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Esprit Series
Lotus Esprit Series User Manual
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KEY
TO
FIG.2
Gear
lever
assembly
Reverse
gate
Gear
lever
knob
Spacer,
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
Nyloc
nut
Washer
Gear
change,
relay
lever
Cross
gate
lever
Pivot
pin
Cross
gate
cable
Cross
gate
cable
rod
~dap(tor
Washer
Clevis
Spirol
pin
Spirol
pin
173
175
Table of Contents
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
The Check Throttle Inner Cable Free Play
273
The Check Accelerator Pedal Travel
273
Erratic or Poor Ldling
273
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
4
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Lotus Esprit Series Specifications
General
Brand
Lotus
Model
Esprit Series
Category
Automobile
Language
English
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