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Lotus 1980 ESPRIT S3, Service Manual

The Lotus 1980 ESPRIT S3 is a classic sports car designed for driving enthusiasts. For those in need of detailed guidance, its comprehensive Service Manual is available for download, free of charge, at manualshive.com. Unlock the potential of your car with this invaluable manual, ensuring optimal performance and longevity.

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Summary of Contents for 1980 ESPRIT S3

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Page 3: ...otus Dealen when necessary Lotus policy is one of continuous product improvement an right i s reserved to alter specificatiom at any time with01 notice Whllst every care has been taken to ensure correctness of it Is impossible to guatuntee complete freedom from error or to accept liability arising from such erron or omissions herein contained shall affect your statutory rights ...

Page 4: ... b u r e t t o r P r i o r t o 86 M Y E M A Turbo HC Dom Exp 87 M Y onwards EMC E s p r i t HC 87 M Y onwards E M D Transmission FB Steering HB Brakes P r i o r t o 85 M Y 85 M Y onwards a Cooling System Fuel System E s p r i t S3 Turbo o m x p o r t U S A Turbo Carburettor U S A Turbo Fuel I n j e c t i o n Bosch K J e t r o n i c E l e c t r i c a l E s p r i t S3 Turbo Dom xport U S A Turbo P r...

Page 5: ...501 Basic E l i t e 521 Basic Eclat 701 Basic Esprit 502 Elite A C 522 E c l a t A C 702 Esprit A C 503 E l i t e A C PAS 523 E c l a t A C PAS 701 Ccmn Esprit Cmunanerative 504 E l i t e Auto 524 Eclat Auto 702 C m Esprit C m A C A C PAS A C PAS 2 S e x r a t e serial number sequences a r e used for the f o l l m i n g groups of chassis m r k e t character 12 1 D A ErGrHrS B CiF K 3 For change po...

Page 6: ...serial nos E l i t e i718 Dan 0236 Exp E c l a t 1034 Dan 0205 Exp Esprit 0934 Dan 0 307 Exp Model Year 1980 B 1981 C 1982 Market Chassis A Australia H I3mort B 49 States h i t LHD USA J Japan C California K Canada D Danestic Puerto Rico E Europe cold L Saudi S 50 States Arabia USA S Sweden G Export hot RHD I series 11 A Series 1 a B Series 2 C Series 3 R e s t r a i n t Active S e r i a l Number ...

Page 7: ...on Cylinder Head Camshafts Valve Mechanism Crankshaft Main Bearing Configuration Flywheel Connecting Rod Gudgeon Pin Piston Liner lubrication System Dellorto Carburettors Zenith Carburetton Ignition System Distributor lgnition Timing Cooling Systern Torque Loading Figures 0APR 1987 Page 7 Page ...

Page 8: ... the purpose of clarification i n the TECHNICAL DATA SECTION ONLY a specification number is allocated to various specifications as listed below In some countries prefix letters may differ from those listed in which case reference should be made to the Lotus Distributor of that country for the relevent specification TECHNICAL DATA SECTION SPEC NO REMARKS 1974 FIRST PREFIX LmTER 907 D D a n e s t i ...

Page 9: ...Letter mly Single Prefix Letter Cnly TECHNICAL DATA S E T I SPEC NO U S A 1975 C Std D A C z PAS L A C PAS R Auto S Auto A C T Auto PAS M Auto A C PAS C tD tZtLt RtStTtMt as for Spec 5 EUROPEAN 1976 80 C tD tZrLr R tS tTIMI as for Spec 5 912 Esprit D Elite Eclat btcel 5 CALIFORNIA 76 79 49 STATES 76 77 J Esprit K Elite Eclat 6 49 STATES 1978 80 1 7 R tS tTIMI as for Spec 5 A H C B H C PAS N H C PA...

Page 10: ...10 2 11 6 bar 150 170 lb in2 spec 10 2 11 5 13 0bar 170 190 Ib in On top of cylinder block adjacent to starter mounting Engine belt tensions Toothed timing belt using Burroughs gauge part number TOOOT0025J 90 95 units cold 6 0 2 0 See Section E A 8 Alternator V belt 12 mm 0 5 in in Talal movement rnodamte Compredsor V be1t 9mmt0 35in 3 8in finger pressure I W C on longest i Power steering pump 12 ...

Page 11: ... exhaust 100 1023 1023 104 104 Valve clearance cold Spec 1 ID Cams lnlet Exhaust Spec 2 3 4 5 6 7 8 9 lnlet 1 b Exhaust blue yellw yellw green green Page 5 l3xhi3ust 1 M 0 P Cam BTDC Pulley Timing Dot 110 red 110 red 110 red 1023 yellow 110 red 45O 35 47 35 65 mrn 1 396 1 404 in 30 73 30 91 rnm 1 210 1 217 in 7 125 7 137 mm 0 2805 0 2810 i n 0 008 0 046 mm 0 0003 0 0018 in 0 10 0 1 5 mm 0 004 0 00...

Page 12: ... 365 37 390 mm 1 471 1 472 in 34 415 34 440 mm 1 355 1 356 in 37 325 37 350 mm 1 4695 1 4705 in 34 380 34 405 mm 1 3535 1 3545 in 37 350 37 375 mm 1 4705 1 4715 in 34 405 34 430 mm 1 l345 l 3555 in 37 375 37 400 mm 1 4715 1 4725 in 34 430 34 455 mm 1 3555 l 3565 in 37 450 37 475 mm 1 4745 1 4755 in 34 505 34 530 mm 1 3585 1 3595 in Dual Free Length Inner 1 Outer I Rate Inner Outer I A l l 907 engi...

Page 13: ...Shaft Running clearance End float 53 34 mm 2 100 in 53 34 mm 2 100 in 7 145 7 170 mm 0 2813 0 2823 in 11 915 11 925 mm 0 4690 0 4695 in 11 940 11 950 mm 0 4700 0 4705 in 11 965 11 975 mm 0 4710 0 4715 in 12 040 12 050mm 0 4740 0 4745 in 11 940 11 950 mm 0 4700 0 4705 in 11 965 11 975 mm 0 4710 0 4715 in 11 990 12 000 mm 0 4720 0 4725 in 12 065 12 080 mm 0 4750 0 4755 in 0 03 0 20 mm 0 001 0 008 in...

Page 14: ... mm 0 0005 0 0022 in 0 0 508 mm 0 0200 in Bearing clearance is measured with Plastigage MAIN EWKlNG SHELL CONFIGURATICN ENGINE TYPE 107 l i t e E c l a t 107 Esprit w i t h ION X d r i l l e d rank I07 Esprit w i t h idrilled crank 112 Esprit 112 E l i t e E d l a t 112 Excel w i t h KIN X d r i l l e d xank 112 Excel w i t h drilled crank 112 E s p r i t HC MAIN BEARING NUMBER FRONT 1 I CENTRE 1 ...

Page 15: ...0 001 in Bearings big end Type Steel backed leaded bronze Static clearance 0 025 0 081 mm 0 0010 0 0032 in End float on crankpin 0 10 0 25 rnm 0 004 OD10 in Small end bore bushed 25 405 25 410 mm 1 0002 1 0004 in Permissable weight variation between rods 2 gramrnes in any set Bearing clearance i s measured with Plastigage a Gudgeoc Piston Pin TYpe Locatiori Diameter Class of fit Piston and Liner F...

Page 16: ...grade A 95 205 95 219 mm 3 7482 3 7488 in 912 HC grade B 95 21 7 95 231 mm 3 7487 3 7493 in Grade diameter 907 912 Std 15 mm 0 6 in up from skirt edge 912 HC 10 2mm 0 4 in up fromskirt edge 1900 pinaxis Gudgeon pin bore offset 907 912 Std 1 52 mm 0 060 in towards thrust face 912 HC 1 50 mm 0 059 in towards thrust face Permissable weight variation betweenpistons 907 912 td 3 5 grammes 912 HC 3 0 gr...

Page 17: ... 0 006 in1 nip up to engine number 12477 0 025 0 13 mrn 0 001 0 005 in O O I Q from engine number 12478 912 HC minus 0 025 to 0 050mm minus 0 001 to 0 002 in Permissable variation between linen 0 03 mm 0 001 in J Piston clearance in cylinder liner 907 0 8 0 13mm 0 004 0 005 in 912 Std 0 11 0 15mm 0 005 0 006 in 912 HC 0 05 0 08mm 0 002 0 003 in Lubrication System a Oil pressure under normal runnin...

Page 18: ...170 38V 42H 70 7482 1 900 1000 2 0 3 0 Dellorto Carburettors E l i t e1 Eclat m Excel Std Spec 9 DHLA 45E A912E0789F A912EO790F 5324A 5323P BluekBlack 37 mn 160 230 7772 8 58 7850 9 8 5g 14 5 15 O 170 50H 95 7482 3 850 950 0 7 1 5 E l i t e1 Eclat auto Esp S3 Std Spec 9 DHLA 45E A912E094OJ A912E094LJ 5324A 5324P Blue 37 m 160 230 7772 8 55 7850 9 8 5g 14 5 15 O 170 50H 95 7482 3 850 950 0 7 1 5 Ek...

Page 19: ...sition Spec 4 6 7 8 1 27 mm 0 050 in Slow running speed 950 1000 rpm Idle CO level normal running tempemture Spec 2 without air injection 2 5 4 0 CO Spec 4 6 This must be checked with the air injection disconnected and a reading taken via a sample pipe before the catalyst To disconnect the air injection remove the air outlet hose between outlet and non return valve from the air pump and blank off ...

Page 20: ...plug gap with contact breaker 0 6 mm 0 023 in with high energy ignition 0 9 rnm 0 035 in DISTFSBVPOR IGNITIaJ TIMING A l l figures 2 Spec 2 25D 8 O 8 0 41584 Retard Spec 3 25D blanked 16 16 41584 off Spec 4 6 25D 8 8 0 41634A Retard 45D 41626 Spec 5 23D4 ar 43D 9 416231 Spec 7 8 45D 41626 8 10 2 with Retard Livnenition I I I I spec 9 43D with go Lumenition Ehergy Iqn Spec 10 45D 419461 w 10 lo0 Cc...

Page 21: ...to O 30 52O 2 4 changed during 1978 to 60 3 o o oO 90 180 270 1 0 1 8 0 23 Microfarad Cooling System TYpe Centrifugal pump and electric fan Header tank cap relief valve pressure 2 2 2 2 0 7kg crn IOIb in or 1 lkg cm 15lb in Thermostat Temperate climates 8 2 High ambient temperatures 74Oc lmpellor vanes to water pump housing 907 0 50 0 75 mm 0 020 0 030 in clearance 912 0 25 0 40 rnm 0 010 0 016 in...

Page 22: ...ch assembly Torque convertor to flexplate O i l sump to main bearing housing 907 O i l sump to main bearing housing 912 Auxil iary housing to cylinder block Auxiliary shaft sprocket Oil pick up pipe union Retaining nut be1t tensioner All other 6mm nuts or setscrews Stud Cylinder head to cylinder block 12mm Main bearing housing 8mm Main bearing housing 12mm Camshaft housing to cylinder head 8mm Sum...

Page 23: ... off pssition Spec 4 6 7 8 1 27 mm 0 050 in Slow running speed 950 1000 rpm Idle CO level normal running temperature Spec 2 withour air injection 2 5 4 0 CO Spec 4 6 This must be checked with the air injection disconnectedand a reading taken via a sample pipe before the catalyst To disconnect the air injection remove the air outlet hose between outlet and non return valve from the air pump and bla...

Page 24: ...NGK BPR7ES Spark plug gap with contact breaker 0 6 mm 0 023 in with high energy ignition 0 9 mm 0 035 in DISTRIBUTOR IGNITICN TIMING A l l figures 2 Distributor W P I Spec 5 1 23D4 or 4 3 1 3 1 41623 Spec 7 8 145D 41626 Spec 9 43D with L m i t i o n wkb Vacuum CaPsae crank0 8 Retard 8 Retard blanked off 8 Retard 8O Retard 22 Advance S t a t i c Ignition Timing m 12 8 16O 8 9 lo0 9 10 Idle Speed Ig...

Page 25: ...8 to 6d0 2 3 O 52O f4 O changed during 1978 to 60 f 3 o o oO 90 180 270 1 0 18 0 23 Microfarad Cooling System TYpe Centrifugal pump and electric fan Header tank cap relief valve pressure 2 2 2 2 0 7kg cm lOlb in or 1 lkg cm 15ib in Thermostat Temperate climates 8 2 High ambient tempemtures 74Oc lmpellor vanes to water pump housing 907 0 50 0 75 mrn 0 020 0 030 in clearance 912 0 25 0 40 rnm 0 010 ...

Page 26: ... Torque convertor to flexplate O i l sump to main bearing housing 907 O i l sump to main bearing housing 912 Auxiliary housing to cylinder block Auxii iary shaft sprocket O i l pick up pipe union Retaining nut bett tensioner A l l other 6mm nuts or setscrews Stud Cylinder head to cylinder block 12mm Main bearing housing 8mm Main bearing hovsing 12mm Camshaft homing to cylinder head 8mm Sump to mai...

Page 27: ...gine Specification Cylinder Head Camshafts Valve Timing Valve Gear Avxiliory Shaft Crankshaft Main Bearing Configuration Flywheel Gnnecting Rod Gudgeon Pin Piston Liner ubrlca tion System Dellorto Carburettor Ignition System ercpe Settings I DEC 1986 Page 7 Page 2 ...

Page 28: ...ia Swi tzerland H Canada 49 States N America J California L 50 States N America C Standard D Air Conditioning A High Compression P High Compression Air Conditioning Wet Sump Introduction From 1980 until late 1981 early 1982 a11 Turbo Esprit engines type 910 were built with a dry sump lubrication system C a r s not fittedwith air conditioning were changed to a wet sump configuration in late 1981 fo...

Page 29: ... 65 bar 9 5 lb in Engine number location On top rear of cylinder block near starter mounting Engine belt tensions Toothed timing belt using Burroughs gauge part number TOOOG0025J 90 95 units cold 60 200c See Section W 9 Alternator V belt 12 mm 0 5 in 4in Total movement using moderate finger pressure on longest be1t run CYLINDER HEAD Compressor V belt A C Vacuum Pump V belt Air Pump V belt 1 9 rnm ...

Page 30: ...104 100 45O 35 47 35 65 mm 1 396 1 404 in 30 70 30 90 mm 1 209 1 217 in 7 125 7 137mm 0 2805 0 2810 in 7 955 7 970 mm 0 31 32 0 31 38 in 0 008 0 046 mm 0 0003 0 001 8 in 0 030 0 070 mm 0 0012 0 0027 in 0 13 0 18 mm 0 005 0 007 in 0 25 0 31 mm 0 010 0 012 in Cam Pulley Timing Dot green green blue Lift 0 378 0 378 0 378 Bore in head Standard 104O 110 110 0 025 mm 0 001 in 0 050 mm 0 002 in 0 127 mm ...

Page 31: ... mm 48 5 mm 1 1 66 i n 1 9 1 i n Valve Guides Rate I I n n e r I O u t e r 1 0 Length lnlet and Exhaust 53 34 mm 2 100 in Internal diameter to ream after fitting Inlet 7 145 7 1 70 mm 0 281 3 0 2823 in Exhaust8 000 8 025 mm 0 3150 0 3159 in Bore in head lnlet and Exhaust Standard 11 915 11 925 mm 0 4690 0 4695 in 0 025 mm 0 001 in 11 940 11 950 mm 0 4700 0 4705 in 0 050 mm 0 002 in 11 965 11 975 m...

Page 32: ... journal No 5 only Crankpin End float Dimension Controlled by Bearings main Number Type Static clearance Maci undenize for regrind 0 025 0 065 mm 0 0009 0 0025 in 0 013 0 038 mm 0 0005 0 0015 in Within 15 gr cm 0 2 oz in 63 L C 8 7 63 51 3 mm 2 4995 2 5005 in 63 500 63 51 3 mm 2 5000 2 5005 in 50 736 50 762 rnm 1 9975 1 9985 in 0 08 0 20 mm 0 003 0 008 in Selective thrust washers on rear main bear...

Page 33: ...ured with Plastigage GUDGEON PIN Type Location Diameter Class of fit PISTONAND LINER Fully floating Circlips 25 40 mm 1 00 in Finger pushfit at20 c 68 Piston Type Material Rings Diameter 910 Std grade A 910 Std gmde 8 910 HC grade A 910 HC gmde B Grade diameter 910 Std 910 HC Gudgeon pln bore offset 910 Std 910 HC Solid skirt Aluminium alloy 2 compression 1 oil control 95 148 95 161 mm 3 7460 3 74...

Page 34: ... axis 95 275 95 288 mm 3 751 0 3 7515 in 95 288 95 308 mm 3 751 5 3 7520 in Measured 70mm from top across thwst axis 95 255 95 269 mm 3 7502 3 7507 in 95 267 95 281 mm 3 7507 3 El2 in 0 025 0 13 mm 0 001 0 005 in minus 0 025 to O 05Omm minus 0 001 to t 0 002 in 0 03 mm 0 001 in 0 1 1 0 15 rnm 0 005 0 006 in 0 048 O O76 mm O OM O O03 in LUBRICATION SYSTEM Minimum oil pressure under normal working c...

Page 35: ...psi Page 9 omestic Export HC DHLA 45M 5390A 5389P A91OE6855F A91OE6856F 35 mm 160 180 7772 14 58 7850 9 8 5g 14 5 15 Omm 200 35 80 7482 3 850 950 rpm 1 0 0 5 8cc 0 stks Blank 4 0 0 5 psi I USA DHLA 45M A910E6633 A910E6632 37 mrn 165 230 7772 13 5 2 7850 9 8 5g 14 5 15 Omm 200 38H 80 7482 3 950 rpm 0 8 8cc 20 stks 110 4 0 4 5 psi IGNITION SYSTEM Type Domestic ROW 1980 early 1983 Coil anddistributor...

Page 36: ... Lucas Constant E n 45m4 Lucas Constant E ewY B e l w 1 000 n i l 2 000 8 3 000 16 1 1 BTDC BTDC 18O pdvance 28O Advance B e l w 1 000 nil 1 500 3 O 2 100 12 2 800 15 5 000 16 Idle 950rpn LEA Prior 86 MY Carb LEA 86 MY onward HCI m Export 87 MY onward 15O 15 BTDC BTDC 2 500 minus 3 5 000 minus 6 45m4 Lucas Constant Ener9 Y 45DM4 Lucas Constant Energy Idle 900 1ooorpn Hot Idle 850 950 rpn f d l a 4...

Page 37: ...pick up pipe union Retaining nut be1t tensioner All other 6 mrn nuts or setscrews Stud Cylinder head to cylinder block 12 mm Main bearing housing 8 mm Main bearing housing 12 mm Camhaft housing to tylinder head 8 mrn Sump to main bearing housing Wastegate to adaptor 1Omm All other non specified 8mm studs Exhaust manifold to cylinder head Wastegate to adaptor Inlet manifold to cylinder head Engine ...

Page 38: ...ON TD D TECHNICAL DATA Page 1 SECTION TD D VEHICLE ESPRIT 53 6 TURBO Page Dimensions Capacities Suspension Steering Clukh Transmission Cooling System Brakes Wheels Tyres Electrical Equipment Torque Settings ...

Page 39: ...rbo Dom Exp 85 MY on 1225 kg 2701 lb p ot wLp r Turbo USA 1226 kg 2703 Ib 308 Gross Weight Series 3 1340 kg 2955 Ib Turbo Dom Exp prior to 85 MY 1389 kg 3063 Ib Turbo Dom Exp 85 MY on 1452 kg 3202 Ib Turbo USA 1453 kg 3200 Ib 1 crlc w CAPACITIES Exce t Drv sum Turbo Engine inc fllter Dry Refill Difference between high and low dipstick marks Dry Sump Turbo Engine inc filter Dry Refill Difference be...

Page 40: ... b a r C h a s s i s h e i g h t below c h a s s i s f r o n t crossmember 170 mm f o r checkLng s u s p e n s i o n g e o m e t r y Camber 0 3 0 n e g a t i v e f 0 3 0 C a s t o r min l o 45 max 3 w i t h i n 0 3 0 s i d e t o s i d e Toe i n 1 6mm e a c h s i d e 0 1 mm S t e e r i n g Axis I n c l i n a t i o n K P I 9 23 nominal F r o n t Hub E n d f l o a t 0 05mm 0 0 0 2 i n maximum R e a r...

Page 41: ... to water pump houring clearance SECTION TD D a Single dry plate Diaphragm spring Hydraulic 15 88 mm 0 625 in 17 78 m m 0 700 in 22 23 mm 0 875 in 216 mm 8 5 in 241 m m 9 5 in 6 3 mm 0 12 in Self adjusting slave cylinder Manual 5 forward gears all syncromesh and reverse Speed in mph k 14 in wheels Cooling system anti freeze corrosion inhibitor DEC 1986 5 teeth 17 teeth I per 1000 rpm 15 in wheels ...

Page 42: ...ical o p e r a t i o n o f r e a r p a d s S e l f a d j u s t i n g WHEELS TYRES 20 0mm 0 7 9 i n S e r i e s 3 w i t h 14 w h e e l s 12 0mm 0 4 7 i n 9 0mm 0 3 5 i n Wheels I ype Size front rear Tyres Type Size front rear spare if fitted Pressure front 19 0mm 0 7 5 i n rear spare 1l Omm 0 4 3 i n S e r i e s 3 w i t h 15 w h e e l s and Turbo Wheels Type early Turbo aIi others Size front rear T...

Page 43: ...ets and with t h e t y r e p r e s s u r e s of o nly t h e l a t e r spec t y r e s i n c r e a s e d a s below a Tyre Pressures P r e 85 M Y c a r w i t h P r e 85 spec t v r e f r o n t 1 45 b a r 2 1 l b i n 2 r e a r 1 70 b a r 2 5 l b i n 2 1 s p a r e 2 05 b a r 30 l b i n 2 P r e 85 c a r w i t h 85 onwards spec t y r e f r o n t 1 60 b a r 2 3 l b i n 2 rear 1 90 b a r 2 7 l b i n 2 s p a...

Page 44: ... o l o w e r l i n k xDamper t o p stem t o c h a s s i s Wheel n u t s o r b o l t s Front Suspension 1985 M Y onwards Page 7 Motorola 70 amp Motorola 90 amp Lucas 2M100 pre engaged 1 02 kgf 36 ozf 40 amp 6 000 rpm 1 99 kgf m 14 4 Ibf ft 463 amps Chloride type 385 Tungstone type 065 Tungstone type 088 55 amp hr 255 amp cold start 330 amp cold start 1 min 1 8 to 1 4 VPC k g f m l b f f t 11 0 15 0...

Page 45: ...e n e d S t e e r i n g r a c k a s s e m b l y t o c h a s s i s 1 7 1 9 12 14 Upper column l o w e r b o l t s 1 1 1 7 8 12 S t e e r i n g column l o c k b o l t s Break o f f t 1 t y p e S t e e r i n g wheel t o column 4 2 4 8 30 35 U n i v e r s a l j o i n t clamp b o l t s 2 2 2 8 16 20 T i e rod l o c k n u t s 6 9 8 3 50 60 Tie r o d end t o s t e e r i n g arm 4 2 4 8 30 35 B r a k e s ...

Page 46: ...t Procedure Page 2 t o 6 7 8 819 9 t o 11 11 12 t o 14 14 t o 16 16 t o 18 19 t o 21 21 t o 24 25 t o 27 27 t o 29 Pearlescent White Paint Procedure B A 13 29 130 Paint Removal B A 14 30 Tne paint procedure contained i n t h i s section is based on t h a t used i n t h e manufacture of Lotus C a r s and commences with t h e bare composite bodyshell It is included here only f o r general guidance i...

Page 47: ...c polyurethane p a i n t s of t h e P420 421 422 l i n e S p r e f i x p a i n t codes were used f o r a s h o r t period only 1976 77 and i n d i c a t e t h a t t h e body was moulded with i n t e g r a l colour using ICI 2 K two pack polyurethane p a i n t of t h e P407 l i n e These c a r s may be r e p a i r e d using ICI PO30 l i n e n i t r o c e l l u l o s e ICI P a i n t Reference Number...

Page 48: ...able Indigo Blue SUPPLIER SPEC NO PJ 0170Y2790 ICI PO302854 PJ 617021280 ICI PO307210 PJ 617021290 PJ 6170x0540 ICI PO309049 PJ 6170x5350 ICI PO308385 PJ 6170x4570 ICI PO306853 PJ 6170x3940 ICI DO309547 PJ 0235X9050RZ ICI Non Gloss PJ 617021920 ICI PO307557 PJ 6170Y3140 ICI PO306854 PJ 6170Y5960 ICI PO309053 PJ 6170A1130 ICI PO314339 PJ 6170W2230Rl ICI PO309052 PJ 617025980RJ ICI PO309055 ICI PO30...

Page 49: ...ecoat Garnet Basecoat V e r s a i l l e s Red Midnight Blue C r y s t a l Blue Calypso Red M a r t i n i Green Essex Blue B r i t i s h Racing Green B r i t i s h Racing Green B r i t i s h Racing Green SUPPLIER SPEC NO I C I PO314963 PJ 6170x2097 I C I PO309501 PJ 6170Y4817 I C I P030TW25028 PJ 6170x5150 I C I PO308662 ICI PO307517 I C I PO309257 I C I PO313141 I C I P030DC27 I C I PO314984 ICI P...

Page 50: ...tallic Black Martini Green Onyx SUPPLIER LOTUS SPhC NO PART NO R E M A R K S PJ 6170A3130 A036B6345V Elan s p r i n t bumpers PJ 6170A8020 A036B6313V Elan bumpers A036B6355V 2s roof ICI P407701 A076B6024V ICI PO30101 ICI P407717 A076B6025V ICI PO30437 ICI P407783 A076B6026V ICI PO30455 ICI P407720 A076B6034V ICI PO30457 ICI P407738 ICI PO30113 ICI P420113 A076B6060 c l e a r ICI P420122 A089B6151V...

Page 51: ...opper Mediterranean Blue I c e Blue Dark Blue Essex S i l v e r New Gold F i a t Grey C h r y s l e r S t e e l Grey Sikkens F158979 ICI P4207517 ICI P4200455 ICI P420GJ23 c l e a r c l e a r ICI P4220628B ICI P4220691 ICI P4229373 ICI P421 5031 ICI P4216056 ICI P4217222 ICI P4217215 ICI P4217220 ICI P4217219 ICI P4217379 ICI P4217221 ICI P4214491 I C I P4215310 t c l e a r c l e a r c l e a r c l...

Page 52: ...d r e f e r t o ICI Health and S a f e t y Information Sheet PV1 S t o r e t h i n n e r s i n accordance w i t h t h e Petroleum Consolidation Act 1928 and t h e Petroleum Mixtures Order 1929 and i n a c o o l p l a c e S t o r e p a i n t hardener and c l e a r c o a t i n accordance with t h e Highly Inflammable Liquids and L i q u i f i e d Petroleum Gas Regulations 1972 Use o n l y a non smok...

Page 53: ...orm a sandwich of p a i n t p r i m e r p a i n t BA 3 B O D Y AND COMPONENT PREPARATION FOR PRIMER COATING 1 Dry f l a t t h e e n t i r e s u r f a c e a r e a u s i n g 240 grade paper Carborundum type t o ensure t h a t t h e r e is no t r a c e of wax o r g l o s s The o p e r a t i o n i s a c l e a n i n g p r o c e s s i n o r d e r t o provide a s u i t a b l e s u r f a c e f o r p a i n...

Page 54: ...a c e s t o be p a i n t e d The s o l v e n t t o be used is Flowline Wax and Grease Remover Ensure t h a t new c l o t h s of woven m a t e r i a l a r e used and t h a t they a r e changed frequently during use so a s t o ensure s u r f a c e c l e a n l i n e s s remove a l l t r a c e s of rubbing down sludge 2 Thoroughly Tak Rag a l l s u r f a c e s t h a t a r e t o be painted t o remove a...

Page 55: ... of t h e body and i t s components Enter t h e booth and Tak Rag t h e body and components f u l l y removing a l l t r a c e s of d u s t and sludge from t h e s u r f a c e s t o be sprayed 7 Immediately a f t e r t h e Tak Rag operation e n t e r t h e spray booth and spray one s t r a i g h t c o a t and one c r o s s c o a t of grey polyurethane primer mixed a s below P U Primer A075B6124 25...

Page 56: ...c o a t adhesion 11 The f i n a l wash down must be c a r r i e d out with de ionised water Dry off thoroughly 12 Before colour coating it is e s s e n t i a l t h a t t h e body and components have a properly cured smooth unbroken and clean polyurethane surface and t h a t they a r e kept dry under cover and out o f d i r e c t r a i n f a l l BA 5 BODY COMPONENT PREPARATION F O R COLOUR COATING ...

Page 57: ...ore P105 0082 converter t h i n n e r t o achieve t h i s v i s c o s i t y 2 Immediately a f t e r t h e Tak Rag operation e n t e r t h e p a i n t spray booth and spray a l i g h t m i s t coat i n s i d e t h e body With spray gun a i r only blow down t h e outside surfaces 3 Spray one s i n g l e c o a t allow s o l v e n t s t o f l a s h o f f t h e 10 minutes one c r o s s coat and a f i n...

Page 58: ...2 and t h i n t o t h e recommendation 8 Apply one coat of paint over a l l r e c t i f i c a t i o n a r e a s wheel arches and apertures and allow 10 minutes f l a s h o f f Continue t o cover a l l surface area t o be painted with one s i n g l e c o a t Allow 10 minutes f l a s h off and spray one c r o s s coat t o a l l surfaces of body and components Wet film thickness 6 thou 9 Allow 30 min...

Page 59: ...1 with de ionised water Remove solvent with a clean new woven c l o t h s changing r e g u l a r l y 2 Mix colour paint a s below For Mono colours ICI P420 Paint 4 p a r t s by volume I C I P210 0760 Hardener 2 p a r t s by volume ICI P850 1196 Thinner 1 part by volume For Metallic colours I C I P421 Paint 4 p a r t s by volume ICI P210 0760 Hardener 2 p a r t s by volume I C I P850 1196 Thinner 2...

Page 60: ...second s i n g l e coat Allow 10 minutes f l a s h off Spray double dust coat Allow 45 minutes f l a s h off 4 Mix c l e a r coat as follows ICI P190 0379 Clear Coat 4 p a r t s by volume I C I P210 0760 Hardener 2 p a r t s by volume ICI P851 0727 Retarder 3 p a r t by volume I C I P850 1212 Thinner 1 p a r t s by volume Spraying v i s c o s i t y is 14 t o 16 seconds BSB4 cup a t 18O material te...

Page 61: ...b l a c k and hammerite t o c u r r e n t s p e c i f i c a t i o n 9 Hand p o l i s h t h e body and components using c l e a d woven c l o t h and M i r r o r g l a z e MGM8 p o l i s h B A 8 P422 LINE 2 PACK ACRYLIC POLYURETHANE SPRAYING I f a c a r f i n i s h e d i n I C I P422 l i n e a c r y l i c polyurethane i s t o be t o t a l l y r e s p r a y e d e i t h e r P422 o r P421 l i n e p a ...

Page 62: ... l e a v e a s c r a t c h f r e e s u r f a c e S p e c i a l c a r e must be taken i n a l l a r e a s a s t h e basecoat c l e a r system a c c e n t u a t e s any s c r a t c h marks 5 E n t e r s p r a y booth and s o l v e n t wipe u s i n g Isopropanol mixed 1 l w i t h c l e a n w a t e r Remove s o l v e n t w i t h c l e a n new woven c l o t h s changing r e g u l a r l y Tak Rag thorou...

Page 63: ...i n t h e f l a s h booth 14 Transfer body and components t o t h e paint curing oven and c u r e f o r 50 minutes a t 80 C 176OF panel temperature 15 Exit oven and allow t o a i r cool t o room temperature F l a t t h e painted surface using wet 1200 grade paper 3hi The f l a t t i n g medium f o r t h i s operation is 1L4 p i n t Finadet No 1 t o 2 gallons o f clean water a 16 Using I C I 2B rub...

Page 64: ...nches from t h e panel s u r f a c e When cool wet f l a t t h e r e p a i r e d area u s i n g 240 grade paper 3M and small hand blocks Confine f l a t t i n g t o t h e f i l l e d a r e a only F l a t t i n g medium i s 1 4 p i n t Finadet No 1 t o 2 g a l l o n s clean water 3 G e l crack d e f e c t s where p o s s i b l e should be returned t o t h e body preparation a r e a I f g e l cracks...

Page 65: ... a t 24 inches from t h e panel s u r f a c e Vet f l a t t h e r e c t i f i e d a r e a s using 400 grade paper 3M Do not rub through t h e polyurethane 7 Mix primer s u r f a c e r a s below Surfacer 22 white A036B6396 and thinner 222 A036B6385 t o 25 28 seconds BS4 cup a t 18 20 C 64 68OF m a t e r i a l temperature Spray with I A D L2 gun with m a t e r i a l nozzle No 6 needle No 6 and p r e...

Page 66: ...c e s of rubbing s l u d g e and d u s t When completely dry u s i n g ICI 2B rubbing compound machine p o l i s h t h e p a n e l s Keep t h e p o l i s h i n g mop moist and do not a l l o w t h e compound t o d r y on t h e mop a s s c r a t c h i n g may r e s u l t Clean t h e mops f r e q u e n t l y where p o s s i b l e t h e mop should be moved i n a f o r e and a f t d i r e c t i o n Us...

Page 67: ...de paper 3M t o complete Mix p a i n t a s follows PO30 type mono paint 40 p a r t s by volume A036B6385 222 t h i n n e r 60 p a r t s by volume t o give 22 secs BS4 cup a t 21 C 70 F This t o be sprayed using a Binks Bullows pressure pot gun Spray l i g h t c o a t s t o o b t a i n d e s i r e d colour matching Continue t o complete a s i n A above Gel Cracks Remove t h e p a i n t primer and g...

Page 68: ... i f i e d a r e a u s i n g hand b l o c k s l u b r i c a n t and 400 grade paper 3M Do not rub through t h e polyurethane I f t h e polyurethane s u r f a c e i s p i e r c e d i t w i l l be necessary t o r e p e a t t h e priming procedure Dry thoroughly d e g r e a s e u s i n g Flowline wax and g r e a s e remover and proceed on t o p r i m e r s u r f a c e r p a i n t i n g and p o l i s ...

Page 69: ...sing 800 grade paper Norton with l u b r i c a n t Dry thoroughly and carry on t o rubbing compound and polishing treatments a s i n A above Panel Chips If t h e s e chips a r e down i n t o t h e gel coat it is necessary t o use P38 polyurethane primer primer surfacer and p a i n t a s described i n C above Scratches minor These should be t r e a t e d a s f o r edge and corner chips above i e to...

Page 70: ... and Tak Rag prepared Clear lacquer should be mixed a s follows I C I P190 0379 C l e a r c o a t 4 p a r t s by volume I C I P210 0760 Hardener 2 p a r t s by volume ICI P850 1212 Thinner 2 p a r t s by volume V i s c o s i t y 23 t o 27 seconds BS4 cup a t 18OC 64OF m a t e r i a l tetoperature I f necessary add more P850 1212 t h i n n e r t o achieve t h i s v i s c o s i t y Mask o f f a r e ...

Page 71: ...ray one s i n g l e coat of c l e a r lacquer allow 15 minutes t o f l a s h o f f a t 18OC 64OF and spray the f i n a l lacquer c o a t Leave t o f l a s h o f f f o r 30 minutes a t lS C 64OF and then apply i n f r a r e d h e a t i n g f o r 30 minutes a t a panel temperature of 60 C 140 F Allow t o a i r cool and then wet f l a t using 1200 grade paper 3M followed by compound and p o l i s h i...

Page 72: ...ey m e t a l l i c Lotus p a r t no A089B6113V I C I P421 5310 and c l e a r l a q u e r u s i n g a f l e x a i d a d d i t i v e i n b o t h c o l o u r and c l e a r c o a t s 1984 model year Excels On m e t a l l i c c a r s RRIM p a r t s a r e p a i n t e d i n t h e same P421 l i n e p a i n t a s i s t h e body t o g e t h e r w i t h a c l e a r l a q u e r and f l e x a i d a d d i t i v...

Page 73: ...llow 10 minutes t o f l a s h o f f and spray one c r o s s coat Allow 30 minutes f l a s h o f f before stoving a t 80 C f o r 50 minutes Rectify minor blemishes with c e l l u l o s e stopper and prepare f o r spraying second c o a t Spray second c o a t a s above and i f necessary with m e t a l l i c c o l o u r s a d u s t c o a t t o rninimise shading For mono c o l o u r s allo 30 minutes f...

Page 74: ...onaco w h i t e L C 1 P420 7517 and a l l o w 45 min f l a s h o f f b e f o r e a p p i y i n g t h e p e a r l e s c e n t c o a t 3 P e a r l e s c e n t F i n i s h A089B6184V I C I 4 2 1 7 8 6 5 Mixing R a t i o P e a r l e s c e n t 4 parts by volume Hardener P210 760 1 p a r t s by volume T h i n n e r s P850 1212 4 p a r t s by volume S p r a y i n g v i s c o s i t y is 16 18 secs BS4 c u...

Page 75: ... c o a t a p p l i c a t i o n 3 F o l l o w p r o c e d u r e BA12 t o a p p l y a c l e a r c o a t o f I C I P190 0379 BA 14 PAINT REMOVAL Under n o c i r c u m s t a n c e s m u s t P a i n t S t r i p p e r be u s e d t o r e m o v e p a i n t f r o m g l a s s f i b r e r e i n f o r c e d p l a s t i c G F R P b o d i e s a s t h i s w i l l a t t a c k t h e g e l c o a t w h i c h MUST o ...

Page 76: ...ures Bodycare General Description Accident Damage Assessment Resin Mix Basic Bonds and Joints Headlamp Bowls and Surrounds Pin Holes or Air Voids Distortion or Wrinkling Split Bonds Replacement Sections Positioning Replacement Panels Bobbins Metal Inserts Body Mounting Points Operation Page I Page ...

Page 77: ... d throughout t h e bodyshell and components t o provide e f f i c i e n t s t r u c t u r e s of high s t r e n g t h and low weight The passenger compartment i n a l l Lotus models i s enclosed by p r o t e c t i v e s t r u c t u r a l beams b u i l t i n t o t h e bodyshell and doors which combine t o provide maximum occupant p r o t e c t i o n Composites have t h e a b i l i t y t o absorb h...

Page 78: ... flexibility of the paint finish which covers the gel coat In some instances gel cracks can take as long as three months to appear Gel cracks can be caused by for example Sitting or leaning heavily on the bonnet or any other flexible panel Knocking doors against obstructions when opening Dropping a sharp or heavy object on a panel Allowing unsecured items to slide about in the boot trunk Closing b...

Page 79: ...b e s t safeguard a g a i n s t unseen contaminants a t t h e same time ensuring t h e r e g u l a r removal of d i r t d u s t and t r a f f i c film I f washing with c o l d water i s not e f f e c t i v e warm water and d e t e r g e n t w i l l remove t h e gummy d e p o s i t s exuded by some t r e e s i n t h e summer months P e t r o l o r white s p i r i t w i l l remove s t a i n s of t h...

Page 80: ...amination with warm water p e t r o l o r white s p i r i t a s a p p r o p r i a t e 3 U s e a good q u a l i t y l i q u i d p o l i s h i n f r e q u e n t l y s a y twice a year t o r e s t o r e high g l o s s and t o remove accumulated t r a f f i c f i l m and scum 4 Park on a hard s t a n d i n g and under c o n d i t i o n s of good v e n t i l a t i o n i f a covered a r e a i s used Win...

Page 81: ... r should be wiped over occasionally with a c l o t h dampened i n warm soapy water Repeat t h e operation using a f r e s h c l o t h and water only avoid flooding the l e a t h e r f i n i s h by drying and polishing with a s o f t dry c l o t h It is important t o use a mild non c a u s t i c soap of t h e t o i l e t kind o r Lux soap f l a k e s and t o avoid t h e use of p e t r o l o r dete...

Page 82: ... r e incorporated within t h e moulded s e c t i o n s by u t i l i z i n g t h e high t e n s i l e and s t r e n g t h c h a r a c t e r i s t i c s of t h e various types of f i b r e reinforcement used BB 4 ACCIDENT D A M A G E ASSESSMENT A l l damage to t h e body must be classed a s s t r u c t u r a l However i n s i d e t h i s broad c l a s s i f i c a t i o n t h e damaged a r e a can be...

Page 83: ...t a l y s t i n t o t h e r e s i n i n t h e proportions of 15cc of c a t a l y s t t o 1 kg 21b o r r e s i n Mix r a t i o 1 150 For Gel coats mix 20cc of c a t a l y s t with 1 kg 2 l b of g e l B B 6 BASIC BONDS AND JOINTS Cut off t h e damaged portion a f t e r marking f o r re positioning of t h e new panel Clean and prepare both e x i s t i n g and new panels removing a l l road f i l t h ...

Page 84: ...s s e n t i a l f o r t h e correct operation of t h e headlamp assembly t h a t t h e replacement section is c o r r e c t l y positioned t h e bowl being attached t o t h e pivot bobbins of t h e new section and t e s t e d f o r clearance i n t h e up and down position before being bonded t o t h e c a r The bowl should be fixed i n t h e most convenient position by taping i n place before lami...

Page 85: ...een caused by t h e f i l l e r shrinking When c e l l u l o s e p a i n t stopper i s used o v e r f i l l a s t h i s stopper has a high r a t e of shrinkage Depressions i n t h e p a i n t s u r f a c e when using a p o l y e s t e r stopper a r e u s u a l l y caused by p a i n t i n g t o o soon a f t e r t h e r e p a i r Therefore befoi e rubbing down and p a i n t i n g make s u r e t h e ...

Page 86: ... c a t i n g new s e c t i o n s c o r r e c t l y r e l a t i v e t o t h e e x i s t i n g panels These moulds a r e d e l i b e r a t e l y l e f t unframed so a s t o accommodate s l i g h t discrepancies and have been made on a standard painted body s h e l l t o allow f o r average paint thickness Due t o t h e material used i n construction of t h e body u n i t cases of severe damage can o...

Page 87: ...t i n consistency t o prevent gel coat crazing caused by small stones etc thrown up by the wheels BB 12 POSITIONING REPLACEMENT PANELS a Line up f l a t surface e g undertray o r f l o o r area using long wooden beams bolted t o undamaged area b Line up main contours e g wing sections using s p l i n t s and b o l t i n t o position with f l a t o r curved s t e e l s t r a p s BB 1 3 BOBBINS M E ...

Page 88: ...ld and body and through t h e bobbin before removing t h e r e p a i r mould Additional 4 i n 10 cm square patches t o make t o up 1 4 i n and 5 16 i n bobbins t h e equivalent of 5 x 1 oz l a y e r s 3 8 i n and 7 16 i n bobbins t h e equivalent of 7 x 1 4 oz 1ayers NOTE Number of patches t o be determined from t h e above The bobbin can then be d i r e c t l y laminated on t h e o l d mounting b...

Page 89: ...ady load with a small engagement of thread To avoid tightening up onto t h e p l a i n shank of t h e b o l t i s i s recommended t h a t only setscrews be used i e those threaded a l l t h e way up t o t h e head Laminating New Bobbin F i r s t l y the laminates from t h e basic mounting s u r f a c e must overlap and i n t e r l e a v e with t h e laminates around t h e bobbins Secondly t h e la...

Page 90: ... h a t t h e bobbin is positioned c o r r e c t l y i n accordance with t h e s p e c i f i c a t i o n concerned DO NOT apply Gel coat t o t h e bobbin s u r f a c e o r s i d e s I t is e s s e n t i a l t o keep t h e Gel coat t o a minimum thickness t o prevent crazing and d e s i r a b l e t h a t t h e general layup thickness t a p e r s gradually away from t h e bobbins Remember t h a t t e...

Page 91: ... s i n g f i x i n g s 1 2 3 4 11 1 2 Use washers where n e c e s s a r y t o avoid s t r a i n i n g any of t h e mountings and d r i l l t h e c h a s s i s f i x i n g h o l e s a t p o i n t s 5 6 7 and 8 by u s i n g a d r i l l through t h e body bobbins a t t h e s e p o i n t s Raise t h e body o f f t h e c h a s s i s once a g a i n and on t h e o l d c h a s s i s measure t h e p o s i ...

Page 92: ...Old body laminated in type bobbins onto new chassis Fit 12 x 28 x 2 5 plaln washer A075W9031F between chassis and body I Use washer A075W9031F b New body or body section bifurcated bobbins onto old chassis Cut 5 m m from the rear end of the crossmember tubes and fit a 12 x 28 x 2 5 plain washer A075W9031F between chassis and body use washer A075W9031F New body on old chassis ...

Page 93: ...AR Just ahead of front seat J u s t ahead of r e a r seat y i n position D r i l l with body i n position Body Bobbin tapped M10 Blind fix within r e a r I seat foam double skin D r i l l chassis before Sides of engine bay f i t t i n g body Below fuel tank i n boot RH ahead of fuel pump ...

Page 94: ... e r lowering t h e body o n t o t h e c h a s s i s check t h a t t h e p e d a l box mounting b o s s e s a r e n o t f o u l i n g t h e body L o c a t e t h e body by i n s e r t i n g f i x i n g s 1 1 12 1 3 1 4 on F e d e r a l c a r s but do n o t t i g h t e n I n s e r t s p a c e r s i f n e c e s s a r y between t h e body and c h a s s i s a t p o i n t s 1 2 and d r i l l c h a s s i...

Page 95: ...FRONT ESPRIT REAR v Front of footwells Chassis drilled with body in position ...

Page 96: ...m e D o o r D r o p G l a s s D o o r G l a s s E x t e r n a l W e a t h e r s t r i p D o o r Q u a r t e r L i g h t G l a s s D o o r S h e l l H e a d l a m p P o d s Front B o n n e t P a n e l T a i l g a t e Front B u m p e r R e a r B u m p e r a n d S p o i l e r E n e i n e B a v V e n t i l a t i o n D e c a l Positioning G l a s s R o o f A b u t m e n BD 1 B D 2 B D 3 BD 4 BD 5 B D 6...

Page 97: ...acement 1 Remove t h e i n t e r i o r A post f i n i s h e r s and screen header r a i l see section V 2 Remove windscreen e x t e r i o r bright t r i m and wiper arm Bore a small hole through the Betaseal and i n s e r t a length of piano wire o r s i m i l a r supplied i n Betaseal K i t approx 1 metre long through the hole With t h e a i d of an a s s i s t a n t i n s i d e the c a r use a s...

Page 98: ... t h e screen i n i t s aperture and provide a 6 7 mm gap between screen top edge and body 7 Clean up t h e laminated edge of t h e g l a s s with a sharp knife 8 Cut the s p e c i a l paper provided i n t h e Betaseal K i t i n t o two With one h a l f use Wipe Cleaner No 4 t o clean t h e perimeter of t h e g l a s s and t h e whole bonding area of t h e body flange With t h e o t h e r h a l f ...

Page 99: ...tre l i n e t o meet f i r s t cut as shown C Measure width of horizontal cut from inside surface t o t h e plane of t h e v e r t i c a l cut If t h i s dimension is less than 5mm cut further across a t 63mm height and then downwards as i n b u n t i l a width of 5mm is achieved D Cut a V notch as shown by continuing one s i d e of t h e vertical cut downwards t o a height of 52mm and intersect w...

Page 100: ... n t o m assembly Push e i g h t 4 mm spacer blocks A075U0588Z i n t o t h e Betaseal from t h e i n s i d e of the bead i n t h e p o s i t i o n s shown F i t t h e screen onto t h e body and use t h e two spacers made i n paragraph 6 t o support t h e g l a s s whilst the Betaseal cures Press gently a l l round t h e edge of t h e glass t o ensure uniform compression of t h e j o i n t Water t ...

Page 101: ...8 hours is r e q u i r e d f o r f u l l c u r e Curing w i l l be slower a t c o o l e r temperatures NOTE Under no circumstances must s i l i c o n d u s t wax e t c be p r e s e n t i n t h e atmosphere d u r i n g bonding A f t e r c u r i n g apply b l a c k S i l a s t i c around t h e b r i g h t t r i m o u t e r edge t o s e a l and b l a c k s t r i p A082U6072V t o t h e lower edge o f ...

Page 102: ...2 TAILGATE GLASS S e r i e s 3 The t a i l g a t e g l a s s i s f i t t e d using Betaseal i n a s i m i l a r manner t o t h e windscreen To replace a t a i l g a t e g l a s s and f i n i s h e r s follow t h e windscreen replacement procedure BD l but p o s i t i o n t h e spacer blocks A075U0588Z a s follows 7 6 5 Turbo The t a i l g a t e g l a s s is f i t t e d using Betaseal i n a s i m i...

Page 103: ...nd and g l a s s Follow t h e Betaseal procedure d e t a i l e d i n BD 1 t o c l e a n prime and bond t h e g l a s s t o i t s surround using s i x spacer blocks A075U0588Z around t h e periphery of t h e g l a s s R e f i t t h e surround t o t h e bulkhead using black S i l a s t i c t o s e a l R e f i t t r i m p a n e l s s e a t b e l t s e t c BD 4 REAR QUARTER LIGHT GLASS The r e a r q u...

Page 104: ...t h e outside perimeter of t h e g l a s s and i n s i d e surface of t h e ABS f i n i s h e r with methylated s p i r i t Wipe dry Apply S o l b i t Primer t o t h e i n s i d e surface of t h e ABS f i n i s h e r and when dry apply double sided tape B075U6070V Peel off t h e backing paper and f i t t h e f i n i s h e r t o t h e g l a s s Refit t h e a i r scoop extractor BD 5 DOOR WINDOW FRA...

Page 105: ...channel t o t h e g l a s s thoroughly clean t h e lower edge and s i d e s of t h e g l a s s and i n s i d e channel with methylated s p i r i t Apply S o l b i t Primer t o t h e lower edge and both lower s i d e s of g l a s s i n a band 12 mm ain wide Also apply t o whole i n s i d e surface of channel Allow t o dry S t r i p both ends of a 450 mm 18 i n length of 10 mm diameter S o l b i t t...

Page 106: ... o u t extruded S o l b i t Disconnect supply 8 F i t drop g l a s s i n t o frame and r e f i t door window frame i n t o door Adjust c a r r i a g e p l a t e t o o b t a i n smooth rise and f a l l of t h e drop g l a s s b e f o r e i n s t a l l i n g window motor Ref it door t r i m BD 7 DOOR GLASS EXTERNAL WEATHERSTRIP To remove w e a t h e r s t r i p f i r s t remove t h e door i n t e r ...

Page 107: ...ith methylated s p i r i t Also i n s i d e window frame channel 4 Apply S o l b i t Primer t o t h e edge of t h e g l a s s and a 6 mm 1 4 i n wide band on both s i d e s of t h e f r o n t and r e a r edge of t h e g l a s s Apply S o l b i t Primer t o a l l s u r f a c e s i n s i d e t h e frame channel 5 S t r i p b o t h ends o f a 1 4 mm 4 f t 6 i n l e n g t h o f 10 mm S o l b i t t o e...

Page 108: ...moved from t h e c a r by s l i d i n g o f f t h e door beam i n s i t u a f t e r removing t h e door window frame BD 5 and l a t c h mechanism fy fie BD 10 HEADLAMP PODS P i v o t F e d e r a l c a r s use a pod p i v o t b a l l j o i n t a t each s i d e of each pod t h e outboard b a l l j o i n t being r i v e t t e d t o t h e body w h i l s t t h e inboard b a l l j o i n t i s f i x e d ...

Page 109: ... R e l e a s e t h e pod outboard p i v o t b o l t and support t h e bonnet panel b e f o r e r e l e a s i n g t h e inboard p i v o t b o l t F e d e r a l o r removing t h e s p l i t p i n and s l i d i n g o u t t h e hinge p i n DOM ROW On r e f i t t i n g e n s u r e t h a t t h e pod i s l o c a t c d c e n t r a l l y u s i n g s p a c e r washers if n e c e s s a r y and t h a t t h e ...

Page 110: ...v o t takes t h e form of a bracket b o l t e d t o t h e roof Three types of t a i l g a t e l a t c h i n g system have been employed Domestic R O W Turbo models have a k e y lockable e x t e r n a l r e l e a s e knob on t h e r e a r s p o i i e r which is connected v i a a l i n k rod t o t h e r i g h t hand t a i l g a t e l a t c h Right and l e f t hand l a t c h e s a r e interconnected ...

Page 111: ...ased and t h e pivot b o l t s withdrawn Note t h a t t h e hinges a r e used t o transmit current t o t h e heated r e a r screen with one wire on each s i d e being f i t t e d beneath t h e pivot b o l t nut and then taken from t h e t a i l g a t e tapping screw t o t h e screen On glass roof c a r s a pivot bracket i s bolted t o the roof on each s i d e s o t h a t a f t e r removal of t h e...

Page 112: ...engine bay v i a t h e NACA duct i n each s i l l The engine airbox is f e d from t h e r i g h t hand i n t a k e vent e a r behind t h e r e a r q u a r t e r window On Federal c a r s t h e l e f t hand i n t a k e e a r i s used t o supply a d d i t i o n a l cooling a i r t o t h e c a r b u r e t t o r a r e a v i a a duct w i t h i n t h e engine cover l i d The engine bay cooling fan f i t...

Page 113: ...Page 20 BD 16 DECAL POSITIONING ESPRIT S3 Early 84 Model Year TAI LGATE NOSE ...

Page 114: ...SECTION BD Page 21 ESPRIT 53 Prior to Model Year Eucept a r l 84 Model Year FRONT REAR QUARTER Blend i n t o n a t u r a l contour s i m i l a r a t a l l wheelarches I NOSE ...

Page 115: ...Page 22 ESPRIT S3 85 Model Year On L REAR QUARTER SECTION BD Waistli ne Fi nisher 1 Stripe NOSE FRONT BUMPER ...

Page 116: ...ESSEX TURBO W a i s t l i n e f i n i s h e r 8omm 85mm 86mm damn 25mm 40mm f o r L o t u s logo o p p o s i t e s i d e N o lower 12mm chromc s t r i p e behim3 r e a r wheelarch I 23mm Nose badge ...

Page 117: ... l l d e c a l h e i g h t of 160mm t o 1 1 6 m a s used on F e d e r a l c a r s SECJlON BD L e f t Lib hand 115mm I s i d e No yap between lower door s t r i p e s s t r i p e and j o i n t l i n e Bonnet s h u t l i n e 150mm F e d e r a l 8Omm o m e s t i c o I N o gap between lower s t r i p e and j o i n t l i n e Not f i t t e d on F e d e r a l cars ...

Page 118: ... TURBO 85 Model Year On SIDE DECAL Waistline Finisher Page 25 g A 20mm from 7bottom edge Stripe Wrapped around Wheelarch Stripe Wrapped around Cut Flush to I Cut Flush to emper edges NOSE Nose Badge FRONT BUMPER ...

Page 119: ...sults i n m i r e r i g i d r e t e n t i o n of t h e roof panel w i t h l e s s l i a b i l i t y f o r r a t t l e s and squeaks The shimming of t h e r e a r c a t c h support b r a c k e t s t o t h e body may t h e n be a d j u s t e d f o r optimum panel h e i g h t and s e a t compression The r e v i s e d c a t c h support b r a c k e t s D082U4974F and r u b b e r b u f f e r s X046B6113...

Page 120: ...ECTION CB ESPRIT S3 TURBO PRIOR TO 85 MODEL YEAR General Description Lubrication Geometry Castor Adjustment Front Wheel Alignment Front suspension Disassembly Front Hub Adjustment Wheel Bearing Replacement Operation Page 2 3 4 4 5 6 6 6 7 ...

Page 121: ...nt Suspension General Layout i ...

Page 122: ...neral Layout Drawing Front Hub Brake Disc Wheel Bearing inner Wheel Bearing outer Oil Seal Front Hub Stub Axle Dust Cap Vertical Link Steering Arm Caliper Mounting Plate Dust Shield Upper Ball Joint Wishbone Arm Pivot Bush Wishbone Stud Wishbone Pivot Lower Trunnion Bush Kit Lower Trunnion Seal Trunnion Top Bolt Trunnion to Lower Link Lower Link Assembly Bush Lower Link Pivot Anti Roll Bar Bush An...

Page 123: ...y an oil filled grease gun to the nipple and pump until oil exudes from the trunnion top seal ing Plug CB 2 GEOMETRY Under normal service conditions i t should only be necessary to check the front wheel alignment A full geometry check i s only necessary following front suspension repair or if excessive tyre wear is evident or steering difficulties experienced Both wheel a1ignment and castor angle ...

Page 124: ...rs A075W4028Zf 2 5 mm thick are fitted between the mounting and chassis on both upper and lower bolts O n each side of the car an equal number of washers must be used top and bottom up to a maximum thickness of three washers Spacer washers ii From VlN 82 85D 1263 82 85 A E G H S 0411 l u s 0399 and 0400 c F B C F K 0104 Shim plates A082C4052 2mm thick may be slid i n behind the mountings after sla...

Page 125: ...bber bush pivots must be tightened only at ride height 150 and 175 m m at front and rear of chassis centre box section On the anti roll bar to lower link bush fixing note that a sp ecial chamfered washer i s fitted between the anti roll bar and the lower link front bush in order to provide for fillet clearance Ensure this washer i s fitted the correct way round L Chamfered Washer Distonce Tube Not...

Page 126: ...at alternate sides of each race Fit new outer races into the hub wing a press Pack the new bearings with an approved Lithium based wheel bearing grease and work well into the roller cages Coat the inside of the hub outer races and cap with grease lnsert the inboard bearing roller assembly and inner race and retain with new oil seal Mount the hub assembly onto the spindle and fit the outboard rolle...

Page 127: ... I FRONT SUSPENSI0 N SECTION CC ESPRIT S 3 TURBO 1985 MODEL YEAR ONWARDS General Description Geometry Castor Adjustment Suspension Disassembly Front Wheel Bearings Operation Page 2 t o 4 CCI 4 CC2 4 5 CC3 5 6 CC4 6 7 ...

Page 128: ...Layout of Front Suspension ...

Page 129: ...sh Upper Wishbone Stud Upper Wishbone Pivot Buffer Wusher Pivot Bush Nut Nyloc 3 UNF Locknut I1UNF Shim Washer Castor Adjust Ball Joint Upper Nut torqloc 7 16 UNF Bolt M8 x 100 Ball Joint Bolt M8 x 60 65 Ball Joint Nut Nyloc M8 Washer Plain Shimplate Castor Adjust Lower Wishbone Pivot Bush Wishbone Rear Pivot Bush Wishbone Front Bush ARB Wishbone C nl C I Ball Joint Lower 8 3 Nut Nyloc M I 4 Pivot...

Page 130: ...r 170mm bklow rear lowei l i n k chassis brackets Camber O0 30 negative 5 O0 30 Castor min lo 45 rnax 3O Within O0 30 side to side K P I 23 nominal Toe in 1 6mm each side 0 1mm CC 2 CASTOR ADJUSTMENT Cars prior to V lN 82 85 D 1937 Dom FF 0602 U S A may be fitted with castor adjustment shims A and 8 as illustrated These shims are available i n various thicknesses Shim Washer A 1 5mm A082C4091 I II...

Page 131: ...m to the chassis and remove assembly to bench Spring Top PIatform Spring Lower Platform Note that early 85 MY cars used parallel coil springs which were superceded by conical springs with the greater diameter fitted lowermat The dianieter of the spring seat on the damper body is correspondingly increased for use with conical springs If replacing a spring or a damper of the earlier parallel spring ...

Page 132: ...bolt i t i s necessary fint to remove the cylinder swing release bolt and swing up the cylinder until the brake pipe clean the caliper top fixing bolt 2 Remove the hub nut and pull off the hub complete with brake disc 3 Prise out the inner oil seal and remove the centre assembly of the inboard bear ing 4 The outer races of both bearings may be removed from the hub wing a drift as shown at alternat...

Page 133: ...mm socket With a suitable spring balance check the force needed to rotate the hub Preload With new oil seal With used oil seal 350 8759 0 8 1 9 Ib 50 500g 0 1 l lb 9 Using a dial gauge measure the hub end float Maximum 0 05mm 0 002 in lmtall the lock ring and split pin I f necessary tightening the hub nut further by by the smallest amount required Refit brake caliper and torque bolts Caliper to ve...

Page 134: ...TION DB ESPRIT S3 TURBO Operation General Description Geometry DBI Rear Wheel Alignment DB2 Rear Suspension Reassembly DB 3 Rear Wheel Bearing Removal D M Rear Wheel Bearing Installation DB5 Drive Shaft C V Joint Boot Replacement DBC Page ...

Page 135: ...a t e a r Suspension General Layout ...

Page 136: ...ut Nyloc Arm to Hub Carrier 16 Mounting Rubber Radius Ann Front 171 inforcing Plate Radius Arm Mounting 18 Spacer Radius Arm Mounting Bolt Radius Arm to Mounting Nut Nyloc Radius Arm to Mounting Washer Large Washer Toe In Adjustment Top Link Rubber Bush Top Link Bolt Top Link to Hub Carrier Lower Link Stud Lower Link to Hub Carrier Split Spacer Hub Carrier Damper Assembly Bush Kit Damper Top Stem ...

Page 137: ...le and accurate method is considered to be the use of para1lel bars as used on production Two ban which are longer than the overall length of the car and 4 axle stands are required The bars should be obtained locally and should be of T or square section and be sufficiently rigid to avoid significant bending or sagging between supports Set up the two ban on each side of the car at wheel centre heig...

Page 138: ...9D4051K Plus One 6mm spacer B079D4051K Ensure at all times that the mounting to chassis fixing bolts are of sufficient length to ensure full engagement of the nyloc fixing nuts NOTE On final assembly use a new nyloc nut on the bolt securing the radius arm to the rubber mounting and torque tighten to 5 5 6 2 kgf m 40 45 Ibf ft with the car at ride height DB 3 REAR SUSPENSION REASSEMBLY On reassembl...

Page 139: ... g t h e new b e a r i n g i n t h e h o u s i n g p r e h e a t t h e hub c a r r i e r t o approx 10oO C and s o a k a t t h a t t e m p e r a t u r e f o r 5 t o 10 mins A c o n v e n i e n t method is t o immerse t h e c a s t i n g f o r 10 m i n u t e s i n b o i l i n g water Do n o t exceed a t e m p e r a t u r e o f 150 C 3 Allow m o i s t u r e t o e v a p o r a t e from t h e hub carri...

Page 140: ... p u l o u s l y c l e a n b e f o r e f i t t i n g t h e washer and hub n u t i g h t e nt h e n u t t o 28 kgf m 200 1 b f f t a n d t h e n i f n e c e s s a r y t i g h t e n f u r t h e r t o e n a b l e t h e s p l i t p i n t o be f i t t e d It i s most i m p o r t a n t t h a t t h e n u t is n o t s l a c k e n e d t o i n s e r t t h e p i n R e f i t t h e hub c a r r i e r a s s e m ...

Page 141: ... seated in shaft groove 9 Fit both boot retaining c l i p a s tightly as possible by had before crimping with pliers i0 Ensure that crimp position of larger clip does not interfere with bolt hole access 11 Pack outer end of ioint with remaining grease 12 Fit new end closure plate ensuringbolt holes are aligned 13 Refit driveshaft ossembly to vehicle toque laadt 60 Ibf ft all driveshaft socket head...

Page 142: ... D i s t r i b u t o r O i l Pump and Auxiliary Housing I n l e t Manifold and C a r b u r e t t o r s O i l Sump Connecting Rod Big End Bearings Engine Assembly Flywheel and Ring Gear Crankshaft Rear O i l Seal Crankshaft P i s t o n s P i s t o n Rings Connecting Rods Cylinder L i n e r s Connection o f O i l Cooler Thermostat Turbo L u b r i c a t i o n System P r e c a u t i o n s S p e c i a ...

Page 143: ......

Page 144: ...ed The gudgeon pins are retained in position by circlips installed i n groovesat each end of the gudgeon pin bore A cast iron flywheel incorporating a steel ring driving gear for the starter is located on the crankshaft flange and retained by two dowels and six bolts fitted without lockwashers EA 1 LUBRICATION General The lubrication system is of the forced feed type the o i l being circulated by ...

Page 145: ...l to returh to sump The correct oil level i s to the upper mark onthe dipstick with the car on a level surface Add oil if netesiary throughthe filler neck on the inlet camshaft cover Do NOT overfill Replace filler a p securely The engine oil should be changed and a new filter fitted at the recommended service intervals Sump capacity is listed in TECHNICAL DATA and should be drained when the oil i ...

Page 146: ... clean with an air I ine Clean the float and float chamber using clean petrol Replace all jets needle valve body and needle valve Using a new gasket fit to float chamber cover replace float assembly Check float setting Refit float chamber cover Zenith Stromberg Carburetten Remove carburetters from the engine to a clean bench Release centre plug from the base of each carburetter Remove float chambe...

Page 147: ... sparking plug leads EAe4 CAMSHAFT COVERS Three different types of camshaft cover have been used A l l 907 engines and naturally aspirated 912 engines prior to 1986 use a saddle type cover with a curved joint face When ref i tting this type of cover i t is essential to use Silastic RTV 732 on the joint face of both housing and cover together with a new gasket D o not overtighten the fixings see To...

Page 148: ... View showing cam followers held by magnets 6 Remove the ten nuts and washers release the nuts diagonally inwards from the outside securing the camshaft housing Care MUST be taken to avoid drbpping any nuts or washers down the inside front of the camshaft housing Remove the housing and discard the gasket if fitted On Turbo engines it is necessary to remove the socket head access plugs and then to ...

Page 149: ...locations Place them in their respective fitting positions noting that the cam follower shims are almost always stuck to the underside of the cam follower If they are not then they will be stuck to the top of the valve stems Keep the shim with its respective cam follower shims ...

Page 150: ...ve thrust washer Remove bolt and washers securing the toothed sprocketto the camshaft Fig 4 Camshaft thrust washer 0 ring WASHER 10 Remove the assembly from the vice and pull off the camshaft sprocket 1 Remove the toothed belt snubber where fitted from the front of the inlet camshaft housing by releasing the two M8 nuts noting the eccentric sleeve fitted on the lower stud 12 Withtlieaidofatwo legg...

Page 151: ...of the camshaft housing insert camshaft into its housing from the front and fit a new front oil seal Fig 8 Camshaft oil OIL seal fitted SEAL Emure oil seal is flush with outer face of housing If seal is fitted to the shoulder inside housing the oil drain hole would be blocked a ...

Page 152: ...spindle and screw into the rear of the camshaft securely Fit the selective thrust washer over its locating dowel and fit the rear seal housing using a new 0 ring andoil seal Apply Silastic RTV 732 into the inside of the V pulley hub and fit onto the adaptor spindle ensuring that the dowel engages into thehub correctly Fit the V pulley onto the hub with the drive line insettowards theengine fit the...

Page 153: ...rfaces of the cylinder head and cam housing Take care not to scratch sealing surfaces use a blunt scraper such as the flat end of a steel rule Degrease and clean the mating surfaces using methylated spirit or similar Lay a thin continuous bead of gasket eliminator approx 1 16 to 3 32 in wide i n the middle of the sealing surface on the cam housing following the outer surface around the stud holes ...

Page 154: ...ptor spindle and screw into the rear of the camshaft securely Fit the selective thrust washer over its locating dowel and fit the rear seal housing using a new 0 ring andoil seal Apply Silastic RTV 732 into the inside of the V pulley hub and fit onto the adaptor spindle ensuring that the dowel engages into the hub correctly Fit the V pulley onto the hub with the drive line insettowards theengine f...

Page 155: ...ad and cam housing Take care not to scratch sealing surfaces use a blunt scraper such a s the flat end of a steel rule Degrease and clean the mating surfaces using methylated spirit or similar Lay a thin continuous bead of gasket eliminator approx 1 16 to 3 32 in wide in the middle of the sealing surface on the cam housing following the outer surface around the stud holes Fit 0 ring on cylinder he...

Page 156: ...sure on the belt Re check all the reletive sprocket positions Check toothed belt tension Section E A 8 Check ignition timing and adjust i f necessary Adjust the inlet pulley snubber where fitted for a clearance of 0 50 0 75 m m 0 020 0 030 in between the back of the toothed belt and the snubber bracket Tighten the securing nuts via the pulley holes to 2 2 2 5 kg m 15 18 1bs ft Replace V belts and ...

Page 157: ...MUST be carried out again NOTE Do NOT turn the camshafts with No 1 piston at T D C as this will cause the valves to be bent Turn the crankshaft back through 90 to bring the pistons half way down the cylinders Do NOT turn the crankshaft BEYOND 90 back as this will also cause the valves to be bent whilst the camshaft driving belt i s off If on the later type of camshaft housings with 0 ring and no g...

Page 158: ......

Page 159: ... mannually adjusted eccentric belt tensioner and later a semi automatic spring loaded tensioner 1986 M Y Excel and U S A Turbo H C I models and other engines at a later date use an H T D igh Torque rive cam belt and ulley set having a rounded tooth profile A manually adjusted eccentric be1t tensioner is generally used with the H T D belt and no snubbers are necessaryA Do NCYT attempt to tension a ...

Page 160: ...Page 78 SECTION EA Fig 11 Engine timing marks Burrouahs wuae in itifin ...

Page 161: ... Page 20 SECTfON EA 0 t 0 Timing marks in line through centre of pulleys fication E Fig 13 Sprocket positions wi th Number 1 cylinder at TDC ...

Page 162: ...he locknut On Federal engines where an air pump is driven off the back of the toothed belt first slacken off the air pump fixings Screw the spring seat adjusting screw clockwise until only one or two threads are showing above the locknut and tighten locknut Tension the air pump to 5 5 kg m 40 Ibs ft using special tool part number TOOOT0320A and a dial torque wrench Entirely release load on air pum...

Page 163: ... 4mm Locking Pin to be tensh e r inserted after loosening fig 14 d Force idler towards tensioner body merely tension timing belt by hand until groove an piston alignr with locking pin hole i n housing and ikert a 4mm diameter pin This locking pin hole may be located on the lower side of the piston bore or on the upper side red by the upper fixing bolt nut washer which must therefore be removed The...

Page 164: ... correct position of crankshaft camshafff andauxiliary shaft sprocket fig 13 2 After fitment adjust belt tensibn and check ignition timing If a new belt has been fitted run the engine for a minimum of two minutes switch off and recheck tension EA 9 DRIVING BELT TENS ONER To Remove Carry out the procedure detailed in Sections 8 for removing the camshaft drive belt although i t will not be necessary...

Page 165: ...the inlet manifold Remove the inlet manifold together with the carburetten Section EA 22 Remove the spark plug leads from the plugs and secure out of the way of cylinder head removal Release the exhaust downpipe from the exhaust manifold and remove manifold see Section St Some engines fitted with the non air conditioning type water pump may require removal of the water pump before the cylinder hea...

Page 166: ...SECTION EA a ...

Page 167: ...d out with the engine removed from the car Section EA 25 1 Remove the inlet manifold and carburetters assembly See Section EA 22 2 Remove the oil feed and drain pipes from the turbocharger and remove the exhaust manifold complete with wastegate and turbo On air injection engines remove the air pump V belt guard and air injection rail 3 Remove the cam covers and check the valve clearances Section E...

Page 168: ... thereon and replace with the same type If the cylinder linen crankshaft or reciprocating components have been changed the piston standout above the liner flange must be measured If the standout i s measured at right angles to the gudgeon pin the height on both sides of the piston must be measured and then averaged Select a gasket from the following table based on the highest standout Standout Des...

Page 169: ...s and spring seat from each valve Remove the valve 3 Repeat the process for the remaining valves Label each valve with its Iocation To Replace 1 Check the valve seats for condition re cutting as necessary and check condition of valve guides Grind i n all valves 2 Lightly lubricate the stem of the valve and insert into its guide 3 Fit spring seat valve springs spring retainer Place the valve spring...

Page 170: ...URE that i t remains in the region of the valve seating only A light coil spring placed under the head of the valve will assist considerably in the process of grinding The valve should be ground to its seat with a semi rotary motion and occasionally allowed to rise by the pressure of the light coil spring This action assists in speeding the grinding operation until a dull even matt finish free fro...

Page 171: ...Check the combustion chamber adjacent to the respective seat for a 1 2 or 5 stamping or alternatively C Dl or E this indicating that an oversize valve seat was fitted in production 0 001 in 0 002 i n and 0 005 in respectively Fig l8 Location of valve seat oversize stamping If this stomping is visible then that size or larger seat MUST be used as replacements The letters C Dl or El refer to the pre...

Page 172: ... of between 100 150 C 212 303 and with Special Tool MA knock the guides out of the head frdm the combustion chamber side To Replace 1 Heat the cylinder head to a temperature of between 1OO I O C 21z o F 2 Locate a new circlip on the new guide and press the guide into its bore from the top until the circlip seats completely in its recess Care must be taken that the guides are NOT driven in further ...

Page 173: ...on EA 8 3 With the aid of Special Tool TOOOTOl7OA pull off the crankshaft toothed pulley followed by the belt guide flange Tighten the tool bolts finger tight only NOTE On dry sump Turbo models first remove the oil pump drive sprocket Fig 19 Using To01 TOOOTOI70A to remove crankshaft sprocket w To Replace 1 Ensure that the engine has nat been turned from the timing position 2 Reverse the removal p...

Page 174: ...new oil seal with Wellseal sealing compound applied to its outer diameter insert into the front cover until flush wifh the rear face 2 Apply jointing compound to both faces of a new gasket and replace front cover with the aid of Special Tool TOOOT0009A On early engines ensure that the stud which retains the camshafts driving belt tensibner i s centralised in the hole of the front cover Secure cove...

Page 175: ...he clips and remove all hses from the water pump housing 4 Where power steering i s fitted remove the power steering pump mounting bracket and secure with hoses attached clear of water pump 5 Release the water pump fixing bolts and remove bolts and washers together with the water pump housing and gasket Discard the gasket Fig 21 Impellor Housing Clearance ...

Page 176: ... only on the hub and opposite end of the shaft NOT impellor Check impellor housing clearance i s to dimension showti i A Fig 21 2 Using a new gdsket to which a suitable jointing compound has been used on both sides refit the housing msembly to the engine tightening all bolts to their specified torque loddihgs see TECHNICAL DATA 3 Replace all ancillariei 4 Refill the coaling system and check for wd...

Page 177: ... the bead of Permabond Fit the water pump fixing bolts and washers and torque tighten to 0 8 1 1 kgf m 6 8 Ibf ft The system may be refilled with coolant immediately after reconnecting hoses Parts Required Permabond A136 Adhesive A912 E6421 Surface Conditioner A905 A912 E6759 ...

Page 178: ...ed with the new filter which is in contact with the oil pump body locate filter on its adaptor and screw on by HAND in a clockwise direction a When the filter seats continue turning the filter for a further two thirds to three quarters of a turn to ensure a m oil tight joint Fig 22 0 Viw jhciwiniiiipump filter b ignition distributor Where an oil cooler i s fitted ensure that the adaptor is not dis...

Page 179: ...f i l t e r t o these cars may result i n insufficient thread engagement w i t h consequent danger of the f i l t e r working loose In order to avoid any confusion i n the U K i t is recommended t h a t U K dealers stock only A prefix filters which are suitable for all cars EA 20 IGNITION DISTRIBUTOR To Remove 1 Turn engine until at the timing psition Section EA 8 2 Remove the distributor cap 3 Di...

Page 180: ...lter and alternator Where applicable remove the compressor rear mounting bracket Fully release all the bolts securing the housing to the cylinder block noting the position of the various bolts some are longer than others and remove housing together with its gasket Discard the gasket With the assembly on a clean bench remove the auxiliary shaft sprocket by releasing its central retaining bolt and w...

Page 181: ...SECIYON EA Page 37 Fig 23 Oil pump auxiiiary housing components ...

Page 182: ... adaptable type auxiliary housing with seperate alternator bracket i e with air conditioning note that the mating faces between the alternator mounting brackkt and auxiliary housing are not tnuching and MUST be sealed with ilasticyApply a bead of Silastic to either one mating face enough to form an approximate 0 5mm thick gasket when the parts are fitted Ensure that the retaining both are replaced...

Page 183: ...e airbox outet cover see Section L 3 Disconnect the water hoses from the manifold 4 Disconnect the breather pipe from the flame trap at the rear end of the airbox backplate Disconnect the throttle and choke cables and the vacuum pipes 5 Disconnect the fuel feed pipe to the carburettnn and fit plug to main fuel pipe to prevent fuel draining from the tank 6 Release the nuts and washen securing the m...

Page 184: ...se the engine mountings and raise the engine 2 3 inches 5 8 cm to gain sufficient sump to crossmember clearance 1 Using a suitable receptacle release the drain plug and allow oil to drain from the sump Remove the dipstick 2 From around the periphery of the sump remove the setscrews and nuts with their plain washers securing the sump to the main bearing housing Release the clutch housing to sump bo...

Page 185: ...s follows Clearance Shim 0 0 1 0 0 030 one 0 020 0 030 0 O5OH two 0 020 0 040 EA 24 CONNECT NG ROD BIG END BEARINGS Dry Sump Turbo see Section EA 28 To Remove 1 Remove the sump Section EA 23 2 Commenciiig with NO 1 from front end connecting rod turn the crankshaft to facil itate removal of cap Mark cap and rod 3 Release the bolts by two or three turns and tap themto release the cap Fully 0 release...

Page 186: ...e clutch cable at its mounting on the bell housing together with i t s bpcket on the main bearing housing or remove clutch slave cylinder from gearbox Remove the speedometer cable from the gearbox Disconnect the downpipe from the exhaust manifold see Section S Disconnect the engine earth strap Release the reverse lamp switch cables at the gearbox Release the propshaft from the final drive 9 For al...

Page 187: ... lever on the transmission and both links from the gearchange relay lever Disconnect the speedo cable from the transmission 8 Remove the rear valance silencer and downpipes 9 Disconnect the driveshafts and handbrake cables and remove the rear calipers and brake discs 10 Disconnect oil cooler hcses On Dry Sump Turbo disconnect the scavenge pump outlet pipe to cooler and the oil supply pipe from tan...

Page 188: ... and refill the coolingsystem Check security of gearbox drain plug Refill gearbox if necessary with recommended oil and replace filler level plug Check security of sump drain plug Refill engine with one of the recommended oils if necessary Replace filler cap securely double notch otherwise an oil loss could occur Esprit models Check the gear linkage and cross gate cable adjustments for correct sel...

Page 189: ...ctor lever on the transmission and both links from the gearchange relay lever Disconnect the speed0 cable from the transmission Remove the rear valance silencer and downpipes Disconnect the driveshafts and handbrake cables and remove the rear calipers and brake discs Disconnect oil cooler hoses On Dry Sump Turbo disconnect the scavenge pump outlef pipe to cooler and the oil supply pipe from tank t...

Page 190: ...p and refill the coolingsystem Check security of gearbox drain plug Refill gearbox if necessary with recommended oil and replace filler level plug Check security of sump drain plug Refill engine with one of the recommended oils if necessary Replace filler cap securely double notch otherwise an oil loss could occur Esprit models Check the gear linkage and cross gate cable adjustments for correct se...

Page 191: ...ield as a template and drill two 8mm clearance holes into the chassis 111 Secure the heutshield with two bolts large plain washers and nyloc nuts i n the following order Bolt head on outside large o d plain washer heatshield chassis nyloc nut EA 26 FLYWHEEL RING GEAR Manual Transmission Since shortly after its introduction 912 engines have been fitted with a flexplate flywheelt which incorporates ...

Page 192: ...eel with the chamfers on the leading face of the teeth relative to the normal direction of rotation Allow the ring gear to coal naturally in the air DO NUT QUENCH Locate the flywheel squarely on the cmnkshaft flange and upon the locating dowels Apply the Loctite AV to threads i n crankshaft then insert the securing bolts and tighten to the specified torque loading see TECHNICAL DATA Check the flyw...

Page 193: ...h the lip of the seal towards t l e inner machined face of the housing insert the new seal with the aid of a press until its inner face is 2 5 mm I0 in from the machined face ensuring during this operation that the seal is entered squarely ...

Page 194: ...head Fig 28 Using Tool MA to fit rear oil seal housing 3 Replace the flywheel 4 Re dssemble the gear box to the engine and replace engine gearbax assembly i n the car EA 28 CRANKSHAFT To Remove 1 Remove the engine gwrbox assembly frm the cur Section EA 25 part gearbox from engine and mount engine on a suitable stand 2 Remove the surnp Secti0n EA023 NOT Dry Sump Turbo 3 Remove the front cover Secti...

Page 195: ...emove the sprayshield from the rear of the cylinder block 6 Identify each connecting rod bearing cap with its rod and then unscrew the connecting rod bearing cap bolts by two or three turns and tap them to release the caps Push the pistons up into the cylinder liners 7 Remove the auxiliary housing Section EA 21 With the aid of Special Tool 83A remove the union screw securing the oil pick up pipe i...

Page 196: ...gh to crankpins 1 2 3 4 to provide big end lubrication Both upper and lower shells for these main bearings are provided with a hole to admit oil from a drilling i n the block and a groove to provide an oil channel around which oil may flow to the big end feed drilling in the journal lhe cross drilled crankshaft is similar i n the above respect but diffen as follows In order to permit the use of pl...

Page 197: ...venge manifold Undersize inside diameter shells to suit reground crankshafts are available for both standard and 0 015 overbored blocks See Parts List MODIFICATION OF 910 912 WIN BEARING PANEL PRIOR TO ENG NO 20875 All 912 natuml ly aspirated 2 2 Iitre and 910 turbocbarged 2 2 litre engines from engine number 20875 incorporate a revised main bearing panel casting ta enable the rear face of No 5 ma...

Page 198: ...ntil e width of the chamfer is 1 1 5mm and is approximately 45 to the ioint face iuke care not to mark any other M B P face with the file Thoroughly clean all swal F from the panel No 5 Main Bearing Notch in Shell iii On reassembly ensure that the correct notched shell is fitted to No 5 rear main bearing i n the prier Part Numbers for the notched bearing shell ONLY fifted to No 5 bearing LOWER hal...

Page 199: ...Fit new selective thrustwashen to the rear main bearing so that the oil grooves the copper side are towards the crankshaft Check the end float between the crankshaft and the thrustwashers see TECHNICAL DATA If a the end float is outside this tolerance replace the selective thrust washers 5 Dry Sump Turbo Only Ensure the crankshaft connecting rod journals and the connecting rods and caps are clean ...

Page 200: ...caps are clean then fit new bearing shells Refit the connecting rods and their caps to their respective journals after applying Graphogen grease to the bearings Tighten the bolts to their specified torque loadings see TECHNICAL DATA Not Dry Sump Turbo To enable the oil pick up pipe and the crankcase breather pipe all 907 and early 912 to be fitted it is necessary to remove both 12mm nuts from main...

Page 201: ...ppermost into its location Tap the breather tube into the bush until approximately 25mm 1 0 in is left protruding Ensure oil gallery and water jacket plugs are also fitted Re assemble the gearbox to the engine and replace engine gearbox assembly i n the car EA 29 PISTONS PISTON RINGS CONNECTING RODS 8 CYLINDER LINERS To Remove 1 Remove engine gearbox assembly Section E A 25 2 Remove cylinder head ...

Page 202: ...he cylinder block they MUST FIRST be fitted clean and dry and pushed fully into their locations A t this point the liner nip should be checked the nip i s the height of the liners ABOVE the cylinder block face and the height of the linen i n relation to each other see TECHNICAL DATA Fig 33 Using Tool TOOOT0003A to check cylinder liner height 1987 ...

Page 203: ...ine u s e s 4 p i s t o n s of t h e same weight grade b u t may m i x A and B p i s t o n l i n e r a s s e m b l i e s S i m i l a r l y connecting rods a r e weight graded i n t o 2 gram matched s e t s and i d e n t i f i e d by a l e t t e r code e t c h e d o r p a i n t e d below t h e f o r g e d FRONT mark on t h e rod I f o r d e r i n g an i n d i v i d u a l connecting rod o r p i s t ...

Page 204: ... l r i n g gap t o t h e r e a r and t h e two compression r i n g gaps 120 t o e i t h e r s i d e Running In When new rings or pistadliner sets have been fitted the running in period must be 800 kilometres 500 miles see Section 0 4 Using a pisten ring compressor insert the piston into the liner with t k FRONT mark towards the front of the cylinder block Fit cylinder liner clamp after replacing t...

Page 205: ...ions clamping the mounting bracket to be coated wTth Ornni Fit thread lock and torque tightened to 11 kgf m 80 1bf ft Dry sunp bracket shown Inlet from Cooler Outlet to Cooler 14 31 LUBRICATION SYSTEM PRECAUTIONS In the event of engine failure involving the possibility of debris entering the lubrication systen it is essential that the following precautions are taken before re assembly i clean and ...

Page 206: ...Page 75 Fig 10 Belt guard components early models I E714 _ I _ A ...

Page 207: ...e seat Front Cover Pilot To locate front cover Camshaft Oil Seal Inserter For inserting oil seal Camshaft Oil Seal Extractor For extracting oil seal Cylinder Liner Extractor For extracting liners Camshaft Oil Seal Sleeve For locating oil seal Oil Pick Up Pipe Union Spanner For tightening union hut Rear Oil Seal Housing Pilot To locate housingon re assembly Crankshaft Sprocket Remover For removal o...

Page 208: ...21V PermabondA136 200 ml A907E6252V PermabondA121 Pipeseal 50ml Page 59 Note Do NOT apply thread locking compound to the following studs a Cylinder Head to Block 12 mm b MainBearing Housing 12mm c Main Bearing Housing 8 mm d o Cam Housing to Cylinder Head 8 mm Application 907 Cam Covers Cam Housings Crank Journals Cam Followers Shims Crank Rear Seal Housing Gasket Sump Joint Cylinder Head Gasket M...

Page 209: ...SECTION EMA Page 7 S E C T I O N EMA U S A ESPRIT TURBO Prior t o 86 M Y Engine Control Components Engine Management System Check Set Up Procedure Engine Diagnostic Procedure Operation Page APR 1987 ...

Page 210: ...idle speed when engine i s cold or air conditioning switched on and also to open throttle on hot start cranking mode A thermostatic switch fitted into the rear of the inlet manifold 0 water rail makes contact at water temperature below 70 C and energises the throttle jack solenoid To aid cold starting the solenoid i s de energised whilst i n the cranking mode At water temperature above 70 c the so...

Page 211: ...ion is switched on the carb vent valve solenoid is energised and the pipe is sealed The purge connection on the vapour canister port PI i s piped to a venturi IT piece fitted between the air pump and filter In this way when the engine is running air is drawn in a through the bottom of the canister to replace gasoline vapoun corsumed by the air pump and fed into the exhaust system for oxidation E N...

Page 212: ...EL PRESSURE ADJUSTMENT SCREW AIR FILTER BOX CONNECT TEST KIT AT THESE POINTS 0 3Ohg and 0 15 I S 1 CENTRE POINT 0 FUEL PRESSURE 0 20 t S I PRESSURE TEST GAUGE KIT LOTUS PART NO TOOT0500 0 30hg Fit exhaust probe to exhaust outlet pipe of turbo charger and connect to CO HC analyser e g Sun EPA 75 or equivalent Connect stroboscopic timing lamp to number one spark plug lead Exhaust probe connection AP...

Page 213: ...ine speed rises to approximately 2 500 rpm 4 Return choke fully after 20 100 seconds dependant on temperature and adjust idle speed at the throttle lever on the front of the carburetton bearing on the throttle jack solenoid to 1000 rpm basic setting r x ACU throttle iack solenoid M Throttle iack idle U_J speed adjusting screw VIEW FROM FRONT Disconnect the hose to the air rail pulse valve and chec...

Page 214: ...with the carbs balanced and rpm and fuel pressure set the idle mixture can be sampled and adjustment made if required i Switch analyser to sample mode and check readihgs NOTE Do not touch idle adjustment screws until CO reading has stabilised The carburetton have been flow tested and only minor adjustment will be required if any ii CO reading should be within 0 2 to 1 2 If higher or lower levels a...

Page 215: ...f t k damper valve see number 8 8 Damper valve with adjustments 1 7 carried out the throttle damper can now be adjusted With the engine at i d k rprnrotate the damper until a distance between damper body and lever is 0 55 0 5 in Lock up the retaining nut open throttle to 2500 rprn and release Idle rprn should be attained within0 8 to 2 0 seconds Damper valve adjustment TO ENGINE VIEW FROM REAR 9 A...

Page 216: ...e vacuum hose at air box to TI connection and note increase in pump vacuum This should rise by approximately 3 Hg 13 O n completion disconnect pressure test gauge kit from components and re connect fuel and vacuum pipes securely When connecting vacuum pipes spray connections with a silicone aerosol and push on connections firmly Disconnect manometer remove balancing tubes and replace vacuum tappin...

Page 217: ...t I A Distributor cap High tension leads Rotor Spark plugs Cold start maladjustment Control pressure too low Fdel pump capakity unsatisfactory Fuel lines filter clogged B C CO misadjustment I Thermal switch incorrect I H I HOT START PROBLEMS Possiblecauses Fuel pump electrical circuit Leak in intake manifold Spark plugs I Cold start maladjustment Cam timing incorrect Control pressure incorrect Fue...

Page 218: ...uel lines filters clogged Cam timing incorrect Fuel pump capacity unsatisfatoty Control pressure maladjustment Fuel lines filters clogged Throttle or throttle linkage misadjustment Incorrect balance C O maladjustment Fuel pump capacity unsatisfactory Incorrect vacuum control of the control pressure Throttle or linkage maladjustment ENGINE STALLS Possiblecauses CO malodjustment I Fuel pump electric...

Page 219: ... It i s essential that the carburettor mountings are not overtightened as the 0 rings may be displaced with a resultant air leak A uniform gap between spacer plate and carburettor and between spacer plate and inlet manifold must be maintained as shown below spacer plate manifold 1 9 mm 0 075 2 Check for air leaks at carburettor balance pipe connections and at cold start air intake pipe connections...

Page 220: ...r cover from the engine bay wall leave the hoses attached and pull open Remove the cleaner element and inspect condition If necessary remove the rubber seal and discard the element Ensure the seal is i n good condition replace if necessary and fit i n position on the new element Note The seal joint must be at the centre top Clean the inside of the air cleaner body and cover keeping dust out of the...

Page 221: ...ANK i ENGINE 4 PICK UP COIL RESISTANCE RESULT Should be Regular sparking TEST6 No sparking TEST 2 Measure voltages at 1 4incl should be 1 More than 11 W 2 l V max below V at 1 j 1V max below V at 1 4 ov 0 1 v All correct v TEST 3 Incorrect reading s SEE CHART SUSPECT Battery discharged lgnit on switch andlor wiring Coil or amplifier Amplifier earth ground Voltage increases while cranking 7 TEST 5 ...

Page 222: ...will not start TEST 7 Should be 1 Ciean dry no tracking marks 2 Clean dry no tracking marks 3 Must not be cracked chafed or perished 1 Must not be open circuit 5 Clean dry and setto correct gap B Check cylinder compressions Remove spark plugs Gnnect a remote control switch to battery and starter motor solenoid Use a compression tester to measure cylinder compressions with throttle fully open Check...

Page 223: ...old start levers With the choke control i n the off position both carb levers should contact their closed stops on the carburettor tops With the choke control operated fully check that both levers are against their fully open stops Adjust the choke cable at the carburettor tmd linkage if necessary CHOKE FULLY OPEN CHOKE FULLY CLOSED STOP STOP aAPR 1987 ...

Page 224: ...t green on exhaust are aligned with a line through the camshaft pulley centres These dots may be viewed from either the front side using a mirror or the rear side If the engine is running the rear side of the pulleys may be viewed with a stroboscope set at TDC or No 1 cylinder Note It is most important that each camshaft toothed pulley isfitted the correct way round i e IN facing forward on inlet ...

Page 225: ...ily be adjusted to specification a restriction in the return line i s indicated Rectify a s necessary If the pressure reading i s too low and cannot readily be adjusted to specification a restriction in the supply line or faulty fuel pump is indicated Check for an unrestricted supply to the fuel pump andfor fuel filter restriction Test fuel pump 2 Start engine and allow to reach normal running tem...

Page 226: ...if necessary but always ensure that idle pressure requirements are met If switch contact is made at idle but fuel pressure remains above 3 5 p s is check fuel pressure regulator solenoid pipework and wiring for leakage or disconnection If no fault is found replace fuel pressure regulator solenoid valve If pressures are found to be correct remove caiburettor tops and check fuel inlet filten cleanin...

Page 227: ...maintaining idle speed adjust throttle coupling screws to balance lower of columns 1 2 with lower of column 3 4 NOTE Ensure that both clamping screws on the balance lever are i n secure contact with thebalance arm Considering the carburettor barrels i n pairs 1 2 and 3 4 note which of the two mercury columns for each pair is higher and gradually move only the corresponding balancing screw until th...

Page 228: ...e adjustment screws until CO reading has stabilised CO reading shquld be betwben 0 2 1 2 If higher or lower ievels are found ensut e carburettors are balanced see Sub Group F beforecontinuing Remove anti tamper plugs and move each mixture screw of a turn i n or out as the reading dictates Check the CO reading and repeat procedureuntil correct specification is achieved A balance between C O and HC ...

Page 229: ... system to permit the removal of the switch from the rear of the inlet manifold 2 Place the switch bulb i n a pan of water with a battery and bulb connected across the switch terminals and a thermometer measuring water temperature Heat the water and check make and break temperatures meet specification Maximum break on rise 70 c Minimum make on fall 60 c APR 1987 ...

Page 230: ...l lows Remove battery from vehicle Constant Current The battery must be charged at a maximum of 5 amps until the battery terminql voltage on charge has stabil ised over a one hour period at which time the voltage will be in the range 16 0 16 5 V Atthis age the battery must be taken off charge IMMEDIATELY to prevent excess gassing with resulting water loss which will ultimately reduce the guarantee...

Page 231: ...notbeenactivated The switch is located i n the ignition box at the rear of the engine bay To re set the switch press down the plunger appearing through the hole i n the top of the ignition box Inertia switch Check for electrical feed at fuel pumpterminals with ignition switched on I a APR 1987 ...

Page 232: ...gram Thermal I w i t i o n Advance C r a n k c a s e B r e a t h e r Valve Cold Enrichment Thermal Valve Plenum P u r g e T h r o t t l e J a c k Soleno id O v e r b o o s t S w i t c h I d l e Speed I g n i t i o n Timing S e t t i n g P r o c e d u r e E M C I 2 3 E M C 2 4 t o 6 E M C 3 6 E M C 4 7 E M C 5 7 E M C 6 7 8 E M C 7 8 E M C 8 8 t o 1 0 a APR 1987 ...

Page 233: ...TO CRANKCASE J COLD ENRICHMENT THERHAL VALYE WHITE NON RETURN VALVE REAR FRONT CARR r I PLENUM Vacuurn Pressure Pipe Connections BLACKIWHITE n Electrical Connections FUEL REGULATING VALVE I SPEED SENSING I SOLENOID VALVE w IGNmION SOLENOtD TO BOOST PURGE PUMP p i n k towards plenum A ...

Page 234: ... r o t t l e jack above 1400 rpm on f a l l 1600 rpm on rise t o reduce emissions on overun See EMC 6 a Non Return Valve F i t t e d i n l i n e a between thermal v a l v e and c a r b s C fm P r e v e n t s boost p r e s s u r e blowing o f f through thermal v a l v e See EMC 3 cj 3 h Cold Enrichment Thermal Valve F i t t e d i n t o r e a r of i n l e t manifold w a t e r r a i l A t Z water tem...

Page 235: ... and a t coolant temperatures below 60 C connects p o r t s ID and 1 Above 60 C p o r t s D and 2 a r e connected The I S V i s mounted on top of t h e r i g h t hand f u e l tank board and i s controlled by a thermal switch f i t t e d i n t o t h e thermostat housing o u t l e t pipe a t t h e f r o n t of t h e engine bay A t coolant temperatures below 70 C on r i s e t h e I S V i s energised ...

Page 236: ...er pressure signal to the distributor for no vacuum advance IGNITION SOLENOID VALVE CARB EDGE PORT CARB PLENUM I Water Temp inlet manifold above 6 0 ERM L thermostat pipe below 7 0 When the coolant temperature inlet manifold reaches 6 0 C the T 1 v changes over and directs a throttle edge drilling acuum signal to the distributor for normal running ignition advance IGNITION SOLENOID VALVE ...

Page 237: ...ing a r e a b l e t o vent through t h e one way valve i n t o t h e airbox I n o r d e r t o prevent t h e s e fumes under low a i r f l o w engine i d l e conditions escaping through t h e i n l e t trunking t o atmosphere t h e valve is a l s o connected v i a a small bore hose t o t h e c a r b u r e t t o r s This enables t h e small q u a n t i t y of crankcase fumes a t i d l e t o pass d i...

Page 238: ...h i s improves h o t s t a r t i n g of t h e engine The pump i s f i t t e d on t h e t a i l g a t e a p e r t u r e R H support b r a c k e t behind t h e q u a r t e r window t r i m p a n e l i n t h e r e a r luggage compartment and i s o p e r a t i v e o n l y when t h e i g n i t i o n i s switched o f f A thermal switch i n t h e t h e r m o s t a t o u t l e t p i p e a l s o used f o r...

Page 239: ...i s e T e s t each o f t h e t h r e e a c t i v a t i n g systems and observe t h e a c t i o n of t h e s o l e n o i d EMC 7 OVERBOOST SWITCH The overboost switch i s f i t t e d t o s a f e g u a r d t h e engine a g a i n s t e x c e s s i v e boost p r e s s u r e i n t h e e v e n t of w a s t e g a t e f a i l u r e by c u t t i n g o u t t h e i g n i t i o n The switch i s mounted on t h...

Page 240: ...i t c h e s t h e d i s t r i b u t o r c a p s u l e t o t h e t h r o t t l e edge p o r t Using a s t r o b o s c o p e c h e c k a d j u s t t h e i g n i t i o n t i m i n g t o l o 0 BTDC a t h o t i d l e Timing marks are p r o v i d e d on t h e f l y w h e e l r i m w i t h an a p e r t u r e and p o i n t e r i n t h e t o p of t h e c l u t c h h o u s i n g a d j a c e n t t o t h e s ...

Page 241: ...t c h e d o f f A d j u s t i d l e s p e e d a t t h e s t o p screw o n t h e f r o n t o f t h e rear c a r b u r e t t o r t o 900 50 rpm U s e t h e c a b l e a d j u s t e r a t t h e anchor b r a c k e t o n t h e c a m c o v e r t o remove t h r o t t l e c a b l e s l a c k and t h e n w i t h t h e a i d o f a n a s s i s t a n t check t h a t f u l l t h r o t t l e can be a c h i e v e...

Page 242: ...m Connection Diagram Thermal I g n i t i o n Advance Crankcase B r e a t h e r Valve Cold Enrichment Thermal Valve Plenum Purge T h r o t t l e J a c k Solenoid A i r I n l e t Temperature Control System I d l e Speed I g n i t i o n Timing S e t t i n g Procedure EMD 1 EMD 2 EMD 3 E M D 4 EMD 5 E M D 6 E M D 7 EMD 8 ...

Page 243: ...CRANKCASE COLD ENRICHMENT THERMAL VALVE DISTRIBUTOR I 0 VACUUM PRESSURE PIPE ELECTRICAL CONNECTION I ARB 1 I ARB 1 WARM AIR INTAKE FROM EXHAUST SttROUD AIR TEMPERATURE CONTROL VALVE I COOL AIR INTAKE FROM LUGGAGE COMPARTMT THERMAL SWITCH OPERATION ru JACK SOLENOID TOAT COMPRESSOR 1 THERMAL SWITCH ENGINE SPEED ...

Page 244: ...al Switch F i t t e d i n thermostat o u t l e t w a t e r p i p e M O R 70 C B O F 60 C Switches a i r b o x purge pump See EMD 5 5 A i r Temperature Control ATC Valve Switches a i r i n t a k e t o warm a i r s u p l v from A e x h a u s t downpipe shroud a t low airbox temps f o r improved c o l d running See EMD 7 C h 0 6 A i r Temperature Control ATC Sensor Regulates vacuum supply t o A T C v...

Page 245: ...etween t h e c r a n k c a s e b r e a t h e r s p i g o t a t t h e rear o f t h e b l o c k and t h e a i r b o x Crankcase e m i s s i o n s developed d u r i n g normal running a r e able t o v e n t through t h e one way v a l v e i n t o t h e a i r b o x I n o r d e r t o p r e v e n t t h e s e fumes under low a i r f l o w engine i d l e c o n d i t i o n s e s c a p i n g through t h e i...

Page 246: ... o n l y when t h e i g n i t i o n i s s w i t c h e d o f f A t h e r m a l s w i t c h i n t h e t h e r m o s t a t o u t l e t p i p e e n e r g i s e s t h e p u r g e pump a t w a t e r t e m p e r a t u r e s above 70 C on r i s e u n t i l c o o l a n t t e m p e r a t u r e f a l l s t o 60 C EMD 6 THROTTLE J A C K SOLENOID The t h r a t t l e jack s o l e n o i d i s d e s i g n e d t o...

Page 247: ... g r e l a y c When a i r conditioning i f f i t t e d compressor i s o p e r a t i n g i n o r d e r t o maintain i d l e speed To set up With t h e engine a t normal running temperature without t h e a i r c o n d i t i o n i n g switched on check adjust i d l e speed a t t h e normal s t o p screw on t h e f r o n t of t h e r e a r c a r b u r e t t o r Correct s e t t i n g 950 c 5 0 rpm Ener...

Page 248: ...round t h e exhaust downpipe The c o l d e r t h e a i r b o x t e m p e r a t u r e t h e g r e a t e r t h e p r o p o r t i o n of warm air d i r e c t e d t o t h e a i r b o x The A T C s e n s o r mounted by a r u b b e r grommet i n t o t h e bottom of t h e a i r b o x is a t h e r m o s t a t i c a l l y c o n t r o l l e d vacuum p r o p o r t i o n v a l v e connected between t h e c a ...

Page 249: ...a b l e t h e engine t o r u n S e t t h e c r a n k s h a f t t o 10 BTDC u s i n g t h e t i m i n g marks and p o i n t e r on t h e f l y w h e e l and c l u t c h housing w i t h t h e r o t o r arm p o i n t i n g towards no 1 t e r m i n a l on t h e d i s t r i b u t o r cap P u l l o f f t h e r o t o r arm and p l a s t i c s h i e l d and t u r n t h e d i s t r i b u t o r body t o a l...

Page 250: ...f u g a l advance o p e r a t i o n f i r s t d i s c o n n e c t and p l u g o r clamp o f f t h e vacuum hose between d i s t r i b u t o r c a p s u l e and T I V Check c e n t r i f u g a l advance c h a r a c t e r i s t i c s a r e a s f o l l o w s crank r D m Below 1 000 2 000 crank 2 n i l 8 1 6 max iii Check Ad j u s t I d l e Speed S t a r t engine and run up t o normal o p e r a t i n ...

Page 251: ...t check t h a t f u l l t h r o t t l e can be achieved The t h r o t t l e p e d a l downstop should b e a d j u s t e d such t h a t t h e c a r b u r e t t o r t h r o t t l e l e v e r s may be h e l d a g a i n s t t h e i r f u l l t h r o t t l e s t o p s w i t h o u t allowing t h e c a b l e t o be o v e r s t r a i n e d To a d j u s t t h r o t t l e jack s o l e n o i d see EMD 6 ...

Page 252: ...inkage TransmissionAssembly Clutch Bellhousing Clutch Shaft Gearbox Rear Housing Gear Selector Removal Gear Selector Replacement Primary Shbft a Bevel Pinion Shaft Differential Shaft Drive Shafts Differential Crownwheel Pinion Differential Bearings Adjustment BacklashAdiustrnent Page ...

Page 253: ......

Page 254: ...at Bracket to Gearbox Washer Spring Bracket to Gearbox Mounting Ehgine Gearbox rear Washer Snubber Washer Flat Nut Nyloc 7 16 UNF Pointer Engine Tinuing Switch Reverse Light Speedo Driven G e a r Nylon Bush Speedo Driven Gear Right Angle Drive Speedo Air Vent Breather End Housing Stud Silencer Gearbox Mounting Bracket Bolt Silencer Mounting Bracket Drain Plug Washer Drain Plug ...

Page 255: ... a i u t c h housing and gearbox Two s h o r t output s h a f t s supported by t h e i r own houqihgs bolted t o each s i d e of t h e t r a n s m i s s i o n use a double b a l l bearing on t h e i r butboard ends and a t a p e r r o l l e r bearing a t t h e inboard ends where they c a r r y t h e crownwheel and d i f f e r e n t i a l assembly Four s e l e c t o r s h a f t s a c r o s s t h e ...

Page 256: ...shape n e c e s s i t a t e s a r e v i s e d s i l e n c e r mounting bracket and t h e c l u t c h r e l e a s e bearing assembly on S e r i e s 3 c a r s i s changed See P a r t s L i s t f o r d e t a i l s PREVIOUS TYPE NEW C35 TYPE j Gearbox Number Locatio Do not remove I f Oil Level Plug I Revised Rear Cover Shape FB 1 GEARSHIFT LEVER AND GEAR CHANGE LINKAGE The gearshift lever operation co...

Page 257: ...e from therelay lever and withdraw tube from chassis Release rear tube from relay lever and cross shaft lever Remove the spring clip and clevis pin securing the crossgate cable extension to the crossgate bellcrank lever Remove the nut and washer securing the crossgate cable to the bellhousing To the gear lever endof the cable attach a i r e u 1 l throughlto aidreassembly Remove the nut and washer ...

Page 258: ......

Page 259: ...able Rear Rod Crossgate Cable Extension Locknut Cable Stiffener Locknut Plain Clevis Pin Rod to Bellcrank Spring Clip Clevis Pin Be1lcrank Lever Cross shaft Pivot Pin Bellcrank Washer Pivot Pin Nut Nyloc Pivot Pin Tube Gearchange Front Tube Gearchange Rear Adjuster Gearchange Tube Locknut Gearchange Adjuster Pivot Pin Gearchange Tubes Nut Pivot Pin Bush Rubber Tube End Bearing Plastic Tube End Rel...

Page 260: ...stment at its mid position Tighten the locknuts With the transmission i n neutral and the cable connected check the position of the gear lever The lever should be vertical orleaning very slightly to the right If necessary disconnect the cable extension rod from the cross shaftbellcrank lever and after slackening the locknut screw the extension rod on or off the cable to achieve t h correct setting...

Page 261: ...cable Release the lower clutch housing to engine bolts Remove the air pump Federal cars Release the Turbo air inlet hose and adaptor Turbo only Release the clutch slave cylinder Remove the starter motor Support the engine and releasethe remaining clutch housing to engine bolts Carefully withdraw the gearbox assembly rearwards to disengage the clutch shaft and lift out To Replace Reverse the remova...

Page 262: ... and lift out the differential Dismantling 1 Slide off the fork arm the rubber dust excluder 2 From inside the bellhousing remove the retaining spring and the thrust bearing assembly 3 Remove the pin securing the fork to the bc li joint and withdraw the fork 1 Reverse the dismantling and removal proceduresfor the clutch bellhousing Seal the mating faces with Silastic Tighten all bolts tospecified ...

Page 263: ...unit a s previously described Remove the rear and top cover on the gearbox Remove the bolt securing the 5th gear synchro assembly together with the deflector To assist in the removal of the bolt slacken the screws securing the reverse gear forkand engage two gears e g 1st gear and reverse gear Remove the locking wire through the screw securing the 5th gear fork and remove the screw Remove the 5th ...

Page 264: ...or crosshaft Reverse Gear Selector 1 Slacken the screws securing the fork A and the operating dog B first removing the locking wire to the selector shaft 2 Withdraw the selector shaft removing the fork the operating dog and shaft locking ball and spring 5th Gear Selector 1 Slacken the screw securing the 5th gear operating dog C after removing the locking wire Fig 5 Gear selectors ...

Page 265: ...e to note the order and position of the plungers NOTE One long plunger between 3rd 4thand 5th selector shafts and shorter plungers between 1st 2nd and 3rd 4th selector shafts and 5th and reverse selector shafts FB 7 GEAR SELECTOR REPLACEMENT 1st and 2nd Gear Selector 1 Locate the locking ball and spring i n position 2 Compress the spring and ball assembly using a 6mm diameter rod 3 Insert the gear...

Page 266: ...eviously described the5th gear operating block and into the differential end of the gearbox casting emuring that the small interlock plunger i s located inside the frontend of the selector shaft 3 Locate the 5th gear operating block on the selector shaft so that the notch on the shaft lines up with the screw hole in the block Screw down the grub screw and lock with wire Reverse Gear Selector 10 Pl...

Page 267: ...Ring Cross ShaftSpindle Selector Shaft reverse Selector Shaft 5th Selector Shaft 3rd and 4th Selector Shaft 1st and 2nd Relay Dog Reverse Selector Shaft Selector Fork reverse Relay Dog 5th Selector Shaft Selector Fork 5th Selector Fork 3rd and 4th Selector Fork 1st and 2nd Locking Screw o r k e l a to Shaft Setscrew Fork Clamping lnterlock Plunger short lnterlock Plunger long Blanking Plug Interlo...

Page 268: ... the 3rd and 4th gear fork Tighten the locknut on the stop and check the clearance Interlock PIungers To Replace 1 Smear the bores of the interlock plungers with a sealing compound and knock i n the blanking plugs at positiom F and G Final Assembly a 1 Fit top cover on the gearbox and replace the transmission unit as previously described FB 8 PRIMARY SHAFT To Remove 1 Remove the Gear Selecton and ...

Page 269: ...clip Remove the circlip from the shaft usingcirclip pliers 3253 T taking care to note the direction i n which i t is fitted Move the pinion shaft towards the bellhousing as described under heading Bevel Pinion and allow gears to rest in the bottom of the casing to provide additional space to withdraw the primary shaft The primary shaft can now be moved towards the bellhousing end until the rear en...

Page 270: ...nchroniser E on the shaft must not exceed 0 1 0 rnm Adjustment of this movement i s achieved by changing the circlip Q for one of a different thickness e Synchro ring D f 4th drive gear R together with its needle bearing cage coated with transmission oil Slide the synchroniser E across to engage the 4th drive gear 3 Pass the input shaft end ofthe assembly through the top openingof the gearbox then...

Page 271: ...I a Gearbox Shafts and Gears a a a ...

Page 272: ... Speed Drive Pinion Needle Roller Bearing 4th and 5th Pinion Double Ball Bearing Primary Shaft rear Syncroniser Assembly 5th Circlip 5th syncroniser Screw 5th Hub to Primary Shaft Roller Bearing Secondary Shaft front 1st Speed Driven Pinion 2nd Speed Driven Pinion Needle Rol IerBearing Sleeve lst 2nd Pinion Bearing Syncroniser Assembly 1st 2nd Syncroniser Ring 1st and 2nd Spacer Washer Selective 3...

Page 273: ... to 14 5 16 5 kgf m 105 119 Ibf ft FB 9 BEVEL PINION SHAFT To Remove 1 Remove the Primary Shaft as previously described 2 Withdraw the bevel pinion through thegearbox casing into the differential housing 3 As the bevel pinion is drawn through the casing remove the3rd 4th driven gear pair adjusting washer 1s t and2nd syncro hub assembly with gears and needle roller bearings NOTE The two rear ball r...

Page 274: ...inner bearing sleeve 0 Coat the bearing before fitting with transmission oil Finally place on the shaft the adjusting washer q and the double pinion r and push the shaft to the rearof the gearbox Fit the rear double bearing c taking care to assemble the double bearing races and bearingring in the original positions b with the small shoulder on the pinion against the Fit the 5th gear pinion double ...

Page 275: ...round face of the bevel pinion uhlock the gauge stem Rotate the fixture in the bearing sr rfaces so the gauge stem passes over the ground face of the pinion until the large needle ofthe dial gauge is about to change direction Lock the needle positions and note the readings Example Totalking needle between0 and 1 Large needle at 86 Remove the fixture and place once again on the surface plate Allow ...

Page 276: ...o specified torque as described i n bevel pinion shaft and lock nut by peening it to the pinion 2 Check that the pinions rotate freely when out of gear 3 Apply sealing compound to cover mating surfaces and tighten all securing screws to the torque specified in the TECHNICAL DATA FB lo DIFFERENTIAL SHAFTS Drive Shafts Dismantle 1 Remove and dismantle the Clutch Bellhousing as previously described 2...

Page 277: ... oil retaining washer and bearing distance bush assembly from the shaft Fig 9 Differential assembly Satellite housing Planet wheel Satellite gear Satellite spindle long Satellite spindle short Screw with dowel Crown wheel screw Planet wheel washer satellite gear washer Gosshead bush Distance piece Distance washer Adjusting washer Crown wheel Roller bearing Spacer Locking nut Nut Grub screw Oil sea...

Page 278: ...crew 22 i n the locking nut 5 Assemble and replace the Clutch Be1lhousing as previously described FB 11 DIFFERENTIAL CROWNWHEEL PINION To Remove 1 Dismantle the Differential Shafts as previously described 2 Using a suitable extractor remove the tapered roller bearings from each end of the crown wheel assembly 3 Remove the eight screws 6 securing the crown wheel to the housing and a remove the foll...

Page 279: ... and this should be 0 1 mm Change the thrust washer to achieve this clearance Using an oil gun inject gearbox oil into the satellite housing lubricating all parts inside Fit the bearings on the satellite housing and crown wheel using a suitable mandrel FB 12 DIFFERENTIAL BEARINGS ADJUSTMENT There are two methods by which adiustments can be made to the differential bearings The f i n t method uses ...

Page 280: ...he differential bearings NOTE The bearings must be fitted with a specified pre load a Place gauge support TOOOT0614 fitted with dial gauge TOOOTO615 on the collar of the right hand drive shaft housing Allow the probe of the gauge to touch the bearing faceof the housing Bring the zero of the movable dial of the gauge i n line with the large needle Note the position of the needle Example Large needl...

Page 281: ...differential fitted with bearings in the end of the gearbox casting b Secure the differential in place using clamps a s necessary c Place new paper gaskets on the left hand and right hand drive shafts assemblies together with any shims removedduring dismantling Locate the drive shafts i n the planet wheel andalign the screw holes Fit screws taking care t i fit the correct lengths and tighten 2 Adj...

Page 282: ...ORTANT The thickness of the washers fitted against the left hand and right hand bearings corresponds to the setting of the bearing stress only To adjust the backlash these washers must be redistributed to the left and right without changing the overall thickness FB 13 BACKLASH ADJUSTMENT a T o check the backlash adjustment both drive shaft housings must be fitted 1 Measure the clearance between th...

Page 283: ...PORTANT The clearance between the teeth is adjusted by redistributing the adjusting washers against the left hand and right hand bearings Under no circumstances must the overall thickness of the washers be altered see DIFFERENTIAL BEARINGS ADJUSTMENT The clearance must be adjusted towithin the limits 0 I 6 mm and 0 24 mm Aim for an average clearance of 0 20 mm Subtract this average clearance from ...

Page 284: ... hand bearing should be reduced to 8 20 0 79 7 41 mm and the thickness of the washers against the left hand bearingshould be increased by the same amount 7 00 0 79 7 79mm d Recheck the backlash measurement to verify t hat the difference between any two measurements around the crown wheel does not exceed 0 10 mm 3 I f backlash is within the tolerance assemble the differential assembly replace the C...

Page 285: ...l Description Steering Wheel Upper Steering Column Assembly Intermediate Steering Column Assembly Track Rod Ends Toe in Adjustment Steering Rack Gaiters Rack Pinion Assembly Sub section HB 1 HB 2 HB 3 HB 4 HB 5 HB 6 HB 7 Page 5 6 8 15 19 20 21 Page 1 ...

Page 286: ...eel Countersunk screw wheel to hub Trim pad steering wheel centre WON S I R TYPE UPPER STEWING COLUMJ Steering column assembly Fixing column to scuttle beam Break out insert Clamp bracket column to pedal box Fixing bracket to pedal box Sealing gasket column to bulkhead Seal plate Fixings seal plate Steering lock Shear bolt steering lock fixing ...

Page 287: ...7 B a l l bearing column top 8 Circlip t o p bearing 9 Cushion ring 10 Circlip cushion ring 11 Column lock 18 12 Shear b o l t column lock 13 Lock b a r r e l keys 14 Ignition switch 15 Turn cancelling sleeve 16 SIR rotary connector 17 Fixing rotary connector 18 Steering wheel 19 Nut wheel t o column 20 Washer wheel t o column 21 SIR i n f l a t o r module 22 Fixing i n f l a t o r module ...

Page 288: ...IXEWEDIATE C O L U M N RACK PINION ASSEMBLY S I R type ...

Page 289: ...ady bracket i n t s h a f t Bush steady bracket Shim i f f i t t e d steady bracket Fixing steady bracket SIR upper intermediate s h a f t HB l GENERAL DESCRIPTION A rack and pinion s t e e r i n g system is used on t h e E s p r i t with t h e s t e e r i n g r a c k assembly clamped t o t h e t h e c h a s s i s f r o n t crossmember behind t h e f r o n t a x l e l i n e On c a r s without a Su...

Page 290: ... boss serves t o operate t h e cancelling mechanism f o r t h e t u r n i n d i c a t o r switch On S I R equipped c a r s primarily USA the t h e s t e e r i n g wheel and hub are integrated i n t o a s i n g l e u n i t which houses an i n f l a t o r module a i r bag a t its centre concealed beneath a moulded t r i m cover h padded cover is designed t o s p l i t open when t h e i n f l a t o r...

Page 291: ...ub Assy Non S I R Cars Apply a small amount of PBC grease t o t h e column s p l i n e s t o a i d subsequent s t e e r i n g wheel removal b u t ensure t h a t t h e threaded s e c t i o n is thoroughly degreased Check t h a t t h e s p l i t t h r u s t c o l l a r i s h e l d i n p o s i t i o n by a rubber band i n t h e groove i n t h e column j u s t below t h e s p l i n e s with t h e tape...

Page 292: ...ds an equal and opposite amount at each side to maintain the toe in setting 4 Check front wheel toe in HB 3 UPPER STEERING COLUMN ASSEMBLY On non S I R Supplementary Inflatable Restraint cars the upper steering column assembly comprises inner and outer columns both of which are telescop ically collapsible if an axial load above a specified figure is applied to the column in the course of an accide...

Page 293: ...ction WA part no EO82TO327J Post Accident Inspection If t h e v e h i c l e has been involved i n an accident o r i f t h e r e is any o t h e r reason t o suspect t h a t t h e upper column assembly may have collapsed c a r r y o u t t h e following inspection Non S I R Cars Remove t h e s t e e r i n g wheel see above remove t h e column shrouds and s e p a r a t e t h e lower end of t h e colum...

Page 294: ... y i n t h e column along t h e d i r e c t i o n of t h e column t h e i n n e r column t e l e s c o p i c r e t e n t i o n mechanism has been overridden and t h e column assembly should be replaced To Remove Upper Steerinq Column Assembly Non S I R c a r s 1 Remove t h e s t e e r i n g wheel s e e Sub section HB 2 2 Remove t h e column shrouds Release t h e two screws a t each s i d e securin...

Page 295: ...o l t heads s e c u r i n g t h e column lock assembly t o t h e column and remove t h e lock Remove and d i s c a r d t h e s h e a r b o l t t h r e a d s TO Ref it Upper S t e e r i n g Column Assembly Non S I R c a r s 1 Feed t h e column through t h e f a s c i a and i n t o t h e p e d a l box clamp b r a c k e t and i n t e r m e d i a t e column upper u j Take care t o a l i g n t h e f l ...

Page 296: ...to secure harnesses and h e a t e r ducting t o t h e column 6 F i t t h e column lower shroud with screw and washer t o t h e column lock and then t h e upper shroud with its f o u r screws 7 R e f i t t h e s t e e r i n g wheel s e e Sub Section H B 2 To Remove Upper S t e e r i n g Column Assembly S I R C a r s WARNING Any work on or remaval of the s t e e r i n g column o n S I R cars r e q u...

Page 297: ...Scuttle beam Single fixing to pedal box Pedal box I break out insert S I R y p e Upper Column Assembly Top bearing Indicator cancelling bush Top bearing housing Steering lock Lock barrel Page 13 ...

Page 298: ...curing t h e t o p bearing housing t o t h e o u t e r column Remove t h e c i r c l i p and p r e s s o u t t h e b a l l bearing assembly To R e f i t Upper S t e e r i n g Column Assembly S I R c a r s 1 I f necessary reassemble t h e column assembly F i t t h e b a l l bearing i n t o t h e t o p bearing housing using a p r e s s and f i t t h e r e t a i n i n g c i r c l i p F i t t h e bear...

Page 299: ...DIATE STEERING C O L U M N ASSEMBLY On non S I R c a r s a s i n g l e intermediate column is used t o g e t h e r with two u n i v e r s a l j o i n t s t o transmit 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 rack pinion s h a f t When r e f i t t i n g t h e intermediate column it is most important 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 wit...

Page 300: ...j o n t o t h e s h a f t to a b u t t h e spacer tube or u n t i l t h e s h a f t end i s f l u s h with t h e i n s i d e of t h e u j yoke F i t t h e pinch b o l t and t i g h t e n t o 22 27 Nm 16 20 1 b f f t From i n s i d e t h e c a r feed t h e intermediate column through t h e bulkhead seal b u t n o t i n t o t h e lower u j b e f o r e s l i d i n g o n t o t h e unfixed upper column...

Page 301: ...inch bolt and tighten to 22 27 Nm 16 20 1bf ft Turn steering wheel 30 counterclockwise M ID sert Pinch b o l t T HD car viewed from LH side with joints phased RHD car viewed from RH side with joints phased Check pinch bolt hole is still in vertical plane before assembly clockwise horizontal horizontal Check pinch bolt hole is still in vertical plane before assdly Page 1 7 ...

Page 302: ...le t h e S I R system and prevent f a l s e codes from s e t t i n g a Turn off ignition b Disconnect t h e negative battery cable and tape back to ensure t h a t it cannot contact t h e battery terminal c From beneath t h e passenger s i d e fascia locate and disconnect t h e s i x way S I R f a s c i a harness connector block d Unplug t h e orange 3 way connectoe t o t h e inflator 1 Remove the ...

Page 303: ...intermediate s h a f t assembly through t h e bulkhead seal through t h e steady bearing and i n t o t h e lower u j with t h e f l a t on t h e s p l i n e s a l i g n e d with t h e pinch b o l t hole F i t t h e pinch b o l t and r e t a i n with a new M 8 Nyloc h a l f nut Tighten t o 24 Nm 18 l b f f t R e f i t t h e upper s t e e r i n g column assembly s e e sub section H B 3 Temporarily f...

Page 304: ...Nyloc nut without washer and torque t i g h t e n t o 41 47 Nm 30 35 1 b f f t Check and a d j u s t t o e i n and t i g h t e n t h e rod end locknuts as above HB 6 STEERING RACK GAITERS The g a i t e r s f i t t e d a t each end of t h e rack assembly a r e a v a i l a b l e as a k i t which i n c l u d e s t h e t w o g a i t e r s and f o u r c l i p s The i n t e g r i t y of t h e g a i t e ...

Page 305: ... smallest amount of f r e e p l a y a t t h e s t e e r i n g wheel Any attempt t o compensate f o r wear i n t h e s t r a i g h t ahead p o s i t i o n by re shimming t h e rack t h r u s t pad may r e s u l t i n t i g h t n e s s o r jamming a t some o t h e r p o i n t of rack t r a v e l The r a t i o of t h e rack and pinion g e a r is 45 l 4 5 nun rack t r a v e l p e r p i n i o n r e v o...

Page 306: ...using and secure t h e u n i t with t h e two clamp brackets i n s e r t i n g t h e tapping p l a t e s i n t o t h e c h a s s i s p l i n t h s Tighten t h e f i x i n g s t o 16 19 Nm 12 14 1 b f f t 4 F i t t h e pinch b o l t and new Nyloc nut t o secure t h e lower u j t o t h e pinion s h a f t and t i g h t e n t o 22 27 Nm 16 20 l b f f t 5 F i t each t r a c k rod end i n t o i t s hub ...

Page 307: ...ble to c a n up to and including 1984 Model Year which use solid brake discs and Girling calipers front and rear Section Page General Description Front Brake Pad Replacement Rear Brake Pad Replacement Handbrake Front Brake Caliper Overhaul Rear Caliper Overhaul Brake Discs Master Cylinder Servo Unit ...

Page 308: ...ables to each rear brake caliper and mechanically operates their hydraulic pistons Each piston incorporates a self adjusting mechanism which operates on footbrake application to compensate for brake pad wear JB 1 FRONT BRAKE PAD REPLACEMENT Minimum pad thickness 3mm Always change brake pads i n axle sets 1 After raising the front of the vehicle remove the front wheels WARNING When both front w hee...

Page 309: ...p up if necessary Tighten the wheel nuts to the specified torque loading CAUTION The brakes will not work at full efficiency until the new brake pads have bedded in If initially the brakes are used too heavily the surface of the pads will burn and irregular braking result Use the brakes gently for the first few miles and gradually build up brake effort JB 2 REAR BRAKE PAD REPLACEMENT Minimum pad t...

Page 310: ...a compensator lever to balance the force applied to each handbrake cable Late cars may be fitted with a multiplier lever pivoting on the handbrake lever mounting plate i n order to increase the leverage and reduce operator effort Access to the handbrake cable adjusters is made via an aperture i n the rear end of the s i l l trim panel covered by carpet The cables should be adjusted to obtain a ver...

Page 311: ... from their cylinden 4 Remove the sealing rings from the cylinders taking care not to damage the bores or grooves 5 Clean all park thoroughly with Girling Cleaning Fluid or unused brake fluid Examine cylinder bores and piston for any signs of scoring scuffing or corrosion Replace the pistons or complete caliper i f there is any daub 6 Lubricate the cylinden and new sealing r i n g with clean brake...

Page 312: ...oubt Lubricate a new piston seal with clean brake fluid and fit into its groove i n the cylinder wall Lubricate the piston and f i t the dust cover onto the piston as shown Offer the piston and dust cover assembly to the cylinder with the piston orientuted to clear the handbrake auto adjustment see JB 2 Locate the l i p of the dust cover into the cylinder groove and carefully push the piston fully...

Page 313: ...erhaul 1 Drain brake fluid from the reservoir disconnect the brake pipes and remove master cylinder assembly to a clean work area 2 Remove the reservoir retaining pins and carefully pull the reservoir from the master cylinder Lever out the two seals 3 Push the plunger down the cyli ider and withdraw the secondary plunger stop pin 9 a 9 22 O J O O O D O O O O O O O O 4 Remove the retaining circlip ...

Page 314: ...SED AT ALL STAGES OF SEAL ASSEMBLY 9 p it secondary plunger seal 20 by squeezing between finger and thumb to stretch over plunger lip Fit washer 19 recupemting seal 1 8 seal retainer 17 and spring 22 Ensure seals are correctly fitted as shown O J O O O D O O O O O O O 10 Fit the primary piston washer recuperating seal seal retainer and spring i n a similar manner 11 Use the special B M S grease pr...

Page 315: ...stop pin to be fitted as shown 15 Whilst holding the plunger pressed in f i t the thin vaccum seal spacer into the end of the cylinder followed by one vacuum seal lip side first a thick spacer the other seal and thick spacer and retain with the circlip 16 Lubricate new reservoir seals with brake fluid and fit into the cylinder Press the reservoir into position and f i t the reservoir retaining pin...

Page 316: ...cover and servo master cylinder 0 ring i n the servo service k i t A075J6033F The vacuum non return valve is incorporated into the vacuum hose elbow connector i n the front case of the servo unit The valve is a push fit into a grommet and is supplied complete with new grommet Use the grease supplied to lubricate the ribs of the NRV before assembly As a quick check of servo operation proceed as fol...

Page 317: ...ariants which use ventilated front disc brake assemblies similar to those used on Excel models and Bendix Series 3 ACG rear disc brake assemblies General Description Front Brake Pad Replacement Rear Brake Pad Replacement Handbrake Adjustment Front Caliper Overhaul Rear Caliper Overhaul Brake Discs Servo Unit Master Cylinder Section ...

Page 318: ...a bolt into the torque plate hole Slide out both brake pads Referring to the illustration remove each anti rattle r i n g u i d e plate support plate ONE AT A TIME and replace with the new item supplied with the new pad set NOTE Pay special attention to the correct assembly of anti rattle springs and pad guide plates to the caliper Most of these are handed Note that the inner pad guide plate forms...

Page 319: ...rk at full efficiency until the new brake pads have bedded in if initially the brakes are used too heavily the surface of the pads w i l l burn and irregular braking result Use the brakes gently for the first few miles and gradually build up brake effort JC 2 REAR BRAKE PAD REPLACEMENT ...

Page 320: ... slot of the piston to screw the piston clockwise down its handbrake adjuster mechanism Take care that the fluid reservoir does not overflow during this operation When fully retracted screw out again until the slot i s parallel with the two support wings and thegroove i s toward the bleed nipple side of the cylinder as shown 6 Fit the brake pads with their anti rattle springs into the caliper brac...

Page 321: ...cation To release the handbrake pull lever up press release button and HOLDING BUTTON PRESSED IN lower lever fully The handbrake lever is connected via a short link to a multiplier lever to increase leverage and reduce operator effort The multiplier lever connects to an actuating link which uses a compensator lever to balance the force applied to each handbmke cable The Bendix calipers incorporate...

Page 322: ...ise the caliper and draw off from the top slide pin 2 Remove the sliding bush and its rubber boots 3 Remove the top pin boot from the caliper using a small chisel as shown 4 Remove the spring ring and boot from the piston bore and use compressed air to eject the piston from the cylinder WARNING Keep fingers well clear during this operation and use rags to guard against brake fluid spray 5 Remove p...

Page 323: ... assembly should be fitted 6 Fit a new seal into the cylinder groove Lubricate the piston and bore with brake fluid and press the piston into the cylinder 7 Smear the exposed part of the piston with the special Lockheed grease supplied i n the seal kit and fit a new dust boot 8 Screw the piston fully in along the handbrake adjuster mechanism and then position with the piston slot parallel with the...

Page 324: ...V 0 UNIT The Master Vac brake servo is with the exception of the air filter and non return valve a non serviceable sealed unit which must be replaced i f found to be faulty The air filter surrounds input push rod should be replaced whenever the brake system is overhauled and cleaned or replaced more frequently if the vehicle is operated i n dusty conditions The vacuum non return valve is incorpora...

Page 325: ...inder to remove the piston Clean all parts with methylated spirit or brake system cleaning fluid and inspect If the master cylinder bore shows any signs whatever of scoring wear or corrosion the complete unit should be replaced Note The screw securing the return spring to the primary piston is factory set and must not be disturbed Coat both new pistorl assemblies from a master cylinder repair kit ...

Page 326: ...ilar manner and retain with the new circlip Using a new sealing washer fit the secondary piston stop screw into the cylinder body Tighten to 1 kgf m 7 5 Ibf ft Press on the primary piston and remove the brass rod from the r eservoir port Refit the reservoir assembly to the master cylinder using new grommets Refit the master cylinder to the servo using a new 0 ring and tightening the two nuts to 1 ...

Page 327: ...s c r i p t i o n D r a i n R e f i l l P r o c e d u r e C o o l i n g F a n s R e p l a c e m e n t o f E a r l y Type Motors C o o l i n g F a n s T h e r m a l T r i p C o o l i n g F a n s T h e r m a l S w i t c h R e p l a c e m e n t o f E a r l y Type Rad D u c t S t a y s KB 1 1 t o 7 KB 2 7 8 ...

Page 328: ...Esprit 53 Cooling System ...

Page 329: ...DodRoW Turbo Coolina System ...

Page 330: ......

Page 331: ...codant Circulation i a r n r n wit 53 8 U S A Turbo I tor ...

Page 332: ...Heater Take Off ...

Page 333: ...hen t h e thermostat opens coolant flows forward t o t h e f r o n t mounted r a d i a t o r b e f o r e r e t u r n i n g t o t h e water pump A header tank is f i t t e d a t t h e r i g h t hand r e a r of t h e engine bay and i s connected with t h e water punp i n l e t pipework S3 U S A o r t h e by pass pipework DOM ROW Turbo The r a d i a t o r i s l o c a t e d i n t h e nose of t h e c a...

Page 334: ...ling f a n motors A074M6027Z with r i v e t t e d metal fan b l a d e s w h i l s t l a t e r c a r s use a f a n motor assembly with an orange p l a s t i c blade I f i t is necessary t o replace an e a r l i e r type f a n motor i t is recommended t o f i t t h e l a t e r type fan motor assembly i n t h e following manner P a r t s Required Fan Motor Fan rad cooling plastic C i r c l i p f a n ...

Page 335: ... d i a t o r and blows backwards r o t a t i n g anti clockwise when viewed from behind The fan f a i l t e l l t a l e w i l l function a s previously KB 4 COOLING FANS THERMAL TRIP Early Turbo models S3 c a r s with a i r conditioning and S e r i e s 3 c a r s with h e a t e r p r i o r t o commonisation with Turbo f a s c i a mid 85 used a fused r e l a y i n t h e cooling fan c i r c u i t l o...

Page 336: ... e t and r a d i a t o r i n l e t u s i n g a s p e c i a l grommet and s p r i n g c l i p Never re use a grommet but renew each t i m e t h e s w i t c h i s removed Cars used i n hot c l i m a t e s a r e f i t t e d w i t h a b l u e c o l o u r coded switch which makes breaks a t temperatures o f 82 72OC The s w i t c h i n g p o i n t f o r c a r s i n temperate c l i m a t e s was r a i s ...

Page 337: ... s e c t i o n channel and u s i n g an L bracket t o f i x t h e s t a y t o t h e c h a s s i s L a t e r c a r s used a more d u r a b l e t u b u l a r s t a y which may be f i t t e d t o e a r l i e r c a r s i n t h e following manner P a r t s Required Rad Duct Support Tube RH A082K4188K Rad Duct Support Tube L H A082K4189K Setscrew M 6 x 20 Tube Chassis A075W10302 Washer f l a t Tube Chas...

Page 338: ...L ESPRIT S3 General Description Installation of Revised Fuel Filteration System Carburettor Theory of Operation Float Level Checking Carburettor Balancing Procedure Carburettor Mounting Operat ion LA 1 LA 1A LA 2 LA 3 LA 4 LA 5 Page 7 Page ...

Page 339: ... l v e a r e c o n t a i n e d w i t h i n t h e s p a r e wheel w e l l a t t h e f r o n t o f t h e b o o t F u e l is t h e n pumped through a p l a s t i c p i p e r u n n i n g t h r o u g h t h e c h a s s i s backbone and i n t o t h e c a r b u r e t t o r s E a r l y c a r s were f i a d a p t o r T h i s was t h e c a r b u r e t t o r t t e d w i t h a f i l t e r i n t h e f u e l p i...

Page 340: ...filter i n l e t reannost connection Reverse t h e flowlock on its existing mounting direction of flow arrow towards engine and f i t new fuel pipe A089M213F from filter t o flowlock C l i p l t i e wrap pipe as shown Connect the e x i s t i n g front t o r e a r f u e l pipe t o t h e flowlock Route pipe i n a loop inside boot do not push pipe forward through g r m e t i n body When r e f i l l i...

Page 341: ...loat 15 controls the fuel flow into the float chamber thereby maintaining a constant level The float chamber is vented to atmosphere via the airbox through the hole 4 in the chamber 3 Starting With the choke valve 8 opened fuel metered through jet 14 passes into the emulsion tube 13 where i t mixes with air from the channel 16 communicating with the float chamber top through hole 6 The mixture for...

Page 342: ...rrels by meats of the dividing bushing 19 Idling Fuel coming from the float chamber metered by the idle jets 21 mixes with the air from the well 23 through channels 22 the mixture thus formed through channels 24 arrives to the adjustment screw 27 and then metered flows into the main barrels 11 downstream the throttle valve 12 Replacing the plug 26 with an adaptor connected to a suitable manometer ...

Page 343: ...attached to spindle 38 by means of the rod 40 and the spring 41 pushes the pump lever 43 which acts directly on the diaphragm 44 held out by the spring 45 Moving pf the diaphragm 44 causes delivery of fuel to the main barrels 11 through the respective valves 36 and jets 37 On closing of throttle valves 12 diaphmgm 44 returns to the original pas ition pushed by the spring 45 and draws fresh fuel fr...

Page 344: ... by the jets 4 7 enters the well 48 and mixes with air metered bythe air corrector 49 The mixture thus formed passes through the inner venturi 50 where i t furthr mixes with air drawn through the main barrel of the carburettor flows into the venturis 51 and then through the main barrels I 1 reaches the engine ...

Page 345: ...dditional amount of mixture flows through the needle jet 52 upstream the inner venturi 50 mixture is composed of fuel drawn from the float chamber through channel 56 and metered by the jet 55 mixed with air metered by the calibrated passage 54 and drawn from the float chamber top 53 ...

Page 346: ...nd if necessary carefully bend the float arm at B to correct LA A CARBUREnOR BALANCING PROCEDURE Ensure ignition timing is correct and the air filter and all trunking etc fitted Remove anti tamper caps from idle C O adjustment screws and balancing screws Replace vacuum tapping screws with manometer adaptors TOOOT04915 and connect to manometer TOOOT0499 Fully close all balancing screws do not graun...

Page 347: ...ilpipe and check C O reading Move a l l idle C O adjustment screws the same amount i n or out of a turn at a time to bring C O level within the range 0 7 1 5 Disconnect manometer and adapton and replace blanking screws Fit new anti tamper caps where necessary Ensure all fuel pipe connections are secure IA 5 CARBURETTOR MOUNTING The spacer plates and 0 rings used at this joint cct as insulators to ...

Page 348: ...ssembly and drain tank COMPLETELY Discard removed banjo bolt ft l t e r assy 4 Use the illustration as a guide and f i t the new fuel f i l t e r assy A089L6012F to the body panel on the right hand side of the fuel tank Remove the RH rear wheel for easier access 2 x 7mm 0 hdes 25mm between centres Riel Filter Fixing Hole Detail Fuel Filter h e 1 Filter bunting ...

Page 349: ...Fixing Fuel Feed Banjo Fuel Return Banjo Copper Washer Banjo Crush Washer Banjo Banjo Bolt Fuel Pipe Tank to Pump Clip Fuel Pipe Grommet Fuel Pipe Fuel Pump Imulator Strip Fuel Pump Clamp Clamping Bolt Plain Washer Nyloc Nut Bolt Clamp to Chassis Washer Fuel Pipe Pump to Filter Clip Fuel Pipe Fuel Filter Insulator Strip Fuel Filter Clamp Clamping Bolt Plain Washer Nyloc Nut Studplate Filter Clamp ...

Page 350: ...SECTION LB FUEL SYSTEM Page I SECTION LB ESPRIT TURBO DOWROW Operation Page General Description Carburettor Theory of Operation Float Level Checking Carburettor Balancing Procedure Carburettor Mounting ...

Page 351: ......

Page 352: ...fuel pressure to 3 5 Ib in 2 during idle and light load conditions but as inlet boost pressure is developed a sersing pipe from the diffuser via the rear carb cold start banjo adds a boost pressure signal to the spring pressure to ersure that 2 fuel pressure is maintained at 3 5 Ib in above boost pressure Excess fuel supplied to the regulating valve is returned via a port i n the bottom of the val...

Page 353: ...th air from the channel 16 communicating with the float chamber top through hole 6 The mixture formed flows through holes 7 into the valve chamber 9 further mixing with air from the two channels 5 From the valve chamber 9 mixture is divided into the two channels 10 which lead into the main barrels 11 downstream of the throttle valves 12 ...

Page 354: ...barrels by means of the dividing bushing 19 Id1ing Fuel coming from the float chamber metered by the idle jets 21 mixes with the air from the well 23 through channels 22 the mixture thus formed through channels 24 arrives to the adjustment screw 27 and then metered flows into the main barrels 11 downstream the throttle valve 12 Replacing the plug 26 with an adaptor connected to a suitable manomete...

Page 355: ...he spring 41 pushes the pumplever 43 which acts directly on the diaphmgm 44 held out by the spring 45 Moving of the diaphragm 44 causes delivery of fuel to the main barrels 11 through the respective valves 36 and jets 37 On closing of throttle valves 12 diaphmgm 44 returrs to the original position pushed by the spring 45 and draws fresh fuel from the fuel well 33 through the valve 35 The ball valv...

Page 356: ...by the jets 47 enterr the well 48 and mixes with air metered by the air corrector 49 The mixture thus formed passes through the inner venturi 50 where it further mixes with air drawn through the main barrel of the carburettor flows into the venbris 51 and then through the main barrels I 1 reaches the engine ...

Page 357: ... LB A CARBURETTOR BALANCING PROCEDURE Ensure ignition timing is correct and the air filter and all trunking etc fitted Remove anti tamper cap from idle C O adjustment screws and balancing screws Replace vacuum tapping screws with manometer adaptors TOOOT0496 and correct to manometer TOOOT0499 Fully close all balancing screws do not graunch Set idle C O adjustment screws 6 x 4 turra open and start ...

Page 358: ... to increase then return unscrew again by a turn HC as hexane should normally be not more than 400ppm C O maximum is 1 0 Maintain idle speed and manometer balance throughout Disconnect manometer and adapton and replace blanking screws Fit new anti tamper caps where necessary Ensure all fuel pipe connections are secure LB 5 CARBURETTOR MOUNT1NG The spacer plates and 0 rings used at this joint act a...

Page 359: ...SYSTEM Page 7 SECTION LC U S A ESPRIT TURBO CARBURETOR General Description Carburettor Theory of Operation Fuel Control Pressure Float Level Checking Carburettor Balancing Procedure Carburettor Mounting Operation Page ...

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Page 361: ...rossover Hose Clip Crossover Pipe Grommet c o Pipe Grcmrnet c o Pipe Ring Cro nrne t Fixing Fuel Fcecl Balijo Fuel 2eturn Banjo Copper Washer Bunj o Crush Vdusher Bot ij o Banjo Bolt Fuel Pipe Tank to Pump Clip Fuel Pipe Grommet Fuel Pipe Fuel Pump lmu ator S h i p Fuel Pump Clamp Clanping 601t Plain Washer I yloc Nut Bolt Clamp f 0 Chassis Washer Fuel Pipe Pump to Filter Cllp Fuel Pipe Fuel Filte...

Page 362: ...o ensure that fuel pressure is maintained 2 at 4 0 4 5 Ib in above boost pressure However a micro switch mounted on the front of the front carburettor and operated by the throttle lever in its fully closed position energises the fuel pressure solenoid fitted beneath the rear of the plenum chamber The signal to the fuel pressure regulator is then switched to number one cylinder inlet manifold depre...

Page 363: ... air from the channel 16 communicating with the float chamber top through hole 6 The mixture formed flows through holes 7 into the valve chamber 9 further mixing with air from the two channels 5 Fr6m the valve chamber 9 mixture is divided into the two cliani lels 10 which lead into the main barrels 11 downstream of the throttle valves 12 ...

Page 364: ...om the float chamber metered by the idle jets 21 mixes with the air from the well 23 through channels 22 the mixture thus formed through channels 24 arrives to the adiustment screw 27 and then metred flows into the main barrels 11 downstream the throttle valve 12 Replacing the plug 26 with an adaptor connected to a suitable manometer i t is possible to check through channel 28 the pressure existin...

Page 365: ...3 which acts directly on the diaphragm 44 held out by the spring 45 Moving of the diaphragm 44 causes delivery of fuel to the main barrels 11 through the respective valves 36 and jets 37 On closing ofthrottle valves 12 diaphragm 44 returns to the original position pushed by the spring 45 and draws fresh fuel from the fuel well 33 through the valve 35 The ball valve 34 eraures that the pump circuit...

Page 366: ...rottle closed there is a clearance of 0 6 O lmm between the end of the pump lever and the diaphragm plunger Full Throttle With the throttle valves 412 opened fuel from the float chamber 46 metered by the jets 47 enters the well 48 and mixes with air metered by the air corrector 49 The mixture thus formed passes through the inner venturi 50 where i t further mixes with air drawn through the main ba...

Page 367: ...l amount of mixture flows through the needle jet 52 upstream the inner venturi 50 mixture is composed of fuel drawn from the float chamber through channel 56 and metered by the jet 55 mixed with air metered by the calibrated passage 54 and drawn from the float chamber top 53 ...

Page 368: ...ification a 0 restriction i n the return line is indicated Rectify as necessary If the pressure reading i s too low and cannot readily be adjusted to specification a restriction i n the supply line or Faulty fuel pump is indicated Check for an unrestricted supply to the fuel pump and for fuel filter restriction Test fuel pump 2 Start engine and allow to reach normal running tempemture Check fuel p...

Page 369: ...at idle but fuel pressure remains a b v e 3 5 p s i check fuel pressure regulator solenoid pipework and wiring for leakage or disconnection If no fault is found replace fuel pressure regulator solenoid valve LC 4 FLOA TLEVEL CHECK NG Remove the carburettor top complete with float assembly Ensure the correct weight of 8 5 g is indicated on the float and that the float assembly pivots freely on its ...

Page 370: ...l balancing screws do not graunch Set idle C 0adjustment screws 6 x tur ns open and start engine With engine at normal running temperature with ACU off and cooling fans a on adjust throttle stop screw to give specified idle speed of 950 50 rpm Adjust throttle coupling to balance lower of mercury columns 1 and 2 with lower of mercury columns 3 and 4 to within 3 mm ensuri ng that the two coupling sc...

Page 371: ...50 ppm for a run in engine 11 Disconnect manometer and adaptors and replace blanking screws Fit new anti tamper caps where necessary Ersure all fuel pipe connections are secure Disconnect exhaust sample probe and refit blanking plug securely LC 6 CARBURETTOR MOUNT1NG The spacer plates and 0 rings used at this joint act as insulaton to absorb vibration and prevent frothing of fuel in the float cham...

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Page 373: ...ngine Management Devices Air Cond Idle Up Solenoid Evapomtive Loss System Engine Warm Up Summary Fuel System Precautiom Engine Management System Check Set Up Procedure Fault Diagnosis Torque Settings Fuel Injection Ignition Box Component Location Wiring Diagram Schematics Fuel lnjection Electrical Component Function Fault Diagnosis Operation LD 1 LD 2 LD 3 LD 4 LD 5 LD 6 LD 7 LD 8 LD 9 LD 10 LD 11...

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Page 375: ...s Valve Allows air to by pass Airflow Semor thus shutting off fuel supply on closed throttle engine overun conditions LD 16 18 lgnition Solenoid Operates Throttle Jacking Capsule at water temperatures below 60 C increased idle speed LD 18 19 Overboost Switch Cuts out fuel pumps i f overboost i s detected LD 3 20 Throttle Position Switch Switches a signal to the electronic controi unit and engine m...

Page 376: ...FUEL ACCUMULATOR FUEL TANK I FUEL PUMPS f p FUEL FILTER JJ LE 395 FUEL SYSTEM SCHEMATIC DIAGRAM ...

Page 377: ...tinuous The fuel injection m y be said to opemte mechanically with the quantity of fuel delivered being regulated by the amount of air drawn i n by the engine The basic system i s regulated to provide the correct air fuel ratio for normal running conditiom and full power running Various supplementary devices are used to modify this ratio to achieve efficient overall performance when cold decelerat...

Page 378: ...gulator I n order to protect the engine from damage if one pump fails the engine overspeed fuel pump failure module senses the failure and limits maximum engine speed to approx 2 800 rpm by cutting out the remaining pump when this speed i s reached The fuel pumps are also cut out i f the Overboost Switch senses too great a boost pressure at the inlet manifold cold start air m i l i e exhaust waste...

Page 379: ...cial fine filter is fitted to protect the system from impurities i n the fuel The filter consists of a sealed cannister containing a paper filter element backed up by a lintor fluff filter and a restraining strainer Fuel Filter 1 Paper Element 2 Lint or Fluff Filter 3 Stminer it i s most important that the filter i s fitted with the arrow stamped on the body pointing i n the direction of fuel flow...

Page 380: ...ef cross section i n the funnel before being restrained by a buffer The rest position of the sensor i s controlled by a preset spring pin The screw setting the fuel control valve operating arm i s preset and requires no adjustment under normal operating conditions Fuel Distributor The fuel distributor comprises i Primary Pressure Regulator System Pressure ii Fuel Control Valve iii Four Distributor...

Page 381: ...ich is fed fuel at primary pressure The fuel then flows through 4 metering slits to the distributor differential valves and then to the fuel injecton As the air flow sensor is deflected further by an increasing airflow so the control valve i s raised i n its barrel progressively opening a larger proportion of the metering slits and increasing fuel flow to the injectors EngineStopped Part Load 1 Co...

Page 382: ...sure when the engine i s cold This reduced force above the control valve at lows the airflow sensor and control valve to move a greater distance for a given airflow and exposea greater proportion of the metering slits More fuel then flows to the injectors to achieve a richer cold running mixture The warm up regulator achieves this control pressure regulation by allowing a proportion of the fuel to...

Page 383: ... upper chamben are isolated from each other and each is connected individually to one of the metering slits Each diaphragm i s spring loaded downwards away from a seat valve leading to one of the fuel iniecton Fuel Intake at Primary Pressure Upper Chamber To Fuel Injector Control Valve Metering Slit Helical Spring Steel Diaphragm Lower Chamber LOW FUEL DELIVERY HIGH FUEL DELIVERY flat As the meter...

Page 384: ...e on and off its seat producing a finely atomised spray Fuel atomisation i s further aided especially at low engine speeds by an air stream flowing around the injector This air stream is supplied via a passageway running across the top of the inlet manifold and a hose connecting with the intake plenum When the engine inlet valves are closed the air fuel vapour cloud formed i s stored i n the intak...

Page 385: ...l fuel necessary for cold starting is supplied by the cold start injector only at cranking and for a maximum duration of between 0 1 and 8 0 seconds dependant on coolant temperature Auxiliary Cold Start Injector Air Valve I Fuel l njector Cold Start The single cold start injector is fitted into an air rail running alongside the fuel injector air stream rail on the inlet manifold Connecting passage...

Page 386: ...ctrical heating time is needed to break the contact When the engine i s at normal running temperature the switch absorbs sufficient heat to keep the contacts open rendering the cold start injector inoperative LD 9 AUXILIARY AIR VALVE In order to overcome the increased friction present i n a cold engine and enable the engine to idle satisfactorily after cold start up an auxiliary air valve is fitte...

Page 387: ...educed the fuel control valve i n the distributor is allowed to move further for a given airflow and open a greater proportion of the metering slits increasing fuel flow to the iniectorr A ENGINE COLD B NORMAL RUNNING 9 8 TEMPERATURE I I 1 _I 1 Valve Diaphragm 4 Valve Spring 7 Spring 2 Return to Tank 5 Bimetal Spring 8 Aneroic Capsule 3 Control Pressure 6 Heating Coil The warm up regulator comists...

Page 388: ...ction of harmful exhaust gas emissions i s achieved primarily through the use of starter and main three way catalysts combined with very accurate fuel metering a The optimum air fuel ratio for minimum emission of all three noxious components carbon monoxide CO unburnt hydrocarborn HC and nitrogen oxide NOx and also for minimum fuel consumption with maximum driveabilitpis about 14 to 1 by weight Th...

Page 389: ...p Signals from the sensor are only processed at engine oil temperatures above 3 5 O a LD 14 FREQUENCY VALVE Timing Vafve Corrections to the fuel delivery as determined by the Lambda sensor and electronic control unit E C U are made by altering the fuel pressure beneath the diaphragm of the differential valves i n the fuel distributor 1 Fuellnlet 2 Small Orifice Fixed Throttle 3 Lower Chamber 4 Fre...

Page 390: ... loop control and may be represented by the following flow chart Rich mixture Injected fuel No Oxygen in quantity increases exhau st gases Regulated fuel pressure decreases Open close ratio e n c l o s e ratio of Frequency Valve of Frequency Valve i s increasing is decreasing Low sensor Regulated fuel voltage pressure increases Injected fuel a Oxygen i n exhaust gases quantity decreases Lean mixtu...

Page 391: ...d by an electric power supply and manifold vacuum but governed by the engine coolant temperature engine speed and the position of the throttle The valve has an air inlet and outlet with the inlet spigot pressed into a grommet i n the air cleaner main body while the outlet i s connected by hose to the air flow sensor lower housing When the valve is triggered to its open position air w i l l be draw...

Page 392: ...tures below 7 0 Cthe high temperature switch supplies current to the ignition solenoid which then directs a vacuum pump fed to the T J C to increase cold engine idle speed Above 7 0 Cthe solenoid i s de energised and the T J C connected with the upstream throttle port LD 19 AIR CONDITIONING IDLE UP SOLENOID The purpose of the A C idle up solenoid is to maintain engine id1e speed when the air condi...

Page 393: ...r Vacuum Pump VACUUM SWITCHING DIAGRAM BELOW 5 3 C WATER TEMP ...

Page 394: ...Vacuum Pump I TO I DISTRIBUTOR CAPSULE I C Vacuum Pump Feed I Upstream Throttle Port Edge Drilling Ignition Solenoid VACUUM SWITCHING DIAGRAM BETWEEN5 3 70 C WATER TEMP ...

Page 395: ...THROTTLE EDGE PORT DISTRIBUTOR CAPSULE u ...

Page 396: ...ystem are vented to the canister via a hose linking the airflow sensor lower body to canister port C In order to cleanse the charcoal of fuel absorbed i n this manner arrangements are made for fresh air to be drawn through the canister and consumed by the engine Two different connections are used to purge the canister under different engine operating conditions Port PI on the canister i s connecte...

Page 397: ...ession greater now with increased airflow below the airflow sensor Crankcase Breather Va Ive Crankcase fumes are ventilated via the crankcase breather valve into the air cleaner housing Positive crankcase pressure developed during normal running is able to vent through the one way breather valve into the air cleaner housing I n order to prevent these fumes under low airflow engine idle conditions ...

Page 398: ...hen 53O C water temp is reached the thermal ignition valve cuts off the vacuum pump supply to the D A C and connects i t with the throttle edge drilling Normal Running Above 7 0 C Water Temp When 700 C water temp is reached the ignition solenoid cuts off the vacuum pump supply to the throttle jacking capsule The a c idle up solenoid valve opens only at idle with the compressor operaying LD 22 FUEL...

Page 399: ...prietory Connect the duty cycle meter to the frequency valve The frequency valve is located ahead of the fuel distributor Disconnect the electrical plug from the valve and plug i n the meter to both the valve and the harness connector block as shown Connect the crocodile clip to a good u Block Connect the exhaust sample probe into the turbocharger adaptor and connect to a CO HC analyser e g Sun EP...

Page 400: ...ST SLACKENING THROllLE POSIT1ON SWITCH MOUNT1NG SCREWS ON REAR OF No 3 4 THROTTLE BODY 0 Switch If adjustment is required fint slacken the throttle p i t i o n switch scram and then adjust idle speed at the stop screw between throttle bodies 2 and 3 Idle Speed Stop Screw Adjvstthrottle cable to suit if necessary After adjustment connect continuity meter TOOOT0568 to the throttle position switch an...

Page 401: ...ssary at the clamp behveen capsule rod and throttle lever Remove electrical bridge and re check idle speed Check duty cycle i s between 45 55 with a 5 to 6 cyclic variation The cyclic variation flicking back and forth over a 5 to 6 range indicates that the closed loop feedback system i s operating with the mixture strength constantly being amended by the frequency valve i n conjunction with the La...

Page 402: ...he mixture setting is correct disconnecting the Lambda sensor should have n o effecfon idle rpm Refer to the following table I O K I O K I SyrtemSatisfactory I Over 55 See Section Under 45 Remark Closed Loop Duty Cycle ii lnjec tor Distribution LD 24E 3 iii Throttle Imbalance LD 24P C O Readings Hiah 1 O K I i Exhaust System Leaking I 2 4 0 1 Closed Loop O K Open Loop Low I 0 K 1 Sensor Faulty I I...

Page 403: ...essure too low Auxiliary air valve does not c l a e Auxiliary air valve does not open Cold start injector does not operate Cold start injector leaking Primary fuel pressure outside specification Sensor plate rest position incorrect Sersor plate and or control plunger sticking Vacuum system leaking Overall fuel system leaking Fuel iniector s leaking or opening pressure low Basic mixture adjustment ...

Page 404: ...hat sufficient fuel is supplied to the injection system Tools required Test Hose TOOOT0579 Graduated Flask TOOOT0582 Electrical Test Bridges TOOOT0569 4 Check Fuel Return Quantity from Distributor Fit the test hose TOOOT0579 to the fuel distributor return connection see Fuel System Precautions LD 22 and place into draduated flask Fit test hose here i n place Trip inertia switch and fit electrical ...

Page 405: ...ce the fuel filter If below specification Check Fuel Delivery Quantity at primary Pump Outlet Fit the test hose to the primary pump outlet connection and place end in graduated flask With electrical test bridges fitted press down inertia switch for exactly 30 seconds and measure fuel quantity delivered Specification 1800 f 1OOcc Ifdelivev is below specification disconnectsupply pipe from pump and ...

Page 406: ...y fuel pressure from gauge Trtp inertta switch Specification 6 0 6 8 Bar O 20 c If pksure is below specification Check Supply Pressure to Fuel Distributor 1 Check gauge valve is fully open 11 Press down tnertta switch and gradually close gauge valve very slowl unttl pressure rkes to 10 0 Bar DO NOT clae gauge valve further as press res I nexcess of 10 Bar are liable to cause damage to the system a...

Page 407: ...EQUIRE ATTENTION UNDER Adjust the shim pack as necessary to correct primary pressure adding O lmm shim thickness increases pressure by about 0 15 bar Renew 0 ring and replace regulator into distributor Re test primary pressure Check Cold Control Pressure Carry out this test ONLY at an ambient temperature of 30 C or lower Fit the test gauge to the warm up regulator as shown See Fuel System Precauti...

Page 408: ...s located at higher altitudes it i s essential that the exact air pressure in known on the day when ths measurements are made in order to determine the correct control pressure Use an accurate barometer or ask the weather bureau or an airport if one or the other i s near and at the same altitude Tolerance of the control pressure altitude curves 0 25 bar If the cold control pressure differs from th...

Page 409: ... i s outside specification replace warm up regulator 6 Check for Fuel System Leaks Internal External With the fuel pumps running carry out a thorough visual inspection of al 1 fuel system connections With the test gauge fitted as in 4 and with the gauge valve open start engine and switch off when warm control pressure i s reached Observe and record the drop i n pressure with time Specification Min...

Page 410: ...amp observe the position of the valve plate which should be partially open dependent on temperature If the valve is completely closed replace the auxiliary air valve Quick Test Clamping off an air valve hose on a cold engine should reduce idle rm Air Valve Hot Test D aconnect R P Mrelay and bridge connector block termiml 30 and 87 After a maxlmum of 5 minutes the auxiliary air w l v e must be comp...

Page 411: ... to the sensor plate Check that the sensor plate i s concentric with and can move freely through the narrowest part of the air funnel Re position if necessary after loosening the plate fastening screw and re tighten to 0 51 0 56 kgf m 3 7 4 1 lbf ft 2 Remove fuel pump control relays and f i t electrical test bridges TOOOT0569 into relay bases for about 10 seconds to run the fuel pump and apply con...

Page 412: ...rapidly back to a position just in front of the zero stop The control plunger follows this rapid movement pf the sensor plate only sluggishly and therefore initially loses contact with the sensor plate lever It must be possible however to feel the plunger make contact with this lever again If this condition i s fulfilled the control plunger can be considered to move freely b Check that the control...

Page 413: ...rews Remove the plunger under certain conditions i n order to do this it may be necessary to blow compressed air against the plunger through the control pressure connection hole Hold the plunger with your hand while doing this Clean the plunger thoroughly with petrol If the plunger s t i l l does not move freely replace the fuel distributor Refit the fuel distributor using a new sealing ring betwe...

Page 414: ...vacuum line switched to the vacuum pump with engine running If a lesser figure is obtained check at the vacuum pump If pump performance is below specification check vac pump exhaust pipe for restriction and V belt drive for fault Replace pump if necessary With satisfactory vacuum pump performance clamp off or disconnect individual components to isolate leaks and replace pipes or components as nece...

Page 415: ...Throttle Port Throttle Edge Drilling Ignition Solenoid i VACUUM SWITCHING DIAGWM BETWEEN 53O 70 C WATER TEMP Vacuum Pump Feed UpstreamThrottle Port Throttle Edge Drilling Ignition Solenoid VACUUM SWITCHING DIAGRAM ABOVE 70 C WATER TEMP ...

Page 416: ...rt Move the hand lever slowly about 2 seconds per stroke back and forth with the stopcock on the pressure gauge open If the pressure does not build up to 1 1 5 bar the injection valve has a leak caused possibly by dirt i n the valve Attempt to flush the injection valve clear by moving the lever back and forth several times vigorously If this attempt is successful continue the test If i t is not po...

Page 417: ...under the opening pressure determined previosly and hold i t constant at that level The injector must not drip for at least 15 seconds 6 Chatter test evaluationof spmy Move the lever back and forth at about 1 stroke per second As this is done the valve must chatter No drops of fuel must form at the mouth of the valve The valve must not produce a cord spray Formation of a single sided atomized spra...

Page 418: ...Page46 SECTION LO Poor spray formation replace injection valves Drop formation a Cord spray Spray in strands ...

Page 419: ... clockwise to reduce the duty cycle rate or counterclockwise to increase the duty cycle meter reading Turn only a small amount at a time and blank off the access hole with finger between adjustments Blip the throttle and re check duty cycle reading When adjustment i s completed refit the anti tamper plug to the access hole Repeat LD 23 checking procedure If a newmixture control unit or component t...

Page 420: ...PLETELY Check that with the accelerator pedal pressed to its fullest extent the full throttle stop bracket on the butterfly spindle is i n contdct with the throttle body abutment Adjust throttle pedal downstop as necessary J THERMO TIME SWITCH To test the switch remove from the manifold and plug the hole to prevent coolant low The switching temperature and time period at 20 C are stamped on one of...

Page 421: ... Bridge connections to high temperature switch in inlet manifold use a spare fuse to activate the capsule Engine speed should hold at 1300 to 1500 rpm Adjust if necessary at the clamp between capsule rod and throttle lever Remove electrical bridge and re check idle speed N THROTTLE POSITION SWITCH Connect continuity meter TOOOT0568 to the throttle position switch With the throttles shut the meter ...

Page 422: ...mbalance is diagnosed i n procedure LD23 check the throttle position switch switch adjustment LD24N CAUTION The throttle bodies and inlet manifold assembly are balanced as a car set by mass flow and rhe throttle bleed channels permanently sealed a t the factory Although provision i s made for measurihg the inlet manifold depression on cylinders 2 3 and adjusting the throttle spindle coupling this ...

Page 423: ...sembly must be replaced as a set mass flowed at the factory LD 25 TORQUE SETTINGS FUEL SYSTEM Fuel Distributor 8 x 1 12x1 5 Fuel Injectors Cold Start Injector Warm Up Regulator 8 x 1 l o x 1 Frequency Valve Fuel h m p Fuel Accumulator Fuel Filter in out Fuel Tank in out 9 Nm 0 9 kgf m 20 Nm 2 0 kgf m 20 N m 2 0kgf m 9 N m 0 9kgf m 9 N m 0 9kgf m 14 N m 1 4kgf m 12 N m 1 2 kgf m 22 Nm 2 2 kgf m 25 ...

Page 424: ...Fuel Pump Main Injection Changeover Confrol Relays Fuse 7 5 Amp Relay I A Fuel Pump Inertia Switch I Ignition t k Relay Amplifier I Over host I 15 A Fuses Switch R P M Relay Fuel Pump Idle Up C o n a l Relay ...

Page 425: ...ng coils of the auxiliary air valve and warm up regulator The closed high temp switch supplies the fast warrr up relay See circuit 3 A feed from the cold start contact on the starter motor solenoid supplies the cold start injector which i s controlled by the thermal ti ne switch Earth signals are supplied to terminals 12 and 6 of the E C U via the low temp switch and fuel by pass control relay via...

Page 426: ...ates speed sensing module in fuel by pass speed sensing relay and allows ignition feed from terminal 15 to energise the relay and earth via terminal 31 and the fast warm up relay Terminal 8 of the fuel by pass speed sensing relay supplies a 12 volt positive to the idle up control relay which prevents the a c idle up solenoid opening and to the idle changeover relay 7 Normal Run Above 700 C Water T...

Page 427: ...earth circuit for the a c idle up solenoid which i s de energised and opened This circuit only operates below 1400 rpm 10 Light Throttle Over 3250 R P M Similar to circuit 6 except The fuel enrichment module supplied with a negative feed from the ignition coil senses when an engine speed of 3250 rpm is reached and allows an ignition feed to operate the relay coil and close the relay contacts This ...

Page 428: ...12 8 Y y 31e 7 e Y N 31b 6 YB I 15 KG Y G 4L G f1gyaEi i 31 IGNITION AUX YLG YU IGNITION WS 5 SOLENOID COI L ve L Y 4Q WY IGNITION G YN YP Y O Y 0 T 1 n i b 0 c SWITCH WY COLD START HEAT1NG 1 I N S O R_ L I I COIL THROTTLE FREQUENCY COLD THERMAL AUXILIARY WARM UP POSITION VALVE START TIME AIR REGULATOR SWITCH INJECTOR SWITCH VALVE 1 BASE CIRCUIT IGNITION OFF COLD ENGINE BELOW 35 ELAY ...

Page 429: ...NIC CONTROL UNIT n il COLD START A s o L HEATING I L COIL THROTTLE FREQUENCY COLD THERMAL AUX LIARY WARM UP POSITION VALVE START TIME AIR SWITCH REGULATOR INJECTOR SWITCH VALVE 2 COLD CRANK BELOW 3 5 OIL TEMP ...

Page 430: ...COIL THROTTLE FREQUENCY COLD THERMAL AUXILIAKY WARM UP POSITION VALVE START TIME AIR REGULATOR SWITCH INJECTOR SWITCH VALVE 3 COLD RUN IDLE BELOW 3 5 OIL TEMP ...

Page 431: ... L I A I ELECTRONIC CONTROL UNIT n u k SENSOR HEATING I COIL THROTTLE FREQUENCY COLD THERMAL POSITION VALVE START TIME SWITCH INJECTOR SWITCH 4 COLD RUN IDLE ABOVE 3 5 OIL TEMP BELOW 70 c WATER TEMP I WY COLD START AUXILIARY WARM UP A1 R REGULATOR VALVE ...

Page 432: ...SWITCH 5 NORMAL IDLE ABOVE 7 0 WATER TEMP 1 WY COLD START FREQUENCY COLD THERMAL AUX LIARY WARM UP VALVE START TIME AIR REGULATOR INJECTOR SWITCH VALVE ...

Page 433: ...TTLE POSITION SWITCH I YLG IGNITION AUX IGNITION SOLENOID 4 1 Y WY A IGNITION r T I WY COLD START FREQUENCY COLD THERMAL AUXILIARY WARM UP VALVE START TIME AIR REGULATOR INJECTOR SWITCH VALVE 6 NORMAL RUN ABOVE 700C W A T E R TEMP ABOVE 1600 rpm B E L O W 3 0 THROTTLE ANGLE ...

Page 434: ...BY PASS I YG tGN ITION AUX IGNITION SOLENOID KG YLG YU L 7 Y b COIL THROTTLE FREQUENC COLD THERMAL POSITION VALVE START TIMF IGNITION POSITIVE WY CO LD START AUXILIAW WARM UP AIR REGULATOR VALVE SWITCH NJECTOR W C H NORMAL RUN ABOVE 70 C WATER TEMP OVER 3 0 THROTTLE ANGLE ...

Page 435: ... AUX s o I HEATING COIL THROTTLE FREQUENCY COLD T H E M A L POSITION VALVE START TIME SWITCH INJECTOR SWITCH WY COLD START AUXlLlART WARM UP AIR REGULATOR VALVE ELAY 8 OVERUN ABOVE 1400rpm DECELERATING FROM ABOVE 1600 rpm ...

Page 436: ...D START ISENSOR I HEATING COIL THROTTLE FREQUENCY COLD THERMAL AUXILIARY WARM UP POSITION VALVE START TIME AIR REGULATOR SWITCH INJECTOR SWITCH VALVE 9 AIR CONDlTlONlNG COMPRESSOR OPERATING A T IDLE ABOVE 70 W A T E R TEMP ...

Page 437: ...SOR HEATING LOW I TEMP SWITCH COIL LIGHT THROTTLE OVER 3250rpfi THROTTLE POSITION SWITCH FREQUENCY VALVE COLD THERMAL START TIME INJECTOR SWITCH B POSITIVE cb 3 AUXILIARY WARM UP I COLD START AIR REGULATOR VALVE ...

Page 438: ...UPVALVE SEE SHT 3A I G L CBHC rGB I RHC CBHC 1 1 TO TACH0 WS SEE SHT 2 TO RPM RELAY 2 SEE SHT 3A RHC b I w p W P 1 1 SECONDARY FUEL PUMP WG 7 0 PUMP KP I FUEL RELAYS I ENGINE WERSPEEDI FUEL PUMP KR FAILURE MODULE N rrr n OVERBOOST WITCH b 8 0 TO BATTERY 01 FUEL PUMPS INERTIA SWITCH ...

Page 439: ...itch pin 6 of electronic control unit to ground Normally open change over relay a Terminals 85 and 8 6 relay windings Terminals 30 51 87A and 87 switching contacts Lotus Part A079M6141F Silver Fuel By Pass Control Relay Location Coil box Mating connector colour Blue Double contact relay controlled by ignition h e 23 in fusebox and throttle position switch Energised when throttle is i n the closed ...

Page 440: ...ve 1600 R P M 6 Fuel By Pass Speed Sensing Relay Location Coil box Mating connector colour Black Additional information see LD 16 88a 31 Controlled by low tersion ignition pulses to give 31e l5 engine speed serrring also thermally inhibited operation by fast warm up relay Energises fuel by pass valve and econ tell tale on deceleration from an engine R P M of greater 1 than 1600 until 1400 R P M wh...

Page 441: ...RP M Relay Location Coil box Mating connector colour Blue 87 31 Blue Senses ignition pulses i n the low tension circuit and requiresa minimum of 4 R P M before making contact and thereby energising the fuel pump and injection circuits There is an inbuilt delay i n the relay that alIo vs the contacts to remain closed for approx 5 seconds after the low temion circuit has ceased to function Moulding ...

Page 442: ... thermal fuel pressure control valve feed 12 volts positive from the R P M relay Positive Negative Connection Connection I Negative Positive 0 0 View on top of Warm Up Regulator b 16 Auxiliary Air Valve a Location Inlet manifold Mating connector colour Black Additional information see LD 9 Electrically operated air valve Feed 12 volts positive from the R P M relay 17 Thermal Time Switch Location S...

Page 443: ... idle change over relay at a throttle opening of 29O and above J r Raistance measurement in ohms between Therm G and Term W and Term G and term W Ground Housing Ground 25 4 0 0 25 4 0 5 0 8 0 100 I60 5 0 8 0 Design 38Oc t Schematic shown i n closed throttle position At a temperature under over O C OC 30 1 4 0 Black I 0 2 Connector Cavity umben Switch Cavity Numbers 20 Frequency Valve Location Fron...

Page 444: ... pass relay under deceleration and the throttle position switch on throttle openings of 29O and above Also at engine speeds aver 3250 rpm Cavity 8 Yellow cable 12 volts positive supply to electronic control unitfrom the R P M relay Cavity 12 Yellow red cable switched to ground to give a 75 duty cycle by the low temperature switch Cavity 15 Yel low orange cable controls the duty cycle open close ra...

Page 445: ...e may cause the fuse i n the other pump circuit to blow due to the increased load imposed on i t dependent on position i n which failed pump fails This circuit is designed as a get you home aid i n the event of failed fuel pump but the vehicle require attention to the fuel pump system as soon as possible 25 Fuel Pump Control Relays 2 Location Coil box Mating connector colour Black Double contact r...

Page 446: ... Turbo Commemorative L u m e n i t i o n Turbo C o n s t a n t E n e r g y F u s e d Fan Relay T u r b o C o n s t a n t E n e r g y Thermal T r i p Turbo 8 7 M Y onwards Component L o c a t i o n Diagram MB 2 H a r n e s s R o u t i n g Diagram MB 3 L u m e n i t i o n I g n i t i o n S y s t e m MB 4 L u c a s C o n s t a n t E n e r g y I g n i t i o n MB 5 M a i n t e n a n c e F r e e B a t t...

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Page 456: ...rol H L Flash H L Flash H L Motor Iul H L Motor RH I WL Motor LH I H L Motor LH Grey Rad Fans if thermal trip fitted Fused Rad Fans if no thermal trip PUMP THERMAL SWITCH Water pumpoutletpipe For component usage 53 RAD FANS IEARLY 53 see circuit diagrams PURGE PUMP 87 MY onTURBO MB 2 COMPONENT LOCATION DIAGRAM ...

Page 457: ...TE S3 1 FAN FAIL RELAY INTERIOR LIGHT DELAY FUSEBOXES AERIAL RELAY 1 1 HAZARD TURN FLASHER UNITS INNER HEADLAMP CIGAR LIGHTER W I P E RELAYS FUSES 17A A C U COMPARATOR INTERIOR UNIT TURBO FAN RELAY DELAY IT b A C COMPRESSOR Q RELAY m MB 2 COMPONENT LOCATION DIAGRAM Fascia ...

Page 458: ...MB 3 HARNESS ROUTING DIAGRAM ...

Page 459: ...i b l e by t h e c o l o u r o f t h e r e s i n o r p l a s t i c block s e a l i n g t h e w i r e s i n t o t h e module u n i t Mk16 u n i t s a r e s e a l e d w i t h r e d o r b l a c k r e s i n Mk17 u n i t s a r e s e a l e d by a w h i t e p l a s t i c clamp O p t i c a l Switch MK 16 o p t i c a l switch u n i t s a r e marked w i t h numbers s i m i l a r t o 8240 t h e 8 and 0 b e i...

Page 460: ...16 systems used a r e c t a n g u l a r connector block between the o p t i c a l switch and power module Mk 17 systems used an oval connector block with r e t a i n i n g prongs which was subsequently found t o be l e s s durable than the e a r l i e r r e c t a n g u l a r type A l l s e r v i c e replacement components a r e supplied f i t t e d with t h e t e c t a n g u l a r type connector a...

Page 461: ... HT l e a d removed from the d i s t r i b u t o r and h e l d a p p r o x i m a t e l y 6 5 mm 114 i n c h from a n e a r t h p o i n t such a s t h e e n g i n e but away from t h e c a r b u r e t t o r s r e g i o n CAUTION H T c a n be dangerous and c a n jump 25 mm 1 i n c h Leads should be handled c a r e f u l l y 1 To t e s t t h e complete system With t h e d i s t r i b u t o r c a p re...

Page 462: ... 16 0 3 w i t h beam i n t e r u p t e d N B The v o l t a g e on t h e r e d l e a d i s a p p r o x i m a t e l y 7 5V 4 Do n o t l e a v e t h e i g n i t i o n o n f o r a long time max 15 m i n s w i t h t h e o p t i c a l s w i t c h assembly d i s c o n n e c t e d NOTE Under no c i r c u m s t a n c e s should a A f u l l p o s i t i v e f e e d be a p p l i e d t o any c o n n e c t i o ...

Page 463: ...g no subsequent adjustment A conventional type rotor arm i s fitted moulded as is the distributor cap from track retardant material The two cables connecting the distributor to the ignition amplifier terminate i n a non reversible shur plug a The high energy coil model 32 C5 is specially designed to achieve the very fast current rise times required for thir system h coil requires no ballast and rs...

Page 464: ...ranking TEST 4 Ohmmeter should show 2 5 kO Correct Changeamplifie If engine will not start TESl 5 Incorrect Changepick up Ifengine will not start TEST 5 Should be good HT sparking Repeat with original HTlead Good sparking If engine will not start w TEST 6 No sparking replace HTlead If engine will not start TEST 6 No sparking Replace coil If engine will eill stat TEST 6 Should be No sparking 7 TEST...

Page 465: ......

Page 466: ... o l l o w s The l i g h t i n g s w i t c h i s l o c a t e d a t t h e l e f t hand t o p of t h e fasc ia b i n n a c l e With t h i s s w i t c h i s t h e u p p o s i t i o n a l l l i g h t s a r e o f f I n t h e c e n t r e p o s i t i o n t h e s i d e r e a r and p a n e l l i g h t s a r e switched on On U K market c a r s f i t t e d w i t h Dim Dip headlamps s w i t c h i n g on t h e...

Page 467: ... e r m i n a l 7 The module p r o c e s s e s t h e s i g n a l s r e c e i v e d v i a t e r m i n a l s 1 and 7 t o o u t p u t a 1 0 v o l t a g e f e e d t o t h e d i p beams v i a t e r m i n a l 5 With t h e headlamps s w i t c h e d o n a f e e d from t h e headlamp s w i t c h i s s u p p l i e d t o module t e r m i n a l 2 When d i p beam i s s e l e c t e d a n a d d i t i o n a l f e ...

Page 468: ...ar Lights Instrument Illumination Clock Door Lamps Interior Lamps Cigar Lighter Stop Lights Reverse Lights Wipers Washer Powerwash Brake Fail Handbrake Warning Seat Belt Logic Water Battery Gauges Heated Rear Screen Window Lift Mirron Radio Radio Amp if fitted Pulsafe Alarm if fitted Alarm Components Location Engine Bay Ventilation Fuse Box Circuits Ratings Relay Connections Splice GI 1 ice A1 Spl...

Page 469: ...Fans Radiator Cooling Fans Window Lift Windscreen Wiper Pumps Fuel HeadlampWash Screen Wash Radio COMPONENT INDEX Sheet Page Radio Amp if fitted Relays ACU Control Brake Fail Dip Beam D I Hazard Unit Engine Bay Vent Engine Management Flash Headlamp Motors Heated Rear Screen Horn Rnternal Fars Lamp Delay Unit Main Beam Power aux Power ign Radiator Cooling Fam Rheostats Solenoids Carb Evap Cold Star...

Page 470: ...nnector Door Harness Connector Direction Indicator Engine Bulkhead Connector Engine Harness Connector Front Harness Connector Left Hand Pumps harness Connector Right Hand Rear Harness Connector Solenoid Switch Warning Light Centre Console Connector Manifold Harness Connector Cooling Fans Harness Connector Cable Colour Code 0 3 aw e R Red S Slate U Blue W White Y Yellow ...

Page 471: ... SHT 2 HEAD LAMP MAINIOIP BEAM CIRCUIT SEE SH1 8 TO START MOTOR SEE SHT 2 T O FUSE BOX FUSE 24 ALARM TO RAD FAN RELAY SEE SH I 5 N SPLICE A SEE SHT 25 I N R 1 N R i w SPLICE B SEE SHZ 26 SPLICE 4 D SEE SHT 27 W 4 W IGN SHEET 1 a ...

Page 472: ...OL TO ENGINE RELAY RELAY SEE SHT 6 ENGINE SPEED LIMITER TO LAMP OELAY UNIT SEE SHT 12 E HC I ALTERNATOR I I I NY ENGINE BAY VENT CIRCUITSEE StiT21 o I RHC 9 1 I L N y a G SPLICE 6 SEE SHT 24 IGNITION WILT I I SEE SHT 27 BATTERY 12 v FUEL 0 FILTER I INERTIA SIN PHC RHE el w P L w P FUEL PUMP START ALTERNATOR IGNITION CUCcT ...

Page 473: ... CIRCUIT WITH THRUTTLE CLOSED1 THROTTLE MICRO SIW FUEL PRESS SOL CARB EVA SOL VENT CIRCUIT ON SHT21 1 I I THERMAL SIW 7O9C MAX BREAK ON RISE I 6 6 MIN MAKE ON FALL f SPLICE O SEE SHT 27 DIVERTER VALVE SOL FUS 801 4COLD START CHANGE OVER SOL RHC 10 2 KU KU THROTTLE SOL 1 SEE A C U CIRCUIT T ON SHT 6 SPLICE 8 SEE SHT 26 ENGINE MANAGEMENT 0 ...

Page 474: ...OLLED BY THERMAL SWITCH F E THROTTLE SOLENOID TO OPERATE WHEN 1 AlC COMPRESSOR I S ENERGISED 2 STARTER MOTOR CRANKING ON HOT START 3 COLD STARTING EXCEPT DURING CRANKING THERMAL SWITCH MAX BREAK ON RISE 70 C MIN MAKE ON FALL 60 C DIVERTER VALVE ENERGISED WHEN COOLANT TEMP ABOVE 609 COLD START CHANGE OVER SOLENOID ENERGISED WHEN CHOKE I S USED BUT NOT WHILST CRANKING FUEL PRESSURE SOLENOID ENERGISE...

Page 475: ...SWITCH F E THROTTLE SOLENOID TO OPERATE WHEN I AIC COMPRESSOR IS ENERGISED 2 STARTER MOTOR CRANKING ON HOT START 3 COLD STARTING EXCEPT DURING CRANKING THERMAL SWITCH MAX BREAK ON RISE 70 C MIN MAKE ON FALL 60 C DIVERTER VALVE ENERGISED WHEN COOLANT TEMP ABOVE 609 COLD START CHANGE OVER SOLENOID ENERGISED WHEN CHOKE I S USED BUT NOT WHILST CRANKING FUEL PRESSURE SOLENOID ENERGISED BY THROTTLE MICR...

Page 476: ... SWITCH F E THROTTLE SOLENOID TO OPERATE WHEN 1 AIC COMPRESSOR I S ENERGISED 2 STARTER MOTOR CRANKING ON HOT START 3 COLD STARTING EXCEPT DURING CRANKING THERMAL SWITCH MAX BREAK ON RISE 70 C MIN MAKE ON FALL 6 0 C DIVERTER VALVE ENERGISED WHEN COOLANT TEMP ABOVE 600 COLD START CHANGE OVER SOLENOID ENERGISED WHEN CHOKE I S USED BUT NOT WHILST CRANKING FUEL PRESSURE SOLENOID ENERGISED BY THROTTLE M...

Page 477: ... THERMAL SWITCH F THROTTLE SOLENOID TO OPERATE WHEN 1 AIC COMPRESSOR IS ENERGISED 2 STARTER MOTOR CRANKING ON HOT START 3 COLD STARTING EXCEPT DURING CRANKING THERMAL SWITCH MAX BREAK ON RISE 70 C MIN MAKE ON FALL 60 C DIVERTER VALVE ENERGISED WHEN COOLANT TEMP ABOVE 6 m COLD START CHANGE OVER SOLENOID ENERGTSEO WHEN CHOKE IS USED BUT NOT WHILST CRANKING FUEL PRESSURE SOLENOID ENERGISEO BY THROTTL...

Page 478: ...THROTTLE SOLENOID TO OPERATE WHEN 1 AIC COMPRESSOR I S ENERGISED 2 STARTER MOTOR CRANKING ON HOT START 3 COLD STARTING EXCEPT DURING CRANKING THERMAL SWITCH MAX BREAK ON RISE 70 C MIN MAKE ON FALL 60 C DIVERTER VALVE ENERGISED WHEN COOLANT TEMP ABOVE 600C COLD START CHANGE OVER SOLENOID ENERGISED WHEN CHOKE I S USED BUT NOT WHILST CRANKING FUEL PRESSURE SOLENOID ENERGISED BY THROTTLE MICRO SWITCH ...

Page 479: ... wu wu 7 7 WU SEE ENGINE MANAGEMENT CIRCUIT ON SHT3 WU LOW FUEL LEVEL I CHOKE WILT BIN A 1 SPLICE G 6 SEE SHT 24 R H C G O G O CHOKE SIW FUEL LEVEL VOLTAGE STABILISER SEE SHT 24 SPLICE G I TO TEMP GAUGE SEE SHT 16 m GAUGE SHEET 4 ...

Page 480: ...Y FAN CFHC FHC FUSE BOX BG BG 1 3 BN BN BN TO A CU C O N T CIK CFH C FHC RELAY SEE SHT 6 G K 8 I CCC B G B G 9 BIN B FAN FAIL WILT POSI7 Q c POST A C U THERMISTOR CONTROL UNIT I I GK BO A C U THERMISTOR I K I L B O u K U CUT OUT KU A C U TEMP CONTROL ...

Page 481: ...GK L r IGNITION SEE SHT 2 FANS CIRCUIT SEE SHT 5 YG WR S W SEE SHT 2 BIN 0 WR 16 TO BRAKE FAIL cWR SEE SHT 15 A C U CONTROL RELAY LOGIC BOX SEE SHT 16 RAD COOLING n u l FANS CIRCUIT RHC EHC SEE SHT 5 KU 9 K K u YP ENGINE MAN CIRCUIT A C U COMPRESSOR AIR CONDITIONING RELAY SHEET b ...

Page 482: ...FUSE BOX SPLICE 6 Y SEE SHT 26 B FAN SPEED SIW INT FAN MOTOR 2 FUSE BOX 21 a W d S P L I C E 0 8 SEE SHT 27 A CU CIRCUIT SEE SHT 6 INTERNAL FANS I SHEET 7 ...

Page 483: ...8 FHC POSITIVE POST NU uwl IIPIMAIN BEAM C COLUMN S I N SEE SHT 9 I B FHC UG FUSE BOX 2 BIN A R H HEAD LAMPS NOT USED SEE POWER WASH CIRCUIT w OUT BOARD ON SHT 1 4 HEAD LAMP MAIN BEAM DIP BEAM FLASH SHEET 8 a ...

Page 484: ... SPLICE A PA 5 P A 8 N SEE SHT 25 FLASH CIRCUIT SEE SHT 8 NLG UG I MOTOR RH RELAY RH HEAD LAMP MOTOR HORNS HORN RELAY FHC FUSE BOX 9 I TO ALARM SEE SHT 27AL 7 Y HC AL4 DIP1MAIN BEAM g COLUMN SIW HORNS DIPIMAIN BEAM COLUMN S W SUPPLY SHEET 9 ...

Page 485: ...POSITIVE LH MOTOR l s A RELAY HEAO LAMP MOTOR OPERATION m PODS DOWN HEAD LAMP OR CIRCUIT ...

Page 486: ...OTOR MOTOR S RELAY I 10A MOTOR 1 i i I 7 I U G NLG TO MA1N BEAM i RELAY COIL 7 2 3 i i i 0 z i NU LIGHT SIW UR n I TO DIP BEAM RELAY COIL 4 HEAD LAMP MOTOR i PODS TRAVELLING UP HEAD L AMP MOTOR CIRCUIT SHEE T 9 I _ _ I ...

Page 487: ...POSITIVE N I HEAD LAMP MOTOR OPERATION HEAD LAMP MOTOR CIRCUIT SHEET 9 0 ...

Page 488: ...HEAD LAMP MOTOR OP I hATION PODS TRAVELLING DOWN NU LIGHT SIW HEAD LAMP MOTOR CIRCUIT SHEET 9 ...

Page 489: ...POSITIVE POST q NLGd HEAD LAMP MOTOR OPERATION HEADLAMP FLASH 1 POD TRAVELLING UP HEAD LA MP MOTOR CIRCUIT 7 ...

Page 490: ...SHT 25 BIN B I 20 12 SPLXE 0 G W 6 1 SEE SHT 27 B A FUSE TO CLOCK RB SEE SHT 12 3 R H SID MARKER B RG FUSE j J LIGHT S W 1 FHC 9 R rR R O R O R H FRONT BOX TO RHC 8 RHC GW B I R H REAR 0 1 SHEET 10 D I HAZARD ...

Page 491: ...C 1 27AL Y AL4 B B CIRCUIT BAT TACHO BOOST SPEEDC TEMF FUEL L H OttC SHT 1 2 FIBRE OPTIC 1 LRO 0 1 8 HAZ R N RN RN RN RN RHC CIRCUIT 8 T RO SEE SHT 10 RB 1 RB r I RO RO LH SIDE LICENCE LICENCE R H SIDE MARKER NO PLATE NO PLATE MARKER LT L H LT R H A A B t B a ...

Page 492: ...CUIT I SEE SHT 10 P SPLICE A N SEE SHT 25 4 FUSE BOX RH FUSE BOX SPLICE A N PANEL LIGHTS SEE SHT 25 0 INTERIOR LAMP _t RW TO R H RHEOSTAT I rRwP SEE SHT 11 L H DOOR SIW L H K H o H c STARTER CIRCUll B W L G W SEE SHT 2 PLG I DHC I 3 1 CIGAR LOGIC BOX DOOTL AMP LIGHTER SEE CIRCUIT ON SHT 16 CLOCK DOOR WARNING INTERNAL LAMPS ...

Page 493: ...SHEET 13 STOP LIGHT RADIO AMP If fitted RADIO SEE CIRCUIT ON SHT 20 REVERSE LIGHT 0 3 Rl 0 Y SPLICE A SEE SHT25 6 N STOP LIGHT S W RHC s 0 STOP LIGHTS LOGIC BOX LH SEE CIRCUIT ON SHT 16 ...

Page 494: ...R LGU PUMP WASHi WIPER MOTOR NLG WIPE siw RHc 1 RLG LGU ULG POWER WASH INTERMITTENT LGB TIMER RELAY WIPE UNIT F H C 8 1 I 0 1 j L G B L G B FUSE BOX FUSE BOX SCREEN WASH PUMP 2 11 NOT USED R U A T U P N S PLICE A A I 3 SEE SHT25 u p HEAD LAMP CIRCUIT SEE SHT 8 POWER WASH 8 WIPER SHEET 14 ...

Page 495: ...TO ACU CONTROL SPLICE G RELAY SEE SHT 6 FUSE BOX SEE SHT 24 SPLICE 0 W G SEE SHT 27 VAC S W BIN BIN B BS W R WR w R 14 BINNACLE J B B W SEE SHT 24 I BRAKE FAIL WR W LT HAND BRAKE WARNING h 0 LOW BRAKE FLUID LEVEL S W I I BRAKE FAILURE WARNING ...

Page 496: ...NSMITTER E E SHT G U 1 4 Gu 3 G U 2 4 L GU T 1 1 f 5 LG TO FUEL GAUGE SEE SHT 12 P TO STOP LIGHT SIN SEE SHT 13 SEE SHT 4 1 BATTERY GAUGE LOGICBOX WATER TEMPERATURE BATTERY GAUGES SHEET I 6 6 5 TO ACU CONT RELAY 4 3 SEAT BELT S W 2 SEE SHT 6 WR 1 p B L F B I BIN A SEAT BELT WILT B p 4 5 SEE SHT 24 ...

Page 497: ...SHEET 17 FUSE BOX A Q W U BIN A HRS eJ1 K SPLICE A N SEE SHT 25 A B TAILGATE HINGES HRS S W SPLICE G SEE SHT 24 HEATED REAR SCREEN H R S SHEET 17 ...

Page 498: ...L H MIRROR R H MIRROR L H DHC 4 I A FUSE BOX B SPLICE B SEE SHT 26 MIRROR CONTROL BU b I 7 YG TO RADIO AMF SEE SHT 20 If fitted MIRRORS Movement by solenoids SHEET 19 ...

Page 499: ...SHEET 18 L H WINDOW LIFT S I N SPLICE B SEE SHT 26 L H WINDOW LIFT MOTOR WINDOW LIFT 7 SU 8 7 6 5 R H WINDOW Y A 4 3 L I F T S I W r sP 2 1 R H WINDOW L I F T MOTOR R H DHC 4 su 0 SHEET 1 11 ...

Page 500: ...MIRROR CONTROL CIRCUIT SPLICE B Y SEE SHT 26 TO CLOCK I I I I YG SEE SHT 12 d d b d b SPLICE A N SEE SHT 25 SEE SHT 1 3 RADIO RADIO AMP If fitted ...

Page 501: ...A HC AL 4 N L WS TO BIN A Io TO HORN SEE SHT9AL SEE SHTZAI TO LIGHTS SEE SHT 11AL TO DI HAZARD SEE SHT lOAL L FACIA HC FACIA HC AL2 AL 2 I LTG WB R I 1 R RB I I 7 R I l O P INUNE FUSE Next to stby I battery I Standby buttery NOTE REED SWITCHES SHOWN DOORS OPEN BEEPER SIREN ULTRACWSTIC DETECTORS PULSAFE ALARM SHEET 20A ...

Page 502: ...Z O O ULTRACOUSTIC DETECTOR in front of right hand headla mp motor SIREN inside right hand BONNET REED TAILGATE R E E D SWITCH STANDBY BATTE below left hand behind left hand seat bottom of B post tunnel vent ...

Page 503: ...START MOTOR SEE SHT 2 I BATTERY 12 v THERMAL SWITCH MAKE ON RISE 8 5 2 BREAK ON FALL 68 C 2 C1 INHIBIT SWITCH 15AMP 3 E H C 5 ENGINE MANAGEMENT CIRCUIT SEE SHT 3 L LGO GF I TIMER ENGINE BAY VENTILATION 0 0 ...

Page 504: ...10A 10A 10A 10A 10A 10A RADIATOR FAN NO l DOOR MIRRORS I RADIO AUX 1 RADIO AMP IAUX I f fitted I INSTRUMENTS WARNING LAMPS R H SIDE 1 TAIL 1 LICENCE NO PLATE LAMPS STOP LAMPS1SEAT BELT BUZ RADIO IMem RADIO AMP If fitted1 ANTENNA HEAD LAMP WASH RADIATOR FAN NO 3 HEATED REAR SCREEN WIPER MOTOR 1 SCREEN WASH HEAD LAMP MOTORS DOWN CONTROL1 HEAD LAMP MOTORS HORN I HEAD LAMP FLASH RADIATOR FAN NO 2 REVE...

Page 505: ...CHANGEOVER DOUBLE CONTACT RELAY CONNECTIONS ELECTRONIC UNIT I l c SHEET 23 ...

Page 506: ... BOX SPLICE 0 FACIA H C SEE SHT 1 G L TG G 4 R H 0 1 W I L T G SEE SHT 10 BRAKE FAIL WARNING CIRCUIT SEE SHT 15 G G G HAND BRAKE W I L T LOW FUELI BRAKE FAIL RELAY SEE SHT 15 CHOKE WILT SEE SHT 15 SEE SHT L SEAT BELT WILT SEE SHT 16 BATTERY GAUGE SEE SHT 16 VOLTAGE STABILISER SEE SHT 16 SPLICE G I SHEET 24 ...

Page 507: ... LAMP M O T O R S p _N SEE SHT 9 I I HORN 8 HEAD LAMP FLASH SEE SHT 9 POSITTVE POST PSEE SHT 1 P SEE SHT 12 A 13 B H R S STOP LAMPS RADIO SEE SHT 13 SEE SHT 20 m 0 INT LAMP 8 CLOCK SEE SHT 12 HAZARD LAMPS SEE SHT 10 N W USEE SHT 17 SPLICE A SHEET 25 ...

Page 508: ...POWER RELAY AUX SEE SHT1 a WINDOW LIFT SEE SHT 18 5 DOOR MIRRORS rYG SEE SHT 19 RADIO Y SEE SHT 20 I INTERNAL FANS I SEE SHT 7 B 22 A ENGINE MANAGEMENT Y G SEE SHT 3 SPLICE 0 SHEET 26 ...

Page 509: ..._ START ALT IGN SEE SHT 3 SEE SHT 2 INTERNAL FANS SEE SHT 7 INDICATORS A 2 0 B G W SEE SHT 10 AIR CON0 g RAD FANS SEE SHT 6 REVERSE LAMPS SEE SHT 19 WIPER MOTOR SCREEN WASH NOT USED SEE SHT 14 G G 1 SPLICE G I BRAKE FAIL W LT SEE SHT 24 SEE SHT 1 5 SPLICE D SHEET 27 ...

Page 510: ......

Page 511: ... N S CONNECTORS FUSEBOX I A HEADLAMP POWERWASH TIMER IF FITTED C HEATED REAR SCREEN RELAY D AIR CONDITIONING DROP OUT RELAY 1 E INTERIOR FANS RELAY F RADIATOR FANS RELAY BRAKE FAIL WARNING LIGHT RELAY REAR HARNESS ...

Page 512: ......

Page 513: ...demist vent duct from the binnacle adaptor LUCAS CONSTANT ENERGY IGNITION The Lucas constant energy ignition system is an inductive system i n which the energy stored i n the coil is maintained constant over a wide range of engine speeds thereby providing consistently high output voltages The system comprises a distributor model 45 DM and ignition coil model 32 C5 an ignition amplifier model AB 14...

Page 514: ...I F I E R J S W I T C H I N G Low Low RESULT J J Should be Regular sparking TEST6 Nosparking TEST 2 Measure voltages at 1 4 incl should be 1 More than 1 1 W 2 lV max below V at 1 3 lV max below Vat 1 4 ov 0 lV All correct I TEST 3 Incorrect reading s SEE CHART S U S P E C T Battery discharged Ignitionswitch andlor wiring Coil or amplifier Amplifier earth ground Voltage increases while cranking TES...

Page 515: ...e will not start TEST 6 No sparking replace HTlead Lf engine will not start w T E T 6 No sparking Replacecoil If engine will not start TEST 6 Should be No sparking TEST 7 HT sparking Replacerotor armlrotor vane If engine will not start TEST 7 Shouldbe 1 Clean dry no tracking marks 2 Clean dv no tracking marks 3 Must not be cracked chaled or perished 4 Must not be open circuit 5 Clean dry andset to...

Page 516: ...move battery from vehicle a Gnstant Current The battery must be charged at a maximum of 5 amps until the battery terminal voltage on charge has stabilised over a one hour period a t which time the voltage w i l l be in the range 16 0 16 5 V A t this stage the battery must be taken off charge IMMEDIATELY to prevent excess gassing with resulting water loss which w i l l ultimately reduce the guarant...

Page 517: ...ct ion Indicators Hazard Rear Lights Instrument Illumination Clock Door Lamps I n t e r i o r Lamps Cigar Lighter Stop Lights Reverse Lights Wipers Washer Brake Fail Handbrake Warning Seat Belt Logic Water Battery Gauge Heated Rear Screen Window L i f t Mirrors Radio Radio Amp i f f i t t e d Low o i l and coolant warning Fuse box Circuits and Ratings Relay connections Splice G I Splice A Splice B...

Page 518: ...t Belt Warning Side Market Front Side Marker Rear Stop1amps Tai lamps Antenna Internal Fans Mirrors Radiator Cooling Fans Window Lift Windscreen Wiper Fue1 Screen Wash Sheet p a 4 Radio Amp i f f i t t e d 20 Relays ACU Control 6 Brake Fail 15 Dip Beam 8 D I Hazard Unit 10 Engine Management 3A Flash 8 Fuel Pump Control 3C Headlamp Motors 9 Heated Rear Screen 17 Horn 9 Internal Fans 7 Lamp Delay Un...

Page 519: ...Door Harness Connector Direction Indicator Engine Bulkhead Connector Engine Harness Connector Front Harness Connector Left Hand Pumps Harness Connector Right Hand Rear Harness Connector Solenoid Switch Warning Light Centre Console Connector Manifold Harness Connector Cooling Fars Harness Connector Coil Ejox Harness Connector Cable Colwr Code 0 Orawe R Red S Slate U Blue W White Y Yellow ...

Page 520: ...D LAMP NU 9 NU MAINIDIP BEAM FHC CIRCUIT SEE SK1 8 N U L u TO START MOTOR SEE SHT 2 TO RAD FAN N SPLICE A RELAY SEE SHT 5 SEE SHT 25 2 N R P N R TO IGNITION Y LY SIW SEE SHT 2 1 Y SPLICE 1 B SEE SHT 26 0 I SPLICE SEE SHT 27 SUPPLIES ...

Page 521: ...1 0 L RHC wR W TO LAMP DELAY WR POSITIVE POST UNIT SEE SHT 12 SEE SHT 1 L N Y I I SPLICE 6 SEE SHT 24 TACH0 TO ENGINE OVERSPEE01 FUEL PUMP FAILURE SPLICE G G SEE SHT 24 RHC IGNITION WILT I TO RPM RELAY 1 I SEE SHT 3A START ALTERNATOR IGNITION SHEET 2 ...

Page 522: ...SPEEDI FUEL PUMP FAILURE MODULE SEE SHT 3C TO COLD START INJECTOR SEE SHT 38 YG Y L G TO THERMAL TIME SWITCH SEE SHT 3B Y N TO THROTTLE POSITION SWITCH SEE SHT 38 TO SENSOR HEATING COIL SEE SHT 38 TO INERTIA SW SEE SHT 3C TO FREQUENCY VALVE SEE SHT 38 TO WATER TEMP SW TO E C U Y L 3 y q 3 P I SEE SHT 3B CBHC TO IGNITION COIL SEE SHT 2 RPM RELAY 2 RPM RELAY 1 FUSE BOX TO ENGINE OVERSPEEDl TO STARTE...

Page 523: ...T 3A I WATER TEMP SWITCH I DECELL CONTROL I SEE SW 3A I I I I I CBHC TO START MOTOR YLG CBHC IDLE SEE CHANGEOVER SHT 3A DECELL CONTROL I SEE SHT 3A YLG WY k FREQUENCY COLD START THERMAL VALVE I INJECTION TIME SWITCH B SHEET 38 THROTTLE POSITION OIL TEMP AUXILIARY WARM UP SWITCH SWITCH AIR VALVE REGULATOR FUEL INJECTION MANAGEMENT SYSTEM ...

Page 524: ...1 SHEET 3C I 1 KP FUEL PUMP RELAYS SEE SHT 27 KR N m t I 1 w 5 KR Y N 6 3 I RHC CBHC w p 4 SECONDARY FUEL PUMP 3i TO BATTERY a POSmVE INERTIA FUEL PUMPS a SWITCH 1 ...

Page 525: ...VOLTAGE STABILISER LOW FUEL LEVEL WltT SEE SHT 24 SPLICE G G SPtICE G TO TEMP GAUGE G BIN 0 SEE SHT 16 SEE SHT 24 RHC FUEL SENDER UNIT GO G O Go I RHC BIN B GB GB GAUGE FUEL LEVEL SHEET 4 ...

Page 526: ...SHEET 5 IFAN MOTOR 1 1 CFHC FHC FUSE BOX PPOSITIVE POST SEE SHT 1 B I N 0 FAN FAIL WILT THERMISTOR OTTER SIW LOW PRESS KU A C U CIRCUIT J SEE SHT 6 0 RADIATOR COOLING FANS 0 SHEET 5 ...

Page 527: ...FANS CIRCUIT SEE SHT 5 YG TO INT FAN RELAY SEE SHT 7 I CCC TO START MOTOR rWR SEE SHT 2 RELAY RAD COOLING K U 1 FANS CIRCUIT RHC K e l EHC SEE SHT 5 KU 9 TO A C U IDLE CONTROL RELAY Ku7 K SEE SHT 3A COMPRESSOR a A I R CONDITIONING SHEET 6 ...

Page 528: ...EET7 FUSE BOX SPLICE 6 Y I SEE S H I 26 INT FAN MOTOR 1 r FUSE BOX FAN SPEED SIW SPLICE D SEE SHT 27 INT FANS RELAY LGS 1 C C C B Y r C C C INT FAN MOTOR 2 YG I INTERNAL FANS a G I A CU CIRCUIT SEE SHT 6 ...

Page 529: ... U B FHC I N BOARD R H HEAD LAMPS 4 U Y OUT BOARD POSITIVE POST NU uw HEAD LAMP MAIN BEAM DIP BEAM FLASH UR SEE SHT 9 DIPIMAIN BEAM COLUMN SiW b h BIN Y 3 B 2 J LIGHT S W L h 8 7 RG SEE FRONT 6 5 SIDE TURN SHEET 8 ...

Page 530: ... SPLICE A P P A 0 N SEE SHT 25 FLASH CIRCUIT SEE SHT 8 MOTOR RH RELAY RH HEAD LAMP MOTOR HORNS I HORN RELAY rm 20A N i i 10 u I I A 17 B FUSE BOX 1 DIPiMAIN BEAM 8 COLUMN SIW HORNS DIPIMAIN BEAM COLUMN SIW SUPPLY 0 7 0 SPLICE A SEE SHT 25 SHEET 9A 0 ...

Page 531: ...LH MOTOR I R r w RELAY UG I I NU LIGHT SiW UR s 8 7 h I TO DIP BEAM 6 5 RELAY COIL 4 3 7 2 11 d HEAD LAMP MOTOR CIRCUIT ...

Page 532: ... LH HEADLAMP LH MOTOR MOTOR S RELAY HEAD LAMP MOTOR OPERATION PODS TRAVELLING UP HEAD LAMP YOTOR CIRCUIT Y SHEET 9C ...

Page 533: ...POSITIVE HEAD LAMP MOTOR OPERATION RS 9 LH MOTOR S RELAY PODS UP TO MAIN BEAM RELAY COIL 1 1 f N U LIGHT SIW UR I TO DIP BEAM RELAY COIL HEAD LAMP MOTOR CIRCUIT SHEET 90 ...

Page 534: ...N L GA LH HEADLAMP MOTOR POSITIVE TO M A I N BEAM RELAY COIL HEAD LAMP MOTOR OPERATION D S TRAVELLING DOWN TO DIP BEAM RELAY COIL HEAD LAMP MOTOR CIRCUIT a SHEET 9E ...

Page 535: ...a POSITIVE 11 HEADLAMP FLASH POD TRAVELLING UP I NU L I G H T SIW HEAD LAMP MOTOR CIRCUIT SHEET 9 ...

Page 536: ...LH REAR 0 1 DIP MAIN BEAM g 0 1 SEE SHT 25 c 4 GW 3 2 1 rn c FUSE BOX SEE SHT 27 D I WILT TO CLOCK I lHAZARD UNIT HAZARD WILT R H REAR 0 1 0 0 1 HAZARD SHEET 10 ...

Page 537: ...FIBRE BAT PRESS TACHO BOOST SPEEDC TEMP FUEL OPTIC RN RN R N RN RN 0 1 HAZ RB 7 R0 I CIRCUIT I LICENCE NO PLATE LT L H LICENCE NO PLATE LT R H RO RHC CIRCUIT Ro SEE SHT 10 R H SIDE MARKER 03 r 0 REAR LIGHTS 8 INSTRUMENT ILLUMINATION SHEET 1 1 ...

Page 538: ...SHEET12 I R H DOOR SiW I SEE SHT 10 I I I I TO RH RHEOSTAT STARTER CIRCUTT sw I LGW I SEE SHT 2 LOGIC BOX I SEE CIRCUIT ON SHT 16 CLOCK DOOR WARNING INTERNAL LAMPS SHEET 12 0 ...

Page 539: ... ON SHT 20 SPUCE A SEE SHT25 N STOP LIGHT SIW RHC RH GP STOP LIGHTS LOGIC BOX SEE CIRCUIT ON SHT 16 STOP LIGHT HIGH MOUNTING STOP LIGHT CI h c FUSE BOX NOT USED SPLICE D 0 SEE SHT 27 Q 2 REV LIGHT SIW RHC IN GEARBOX RH s 6 c G I REV LIGHTS REVERSE LIGHT ...

Page 540: ...SHEET 14 FUSE BOX IL SPLICE D I SEE SHT 27 WIPER MOTOR INTERMITTENT WIPE UNIT FHC LGB u SCREEN WASH PUMP WIPERS SHEET 14 ...

Page 541: ... B W C S W G A SPLICE G SEE SHT 24 G TO ACU CONTROL G HAND BRAKE WARNING SPLICE 0 W B A SEE SHT 27 LOW VAC S W 1 o b 1 BS LL TO D I IHAZARD RELAY SEE SHT 10 B BS LOW BRAKE FLUID BIN A LEVEL S I W L B S B I 1 BRAKE FAIL WILT BRAKE FAILURE WARNING ...

Page 542: ... 6 5 4 3 2 1 w SEAT BELT SIN TO ACU CONT RELAY SEE SHT 6 WR L p B F B l l BIN A SEAT BELT WILT B p 5 SEE SHT 24 SEAT BELT I LOGIC STABILISER TEMP GAUGE BIN RHC EHC TEMP TRANSMITTER SEE SHT 4 2 4 u u LG I TO FUEL GAUGE SEE SHT 4 1 BATTERY GAUGE WATER TEMPERATURE 8 BATTERY GAUGES iB ...

Page 543: ...FUSE BIN A SPLICE A N SEE SHT 25 1 2 3 4 HRS 51W G SPLICE G l1 SEE SHT 24 TAILGATE H I N G E S HEATED REAR SCREEN HRS SHEET 17 ...

Page 544: ...SHEET 18 SPLICE B SEE SHT 26 A L H WINDOW LIFT SIW I S N J L H OH sR L H WINDOW LIFT MOTOR R H WINDOW LIFT SIN U R H DHC A s u m WINDOW LIFT R H WINDOW LIFT MOTOR SHEET 18 ...

Page 545: ...MIRROR CONTROL SWITCH CHANGEOVER SWITCH MIRRORS Movement by motors SHEET I9 9 ...

Page 546: ...SHEET 20 MIRROR CONTROL CIRCUIT RADIO RADIO AMP If fitted ...

Page 547: ...BIN 8 i yG R G LEVEL LowMODULE OIL LOW OIL LEVEL PROBE LOW OILWlLt SPUE 0 j SEE SHT 26 LOW COOLANT EHC WlLt 1 LOW COOLANT LEVEL PROBE LOW COOLANT LEVEL MODULE LOW OIL COOLANT WARNING SHEET 21 ...

Page 548: ... PLATE LAMPS 1 0 15A STOP LAMPS SEAT BELT BUZ RADIO Mem 1 RADIO AMP If f ttedl ANTENNA 12 10A RADIATOR FAN NO 3 13 5 A HEATED REAR SCREEN 14 ISA WIPER MOTOR SCREEN WASH 15 SA HEAD LAMP MOTORS DOWN CONTROL 16 1OA HEAD LAMP MOTORS 17 10A HEAD M P FLASH early cars 2Q4 to include horn no line fuse I I 18 10A I RADIATOR FAN N O 2 1 26 10A INDICATORS 21 10A A C U COMPRESSOR IA C U CONTROL 22 10A ENGINE ...

Page 549: ...CHANGEOVER DOUBLE CONTACT ELECTRONIC UNIT RELAY CONNECTIONS SHEET 23 ...

Page 550: ...10 FUSE BOX SPLICE D M FACIA H C SEE SHT 1 I R H 0 1 W I L T G SEE SHT 10 1 BRAKE FAIL WARNING CIRCUIT SEE SHT 15 G SEAT BELT WILT SEE SHT 16 BATTERY GAUGE SEE SHT 16 G VOLTAGE STABILISER SEE SHT 16 HAND BRAKE WILT LOW FUELI BRAKE FAIL RELAY SEE SHT 15 CHOKE WILT SEE SHT 15 SEE SHT 4 SPLICE G ...

Page 551: ... 16 B HEAD LAMP M O T O R S p SEE SHT 9 HEAD LAMP FLASH A17 B P N SEE SHT 9 SEE SHT 17 CIGAR LIGHTERS DOOR LAMPS SEE SHT 12 cn h c 2 0 2 L h INT LAMP CLOCK SEE SHT 12 HAZARD LAMPS SEE SHT 10 STOP LAMPS RADIO SEE SHT 13 SEE SHT 20 SPLICE A SHEET 25 ...

Page 552: ...SHEET 26 POWER RELAY AUX 1 SEE SHTl WINDOW L I F T SEE SHT 18 YG YG I INTERNAL FANS I SEE SHT 7 SPLICE 5 DOOR MIRRORS SEE SHT 19 RADIO SEE SHT 20 FUEL INJECTION MANAGEMENTSYSTEM SEE SHT 3A ...

Page 553: ... G W SEE SHT 10 SEE SHT 1 PW I REVERSE LAMPS SEE SHT 19 NOTUSED G I SPLICE G SEE SHT 24 RHC START A LT IGN SEE SHT 2 INTERNAL FANS rG SEE SHT 7 L G A I R CONO g RAD FANS SEE SHT 6 w RAD COOLING FANS SEE SHT 5 BRAKE FAIL WILT SEE SHT 15 SCREEN WASH _ h SEE SHT 14 CI m c 3 0 2 SPLICE D 3 m SHEET 27 ...

Page 554: ...aQADIATOR COOLING FANS WINDSCREEN WIPER MOTOR COMPONENT LOCATION DIAGRAM 1 u ...

Page 555: ...ZARD LAMPS FLASHER UNlT C HEATED REAR SCREEN RELAY D AIR CONDITIONING DROP OUT RELAY E INTERIOR FANS RELAY F RADIATOR FANS RELAY FUSEBOX LIGHT SWITCH SEAT BELT LOGIC WIPER DELAY AC U CONTROL UNIT UNIT UNIT RELAY COMPONENT LOCATION DIAGRAM Z ...

Page 556: ...TI HEATED REAR MDW HARNESS ROUT NG DIAGRAM u ...

Page 557: ...e panel Voltmeter and fuel gauge illumination bulbs may also be replaced after removal of the appropriate side panel The Brake fail warning lamp relay may also be reached after removal of the left hand side panel For access to an instrument housed i n the centre panel it i s necessary first to remove the binnacle assembly from the fascia After removal of the four M6 bolts securing the binnacle ass...

Page 558: ...TION Page I SECTION O B ESPRIT 53 TURBO Dornertic Export Page Recommended Lubricants Bodywork Defects Sample Sheet Pre Del ivery Inspection Sample Worksheet Fint After Sales Service Sample Worksheet Maintenance Plan Sample Worksheet ...

Page 559: ... l l y Formula SAE 5W 50 I n s e v e r e w i n t e r c o n d i t i o n s below lS C a SAE 10W 40 O i l or Mobil 1 R a l l y Formula SAE 5W 50 i s recommended When reco mrnended p r o d u c t s a r e u n o b t a i n a b l e engine l u b r i c a n t s meeting t h e f o l l o w i n g s p e c i f i c a t i o n s may be used VISCOSITY Above 0 C SAE 20W 50 Below O C SAE 15W 40 Below 15OC SAE 10W 40 PERF...

Page 560: ...TION OB Page 3 0 Bodywork Defects Sheet DEFECT CODE I UNIT No I A B C D E F G H J K 1COLOUR I SCRATCHES OVERSPRAY DIRTUNDERPAINT RUN SINKAGE THIN PAINT GEL CRAZING CHIPS PIN HOLES FLAKING I OWNER APR 1987 ...

Page 561: ...Page 4 SECTION OB D T Bodywork Defects Sheet P APR 1987 DEFECTCODE A B C D E F G H J K SCRATCHES OVERSPRAY DIRT UNDER PAINT RUN SINKAGE THIN PAINT GEL CRAZING CHIPS PIN HOLES FLAKING ...

Page 562: ...g speed I Check power assisted steering fluid level and system for leaks when fitted 1 I I Check automatic transmission fluid level when fitted I I ELECTRICAL 0 Check security of battery terminals Check operation of all lamps Check operation of horns and direction indicators Check opemtion and park position of screen wipers Check operation of windscreen washers Check operation of all instruments C...

Page 563: ... supplying Distributor importer dealer to ensure that the car is delivered to the customer in the best possible condition b A l l costs incurred during the inspection are the responsibility of the supplying distributor importer dealer c F ilure to return a signed copy of this inspection to Lotus Can Limited by the distributor importer dealer may result in warranty claims on the particular car bein...

Page 564: ...k fuel pipe connections on carburettors Inspect foot brake system for leaks and correct operation Check handbrake adjustment and operation lnspect all brake pipes and vacuum pipes and connections for damage chafing or leaks Check brake clutch and P A S fluid reservoir levels lnspect operation of brake fail handbrake warning lamp e n valve timing 0 Check clutch operation and adjust if necessary Che...

Page 565: ...edmodels Renew fuel filter Turbocharged models Check fuel connections to carburenors Check security of all fuel system connections Check thronle kickdown cruise control cable adjustment Check adjust idle speed CO level lnspect operation condition of cooling fans e L C A B C o n 0 0 0 0 48 000 mls intervals n o 0 0 0 0 o n 0 e 0 0 0 o n 0 o n 0 0 0 O D 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Work completed b...

Page 566: ...This service has been completed in accordance with the Maintenance Schedule Dealer s Stampr Signature A SERVICE At 30 000 mls 50 000 km or 6 months from last Service whicheversooner Mileage Date B SERVICE AT 36 000 mls 60 000 km or 6 months from last Service whicheversooner Mileage Date A SERVICE At 42 000 mls 70 000 km or 6 months from last Service whicheversooner Mileage Date C SERVICE AT 48 000...

Page 567: ...RICATION Page 7 SECTION O C U S A ESPRIT TURBO Page Recommended Lubricants Pre Del ivery lnspection Sample Worksheet Bodywork Defects Sample Sheet Maintenance Schedule Except California Maintenance Schedule California a APR 1987 ...

Page 568: ... 1 Rally Formula SAE 5W 50 a In severe winter conditions below 15OC a SAE 10W 40 Oil or Mobil 1 Rally Formula SAE SW St is recommended When recommended products are unobtainable engine lubricants meeting the following specifications may be used VISCOSITY Above 0 C SAE 20W 50 Below O C SAE 15W 40 Below 15 C SAE 10W 40 PERFOFUIANCE API Service SF API Service SF API Service SF TRANSMISSION SAE 80 API...

Page 569: ...e idling speed 1 Check power assisted steering fluid level and system for leaks when fitted I I Check automatic transmission fluid level when fitted I I I ELECTRICAL Check security of battery terminals Check operation of all lamps Check operation of windscreen washers Check operation of all instruments 0 1 I Check operation of headlamps and door windows 1 Check operation of horns and direction ind...

Page 570: ...supplying Distributor importer dealer to ensure that the car is delivered to the customer i n the b st possible condition b A11 costs incurred during the inspection are the responsibi svpplying distributor importer deal er c Failure to return a signed copy of this inspection to Lotus lity of the Cars Limited by the distributor importer dealer may result i n warranty claims on the particular car be...

Page 571: ...SECTION OC Page 5 Bodywork Defects Sheet DEFECTCODE A SCRATCHES B OVERSPRAY C DIRT UNDER PAINT D RUN E SINKAGE F THIN PAINT G GEL CRAZING H CHIPS J PIN HOLES K FLAKING APR 1987 ...

Page 572: ...cks hinaes and catches Lubricate speedo aigle drive Repack front hubs BRAKING SYSTEM Check brake fluid level Check entire system for leaks and damage to pipes Renew hvdraulic fluid and seals Check brake paddlinings for wear Check o eration of brake fail warning lamp x Check torque of caliper mounting b o k x Check handbrake adjustment x CLUTCH Check and adjust if necessary x Check clutch fluid lev...

Page 573: ...ES Check tyre condition and pressures including spare Check torque of all wheel nuts Check road wheel balance BODY Check all hinge and lock operations Check seat belts and seat adjustments Check air conditioning operation Top up screen washer reservoirs GENERAL Inspect condition of all major unit mounting rubbers Check torque loading of major unit mounting bolts APR 1987 ...

Page 574: ...on and tension adjust if necessary x Renew air cleaner elements Renew fuel filter x NOT HCI models lnspect fuel system cap tank lines and connections Torque exhaust system mounting bolts LUBRICATION Renew engine oil and filter 0 Renew transmission oil x Check and if necessary top up transmission oil Lubricate lower fleering swivels if applicable x Lubricate locks hinges and catches Lubricate speed...

Page 575: ...struments x x x x WHEELS AND TYRES Check tyre cond tion and pressures including spare x x x x Check torque of all wheel nuts x x x x Check road wheel balance x BODY Check all hinge and lock operations x x Check seat belts and seat adjustments x x x x Check air conditioning operation x x Top up screen washer resetvoirs x x x x GENERAL Inspect condition of all major unit mounting rubbers x Check tor...

Page 576: ...g Operating Principles Aitflow Distribution Refrigerant Handling Refigerant Pipework Precautions Charging Unit with Refrigerant Refrigerant Quick Check Procedure Recommended Refrigerant Oil Refrigerant Oil Level Checking Procedure Compressor Removal of Heater Air Conditioning Assembly PB9 PBl0 ...

Page 577: ...r provides a means of checking the system is full of refrigemnt and operating correctly High pressure liquid enters the expansion valve where it expands rapidly changing from high to low pressure liquid As the refrigemnt expands i n the evaporator i t begins to boil absorbing heat from the core and cooling the air passing through to the passenger compartment The compressor draws off the low pressu...

Page 578: ...olled by a capillary tube strapped to the outlet pipe of the evaporator a s the temperature changes at the outlet pipe so the refrigerant flow through the valve changes When liquid to the core of the evaporator exceeds requirement the outlet temperature drops this is sersed via the capillary tube closing down the expansion valve and reducing the flow of liquid refrigerant The expansion valve i s p...

Page 579: ...ents The heater air conditioning unit itself contains two flaps a mode flap controlling airflow through the heater matrix and a screen flap controlling airflow to the windscreen vents The fresh air flap and mode flap are opemted by vacuum actuators supplied with vacuum on Domestic and ROW cars by the inlet manifold via a non return valve and reservoir mounted on the left hand fuel tank board whils...

Page 580: ...e air conditioning switched on this is the haximum refrigerationt setting Air is drawn by the fan from the interior of the car through the re circulation vent and is blown through the evaporcitor to the centre and outer face level vents Also through the footwell bleed holes deleted mid 86 TURBO INTERIOR fresh air recirc flap valve SERIES 3 HEATER ONLY OFF VENT HEATER DEF T n a COLD HOT DEF SERIES ...

Page 581: ...air at ambient temperature is supplied to the outer and centre face level vents With the air conditioning switched on this is the normal refrigeration setting supplying refrigerated fresh air to the centre and outer face level vents either by ram effect or fan assisted TURBO INTERIOR SERIES 3 HEATER ONLY OFF VENT HEATER DEF 0 0 n n COLD HOT DEF SERIES 3 WITH A C DEF 0 U U 1 COLD HOT DEF ...

Page 582: ...control i n the red sector heated fresh air is supplied by ram effect or fan assisted to both screen and footwell vents Ambient air is s t i l l available from the outer face level vents The air conditioning may be used with this setting to produce de humidified air Close off the outer face level vents for optimum performance TURBO SERIES 3 HEATER ONLY OFF VENT HEATER DEF D r l n COLD HOT DEF SERI...

Page 583: ...all air to the windscreen vents This i s the defrost position With the temperature control i n the red sector heated air is supplied solely to the screen keep outer face level vents clcsed TURBO SERIES 3 HEATER ONLY OFF VENT HEATER DEF E 0 r1 I COLD HOT DEF SERIES 3 WITH A C OFF AC DEF v L7 0 a COLD HOT DEF ...

Page 584: ...gas which will also attack metal 6 Do NOT expose the eyes to vapourised or liquid refrigerant ALWAYS wear safety goggles when handling refrigerant P R 4 REFRIGERANT PIPEWORK PRECAUTIONS The following precautions should be read carefully before carrying out any work on the refrigerant pipework 1 When disconnecting any pipe or flexible connection the system MUST FIRST BE DISCHARGED OF ALL PRESSURE O...

Page 585: ...s this unit is con structed from aluminium A l l joints should be coated with refrigeration oil BEFORE making any connections as this will aid seating A l l pipes and haes MUST BE FREE from any kinking The efficiency of the system can be impaired by a single kink or restriction Flexible hoses should not be bent to a radius which is less than ten times the diameter of the hose PB 5 CHARGING UNIT WI...

Page 586: ...ur i t is therefore advised to carry out the checks in a covered garage 4 Increase the engine speed to 2000 r p m and check that the refrigerant passing the sight glass is clear of bubbles If a continuous stream of bubbles s t i l l persists then the refrigerant charge should be increased until the bubbles are no longer present 5 Before disconnecting the service valves from the compressor check th...

Page 587: ...45 secs before foaming and settling away from glass Refrigerant foams and settles away from sight glass in less than 45 secs Cause System low on charge System is either fully charged or empty System empty or nearly empty Even though a differential i s noted there exiis a possibility of overcharge An overcharge filled system will result i n poor cooling System over charged Remedy Check with leak de...

Page 588: ...or air conditioning unit 3 fluid ozs PB 8 REFRIGERANT OIL LEVEL CHECKING PROCEDURE To check the refrigerant oil level during servicing of the Compressor or the system proceed i n the following manner 1 Run the compressor at the engine idle speed for 10 minutes 2 Recover all the refrigerant 12 from the compressor being careful not to lose any oil 3 Place the angle gauge Sankyo Part No 32448 across ...

Page 589: ...n 3 compressor angle and the oil level increment with those shown in following table 8 If the increments indicated on the dipstick do not fall between the figures given i n the above table add or subtract oil until the mid range figure i s achieved 9 Refit oil filler plug and tighten to 6 to 9 ft lbs 0 8 to 1 2 kg m Ensure the O ring is not twisted and that the O ring seating is clean before fitti...

Page 590: ...ressor to the mounting bracket Drain the oil from the compressor and measure the amount drained Make a note of the amount of oil dmined as this information is required when replacing the compressor To Replace 1 Reverse the removal procedure Refill the compressor with the same amount of new oil as that drained during removal plus an additional one fluid ounce Before assembling the pipwork lubricate...

Page 591: ...ide front luggage compartment Remove bulkhead ABS cover Disconnect both fan motors release the two screws and remove the motor scroll casing from the unit 3 Remove the re circulation vent flap and through the aperture exposed disconnect the inlet water hose from the water valve Disconnect the control cable to the valve and release the valve from the pedal box 4 Release the dividing panel fixings T...

Page 592: ... Release the vacuum supply pipe and fresh air flap actuator vacuum pipe Release drain pipe from beneath unit Carefully withdraw unit towards passenger side of vehicle taking care not to damage the water valve capillary tube To Replace Reverse the removal procedure positioning the unit such that the dimension from the inboard edge of the large hole in the bulkhead passengers side to the end of the ...

Page 593: ...SECTION QB CLUTCH Page 7 SECTION QB ESPRIT S3 AND TURBO Operat ion Page General Description Adjustment Hydraulic Units Clutch Assembly Release Bearing Spigot Bearing Clutch Shaft ...

Page 594: ...CLUTCH SYSTEM DIAGRAM ...

Page 595: ... a v e c y l i n d e r is mounted on t o p o f t h e c l u t c h h o u s i n g t o g e t h e r w i t h a r e l e a s e f o r k p u l l o f f s p r i n g S e r i e s 3 c a r s from l a t e 8 4 and a l l Turbo models u s e a s e l f a d j u s t i n g s l a v e c y l i n d e r mounted o n t h e r i g h t hand s i d e o f t h e c l u t c h h o u s i n g QB 1 ADJUSTMENT P e d a l With t h e c l u t c h...

Page 596: ...t s return stroke The adjuster i n the release fork end should be s e t such that 22m of adjuster projects beyond the locknut a s shown i n the diagram NmE A previous specification called for the adjuster t o be screwed i n fully However the 22m setting allows a greater degree of clutch f r i c t i o n plate wear a t o take place before the slave cylinder piston tops out on its return stroke causi...

Page 597: ...i g h t e n locknut and r e f i t spring A s t h e c e n t r e p l a t e wears i n s e r v i c e the clearance w i l l reduce QB 2 HYDRAULIC UNITS Service k i t s a r e a v a i l a b l e f o r both t h e master and slave oylinders Before commencing work on t h e hydraulic system take precautions a s necessary t o p r o t e c t paintwork from brake f l u i d s p i l l a g e NOTE For cleaning purpos...

Page 598: ...e r type covers and release bearings may be used a s a pair on any car QB 4 RELEASE BEARING Several d i f f e r e n t types of r e l e a s e bearing have been used and great care must be taken t o ensure t h e c o r r e c t fitment Summary S e r i e s 3 P r i o r t o t h e introduction of t h e C35 type gearbox l a t e 1983 S e r i e s 3 c a r s w e r e f i t t e d with a cast i r o n r e l e a s ...

Page 599: ... with i t s i d e n t i f y i n g numbers f a c i n g outwards i e towards gearbox and pressed i n ONLY UNTIL FLUSH with t h e r e a r face of t h e crank Ensure t h e bearing i s l u b r i c a t e d with e i t h e r Esso Unirex N 3 o r S h e l l Alvania Spigot bearing MUST BE FITTED flush with crank Thrust washer I t i s e s s e n t i a l t h a t t h e Nylatron t h r u s t washer Ao79F 4029F is f...

Page 600: ...A089F 6060 t o s p i g o t s h a f t and i n s i d e s u r f a c e of s l e e v e F i t s l e e v e o n t o s h a f t and r o t a t e two o r t h r e e t i m e s t o e n s u r e even d i s t r i b u t i o n of adhesive i i i Remove s l e e v e re apply adhesive and r e p e a t ii i v To e n s u r e s l e e v e t o s h a f t c o n c e n t r i c i t y t h e f i n a l f i t t i n g should be performe...

Page 601: ... r e Consolc Tunnel S i d e s INTERIOR TRIM SECTION VB ESPRIT 53 T U R B O Instrument Binnacle Fascia Cant R a i l s A Post Covers Windscreen Header Rail Rear Bulkhead T r i n Door Trim Panel Ocerat i o n VB 1 Page I ...

Page 602: ... e t h e two wing n u t s v i a t h e r a d i o a p e r t u r e s e c u r i n g t h e t o p of t h e c e n t r e c o n s o l e 6 Release t h e f i x i n g a t t h e r e a r of t h e c o n s o l e and remove t h e g e a r l e v e r knob Withdraw t h e c o n s o l e unhooking t h e tongue a t its f r o n t end from t h e f a s c i a Choke window switch w n e l VB 2 TUNNEL S I D E S A f t e r removin...

Page 603: ...rked and d i s c o n n e c t e d from t h e s w i t c h e s and gauges R e l e a s e t h e s p e e d o c a b l e o i l p r e s s u r e gauge p i p e h e a t e r c a b l e s and vent d u c t i n g During 1985 t h e S e r i e s 3 f a s c i a and b i n n a c l e was changed t o t h a t o f t h e DOM ROW Turbo t y p e On t h e s e c a r s t h e r h e o s t a t knobs a r e p u l l e d o f f t o r e v e...

Page 604: ...r i n g wheel column s h r o u d s column s w i t c h e s 2 Remove i n s t r u m e n t b i n n a c l e U S A o r d i s m a n t l e i n s t r u m e n t s w i t c h p l a t e s DOM ROW t o d i s c o n n e c t h a r n e s s p i p e s and c a b l e s 3 R e l e a s e t h e t h r e e f i x i n g s s e c u r i n g t h e glovebox f l o o r t o t h e f a s c i a and remove t h e A p c s t c o v e r s VB 6 ...

Page 605: ...HEADER RAIL On c a r s with a g l a s s o r removeable roof panel p u l l o f f t h e w e a t h e r s t r i p from t h e f r o n t o f t h e a p e r t u r e and peel o f f t h e header r a i l t r i m m a t e r i a l Remove one c a n t r a i l CVB 5 and r e l e a s e t h e t o p of t h a t s i d e s A post cover Release t h e f o u r screws s e c u r i n g t h e header r a i l and withdraw w h i l...

Page 606: ... i p p i n g t h e t o p edge on s o l i d roof cars from t h e f i x i n g dowling Sun roof can U S A type tailgate release handle Fixed roof can VB 9 DOOR TRIM PANEL The t r i m panel i s secured b y a s i n g l e screw a t t h e f r o n t and r e a r o f t h e p a n e l a l i p along t h e t o p edge and t h e i n t e r i o r r e l e a s e handle b e z e l To remove t h e b e z e l s l a c k e ...

Page 607: ......

Page 608: ......

Page 609: ... Danestic h Export 5 6 12 14 t o 17 Manufacturer Rxamle A typical change point d d Identifier be listed as follcars 82 D 1100 c Turbo ll00 82 mG J S 0 3 4 1 Turbo 0341 S C C Note that ttm Nmbers are needed to 1 2 3 4 identify the single change point due L Dcmestic 2 49 States WA 3 California 4 Sweden Australid Switzerland 5 Japan 6 50 States WA Engine Type 907 2 Litre 910 2 2 Turbo P h t 912 2 2 N...

Page 610: ...es H F I I T E R m C0W ITIONIN Heater WC Casirg h r Cm tiorung P l d i n g Heater P1uwbir g BLcwer M o r S w h a n i c a l l y Cperated Parts Controls Vacuum Operated Parts Controls Trunking Vents Plenum Chamber gASSIS Chassis Fram SUSPENSION Prior to 85 M Y Front SuspMsion 85 M Y n Front suspension Rear Suspension Drive S h a f t s S T g E I U N Steerina Rack Assv I n t e m d i a t e C o l m BRAK...

Page 611: ...ted Talbot 910 2 2 Litre Turbocharged 912 2 2 Litre Naturally Aspirated Mtus This publication has been designed primarily for W u s Dealers and will be updated by issue of Service Bulletins to Lotus Dealers when necessary Lotus policy is one of continuous product irrprwenwt and the right is reserved to alter specifications at any tim without prior notice Whilst wery care has been taken to ensure c...

Page 612: ...MID NOSE SECTION 28 INCHES FRONT TO REAR SHUT LINE TURBO 1o olA ...

Page 613: ... I1 Body S e c t i o n Mid Nose LH H a l f I1 I I I I I1 I I I1 I1 Body Section Full Nose Full Width I I I I I I I1 I I I I I I Body Section Full Nose RH Half I I I I 1 1 I I I I I I n Body Section Full Nose LH Half I1 I I I1 I1 1 1 I I 1 1 Body Section Roof NOT Glass1 Roof Body Section Roof G l a s s Roof Models PART NUMBER QUANTITY REMARKS W G l a s s Roof G l a s s Roof N X G l a s s Roof G l a...

Page 614: ......

Page 615: ...ody Section Full Rear F u l l Width Body Section F u l l Rear RH Half Body Section Full Rear LH Half Bulkhead Upper Timber Bulkhead Upper Timber Wllkhead Centre Timber Bulkhead m r Timber Speaker Enclosure Rear Wllkhead ABS PART NUMBER QUANTITY ALL 1 1 1 1 1 1 1 1 1 1 2 MAY P 9N REMARKS Not G l a s s Roof1 Glass Roof Models ...

Page 616: ...1 TURBO I 10 05A ...

Page 617: ...er Bracket Tailgate Aperture RH Stiffener Bracket Tailgate Aperture RH Stiffener Bracket Tailgate A p e r t u r e RH Stiffener Bracket Tailgate Aperture IlI Setscrew Thinhead M8 BrM Aperture Washer F l a t Setscrew M8 x 25 Brkt Body Washer Large O D Brkt Body Nut Nyloc M8 rkt Body Jacking P l a t e Jacking Plate P q Rivet Jacking Plate to Body T w Eye Front Reinforcing Plate Tad Eye Setscrew M6 x ...

Page 618: ...I 1 TURBO i 10 07A ...

Page 619: ...d Outer Pivot Bearing Housing LH Outer HInner Bearing Housing RH Outer LH Inner Pcp Rivet Bearing Housing Fix Bearing Bush Pod Inboard Pivot H i n g e Pin Pd Bonnet S p l i t Pin Hinge Pin Retention R Pin Hinge Pin Water Shield Pcp Rivet Shield to Body PART NUMBER QUANTITY ALL ucas HellaHeadlanps Cibie Headlanps u c a s e l l a Headlanps Cibie Headlanps Cars prior V I N 82 D 2265 82 0624 W i l l a...

Page 620: ...1 TURBO 10 09A ...

Page 621: ...ping Plate Bonnet Hinge G r i l l e Bonnet Screw G r i l l e to Bonnet Insert Bush G r i l l e to Bonnet Striker Bonnet Catch Shim Plate Striker to Bonnet Setscrew M 8 x 25 Striker to Bonnet Washer Spring Striker to Bonnet Washer Flat Striker to Bonnet Tapping Plate Bonnet Striker Bracket Bonnet Latch D i s c Mamting Setscrew 10 UNF x 3 4 Bracket Body Washer Flat Bracket Body PART NUMBER a QUANTIT...

Page 622: ...1 TURBO 10 09A ...

Page 623: ...Stay Telescopic Bonnet Support Stay Telescopic Bonnet Support Bracket Bonnet Stay to Bonnet Gas Strut Bonnet Support Bracket G a s S t r u t to Bonnet Wheelarch Washer Flat Strut to Brackets Nut Nyloc Strut to Brackets Setscrew Strut Stay Bracket to Wheelarch Nut Nyloc M5 1 1 1 1 I t Washer F l a t 11 n I I 11 Washer Large O D I 1 9 I Setscrew M5 x 12 Brkt to Bonnet Washer Shakeproof Brkt to Bonne...

Page 624: ......

Page 625: ...ge O D Bracket to Body Nut Nyloc M8 Bracket to Bady Gasket Bracket to Body Setscrew M8 x 25 i n g eladen nail gate Washer Spring Hinge ladefiailgate Washer Flat Hinge l a d e f i a i l g a t e Tapping Plate Hinge Blade LH Tapping Plate Hinge Blade R H Lcxlvre Tailgate Nut Nyloc M 6 Washer F l a t G r m t h v r e Front E d g e Fixings Screw Louvre Side Fixing G a s Strut Tailgate Support Gas Strut ...

Page 626: ......

Page 627: ... Cross Shaft Tailgate Latch Bearing Bracket Cross Shaft Washer Flat Bearing Bracket Fix Nut Nyloc M 8 Bearing Bracket Fix Support Bracket IH Latch Cross Shaft Support Bracket RH Latch Cross Shaft Support Bracket LH Latch Cross Shaft Support Bracket RH Latch Cross Shaft Support Bracket RH Latch Cross Shaft Screw Thinhead M6 Support Brkt T q Studplate M 6 x 16 Support Brkt Bottom Washer Flat Support...

Page 628: ...TURBO 10 11A ...

Page 629: ...e Bracket Release Lever Recess Release Lever ABS Recess Release Lever ABS Washer Flat Brkt Recess to Bulkhead Nut Nyloc M 6 Brkt Recess to Wllkhead Cable ailg gate Release Cable Tailgate Release Adaptor Tailgate Channel Drain LH Adaptor Tailgate Channel Drain RH Adaptor Tailgate Channel Drain Pop Rivet Drain Adaptor Fix Elbow Tailgate Channel Drain Hose Tailgate Channel Drain Clip Drain H o s e Se...

Page 630: ...TURBO 10 13A ...

Page 631: ...loor to Body Pulsert M6 Floor to Body Lid n g i n e Bay Lid Engine Bay Tongue Engine Lid Front Hinge Eye Engine Lid Front Hinge Setscrew 10 UNF x Tongueme Washer Nut Nyloc 10 UNF Twist Iack Catch Male Engine Lid Rubber Washer M a l e Catch Twist Lock catch Ferrrale Engine Lid Pop Rivet Catch Fixing PAFIT NUMBER QUANTITY ALL 1 1 1 8 8 8 2 2 2 3M 1 1 1 3m 4 8 8 1 1 1 1 1 1 1 1 1 2 2 8 8 8 4 4 4 8 Fo...

Page 632: ......

Page 633: ...eld Engine Lid Aperture Screw M6 x 12 Water Shield Fix Washer Shakeproof Water Shield Fix Jacknut M6 Water Shield Fix Trim Panel Rear 1 4 IH Trim Panel R e a r 1 4 LH Trim Panel R e a r 1 4 RH Trim Panel R e a r 1 4 RH Trim Panel R e a r l 4 RH Clip Bracket Trim Panel to g gate Pgerture Pop Rivet Brkt to Panel Screw Brkt to Body Spire Nut Brkt to Body Screw Panel to Engine Bay Washer Flat Panel t ...

Page 634: ......

Page 635: ... Engine Ray Jacknut M5 Panel Rear to Eng Ray Washer Flat Panel t o Engine Ray Undertray Engine Ray Undertray Engine Bay Undertray Engine Bay Retaining Strip Undertray Front Pop Rivet Retainer to Body Setscrew M 6 x 20 Undertray Fixing Washer Flat Undertray Fixing Pulsert M6 Undertray Fixing PART NUMBER a QUANTITY ALL REMARKS R B Shorter Undertray B082B4292K R B A082B4559K Turbo 10 13A P q e 3 ...

Page 636: ...TURBO 10 1SA a ...

Page 637: ...r Plain Bracket to Post Washer Spring Bracket to Post Tapping Plate Bracket to S i l l Setscrew M 8 x 20 Bracket to S i l l Washer Plain Bracket to S i l l Washer Spring Bracket to S i l l Hinge Bracket Upper Ill Hinge Bracket Upper RH Hinge Bracket Iaer CLanp Plate Door Hinge Shim 18 s q Hinge to Body Shim 18 swg Hinge to Body Shim 12 swg Hinge to Body Shim Abrasive Hinge to Body Nut Nyloc 3 UNF ...

Page 638: ...TURBO 10 ISA e ...

Page 639: ...g R H Spring Door Check IH Spring Door Check RH Guide Check Strap Setscrew M 6 x 30 Guide to Brkt Washer Plain Nut Nyloc M6 Guide to Brkt Bolt M 8 x 45 Strap to Hinge Nut Nyloc M8 Strap to Hinge Bracket Check Strap Guide to Beam IH Bracket Check Strap Guide to Beam RH Bracket Window Motor Mamting Id3 Bracket Window M o r Mmnting RH Studplate M6 Bracket to D o o r Beam Nut Nyloc M6 Bracket to Door ...

Page 640: ...TURBO 10 17A 0 0 ...

Page 641: ...rew 10 UNF x 3 4 Handle to Door Screw 10 UNE x l H a n d l e t o Door Washer Handle to Door Bezel Door Handle Latch Mechanism Door b k RH Latch Mechanism Door hxk IH Plate Latch to Door Beam Bolt M 6 x 45 Latch to Beam Nut Nyloc M6 Latch to Beam Trunnion Rcds to Latch Circlip Latch Trunnions Clip Rod End Ext Release t o Latch Clip Rod End Exterior Handle Bracket Rod Guide Guide Clip Interior Handl...

Page 642: ......

Page 643: ...er Post RH Striker Post LH Washer Large O D Striker Post Top Nut Nyloc M8 Striker Post Top Washer 1 Setscrew M12 x 30 Striker Post tan Striker Plate Door Latch Spacer 3mn Striker to Body Spacer 1 5mn Striker to Body Abrasive Washer Striker to Body Friction Plate Striker to Body Shim l h Striker Post to Body Shim M I I Striker Post to Body Tapping Plate Door Latch Striker Screw M 6 x 35 Striker Fix...

Page 644: ......

Page 645: ...i x i n g Setscrew M 8 x 25 Wlnper Centre i x i n g Washer Flat Bunper Centre i x i n g Nut Nyloc M8 Bunper Centre i x i n g Shim Plate Bunper Outboard i x i n g Stud M 6 x 30 E m p e r Outboard Fixing Washer Flat Bunper Okbua rd Fixing Washer spring Bunper Outboard i x i n g Nut Plain M6 Burrper Outboard Fixing Spoiler Front Spoiler Front Setscrew M 8 x 25 Spoiler To l3ody Pulsert M8 Spoiler to B...

Page 646: ...I TURBO ...

Page 647: ...oiler Screw s t Undershield to Rad Duct Washer Undershield Fix Spire Nut Undershield Fix Sill Iil Sill RH Spoiler Rear Spoiler Rear Pulsert M6 Spoiler ixing Setscrew M6 x 25 Spoiler Fixing Washer Large O D Spoiler Fixing Washer Shakeproof Spoiler Fixing Screw s t Spoiler Fixing Spire Nut Spoiler Fixing Foam Strip Spoiler Seal PART NUMBER a QUANTITY ALL 6 6 5 5 5 1 1 5 5 1 1 12 12 7 5 14 6 20 20 1 ...

Page 648: ...I TURBO 10 23A ...

Page 649: ... Washer Flat Bunper to Body Washer Spring Bumper to Body Seal Neoprene Bunper to Body R e a r Valance Pulsert M8 Valance to Body Setscrew M 8 x 25 Valance to Body Washer Spring Valance to Body Washer Flat Valance to Body Setscrew M 8 x 20 Valance to Emper Washer Flat Valance to Wlnper Nut Nyloc M8 Valance to Bunper PART NUMBER a QUANTITY MAY pcjr i REMARKS Turbo 10 23A Page 3 ...

Page 650: ......

Page 651: ...nisher Windscreen L H Finisher Clip Windscreen Top Corner Black Strip 1 3 4 Screen Bottan G l a s s Door l 4 Light RH Tinted Glass Door l 4 Light RH Clear Glass Door l 4 Light LH Tinted Glass Door 1 4 Light LH Clear Drop G l a s s Door RH Tinted Drop Glass Door RH Tinted Drop Glass Door RH Clear Drop Glass Door LH Tinted Drop Glass Door LH Tinted Drop G l a s s Door LH Clear Finisher W r Top Exter...

Page 652: ...TURBO 11 01A ...

Page 653: ... 4 Light RH Clear Glass R e a r 1 4 Light LH Tinted G l a s s R e a r V 4 Light LH Clear Spacer 4mn Glass to Body Trim ABS R e a r 1 4 G l a s s RH Trim ABS R e a r 1 4 Glass LH S i l l Finisher Rear V 4 G l a s s R H S i l l Finisher R e a r 1 4 Glass IH Nut 10 UNF Finisher Fixing Washer Finisher Fixing G l a s s Rear Bulkhead Spacer G l a s s to Surround Surround Bulkhead Glass Mamting Surround ...

Page 654: ...TURBO 11 01A ...

Page 655: ...DESCRIPTION Glass Tailgate Heated Glass Tailgate Unheated Spacer 4mn Glass to Tailgate Surround Tailgate Glass PART NUMBER QUANTITY ALL 1 1 4 1 H A Y 199 REMARKS Turbo 11 Ol A Page 3 ...

Page 656: ...TURBO 11 02A ...

Page 657: ...late RH Wheel Carriage P l a t e Shoulder Pin W h e e l Pivot Washer W h e e l Pivot Carrier Channel D r o p Glass L i Carrier Channel Drop Glass RH Nut Nyloc M6 Channel to Carrier Pad D r o p Glass Abutrrrent Window Motor LH Window Motor RH Screw 1 4 UNF x 3 Motor to Brkt Finisher Front Door Shell Mindcrw Fran e LH Finisher Front Door ShelIJWindow Frame RH Finisher Rear Door Shellhindcrw Fram IlI...

Page 658: ...FOR WIND DEFLECTOR SEE 12 01A TURBO 11 OSA ...

Page 659: ... Slot Recess to Body Washer Slot Recess to B d y Catch Handle Assy Roof G l a s s Rear Sliding Pin Assy Catch Handle Screw M 4 x 10 Sliding Pin Assy to Brkt Washer Sliding Pin Assy to Brkt Mmnting Bracket Sliding Pin Body Mounting Bracket Sliding Pin ody Buffer Rubber Roof Abutmnt Shim Mounting Bracket to Body Screw M6 x 16 Brkt to Body Washer Bracket to Body R e c e s s M l d i n g Catch Bracket ...

Page 660: ......

Page 661: ...oop Fix Washer F l a t Nut Nyloc 10 W Finisher B1 Post L H Finisher B Post RH Pop Rivet Finisher Fix Foam Mesh B Post Ventilation Wind Deflector Retainer Tongue LH Wind Deflector Retainer Tongue RH Wind Deflector Screw 10 UNF Tongue to Deflector Washer Tongue to Deflector Strap Deflector Retaining Rivet Strap to Deflector Spring Clip Strap Rivet PART NUMBER 0 QUANTITY ALL lYAY lgg1 REMARKS I With ...

Page 662: ...4 PRIOR TO 85 M Y v 7 1905 M Y 22 21 TURBO 12 05A 8 a a ...

Page 663: ......

Page 664: ...TURBO 12 OSA 16 I w YE ...

Page 665: ...file Finisher Strip Waistband Squarev Profile Finisher Strip Waistband vRcmndedvProfile Carrier Waistband Finisher t o Door Screw s t Carrier to Door Pop Rivet Carrier to Door Double Sided Tape Carrier to Door Adhesive P a r t A Waistband ini is her Adhesive Part B Waistband ini is her PART NUMBER QUANTITY Mfiy 1991 REMARKS Prior 85 M Y I I 85 86 M Y I I 1 87 M Y on 1 1 Prior to 85 M Y Prior to 86...

Page 666: ...I TURBO I 12 09A I ...

Page 667: ... F l a t Bezel Mirror Door Mirror RH Less Mirror G l a s s Door Mirror RH Less Mirror G l a s s Door Mirror LH L e s s Mirror G l a s s Door Mirror LH Less Mirror G l a s s Glass Pad Assembly Convex Gasket Door Mirror Washer Mirror to Door Nut Nyloc M6 Mirror to Door PART NUMBER QUANTITY REMARKS 1 Optional 1 1 Optional 1 1 Prior to VIN 82 D 2137 1 82 0606 1 1 1 Fran VIN 82 D 2137 82 0606 Turbo 12 ...

Page 668: ...TURBO l3 03A ...

Page 669: ... Bolt M 8 x 20 Button H e a l Spacer Locking Plate T i l t Pawl Pop Rivet Lacking Plate Fix Washer Drive Plate Clanp Washer Recline Mechanism Shaft Handwheel Seat Recline Trim Handwheel Centre Badge Handwheel Trim Centre Seat Runner Locking Seat Runner Non Lockiq Setscrew Runner to Seat F r m Washer Runner to Seat F r a m Washer Flat Large O D Floor Underside Nut Nyloc M8 Runner to Floor PART NUMB...

Page 670: ......

Page 671: ...90mn Hogring Flexolator to Suspension Unit Tube Clip Trim to Fram Rivet Rokut Cushion Unit to Fram Backboard Fmn 3mn Seat Backboard Staple Bracket Seat Backboard Fix Pop Rivet Bracket to Backboard Washer Pop Rivet Screw Backboard to Seat Fram Screw Press Stud Fix Press Stud Headrest Collar Fix Spire Nut Press Stud Fix PART NUMBER a QUANTITY ALL REMARKS Quantities A r e Per Car Fixed Seat Prior 87 ...

Page 672: ......

Page 673: ...aint Trim Cover Seat Head Restraint Trim Cover Seat Head Restraint Removeable Trim Cover Head Restraint Frame Seat Backboard T r i m e l Seat Backboard T r i m PART NUMBER a QUANTITY PRIOR 87 M Fixed Backrest Reclining 1 Early Cars With 3 Piece Seat Trim 1 Prefix Trim Part Numbers With A A l l W t h e r S t a t e Smooth or Ruched B A l l Cloth F Leather Cloth S t a t e Smooth or Ruched Also Specif...

Page 674: ......

Page 675: ... Belt Assembly Seat Belt Assembly Seat Belt Assembly Finisher Seat Belt Bulkhead Slot Button Slot Finisher Fixing Cover Seat Belt Reel ABS Screw Belt Reel Cwer PART NUMBER 0 QUANTITY ALL 2 2 2 2 4 2 8 REMARKS Turbo 13 27A ...

Page 676: ......

Page 677: ...8 Downstcp Buffer Pedal Dawnstop Spring Throttle Pedal Return Abutment Bracket Throttle Dawnstop Setscrew M 6 x 16 Bracket Fix Washer Large O D Bracket Fix Nut Nyloc M6 Bracket F i x Throttle Cable Inc Adjuster Grartmret Throttle Cable Clevis Pin Cable to Pedal Washer Cable C l w i s to Pedal S p l i t Pin C l w i s Retaining Abutment Throttle Cable Pop Rivet Abutmnt t o Body PART NUMBER a QUANTIT...

Page 678: ......

Page 679: ...Spirol Pin M 5 x 30 Lever to Pedal Shaft Throttle Cable Inc Adjuster Gromrret Throttle Cable Washer Cable Clevis to Lever S p l i t Pin Cable Clevis to Lever Abutment Throttle Cable Front Pop Rivet Abutment to Body Bracket Throttle Cable Abutment Trunnion Barrel Carb Throttle Lever Barrel Solderless Nipple Modify Screw Solderless Nipple PART NUMBER a QUANTITY This Page RHD Only For LHD See 14 01B ...

Page 680: ......

Page 681: ...edal Brake and Clutch Pedal Brake and Clutch Pad Brake Clutch Pedals Pivot Bush Brake Clutch Pedals Spacer rake clutchPedals Shaft Brake and Clutch Pedal Pivot S p l i t Pin Pedal Shaft Retaining Setscrew M 8 x 50 Brake Clutch Upstop Locknut M8 rake ClutchUpstop Switch Stop Light Locknut Stop Switch PART NUMBER QUANTITY plpy w 9 1 1 REMARKS This Page RHD Only For LHD See 14 01B Used With Extension...

Page 682: ......

Page 683: ...able Abutnmt Choke Cable Micro Switch Choke Warning Choke Cable inc Micro Switch Mounting Plate Choke Cable t o Fascia Pop Rivet Mcunting Plate to Fascia Clip Choke Cable to Engine Bay R e a r Choke Cable inc Micro Switch Mounting Plate Choke Cable to Fascia Pop Rivet Mamting Plate to Fascia Washer Pop Rivet Clip Choke Cable to Plate PART NUMBER QUANTITY REMARKS This Page RHD Only For LHD See 14 O...

Page 684: ...TURBO LHD lLOl B ...

Page 685: ...Trunnion Barrel Carb Throttle Lever Spring Plate Throttle Return Spring Pedal Clutch Pedal Clutch Pedal Brake Pedal Brake Pad Brake Clutch Pedals Pivot Brush Brake Clutch Pedals Spacer rake ClutchPedals Shaft Brake Clutch Pedal Pivot S p l i t Pin Pedal Shaft Retaining PART NUMBER QUANTITY This Page LHD Only For RHD See 14 01A On Plenum B Plate With Hairpin Type Less Clanp Screw Cab Lever Return S...

Page 686: ......

Page 687: ...te Choke Cable to Fascia Pop Rivet Mounting P l a t e to Fascia Clip Choke Cable to Engine Bay Rear Choke Cable inc Micro Switch Mamting Plate Choke Cable to Fascia Pap Rivet Mounting P l a t e to Fascia Washer Pop Rivet Clip Choke Cable to P l a t e PART NUMBER 0 QUANTITY MAY 1991 REMARKS This Page IlZD Only For RHD See 14 01A T h r e d Nut F i t t i n g 1 Quickfit Push mist U s e d with Pedal Bo...

Page 688: ...TURBO 1 14 05A ...

Page 689: ...Nut Column S h r a d Fixing PART NUMBER QUANTITY RHD MAY 1991 REMARKS With Rectangular Centre Vents With R a n d Centre Vents No Choke Aperture R m d Centre Vents Choke Cable Aperture 1 With Rectangular Centre Vents With R a n d Centre Vents No Choke Aperture R m d Centre Vents Choke Cable Aperture 1 With Perforations f o r Concealed Speakers Plain Cut Speaker Apertures i f Required Prefix T r i m...

Page 690: ...TURBO 14 07A ...

Page 691: ...Bracket Screw s t No 6 x f Panel Fix Spire Nut Panel Fix Mask Instrument Panel ABS Mask I n s t m n t Panel ABS Side Panel Binnacle RH S t e e l Side Panel Binnacle IH Steel Bracket Fuelfloltn er Mounting Mask Side Panel RH ABS Mask Side Panel IH ABS PART NUMBER a QUANTITY ALL MAY IS REMARKS White Illumination Green Illumination R B E082U473QJ 87 M Y on Prior to 87 M Y 1 1 87 M Y on 1 1 Prior to 8...

Page 692: ...1 I 1I 1I 1 I I I I i TURBO I 14 08A I 1 ...

Page 693: ...Bracket F i x S p i r e Nut Top F i x Edge Protector Neoprene Centre Console Trimfed inc G a i t e r Brkts Blanking Panel Trimrred Radio Aperture Fastener Blanking Panel F i x Bracket Centre Console Rear Setscrew M 6 x 20 Console to Tunnel Washer F l a t Console to Tunnel Rawlnut M6 Console to Tunnel PART NUMBER a QUANTITY ALL REMARKS F e t t l e Radio Aperture as Required P r i o r to V I N 82 D ...

Page 694: ...I _ TURBO 23 14 08A ...

Page 695: ...Retaining Ring Gear Lever Gaiter Choke Window Switch Panel T r i m Window Switch Panel Trimred PART NUMBER QUANTITY ALL 1 2 2 2 2 1 1 1 1 REMARKS Fran VIN 82 D 2271 1 82 0623 1 1 1 With Tunnel Mated Choke Control With Fascia Mnted Choke Control Prefix Trim Part Numbers With A mther StateSmooth or Ruched B Cloth BrushedVelour Also Specify or Supply Sanple of Colour and Vehicle Identification Turbo ...

Page 696: ......

Page 697: ...cia Setscrew M 6 x 18 Binnacle to Brkt Washer Large O D Binnacle to Brkt Fascia l a n k i n g Panel Trim RHD Fascia l a n k i n g Panel T r i d LHD PART NUMBER QUANTITY REMARKS I Prefix Trim Part Number With A Leather B Cloth Brushed Velcur 1 Also Specify or Supply Sanple of Colour and Vehicle Identification Turbo 14 10A ...

Page 698: ......

Page 699: ...ox Lid R H Hinge Glwebox Lid IH Screw Hinge to Fascia Beam Latch Glwebox Lid Bracket Latch to Fascia Screw Latch to Bracket Nut 4BA Latch to Bracket Nut Nyloc 6BA Striker to Lid Washer Striker to Lid PART NUMBER QUANTITY ALL REMARKS refix Trim P a r t Nunhers With A Leather State 31 0thor Ruched B Cloth Brushed V e l a r Also Specify or Supply Sanple of Colour and Vehicle d e n t i f i c a t i o n...

Page 700: ...j I I TURBO 15 01A ...

Page 701: ...O Sun Visor Drivers RHO with tbcwent Strap Sun V i s o r Drivers LED Sun Visor Drivers LHD with Docummt Strap Sun Visor Passenger RIO Sun Visor Passenger LHD Swivel Sun V i s o r Washer Sun V i s o r Swivel Washer Sun V i s o r Swivel Nut Nyloc M6 Sun Visor Swivel PART NUMBER QUANTITY FIXED ZEOOF GLASS ROaF MAY 14 iir REMARKS No Clock Essex Cars Only For Rocking Bar Type Clock For Pin Button Type ...

Page 702: ... TURBO I 15 11A ...

Page 703: ... Clip to uLkheadTrim Screw Clip to Body Slot Finisher Seat Belt Button Slot Finisher Retaining PART NUMBER QUANTITY FIXED ROOF GLASS R m 1 1 1 4 4 2 1 1 2 4 m u IYYl REMARKS For I n t e r i o r Lanp with Rocking Lens Switch For Interior Lanp with Button Switch 87 M Y on For Interior Lanp with Rocking Lens Switch For Interior L a q with Button Switch 87 MY on Prior to 87 M Y 87 M Y on Prefix Trim P...

Page 704: ...TURBO 15 13A a ...

Page 705: ... M 5 r a c k e t t u d P l a t e B R T NUMBER a QUANTITY REMARKS N o Ashtray No Speaker 1 N o Ashtray Speaker Perforations With Ashtray No Speaker 1 N o Ashtray No Speaker 1 N o Ashtray Speaker Perforations With Ashtray No Speaker I t N o Ashtray No Speaker 1 No Ashtray Speaker Perforations With Ashtray No Speaker 1 No Ashtray No Speaker 1 No Ashtray Speaker Perforations With Ashtray No Speaker 1 ...

Page 706: ...TURBO 15 13A 0 ...

Page 707: ...e Top Fix Setscrew M 6 x 16 Handle m r Fix Spacer Handle Iower to Door Nut Nyloc M6 Handle Imer Fix Screw Door Trim Panel Fixing Tapping Plate Door Panel Screws Pop Rivet Tapping P l a t e t o Door Shell PART NUMBER QUANTITY REMARKS 1 1 1 1 87 M Y on 1 1 1 For Clip on W Strip Inc i n T r i m d Door For Stick on W Strip anel All Door Trim Panels Inc Flange Suitable f o r Stick ont Type m t h e r s ...

Page 708: ...TURBO I 15 19A ...

Page 709: ...s t Fixing Plate Gear Lever Aperture Gasket Aperture Plate to Body Screw Aperture Plate t o Body Gaiter Gear Lever lher Clanp Ring Gear Lever Imer Gaiter Screw Gaiter Clanp Ring Fixing Plate Tunnel I a a n Retaining Screw Plate t o Body PART NUMBER a QUANTITY ALL I REMARKS Alternatives 1 Prior to 87 M Y 87 M Y on Prefix Trim Part Numbers With A Leather State Smoath or Ruched B Cloth Brushed Velour...

Page 710: ...TURBO i 15 24A ...

Page 711: ...r W a l l Floor R e a r Transan Battery Board Carpeted Button Durable Dot Carpet Fixing Socket Durable Dot Carpet Fixing Bracket Battery Board Top Lccating Pop Rivet Battery Board Bracket Washer Pop Rivet I n f i l l Panel IH Rear Corner Rear Bulkhead Rear Quarter Light Trim Panel RH Rear Quarter Light Trim Panel III PART NUMBER QUANTITY PRIOR 1 5 M Y 1 1 6 6 1 1 1 1 923 REMARKS Turbo 15 24A ...

Page 712: ...TURBO 15 30A ...

Page 713: ...l RH Carpet S i l l LH Carpet S i l l llI Carpet S i l l LH Inc H E3rake G a i t e r Gaiter Carpet Tunnel Side R H Carpet Tunnel Side LH Carpet Rear Bulkhead RH Carpet Rear Bulkhead LH Ashtray S i l l m t e d P RT NUMBER a QUANTITY REMARKS Specify or Supply Sanple of Colour I Vehicle Identification Number VIN State i f Ashtray i n S i l l I For D o o r Mounted Ashtrays See 15 13A Includes GRP With...

Page 714: ...1 TURBO 16 01 A ...

Page 715: ...m Tunnel Side RH Foam Tunnel Tcp Foam Tunnel Side IH Foam Front Floor LH Foam Underseat Foam Rear Bulkhead Uwer RH Foam Rear Bulkhead Upper Foam Rear Bulkhead Iaer LH Felt Wheelarch LH Felt Wheelarch RH PART NUMBER e QUANTITY REMARKS Turbo 16 01A ...

Page 716: ......

Page 717: ...x f Mat Fixing Cup Washer Mat Fixing Screw Faam Tunnel Top Underside Faam T U M Side Underside Faam Pedal Bax Seal Foam Chassis Front Crossnrember Pad Anti Squeak Sound Proofing Engine Bay Sidewall PART NUMBER QUANTITY ALL 1 14 14 1 2 2 1 1 1 REMARKS 87 M Y on Turbo 16 02A ...

Page 718: ......

Page 719: ...Lead Heated R e a r Screen Ignition Harness Ignition Harness P Clip Ignition Harness to Ign Bax Screw P Clip Fix Spire Nut P Clip Fix Screw No 6 x 3 4 Laan Fix P Clip Loan Fix PI Clip Door Mirror Control Harness P q Rivet Clip Fix PART NUMBER a QUANTITY ALL 1 1 1 2 2 1 1 1 2 1 2 1 2 1 1 1 1 1 2 2 2 2 1 1 1 1 1 1 1 6 2 4 4 REMARKS Prior to 87 M Y 1 1 87 M Y on H C Engines only 1 I F r m VIN 82 D 21...

Page 720: ...026 010 008 019 018 017 TURBO 17 01A ...

Page 721: ...ll Screw No 6 x 1 4 P Clip Fix Harness Radio Feed Harness A e r i a l Switch Speaker Lrxm Front Speaker Loan Rear m d Ignition Anplifier to Distributor Gram Ignition Box Harness Engine Managanent Diode 1AM Black PART NUMBER QUANTITY ALL REMARKS m r o l a Sparkanatic Blaupunkt For Blaupunkt Quickfit Fascia Speakers Routed Along Tunnel With Lucas Constant Energy Ignition 87 M Y on Turbo 17 01A Page ...

Page 722: ......

Page 723: ... i o r Lamp T i m 4 Switch Horn Lclw Note Horn High Note Bracket Horn Mamting Air Horn K i t PART NUMBER a QUANTITY PRIOR 87 M Y Inner H L 21 Rad Fans 1 For Cars F i t t e d With T h e m l Trip Interior Fans 1 For Cars NCTT F i t t e d With Orange Cartier Relay1 R B B079M6141F Horn 11 H L Control 1 Prior t o Fi t of Diode 1 H L Flasher 11 H L Motor R H 11 H L Motor LH 11 Fan F a i l 1 Prior t o T ...

Page 724: ......

Page 725: ...Sensing Screw Relay Fix Nut Nyloc 10 LJNE Relay Fix Washer Relay Fix Ignition Solenoid Valve Screw s t No 8 x 3 8 Solenoid Fix Washer Solenoid Fix Overboost Switch Screw No 8 x 3 Switch Fix Purge w Resilient Mounts Purge Purrp Nut M6 Purge Pump Fix Washer Internal Spring Purge Punp Fix Thermal Switch Purge hmp Control G r m t Purge Punp Switch Clip Switch Retention Solenoid Valve Purge i n e Shut ...

Page 726: ......

Page 727: ...ing Switch Dip Flash Turn orn Switch ip Flash l urn horn Switch W a s h h i p Switch Waswipe Bracket Switches to Column Screw 10 W x 119 Screw 10 W x 135 Spacer Switches to C o l m Switch Lighting Clip Bulbholder Switch Hazard Warning Lanps Switch Rear Fog Lanps Switch Heated Rear Screen Switch Window L i f t Clip Window Switch Retention PART NUMBER 0 QUANTITY ALL 1 1 4 1 2 1 1 2 2 2 4 2 2 2 8 1 1...

Page 728: ......

Page 729: ...Fan Speed Switch Knob Control Switch Assy Fridge T a p Control Switch Fridge Tenp Cwer Control Switch ABS Control Unit Fridge Tenp Harness Control Unit to Relay Knob Fridge Switch Knob Fridge Switch Cap Fridge Switch Kncb PART NUMBER p 0 QUANTITY ALL MAY 1991 REMARKS Prior to Change Point 1 1 Fran Change Point 1 1 Prior to Change Point Fran Change Point R B Kncb A089P6102F Cap A089P6103F Prior to ...

Page 730: ......

Page 731: ...l l q a l e Light Assanbly RH Tell Tale Light Assembly R H T e l l q a l e Light Assanbly LH Tell Tale Light Assembly LH T e l l q a l e Light Assanbly Centre Lens Lm Oil Pressure TellJI ale Lens Law Coolant Level Tell Tale PART NUMBER QUANTITY PRIOR 87 M Y 1 1 1 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 MAY 1991 REMARKS 3arly Cars F l a t Connector Block 1986 M Y Round Connector Block...

Page 732: ......

Page 733: ...e Nut Fitting pipe Boost Gauge Nut Fitting Pipe Boost Gauge Plain End Connector Tube Boost Pipe to Engine Restrictor Boost Gauge Pipe Washer Oil Boost Pipe to Gauge PART NUMBER a QUANTITY WAY is91 REMARKS R B Items 5 6 7 and Take Off Elbow A910E6772 See 42 0l A Turbo 17 09A ...

Page 734: ...LUCAS UNEAR UFFUPON PATTERN SIDEITMW INDICATOR LAMP ...

Page 735: ... i d e h u r n Lanp Setscrew M 6 x 25 Lanp Fix Washer M6 Lanp Fix Washer Lanp Fix Nut Nyloc M6 Lanp Fix Rear Lanp Assy LH Rear Lanp Assy RH Nut Lanp Fix Washer Lanp Fix Licence Plate Lanp Screw Lanp Fix Door Open Warning Larrp inc Gasket 1 Shield D o o r Lanp IH Shield Door Lanp RH Screw Lanp Fix Spire Nut Lanp Fix PART NUMBER QUANTITY ALL 3 B Lanp A082M6180F and x t e n s i o n Harness A082M4188F...

Page 736: ...STRATED ...

Page 737: ... P q Rivet Mtg Plate to Pod Washer Pop R i v e t Surround Headlanps LH Surround Headlanps RH Screw Surround to Pod Surround Headlanps LH Surround Headlanps RH Surround Headlanps IH Surround Headlanps RH Button Clip Surround to Pod PART NUMBER a QUANTITY RHD 4 4 2 2 4 2 2 16 16 2 12 12 12 32 32 1 1 8 1 1 1 1 12 Mirv yj REMARKS Fram unit Bulb Includes H 4 Bulb Frame Unit Bulb Includes H 4 Bulb Main ...

Page 738: ......

Page 739: ... Connecting Link Pod Actuation Rod End 1 4 UNF Connecting Link Locknut 1 4 LINE Rod End Linkage Assembly Pod Actuation Setscrew M 6 x 30 Link to Pcd Nut Nyloc M6 Link Fixing Bracket Link to Pod Setscrew M 6 x 18 Bracket to Pod Washer Shakeproof Bracket t o Pod Washer Flat Bracket to Pod Tapping Plate Bracket to Pod PART NUMBER e QUANTITY ALL R B A082M4584F Inc Rotary Link 1 R B Assembly A082U5006F...

Page 740: ......

Page 741: ...rior Lanp Mamting Bulb Festoon Interior Lanp 6W Interior Lanp with button switch Bracket Interior Lanp Mamting Bulb Festoon Interior Lanp 10W Door Switch Courtesy Lanp Spacer Washer Fibre Switch Adjust PART NUMBER QUANTITY ALL 1 1 1 1 1 1 2 rn REMARKS Fran 1986 Turbo 17 17A ...

Page 742: ......

Page 743: ...Rivet rip Connector Mldghrkt Screw Mounting Bracket to Body Inertia Switch Fuel Punp Cut Out Bolt M5 x 50 Switch Fix Nut Full M5 Switch Fix Washer Shakeproof Switch Fix Fusebox Screw 2BA x 1 Fusebox Fixing Nut Nyloc 2BA Fusebox Fixing PART NUMBER QUANTITY ALL REMARKS Red Spot R B BO82M6196F Green Spot Turbo l7 lgA ...

Page 744: ......

Page 745: ...cking Plate Pantograph Arm Lacking Plate Pantograph Ann Screw Locking Plate to Body Wheelbox Assembly Inc Nuts Bracket Wheelbox Stabilising Setscrew Bracket to Body Washer Bracket to Body Nut Torqloc Bracket to Body Spacer Wheelbax to Body 13m Spacer Wheelbox to Body hrm Spacer Locking Plate to Body Arm Spacer Imking Plate to Body 6 5mn PART NUMBER QUANTITY REMARKS El B A085M6163F Bronze Coloured ...

Page 746: ......

Page 747: ... Fix Screw Rear Speaker Fix Speaker Cable Rear Short Speaker Cable Rear Lmg Speaker Cable Front Speaker Oval Door Mamted Harness Door Speakers Speaker Fascia I O W Speaker Cable Front Speaker Fascia Quickfit 15W Locm Front Speaker Loan Front Speaker PART NUMBER QUANTITY ALL M A U M REMARKS National Panasonic 973 National Panasonic 583 Motorola Lotus S p a r k t i c SR309F Blaupunkt Cambridge Blaup...

Page 748: ...LHD SHOWN ...

Page 749: ...bly Washer W i p e r Arm Nut W i p e r Blade Grarmet Washer Tubing Washer hurp Reservoir Assembly Mounting Bracket Washer Reservoir Screw Washer Brkt t o Body Washer Washer Brkt t o Body Washer Tubing 4mn Twin Jet Windscreen Washer PART NUMBER a QUANTITY MAY REMARKS with p g swivel joint with p g ball joint with p g swivel joint Eblt on with p g b a l l joint W i p e r Arm with p g swivel joint wi...

Page 750: ...TURBO 17 27A a LHD SHOWN a ...

Page 751: ...ternal F i t Relay Electric Aerial A e r i a l Electric Internal F i t Jup Harness Aerial Junp Harness Ignition Feed J q H a r n e s s Aerial Radio Harness Radio Feed PART NUMBER 0 QUANTITY ALL I P 1 1 1 2 2 2 1 1 1 1 1 1 1 1 REMARKS Blauplnkt 1 Routed Along S i l l R a k e d Along Tunnel 1 Clarion Radio 1 Nat Panasonic Mtorola Sparkamtic For A082M6149F See S B 1984 10 W i t h Nat a n a s o n i c ...

Page 752: ......

Page 753: ...g Earth Bond Chassis to Bulkhead Earth Braid Engine to Chassis Capacitor 2 mE Ignition Coil Capacitor 1 mE Fuel Plmp Capacitor 1 mE Stop Switch Capicitor 1 mE Voltage Stabiliser Choke Voltage Stabiliser Earth m d Timing Belt Tensioner Earth Bond Seat Tanks to Chassis Earth Bond Electric Aerial PART NUMBER QUANTITY ALL REMARKS Turbo 17 29A ...

Page 754: ......

Page 755: ... Battery Stud Washer Flat Battery Stud Washer Spring Battery Stud Wing Nut M6 Battery Retention Pad a t t e r y Battery Cable Positive Battery Cable Positive Battery Cable Negative Battery Cable N e g a t i v e Bolt 5 16 BSW Battery Terminal Nut 5 16 BSW Battery Terminal Gr t Battery Cable Harness Grcmuret Pos Cable Gr t Pos Cable P Clip Battery ad Securing Pop Rivet P Clip Washer Pop Rivet PART N...

Page 756: ......

Page 757: ...to Tunnel Pop Rivet M t g Brkt to Tunnel Bush F l a p Pivot Inner Bush F l a p Pivot Outer Closing Panel Screw Closing Panel to Case Drain Adaptor Main Case Drain Tube 5 8 I W Screw U p p e r r n r Case F i x Hose Clip 16 25mn Drain Tube PART NUMBER a QUANTITY RHD REMARKS I c Heater Matrix E p 0 r a t o r 9 C Only Vac Valves Control Cables Rotary Controls Heater Only Air Conditioning H e a t e r O...

Page 758: ......

Page 759: ... Evaporator t o Carpressor Flare Gasket Hose to Evaporator Hose Carpressor to Condenser Hose Conpressor t o Condenser Hose Carpressor t o Condenser Hose Conpressor to Condenser Heatshield Wrap Discharge Hose G r m t Fridge o s e h n g i n e Bay Black G r a r m t Fridge Hose Engine Bay Grey Hose Condenser to Receiver Drier Ow Ring j Condenser Inlet 0 Ring 3 811 Condenser Outlet Plate Grarmet G r m ...

Page 760: ...TURBO 18 03A ...

Page 761: ...to u c t Washer 25mn O D Condenser to Duct Bracket Condenser Support Bracket Condenser Support Setscrew M 6 x 16 Brkt to Condenser Washer Flat Brkt to Condenser Nut Nyloc M6 Brkt to Condenser Neoprene Strip Antixhafe Tape Non Drip Evaporator Connections Thermistor PART NUMBER a QUANTITY RHD REMARKS I Prior to 87 M Y 87 M Y On mn Strapped to Evaporator Turbo 18 03A Page 2 ...

Page 762: ......

Page 763: ... a r y Line Hose Water Valve to Matrix H o s e C l i p Hose Valve Inlet Matrix O u t l e t H o s e C l i p Gram Hoses Thrcugh Body Connector Pipe Heater Hose Elbow Hose Heater Pipe Front Hose Clip Elbow Hose Pipe Heater Water Thrcugh Chassis Gram Pipes Chassis Hose Heater Feed Return H o s e Clip Feed Return Hose Transfer Pipe Heater P i p e to Plenum PI Clip Transfer Pipe to Plenum E l b w Hose W...

Page 764: ...Ii TURBO 1 18 07A ...

Page 765: ...B l m e r Motor Fan Assembly Bottan Clanp Motor to Housing Setscrew M5 x 20 Motor Clarrp Washer Motor Clanp Screw Jacknut M5 Motor Clarrp Screw PART NUMBER e QUANTITY ALL 1 1 6 6 6 6 C C W Rotation Vie Motor End CW Rotation Viewed Motor End Turbo 18 07A ...

Page 766: ...TURBO 10 0 9A ...

Page 767: ...Stud Cam Vacuum Valve rating Trunnion Cable to Cam Spacer Lever to Cam Spring Cam Return Spring Cam Return Lever B e l l Crank Defrost F l a p Bush Lever P i v o t Clip Lever P i v o t C l i p Lever to F l a p Rod Setscrew 1 0 UNF x 3 8 Cam Operating Washer Cam Setscrew Nut Nyloc 1 0 UNF Cam Setscra Rotary Control Tenperature Rotary Control A i r D i s t r i b u t i o n Nippleflrunnion Ratary Cont...

Page 768: ...TURBO 10 0 9A 0 ...

Page 769: ... a r y Controls Knob Rotary Controls PART NUMBER QUANTITY RHO REMARKS With Essex Turbo Cockpit Unit With Hole f o r Ccrrpressor Indicator Light For Face Mounted Radio or No Radio With No Hole f o r Conpressor Indicator Light For Face Mounted Radio o r No Radio With Hole f o r Conpressor Indicator Light For Bax Mounted Type Radio With No Hole f o r Conpressor Indicator Light For Bax Mounted Type Ra...

Page 770: ......

Page 771: ...nector ITt Piece Vacuum Pipes Vacuum Pipe Elbaw Connector Unequal Bore Bracket Vac Actuator to Bulkhead Screw No 6 x 3 4 Brkt to Bulkhead Spire Nut Brkt to Bulkhead Clevis Pin Actuator to Flaps Washer Clevis S p l i t Pin Clevis Retention Flap Fresh A i r Intake Flap Air Re Circulation Flap A i r Re Circulation Lev Fresh Air Re Circ Flap Grub Screw Lever to Flap Shaft Bracket Fresh Air Re Circ Fla...

Page 772: ......

Page 773: ...Reservoir T Piece T Piece Tubing Vacuum Nylon Connector Hose PIC Vacuum Hose Rubber Non Return Valve In Line Non Return Valve In Line Hose Clip Gromnet Engine Bay W a l l PART NUMBER a QUANTITY RHD 4 4 I m 2 4 2 4 1 1 3 3 3 3 1 1 A R A R A R 1 1 3 1 LHD 4 4 I m 2 4 2 4 1 1 3 3 3 3 1 1 WR A R WR 1 1 3 1 I REMARKS 4 With A C 1 4 With A C 1 1 1 1 R B A075W5014E 1 1 1 1 1 1 1 R B A075L6043V 1 1 R B A0...

Page 774: ...LHD ILLUSTRATED 037 ...

Page 775: ...et Fan Scroll Washer Pop Rivet Screw Scroll to Scroll Extension Spire Nut Ducting 1iW F o o t e l l Bulkhead Sealing Panel Inboard Bulkhead Sealing Panel Intxxrd Bulkhead Sealing Panel Outbuard Bulkhead Sealing Panel Outtxxrd Pop Rivet 1 8 Sealing Panel Joint Washer Sealing Panel J o i n t Screw M i n g Panel Fixing Flap Cabin Pressure Relief Hinge Pressure Relief FLap P q Rivet Flap Fixing Grarme...

Page 776: ...I LHD ILLUSTRATED ...

Page 777: ...r F L V Retaining P q Rivet C l i p to F L V Washer Pop R i v e t Adaptor 90 F L V to Ducting Adaptor 90 F L V to Ducting Adaptor 90 F L V to Ducting Face Level Vent Centre Rectangular Clip Centre F L V Retaining Pop Rivet C l i p to F L V Washer Pop Rivet Adaptor S t r a i g h t F L V to Ducting Face Level Vent Centre R a n d Retaining Ring R m d Vent Nut Nyloc M3 Vent Fixing PART NUMBER QUANTITY...

Page 778: ...TURBO 1 1 30 01A I ...

Page 779: ...pre 85 chassis the following parts m y a l s o be required t o f i t the latest pre 85 specification Chassis dependent on VIN Anti Roll Bar Fixings see 31 01 A Rear Top Link Fixings see 31 03A Engine Writings see 40 01A tmte When replacing a Pre 87 M Y Zhassis t h e oil cooler hoses must be run through t h e Chassis backbone with 190mn of edge protector AX75L602W i n the Chassis rear diaphragm and...

Page 780: ......

Page 781: ...l Link RH Plug Lubrication Vertical Link Steering Arm RH Steering Arm LH Caliper Mounting Plate R H Caliper Mounting Plate LH Sealing Ring Dust Shield IH Dust Shield RH PART NUMBER QUANTITY ALL REMARKS This Page Prior t o 85 Model Year For 85 M Y Cars see 31 01B 1 Carpanotive Wheels BBS Wheels Ground Finish R B C075J0297F in pairs Non Directional Machined Brake Disc to Hub 1 Stub Axle to Vertical ...

Page 782: ......

Page 783: ...er Wishbone Stud Access Screw C w e r Fixing Loher Trunnion RH Lower Trunnion LH Bush K i t L o w e r Trunnion Seal Trunnion Top Bolt 7 16 U N F Nut 7 16 U N F Washer Lower Link LH Loher Link RH PART NUMBER QUANTITY REMARKS This Page P r i o r to 85 Model Year For 85 M Y Cars See 31 01B 1 Caliper P l a t e to Vertical Link Caliper latefierticalLink Steering Arm Upper B a l l J o i n t to Vertical ...

Page 784: ......

Page 785: ... Spring A R B to Chassis Mounting Rubber A R B to Chassis Clanp P l a t e Shim Plate Castor Adjust Setscrew M12 x 35 A R B to Chassis Washer Spring A R B to Chassis F RT NUMBER a QUANTITY ALL This Page P r i o r to 85 Model Year For 85 M Y C a r s See 31 01B 1 Lover Link t o Chassis 1 Up to VIN 82 D 1262 82 0410 exc 0399 0400 Fran VIN 82 D 1263 82 0411 plus 0399 0400 Anti Roll Bar to L o w e r Lin...

Page 786: ......

Page 787: ...r For 85 M Y Cars See 31 OlB R B C08X4014F I n P a i r s Green Spot on Laer Body I f f i t t i n g to early car up to approx VIN 82D 1029 82H 03341 with 1 6 m d i e t e r darrper stem hole i n chassis F i t only i n pairs with 2 off Top Stem Bush K i t A08X6032F Later cars have 19 5m double thickness hole and use Bush K i t A082C6033F With 16 mn Darrper Stem Hole i n Chassis With 19 5m Darrper Ste...

Page 788: ......

Page 789: ...ed Bolt Brake Disc t o Hub Washer Brake Disc to Hub Grease Seal Front Hub Washer Claw Bearing Retaining Nut Bearing Retaining Split Pin Locking Cap Locking Cap Bearing Nut Grease Cap Hub Bearing Arm Upper Wishbone Pivot Bush Upper Wishbone Stud Upper Wishbone Pivot Buffer Washer Pivot Bush Nut Nyloc 3 UNE Locknut 3 UNF PART NUMBER a QUANTITY b l N i REMARKS This Page 85 W e 1 Year On For Cars Prio...

Page 790: ......

Page 791: ...bone Rear Pivot Bush Lower Wishbone Front Bush Anti Roll Bar Imer Wishbone Ball Joint Lower Nut Nyloc M14 Pivot mlt 4 UNF x 6 Nut Nyloc 4 UNE Pivot mlt 4 UNF x 2 3 4 Nut Nyloc 4 UNE Anti Roll Bar Bush Anti Roll Bar to Chassis Clanp Anti Roll Bar to Chassis Setscrew M12 x 35 ARB to Chassis Washer Flat I I n I I PART NUMBER a QUANTITY ALL MAY 19 REMARKS This Page185Model Year On For Cars Prior to 85...

Page 792: ......

Page 793: ... with White Spot Danper Front Black with Red Spot Bolt 4 UNF x 34 Nut Nyloc 4 UNF Bush Kit Oanper Top Stem Blanking Plug Plastic Cwer Wishbone Stud Access Cwer Wishbone Stud Access Gromnet Wishbone Stud Access Screw Cwer Fixing PART NUMBER a QUANTITY REMARKS This Paqe 8 5 Model Y e a r On For Cars Prior t o 85 M Y See 31 01A Heater Only 1 With A C Replaced by Heater Only Conical Spring Danper With...

Page 794: ......

Page 795: ... Carrier RH H u b Carrier ul Radius Am RH Radius Arm RH Radius Am R H Radius Arm RH Radius Am ul Radius Arm ul Radius Am IH Radius Arm IH Bolt Ml0 x 120 Rad Arm Hub Carrier Bolt Ml0 x 130 Rad W H u b Carrier Nut Nyloc Mlo Washer Plain PART NUMBER a QUANTITY ALL MFil Ngl REMARKS C o n p m t i v e Wheels Caqmrotive Wheels BBS Wheels D Sha t to Adaptor and Outboard D Shaft Carpcmotive Wheels BBS Whee...

Page 796: ......

Page 797: ...NF x 5 Link Chassis Spacer S p l i t Washer 3 x 1 1 4 Nut Nyloc 4 UNF Upper Link Less Bushes Bush Upper Link Silentbloc Bolt f UNF x 5 Link Chassis Spacer S p l i t Washer f x 1 3 4 Nut Nyloc f UNF Bolt 4 UNF x 4in Link Chassis Spacer Washer 3 x 1 3 4 Nut Nyloc 4 UNF PART NUMBER QUANTITY REMARKS Radius Arm to Chassis Radius Arm Mmnting to Chassis 1 1 Radius Arm to Mounting 1 Xorrpornotive W h e e ...

Page 798: ......

Page 799: ... 4It Link Spacer Washer 31 Hardened L i n k k a r r i e r Washer 3 1 1 x 1 3 4 Locknut 311 UNF Nut Nyloc 3 UNF Danper Assy Includes A082C6033F Danper Assy Includes A082C6033F PART NUMBER QUANTITY ALL 1 1 Capomotive Wheels 1 1 BBS W h e e l s 1 1 Ccrrpanotive Wheels 1 BBS Wheels 1 1C t ive W h e e1s BBS Wheels Prior t o 85 M Y R B C082D4058F Prior t o 85 Model Year Blue With Green Spot on Zlowzr Bo...

Page 800: ......

Page 801: ...r Carrier Road Spring reen Green Road Spring Green Green Road Spring Green Insulator Rear Spring G r m t RH Wheelarch PART NUMBER a QUANTITY ALL 2 2 2 2 4 2 2 2 2 2 2 1 REMARKS 1985 Model Y e a r Onward Black With White Spot on Umer Body 16rm Chassis Hole 1 Prior t o 19 5rrm Chassis Hole 1 85 M Y 1985 Model Y e a r On Heater only cars A C cars R B D079D4003F i n pairs A C cars 4 longer than E079D4...

Page 802: ...TURBO 32 01A i LHD ILLUSTRATED ...

Page 803: ... J o i n t Track Rod End Locknut 4 UNF Ball J o i n t Tapping Plate Steering Rack Mxnting Shim Rack Assy to Chassis Clarrp Bracket Rack Assy to Chassis Clarrp Bracket Rack Assy to Chassis Rubber Mounting Rack Assembly Rubber M a t i n g Rack Ass ly Setscrew M 8 x 20 Clanp to Chassis Washer Spring Clarrp to Chassis Gaiter Set Steering Rack inc c l i p s PART NUMBER QUANTITY I MAY 1991 I I I REMARKS...

Page 804: ......

Page 805: ...Assembly Setscrew MI0 x 25 Colurm Scuttle Washer Flat Column Scuttle Washer Shakeproof Colurm Scuttle Nut Special Column Scuttle Clanp Column t o Pedal Box Clanp C o l m t o Pedal Box Nut Nyloc M8 Clanp t o Pedal Bax Washer Flat Clanp t o Pedal Box Lock Steering Column c w Ignition Switch Shear o l t k k t o column Seal Plate Column to Bulkhead Seal Plate Column to Bulkhead Gasket Seal Plate to Bu...

Page 806: ......

Page 807: ...Plain 10 mn Ring Dowel Caliper Adaptor Caliper t o Brake Hose Pad Danping Spring Return Spring RH Return Spring IH Seal K i t Rear Caliper Guide Pin K i t Piston K i t Rear Caliper IlI Piston it Rear Caliper RH Bleed Screw Rear Caliper PART NUMBER QUANTITY MAY 1991 I REMARKS 1 I I This Page prior to 85 M Y For 85 M Y See 33 01B Includes Brake Pads Includes Brake Pads Includes Pins Clips Includes 4...

Page 808: ......

Page 809: ...IPTION D i s c Rear Brake Nut M12 D i s c Fixing Washer Spring D i s c Fixing PART NUMBER a QUANTITY MAY 1 9 9 1 iI I REMARKS This Page Prior to 85 M Y For 85 M Y See 33 01B Turbo Prior to 85 M Y 33 01A Page 2 ...

Page 810: ...1 33 018 TURBO 85 M Y ON1 ...

Page 811: ... Calipers Cylinder Assembly RH Cylinder Assembly LH Seal K i t Rear Caliper Abutrrent Park Braking Cable RH A b u b n t Parking Brake Cable LH Setscrew M8 x 20 Abutmnt Caliper Spring Washer Ahtment Caliper Bolt M12 x 85 Caliper Fix Top Bolt M12 x 75 Caliper Fix Bottan Washer Flat Caliper Fix PART NUMBER e QUANTITY ALL MAY 15si REMARKS This Page 85 M Y Onward F o r C a r s P r i o r t o 1 8 5 M Y S...

Page 812: ......

Page 813: ... Brake Disc Rear Nut M12 D i s c Fixing Washer Spring D i s c Fixing PART NUMBER a QUANTITY ALL MAY f i REMARKS j This Page 85 M Y Onward For Cars Prior to 85 M Y See 33 01A White Colour Code or Cast Part Nunher Turbo 85 M Y On 33 01B Page 2 ...

Page 814: ......

Page 815: ...Bun Grarmet Servo H o s e Bundy Pipe Servo Vacuum Hose Vacuum Bundy to Manifold Clip Vacuum Hose Brake Master Cylinder Assy Nut M10 M Cylinder to Servo Washer M Cylinder to Servo Reservoir K i t Master Cylinder Fluid Leuel Warning Indicator Service K i t Master Cylinder Banjo Master Cylinder t o Front Pipe Gasket Banjo Gasket Banjo Bolt Banjo Gram Pipes Thro Bulkhead Pipe Front Brake M C to 3 Way ...

Page 816: ......

Page 817: ...ded Union to Rear 3 ay Union 3 Way R e a r Pipe Brake 3 Way to R H Hose Pipe Brake 3 Way to LH Hose Pipe Brake 3 Way to LH Hose Clip Brake Pipe Screw Clip to Chassis Hose Rear Brake Hose Rear Brake Armoured Locknut Rear Brake Hose Washer Shakeproof 10 mn Bracket Hose Pipe to Caliper LH Bracket Hose Pipe to Caliper R H Pipe Brake Hose to Rear Caliper PART NUMBER QUANTITY RHD REMARKS I This Page Pri...

Page 818: ......

Page 819: ...l u i d Reservoir Repair K i t Master Cylinder G r m t Pipes Through Body Nut Nyloc M8 M Cylinder to Servo Washer Flat W l i n d e r to Senro Pipe Brake W y l i n d e r to RHF Hose Pipe Brake M Cylinder t o RHF Hose Pipe Brake W y l i n d e r t o LHF H o s e Pipe Brake M Cylinder to IHF Hose Clip Brake Pipe to Chassis Screw Pipe Clip t o Chassis Hose Front Brake Locknut Front Brake Hose Washer Sha...

Page 820: ......

Page 821: ...assis Screw Pipe Clip to Chassis Hose R e a r Brake Lacknut Rear Brake Hose Washer Shakeproof Brake Hose Bracket Rear Hose t o Caliper Pipe Brake R e a r hose to Caliper Hose Vacuum Servo t o Bundy Bundy Pipe Servo Vacuum ThrowChassis Hose Vacuum Bundy t o Manifold Hose Clip Vac Hose Grorrmet Servo Vac Hose Hose Vacuum T Piece to Bundy pipe Bundy Servo Vacuum Clip Hose Hose Vacuum Bundy to T Piece...

Page 822: ......

Page 823: ...ESCRIPTION Switch Low Vacuum Screw s t No 6 x I 1 Switch Fixing Nut Spire No 6 Switch Fixing ITt Piece I m Vacuum itchTake PART NUMBER QUANTITY RHD REMARKS I 1 1 87 M Y on 1 1 Turbo 85 M Y On 33 038 Page 3 ...

Page 824: ......

Page 825: ... Bracket Handbrake Microswitch Setscrew M 6 x 30 Switch Brkt Fix Washer Flat Switch Brkt Fix Nut Nyloc M 6 Switch Brkt Fix Microswitch Handbrake Tell tale Screw s t Switch t o Brkt Screw M 3 x 16 Switch to Brkt Nut Nyloc M 3 Switch t o Brkt Clevis Pin Handbrake t o i n k c t Rod Spring Clip Clevis Retaining Washer Handbrake Clevis Washer Clevis Spring Clip PART NUMBER e QUANTITY PRIOR 85 MY 1985 I...

Page 826: ...LHD 85 MY SHOWN TURBO 33 05A 0 0 a ...

Page 827: ...nsator H Brake Cables Clevis Pin Conpensator Washer Clevis Pin Spring Clip Clevis Retaining Cable Handbrake Cable Handbrake Cable Tie Handbrake Cable Abutment Handbrake Cable Forward Abutment Handbrake Cable Forward Setscrew M8 x 25 Abutment to Body Washer Spring Abutment to Body G r m t Plate Handbrake Cables Gramnet Handbrake Cable Screw Grarmet Plate Fix PART NUMBER a QUANTITY PRIOR 85 MY 1 REM...

Page 828: ...025 TURBO 34 01A e ...

Page 829: ...Valve Tyre Spare Wheel Road Wheel Tyre Assembly Front Road Wheel Tyre Assembly Front Road Wheel Front Tyre Front 195 60 VR15 Goodyear NIP Tyre Front 195 60 VR15 Goodyear NIP Valve Front Tyre Road Wheel Tyre Assembly Rear Rcad Wheel Tyre Assembly Rear Road Wheel Tyre Rear 235 60 VR15 Goodyear NIP Tyre Rear 235 60 VR15 Goodyear W J Valve Rear Tyre Wheel Tyre Assembly Spare Wheel Tyre Assembly Spare ...

Page 830: ......

Page 831: ... l Bolt Finisher Wheel Centre With Old Badge Finisher W h e e l Centre With New Badge Clanp Bolt Spare Wheel Securing Clanp Plate 0 Ring Clanp Bolt Tapping Plate Clanp Bolt Pcp i v e t Tapping Plate to Body PART NUMBER a QUANTITY PRIOR 85 M Y REMARKS Turbo 34 01A Page 2 ...

Page 832: ......

Page 833: ...2 Cylinder Head t o Block Plug 1 NETT Cylinder Block Plug 1 4 BSP Oil Gallery Spirol Pin Cylinder Head to Block Union O i l Pressure Gauge Take Housing Rear Crank Seal Housing Rear Crank Seal Seal Crankshaft Rear Red Seal Crankshaft Rear Black Gasket R e a r Seal Housing Setscrew M 6 x 25 Rear Housing lock Washer Flat R e a r Housing lock Button Head Screw Housing Block MBH Washer Thin o u s i n g...

Page 834: ......

Page 835: ...ck Tube to Plenum Clip Plastic Dipstick Tube Bracket Front Cover Gasket Front Cwer Setscrew M 6 x 25 Front Cover Washer Flat Front Cover Seal Crankshaft Front 1 Engine to Clutch Housing Snapper Clip Breather Hose Hose Clip Breather Hose Hose Breather Crankcase Oil Tank Hose Breather Crankcase hrbo Intake Hose Breather C r a n k c a s e h b o Intake Hose Breather Crankcase irF i l t e r h m t i n g...

Page 836: ......

Page 837: ...gine RH With Relay Lever Pivot inc Bush Bush Gear Change Relay Lever Pivot Mounting Bracket Engine RH Without Relay Lever Pivot Edge Finisher Engine Mamting Brkt Bolt M8 x 40 Bracket to Engine Setscrew Cap Head M8 x 35 Brkt to Engine Washer Spring Bracket to Engine Ld PART NUMBER a QUANTITY vim SUMP 1 1 2 2 2 2 4 6 2 2 1 1 1 1 1 4 m 6 6 6 MAY IQ d1 REMARKS Use With Mtg Rubber A085E6012F 1 1 1 Fixi...

Page 838: ...TURBO 4003A ...

Page 839: ...Smp Screw Baffle to Sunp Setscrew M 8 x 25 Sunp to MBH Bolt M 8 x 45 Sunp to MBH Bolt M 8 x 65 Smp to MBH Bolt M 8 x 50 Sunp to MBH Nut Nyloc M8 Swrp to MBH Washer Flat Sunp to MBH Bolt M 8 x 30 Smp to MBH Bolt M 8 x 80 Sunp to MBH PART NUMBER e QUANTITY REMARKS Turbo 4 ...

Page 840: ...1 I 1 TURBO 40 05 A ...

Page 841: ...ve O D 0 005 Circlip Valve Guide Seat Insert Inlet Valve O D Std Seat Insert Inlet Valve O D 0 001 Seat Insert Inlet Valve O D 0 002 Seat Insert I n l e t Valve O D 0 005 Seat Insert Inlet Valve O D Std Seat Insert Inlet Valve O D 0 001 Seat Insert Inlet Valve O D 0 002 Seat Insert Inlet Valve O D 0 005 Seat Insert Exhaust Valve O D Std Seat Insert Exhaust Valve O D 0 001 Seat Insert Exhaust Valve...

Page 842: ...TURBO 40 05A ...

Page 843: ...Cam Hsg t o Head Seat Valve Spring Spring Valve Inner Spring Valve Outer Retainer Valve Spring Collet I n l e t Valve Collet Exhaust Valve Valve Inlet Valve Exhaust Gasket Cylinder Head Washer Cylinder Head t o Block Nut M12 Cylinder Head t o Block Stud EMmust Manifold t o Head Stud Inlet Manifold t o H e d PART NUMBER QUANTITY H C m1m 1 2 2 1 1 1 4 16 16 16 16 16 16 8 8 1 10 10 12 9 Turbo 40 05A ...

Page 844: ...TURBO Prior 87MY H C 40 07A ...

Page 845: ...pet Selective Rear Cwer Canshaft Housing 0 Ring Rear cover Washer Large O D Washer Spring Ton Bolt Hausing to H e d Washer Flat Housing to Head Nut M8 Hausing to He Stud Cam Cover to Housing Screw Chrcarred Cam Cwer to Hsg Rubber Washer Cam Cwer Screw Spirol Pin Gasket Lacation Gasket Cam Carer t o Hsg Gasket Cam Cwer t o Hsg PART NUMBER QUANTITY PRIOR 22911 F R O M 22911 1 1 2 2 2 2 2 2 2 16 16 2...

Page 846: ...TURBO Prior 87 MY H C 40 07A ...

Page 847: ...tud Snubber Fixing Washer F l a t Snubber Fixing Nut M8 Snubber Fixing Cap O i l F i l l e r Setscrew M5 x 12 Cap Retention Washer F l a t Cap Retention Washer Shakeproof Cap Retention Gasket F i l l e r Cap PART NUMBER 0 QUANTITY PRIOR 22911 FROM 22911 1 1 10 1 2 1 1 2 2 2 1 1 1 1 1 M M q REMARKS Eng No 22911 B u i l t January 1986 This Page P r i o r t o 87 M Y H C Dry Sunp Only R B B910E0992K W...

Page 848: ...TURBO Prior 87MY H C 40 07A ...

Page 849: ...4 0 O7A I t e m 015 TAPPET SHIMS Shim Part No Shim Part No Shim Part N o Shim Part N o Turbo 4 0 O7A Page 3 ...

Page 850: ...TURBO 87MY M 40 078 ...

Page 851: ...g Washer Thrust Washer t o Carrshaft R e a r Cwer Canshaft Housing 0 Ring R e a r Cwer Stud Cam Housing R e a r Bracket Diffuser Support Washer Plain Bracket to Diffuser Nut Nyloc M6 Bracket to Diffuser Camshaft Type 107 1 Woodruff Key Carrshaft Pulley O i l Seal Camshaft Front Blanking Plug Carrshaft Front Cam Cwer Inlet Red Cam Cwer Ekhaust Red Screw Cam Cwer Fix 0 Ring Cam Cwer Fixing Screws Ga...

Page 852: ...II I TURBO 40 09A ...

Page 853: ...5mm Width O i l Control Ring 5mn Width O i l Control Ring rm Width O i l Control Ring Connecting Rod Connecting Rod 1 Cap to Rod Bolt Cap to Rod Bush Smll End Bearing S h e l l Big End SLD Bearing Shell Big End 0 010 Bearing Shell Big End 0 020 PART NUMBER a QUANTITY 87 M Y H C R B B910E6919F Includes Items up to A008 inc I I I1 I I II I 1 I1 I n t e r n a l Tap Bevel I n t e r n a l Tap Bottom Be...

Page 854: ...TURBO 40 11A ...

Page 855: ...l Main Bearing 0 020 I D Std O D I1 I I I I I I 1 II I I PART NUMBER QUANTITY REMARKS Groove Hole Upper except Centre Plain Hole W p p e r Centre Plain kmer Qty 5 f ram Engine No 20875 Plain Notch War bwr up to Engine No 20874 Growe Hole Upper except Centre Plain Hole 1 Upper Centre Plain bwr Qty 5 from Engine No 20875 Plain Notch Rear b w r up to Engine No 20874 Groove Hole 1 Upper except Centre ...

Page 856: ...TURBO 40 11A ...

Page 857: ...RT NUMBER QUANTITY REMARKS Growe Hole1 Upper except Centre Plain Hole 1 Upper Centre Plain Imer Q t y 5 from Engine No 20875 Plain Notch Rear Uwer up t o Engine No 20874 Groove Hole Upper except Centre Plain Hole Upper Centre Plain Lower Qty 5 from Engine No 20875 Plain Notch Rear m r up to Engine No 20874 Growe Hole 1 Upper except Centre Plain Hole Upper Centre Plain lhwer Qty 5 from Engine No 20...

Page 858: ... 13 PRIOR b7 N Y TURBO 12 40 13A ...

Page 859: ...6 x 35 Purrp to Block Bolt M6 x 55 P u q to Block Washer Flat Water Plmp Fixings Hose Inlet Manifold to Punp H o s e Clip 32 50 Elbow Hose Cylinder Head to Punp Hose Clip T h e m s t a t Cwer Outlet Elbow Gasket T h e m s t a t Cover Setscrew M 8 x 25 T h e m s t a t Cwer Washer Flat T h e m s t a t Cwer T h e m 1 Transmitter Tenp Gauge T h e m s t a t 74OC T h e m s t a t 82OC PART NUMBER a QUANT...

Page 860: ...022 TURBO 4015 A ...

Page 861: ...Washer Spring Punp to Am Hsg Washer Flat Purrp to Aux Hsg Shaft Rotor Assembly Auxiliary Shaft Adliary Shaft Rotor Oil murp Woodruff Key Oil Pmp Rotor Circlip Rotor to Shaft Annulus Oil Pump Circlip Pulley Abutment Spring Dist Drive Aux Shaft Spring Dist D r i v e Shaft Oil Seal Aux Shaft Front Oil Seal Am Shaft Rear Adaptor Union Oil Filter Gasket Am Hsg to Cylinder Block PART NUMBER QUANTITY DRY...

Page 862: ...TURBO 40 15A ...

Page 863: ... Block Bolt M8 x 105 A l t rM Housing Block Washer Flat Aux Hsg Fixings Mounting Bracket Alternator Mounting Bracket Alternator Mounting Bracket Alternator Spacer Alt BrM to Hsg Bracket A C Ccnpressor Rear Spacer Conp Brkt to Hsg PART NUMBER e QUANTITY DRY SUM MM 7991 REMARKS Wet U s e Torx Bolt A912E1692K Smp a t front lower location i f Without insufficient hex head s C clearance U s e d with Al...

Page 864: ...1 TURBO 4015 A ...

Page 865: ...Ring Drain Pipe to Sunp Setscrew M 6 x 16 Pipe t o Sunp Washer Spring Pipe to Sunp Gasket Drain Pipe t o Turbo Setscrew M 8 x 20 Pipe to Turbo Washer Spring Pipe to Turbo Hose Assembly Turbo O i l Feed Hose Assembly Turbo Oil Feed Flange Adaptor Turbo to O i l Feed Hose Gasket Flange Adaptor to Turbo Setscrew M 8 x 20 Flange to Turbo Washer Spring Flange t o Turbo PART NUMBER QUANTITY DRY 3 u I P ...

Page 866: ......

Page 867: ...Outlet Union Pulley O i l Punp 0 010 Diameter Pulley O i l mnrp Standard Pulley O i l Rmp 0 010 Diameter Key Pulley to Shaft Washer Pulley Rear shaft Washer Conical Pulley Ret O i l Seal Punp Shaft Front Bolt Socket Head Pulley Ret Belt O i l Punp Drive 9 8 Belt O i l Punp Drive 7 6 5 Belt O i l Punp Drive 4 3 2 Belt O i l Plmp Drive l std l Belt O i l Punp Drive 2 3 Belt Oil Plmp Drive 4 5 6 Belt...

Page 868: ......

Page 869: ...rge O D Washer Spring 8mn Oil Pick W t r a i n e r Assanbly Gasket Pick Up to Tank Screw Pick Up to Tank Adaptor Pick Up Assembly t o Hose O i l Hose Assanbly Tank t o Punp Drain Plug Dipstick including 0 Ring 0 Ring Dipstick F i l l e r Cap O i l Tank Gasket F i l l e r Cap Hose Breather Crankcase t o Sleeve Sleeve Junction Hose Breather Sleeve Oil Tank Clip Breather Hose Gromrret Breather Hose B...

Page 870: ...TURBO 4OA7 A ...

Page 871: ...n Pak ler Module MK16 Lwnition P m r Module MK17 Lumnition Power Module MK17 Setscrew M5 x 20 e l e Fixing Washer Smn Module Fixing PART NUMBER 0 QUANTITY ALL REMARKS R B C907E090W See Optical Switch Ranarks Prior 87 MY 87 M Y on HC 1 Used With Lwnition Used With ConstantEnergy Early Cars With H T Coil Near Battery R B A910E9197F When Replacing Mk16 Switch With MK17 Switch Use With Adaptor A083M63...

Page 872: ......

Page 873: ...etscrew M 6 x 20 Ign Box Fixing W a s h e r 2 O D Ign E QX Fixing Nut Nyloc M6 Ign Box Fixing Grormrst Harness T h o Bax G r m t H T a r n e s s g n Boor I g n i t i o n Coil H T I g n i t i o n C o i l H T Ballast Resistor I g n i t i o n C o i l Setscrew M 6 x 16 C o i l Fixing Washer C o i l Fixing Nut Nyloc M6 C o i l i x i n g PART NUMBER QUANTITY ALL When Required When Required MAY iS 31 REM...

Page 874: ......

Page 875: ...tor to Aux Hsg Nut Nyloc M8 Alt to Aux Hsg Strap Alternator Adjusting Bolt Strap to Alternator Bolt Strap to Alternator Spacer Strap to Alternator Washer Plain Strap to Alternator Nut Nyloc M8 Strap to Alternator Bolt Ml 0 x 45 Strap to Engine Washer Spring Strap to Engine Washer Plain Strap to Engine Steady Bracket A k e r t o r Strap Alternator Adjusting Nylon Bolt Ml0 x 45 Strap Brkt Engine Was...

Page 876: ...TURBO 40 19A ...

Page 877: ...to Aux Hsg Washer Flat Alt to Aux Hsg Nut Nyloc M8 A l t to Aux Hsg Starter Motor Lucas 3N00 Starter Motor Lucas M 8 0 R Insulation Sleeve Unused Terminal Bolt Ml0 x 75 S t a r t e r to Engine Bolt Ml0 x 80 Starter to Engine Washer Starter to Engine Nut Nyloc MlO Starter to Engine PART NUMBER QUANTITY DRY s w 1 1 1 2 2 4 2 1 1 87 M Y on 1 1 Prior to 87 M Y with q C I87 M Y on with without A C R B ...

Page 878: ...i TURBO tQZlA I I I I I 0 ...

Page 879: ...ptor Stud M8 Wastegate to Adaptor Stud M10 Wastegate to Adaptor Reducing Sleeve lo Wastegate to Adaptor Washer em Wastegate to Adaptor Locking Plate Wastegate Adaptor Nut M8 Wastegate to Adaptor Nut M10 Aerotight Wastegate to Adaptor Wastegate A s s d l y 4 x M6 Stud Fixing PART NUMBER QUANTITY H C t E I N E 4 1 2 4 12 4 1 1 4 2 2 1 2 2 2 REMARKS Alternative Top Fixings i f Insufficient Clearance ...

Page 880: ...I TURBO 1 4Q21A ...

Page 881: ...ontrol Pipe Boost Control El Turbo to Boost Control Pipe Olive Boost Control Pipe Sleeve Nut Boost Control Pipe Turbocharger Assembly Gasket Turbo to Wastegate Adaptor Bolt Turbo to Wastegate Adaptor Lackplate Turbo to Wastegate Adaptor Stud Turbo to Exhaust Pipe Nut Exhaust Pipe to Turbo Lmkplate Exhaust Pipe to T u r k Gasket Exhaust pipe to Turbo PART NUMBER a QUANTITY SID WINE 1 1 1 2 2 2 1 1 ...

Page 882: ...TURBO 4Q23A a ...

Page 883: ...sor R e a r Fixing Nut Ml0 Conpressor R e a r Fixing Bracket Carpressor Front to Block Bracket Conpressor Front to Block Bolt Carpressor to Front Bracket Nut Ml0 Conpressor t o Front Bracket Washer Carpressor to Front Bracket Idler Pulley Adjuster Bracket 27mn offset Idler Pulley Adjuster Bracket lOmn offset Stud Pulley racket ConpBracket MBH Washer Flat Pulley Bracket Fixing Nut Nyloc M8 Pulley B...

Page 884: ...1URBO 6023A ...

Page 885: ...ILLUS NO DESCRIPTION Washer Flat Idler Pulley Adjust Nut Nyloc M8 Idler Pulley Adjust PART NUMBER QUANTITY MAY 1991 REMARKS n rb o 4O 23A Page 2 ...

Page 886: ...I TURBO 737M Y H C I 4Q27A ...

Page 887: ... Setscrew M 1 0 x 30 Carrier to Brkt Washer Spring Carrier to Brkt Washer Flat Adjusting Slot Setscrew M 8 x 25 Brkt to Water Punp Washer Spring Brkt t o Water Punp Hub V Pulley V Pulley Vacuum Punp Setscrew M 8 x 16 Pulley to Hub Washer Spring Pulley t o Hub Hose A i r Exhaust Clip Hose t o Punp Outlet Clip Hose to Chassis Screw Clip to Chassis Washer Clip to Chassis P A R T NUMBER QUANTITY H A Y...

Page 888: ...i I C TURBO 60 28A ...

Page 889: ... Mounting 0 Ring Engine Upper Gasket Set Canprising Cylinder Head Gasket I n l e t Manifold Gasket Diffuserfilenun Gasket Thermostat Housing Gasket Camshaft Cover Gasket Camshaft Cwer Screw 0 Ring Camshaft Front Oil Seal Camshaft Rear Cover 0 Ring Camshaft Housing Access Plug 0 Ring Camshaft Housing O i l Feed 0 Ring Carburettor Mounting 0 Ring WRT NUMBER QUANTITY STD H C Replaces Earlier Cork Typ...

Page 890: ...TURBO 40 28B ...

Page 891: ...Oil Punp Gasket Rear Seal Housing Gasket Scavenge Manifold Gasket Crankshaft Front O i l Seal Crankshaft Rear Oil Seal O i l Pick Up Pipe Olive 0 Ring O i l Tank Hose to Punp 0 Ring Turbo Drain t o Sunp Gasket Turbo Drain to Turbo PART NUMBER a QUANTITY REMARKS N o t used on 87 M Y Dry Sunp Engines Only Dry Sunp Engines Only Turbo 4O 28B ...

Page 892: ......

Page 893: ...sioner Spring Hex Head Locknut Spring Seat Yoke Front Belt Tensioner Yoke Rear Belt Tensioner Bush Pivot Belt Tensioner Pin Pivot Belt Tensioner Spirol Pin Pivot Pin Retention Rubber Washer Ydce Pivot Pulley Bearing Belt Tensioner Locking Pin 4 mn Tensioner Piston Belt M6 x 30 Yoke Clanping Nut Nyloc M6 Yoke Clanping Washer flat Yoke Clanping Bolt M8 x 35 Yoke Centre Clanping Nut M8 Yoke Centre Cl...

Page 894: ......

Page 895: ...o Block Washer Spring Tensioner Fixing Washer Flat Tensioner Fixing Toothed Pulley Crankshaft Cam Belt Drive Woodruff Key Crankshaft to Pulley Flange Crank Pulley Rear Oil Rmp Drive Pulley Flange Tooth Belt eparation PART NUMBER QUANTITY EATER 3NLY 2 1 1 I 1 1 1 1 1 1 1 1 I4AY 1991 REMARKS Wter cars with no snubber Dry Sunp Only 1 Turbo Prior to 8 7 M Y 1 41 OLA Page 2 ...

Page 896: ...I TURBO 87 MY ON 1 I 41 01B ...

Page 897: ...lock Washer Flat Tensioner brkt Fixing Stud NO Tensioner Fixing Eccentric Hub Belt Tensioner Pulley Bearing Belt Tensioner Nut NY OC MlO Washer Plain Tensioner Fix Toothed Pulley Crankshaft Can Belt Drive Flange Toothed Pulley Rear Woodruff Key Toothed Pulley PART NUMBER QUANTITY REMARKS Ehmded Tooth P r o f i l e H T D Green Dots 104O M O P Heater Only Cars 1 For q C Cars see 40 23A 1 Rounded Too...

Page 898: ...PRIoR 87MY WITH AIC PRIOR 87 MY WITHOUT AIC TURBO 41 03A ...

Page 899: ... t o Alternator V Pulley Crankshaft Triple Groove V Pulley Crankshaft Triple Groove V Pulley Crankshaft Double Groove Spirol Pin V Pulley Locating Washer Conical Pulley Retention Washer Plain Pulley Retention Washer Spring Pulley Retention Bolt V Pulley to Crank Setscrew 4 UNF x If Pulley Crank PART NUMBER a QUANTITY Prior to 87 M Y 87 M Y on Prior to 87 M Y with Heater Only Prior to 87 M Y with q...

Page 900: ...TURBO 4201A ...

Page 901: ... l a t C w e r to Body Nut Pulsertl M6 C w e r to Body Trunkins Airbox to Turbo Trunking Airbox to Turbo Hose Clip Trunking to A i r b o x Hose Clip Trunking to Turbo Slewe Adaptor Sleeve Turbo Inlet Seal Adaptor Sleeve to Turbo Plenum Backplate Carburettor Plenum Backplate Carburettor Gasket Diffuser to Backplate Gasket Plenum C w e r to Backplate Plenum Chamber C w e r Carburettor Plenum Chamber...

Page 902: ...See 17 0 O O L TURBO 4201A see GROUP 10b5 ...

Page 903: ...a r t Take Off Helicoil Insert Hose Turbo to Diffuser Hose Turbo t o Diffuser Clip Turbo di f fuser H o s e Gasket Plenum Backplate to Carb Gasket Plenum Backplate to Carb Gasket Plenum Backplate to Carb Gasket Plenum Backplate t o Carb A i r F i l t e r Element Seal F i l t e r Element Plenum LH A i r Scocp Adaptor Plenum to Hose Pop Rivet Adaptor to Plenum Washer Adaptor to Plenum Trunking Adapt...

Page 904: ......

Page 905: ... Sidewall Pop Rivet Deflector Fix Washer Deflector Fix Elbow Adaptor Plenum Purge Pipe Purge Elbcrw Solenoid Valve Pipe Purge Solenoid alve Purge Purrp Pipe Purge Purge Punp Exhaust Clip Norma 12 20mn Pipe Fix Gromnet Purge Sidewall PART NUMBER QUANTITY Turbo 42 01A Page 3 ...

Page 906: ......

Page 907: ...rkt to Plenum Linkage A s s d l y Cold Start Interconnect Linkage Assembly Cold Start Interconnect Screw Drilled Cable to Lever Screw Link to Lever P i v o t Bush Choke Linkage P i v o t Bush Choke Linkage Washer F l a t Washer Spring B e l l Mouth Carb I n t a k e B e l l Mouth Carb I n t a k e Pipe Steel Braided P E W to F r o n t Carb Pipe Steel Braided PRV to Rear Carb Adaptor F u e l P i p e ...

Page 908: ......

Page 909: ...kt Fix Lever Throttle Spindle Adjusting Screw Lever to Solenoid Clip Adjuster Screw Imking Plug Anti4 per CO Air Bleed Plug Anti4 amper Throttle Coupling Plug Anti Tanper Air Bleed Earth Iead Carburettor ngine PART NUMBER QUANTITY PRIOR 87 M Y MAY 1991 REMARKS Nylon Metal Turbo 42 03A Page 3 ...

Page 910: ......

Page 911: ... Washer Banjo S m l l Hose Cold S t a r t Banjo to Diffuser Pipe Carburettor Bdlance Pipe Cold S t a r t A i r Supply Diffuser Carbs Bolt Banjo Bdlance Pipe Cold S t a r t Air Pipe Washer Banjo Large Washer Banjo Small Hose Cold S t a r t Banjo t o Diffuser Solenoid Throttle Jacking Bracket Solenoid t o Carb Setscrew M 4 x 6 Solenoid Fix Washer Solenoid Fix Washer Spring Solenoid Fix Setscrew M 6 ...

Page 912: ......

Page 913: ...ir Tube Idle Air Tube P u q Jet 48H Special Purr Jet 35 Filter Punp Jet Starter Jet 80 Wlsion Tube Starter Air Bleed Screw 0 Ring Air Bleed Screw Plug Vacuum Tapping Orifice Accelerator Punp Diaphragm Accelerator Purrp Diaphragm Adaptor eng man Spring Anchor PART NUMBER QUANTITY MAY 91 REMARKS Quantities are per car If Fitted Turbo 42 04A Page 2 ...

Page 914: ......

Page 915: ... Punp Jet 0 Ring I d l e Ermlsion Tube Needle Valve Float 200 Gasket Needle V a l v e F i l t e r Needle V a l v e Gasket K i t All Gaskets Seals for 2 Carbs Gasket K i t All Gaskets Seals for 2 Carbs Choke 36mn Choke 35mn Auxiliary Venturi Auxiliary venturi Screw Auxiliary Venturi Retaining Float Assembly 8 59 Accelerator Punp Body 27 Main Jet 185 Main Jet 160 PART NUMBER QUANTITY REMARKS antitie...

Page 916: ...TURBO 4 2 04A ...

Page 917: ... Head Washer Manifold to Head Spacer Manifold to Carburettors 0 Ring Manifold Spacer Carb Nut Carb to Manifold Cup Washer Carb to Manifold Rubber Washer Carb to Manifold Connector Union Manifold Vacuum Hose Manifold to Vacuum R a i l Hose Clip Connector Hose Vacuum Rail Balance Pipe Connector Union Vac R a i l Connector Union Manifold Vaclnrm Blanking Plug Manifold Tract 3 4 PART NUMBER a QUANTITY...

Page 918: ...see TURBO 87MY ON 4207B ...

Page 919: ...Nut Manifold to Head Washer Manifold to Head Stud Manifold to Carburettors Spacer Manifold to Carburettors 0 Ring Manifold Spacer arb Nut Carb to Manifold Cup Washer Carb to Manifold Rubber Washer Carb to Manifold PART NUMBER 0 QUANTITY REMARKS Turbo 87 M Y ON 42 078 ...

Page 920: ...041 060 See 33 038 TO HEATER TURBO 87M Y HC See 18 OSA TO k BRAKE SERVO 43 03A ...

Page 921: ... Piece T Piece Hose Vacuum T Piece to Overboost Switch Overboost Switch Hose Vacuum unct i o n Connecting T Piece Rear Carburettor Connection Hose Vacuum Rear Carb to T Piece Pipe Connecting 1 4 0 Carburettor Elbow Connecting p i p e to Carburettor Clip E l b P i p e Connector 4 Way Hose Vacuum 4 Way to D i s t r i b u t o r Hose Vacuum 4 Way to Pressure Reg Valve Hose Vacuum 4 Way to Plenum Adapt...

Page 922: ......

Page 923: ...pe Vacuum Supply Gr rranet E n g i n e Bay Sidewall Boostflac Pipes Connector Hose T P iece Hose Connector Hose Vacuum T Piece to Vacuum Pun P i p e C B V to A i r b a x Hose C B V to Crankcase C l i p Hose C B V Hoses PART NUMBER QUANTITY MAY 1991 REMARKS l a c k B l u e 40 krm of A910E6785F Black 1 0 h of A910E6786F 34Onn n l e n g t h Turbo 87 M Y On1 43 03A Page 2 ...

Page 924: ...TURBO 64 01A ...

Page 925: ...ank LH Integral Fuel Pipe Spigot Fuel Tank RH Requires Banjo Offtake Fuel Tank RH Integral Fuel Pipe Spigot Grarmet Crossover Hose Body Ring Gram Fixing Screw Ring Fixing Spire Nut Ring Fixing SCrW Ring Fixing Washer Ring Fixing F m Tank Clanping F m Tank Seating Pad Self Adhesive Noise Danping Pad Self Adhesive Noise Darrping Pad Self Adhesive Noise Darrping Pad Self Adhesive N o i s e Danping Se...

Page 926: ...002 b TURBO 4601A ...

Page 927: ...der Fixing Capscrew 10 UNF x f Sender Fix Washer Fibre Sender Fixing Board Fuel Tank Top LH Board Fuel Tank Top R H Bracket Tank Board to Bulkhead Bracket Tank Board to Wheelarch Studplate Bracket to Bulkhead Washer Plate Bulkhead Brkt Board Washer Plate Wheelarch Brkt Board Washer Plate Wheelarch Brkt Budy Setscrew M 8 x 20 Wheelarch Brkt Nut Nyloc M8 Bulkhead Brkt PART NUMBER QUANTITY ALL MAY my...

Page 928: ...TURBO 44 03A ...

Page 929: ...Plmp Brkt to Body Nut 5 16 UNF Bobbin to Punp Brkt N u t Nyloc 5 16 UNF Bobbin to Body Tapping Plate Pump Bracket to Body Pop Rivet Tapping Plate to Body Washer Flat Bobbin Fix Washer Spring Bobbin to Pump Brkt Pipe Punp to F i l t e r Pipe mmp t o F i l t e r Clip Oetiker 9 16 P Clip Open mmp to F i l t e r Hose Screw PI Clip Fixing Filter Fuel Clanp Fuel F i l t e r Insulator Strip Clanp to F i ...

Page 930: ...TURBO b4 03A ...

Page 931: ... M y Nut 5 16 UNF o b b i n to Pump Brkt N u t Nyloc 5 16 UNF Bobbin to Body Tapping Plate murp Bracket t o Body Pop Rivet Tapping P l a t e to Body Washer F l a t Bobbin F i x Washer Spring Bobbin to Purrp Brkt Pipe Punp to F i l t e r Pipe Punp to F i l t e r Clip Oetiker 9 16 P Clip Open mmp to F i l t e r Hose Screw PI C l i p Fixing F i l t e r Fuel Clanp Fuel F i l t e r Insulator S t r i p ...

Page 932: ...1 TURBO I I 4LO3A ...

Page 933: ...pe Dunlop Bundy to P R V Clip Pipe to Bundy P R V Pipe S t e e l Braided P R V to RH Tank Pipe Dunlop P R V to RH Tank Clip Pipe to P R V and Tank Tie Wrap Return Hose to Chassis PI Clip Return Hose to Bcdy Screw s t PI Clip Fixing Gram Return Hose Body Banjo RH Tank Ccpper Washer Banjo Crush Washer Banjo Bolt Banjo PART NUMBER QUANTITY ALL Cut From A075L6043V 35 krm Zut Fran A075L6043V 20 hrm t C...

Page 934: ...TURBO 4L 05A ...

Page 935: ...ixing Pop Rivet Washer Breather Hose 200 mn Anti Surge to IT1 Piecc Breather Hose 2 m Anti Surge to IT Piece T Piece Breather Hose Breather Hose 3 2 m Clip Hose to TI Valves P Clip Breather Hose Fixing Pop Rivet Breather Hose Fixing Washer Breather Hose Fixing PART NUMBER a QUANTITY ALL 2 2 2 2 2 2 2 2 2 1 1 1 1 5 4 4 4 REMARKS 5 M I D U s e with 6 3 m F i l l e r Neck Spigot 7 lmn I D Use with 8m...

Page 936: ... TURBO 45 03A I i ...

Page 937: ...Bracket Silencer Mounting Bracket Silencer Writing Bracket Silencer Mounting Stud Bracket to Gearbox Stud M 7 x 128 Bracket to Gearbax Nut Nyloc MI Bracket to Gearbox Washer Flat Bracket t o Gearbox Bolt Bracket to Gearbox Bolt Bracket t o Gearbax Bolt M 7 x SO Bracket to Gearbox PART NUMBER QUANTITY REMARKS R B B082S4105F 84 M Y On Prior to C35 G Box With C35 G Box R B D082S4126F Fixings R B B079...

Page 938: ...TURBO 4505A ...

Page 939: ...sher S Proof Ferro Shield Fix Nut Nyloc M6 Ferro Shield Fix Heatshield Engine Bay R e a r Screw M 4 x 10 Heatshield Fix Washer Shakeproof I Spacer Insulating In Washer F l a t 1 1 I I Nut Nyloc w I I Heatshield LH Engine Mounting Setscrew M 6 x 20 Shield to Chassis Washer Large O D In nu Washer Flat I I I Nut y l o c M6 I I I I I I Heatshield LH Radius Arm Mtg Clip Shield to Chassis Setscrew M 6 x...

Page 940: ...TURBO 4505A 0 ...

Page 941: ...Cwer Heatshield Engine mnting Setscrew M6 x 16 Heatshield Fix Washer Flat Heatshield Fix Washer M6 x 12 Heatshield Fix Nut Nyloc M6 Heatshield Fix Heatshield Turbo Heatshield Turbo Reflector Turbo Heatshield Washer Flat M6 x 15 Shield Diffuser Brkt Washer Flat M6 x 15 11 I It Washer Spring Nut M6 Washer Jbad Spreader Spacer Heatshield Bolt M6 x 30 Heatshield Cwer Housing Washer Spring Heatshield L...

Page 942: ......

Page 943: ... Chassis Spacer Washer Stay to Chassis Setscrew M6 x 20 Stay to Duct Washer Large O D Stay to Duct Washer Flat Stay to Duct Nut Nyloc M6 Stay to Duct Radiator Radiator Foam Radiator top to Body Foam Radiator bottan to Duct Drain Plug Radiator Setscrew M6 x 25 Radiator to Duct Washer S Proof Rad to Duct Washer Large O D Rad to Duct PART NUMBER QUANTITY ALL MAY i991 REMARKS Used With 306mm Support S...

Page 944: ......

Page 945: ...Fan Shroud to Caw1 Washer Pop Rivet Hose Cylinder Head to Water Pipe Hose Clip 32 50 Hose Water R a i l to Water Pipe Pipe Cylinder Head t o T h e m s t a t Hose Air Bleed Hose Clip A i r Bleed Hose Clip Bleed H o s e to Engine Bay Hose T h e m t a t I n l e t Hose ThenuDstat Inlet Hose Clip 32 50m T h e m s t a t Hose T h e m s t a t Outlet Hose Clip 32 50mn Connector P i p PART NUMBER QUANTITY A...

Page 946: ......

Page 947: ...nk By ass Junction Pipe Stat H Tank By pass Hose T h e m s t a t By Pass H o s e Clip 32 50 Hose Junction Pipe to H Tank Pipe Hose Clip 32 50 Pipe Header Tank Pipe Header Tank Hose Header Tank to Water Pipe Hose Header Tank to Water Pipe H o s e Clip 32 50 Hose Junction Pipe to By Pass Pipe H o s e Clip 32 50 Pipe Radiator By Pass Hose Radiator By Pass H o s e Clip 32 50 PART NUMBER 0 QUANTITY ALL...

Page 948: ......

Page 949: ...athing t o Chassis Hose stepped Return Pipe Front Pipe E l b Radiator Outlet Hose Rad Outlet to Elbow Hose Rad Outlet to Return Pipe H o s e Clip 32 50 G r m t Water ipes Chassis Terp Transmitter Water Gauge Header Tank Setscrew M 8 x 20 Header Tank Fix Washer Flat Header Tank Fix Nut Nyloc M8 Header Tank Fix Pressure Cap Header Tank 10 p s i Pressure Cap Header Tank 15 p s i El Header Tank Overf ...

Page 950: ......

Page 951: ...a t M 6 x 16 I I Washer F l a t M 6 x 12 I IS Nut N o c M 6 I 1 1 I1 Y Piece Heater Return Hose t o Header Tank Hose Header Tank t o Y Piece Junction Pipe Return Pipe Bypass Hose T h e m s t a t to Bypass Pipe Hose Bypass Pipe t o Junction Pipe T h e m s t a t Clip Hose 8 16mn Clip Hose 25 40mn Clip Hose 20 32mn Tie Wrap Hose Securing Grarmet Rear Quarter Trim Panel PART NUMBER a QUANTITY ALL MAY ...

Page 952: ......

Page 953: ...t Nyloc M6 Stay to Chassis Spacer Washer Stay to Chassis Setscrew M 6 x 20 Stay to Duct Washer 25 O D Stay to Duct Washer Flat Stay to Duct Nut Nyloc M6 Stay to Duct Radiator Radiator Drain Plug Radiator Setscrew M 6 x 18 Rad to Duct Washer 25 O D Rad to Duct Washer Spring Rail to Duct Foam Rad tq to Body Foam Rad Bottan to Duct C w l Rad Fans C w l Rad Fans w e Clip Cowl to Radiator Screw s t C w...

Page 954: ......

Page 955: ...pe t o Junction Pipe Hose Clip Junction Pipe Header Take Gram Junction Pipe Chassis Hose Purtp Inlet H u s e Clip Rubber Pad Hose Chassis Hose Header Tank Feed Connector Pipe Header H o s e Hose Connector to Header Tank H o s e Clip Header Hose P Clip Header Hose t o Chassis Tie Wrap 290mn Hose Securing Hose Clip Hose Thenmstat Housing to Pipe Pipe Engine Outlet Bracket Water Pipe Fixing The Switc...

Page 956: ......

Page 957: ... M6 x 20 Header Tank F i x Washer I n t e r m 1 Spring Header Tank Fix Washer M6 x 12 Header Tank F i x P r e s s u r e Cap Header Tank 1 5 psi Hose Air Bleed Hose C l i A i r Bleed Hose C l i p A i r Bleed Hose to Airbox Pap Rivet Sealed C l i p to A i r h Hose Header Tank O v e r f l w Elbaw Header Tank Overflow Hose C l i p Hose to Header Tank C l i p O v e r f l w Hose to Body Pop Rivet C l i ...

Page 958: ......

Page 959: ...ose Assembly S t a t to Engine O i l Hose A s s d l y Engine to S t a t 5 8 S t a t O i l Hose Assembly Engine to S t a t 3 411 S t a t T h e m s t a t O i l Cooler T h e m s t a t Oil Cooler Bracket T h e m t a t Mounting Bracket Thermstat M n t i n g Nut Nyloc M 6 Washer F l a t PART NUMBER QUANTITY DRY SUMP 1 1 1 1 2 2 2 1 1 1 1 1 1 4 m SUMP 1 1 1 1 1 1 1 2 2 H A Y 1991 REMARKS dhen No O i l Co...

Page 960: ...TURBO 46 03A ...

Page 961: ... Fixing Spire Nut C l i p Fixing G r a m e t O i l Hose Chassis Edge Protector O i l Hose Chassis Rr Diaphram Foam Tube O i l Hose Chassis Front X rtlember T i e Wrap O i l Hose Cooler O i l S i l v e r Cooler O i l Black P l a t e Spreader Setscrew M 6 x 20 Washer 6 m F l a t Nut Nyloc M 6 PART NUMBER a QUANTITY DRY SUM 1 2 4 4 4 REMARKS 3 4 5 8 BSP 5 8 BSP x 2 Interim Spec Without T h e m s t a ...

Page 962: ...TURBO 47 01A a ...

Page 963: ...Screw Slave Cylinder Pushrod Clutch Operating Pressure Plate Assy Straight Fingers Pressure Plate Assy Curved Fingers Friction Plate Friction Plate Setscrew Cwer to Flywheel Washer Spring Cwer to Flywheel Release Bearing Assembly Curved Face Release Bearing Assembly Flat Face Spring Clip Release Brg to Fork Fork Clutch Release Ball Pin Fork Pivot S p l i t Pin Fork to Pivot Grarmet Fork to Housing...

Page 964: ...PREVIOUS TYPE I TURBO 47 02A I C35 TYPE I 1 Gearbox Number Locati DO not remove I 4 O i l Level Plug Revised Rear Cover Shape ...

Page 965: ...h h o u s i n g Drain P l u g C35 t y p e g e a r b o x e s have o n l y one o i l d r a i n p l u g which is s i t u a t e d b e n e a t h t h e main case They are n o t f i t t e d w i t h t h e a d d i t i o n a l rear case d r a i n p l u g as used on p r e v i o u s t y p e gearboxes TU3AAK 2 FEZ 387 L e v e l P l u g The o i l l e v e l p l u g p a i n t e d y e l l o w is f i t t e d i n t ...

Page 966: ......

Page 967: ...box Bolt M14 x 90 racket Gearbox Washer Spring Bracket to Gearbox Washer Flat Bracket to Gearbox Clutch Shaft Sleeve Clutch Shaft Spigot 18 5mn Long Thrust Washer Nylon Shaft Spigot Brg Plug Gearbox Joint Face Stud Silencer Mamting Bracket Nut MI Nyloc Pointer Engine Timing Gasket Output Shaft Housing Bolt Ml0 x 35 Clutch Hausing Engine Bolt Ml0 x 50 Clutch Housing ngine Bolt Ml0 x 60 Clutch Hausi...

Page 968: ......

Page 969: ...ing End Cwer End Cover Core Plug End Cwer Blanking Screw M7 x 100 Rear Cwer Fix Screw M 7 x 28 Rear Cwer Fix Screw M 7 x 40 Rear Cwer Fix Screw M 7 x 28 R e a r Cwer Fix Screw M7 x 95 R e a r Cwer Fix Bolt M7 x 45 Silencer B r k t h r Cwer Screw M 7 x 100 Silencer Brkt Rear Cwer Screw M7 x 45 Silencer r k t R e a rCwer Screw M 7 x 25 Silencer Brkt Rear Cwer Screw M 7 x 45 Silencer Brkt Rear Cwer S...

Page 970: ......

Page 971: ...d M12 x 58 G B to Clutch Hsg Washer 12mn G Box to Clutch H s g NU m 2 G B to clutch s g Speedo Driven Gear 17 Teeth Nylon Bush Speedo Driven Gear Nylon Bush Speedo Driven Gear Right Angle Drive SpeedD Right Angle Drive Speedo 0 Ring Speedo Angle Drive PART NUMBER QUANTITY PRIOR C35 1 1 5 3 1 1 1 2 2 4 4 1 1 1 1 1 REMARKS 1 1 Inside End Cwer 1 1 Replaces Earlier Bush With Steel Cap R B B079F6292F W...

Page 972: ......

Page 973: ...e Cable Extension 240mn Rod Crossgate Cable Extension 442mn Rod Crossgate Cable Extension 42211m 1 Locknut Cable Stiffener Lmknut Crossgate Cable to Ext Rod Clevis Pin Rod to Bellcrank Spring Clip Clevis Pin Washer Clevis Pin Bellcrank Lever Crossgate Bellcrank Lever Crossgate Bush Bellcrank Lever Pivot Pin Bellcrank Lever PART NUMBER QUANTITY tlAY I991 REMARKS M7 Knob Thread R B A082F6313F For Ge...

Page 974: ......

Page 975: ...in Relay Lever Pivot Thrust Washer Relay Lever Pivot Washer Flat Relay Lever Pivot El Clip Relay Lever Pivot pivot Bracket Relay Lever Inc Bush Bush Relay Lever Pivot Setscrew M 6 x 18 Pivot Brkt Chassis Nut Nyloc M6 pivot Brkt Chassis Washer Flat Pivot Brkt Chassis Edge Protector pivot rkt A C Pipes PART NUMBER e QUANTITY ALL 2 1 4 4 4 8 4 4 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 3 3 3 REMARKS U Thread ...

Page 976: ...TURBO ...

Page 977: ... Shaft Assembly Cross Shaft Assedly 0 Ring Cross Shaft 0 Ring Cross Shaft Selector Shaft Reverse Selector Shaft 5th Selector Shaft 5th Plunger Interlock Relay Thro Rod Selector aft 3rd 4th Selector Shaft 3rd 4th Plunger Interlock Relay Thro o d Selector Shaft 1st 2113 Relay Dog Reverse Selector Shaft Selector Fork Rwerse Relay Dog 5th Selector Shaft PART NUMBER QUANTITY PRIOR C35 1 4 3 5 4 2 2 4 1...

Page 978: ......

Page 979: ...0 Adjusting Washer 3 05 Adjusting Washer 3 10 Adjusting Washer 3 15 Adjusting Washer 3 20 Adjusting Washer 3 25 Adjusting Washer 3 30 Adjusting Washer 3 35 Crown Wheel and Pinion Roller Bearing PART NUMBER QUANTITY ALL j 85 REMARKS Turbo 47 11 Page 2 ...

Page 980: ...TURBO 47 15A 0 ...

Page 981: ...Washer 1 58 Planet Wheel Washer 1 64 Planet Wheel Washer 1 70 Planet Wheel Washer 1 76 Planet Wheel Washer 1 8 2 Satellite Gear Washer 1 54 Satellite Gear Washer 1 62 Satellite Gear Washer 1 7 0 Satellite Gear Washer 1 7 8 Crosshead Bush Spacer Spacer 2 9 Spacer 3 3 Spacer 3 7 Spacer 4 1 Spacerf 4 5 Spacer 4 9 Spacer 5 3 Spacer 5 7 PART NUMBER QUANTITY ALL REMARKS VBA082F6318F 5elective Selective ...

Page 982: ...TURBO 67 11A a ...

Page 983: ...asher 3 01 Spacer Washer 3 05 Spacer Washer 3 09 Spacer Washer 3 13 Driven Pinion 3rd 4th Secondary Shaft Double B a l l Bearing Secondary Shaft Rear Double Ball Bearing Secondary Shaft Rear Driven Pinion 5th Secondary Shaft Nut Speedo Drive Gear Idler Gear Reverse Inc Bush Spindle Reverse I d l e r Gear Screw Reverse Gear Spindle Nut Reverse Spindle Screw PART NUMBER QUANTITY PRIOR C35 Selective ...

Page 984: ...1 TURBO 47 11A ...

Page 985: ...3 Spacer Washer 1 77 Spacer Washer 1 81 Spacer Washer 1 85 Spacer Washer 1 89 Spacer W a s h e r 1 93 Spacer Washer 1 97 Spacer Washer 2 01 Spacer Washer 2 05 Spacer Washer 2 09 Spacer Washer 2 13 Spacer Washer 2 17 Spacer Washer 2 21 Spacer Washer 2 25 Spacer Washer 2 29 Spacer Washer 2 33 Spacer Washer 2 37 Spacer Washer 2 41 Spacer Washer 2 45 Spacer Washer 2 49 Space1 dasher 2 53 Spacer Washer...

Page 986: ...TURBO 47 07A ...

Page 987: ...ynchro 2 25 Stop i n g 3rd 4th Synchro 2 30 Stop i n g 3rd 4th Synchro 2 35 D r i v e Pinion 4th Primary Shaft Drive Pinion 5th Prirmry Shaft Needle Roller Bearing 4th 5th Pinion Needle Roller Bearing 4th 5th Pinion D o u b l e B a l l Bearing P r i m Shaft Rear Double B a l l Bearing Prirmry Shaft Rear Synchroniser Assembly 5th Synchroniser Assembly 5th Circlip 5th Synchroniser Screw 5th Hub to P...

Page 988: ......

Page 989: ...y to Shaft Locking Wire Forkhelay Screw Screw 5th Fork to Shaft Spring Washer 5th Fork Screw Setscrew M9 x 25 Fork Clanping Interlock Plunger Short Interlock Plunger Long Blanking Plug l2m Diameter Blanking Plug 17mn D i a m t e r Detent Ball Selector Shaft Spring Detent Bdll Spring Detent Ball PART NUMBER a QUANTITY PRIOR C35 REMARKS Turbo 47 06A Page 2 ...

Page 990: ......

Page 991: ...Hsg hrans Bolt MI x 25 Output Hsg hrans Bolt M7 x 70 Output Hsg Trans Bolt M9 x 30 Output Hsg firans Bolt M9 x 75 Output Hsg hrans Shaft Diff Output RH Shaft Diff Output Ill Wisher Oil Retaining O i l Seal Output Shaft Thrust Ring Double Bdll Bearing Ring Nut Bearing to Housing Ring Nut Bearing to Housing Imking Screw Ring Nut to Housing Nut E3earing to Output Shaft Imking Screw Output Shaft Nut P...

Page 992: ...TURBO 60 01A ...

Page 993: ...rap Hook Fix Washer Rivet Jack Scissor Type Jack With Integral Baseplate Handle 145mn Crank Handle 265mn Crank Strap Jack Retention Front Strap Jack Retention Rear Anchor Hook Jack Strap P q Rivet Strap and Anchor Fixing Clip Jack H a n d l e Stowage 2 Hole Fix Clip Jack Handle Stawage 1Hole Fix PART NUMBER a QUANTITY ALL B r F l REMARKS With Conpomotive Wheels1 With BBS Wheels 1 1 1 1 R o l l 1 t...

Page 994: ...TURBO 60 02A ...

Page 995: ...haft Oil Seal Pilot Rear O i l Seal Crankshaft Puller Crankshaft Pulley Pilot Front Cover Clips Tool Retention set c w Fixings Shadow Sheet Self Adhesive Tool Board Burroughs Gauge Toothed Belt Burroughs Gauge Toothed Belt Tom Socket Cam Housing Bolt Carburettor Balance Pdaptors Carburettor Float Setting Bar Carburettor Manarreter Rear Brake Caliper Spreader Screen R novalTool PART NUMBER QUANTITY...

Page 996: ......

Page 997: ...TUS PAINT CODES TOUCH IN PAINT STICK NUMBERS LOTUS LOTUS LOTUS LOTUS PAINT COLOUR TOUCH IN PAINT TOUCH IN TOUCH IN KIT CONTAINING PAINT LACQUER STICKS LOTUS PAINT CODES TOUCH IN PAINT STICK NUMBERS 80 20A ...

Page 998: ...aft Nut Spanner Bearing to Housing Lock Ring Dial Gauge Support Dial Gauge Pinion Setting Fixture Spanner Speedo Drive Nut Syncro Gauges set of 6 Reverse Selector Gauge Circlip Pliers 3rd 4th Syncro Hub PART NUMBER QUANTITY ALL 1 1 1 1 1 1 1 1 1 1 REMARKS lst 2nd gear Turbo 6O O4A ...

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