Lotus Esprit Series

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BODY

Page

B25

F.ig.

Tai

lga

Cornponen

ESPRIT

~SSW

04/78

Main Page

Introduction3
General3
Manual Format3
Chassis (Car) Number4
Vehicle Identification4
Technical Data5
Dimensions6
Capacities6
Engine7
Belt Tensions7
Cylinder Head8
Valves8
Valve Guides9
Valve Seat Inserts9
Valve Springs9
Camshafts10
Cam Followers10
Auxiliary Shaft10
Crankshaft10
Flywheel11
Connecting Rod11
Gudgeon (Piston) Pin11
Piston and Liner11
Oil Pressure under Normal Operating Condition (Hot)12
Lubrication System12
Settings13
Fuel System13
Needle14
North American Spec. with Zenith-CD Carburettors14
Distributor14
North American Specification15
Cooling System15
Clutch16
Transmission16
Front Suspension16
Steering Angles17
Steering17
Rear Suspension17
Brakes18
Wheels and Tyres18
Wheel Type18
Tyre Pressures European Spec18
Electrical Equipment19
Battery Type19
Headlamps19
Sidelamp19
Torque Loading Figures20
Gearbox21
Torque Wrenches23
Model S2 Characteristics23
Hubs23
Commemorative Vehicles24
General Description28
Accident Damage28
Body Care32
Bright Metal32
Accessing Accident Damage33
Windscreen Cleaning33
De-Waxing33
Alloy Wheels33
Body38
Resin MIX38
Basic Bonds and Joints38
Headlamp Bowls and Surrounds39
Superficial Defect Repairs39
Pin Holes or Air Voids39
Replacement Sections40
Split Bonds40
Distortion or Wrinkling40
Positioning Replacement Panels41
Bobbins41
Bobbins Pulling out42
Stripped Threads42
Laminating New Bobbin44
Loyup Around Bobbins44
Mounting Points45
Paint Procedure45
To Paint Cellulose45
To Paint Polyretnane46
Painting Equipment47
Bonnet48
Adjustments50
Bonnet Catches50
Tailgate50
Tailgate Mechanism51
Doors56
Door Lock Striker Adjustment56
Door Lock Striker Removal56
Door Hinges56
Door Adjustments57
Door Trim Panel Removal60
Vertical Adjustments60
Door Trim Panel Replacement61
Interior Door Handle Removal61
Interior Door Handle Replacement61
Exterior Door Handle Rmeoval61
Window Operating Motor Removal62
Window Motor Location62
Window Operating Motor Replacement63
Door Check Strap Removal63
Door Check Strap Replacement63
Door Removal63
Windscreen (Windshield)66
Section through Windscreen and Fixing Clips67
'Solbit' Retainer in Position67
Headlamp Motor Removal69
Headlamp Motor Replacement69
Lamp Pod Removal69
Lamp Pod Replacement69
Headlamp Pod Adjustments74
Instrument Binnacle74
Safety Belts75
Safety Belt Fixings76
Front Bumper77
Rear Bumper77
Valence78
External B/C Post Finisher78
Front Seat79
Door Lock80
Door Lock and Linkages80
Rear Quarter Light81
Door Window Frame82
Door Shell Fixing Bolts83
Door Shell83
Quarter Light Glass (Door)84
Fitting Quarter Ligtit Glass84
Section through Internal Finisher85
Door to Window Finishers86
To Remove Internal Finisher86
To Remove External Finisher86
Engine Cover87
Engine Compartment Air Flow87
Leather Upholstery88
Windscreen and Tailgate Glass89
Application of Glass Primer90
Sealant Application Nozzle91
Instructions for Cutting Nozzle91
Suspension and Steering Geometry98
Prepomtion of Vehicle98
Anti-Roll Bar98
Lower Link99
Coil Spring100
Damper100
Upper Wishbone101
Damper Top Mounting101
Front Hub102
Bearing Housing & Driveshaft Assembly106
Radius Arm Mounting107
Radius Chassis Mounting107
Rear Wheel Toe-In108
Lower Link Inner Attachment109
Hub Bearing110
Damper & Spring Assembly111
Oil Level114
Oil Filter114
Engine Tune115
Compression Check116
Camshaft Covers116
View Showing Cam Followers Held by Magnets118
Camshaft Driving Belt125
Belt Tension Check125
Burrough's Gauge in Position125
To Remove Timing Belt126
Automatic Belt Tensioner126
Driving Belt Tensioner129
Cylinder Head Nuts Tightening/Loosening131
Front Cover and Oil Seal138
Water Pump139
Water Pump Assembly140
Ignition Distributor141
Oil Pump and Auxiliary Housing142
Connecting Rod (Big-End) Bearings146
Engine Transmission Assembly146
Flywheel and Ring Gear148
Crankshaft Rear Oil Seal149
Location of Spray Shield149
Rear Oil Seal and Housing150
Oil Pick-Up Pipe and Union Spanner152
Special Tools159
Exhaust Emission Control161
Emission Control161
Anti-Run on System161
Evaporation Control System161
Exhaust Concentration Test162
Procedure for Tensioning Pump Drive Belt162
Lumenition Distributor165
To Test the Complete System165
To Test the Power Module (and Coil)165
Gearshift Lever and Gear Change Tube Assembly171
Transmission Assembly175
Clutch Bell Housing176
Drive or Input Shaft177
Front End of Gearbox177
Gearbox Rear Housing178
Rear Housing with Cover Removed178
Gear Selecton179
Reverse Gear Selector179
3Rd and 4Th Gear Selector180
1St and 2Nd Gear Selector180
Interlock Plungers180
Gear Selector Replacement180
Primary Shaft Assembly185
Bevel Pinion Assembly187
Differential Assembly191
Differential Bearings Adjustment194
Backlash Adjustment197
Hubs, Wheel, Tyres200
Tyres201
Spare Wheel201
Front Hubs202
Rear Hubs203
Steering Column Lock/Ignition211
Braking System214
Front Brake Pads217
Service Arid Repair221
Rear Brake221
Resetting 'The Adiustable Piston221
Operation of the Handbrake221
Fitting of New Brake Pads222
Rear Brake Adjuster222
Bleeding the Braking System223
Master Cylinder224
Servo Unit225
Pedal Box225
Handbrake Cable Adiustment226
Handbrake Lever Removal226
Handbrake Cable Removal226
Handbrake Assembly226
Radiator, Drain Tap231
Cooling System Inhibitor232
Radiator232
Thermostat233
Thermostat Removal233
Radiator Removal from Vehicles with Air Conditioning234
To Replace Radiator on Air Conditioned Vehicles235
Table of Contents236
General Description239
- Cleaning the Fuel System239
- Zenith Carburetters240
- Fuel Tanks240
Fuel Tank Sender Unit241
Fuel Gauge241
Fuel Pump241
- Cross-Of Fuel Pump242
- Flowlock243
- Fuel Filter243
- Description244
- Adjusting249
- Cleaning254
- Overhaul255
Dellorto Carburetters258
- Description258
  - Acceleration262
  - Main263
- Adjusting263
  - Anti-Tamper Device264
  - Float Chamber Level266
- Removal266
- Cleaning269
- Overhaul269
Evaporative Loss Control270
Air Cleaner270
Choke Control271
Throttle Cable272
- The Check Throttle Inner Cable Free Play273
- The Check Accelerator Pedal Travel273
- Erratic or Poor Ldling273
Carburetter Fault Finding273
- Hesitation or Flat Spot274
- Heavy Consumption274
- Irregular Firing of Engine275
- Vehicle Lacking Power275
- Cold Starting Difficulties275
- Fuel Leakage275
- Insufficient Acceleration276
Model S2 Characteristics278
- Component Locations279
- Component279
- Relays279
- Bulbs and Light Unit Replacement280
- Headlamp Beam Alignment280
- Front Flasher/Sidelamp280
- Headlamp Trimming Screws281
- Instrument Panel Warning Lamp282
- Number Plate Lamp282
- Interior Lamp282
- Side Marker Lamp282
- Instruments285
- Veglia Instrument Panel285
- Fitting a New Print Circuit285
- Smith Instrument Panel286
- Switches and Controls286
- Combined Ignition/Starter Switch286
- Combined Side, Rear and Headlamp Switch287
- Direction Indicators, Headlamps and Horn Switch287
- Windscreen (Windshield) Wiper/Washer288
- Direction Indicators/Headlamps/Horn288
- Binnacle Illumination Lamps Switch289
- Door Window Operating Switches289
- Windscreen (Windshield) Wipermasher Control289
- Heater Fan Switch290
- Warning Switch290
- Interior Light Switches290
- Column Mounted Switches291
- Ignition Switch291
- Radio291
- Alternator Belt Adiustment292
- Alternator Belt Adjustment292
- Radio Suppression292
- Screen Wipe Motor293
- Alternator293
- Fuses293
- Location of Fuses293
- Fault Finding294
- Warnings294
- Alternator Circuit295
- Engine Running Faster than Idle297
- Load Graph298
- Alternator Test Circuit298
- Lucas Alternator298
- S2 Characteristics299
- Engine Bay Blower299
- Door Mirrors299
- Clock300
- Loudspeakers300
- Wiring Diagram302
- Lubrication/Maintenance312
- Road Test313
- Mechanical313
- Pre-Delivery Inspection313
- Electrical313
- Wash Car and Polish & Follows314
- Schedule of Free Alter Sales Services314
- Lubrication314
- Steering and Suspension315
- Air Conditioning316
- Heater318
- Recommended Lubricants322
- Heating/Ventilation324
- Air Flow325
- Operation of Controls325
- Lever Position325
- Heater Controls325
- Defrost326
- Hot Air to Screen and Footwells326
- Cold Air to Footwell326
- Heater Unit Assembly326
- Clutch Lever Adiustment329
- Clutch Assembly330
- Clutch Driven Plate330
- Downpipe339
- Silencer339
- Manifold340
- Refrigerant Circuit347
- Condenser347
- Receiver-Drier348
- Expansion Valve348
- Temperature Control Switch348
- Refrigerant Handling349
- Refrigerant349
- Controls Operation350
- Refrigerated Air351
- Ambient351
- Charging Unit with Refrigerant353
- Fresh Air from Face Level Vents353
- Air Conditioner Unit356
- Fitting a New Air Conditioning Unit358
- Compressor358
- To Fit New Compressor359
- Recommended Refrigerant Oil360
- Refrigerant Level Checking Procedure360
- Refrigerant Quick-Check Procedure361

Lotus Esprit Series - Page 53

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