Lotus TURBO ESPRIT Service Manual page 299

On e a r l y c a r s , t h e column must b e p a s s e d b e n e a t h t h e s c u t t l e beam b e f o r e
p u l l i n g back o n t o t h e s c u t t l e beam p l a t f o r m s .
F i t t h e s p a c e r washers
between column f l a n g e and beam, and r e t a i n w i t h f i x i n g s shown b u t do n o t
t i g h t e n .
On l a t e r c a r s , tila s c u t t l e beam i n c o r p o r a t e s two weld s t u d s o n t o which t h e
u p p e r column f l a n g e
i s
f i t t e d from b e n e a t h and r e t a i n e d w i t h w a s h e r s and
Nyloc n u t s . Do n o t t i g h t e n .
3 .
S e c u r e t h e column assembly lower b r a c k e t
t o
t h e p e d a l box w i t h t h e s i n g l e M 8
b o l t w i t h shakeproof and f l a t washer.
4 . ~ i g h t e n t h e s t e e r i n g column f i x i n g s i n t h e f o l l o w i n g o r d e r :
-
column t o p e d a l box; 24 Nm ( 1 7 . 5 1 b f . f t ) .
-
column t o s c u t t l e beam ( 2 o f f ) ; 1 5 Nm ( 1 1 1 b f . f t ) .
-
u p p e r column u / j t o upper i n t e r m e d i a t e s h a f t ; 40 Nm (30 1 b f . f t ) .
5.
F i t t h e s t e e r i n g l o c k t o t h e t o p b e a r i n g h o u s i n g u s i n g new s h e a r b o l t s , and
t i g h t e n u n t i l t h e b o l t heads s h e a r .
6 . F i t t h e i g n i t i o n s w i t c h and r e t a i n w i t h t h e g r u b s c r e w . S l i d e t h e two column
s w i t c h e s i n t o t h e column t o p b e a r i n g c a r r i e r and p l u g i n t h e i r b l o c k
c o n n e c t o r s .
7 . R e f e r t o s e p a r a t e manual ' S e c t i o n
WA'
(E082T0327J) t o :
-
r e f i t t h e knee b o l s t e r (Sub-Secion WA.3
-
C)
-
r e f i t t h e r o t a r y c o n n e c t o r (Sub-Section WA.3
-
K )
-
r e f i t t h e s t e e r i n g wheel ( S u b - S e c t i o n WA.3
-
J )
-
r e f i t t h e i n f l a t o r module ( S u b - S e c t i o n
WA.3
-
I )
HB.4
-
INTERMEDIATE STEERING C O L U M N ASSEMBLY
On non-S.I.R.
c a r s , a s i n g l e i n t e r m e d i a t e column i s u s e d t o g e t h e r w i t h two
u n i v e r s a l j o i n t s t o t r a n s m i t t h e motion of t h e upper s t e e r i n g column t o t h e
s t e e r i n g r a c k p i n i o n s h a f t . When r e f i t t i n g t h e i n t e r m e d i a t e column, it i s most
i m p o r t a n t t h a t t h e two j o i n t s a r e c o r r e c t l y phased w i t h r e s p e c t t o e a c h o t h e r .
On c a r s f i t t e d w i t h S . I . R . (Supplementary I n f l a t a b l e R e s t r a i n t ) , t h e s h o r t e r
u p p e r s t e e r i n g column assembly n e c e s s i t a t e s t h e u s e o f t w o i n t e r m e d i a t e columns
and t h r e e u n i v e r s a l j o i n t s , w i t h t h e lower i n t e r m e d i a t e column s u p p o r t e d i n a
c h a s s i s mounted b e a r i n g . The d e s i g n o f t h e i n t e r m e d i a t e column s y s t e m
i s
s u c h
as
t o p e r m i t assembly o n l y w i t h t h e c o r r e c t p h a s i n g of t h e t h r e e u n i v e r s a l j o i n t s .
To Remove I n t e r m e d i a t e S t e e r i n g Column Assembly: Non-S.I.R. c a r s
1. Remove t h e p i n c h b o l t s e c u r i n g t h e u p p e r u / j t o t h e u p p e r column.
2. Remove t h e t w o n u t s and b o l t s s e c u r i n g t h e upper column assembly t o t h e
s c u t t l e beam, and s l a c k e n t h e clamp b o l t s e c u r i n g t h e lower end o f t h e column
t o t h e p e d a l box.
Draw t h e u p p e r column assembly i n t o t h e
car
o n l y
s u f f i c i e n t l y
t o
d i s e n g a g e t h e i n n e r column from t h e u p p e r u / j .
3 . From b e n e a t h t h e c a r ,
remove
t h e p i n c h b o l t s e c u r i n g t h e lower u / j t o t h e
i n t e r m e d i a t e column and withdraw t h e i n t e r m e d i a t e column i n t o t h e c a r .
4 . I f n e c e s s a r y , remove t h e p i n c h b o l t s e c u r i n g t h e lower u / j t o t h e s t e e r i n g
r a c k p i n i o n s h a f t , a n d
remove
t h e
lower
u / j .