Lotus Esprit Series Manuals

Manuals and User Guides for Lotus Esprit Series. We have 1 Lotus Esprit Series manual available for free PDF download: Workshop Manual

Lotus Esprit Series Workshop Manual (363 pages)

Brand: Lotus | Category: Automobile | Size: 7 MB

Introduction
3
General
3
Manual Format
3
Chassis (Car) Number
4
Vehicle Identification
4
Technical Data
5
Dimensions
6
Capacities
6
Engine
7
Belt Tensions
7
Cylinder Head
8
Valves
8
Valve Guides
9
Valve Seat Inserts
9
Valve Springs
9
Camshafts
10
Cam Followers
10
Auxiliary Shaft
10
Crankshaft
10
Flywheel
11
Connecting Rod
11
Gudgeon (Piston) Pin
11
Piston and Liner
11
Oil Pressure under Normal Operating Condition (Hot)
12
Lubrication System
12
Settings
13
Fuel System
13
Needle
14
North American Spec. with Zenith-CD Carburettors
14
Distributor
14
North American Specification
15
Cooling System
15
Clutch
16
Transmission
16
Front Suspension
16
Steering Angles
17
Steering
17
Rear Suspension
17
Brakes
18
Wheels and Tyres
18
Wheel Type
18
Tyre Pressures European Spec
18
Electrical Equipment
19
Battery Type
19
Headlamps
19
Sidelamp
19
Torque Loading Figures
20
Gearbox
21
Torque Wrenches
23
Model S2 Characteristics
23
Hubs
23
Commemorative Vehicles
24
General Description
28
Accident Damage
28
Body Care
32
Bright Metal
32
Accessing Accident Damage
33
Windscreen Cleaning
33
De-Waxing
33
Alloy Wheels
33
Body
38
Resin MIX
38
Basic Bonds and Joints
38
Headlamp Bowls and Surrounds
39
Superficial Defect Repairs
39
Pin Holes or Air Voids
39
Replacement Sections
40
Split Bonds
40
Distortion or Wrinkling
40
Positioning Replacement Panels
41
Bobbins
41
Bobbins Pulling out
42
Stripped Threads
42
Laminating New Bobbin
44
Loyup Around Bobbins
44
Mounting Points
45
Paint Procedure
45
To Paint Cellulose
45
To Paint Polyretnane
46
Painting Equipment
47
Bonnet
48
Adjustments
50
Bonnet Catches
50
Tailgate
50
Tailgate Mechanism
51
Doors
56
Door Lock Striker Adjustment
56
Door Lock Striker Removal
56
Door Hinges
56
Door Adjustments
57
Door Trim Panel Removal
60
Vertical Adjustments
60
Door Trim Panel Replacement
61
Interior Door Handle Removal
61
Interior Door Handle Replacement
61
Exterior Door Handle Rmeoval
61
Window Operating Motor Removal
62
Window Motor Location
62
Window Operating Motor Replacement
63
Door Check Strap Removal
63
Door Check Strap Replacement
63
Door Removal
63
Windscreen (Windshield)
66
Section through Windscreen and Fixing Clips
67
'Solbit' Retainer in Position
67
Headlamp Motor Removal
69
Headlamp Motor Replacement
69
Lamp Pod Removal
69
Lamp Pod Replacement
69
Headlamp Pod Adjustments
74
Instrument Binnacle
74
Safety Belts
75
Safety Belt Fixings
76
Front Bumper
77
Rear Bumper
77
Valence
78
External B/C Post Finisher
78
Front Seat
79
Door Lock
80
Door Lock and Linkages
80
Rear Quarter Light
81
Door Window Frame
82
Door Shell Fixing Bolts
83
Door Shell
83
Quarter Light Glass (Door)
84
Fitting Quarter Ligtit Glass
84
Section through Internal Finisher
85
Door to Window Finishers
86
To Remove Internal Finisher
86
To Remove External Finisher
86
Engine Cover
87
Engine Compartment Air Flow
87
Leather Upholstery
88
Windscreen and Tailgate Glass
89
Application of Glass Primer
90
Sealant Application Nozzle
91
Instructions for Cutting Nozzle
91
Suspension and Steering Geometry
98
Prepomtion of Vehicle
98
Anti-Roll Bar
98
Lower Link
99
Coil Spring
100
Damper
100
Upper Wishbone
101
Damper Top Mounting
101
Front Hub
102
Bearing Housing & Driveshaft Assembly
106
Radius Arm Mounting
107
Radius Chassis Mounting
107
Rear Wheel Toe-In
108
Lower Link Inner Attachment
109
Hub Bearing
110
Damper & Spring Assembly
111
Oil Level
114
Oil Filter
114
Engine Tune
115
Compression Check
116
Camshaft Covers
116
View Showing Cam Followers Held by Magnets
118
Camshaft Driving Belt
125
Belt Tension Check
125
Burrough's Gauge in Position
125
To Remove Timing Belt
126
Automatic Belt Tensioner
126
Driving Belt Tensioner
129
Cylinder Head Nuts Tightening/Loosening
131
Front Cover and Oil Seal
138
Water Pump
139
Water Pump Assembly
140
Ignition Distributor
141
Oil Pump and Auxiliary Housing
142
Connecting Rod (Big-End) Bearings
146
Engine Transmission Assembly
146
Flywheel and Ring Gear
148
Crankshaft Rear Oil Seal
149
Location of Spray Shield
149
Rear Oil Seal and Housing
150
Oil Pick-Up Pipe and Union Spanner
152
Special Tools
159
Exhaust Emission Control
161
Emission Control
161
Anti-Run on System
161
Evaporation Control System
161
Exhaust Concentration Test
162
Procedure for Tensioning Pump Drive Belt
162
Lumenition Distributor
165
To Test the Complete System
165
To Test the Power Module (and Coil)
165
Gearshift Lever and Gear Change Tube Assembly
171
Transmission Assembly
175
Clutch Bell Housing
176
Drive or Input Shaft
177
Front End of Gearbox
177
Gearbox Rear Housing
178
Rear Housing with Cover Removed
178
Gear Selecton
179
Reverse Gear Selector
179
3Rd and 4Th Gear Selector
180
1St and 2Nd Gear Selector
180
Interlock Plungers
180
Gear Selector Replacement
180
Primary Shaft Assembly
185
Bevel Pinion Assembly
187
Differential Assembly
191
Differential Bearings Adjustment
194
Backlash Adjustment
197
Hubs, Wheel, Tyres
200
Tyres
201
Spare Wheel
201
Front Hubs
202
Rear Hubs
203
Steering Column Lock/Ignition
211
Braking System
214
Front Brake Pads
217
Service Arid Repair
221
Rear Brake
221
Resetting 'The Adiustable Piston
221
Operation of the Handbrake
221
Fitting of New Brake Pads
222
Rear Brake Adjuster
222
Bleeding the Braking System
223
Master Cylinder
224
Servo Unit
225
Pedal Box
225
Handbrake Cable Adiustment
226
Handbrake Lever Removal
226
Handbrake Cable Removal
226
Handbrake Assembly
226
Radiator, Drain Tap
231
Cooling System Inhibitor
232
Radiator
232
Thermostat
233
Thermostat Removal
233
Radiator Removal from Vehicles with Air Conditioning
234
To Replace Radiator on Air Conditioned Vehicles
235
Table of Contents
236
General Description
239
- Cleaning the Fuel System
  239
- Zenith Carburetters
  240
- Fuel Tanks
  240
Fuel Tank Sender Unit
241
Fuel Gauge
241
Fuel Pump
241
- Cross-Of Fuel Pump
  242
- Flowlock
  243
- Fuel Filter
  243
- Description
  244
  - Zenith Starting Device
    246
  - Idling
    247
  - Normal Running
    247
  - Zenith Throttie Iever Setting
    247
  - Temperature Compensator
    248
- Adjusting
  249
  - Depression Valve
    249
  - Flexible Carburetter Mounting
    249
  - Throttle By-Pass Valve
    249
  - Synchronisation
    250
  - Zenith Adjusting Screws
    250
  - Float Height
    253
- Cleaning
  254
- Overhaul
  255
  - Air Valve/Diaphragm Assembly
    257
  - Air Valve Rod and Guide
    258
  - Float Chamber Removal
    258
Dellorto Carburetters
258
- Description
  258
  - Acceleration
    262
  - Main
    263
- Adjusting
  263
  - Anti-Tamper Device
    264
  - Float Chamber Level
    266
- Removal
  266
- Cleaning
  269
- Overhaul
  269
Evaporative Loss Control
270
Air Cleaner
270
Choke Control
271
Throttle Cable
272
Carburetter Fault Finding
273
- Hesitation or Flat Spot
  274
- Heavy Consumption
  274
- Irregular Firing of Engine
  275
- Vehicle Lacking Power
  275
- Cold Starting Difficulties
  275
- Fuel Leakage
  275
- Insufficient Acceleration
  276
Model S2 Characteristics
278
- Component Locations
  279
- Component
  279
- Relays
  279
- Bulbs and Light Unit Replacement
  280
- Headlamp Beam Alignment
  280
- Front Flasher/Sidelamp
  280
- Headlamp Trimming Screws
  281
- Instrument Panel Warning Lamp
  282
- Number Plate Lamp
  282
- Interior Lamp
  282
- Side Marker Lamp
  282
- Instruments
  285
- Veglia Instrument Panel
  285
- Fitting a New Print Circuit
  285
- Smith Instrument Panel
  286
- Switches and Controls
  286
- Combined Ignition/Starter Switch
  286
- Combined Side, Rear and Headlamp Switch
  287
- Direction Indicators, Headlamps and Horn Switch
  287
- Windscreen (Windshield) Wiper/Washer
  288
- Direction Indicators/Headlamps/Horn
  288
- Binnacle Illumination Lamps Switch
  289
- Door Window Operating Switches
  289
- Windscreen (Windshield) Wipermasher Control
  289
- Heater Fan Switch
  290
- Warning Switch
  290
- Interior Light Switches
  290
- Column Mounted Switches
  291
- Ignition Switch
  291
- Radio
  291
- Alternator Belt Adiustment
  292
- Alternator Belt Adjustment
  292
- Radio Suppression
  292
- Screen Wipe Motor
  293
- Alternator
  293
- Fuses
  293
- Location of Fuses
  293
- Fault Finding
  294
- Warnings
  294
- Alternator Circuit
  295
- Engine Running Faster than Idle
  297
- Load Graph
  298
- Alternator Test Circuit
  298
- Lucas Alternator
  298
- S2 Characteristics
  299
- Engine Bay Blower
  299
- Door Mirrors
  299
- Clock
  300
- Loudspeakers
  300
- Wiring Diagram
  302
- Lubrication/Maintenance
  312
- Road Test
  313
- Mechanical
  313
- Pre-Delivery Inspection
  313
- Electrical
  313
- Wash Car and Polish & Follows
  314
- Schedule of Free Alter Sales Services
  314
- Lubrication
  314
- Steering and Suspension
  315
- Air Conditioning
  316
- Heater
  318
- Recommended Lubricants
  322
- Heating/Ventilation
  324
- Air Flow
  325
- Operation of Controls
  325
- Lever Position
  325
- Heater Controls
  325
- Defrost
  326
- Hot Air to Screen and Footwells
  326
- Cold Air to Footwell
  326
- Heater Unit Assembly
  326
- Clutch Lever Adiustment
  329
- Clutch Assembly
  330
- Clutch Driven Plate
  330
- Downpipe
  339
- Silencer
  339
- Manifold
  340
- Refrigerant Circuit
  347
- Condenser
  347
- Receiver-Drier
  348
- Expansion Valve
  348
- Temperature Control Switch
  348
- Refrigerant Handling
  349
- Refrigerant
  349
- Controls Operation
  350
- Refrigerated Air
  351
- Ambient
  351
- Charging Unit with Refrigerant
  353
- Fresh Air from Face Level Vents
  353
- Air Conditioner Unit
  356
- Fitting a New Air Conditioning Unit
  358
- Compressor
  358
- To Fit New Compressor
  359
- Recommended Refrigerant Oil
  360
- Refrigerant Level Checking Procedure
  360
- Refrigerant Quick-Check Procedure
  361

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Lotus Esprit Series Workshop Manual (363 pages)

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