Lotus TURBO ESPRIT Service Manual page 203

SECTION EA
Page
55
2. When l i n e r n i p i s c o r r e c t , w i t h d r a w t h e l i n e r s , a p p l y
'Hylomar' o n t h e l i n e r f l a n g e t o c y l i n d e r b l o c k m a t i n g f a c e a n d
r e p l a c e l i n e r s .
3 . I f r e p l a c e m e n t p a r t s a r e t o be f i t t e d , e n s u r e t h a t t h e p i s t o n s
and t h e c o n n e c t i n g r o d s a r e b o t h b a l a n c e d s e t s .
Note t h a t a l l 907 and s t a n d a r d 912/910 e n g i n e s u s e c a s t i r o n
c y l i n d e r l i n e r s w i t h c a s t aluminium a l l o y p i s t o n s . 912/910
' h i g h c o m p r e s s i o n ' e n g i n e s u s e f o r g e d aluminium a l l o y c y l i n d e r
l i n e r s w i t h a ' N i k o s i l ' c o a t e d b o r e , t o g e t h e r w i t h
f o r g e d aluminium a l l o y p i s t o n s . The a l l o y l i n e r s h a v e a
l a r g e r s p i g o t d i a m e t e r a n d c a n n o t be f i t t e d t o s t a n d a r d
e n g i n e s .
P . i s t o n s and l i n e r s a r e o n l y s u p p l i e d t o g e t h e r a s matched p a i r s .
Two *grade d i a m e t e r s a r e u s e d ,
' A '
and
' B '
w i t h
' A '
p i s t o n
(marked a s crown) f i t t e d i n t o
' A '
l i n e r s (marked on l i n e r
t o p r i m o r on s i d e f l a t ) and
' B '
i n t o
' B ' .
P i s t o n s a r e a l s o
w e i g h t g r a d e d i n 3 . 5 gram ( c a s t p i s t o n s ) o r 3.0 gram ( f o r g e d
. p i s t o n s ) i n c r e m e n t s , a n d a r e marked i n t h e f o l l o w i n g manner:
C a s t p i s t o n s ; c o l o u r e d p a i n t s p o t on crown, w i t h c o r r e s p o n d i n g
i n i t i a l l e t t e r ( s ) , e n g r a v e d on gudgeon p i n b o s s u n d e r s i d e .
Forged p i s t o n s : stamped on crown w i t h 2+,
1
t ,
0 ,
1- o r 2-
.
Each e n g i n e u s e s 4 p i s t o n s o f t h e same w e i g h t g r a d e b u t may
m i x
' A '
and ' B ' p i s t o n / l i n e r a s s e m b l i e s . S i m i l a r l y , c o n n e c t i n g
r o d s a r e w e i g h t g r a d e d i n t o
2
gram matched s e t s , and i d e n t i f i e d
by a l e t t e r c o d e e t c h e d o r p a i n t e d below t h e f o r g e d 'FRONT'
mark on t h e r o d .
I f o r d e r i n g an i n d i v i d u a l c o n n e c t i n g r o d o r p i s t o n / l i n e r , t h e
w e i g h t g r a d e symbols must be q u o t e d .
F i t e a c h c o n n e c t i n g r o d t o i t s p i s t o n w i t h b o t h ' f r o n t ' m a r k s
f a c i n g t h e same way ( f o r g e d p i s t o n s have a r r o w stamped on crown
p o i n t i n g f o r w a r d s ) and i n s t a l l t h e gudgeon p i n a n d c i r c l i p s .
i ) F i t t h e o i l c o n t r o l r i n g s :
907/910/912 S t d : The o i l c o n t r o l r i n g s c o n s i s t o f a n e x p a n d e r
r i n g and two s t e e l r a i l s which a r e f i t t e d above a n d below
t h e e x p a n d e r r i n g . They FUST a l w a y s b e f i t t e d BEFORE t h e
c o m p r e s s i o n r i n g s , working downwards from t h e p i s t o n
crown. F i t t h e e x p a n d e r r i n g on t h e p i s t o n a n d e n s u r e t h a t
t h e c o l o u r e d e n d s a r e b u t t i n g . F i t o n e end o f a s t e e l r a i l
i n t o t h e g r o o v e below t h e e x p a n d e r r i n g , h o l d i n g t h e r a i l
end w i t h a thumb w h i l s t e a s i n g t h e r a i l o v e r t h e p i s t o n
and i n t o i t s l o c a t i o n , and r e p e a t t o f i t t h e o t h e r s t e e l r a i l
above t h e e x p a n d e r . P o s i t i o n t h e g a p s i n t h e two r a i l s ,
25mm e a c h s i d e o f t h e e x p a n d e r g a p .
912/910
t h e one
e a c h t o
'HC': F i t t h e e x p a n d e r s p r i n g f i r s t , f o l l o w e d by
p i e c e o i l c o n t r o l r i n g , a n d p o s i t i o n t h e e n d s o f
be d i a m e t r i c a l l y o p p o s i t e
APR 1987