rod, turn the cronk- shaft to facilitate removol of cop.
Page 147 Page E36 A l l water hoses, throttle and choke cobles; fuel feed pipe to the carburetters; vacuum pipes for brake servo systems; cables from alternator, starter motor, ignition distributor and temperature sender unit; o i l pressure pipe. Disconnect air trunking and remove airbox. Disconnect the hydraulic pipe from the clutch slave cylinder on the bell- housing.
Page 148 ENGINE Page E37 and replace filler/ievel plug. Check the gear and cross-gate cable adjustments for correct selection of a l l gears, odjust necessary. Check security of sump drain plug. Top up engine oil with one of the re- commended oils necessary.
Page 149 Page E38 NOT' Allow the ring geor to cool naturally in the air. D O rotation. QUENCH. Locate the flywheel squarely on the crankshaft flange and upon the locating dowels. Apply the Loctite 'AV' to threads i n crankshaft, then insert the securing TECHNICAL DATA).
Page 150 ENGINE Page To Replace W i t h the l i p of the seal towards the inner machined face of the housing, 2.54 insert the new seal with the aid of a press, until its inner face i s (.
Page 151 Page CRANKSHAFT To Remove engine from the transmission unit and mount the engine on a sviiob!e siond. Remove the sump. Remove the front cover. Remove the rear o i l seal housing. Unscrew the connecting rod bearing cop bolts by two or three turns, and them to release the caps.
Page 152 ENGINE Page E41 Fig.25 O i l pick-up pipe and union spanner L i f t outthe crankshaft. Remove the main shelI'beorings from both the bear- ing housin main bearing locations i n the cylinder block. To Replace NOTE: O n engines with a cross drilled crank (from engine N o . 13277, including a l l the bearing Federal, North American spec.
Page 153 Page are clean, then f i t new bearing shells. Apply a small amount of 'Cylesso' (or graphogen grease) to the bearing shells. *Oversize refers to the outside dimension of the bearing shell. Ensure that the crankshaft main journals are clean, then f i t the crankshaft. Spin the crankshaft to ensure even distribution of the 'Cylesso' Fit new selective thrustwashen to the rear main bearing so that the o i l grooves (the...
Page 154 ENGINE Page Fit the locatin g dowels, one to eoch end stud on the RH side of the engine the cylinder block and bearing housing ore free of foreign matter, then apply F i t the main bearing housing. housing to the cylinder block, tightening the nuts i n sequence, diagonally outwards, to their specified torque lwdings (see TECHNICAL DATA).
Page 155 Through the drillins ot the rear end on the main beoring housing, push i n the F i t breather pipe until its mounting brocket i s locoted on the RH stud. washer and nut, tightening to its specified torque loading. Through the drillin g at the front end of the main bearing housing, push i n o i l pump pick-up pipe until its mounting brocket i s locoted on the LH stud.
Page 156 ENGINE Page Using Tool to extract c y linder liners Fig.28 To Replace Clean piston and fit the connecting rod with 'FRONT' marks on both connecting rod and piston facing the some way. Secure the rod to the piston with gudgeon pin and circlips.
Page 157 Page Using Tool to check cylinder liner height Using a piston ring compressor, insert the piston into the liner with the 'FRONT' F i t mark towards the front of the cylinder block. cylinder liner clamps after replacing the pistons i n the liners. necting rod caps securing with their bolts.
Page 158 ENGINE Page holdin g the rail end with a thttmb, whilst easing the rail over the piston and into its locntion. Repeat operation to f i t the other steel rail above the expander ring. Position the lower steel rail, 25mm ring gap and the upper steel roil gap, 25mm to the RIGHT of the expander ring gap.
Page 159 SPECIAL TOOLS Cylinder Liner Clamps TOM) To retoin cylinder liners Cylinder Liner N i p Gauge TOM) To check liner height T 0 0 0 4 Valve Guide Drift TOM) To ossemble/remove guides TOM) TOOO T 0094 Exhaust Valve Seat Drift For inserting valve seat TOM) Front Cover Pilot...
Page 160 ENGINE Page E49 cam fol\owers during Magnet Assembly To retain (4 off For checking timing belt Type BT-33-8& Burroughs Gauge 5-20 SEALERS, GREASE, LOCTITE, OIL Application Part Number Camshaft cover gasket A036 E 6038V Main and big-end journals A907 E 61.78V Cylesso Cam followers and shims A907 E 61 18V...
Page 161 Page E50 EMISSION CONTROL & Vehicles fitted with an emission control system hove an evaporation control system, anti- run-on system, exhaust emission control system and a vopour control. Evaporation Control System The evaporation control prevents petrol vopaur escaping to atmosphere from ttie fuel tank and carburetters.
Page 162 EN G IN E Page EXHAUST TEST CONCENTRATION Unscrew the plug fitted i n the front end of the cotolytic converter ond f i t odopter and sample pipe (Part N o . TOOQT0321A). with engine at normal running temperature. and diverter valve) from the air pump and blank off the hose with plug (Port N o .
Page 163 Page E S P F...
Page 164 ENGINE Page ~ 5 3 KEY TO FIG A i r Pump Assembly Support Bracket, A i r Pump Bolt, Tension Strap, A i r Pump Spacer, Tension Strap 'V' Belt, A i r Pump Drive A i r Filter Hose, A i r Pump Inlet Hose C l i p Hose, A i r Pump to Diverter Volve...
Page 165 Page LUMENITION DISTRIBUTOR The 'Lumenition distributor' i s basicall y o Lucos distributor with the contact breaker and condenser replaced by an lnfra-red Sensor Unit (A907E6331F) arid o four bladed interrupter fitted i n place of the contact breaker. solid state power module (A075M0335F) on the rear wheelarch or R H body reinforcing channel i n the rear compartment.
Page 166 ENGINE Page NOTE: voltage of volts should be present on the red wire of the 3-woy connector. CAUTION: Under no should o full positive feed be applied to Core shoiAd be token not to 'short' the coil terminals as this puts o full feed to the coil (brown) wire.
Page 168 Page SECTION F Description GENERAL DESCRIPTION GEARSHIFT LEVER AND GEAR CHANGE TUBE ASSEMBLY TRANSMISSION ASSEMBLY DRIVE OR I N P U T SHAn GEARBOX REAR HOUSING GEAR SELECTORS REMOVAL GEAR SELECTOR REPLACEldNT PRIMARY SHAFT BEVEL PINION SWAFl DIFFERENTIAL SHAFTS DIFFERENTIAL CROWN WHEEL AND PINION IFFERENTIAL BEARIWS AD J U S TM ENT B A C K LA S H ADJUSFMNT...
Page 169 Page Transmission...
Page 170 T RAN S M IS S Page KEY TO FIG.1 Gearbox housing Pointer, engine tunlng Switch, reverse light Gearbox drain tube Speedometer plnlon Speedometer cable Speedometer driveshaft Retaining clip ESPRIT...
Page 171 Page GENERAL DESCRIPTION The transmissiorl i s a single unit comprising a manual 5 speed gearbax, directly operating mechanism. The gearbox has five forward gears with synchromesh operation The output shaft of the gearbox ends i n a pinion which engages the crown wheel i n the differential.
Page 172 Page L i f t the assembly to gain occess to the pivot bolt, unscrew the bolt and l i f t out the lever assembly. Remove bolt (item 13, fig.2) on the left-hand side of the engine and the bolt (item fig.2) i n the rear of the chossis box member.
Page 173 TRANSMISSION 2 -Gear Change Mechanism...
Page 174 KEY TO FIG.2 Gear lever assembly Reverse gate Gear lever knob Gear change tube, forward Gear change tube, intermediate Gear chonge tube, rear Link, adjustable Pivot pin Rubber bush Bearing Gear chonge swing link Pivot pin Stub, swing link Washer Gear change, relay lever Cross gate lever Pivot pin...
Page 175 selector lever in the neutral position, adjust length of the tube Fit without The bowden cable i s odjusted by the clevis screwed to the end of the cable (bell howing end) and access from under the rear of the vehicle. To that the gearahtft lever i n the neutral poaitlon when sitting i n the driving reat.
Page 176 TRANSMISSION Page Dismantling Support the transmission unit on a suitable surface on a bench and remove the brake calipers and brake disc assemblies. Remove the gearbox top cover together with the selector cross-shaft. Remove the drive shaft bearing housin g assemblies the adiusting washers and spacers.
Page 177 fork Remove the pin securing the to the ball joint and withdraw the fork. Unscrew the fork pin and remove. To Replace Reverse the dismantling and removal procedures for the c l u k h bellhousing. Seal the matfng faces with "SilasticJ'. Tightan a l l boltn Fig.3 Front end of gearbox To Remove...
Page 178 Page F11 To Replace Reverse the removal procedure for the input shaft and clutch belfhousing. REAR HOUSING GEARBOX To Remove Remove the transmission unit as previous1 described. Remove the rear and top cover on the gearbox. Remove the bolt securing the 5th gear synchro ossembly together with the deflector.
Page 179 Gear selecton GEAR SELECTORS REMOVAL (Figure Remove the tranamisslcn unit and gearbox rear housing as previowly described, Remove the gearbox top cover together with the selector c r w - (B), Slacken the screws securing the fork (A) and the opemtlng dog removing the locking wire, to the selector rhaft.
Page 180 Page F13 Remove the shaft, the operating dog and shaft lockin g ball and spring, and the small interlock plunger inside the front end of the shaft. 3rd and Gear Selector Slacken the screw securing the fork after removing the locking wire. Remove the shaft, the fork, the shaft locking ball and spring, and the small interlock plunger inside the front end of the shaft.
Page 181 3rd and 4th Gear Selector Place the first interlock plunger in from the opening at figure locate i n the and 2nd selector shaft notch. Insert the gear selector shaft through the gearbox outer casting, f i t lock:ng ball and spring as previously described, the operating fork and into the differential end of the gearbox cbsting, taking care to correctly locate the small plunger inside the front end of the selector shaft.
Page 182 TRANSMISSION Page fork, up against the gauge. Tighten the two lockin g screws to a torque of 4th Gear Stop Adjustment Replace the 'Gearbox Rear Housing' as previously described. Engage the 4th gear. Gently push the slider against the fork. Measure the clearance between the slider and the 4th gear pinion, using feeler gauges.
Page 183 Page F16 Gearbox Fig.6 gear train 04/78...
Page 184 TRANSMISSION Page KEY TO FIG.6 Needle bearing (4th/5th) Primary shaft Needle bearing (3rd) Drive shaft (Input shaft) Bolt and deflector Circlip Circlip Flange Reverse gear spindle Support tube Screw Spring Reverse gear 3rd gear pinion 4th gear pinion 3rd and 4th gear train 5th gear pinion 2nd gear idler pinion 3rd and 4th...
Page 185 Fig.7 Primary shaft assembly Move the primary mainshaft towards the bellhouring, separating the 4th gear loose pinion to gain access the synchro hub assembly retaining circllp. Remove the circlip from the shaft using circlip plien taking care to note the direction i n which fitted.
Page 186 TRANSMISSION Page bearing cage. the control shaft i s fitted, remove the lockin g ring securing the control shoft to the primary shaft and remove the control shaft and spring. To Replace (Q), the input shaft i s disconnected, f i t the spring then the input shoft (J).
Page 187 TRANSMISSION Page locking compound ond tighten screw and lock with nut. F i t the 5th gear idler (S) together with its needle rollet cage smeared with transmission oil, synchroniser (B) and operating fork assembly on the prirmry Secure with the deflector (T) and bolt and tighten to shaft.
Page 188 TRANSMISSION Page Check a l l ports ore cleon and there are no abrasive or metal particles adhering to the parts. F i t the front roller beoring (I) on the pinion (k) using a suitable length (240 mm) of tubing (inside diameter mm).
Page 189 Page This distance different for each bevel pinion and i s checked using the distance gauge fixture 3170-T fitted with dial gauge 2437-T. The fixture designed so that the distance between the centre line of the ground contact faces (drive shaft bearing surfaces) and the faces of the probes i s This figure i s engraves on the fixture between the probes.
Page 190 TRANSMISSION Page F23 2.72 2.81 0.09 = As washers are i n thickness from 1.65 mm to 3.13 mm i n steps of 0.04 mm, the nearest to the calculated thickness i s 2.73 mm. F i t the new adivsting washer and replace the bevel pinion as previously described.
Page 191 TRANSMISSION Page Fig.9 Differential assembly Remove the sealing rlng f q m the shaft housing. Remove the ail retolnlng washer and bearing distance bush assembly from the shaft. To Assemble NOTE: The differential drive shaft on the left-hand side of gearbox i s the shorter. (21) (18) Fit the bearing...
Page 192 TRANSMISSION Page F25 KEY TO FIG.9 Satellite gear Satellite spindle, long Satellite spindle, short Screw with dowel Crown wheel screw Planet wheel washer Satellite gear washer Crosshead bush Distance piece Distance washer Adjusting washer Crown wheel Roller bearing Spacer Locking nut Grub screw Bearing Grub screw...
Page 193 Fit the differential shaft into the housing and position using o tube of 30 mm inside diometer under a press. Tighten the bearing loclcing nut Tighten the grub screw (22) i n the locking nut. Assemble and replace the 'Clutch Bellhousing' previously described.
Page 194 Page torque of 11.5 to 13 kg/m (83 to Check the minimum clearonce of the second planet wheel and this should be 0.1 mm. Change the thrust washer to achieve this clearance. a l l parts inside. Fit the bearings on the satellite housin g and crown wheel using mandrel 1769-T .
Page 195 ht-hond drive shaft, adjusting woshen and distance piece. NOTE: The bearings must be fitted with o specified prelcad. Place gouge support 1754-T, fitted with dial gouge 2437-1, collar of the right-hand drive shaft housing. Allow the probe of the gauge to touch the bearing face of the housing. Bring the +em of the movable dial of the gouge i n line with the large needle.
Page 196 TRANSMISSION Page Example: Left-hand bearing washers Ri g ht-hand bearing washers Overall thickness Method Fitting the differential ossembly Place the differential, fitted with beorings, i n the end of the gearbox casting. Secure the differential i n place using the two clamps MR630-64/16, tightening the nuts by hand only.
Page 197 IMPORTANT: The thickness the washers fitted against the left-hond and right-hond bearings corresponds to the setting of the beoring stress only. To odjust the backlash these washers must be redistributed to the left and right, without changing the overall thickness. check the bocklash odiustment both drive shaft housings must be fitted.
Page 198 TRANSMISSION Page Repeat the procedure on teeth at obout 90°, the crown wheel from the first measurement. The difference between any two measurements should not exceed 0.10 mm. a reading exceeds this figure i t w i l l indicate the crown wheel i s running out of true or i s badly fitted.
Page 199 Page I f backlash i s within the tolerance, assemble the differential assembl y , lace the Clutch Bellhousing and refit Transmission Unit. ESPRIT...
Page 200 HUBS, WHEEL,TYRES Page SECTION G Page Description GENERAL DESCRIPTION TYRES SPARE WHEEL FRONT HUBS REAR HUBS MODEL ESPRIT...
Page 201 In order to obtain the correct handling 'feel' and minimum feedback, i t i s very important that tyre uniformity, i.e. radial arid lateral run-out i s of the high standard set by Lotus C a n Limited. any difficulty i s experienced with replacement tyres, reference should be made to the tyre manufacturer concerned.
Page 202 HU B S, WHEEL,TYRES Page FRONT To Adjust Remove the road wheel. Remove the dttst cover (A) and extract the split pin (B) retaining the hub securing n t ~ t (C). Tighten the hvb nut to its specified torque loading (see TECHNICAL DATA), Slacken nut while rotating the hub to ensure bedding of the taper rollers.
Page 203 Page Front hub Refit the brake caliper and tighten the mounting bolts to their specified torque loading. Refit the road wtieel and tighten nuts to their specified torque loading. A l l NOTE: Specifications and Torque L.oadings w i l l be found i n TECHNICAL DATA.
Page 204 Page f i t the cone spacer with its tapered end towards the hob, followed by the hub retaining nut. Tighten the hub nut to its specified torque loading. F i t a new split pin to retain the hub nut. Do slacken the nut i n order to insert the split pin;...
Page 205 MODEL DATA TECHNICAL are Wheel P , . - ONLY The spore wheel si~pplied with i s for EMERGENCY and should be with the norniol wheel urci use, differerttiol tyre wear could L e s-xpliienced ond the handling churacteristics of the vehicle w i l l be modified.
Page 206 STEERING Page til Description GENERAL DESCRIPTION STEERING WHEEL INTERMEDIATE COLUMN STEERING COLUMN STEERING COLUMN L.OCK/IGNITION SWITCH STEERING UNIT 04/78...
Page 207 Page H2 ESPRIT...
Page 208 Page KEY TO FIG. l Steering Unit Shims, mounting plote Mounting plote, steering unit Track rod end Bush, non-pinion end Clamp, pinion end Bush, pinion end Steering col urnn assembly Seal plote, steering column Intermediate steering column assembly Universal joint Steering wheel Collet, steering colomn ring...
Page 209 Page H4 GENERAL DESCRIPTION steering assembly comprises a collopsible type column, short intermediate column and a steering unit of the rack and pinion type. The track rod ends terminate i n ball-joints and these i n turn are attached to the steering arms. The steering unit i s attached to the chossis by two clamps with rubber bushes.
Page 210 STEERING Page H5 Ensure the front wheels and steering wheel ore in the straight-ahead position. From inside the vehicle feed the intermediate shaft, spline end first, through the body and engage the spline in the lower universal ioint. Slide the inter- mediote shaft back to engage the spline on the steering column.
Page 211 STEERING Page H6 joint and secure by the clam p in g bolt. Reconnect the battery and check the correct function of the switches. STEERING COLUMN LOCK/IGNITION SWITCH To Remove Remove the steering column ossembl y. D r i l l out the lock/ignition switch clamp bolts and remove the lock assembl y . Fit new lock/igriitiori switch assembly, ensuring that the spigot locates ~ : t h the hole i n the column orid secure clamp with the bolts provided.
Page 212 STEERING Page Check and adjust front wheel toe-in at ride hei g ht, see TECHNICAL DATA. WARNING: When the car i s raised from the ground so that the front wheels ore clear, do move the road wheels quickly from lock-to- lock, as this w i l l cause an hydraulic pressure to build up within the steering unit, and may burst or blow off the bellows.
Page 214 BRAKING SYSTEM Page SECTION J Page Description GENERAL DESCRIPTION FRONT BRAKE PADS REAR BRAKE J l 0 BLEEDING THE BRAKING SYSTEM J 11 MASTER CYLINDER SERVO UNIT PEDAL BOX HANDBRAKE ASSEMBLY ESPRIT...
Page 215 Fig. I Braking system...
Page 216 BRAKING SYSTEM Page KEY TO FIG. 1 Brake Master Cylinder Servo Assy Front Hose 3 Way Union Double Ended Union Bundy Pipe, 23.01', Master Cyl to Front 3 Way Union Bundy Pipe, 131.5", Double Ended Union to Rear 3 Way Union Bundy Pipe, 20.01', Front 3 Way Union to Front Hoses Bundy Pipe, 26.5", Rear 3 Way Union to Rear Hoses...
Page 217 BRAKING SYSTEM GENERAL DESCRIPTION The braking system consists of a Type 28 Supervac servo unit attached to a tandem master c y linder with a bore of 19.05 mm (0.75 in) operating Type sliding calipers with 275 mm (10.82 in) diameter discs at the rear; the rear brakes are mounted inboard.
Page 218 BRAKING SYSTEM Page J5 Fig.2 Front brake pods removal Operate the brake pedal several times to bring the pads into correct operating position. Check that the pads ore free to move and that the retaining pins are not fouling the pads. Replace the road wheels, lower the vehicle to the ground, check the brake fluid and top up necessary.
Page 219 ESPRIT Issue 04/78...
Page 220 BRAKING SYSTEM Page KEY TO FIG. 3 Front Coliper, RH Front Brake Pads Dust Shield, Front Caliper Rear Caliper, RH Bolt, Primary Bolt, Secondory, (Bushed) Rubber Sleeve Brake Pads Rear Bolts, Self-Locking Rear Disc Drive Shoft Adaptor Front Disc ESPRIT Issue 04/78...
Page 221 REAR BRAKE Each rear broke hos o sliding coliper operated by a single hydraulic c linder or hand- brake cable, located on the outside of the disc. As there i s only one cylinder i n each brake, no bridging pipes ore required, this w i l l reduce the risk of fluid vapourization.
Page 222 BRAKING SYSTEM Page Fig.4 Rear brake adjuster Fitting of new brake pads When the brake pad linings have worn to mm, the pads should be replaced. Always new pads i n axle sets. retaining self-lockin g screws fram the primary and secondary mm spanners.
Page 223 Page spiritus. there i s the sli g ht- Examine the bolts for visible marks of damage or wear. est doubt about the condition of the parts, new bolts and dust-covers must be fitted. When replocing the two bolts, care must be taken to ensure that the bolt with the bushing i s fitted to the secondory side (trailing) and the steel bolt to the primary side (leading i n disc forward rotation).
Page 224 BRAKING SYSTEM Page WARNING: Frequently check the level of fluid in the reservoir whilst bleedin g the braking system. Remove the dust cap from the right-hand front bleed nipple and f i t a bleed pipe from the nipple to a suitable container. Immerse the end of the pipe i n the container i n clean fluid.
Page 225 SERVO UNIT To Remove Disconrrect the two pipes of the master cylinder, draining any fluid into suitable receptacle. Insert plugs into the pipes to prevent the ingress of foreign matter. Disconnect the electrical connections to the reservoir cap. Disconnect the vacuum pipe from the non-return valve on the servo unii. From inside the vehicle and beneath the scuttle, remove the split pin and clevis piri securing the master cylinder push-rod to the brake pedal.
Page 226 Page Unscrew the two nt~ts securing the servo mounting bracket and the four bolts the pedal box to the chassis. Remove the pedal box. To Replace Reverse the removal procedure. Tighten a l l bolts to the torque loadings specified i n the TECHNICAL DATA. Bleed the braking and clutch systems.
Page 227 Page Compensator ..ESPRIT...
Page 228 COOLING SYSTEM Page SECTION K Page Description COOLING SYSTEM INHIBITOR RADIATOR THERMOSTAT HEADER TANK MODEL ESPRIT...
Page 229 ESPRIT...
Page 230 COOLING SYSTEM Page ~3 TO FIG. 1 Radiator, (Domestic/European) Radiator, (Federal) Motor Fan Assy, (Domestic/European) Fan Motor, (Federal) Fan Cowl, (Federal) Fan Motor Mounting Bracket, (Domestic/European) Fan Motor Mountin g Bracket, (Federal) Otter Switch, Radiator Fan (Thermostat) Header Tank Pressure Cap Main Water Pipe, Radiator Feed Main Water Pi e, Radiator Return (Domestic/European)
Page 231 GENERAL DESCRIPTION The engirie i s connected to a cross-flow rodiotor o r d o coraztonf h-ad of woter being supplied a remote header tank. To prevent over-heating electrically operated coolirig fans are provided, these being mounted or1 o squore section frame fixed to the chassis behind the radiator.
Page 232 COOLING SYSTEM Page To Refill Turn the radiator drain tap clockwise to close. Check that the air temperature control i s still a t HOT. Refill the cooling system to within in) from the bottom of the header tank filler neck. lace the header tank cap.
Page 233 Page To Replace Reverse the removal procedure, but ensurt ioam r pclds are cc.;.r:ctly located before finally securing the radia!;.:.. THERMOSTAT To Remove Drain the coolin system as previoi~s!y de>rri~,ed. Disconnect the hose frorn the thermostat housiny. lift Remove the two bolts and off the thermostat hour iing.
Page 234 Page HEADERTANK To Remove Drain the cooling system as previously described. Release the hose clips and remove the hoses from the header tank. a l l Remove the nuts securing the tank and remove the tank. To Replace Reverse the removal procedure. MODEL S2 C H A ~ ~ E R l S T l C S The coolin system for the model...
Page 235 To Replace Radiator on Air Conditioned Vehicles Reverse the removal procedure, but first locate radiator air duct assembly side bolts, then locate radiator and condenser top bracket screws before tightenin g a l l bolts and screws. Ensure foam pads are correctly located before finally tightening down.
Page 236 FUEL SYSTEM Page SECTION L Description Poge GENERAL DESCRIPTION FUEL SYSTEM CLEANING FUEL TANK FUEL TANK SENDER UNIT FUEL GAUGE FUEL PUMP FUEL FILTER/FLOWLOCK VALVE ZENITH-STROMBERG CARBlJRETTERS Description Adjusting Removal L 18 Cleaning Overhaul Description Adjusting Removal Cleaning Overhaul EVAPORATIVE LOSS CONTROL AIR CLEANER CHOKE CONTROL THROTTLE CABLE...
Page 237 FUEL SYSTEM Page ESPRIT...
Page 238 Page KEY TO FIG.l Fuel Tank Fuel Tank Sender Unit Sender Unit Gasket Filler Cap Assy Filler Neck Hose, Filler Neck to Tank Grommet, Filler Neck Ring Cross Feed Pipe Flexible Cross Feed Pipe Tank Vent Pipe Fuel Pump "Metalastik" Mount Fuel Pipe Tank to Filter/Flowlock Fuel Pipe...
Page 239 Page GENERAL DESCRIPTION The fuel system tanks are situated i n the rear comportment, one each side of the engine under the floor ponelling. Recesses rnoulded into the body accommodate the tanks and access holes, covered by large rubber bungs, are reached from under the car. Two flush fitting filler caps are situated on the rear quarter panels;...
Page 240 FUEL SYSTEM Page L5 WARNING: Do not use a probe or wire to clear the jets as this may enlarge or damage the jet orifice. Remove the screws retaining the float chamber coven. Remove the remaining jets and as i n above.
Page 241 FUEL SVSTEbI Page L6 Release the clips and remove the rubber hoses connecting the fuel tonks to the f i l l e r necks, first disconnect :he breother pipes from the f i l l e t necks. From each tank, remove the two bolts securing the tank i n the body. One bolt is i n the forward port of the rear wheel arch and the other belt on the inside (chassis side).
Page 242 FUEL SYSTEM Page Fig.2 KEY TO FIG.2 Perforated diaphragm plate Body casting Fuel outlet Coil housing Contact breaker ossembl y Fuel inlet Spring blode Fuel filter Pedestal moulding Outer rocker Valve cover Toggle spring Moin diaphragm Inner rocker Main pumping chamber Coil Earthing screw Trunnion...
Page 243 Page Disconnect the electric01 supply coble at the terminal on the pump. Unscrew the two bolk securing the pump to the bracket and where the pump i s fitted under the engine compartment floor panel remove the nut securing the pump to a 'Metalostik' mounting.
Page 244 FUEL SYSTEM Page L i f t the engine cover to gain occess to the valve secured to the chassis tabular frame by a clamp. Remove the fuel pipes from the valve and remove. Secure the flowlock valve in the clamp on the chassis and reconnect fuel pipes and tighten.
Page 245 Page Operation The petrol inlet i s a porollel tube connecting the two corburetter~, into which a flexible fuel pipe from the 'Flowlock' valve i s fitted. Fuel passes into the f l w t chamber, via a needle valve, where the flow controlled b y the needle i n the valve and twin floats mounted on a common arm.
Page 246 FUEL SYSTEM Page Fig. Zenith starting device NOTE: Do not pump, or hold oper the throttles, as this reduces the effectiveness of the cold start device (choke). I t i s olso important to note that there are two positions (Winter and Summer) on the This starting limiting pin.
Page 247 Page T h r o t t l e Fast Fast ldle Fig.5 Idling Fuel for idling i s provided by the jet orifice, the amount being controlled by the regulated b y adjustment of the throttle stop screw, which limits the closure of the throttle when the accelerator pedal i s released.
Page 248 Page L13 The jet/needle relotionship i s set during production and SHOULD be altered. When the throttle opened, air flow under the air volve increases ond a temporary rise in mixing chamber depression i s transferred vio drillings i n the air volve to the depression chamber which seoled from the main body by a diaphragm.
Page 249 Page Depression Valve valve was fitted to earlier vehicles only. I t controls the admissiorl of vacuum to the by-pass valve, thus ensuring smoother transition between deceleration and idle. The valve i s pre-set and requires no attention i n Service. Throttle By-Pass Valve The throttle by-pass valves are incorporated to prevent excessive rates of hydrocarbon and C O...
Page 250 FUEL SYSTEM Page L15 Fast Synchronisation (figure 6) Loosen the clamping bolt on the throttle spindle coupling between the carburetters. Unscrew the throttle stop screws to permit the throttle i n are just contacting the levers. Rotate the stop screws a further one-ond-a- provide a basis from which the final idle speed can be set.
Page 251 FRONT CARBURETTER ONLY REAR CARBURETTER ONLY ESPRIT...
Page 252 FUEL SYSTEM Page KEY TO FIG Throttle spindle, rear ring seal Butterfly valve Sealing plug and ring Spring, throttle return Float chamber Lever, throttle stop Gasket, float chamber Flwt Washer and arm assembly Washer, shakeproof Pivot, float Needle valve and filter Screw, fost idle Washer, needle valve Metering needle assembly...
Page 253 normal operating temperature. i t s Remove the cover of the air cleaner. similor instrument), adjust the throttles synchronisation, ond the idle speed to that given i n TECHNICAL DATA. A t this point, tighten the clamping bolt on the throttle spindle. Refit the cover of the air cleaner, and re- check the idling speed.
Page 254 FUEL SYSTEM Page feed tube. Remove the gaskets and discard. Further dismontling can be carried out as desired on a bench. i s suspected that an air leak i s evident between the adaptor flanges and the inlet manifold, the rings may be damaged.
Page 255 Page and withdrow float chomber vertically away from body to cleor the float mechanism. Toke off float chamber gasket. noting carefully the top i n order to ensure correct re-assembly, take out floats. Unscrew hexagon bodied needle valve from carburetter body. Take off ring from centre plug then thoroughly cleanse a l l ports that have so far been removed.
Page 256 Page L21 assembly a new washer. Unscrew damper assembly from centre of cover. Unscrew the four cover fixing screws and carefvlly l i f t off cover. Remove air valve r~ spring then take out air valve and diaphra g m assembly. Avoid possibility of corrosion to shaft fram perspiration of hands b y lifting upwards with the diaphragm.
Page 257 When refitting the cover, hold the air vclve with finger or in air intake evenly then check movement of the air volve. the full travel i s essential, and, when ;eleosed from uppermost positio air valve should fall with a sharp metallic click onto the carburetter bridge. Top up damper reservoirs with the recommended oil (see Section (6.35 within...
Page 258 Page ~ 2 3 b y a ring and screws with lockwoshers ond i t i s necessory to ensure the bead i s correctly located and the screws fully tightened. Location for the bead and tab on the outer radii of the diaphragm i s provided by a location channel at the top of the main body.
Page 259 The throttle plates in each carburetter are on a common spindle and the synchronising linkage between the corburetters ensures that the throttle plates i n each carburetter open an identical amount. I t should be remembered that one barrel supplies one cylinder only, since the inlet tracts are not interconnected.
Page 260 FUEL SYSTEM Page When the starter valve i s opened, the fuel, set by the jet (12) enters the emulsion tube ( l l ) , where i t mixes with the air from the channel the mixture passing into (5).
Page 261 Page (figure The fuel from the float chamber, i s set by the idle iet (20). This fuel mixes with the (19). a i r from the emulsion tube via the channels The mixture then passes through the channels (211, to the adiustmerit screws (22), then having been metered, to the idle and progression circuits (13)
Page 262 FUEL SYSTEM Page L27 Acceleration (13) (28) When the throttle valves are opened, the lever attached to (29) (32) pushes a rod and spring this i n turn actuating a lever thus operating (30). The diaphragm i s held i n position the diaphragm o spring (24)
Page 263 Page L28 When the throttle valves (13) are opened, the fuel from the float chamber, set by the The mixture thus made, enters the channels passes to the auxiliary (38) venturi where farther mixing with air from the moiri intake, the mixture passes to the main barrels (10).
Page 264 FUEL SYSTEM Page Anti-tamper adaptor in poaition on carburettor Sealing Cap Spring Bras-Washer Carburettor Boss Fig. Anti-tamper Device...
Page 265 that position. The throttle valves should all close perfectl y . G i v e FULL TURN screw so that i t now i n contact with the lever. Fully close the mixture screws then 'back off' TWO FULL TURNS. Start the engine and allow to reach its normal operating temperature.
Page 266 Page When correctly set, and with the float chamber cover i n the vertical position with the f l w t s hanging down, but with the tab of the f l w t s in light contact with the needle, the measurement should be mm, including 'A').
Page 267 Fig. ESPRIT...
Page 268 FUEL SYSTEM Page KEY TO F I G . Connecting link Fuel filter Needle valve Gosket, float chomber Jet, slow running Screw, idle mixture Gosket, pump body ESPRIT 04/78...
Page 269 FUEL SYSTEM the arti- vibration spacers. rther dismantlin can be carried out desired on clean bench. verse the removal procedure, but use new rings at either side of the anti-vibration spacen. MUST When replacing the securing nuts and washers, note that the~e be a mm) between the carburetter flange and the spacar, otherwise the carburetten will t i l t with the possibility of air leaks through...
Page 270 FUEL SYSTEM Page ~ 3 5 mointain peak performance. I f any doubts exist on the correct functioning re-assembling of any port ALWAYS replace with new parts. When carburetters always use new seals and gaskets. LOSS EVAPORATIVE CONTROL To sliminote fuel vapourisation into the atmosphere, and thus comply the fuel Motor Vehicle Safety Standards, an 'evaporotive circuit' i s incorporated in' system of cars fitted with Zenith carburetters.
Page 271 Fig. A i r cleoner CHOKE CONTROL To Remove Remove the tunnel top Pull up choke control on the tunnel switch panel exposing the inner cable end, pull cable through. The outer casing is removed b y first releasing i t at the carburetters clamp, then releasing the clamp under the carpet on the tynnel housing and before pulling out outer casing see 'To Replace'.
Page 272 FUEL SYSTEM Page THROTTLE CABLE To Remove Disconnect the inner cable from its lever on the carburetters. .Disconnect the outer cable from its bracket on camshaft cover. Disconnect the inner cable from the accelerator pedal. (Relwse the inner cable from the clevis.) Before pulling out the cable see 'To Re lace To Replace...
Page 273 Page L38 that FULL THROTTLE released, the throttles are fully closed. Finally tighten the locknuts securing the outer cable. The Check Throttle Inner Cable Free Play With the inner cable attached at both ends, ond at a point midway between the end of the outer cable and the lever on the carburetters, a movement of 3/16 between...
Page 274 FUEL SYSTEM Page cover removed. The depression holes at the base of the air valve should be i n line with and towards the throttle spindle. Renew diophrogm i f damage is evident. When replacin g depression chamber cover the domper ventilation boss must be towards the air intake.
Page 275 Page Fuel Leakage thread. Thorou i t s clean fuel filter. and valve, and fully tighten valve seat. F l w t not free, or heavy: Fit new float assembly. Fuel feed pipes loose, or broken. Tighter\ pipe unions, or replace pipes. Gaskets hardened, perished or loose: Fit new gaskets.
Page 276 FUEL SYSTEM Page Insufficient Acceleration Accelerator pump defective, or faults i n circuit: Overhaul pump and its circuit. Emulsion tube blocked or defective: Reploce emulsion tube. MODEL S2 CHAW\CTERISTlCS UNIT FUEL TANK SENDER To Remove Remove the engine cover. Remove RH engine compartment floor p n e l to gain occess to the top of the fuel tank.
Page 278 ELECTRICAL EQUIPMENT SECTION M Description GENERAL DESCRIPTION BULBS AND LIGHT UNIT REPlACEMENT INSTRUMENTS SWITCHES AND CONTROLS COLUMN MOUNTED SWITCHES IGNITION SWITCH ALTERNATOR BELT ADJUSTMENT RADIO SUPPRESSION FUSES ALTERNATOR MODEL S2 CHARACTERISTICS ESPRIT...
Page 279 Page GENERAL DESCRIPTION The electrical system derives its volts, negative earth, supply from a belt driven alternator and a lead/acid battery. Fuses protect the circuifs i n the' system, the fuses are located i n the glove box i n the facia. Wiring diagmms for Federal and Domestic vehicles w i l l be found a t the end of this section of the manual.
Page 280 ELECTRICAL EQUlPMERlT Page Raising and lowering the headlamp pods when the lights are switched on and off respective1 y. To flosh the headli hts momentarily when the stolk switch pulled back ogainst the bias spring. To heat the rear screen when selected. O n Federal vehicles only a relay connects ARO valve and oil pressure swttch to the supply.
Page 281 Page Fig. Replace the bulbs as necessary, then refit lens, correctly positioning the Series vehicles To p i n access to the rear flasher and reverse lamps i t i s necessary to This remove the four screws securing the rear and stop light lens. off and secure the inner edges of the other two lenses.
Page 282 Page Replace defecflve bulb ond refit banjo type fixing. Number Pl a te- Remove the two screws which secure the colllbined lens/buih hclder. Replace the bulb and refit the lens, securing with screws. i t s Side Marker Lamp (whcn fitted) W i t h the old of a small screwdriver inserted between the bezel and the rubber lamp body, 'peel' the bezel from its location.
Page 283 Fig. ESPRIT...
Page 284 Page KEY TO FIG. Speedometer Tachometer Gauge, battery condition Gauge, water temperature Gouge, oil pressure Gauge, fuel Body Warning light panel Printed clnuit Front panel Temperature tmrducer pipe ESPRIT...
Page 285 ELECTRICAL EQUIPMENT three panel illurtiination bulbs. INSTRUMENTS two instrument panels i s fitted i n the vehicle, check which i s fitted before attempting any servicing. Veglia Instrument Panel Should any the instruments become faulty i n this instrument panel, i t i s necessary to replace the complete panel assembly.
Page 286 ELECTRICAL EQUIPMENT With two pieces of wire connect the -ve terminal, lower of the group of three, to the RH side contacts (as viewed from reor) of the 'Hazor~l' and figure 3 inset for connections. 'Heated Rear Screen' warning lamps. To Replace Smith Instrument Panel instrument panel.
Page 287 Page Fig.4 Combined ignition/storter switch Combined Side, Rear and Headlamp Switch The toggle switch for these functions i s situoted the top left-hand corner of the left hand switch panel, marked 'LIGH15'. a two poscrlon swcrcn, me rirsr to be selected. The second position switches on the headlights and at the mme tlme operates the headlamp pod l i f t motor.
Page 288 ELECTRICAL EQUIPMENT Page Fig.5 Direction indicators/headlamps/horn Headlamps the normal central position of the switch stalk full main beam will be selected. These functions are operative only when lighting switch on the instrument binnacle i s i n i t s fully down position. Fig.
Page 289 Page Windscreen (Windshield) Wipermasher Control Wiper Move lever downwards until locks i n the first position of fig. 6) for normal wiper speed. A high speed wiper actiori can be selected by moving the lever down further until i t locks i n the second position '2' of fig.
Page 290 ELECTRICAL EQUIPMENT Pape de-icing fluid around the window seals. Do NOT use radiator anti-freeze solutions as these could have a disastrous effect on the window and body finish. seals Do not leave small children unattended i n the vehicle when the WARNING: ignition key i n either the...
Page 291 ELECTRICAL EQUlPMlEMT Page M 14 C O L U M N MOUNTED SWITCHES To Remove Disconnect the battery terminals. Remove the steering wtieel (see Section 'H'). b y pulling off from column. cables, and remove switches. To Replace Reverse the removal procedure, referring to the Wiring Diagrams for correct cable replacement.
Page 292 Alternator belt adiustment ALTERNATOR BELT ADJUSTMENT To Adjust The altemator drive belt should be correctl tensioned to give a total movement of (0.50 in) on the longest run of the belt. Slacken the top mounting bolt of fig. 7 and the adiuster bolt of fig.7 Move the altemator until the correct tension i s achieved, then ti g hten a l l bolts.
Page 293 ELECTRICAL EQUlPMENT SCREEN MOTOR WIPE 'Scotchlock' connector and ring terminal to casing bolt. ALTERNATOR rod ccpocitor fitted b y manufacturer. FUSES The fuses mounted i n two prising off the covers, exposing four fuses i n each unit with two spares i n each. fuses are ampere and protect the following circuits: Heoc amp l i f t rnotor(s)
Page 294 Page M 17 ALTERNATOR To Remove Disconnect both battery terminals. Loosen the alternotor fixing bolts and move the alternator down to loosen the belt. Disconnect the electrical connections to the alternator, l i f t off the belt and remove the fixing bolts. To Replace Replacement the reverse of the removal procedure.
Page 295 r w d i n g (ignore very small readin g s) this w i l l indicate o short circuit i n the diode block. REGULATOR FIG. 8 ALTERNATOR CIRCUIT (MOTOROLA) ground, and ttie positive terminal of the battery and ground. The voltmeter reodings should be the same and steady a t volts.
Page 296 ELECTRICAL engine speed to just foster than idle ond a reoding of more thon should be obtained. less than Switch off engine and disconnect ammeter and reconnect field. Run 0-30V the engine at a speed just foster than idle, and using the voltmeter check the voltage r w d i n g between the output terminal (B+) and ground, and the positive terminol on the battery and ground.
Page 297 ELECTRICAL EQUIPMENT FIG. 10 WITH IGNITION ON ENGINE NOT RUNNING normal mndltlons GULATOR CONNECTED VEHICLE HARNESS FIG. 11 WITH IGNITION ON ENGINE RUNNING FASTER THAN IDLE TO VEHICLE HARNESS be used Connections have to...
Page 298 ELECTRICAL. EQUIPMENT Page The Lucas alternator has been designed for minimum maintenonce during a service. Examine the brushes after 120,MX) kilometres (75,000 miles) and renew i f necessary. Check the cutput the alternator using the test circuit shown 13.5 wits fig.
Page 299 EQUIPMENT MODEL S2 CHARACTERISTICS lristrument Panel The instrument ponel i n the model S2 i s fitted with Smith's instruments and the switch panels lever type switches. Each switch is illuminated by a single light source, fed to the switches through fibreoptic strands. The bri g htness of the switch illumination is controlled by rotating the illumination switch on the right-hand control ponel i n the binnacle.
Page 300 ELECTRICAL EQUIPMENT amp line fuse (red wire) protects the mirror drive circuit and power i s derived from the ignition l i v e terminal on the fuse box. The mirror wiring loom i s attached to the main loom behind the facia support beam, and i s sealed where the loom passes through the polythene sealing on the inner door panel.
Page 312 Page SECTION 0 Description Page GENERAL PRE-DELIVERY INSPECTION SCHEDULE OF FREE AFTER SALES SERVICE (500 miles, 800 SCH E D UL E OF 'A' SERVICE (5,000 miles, 8,000 km) SCHEDULE OF 'B' SERVICE (10,000 miles, 16,000 RECOMMENDED LUBRICANTS 01 1 ESPRIT ,Issue 04/78...
Page 313 GENERAL FREE The Voucher Service commences with a "After Sales Service The Voucher for This this Service w i l l be accepted by the selling Dealer. i s carried out a t 500 miles (800 kilometres). Further Vouchers ore included i n the Owners Haridbook to cover lubrication and maintenance at intervals of every 5,000 miles (8,000 km) up to and including 50,000 miles (80,000 km).
Page 314 A l l cost incurred during the inspection are the responsibility of the supplying Failure to return a signed copy o f this inspection to Lotus Cars Limited by may result i n warranty claims on the particular w r being rejected.
Page 315 Page timing belt condition and tension, odjust necessary. Ctieck ignition contact lrieilker points settings and ignition tiniing and adjust necessary. Clean and reset spark plug points. Check alternator mounting bolts for tightness. Check a l l V-belt condition and tension, adjust necessary.
Page 316 Page 0 5 system fans, instruments, windscreen wiper, screen washer, and intern01 and external lamps. Check security of bottery terminals and rnoin earth connections. Check electrol te level of battery ond top up i f Check alignment and focussing. Check condition of a l l wheels, tyres and tyre volve assemblies. Set tyre pressures. Clean and balance a l l road wheels exclusing spare.
Page 317 contact breaker points settings and odjust necessary. Check ignition timing and adjust necessary. Clean ond reset spark plug points. Check alternator mounting bolts for tightness. belt condition and tension, adjust i f necessary. Check arid adjust air conditioning compressor belt tension and check mounting bolts for ti g htness (when fitted).
Page 318 Page wheel bearings necessary Electrical Check operation and Functio,.~ system fans, screen wiper, screen ,vasher und infernoi und exteir,ol lut.;!:: battery and top necessary. (:hecl : Wheels and Tyres Clean ond balance a l l road wheels excluding spare. Tighter1 u l l wheel nuts to specified torque locldiilg.
Page 319 Page SCHEDULE SERVICE (10,000 MILES, 16,000 KILOMETRES) Lubrication Drain engine arid tror~smission oil and refill with new oil. Fit new engine o i l filter. Lubricate drive shaft uriiversal joints throttle linkoge arid controls, door locks and bonnet catches. Lubricate hondbrake linka g e. Engine Check valve clearances and adjust i f necessary.
Page 320 Page Clutch Check and i f necessary top up clutch fluid reservoir. Check operation of clutch and adjust i f necessary. Steering and Suspension Check security of a l l steering connections, including column clamps and mountings. Check steering unit and anti-roll bar mountings, for tightness. Check cond'rion of anti-roll bar mounting rubbers.
Page 321 Page Heater ( i f fitted) Check operation of all controls, and fan speeds. Check engine transmission and drive shafts mounting bolts to specified toque loadicgs. Check condition of all moior unit mounting rubbers. Ensure steering wheel and u p ESPRIT...
Page 322 C) Mobil SHC must be used when no o i l cooler i s fitted, Engine (obove and below When an oil cooler is fitted lubricants listed below may be used. Lotus Cars Ltd.recommend Valvoline oils and greases, as follows: HP High Valvoline HD 20W/50All Climate or...
Page 324 Page SECTION P Description Foge GENERAL DESCRIPTION OPERATION OF CONTROLS HEATER UNIT ASSEMBLY ESPRIT...
Page 325 Page P2 GENERAL DESCRIPTION The heater unit i s designed to deliver fresh cir to either the windscreen for demisting, or to the interior of the vehicle, or a proportion to both, at any temperature between cold and hot dependent upon the position of the controls. scuttle sill and one i n the binacle.
Page 326 Page P3 A two position fan switch increases the a i r flaw speed, the first position being 'slow' speed and the second 'fost' speed. Typical heater control positions are as follows: Defrost M o v e upper lever to the centre position. M o v e lower lever backwards to the 'hot' position.
Page 327 Remove the four screws securing the heater box assembly to the inside of the To Replace Reverse the removal procedure ond refill the cooling system. flaps Check the operation of the heater controls for full movement of the uniform seating of flops on the seals, adjust necessary.
Page 328 CLUTCH Page SECTION Q Description DESCRIPTION MAINTENANCE ADJUSTMENT CLUTCH ASSEMBLY CLUTCH DRIVEN PLATE RELEASE BEARING ESPRIT 04/78...
Page 329 Fig. Clutch lever adiustment The clutch assembly comprises a diaphrogm spring type pressure plate with a single dry driven plate. The driven plate i s free to slide along the splines of the t m n m i u i m control shaft, the forward end of which forms a spigot t o f i t into the bearing in the centre the crankshaft.
Page 330 CLUTCH Page easily. After adji~stment release the spring lug and the odjusfer w i l l be locked i n position. ASSEMBLY CLUTCH To Remove 'F' ENGINE. Remove the transmission unit from the vehicle, see Section Remove the clutch assembly from the flywheel by progressively releasing the securing bolts around the periphery of the cover.
Page 331 Page ESPRIT Fig.2 Clutch mechanism...
Page 332 CLUTCH Page KEY TO Cover ossernbl Driven plate Release bearing Spring retaining release brg/fork Release fork Dust cover Fork return spring Adjusting screw, fork Fork spring lug Clutch rmster cylinder Clutch slave cylinder Banjo union Banjo bolt Gasket, large I/D Gasket, srmli Push Flexible pipe...
Page 333 Page When the clutch has operated satisfactoril y for some time the surface of the facings w i l l have acquired a high polish, throu g h which the groin of the facing moterial can be seen clearly. Under certain circumstances small quantities of lubricatin g o i l may enter the clutch This housirig and contaminate the surface facings.
Page 334 CLUTCH Page RELEASE BEARING To Remove Remove the tronsmission unit from the vehicle (see Section ENGINE). Pull the spring lug back against the return spring and remove the adiuster taking care not to lose the push-rod. Remove the lever grommet (rubber seal) from the exterior of the bellhousing. Release the split pin securing the fork to the ball pivot and remove the c l i p retaining the release bearing to the fork.
Page 336 EXHAUST SYSTEM Page SECTION S Description Page GENERAL DESCRIPTION DOWNPIPE SILENCER M A N IFOLD ESPRIT...
Page 337 EXHAUST SYSTEM Page ESPRIT...
Page 338 EXHAUST SYSTEM Page KEY TO FIG. Silencer Federal Catalyst Fedeml Only Intermediate Pipe UK and Europe Down Pipe Assy UK and Europe Down Pipe Assy Federal Pipe Clamp Silencer Mmrnting Strap UK and Europe Silencer Mounting Stmp Federal Exhaust Manifold Stud, Manifold to Head Gasket, Manifold t o Head Nut, Manifold to Head (Copperised)
Page 339 Page GENERAL DESCRIPTION The exhaust system comprises a manifold attached to twin downpipes termir~ating i n a converter on Federal vehicles. Both systems have a single silencer mounted across the rear of the vehicle terminating i n twin outlets. The systems are rigidly mounted to a bracket on the rear of the transmission casting.
Page 340 EXHAUST SYSTEM Page To Replace Reverse the remo+o! instructions, apply 'Firegum' or similar, to the pipe Take care when refitting silencer mounting straps not to domoge the small heat shield fitted on gearbox mounting plate. MANIFOLD To Remove Disconnect the downpipe from the monifold at the flange joint and discard the gasket.
Page 342 AIR CONDITIONING Page SECTION T Page Description GENERAL DESCRIPTION CONDENSER RECEIVER-DRIER EXPANSION VALVE TEMPERATURE CONTROL SWITCH REFRIGERANT HANDLING REFRIGERANT PIPEWORK CONTROLS OPERATION Maximum Refrigerated Air Defrost Air to Screen and Footwells Fresh Air from Face Level Vents CHARGING UNlT WITH REFRIGERANT CONDENSER RECEIVER-DRIER AIR CONDITIONING UNlT...
Page 344 AIR CONDITIONING Page T3 KEY TO FIG. Expansion Valve. Water Valve. Abutment Clip. Vacuum Motor. Clevis Pin, Vac. ~ o t o r / F l a ~ s . Elbow, Vac. Pipe. Tee Piece. Elbow, Vac. Pipe. Vacuum Pipe. Vacuum Switch.
Page 345 KEY T O Condenser. Hose, Condenser/Receiver Drier Hose, Compressor/Condenser. Receiver Drier. Bracket, Receiver Drier. Hose, Receiver Hose, Expansion Valve Compressor. Cowl, Condenser Far] Fan, 10". Fan Motor. Fan Cowl and Motor Mounting. Vacuum Reservoir. Elbow. Piece. Sleeve. Elbow. Pipe. Vacuum Sleeve.
Page 346 AIR CONDITIONING Page 12/78...
Page 347 AIR CONDIITIBNIMG Page GENERAL DESCRIPTION 'ON' W i t h the air conditioning control and engine running, the compressor clutch operates engaging the compressor. Low pressure vapour entering the compressor i s pressure vapour at the output and discharged into a condenser. vapour i s cooled i n the condenser chan g in g into a li uid, from here i t flows into the receiver-drier, where any foreign matter is expelled.
Page 348 AI R ' C O N DIT I O N I N G Page bnd condensing i t into a high pressure liquid. The construction of the condenser i s similar to the engine radiator but i s designed to withstand hi g her pressures. RECEIVER-DRIER Located i n the front c~mpartment on the right hand side i t s purpose is t o ensure a supply of liquid refrigerant to the expansion volve i n an operational condition.
Page 349 Page switch and the whole unit i s replaced found t o be faulty. REFRIGERANT HANDLING The refrigerarit used in the air conditioning system i s 'Freon arid the followirig MUST precautions ALWAYS OBSERVED: leave refrigerarit drums open always make sure the caps are securely closed.
Page 350 AIR CONDITIONING Page ately they ore opened to prevent the ingress of moisture and/or dirt. PRIOR TO FITTING, new, and should only be opened IMMEDIATELY A N D ROOM TEMPERATURE, to prevent condensotion of any moisture which 'The receiver-drier should be the LAST component to be connected, this i s to ENSURE optimum deh dration ond rmximum moisture protection of the system.
Page 351 OFWAC OFWAC REFRIGERATED AIR OFWAC AMBIENT DEFROST Fig.3 Controls ESPRIT...
Page 352 Page Maximum Refri g erated A i r ( ~ u l l down) Move upper lever forward (OFF/AC) position. Move lower lever forward (COLD) position. Temperatvre Control Switched turned fully clockwise. Switch fan speed to Fast. This setting gives recirculating refrigerated air from the face level vents. For the best WARNING: directed at persons during maximum refrigerated air conditions, as this can cause discmfort ( i...
Page 353 AIR COWDITIONING Fresh A i r from Face Level Vents Move upper lever between the centre position and (OFF/AC) position. Move lower lever forward (C0L.D) position. Temperature Control Switcti to OFF. Select fan speed to suit or use ram effect. Fresh air may be obtained from both outboard face level vents, when the air conditioning unit i s set in the heating mode.
Page 354 AIR CONDITIONING Page Increase the engine speed to 2000 r.p.m. and check thot the refrigerant passing the sight glass clear of bubbles. I f a continuous stream of s t i l l bubbles persists then, the refrigerant charge should be increased until the bubbles are no longer present.
Page 355 AIR CONDll+lOl\a!MG RECEIVER-DRIER To Remove Depressurise the system previously described. Release the inlet and outlet unions on the receiver-drier, using two spooners (one on each union). Cap off all pipes ond unions IMMEDIATELY the joints ore opened. lift Release the clamp bolts securing the receiver-drier to the body and out unit from the clamp.
Page 356 AIR CONDITIONING Page Drain the cooling system described in the C O O L I N G SYSTEM section of this manti~l Disconnect the battery terminals. From inside the front comportment remove the following: Unscrew and remove the cover over the motor assembly on the front compartment bulkhead.
Page 357 Disconnect the two ewlant pipes carrying F r m , taking the necessary prtxautiens REFRIGERANT PIPEWORK. Remove the face level vent and pipe the passenger ride. The vent is retained by spring back clips (one each side), using screwdriver or similor the clips and withdraw vent.
Page 358 AIR CONDITIONING Page CAUTION: when removing the A/C unit from the vehicle. Remove the air conditioning unit from the passenger side of the vehicle. To Replace Reverse the removal procedure. Make sure when theairconditioning unit i s being relocated in the vehicle, the short control cable i s fed corefully through the hole i n the facia, avoid kinking.
Page 359 Depressurise the air conditioning system by slackening the union nut securing the pipe to the receiver-drier. Take the necessary precautions described under the heading 'Refrigerant Pipework'. Remove the pipe connections to the compressor, taking the necessary precautions described under the heading 'Refrigerant Pipework'. Loosen arid remove the compressor drive belt and disconnect the electrical connections to the compressor clutch.
Page 360 AIR CONDITIONING Page RECOMMENDED REFRIGERANT OIL The refrigerant o i l recommended for use in the compressor and to lubricate flared pipe ends and union threads are: Frigidair 525 Shell Clavus Texaco Capel la (Waxfree) Sunisco B P Energol LPT5OO NOTE: The above oils ore not given i n any order of preference and a l l are Keep the oil contoiner ti g htly copped at a l l times.
Page 361 32447) Insert dipstick (tool number with the angled 'stop' towards highest part of compressor, just inside the plug hole. Align the angled bottom of the 'stop' with the top surface of the o i l filler hole, and insert the dipstick until i t reaches the 'stop'.
Page 362 AIR CONDITIONING Page Start engine and 'run' a t Set controls for maximum cold, with fan at fast speed Symptom Cause Remedy Continuous bubbles System low on Check with leok detector. fill Correct leak, any, and present i n sight glass. charge.

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