Lotus TURBO ESPRIT Sports Car Manuals

Manuals and User Guides for Lotus TURBO ESPRIT Sports Car. We have 1 Lotus TURBO ESPRIT Sports Car manual available for free PDF download: Service Manual

Lotus TURBO ESPRIT Service Manual (998 pages)

TURBO ESPRIT; ESPRIT S3 Lotus

Brand: Lotus | Category: Automobile | Size: 42 MB

Contents
4
Vehicle Identification Number
5
Notes
5
Domestic & Export
6
Technical Data
7
Camshafts and Valve Timing
11
Valves
11
Valve Seat Inserts
11
Outside Diameter of Seat
12
Valve Springs
12
Valve Guides
13
Camshafts
13
Cam Followers
13
Auxiliary Shaft
13
Crankshaft
14
Main Bearing Shell Configuration
14
Flywheel
15
Flexplate Flywheel
15
Connecting Rod
15
Identification
16
Dellorto Carburettors
18
Zenith Carburetton
19
Torque Loading Figures
22
Tyre Replacement
43
Identification of Tyre Spec.
43
Electrical Equipment
44
Torque Settings
44
Paint Procedure
46
Paint Codes
47
Paint Reference Number
47
Essential Working Practice
52
Body and Component Polyurethane Primer
54
Nitro-Cellulose Paint Rectification
66
Orange Peel or Cratches Caused by Compounding
66
Scars or Sinkages
66
Gel Cracks
67
Blisters
68
Chips and Scratches
69
Edge/Corner Chips
69
Panel Chips
69
Paint Procedure for Prim Components
72
Pearlescent White Paint Procedure
74
Prim Components in Pearlescent White
74
Bodycare and Repair
76
Body
96
Door Drop Glass
105
Door Glass External Weatherstrip
106
Door Quarter Light Glass
107
Door Shell
108
Front Bonnet Panel
110
Tailgate
110
Latch Adjustment
111
Decal Positioning
113
Glass Roof Adjustment
119
Front Suspension
120
General Description
122
Key to Front Suspension General Layout Drawing
122
Lubrication
123
Geomerty
123
Castor Adjustment
124
Front Wheel Alignment
125
Front Suspension Disassembly
125
Front Hub Adjustment
125
Wheel Bearing Replacement
126
Key to Suspension Layout Diagram
129
Geometry
130
Suspension Disassembly
131
Spring/Damper Removal
131
Spring Top Platform
131
Front Wheel Bearings
132
Suspension Re-Assembly
132
Rear Suspension
134
Table of Contents
134
Key to Rear Suspension General Layout Drawing
136
General Description
137
Rear Wheel Alignment
137
Rear Suspension Reassembly
138
Rear Wheel Bearing Removal
139
Rear Wheel Bearing Installation
139
Drive Shaft C.V. Joint Boot Replacement
140
Engine
142
Engine & Transmission Assembly
143
Oil Level
145
Oil Filter
145
Not Dry Sump Turbo
145
Dry Sump Turbo
145
Engine Tune
146
Compression Check
147
Camshaft Covers
147
Turbo
147
View Showing Cam Followers Held by Magnets
148
Camshaft Sprocket Held in Vice
149
Camshaft Thrust Washer & O Ring
150
Releasing the Camshaft
150
Camshaft Oil Seal Fitted
151
Toothed Belt Guard
157
Upper Section
157
Belt Guard Components
158
Camshaft Driving Belt
159
Lower Section
159
Engine Timing Marks
160
TDC Position of Distributor Rotor Arm
161
Sprocket Positions with Number 1 Cylinder at TDC
161
Manual Tensioner
162
Semi-Automatic Tensioner
162
Driving Belt Tensioner
164
Cylinder Head
165
Cylinder Head Nut Tightening/Releasing Sequence
165
Head Gasket Selection
168
Decarbonize Cylinder Head & Pistons
169
Location of Valve Seat Oversize Stamping
171
Crankshaft V Pulley
172
Crankshaft Sprocket
173
Front Cover & Oil Seal
173
Water Pump
175
Ignition Distributor
179
Oil Pump & Auxiliary Housing
180
Oil Pump/Auxiiiary Housing Components
181
Inlet Manifold & Carburetorrs
183
Oil Sump
184
Connecting Rod Bearings
185
Engine Assembly
185
To Fit Heatshield
191
Flywheel & Ring Gear
191
Heat Shield Position on Chassis
191
Cranksahaft Rear Oil Seal
192
Rear Oil Seal and Housing
193
Location of Spray Shield
193
Oil Pick-Up Pipe and Union Spanner
195
Cross-Drilled Crankshafts
196
Oversize Outside Diameter Main Bearing Shells
196
Engine Inverted with Sump Removed
200
Pistons, Piston Rings, Connecting Rods & Cylinder Liners
201
Connection of Oil Cooler Thermostat
205
Lubrication System Precautions
205
Belt Guard Components (Early Models)
206
Sealants, Adhesives
208
Engine Management
209
Engine Control Components
210
Ignition Solenoid
210
Fuel Pressure Solenoid
210
Throttle Jack Solenoid
210
Evaporative Control System
211
Special Tools Rewired
211
Mixture Setting
214
Engine Diagnostic Procedure
217
Intake Manifold Leaks & Air Filter Inspection
219
Ignition System & Cylinder Compressions
221
Cold Start System Maladjustment
223
Check Cam Timing
224
Fuel Control Pressure
225
Carburettor Balance
227
Co Adjustment
228
Thermal Switch
229
Battery Re-Charging Procedure
230
Fuel Pump Electrical Circuit
231
Engine Management Vacuum Connection Diagram
233
Vacuum Pump
234
Ignition Solenoid Valve
234
Overboost Switch
234
Purge Pump
234
Thermal Ignition Advance
235
Vacuum Circuits
235
Water Temp
235
Crankcase Breather Valve
237
Cold Enrichment Thermal Valve
238
Plenum Purge
238
Initial Ignition Timing Setting
240
Check/Adjust Idle Speed
241
Gearbox/Transmission
252
Transmission Assembly
253
Key to Transmission Assembly Drawing
254
C35 Introduction
255
Drain and Level Plug
256
Gearshift Lever and Gear Change Linkage
256
Tube Linkage Basic Setting
260
Crossgate Cable Basic Setting
260
Gear Selector Replacement
265
3Rd and 4Th Gear Selector
265
1St and 2Nd Gear Selector
265
Interlock Plungers
265
Gear Selector Mechanism
267
4Th Gear Stop Adjustment
268
Final Assembly
268
Primary Shaft
268
Primary Shaft Assembly
269
Gearbox Shafts and Gears
271
Bevel Pinion Shaft
273
Bevel Pinion Assembly
273
Differential Assembly
277
Fuel System
376
General Description
377
Fuel Injection System Description
377
Fuel Feed (Pump, Accumulator, Filter)
377
Mixture Control Unit
379
Mixture Adaptation
385
Thermaltime Switch
386
Auxiliary Air Valve
386
Warm up Regulator
387
High Altitude Compensation
388
Exhaust Emission Control
388
Frequency Valve
389
Electronic Control Unit
390
Sheet
474
Splice
479
See Sht
481
To Start Motor See Sht
481
See Sht 2
481

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