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Lotus Esprit Series, Workshop Manual

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Lotus Esprit Series Workshop Manual Download Page 241

FUEL 

Page 

L6 

6. 

Release  the clips 

remove the rubber hoses  connecting  the  fuel  tonks  to 

the  f i l l e r  necks,  first  disconnect 

breother  pipes  from the  f i l l e t  necks. 

7. 

From each  tank,  remove the  two bolts securing  the  tank  i n  the body.  One 

bolt  is i n  the forward port  of  the 

wheel 

and  the other belt on the 

inside (chassis  side). 

Replace 

1. 

Reverse the removal  instructions. 

FUEL 

TANK 

SENDER 

To Remove 

1. 

Remove  the engine cover. 

2. 

Remove  the battery. 

3. 

Remove 

RH 

engine compartment  floor panel  to gain access  t o  the  top of the 

RH 

fuel  tank. 

4. 

Visconnect  sender unit electrical  connections. 

5. 

Unscrew  the  three screws securing  the sender  unit  to the  top of  the  tank. 

To Replace 

1. 

Fit a new  sealing  ring and coat  the threads of the  three  retaining screws with 

Avdelbond-A-115 or similar.  Ensure 

threads are fitted,  but  take care 

that  excess does not f a l l  into tank.  Tighten screws  t o  

5 

t o  

7 

only 

(hand tight),  do not 

as  the 

w i l l  distort  and screw  threads 

may strip. 

2. 

Reverse  the removal  instructions  from 

4 

to 

1. 

FUEL 

GAUGE 

Detailed instructions for removal  and replacement  of  the fuel  gauge are given i n  

Section 

M 

under  the heading 

INSTRUMENTS. 

FUEL  PUMP 

To Remove 

1. 

Disconnect the battery. 

2. 

Remove  the pipes  from the pump  which  i s  accessible from under  the LH  side 

o f  the vehicle on  the back  of the engine bulkhead.  Some  vehicles have  the 

petrol pump f i t t e d  under  the 

RH 

engine compartment  floor ponel.  Insert a 

plug i n  the pipe from the  tanks,  otherwise  the  fuel  w i l l  drain out. 

Issue 

04/78 

Summary of Contents for Esprit Series

Page 1: ... U S LiUP9 i d Norwich Norfolk N f 4 8EZ England Jelegrants Lotus Norwich relex Si 4E i Telephone Wymondha m 0953 602674 lotus Cars Lid 1982 ...

Page 2: ......

Page 3: ...lletins and Parts Bulletins will be ussued when necessary to update the manual MANUAL FORMAT 2 S The manual is divided into sections which are identified by letters These letters are i 9 r CA C P t t T Z C l S _hedv e here the 1 numbers e g A907E or 0 7 9 carry the identifying letters for the ENGINE lktter E and TRANSMISSION letter F The sections i n this monual are as follows INTRODUCTION TECHNIC...

Page 4: ...and rear of the cylinder block above the starter motor In all communication with the Factory the Chassis Number MUST BE QUOTED IN FULL An example of the Chassis Car Number i s given below together with the full identification breakdown 76 05 100 G Chassis Car Number 76 05 Denotes year and month of manufacture 1976 May 2 100 Denotes the number G Denotes the Territory the car i s destined for G Deom...

Page 5: ... c cf Poge 2 2 3 3 Valve Guides Camshafts 8 Cam Followers Auxiliary Shaft Crankshaft Flywheel Connecting Rod Gudgeon Pin Piston and Liner Lubrication System FUEL SYSTEM IGNITION SYSTEM DISTRIBUTOR COOLING SYSTEM CLUTCH TRANSMISSION FRONT SUSPENSION STEERING REAR SUSPENSION BRAKES WHEELS AND TYRES ELECTRICAL EQUIPMENT TORQUE LOADING FIGURES MODEL S2 CHARACTERISTICS ...

Page 6: ... ins 165 ins 167 71 ins 73 25 ins 43 75 ins 6 ins 38 ft 2012 82 lbs l C l 1heI A a I Ai CAPACITIES Engine Inc Filter Dty 5 95 litres 10 5 imp pts 12 6 US pts Refill 4 83litres 8 5imppts 10 2USpts ntcr L L L a I J I I v l t r r l r v L s uw1nrr w88 s u t s U U IVW U S B S R IIIUU 0 85 litres 1 5 imp pts 1 8 US pk W Transmission 2 25 litres 4 imp pts 4 8 U S pts Cooling System 10 8 litres 19 imp pts...

Page 7: ...ear of cylinder block adjacent to starter mounting BELT TENSIONS Toothed timing belt 133 teeth C h c With both iypes of belt tensioners set the belt tension to an average reading of 90 95 units cold 120 125 units hot Check to6thed belt tension between 1 auxiliary and inlet camshaft pulley with Burroughs Gauge Type BT 33 86b 5 20 IMPORTANT Check the belt tension with number 1 or 4 cylinder at TDC a...

Page 8: ...B T D C 26OB T D C Valve M O P Maximum openinn noin European Spec Inlet O A T D C Exhaust 102 5 B T D C NorthAmerican Spec Inlet O O A T D C Exhaust lloOB T D C Angle of valve seats 45O VALVES j_ Z2 S Head diameter inlet 35 56 mm 1 40 ins exhaust 30 86 mm 1 215 ins Stem diameter inlet exhaust 7 137 m m 0 281 ins Stem clearance in guide inlet 0 0076 0 0457 mm 0 0003 0 00 18 ins exhaust 0 0076 0 058...

Page 9: ...5ins Exhaust 34 3789 34 4043 m m 1 3535 1 3545 ins 0 0254 m m 0 001 ins Inlet 37 3507 37 3761 m m l 4705 1 4715 ins Exhaust 34 4043 34 4297 mm l 1345 1 3555 ins 0 0508 m m 0 002 in Inlet 37 3761 37 4015 mm 1 4715 1 4725 ins Exhaust 34 4297 34 4551 m m 1 3555 1 3565 ins O 127 m m 0 005in Inlet 37 4523 37 4777 m m 1 4745 1 4755 i Exhaust 34 5059 34 5313 mm 1 3585 1 3595 in v Valve Springs Dual Free ...

Page 10: ...5 in CAMSHAFTS End float Dimension 0254 2032 mm 001 008 in Controlled by Selective thrust washers Running clearance 0254 0635 m m 001 0025 in i E CAM FOLLOWERS Bore i n camshaft housings 34 925 34 9402 mm 1 3750 1 3756 in Outside diameter 34 904 34 912 mm 1 3742 1 3745 in AUXILIARY SHAFT Running Clearance End float 025 065 mm 000P 0025in 0127 0381 mm 0005 0015 in Balance inc flywheel 8 clutsh With...

Page 11: ...ECTING ROD Type I I I section Material Steel forging I Distance between centres 139 7 mm 5 5 in 0254 mm 001 in fi 5 rings big end Type Steel backed leaded bronze Static clearance 0254 0813 mm 001 0032 in End float on crankpin 1016 254 mm 004 010 in Small end bore bushed 25 405 25 410 mm 1 0002 1 Q004 in 1 Permissible weight variation between rods 2 grammes in any set Bearing clearance i s measured...

Page 12: ...mm 1 015 065 in rermlssible welght variation between pistons 3 grammes Piston ring to groove clearance Compression 0381 0889 m m 0015 0035 in L Oil Control 0381 0635 mm 0015 0025 in Measured at grade diameter is cn g de dloiiietei iri 15 6876 mm i 594 in up from sikirt edge Cylinder liner Type Slip fit wet Material Cast iron Internal diameter Grade A 95 2754 95 2881 m m 3 7510 3 7515 in Grade B1 9...

Page 13: ...pe and number Dellorto Dhlo 45E two Slow running speed 950 1000 r p m Idle CO level hot 1 5 3 m Identification Green Paint spot on Dellorto cast label and no vacuum take off on rear carburettor SETTINGS Choke 36 Starter Jet 70 Main Jet 160 Main Emulsion Tube 7772 8 Main Air Corrector 230 Starter Emulsion Tube 7482 1 Idle Jet 50L F l w t Setting Height 16 5 17 0 mm Idle Jet Holder 7850 7 Needle Vol...

Page 14: ...0 engine r p m Set distributor to give 25 BTDC ignition timing at between 3 500 and 4 000 r p m This will givean idle r p m figure 0 0 m berween I I I D I UL oecaure of disrriburor tolerances North American Spec with Zenith CD Carburettors G Static ign timing 8 BTUC at idle 950 1000 r p m 0 TDC Coil type Lucas 45232E Spark plug Type European Spec N G K BP6ES North American NGK BPSES Gap 584 mm 023...

Page 15: ...180 g70 lQ Cam dwell angle 60 3 25 4 52 4 43 8 45D4 1 3 4 2 Firing order Condenser capacity 18 23 m f d COOLING SYSTEM 3 i t XL C r Centrifugal pump and electric fan L h i c operated by thermal switch 2 I f Radiator cap relieve valve pressure L 70 kg cm sq 10 ibs in sq Thermostat nominal opening temperature 8 2 winter 74OC summer Impeller vanes to water pump hwsing clearance 508 762 mm 020 030 in ...

Page 16: ... Final drive 4 3 7 5 l Speedometer Gears Driving Gear Driven Gear FRONT SUSPENSION p Front Hub End Float Borg B Beck diaphragm spring Single dry plate Hydraulic 15 87 mm 625in 22 22 m m 875in 21 59 cm 8 5 in 6 3 mm 1 2 in Manual 5 forward gears All synchromesh and reverse a 0 4 8 vuv I l 35 16 27 59 20 24 13 77 9 15 5 Starts 17 Teeth Independent by twin upper wishbones with single lower link and a...

Page 17: ... to 5 mm 1 8 3 16 in At ride height 2 people in car Lock angles Front 32 Rear 33O Turns Lock to lock 2 7 8 REAR SUSPENSION Independent by diagonal trailing orrn ond c c L S later01 link with fixed length drive shafts Coil springs ond telescopic shock absorbers 4 Dom Eur Federal 7 L Reor Spring Colour Code None Green Yellow 1 Number of Effective Coils l 0 10 5 Length Free 34 80 cm 34 29 cm Coil Dia...

Page 18: ... brakes Disc diameter 275 m m 10 82 in Disc thickness 10 m m 0 393 in Minimum thickness 9 mm 0 354 in Total disc run out 0 09 m m 0 0035 in TIR Lining area per brake 64 sq cm 9 92 sq in Braking area per brake 68 sq cm 105 2 sq in Handbrake Mechanical rear wheel only WHEELS AND TYRES Wheel Type Size front Size rear Tyres Type Size front Size rear Tyre Pressures European Spec Front Rear Series I Bol...

Page 19: ...nner N o l outer N o 2 Sidelamp 5W Front and Rear Indicators 21W Stop Lamps 21W Tail Lamps 5W Number plate lamps 6W Panel Lamps 3W S Interior Lamps 6W Warning Lamps 2W Capless Reverse Lamps 21W Festoon A Iternator Lucas 18 ACR 45 amp Starter Motor Type Lucas 3M100 Drive Pre engaged Fuses Located inside the glove box Seven circuits ore protected by foses headlomps motor offside side lights nearside...

Page 20: ...il sump to main bearing housing all 981 10 Auxiliary housing to cylinder block 1 SO 2 07 i Auxi Iiory shaft sprocket 3 46 Oil pick up pipe union 4 7 6 Reioining nui orli iensior ri 3 464 lS A l l t h e r 6 m m nuts or setscrews 96 1 10 Stud Cylinder head to c nder block 1 2 mm Q 5 53 Main bearing housing 8 mm 1 66 Main bearing housing 1 2 mm 5 53 Camshaft housing to cylinder head 8mm l 66 Sump to ...

Page 21: ... Ball joint to vertical link upper 5 93 6 53 43 48 I 1 I I1 lower 9 11 9 94 66 72 Lower link to chassis 6 91 8 29 50 60 Anti roll bar to wishbone 4 15 4 84 30 35 Anti roll bar to chassis 6 91 8 29 56 60 _ S Damper Lower link 4 15 4 84 30 35 3 4 Top stem mounting j Tighten with suspension at ride height 2 people in car 8 i Nut i s nipped to shoulder on stem holding top of stem with sponner then loc...

Page 22: ... arm lower link and damper Damper top stem mounting C Caliper to mtg bracket Brkt 3 hole to chassis rive Shaft to Adaptor 3 Drive Shaft Adaptor Rear Disc to gearbox Rear radius arm mounting to chassis f b Ibs ft 1 66 12 14 1 11 1 66 8 12 2 21 2 76 16 20 Tighten with suspension at ride height 2 people in car 2 _ i N u t is nipped to shoulder on stem holding top of stem with spanner then locknut tig...

Page 23: ...o be fitted This i s IMPORTANT ond nut must NOT be slackened to insert the pin Torque Wrenches Torque wrenches in daily use should be checked at intervals NOT EXCEEDING 3 months to ensure that accuracy is maintained MODEL S2 CHARACTERISTICS WHEELS AND TYRES SERIES 2 Wheel type Bolt on Alloy P Size front 7JK X 14 Size rear 7 5JK X 14 Tyres Type Dunlop SP Sport Super Size front 205 6OVR X 14 Radial ...

Page 24: ...this specification have o prefix letter H on the engine number Ignition Timing Static ignition timing 1O0 BTDC A t idle speed 2 BTDC A t 3000 rpm 24 26 with vacuum blocked off Commemorative Vehicles For these vehicles the Lumenition distributor Part No A907E0901J is used as the engine is fitted with Dellor to carburetters The power module A075M0335F i s located on the engine bay side of the right ...

Page 25: ...CHASSIS Page AI SECTION A Description GENERAL DESCRIPTION ACCIDENT DAMAGE FRONT SLJSPENSION FULCRUM PINS Page A3 A3 A3 ESPRIT Issue 04 78 ...

Page 26: ...CHASSIS Page A 2 ESPRIT Issue 04 78 ...

Page 27: ...osing Plate Mounting Bracket Bracing Strut Assembly RH Bracing Strut Bracket R H Tapping Plate Bracing Strut RH Cross Beam Rear Suspension Assembly Gear box Mounting 3 Hole R H Bolt 4 UNF X 3 Tabwasher Coliper Suspension Bracket R H ESPRIT issue 04 78 ...

Page 28: ...echanism attachments should be carefully examined for both rnis alignment and micro cracks I t i s recommended that a new chassis i s fitted if the front suspension fulcrum pins are badly bent or damaged This also opplies to the upper wishbone and ar lower links i f these are badly damoged lrispect the main unit mounting points thoroughly if the vehicle has been involved in a collision where the b...

Page 29: ...G RAIL FINISHER WINDSCREEN WINDSHIELD HEADLAMPS INSTRUMENT BINNACLE SAFETY BELTS FRONT BUMPER EXTERNAL B C POST FINISHER FRONT SEAT DOOR LOCK REAR QUARTER LIGHT DOOR WINDOW FRAME DOOR SHELL FRONT QUARTER LIGHT DOOR TO WINDOW FINISHERS MODEL S2 CHARACTERIgICS Page B4 B4 B5 B5 B1l B17 B19 B22 B28 B35 B38 B40 B46 B47 B49 B50 B51 B52 B53 B54 B55 B56 B58 B59 ESPRIT Issue 12 78 ...

Page 30: ...per Uom tur Front Bumper Federal Rear Bumper Dom Eur Rear Bumper Federal Plinth Rear Bumper Federal o I a r I u t g r l v u s i r a u r r s Rear A Window Frame Top Sides LH Rear A Window Frame Bottom LH Finisher R y r 4 Window S i l l Door Seal Side Capping Rail RH Finisher Side Capping Rail RH Waist Lirie Finisher Body Waist Line Finisher Door Finisher A Post Front 4 Light RH Engine Cover Finishe...

Page 31: ...BODY Pass 133 Fig 1 Body Components ESPRIT issue 04 78 ...

Page 32: ...tergents as directed by the manufacturers will expedite washing Use only preparations of reputable manufacture When dust and mud have been removed with spozss n c cts f fig y dry with o chamois leather Provided that the car i s kept clean by frequent washing i t will be found that polishing i s almost unnecessary The bodywork can if desired be protected with a good soft wax polish using a haze rem...

Page 33: ...the spare wheel and wash thoroughly to remove all accumulated road filth from wheels and tyres DE WAXING The vehicle is protected with Lacroe Autoprotective wax this is indicated by a label on the windscreen To de wax proceed in the following manner 1 Wash the vehicle by hand or machine to remove dust and dirt particles Wipe off surplus water h 2 Polish by hand with a soft clean cloth or buff with...

Page 34: ...IG 2 Body Section Mid Nose Full Section Body Section Mid Nose RH Section D d C w4 4 bJ rtinr 1 Body Section Full Nose Full Section Body Section Full Nose RH Section Body Section Full Nose LH Section Roof ESPRIT Issue 04 78 ...

Page 35: ...BODY Page 87 Fig 2 Front Body Sections ESPRIT Issue 04 78 ...

Page 36: ...ull Section Body Section Short Rear RH Section Body Section Short Rear LH Section Dody Secrion rut Rear rut1 J CTIUII Body Section Full Rear RH Section Body Section Full Rear LH Section Bulkhead Upper Bulkhead Centre Rv G I eec Lower ESPRIT Issue 04 78 ...

Page 37: ... BODY Page 69 Fig 3 Rear Bcdy Sections ESPRIT Issue 04 78 ...

Page 38: ...nox M50 M i x hardener catalyst into the resiri in the proportions of 15 cc of catalyst to 1 kg 2 lb of resin M i x ratio l 150 For Gel coats mix 20 cc of catalyst witti 1 kg 2 lb of gel BASIC BONDS AND JOINTS Cut off the damaged portion after marking for re positioning of the new panel Clean and prepare both existing and new panels removing all road filth and under seal from the existing panel Cu...

Page 39: ...rk through the actual lamp unit hale Alternatively where a less serious impact has occurred and the lamp surround can be satisfactorily repaired without resorting to a replacement section i t i s recommended that a small jig be made to embrace both pivot mounting bolts of the bowl width These can be screwed into the body bobbins serving to correctly locate them whilst providing sufficient access t...

Page 40: ...g up Clamping pressure should always be applied evenly using a small slip of wood or rnetal if dim lirig of the panel surfoce i s to be avoided Where possible all splits should be laminated from the inside REPLACEMENT SECTIONS l Where ttie repair of a damaged vehicle calls for replacement sections or anels i t i s 7 I recommerided that these be obtained direct from Lotus Cars Ltd li Standard secti...

Page 41: ...arried out in the vicinity of the front wheelarches ensure the tyres do not foul the front lower flange when the wheels ore on full lock Undeneirl the wheelarch area to a depth of l25 in 3 mm using 3M material or i t s equivalent in consistency to prevent gel cwt crazing caused by small stones etc throwh up by the wheels POSITIONING REPLACEMENT PANELS a Line up flat surface e g undetry or floor ar...

Page 42: ...ove The bobbin can then be directly laminated on the old mounting by using the techniques described arid overlapping the new laminate on to the old by several inches centi metres whenever possible I t e iarger bobbins are used oniy where rhe ioadings are known ro be high e g body mountings seat attachments etc Smaller bobbins are used as a locntory point or a blind attachment point Typical instanc...

Page 43: ...BODY Page B15 Fig 4 Body Mountings ESPRIT issue wne ...

Page 44: ...two layers ot tape or cloth stiould be wound round the waist of the bobbin Finally plasticine or similar plugs should be used during laminating to keep the resin out of the bobbin threads Wtien properly laid the visible rough side wall will be nearly vertical in line with the bobbin top profile In effect a strong reinforcing ring of laminate surrounds the bobbin and ihis ring musk be properly conn...

Page 45: ...cedures following cover cellulose and polyurethane paint finishes To identify the finish check paint code prefix on chossis plate a code letter L indicates cellulose finish and code letter S1 polyurethane finish TO PAINT CELLULOSE L code 1 Vacuum clean to remove all dust solvent wipe and tack rag 2 Spray one cross coat of polyurethane part No 368 6136 mixed 5 parts to 1 part catalyst art No 36B 61...

Page 46: ...rnid conditions or lack of adequate I air movement or heating exists in a spraying area a defect known as Blushing or Blooming can occur on finish colour a milky dulling of the paint appearing soon after application whilst the film is hardening This 1 L 1 L I A L_ A L c r ruuaru 8 s yasrspaiutrusc u n ultl vap rn n r I I U I D I U I C UYC I V is awt IUCT temperature of a newly applied paint film b...

Page 47: ... clothing and air fed masks or graphite type filter masks when this rnateriol i s being sprayed 1 Flat entire panel surface using 320 paper 2 Spot prime any filled areas using original polyurethone colour material Allow to cure and flat 3 Spmy 2 single coats of colour allow 20 minutes flash off between coats and 30 minutes after final coat 0 4 Cure at 50 C for 50 minutes or 6 hours at roam tempera...

Page 48: ...t misplaced 2 With the aid of an assistant release the bolts securing the bonnet to the hinge bracket and remove the bonnet 9 KEY TO FIG 5 Bonnet Assembly Hinge Blade Single Motor Headlamp System Hinge Pin Single Motor Headlamp System Hinge Blade Two Motor Headlamp System see BJA for detail Support Stay bonnet Latch Bracket Borin3t Lock Latch Disc Bonnet Lock Grille Bonnet Bonnet Seal Bonnet Plenu...

Page 49: ...BODY Page B21 Fig 5 Front Compartment Bohnet ESPRIT Issue M E ...

Page 50: ...er the dash board on the driver s side is always kept free Do not fit any electrical equipment such as cassette player or radio telephone over ttie handle 3 The catches must hit the catches pieces in the middle otherwise distortion of the bonnet lid may result To adjust loosen the catch pieces move to desired position and tighten bolts TO REMOVE 1 Lift the tailgate and allow the gas struts to supp...

Page 51: ...ed clear of the cnr Fig 6 Tailgate Hinge TO REPLACE 1 Reverse the removal procedure TAILGATE RELEASE MECHANISM The mechanism comprises of a cable assembly running from a remote controlled release handle i n the rear of the door aperture on the driver s side From the handle the U cable paueri to a lever in the rear middle of the boot trunk opening The cable can be adjusted at the adjuster fitted on...

Page 52: ... Clips Hinge Blade RH Bolt Bolt Plunger Housing Tailgate Lift jprtng laltgare Llrr Rubber Buffer Tailgate Lift Screw Pozi Gas Strut Tailgate Lock n _k t i t LQCL RUI Striker Tailgate Lock Tapping Plate Striker Grommet Cable Tailgate Release Lever Tailgate Lock RHD Insert Tailgate Release Handle Clevis Pin Lead Heated Rear Screen ESPRIT iisue 04 78 ...

Page 53: ...BODY Page B25 F ig 7 Tailgak Cornponenk ESPRIT SSW04 78 ...

Page 54: ...Upper Shim Lower Tie Rod Hinge Washer Bush Hinge Pin Hinge Pin Check Strap Assy LH Window Motor LH G r r U OI ClCKI2l I Y t I I U V W i a u l u r r q a j r I Door Wipe Seal Long Door Wipe Seal Short LH Window Frame LH Silent Chonnel Guide Rail Window Lift LH Bracket Carriage Glass LH ESPRIT Issue 04 78 ...

Page 55: ...Fig 8 Door Components BODY Page B27 ESPRIT Issue ...

Page 56: ...rator holds the topping late and packing pieces take care not to drop these as rney may be difficult to retrieve 3 The right hand tapping plate i s accessible after removal of the battery and battery support panel DC C P LOCK ZTR KER REPLACEMENT l l 1 Reverse the removal procedure and adjust striker before finally tightening screws i9 DOOR HINGES Incorrect door adjustment or badly worn bushes can ...

Page 57: ...g manner 1 Loosen the two bolts securing the front end of the door assembly near the hinge 2 Loosen the two bolts securing the back end of the door assembly about the door lock 3 Move the door to the desired position and tighten up all bolts 4 Adjust the lock striker if necessary Fig 9 Door Hinge ESPRIT Issue 04 78 ...

Page 58: ...acket tlandle to Body Door Handle Interior RH Operating Flop Pivot Pin Door Lock RH Striker Plate Rod Interior Release to Clip RH Rod Lock to Exterior Lock P RUO n r r r r t IUI L i i I V C I I Y Rod Exterior Release to Lotch RH Rod Lock to Clip Adjuster Clip Clip U Door Lock Push on Clip Bust1and Clip Assembly ...

Page 59: ...BODY Page B31 Fig 10 Door Lock Componenh ESPRIT Issue 04l78 ...

Page 60: ...st sufficient to allow up or down movement Move the door assembly to the required position and tighten clamping bolts DOOR TRIM PANEL REMOVAL 1 Remove the trim inside the interior door handle and loosen the three screws securing door handle assembly to the door Remove the PVC trim surround i n its two holves Fig 11 Interior door handle trim ESPRIT Issue o4ns ...

Page 61: ...ll rod and the lock operating rod from the nylac block 3 Release the three screws securing the handle to the door Do NOT misplace the tapping plate inside the door INTERIOR DOOR HANDLE REPLACEMENT 1 Reverse the removal procedure EXTERIOR DOOR HANDLE REMOVAL l 1 Remove the door trim panel 2 Partly remove the PVC sheeting now revealed Disconnect both lock operating rods from the door handle assembly...

Page 62: ...m Fig 12 Window motor location 3 Support the window with a suitable piece of wood or top the glass to its frame to avoid the possibility of the glass becoming dislodged from its operating channels 4 Release the four bolts securing the motor mounting bracket to the door beam and slide motor operating arm from the window channel I I Remove motor together with its mounting bracket ESPRIT 1 ...

Page 63: ...side of the door hinge 3 With the aid of a second operator supporting the door remove the hinge bolts 4 Ease door from its location pull adiusting shims from between body and hinges and remove door assembly complete with hinges DOOR REPLACEMENT 1 Reverse the removal procedure replacing all parts and adjust hinges and lock striker as necessary SIDE CAPPING RAIL FINISHER TO REMOVE r 1 Remove the qua...

Page 64: ...l and then carefully l i f t away the capping roil releas ing i t from the finisher TO REPLACE 1 Clean the body surface where the capping rail i s to be fitted ond apply sealant along the lower inner edge of the capping coil 2 Feed the capping rail under the finisher ond check alignment along the length and at both ends Clamp ternpororily in position ...

Page 65: ... 17 mm diameter taking care not to drill near or on existing holes as this could weaken the fixing P o p rivet the copping rail to body and remove any excess sealant using a suitable solvent Fig 14 Cutting windscreen Solbit retainer ESPRIT Issue o4ns ...

Page 66: ... 1 yard l metre long through the hole r With the aid of a second operator inside the car use a sawing action with ttie wire and cut through the Solbit to free the screen l a k e care not to damaoe the interior trim during the ck ttin n e r t i n n 1 TO REPLACE 1 Remove remaining Solbit from the body flange and wipe clean with methylated spirits or similar It i s important to make sure these surfac...

Page 67: ... 4 Strip the ends of the Solbit sealing retaining medium to expose approximately 12 mm 5 in of the internal heating wire Connect the exposed ends to a variable current transformer or two 12V batteries and apply approximately 24 volts to the Solbit until the surface i s tacky Disconnect Solbit from transformer Fig 17 Solbit retainer in position i h 5 Starting at a lower corner of the aperture apply...

Page 68: ...mer and using side cutters trim Solbit flush with the screen 8 The corner mitres on the windscreen finishers should be checked before fitting to ensure a snug fit when in place 9 Fit the corner inserts Part No A079U4051 in the top left and right hand mitres and position the assembly on the retaining clips 10 When satisfied the finishers are located correctly press finishers dawn on to the retainin...

Page 69: ...ng the headlamp motor mounting bracket and withdraw motor assembly 3 The motor unit can now be unscrewed from the mounting bracket HEADLAMP MOTOR REPLACEMENT 1 Reverse the removal procedure but be sure the rod end link is correctly located before tightening up the bracket fixing bolts LAMP POD REMOVAL 1 First remove the bonnet to gain access to the pad fixing screws 2 Unscrew the two nyloc nuts on...

Page 70: ...y icroswitches Switch Plate Long Link Headlamp Operation Short Link Headlamp Operation P cdEnd Ink Weadlamo Pctuction Shoulder Bush Cross shaft LH Cross shaft R H Cross shaft Coupling Bearing Bracket Headlamp Support Stay ROW Bearing Bracket Headlamp Support Stay Fed Assy Headlamp Jack Spring Rubber Stop ESPRIT Issue Wff8 ...

Page 71: ...BODY I Fig l8 Headlamp Assembly Single motor ESPRIT Issue 04 78 ...

Page 72: ... Headlamp Motor Rotary Link dod End Connecting Link Headlamp Actuation R c k L cA F 4 c cf c 3 A Bearing Housing R H Pod Glacier Bush Water Shield Hinge Pin Pod and Bonnet Hinge Blade RH Spring Clip Pod Outer Pivot Pin M 6 Jocknut M6 X 30 Screw M6 Locknut ESPRIT Issue O d n a ...

Page 73: ...ESPRIT Issue 04 78 ...

Page 74: ... over the steering column Switches ond controls ore mounted on the angled side ponels in the binnacle and the indicator lamps and meter on the centre panel TO REMOVE 1 Unscrew the switch ponels on eoch side of the binnacle orid dis connect electrical connections 2 The heater control ponel con now be uncoupled and the hoses dis connected from the vents To uncouple the heater control remove the two ...

Page 75: ...ke care not to damage the feed slot trim when pulling through belt and anchor plate 3 Remove the belt lock from the chassis centre section by removing the screw at B and disconnect the Fasten Seat Belt warning lamp wires TO REPLACE 1 Reverse the removal procedure taking care the reel assembly i s mounted vertically this ensures the sensing weight i s i n the correct position NOTE I f a new reel as...

Page 76: ...lack the reel 2 The reel should run free when the car i s stationary and when the car is travelling at a constant speed 3 The recommerided method of testing the seat belts on the road is to use a brake testing meter The rneter should give a reading of 50 when the reel is locked If a deacceleration greater than 500 i s required to lock the reel then the belt must be replaced ESPRIT Issue oai7p ...

Page 77: ... secured with eight bolts and all others are secured with 2 fixing bolts the side indicator lamp fixing screws and 5 self tapping screws along the bottom of the bumper 1 Reverse the removal procedure but first clean the surfaces on the body which come in contact with bumper and apply sealant to the bumper before fitting Fit the finishing strip 2 Reconnect the wires to the side indicator lamps wher...

Page 78: ...INISHER TO REMOVE 1 Remove the quarter light see Page S partly remove the door seal alongside the finisher 2 Drill out the pop rivets securing the finisher to the body and prise off the finisher taking care not to damage the side capping rail TO REPLACE W 1 Reverse the removal procedure but first clean the surfaces on the B C post and apply sealant before fitting NOTE I f a new finisher i s fitted...

Page 79: ... nuts with their flat washers from the s a t runner mounting bolts The nuts are on the underside of the body 2 Do not remove the bolts at this stage 3 Slide the seat fully forward and release the nuts and washer from both rear mounting bolts 4 Disconnect the seat sensor wires if fitted Remove the seat assembly I TO REPLACE 1 Reverse the removal prokedure ESPRIT ...

Page 80: ...LOCK 1 0 REMOVE 1 Remove the door trim panel and PVC sheeting from the door 2 Remove the exterior door handle assembly A 3 Disconnect both remote control rods E and F from the lock assembly 4 Release the four bolts securing the lock B to the door and remove the lock assembly together with the two rods C B D b Fig 22 Door lock and linkages ESPRIT Issue 04 78 ...

Page 81: ...door lock and the door handler are functioning correctly I f not adjust the control rods as necessary 2 To adjust the locking rod C from the exterior door handle to the lock assembly disconnect the rod from the exterior door handle and screw it in OF out as required G 3 A l l the other rods can be adjusted on their connecting clips H J a K REAR QUARTER LIGHT TO REMOVE 1 From inside the engine comp...

Page 82: ...oor lock assembly Fig 23 Window Frorne fixing bolts 2 Access to the bolts securirig the window frame i s through the access C hole i n the door shell The bolt heads ore retained i n longitudinal slots in the door beam therefore i t will be necessary to carefully lift the frame off the bolts before withdrawing the window frame together with the window gloss 3 Further dismantling of the window frome...

Page 83: ...tioning correct1 when fully ossembled DOOR SHELL TO REMOVE 1 Remove the door window frame 2 Remove the two bolts at the front inside edge and the two bolts at the rear edge of the door securing the shell to the door beam 3 Slide off the door shell from the door beam TO REPLACE 1 Reverse the removol procedure NOTE Assemble door assembly i n the following order a Fit the door beam to the car b Fit t...

Page 84: ...one hour and remove the glass or if the glass cannot be removed break the glass Fig 25 Fitting Quarter Ligtit Glass Remove remaining glass and Solbit from inside the quarter light channels i n the window frame TO REPLACE Clean the new glass with methylated spirit around the front and rear edge of the glass Apply Solbit Primer to the edge of glass and a 0 25 inch wide band on both sides of the fron...

Page 85: ...to the 6 volt power source apply pressure to the lower edge of the glass and as the Solbit starts to flow push the glass fully into the window frome Connect the copper wire ends of the Solbit to the 6 volt power source apply pressure to the lower edge of the gloss and as the Solbit starts to flow push the glass fully into the window frame Keep the gloss central in the window frame channel and cont...

Page 86: ...cess to the three fixing studs 4 securing the external finisher Loosen the nuts on the studs ond lift off the finlst erfrnm the door 2 The rubber seal can be reploced by drilling out the 13 pop rivets and fitting o new seal with pop rivets TO REPLACE 1 Apply sealant along the top edge of the door and locate the finisher in the three slots with washers agairlst the nuts Push down on the finisher ab...

Page 87: ...2 Unscrew wire clip securing the flexible ducting tube to the airbox and pull out the ducting tubes from the engine cover 3 Unclip the elastic straps from both sides of the cover and the two on the inside at the rear of the cover TO REPLACE 1 Reverse the removal C ENGINE COMPARTMENT AIR FLOW Air to the airbox i s first picked up through the left hand air scoop where i t i s expelled into the engin...

Page 88: ...is important that the soap used i s a mild non caustic scap such as roiier soap F l l c w hi by r enn water applied on a fresh clean cloth ovoid flooding the surface of the leather Then dry and polish leather surface using a soft dry cloth After approximately one year i t is recommended that the leather i s treated with Connolly s Cee Bee Hide Food follow the instruction i b i on the container CAU...

Page 89: ...iner materid to free the screen Take care not to damage the interior trim during the cutting operation 4 Remove any remaining sealindretoiner material and the trim clips Wipe the body flange with methylated spirit or similar until the surface i s perfectly clean If traces of sealing retaining material such as Solbit are still L visible use Wipe Cleaner No 4 to remove and wipe dry TO REPLACE 1 Appl...

Page 90: ... 20mm wide application of primer around the perimeter of the gloss Fig 28 Application of Gioss Primer 5 Apply glass primer around perimeter and lominated edge of glass until a deep black colour i s achieved Allow to air dry until dry to the touch NOTE In order to cover bus bar connections on the heated toilgate glass e stop the primer short of the tag and gently bend tag upwards Use masking tape t...

Page 91: ...l until 5mm i s reached d Cut down to the 55mm dimension and then make the angled cut from the 66nm to the 55mm dimension 7 Pierce membrane in cartridge thread screw on application nozzle and insert in cartridge g q 8 Extrude a continuous bead of sealant on the perimeter of the glass using the edge of the glass and the shape of the nozzle as a guide When extruding the bead of moterial hold the gun...

Page 92: ...locks on each corner of the screen as snown i r t fig 31 Spacer block Part N o AWSU0588Z 8 off size 4mm X 4mm X l h m Sealant Typical Block Position locks 1 3 5 and 7 to b e B ositioned 75mm inboard from corner of glass 1 Fig 31 Position of Rubber Spacing Blacks 10 Gently lower the glass onto the body flange locating the correct positiorl by lining up or the tape 0 ESPRIT ccttr 17VR ...

Page 93: ...he seal area with a wooden spatular or similar 12 Before replacing any bright trim carry out a water test on the glass If a leak is detected mark the position and dry thoroughly using a blow dryer or similar Extrude a sniall amount of sealant on the suspect area paying special attention to any trim fixing clips NOTE Rubber spacing blocks can be left between the glass and body if the blocks do not ...

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Page 95: ...FRONT SUSPENSION Page cl SECTION C Description GENERAL DESCRIPTION SUSPENSION AND gEERING GEOMETRY ANTI ROLL BAR LOWER LINK COIL SPRING DAMPER UPPER WISHBONE FRONT HUB i ESPRIT Issue 04 78 ...

Page 96: ...FRONT SUSPENSIGN Page C2 ESPRIT ...

Page 97: ... H Vertical Link R H Front Hub Bearing Kit Steering Arm R H Upper Wishbone R H Pivot Bolt Upper Wishbone Washer lnner Wosher lnner Washer Outer Nut Nyioc M12 Lower Wishbone R H Pivot Pin Lower Wishbone Washer Washer Nut Nyloc M12 Ball Joint Upper Ball Joint Lower Anti roll Bar Bush Anti roll Bar Washer 40 o d 10 i d X 3 5 mm ESPRIT ...

Page 98: ...extreme difficulty and or person01 injury may 8 I I L I l W 8 1 I I I I1IU l Y S S li O S v I SUSPENSION AND STEERING GEOMETRY Under normal service conditions i t should only be necessary to check the front wheel alignment A full geometry check is only necessary followir gthe rectlfication of repair damage i o ihe froni suspension or sieering or i f excessive iyre wear i s evideni or steering dlff...

Page 99: ...ar mounting Y 3 Secure the anti roll bar with its clamps to the chassis and tighten all bar fixing screws to the torque loadings specified in the TECHNICAL DATA 4 Replace the rood wheels LOWER LINK To Remove 1 Remove the road wheel and the anti roll bar 2 Apply clamps to the coil spring and carefully compress the spring 3 Support the hub assembly and remove the damper lower mounting bolt 4 Unscrew...

Page 100: ...e lower link ot the bottom therefore a spring compressor or clamps are ESSENTIAL i n the dismantling process 1 Remove the road wheel and compress the spring 2 Remove the lower link as previously described taking care to support the hub assembly 3 Carefully withdraw the compressed spring and release clamps To Replace 1 Check the rubber abutment ring is i n good order and reploce if neceraary 2 Reve...

Page 101: ...t moulded rubber bush metal cup washer nut and locknut and tighten to the instructions given in the TECHNICAL DATA Top stem mounting UPPER WISHBONE To Remove 1 Remove the rood wheel and prepare to support the suspension unit on an axle stand or trestle NOTE As a precaution fit spring clamps to the spring and tighten sufficient to prevent further extension of the spring 2 Unscrew the upper ball joi...

Page 102: ... Unscrew brake caliper and support the assembly ensuring that the flexible hose is not kinked 3 Lever off hub cap and remove split pin from the castle nut 4 Unscrew castle nut remove together with washer 5 ithdrawthe hub assembly together with brake disc from the vertical link To Replace 1 Fit a new sealing ring to the hub and apply onti friction bearing grease to all bearing races and the frictio...

Page 103: ... SECTION D Description GENERAL DESCRIPTION BEARING HOUSING DRIVESHAFT ASSEMBLY RADI IS ARM RADIUS ARM MOUNTING REAR WHEEL TOE IN LOWER LINK WHEEL BEARINGS DAMPER SPRING ASSEMBLY Page D4 D4 D4 D5 D6 D6 D8 D9 ESPRIT Issue 04 78 ...

Page 104: ...REAR SUSPENSION Page D2 ESPRIT Issue adns ...

Page 105: ...nsulator Radius Arm Assy LH Rubber Mounting Radius Arm Plate Reinforcing Radius Arm Mounting Shaft Outboard Joint Universal Shaft Intermediate Flange Driveshaft Rear Hub Assy Cone Hub Retention Hub Nut Lower Link Assy Bush Lower Link Rear Hub Carrier Bearing Rear Hub Circlip Bearing Retaining Spacer Adiustable Seal Outer Seal Inner ESPRIT Iccsio ofil7n ...

Page 106: ...e bolts securing the C L 1 zr G 2 L C 2 r 3 Remove the lower damper mounting stud this will release the damper coil spring assembly and the lower link assembly 4 Unscrew the radius arni assembly from the bearing housing and lift away the bearing housing assembly together with the driveshaft 1 Reverse the removal procedure Tighten all bolts nuts to the torque lwdlngs specified in the TECHNICAL DATA...

Page 107: ... of the washers 2 Check the rear wheel toe in and adjust i f necessary see Rear Wheel Toe in l Fig 2 Radius orm to chassis mounting RADIUS ARM MOUNTING To Remove 1 Remove the road wheel 2 Remove the nut securing the radius arm to its pivot mounting bolt 3 Ease the radius arm from the mounting bolt noting the amount of spacers on each side of the arm this i s necessary to achieve correct toe in whe...

Page 108: ... NOTE When removing or replacing the securing nut from its mounting bolt i i t is necessarv to orevent the bo t turnina in the rubber mountlna using a spanner on the head of the bolt 3 When checking the rear wheel toe in the car should be at ride height see Rear Suspension under Torque Loading Figures in the TECHNICAL DATA section 1 Remove the road wheel and support the hub assembly g 2 Remove the...

Page 109: ...ttachment To Replace l Reverse the removal procedure taking care to fit washers i n correct order see illustration and tighten all bolts nuts to the torques specified i n the TECHNICAL DATA Washer Y Fig 4 Lower link hub ottachment ESPRIT Issue 04 78 ...

Page 110: ...ibed i n Section G 3 With the bearing tlousing driveshaft assernbly on the bed of a press press out the driveshaft assembly from the outside hub side of the housing 4 Remove both oil seals and the circlip securing the bearing 5 Using a suitable spaca e g a length of tube press outer track of bearing from the housing I Cone Spacer Fig 5 Hub bearing ...

Page 111: ...g housing and driveshaft assembly to the car Tighten all bolts nuts to the torqves specified in TECHNICAL DATA DAMPER 8 SPRING ASSEMBLY To Remove NOTE The spring abutts the chassis at the top therefore i t i s essential that a spring compressor i s used when removing the spring L r 1 Remove the road wheel 2 Remove the lower damper mounting stud this will release the damper spring assembly and the ...

Page 112: ...CRANKSHAFT V BELT PULLEY CRANKSHAFT SPROCKET FRONT COVER AND OIL SEAL _ I WATER PUMP OIL FILTER IGNITION DISTRIBUTOR OIL PUMP AND A LXILIARY HOUSING INLET MNIFOLD OIL SUMP CONNECTING ROD BIG END BEARINGS ENGINE TRANSMISSION ASSEMBLY FLYWHEEL AND RING GEAR CRANKSHAFF REAR OIL SEAL CRANKSHAFT PISTONS RINGS CONNECTING RODS a CYLINDER LINERS SPECIAL TOOLS SEALERS GREASE LOCTITE OIL EMISSION CONTROL LI...

Page 113: ... inclusive angle of 38 They are operated by the cam shafts acting directly on the cam followers tappets the camshafts being driven at half erigirie speed by o toothed belt The camshafts end flw i s taken by a thrust washer at the rear end of each shaft The toothed driving belt also drives the auxiliary shaft this in its turn driving the oil pump and ignition distributor The crankshaft of cast iron...

Page 114: ... wiped replaced and finally withdrawn and checked the depth of the oil on the end of the dipstick indicating the level of the oil i n the sump If the addition of oil i s necessary remove the filter cap on the inlet camshaft cover and add new engine oil of correct grade see TECHNICAL DATA until the dipstick indicates that the oil i n the sump has reached the required level Do NOT overfill Replace t...

Page 115: ...se wire OS is wiii eniarge rne jer or rice 7 2j C c Remove the needle valve and valve body and blow clean with an air c line d Clean th eloat and float chamber using clean petrol e Replace all jets needle valve body and needle valve f Usinn n r nw nncL t fit C S chcmbe r l r F s F assembly Check float setting Refit f l w t chamber cover 6 When ZENITH STROMBERG carburetters are fitted proceed as fo...

Page 116: ... given in TECHNICAL DATA A t altitudes above sea level proportionally lower pressures will be obtained m Compression is checked with the starter motor turning the engine at opproxi motely 200 r p m Battery and starter motor must of course be in good condition 3 Test the remaining cylinders i n a i i m i L r manner i C f aY 4 Repiace sparking plugs re connect the sparking plug leads and relet throt...

Page 117: ...two cam followers to hold the cam followers in their respective bores 6 Remove the ten nuts and washers reiease the nuts diagonaiiy inwaras irom the outside securing the camshaft housing and remove the housing Care MUST be taken to avoid dropping any nuts or washers down the inside front of the camshaft housing 7 Repeat the process for the other housing BEFORE removing the exhaust camshaft housing...

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Page 119: ...INE Page E8 1 s t ielliovr i 111 i i wost ers securing the sprocket to the camshaft 10 e v e l i i l c ond pull off the camshaft sprocket b Fig 2 Camihuft i ousing corn followers 8 Shims ESPRIT Issue 04 78 ...

Page 120: ...ENGINE Page E9 Fig 3 Cornshoft sprocket held in vice Fig 4 Cornshaft thrust wosher 0 ring ESPRIT Issue 04 78 ...

Page 121: ... in the centre bolt to push out the camshaft towards the front b of housing together with its oil seal Fig 5 Releasing the camshaft 12 Repeat the process for the other camshaft and sprocket 1 g q I Fig 6 Using Tool 72A to align camshaft oil seal Fig 7 Using Tool 1W to insert camshaft oil real ESPRIT z ssue ...

Page 122: ... sprocket to exhaust and relevant IN timing marks on sprocket to inlet camshoft h 3 Fit the selective thrustwosher with its retaining bolt and spring washer ensuring that i t i s located on the dowel protruding from the rear end of the camshaft 4 Hold the camshaft sprocket in the vice see CAMSHAFTS To Remove g T G instruction 10 Tighten thrust washer ond sprocket retaining bolt to the torque ding ...

Page 123: ...ousing following the outer surfoce orourld the stud holes Fit 0 ring on cylinder heod dowel arid carefully place cam housing on cylinder head studs and secure with washers and nuts Tighten W the nuts to the specified torque loadings diognonally outwards from the eenPr 7 Check and adjust valve clearances if necessary as described in the VALVE CLEARANCES 8 Refit camshaft drive toothed belt check ten...

Page 124: ...valve stem ONLY use ONE shim to each valve NOTE A Thinner shin1 will inciease the valve clearance whereos a thicker shim will decrease the clearance 3 Replace the camshcfts after adiustmer t and recheck the cleamnce If the Q clearance is s t i l l incorrect then the whole of the above proceduru MUST be carried out again ti NOTE Do NOT turn the camshafts with No 1 piston at T D C as this will cause...

Page 125: ...elt is removed or a new belt i s fitted Fig l0 Burrough s gauge i n position Belt Tension Check Check the belt tension using a Burrough s Gauge BT 33 86A 5 20 fitted between the auxiliary shaft sprocket and the inlet cam shaft sprocket Check TECHNICAL DATA for the correct tension 1 Fully extend the hook by pushing handle completely down 2 Insert the belt between nose piece and hook ensuring hook i...

Page 126: ...king the average of three readings for the mean belt tension inserted after loosening Fig ll Automatic belt tensioner 2 L X To Remove Timina Belt b p s z tt wsi p s C S s e a c i I Set the engine in the timing position with number one cylinder piston at T D C Align the timing mark on the crankshoft V pulley or flywheel with timing pointer A t this point the marks on the camshaft sprocket should al...

Page 127: ...til the adjusting screw i s protruding a maximum of 12 mm 0 5 in from the tensioner hawing Timing rmrks i n line through centre of pulleys referdo technical data far relevant specification is NEW MARKS ON PULLNS _ s Crankshaft Sprocket Fig l2 Sprocket positions with Number 1 cylinder at TDC 6 Force idler wheel towards tensioner body this can be achieved by pulling on the timing belt until the groo...

Page 128: ...ioner body i s centred in the adjuster piston hole 2 Fit toothed belt to pulleys Pull the belt sufficient to force the idler bearing on tensioner towards tensioner body Remove locking pin and release g 2 pressure on be1t 3 Ifon auxiliary pulley snubber is fitted adjust i t for a ciearance6f 0 4 mm 0 l mm 016 004 in between the pad and toothed belt c U L Refit crankshaft V pulley and adjust belt te...

Page 129: ...ic adiusters a Remove the alternator together with the adjusting strap arid fixirtg nuts and bolts b Release the tension on the driving belt c Remove the lower fixing bolt and remove the nuts secs rlnathe adjuster to the fixirig stud slide off the automatic adjuster To Remove 1 Disconnect the battery Drain the cooling system Section K F 3 Release the clips or screws securing the air trunkirig to t...

Page 130: ...ENGINE Page E19 ESPRIT Issue 04f78 ...

Page 131: ...asket Cyt Head DaDth Pad K Fig 14 Cylinder Heod Nuts tighterlingjloosening sequence i WARNING Do NOT loy the cylinder heod face down on the bench unless i t i s c S coveitso with protective niorer otherwise the mating face of the cylinder heod could be domoged Do NOT turn engine without Cirst fitting cylinder liner clamps otherwise the location of the liners could be disturbed To Replace I 1 Remov...

Page 132: ...aft carrier housings Check volve clearances Replace camshaft drive toothed belt spark plug leads and set stalt ignition timing see CAMSHAFT DRIVING2BEL T replacement and adjustment AV Fit carburetters together with the inlet manifold but do not fit air cleaner G C and cover at this stage g i eh m Replace water hoses Close coolant drain tap on radiator and refill the y g I cooling system L W Check ...

Page 133: ...ition of volve guides Grind i n all valves 2 Lightly lubricate the stem of the valve and insert into ih wide 3 Fit sprlng seat valve springs spring retainer Place the valve spring compressor in position and comprea the volve springs suffialently to fit the split collets Release the volve spring compressor Check both halves of the collets are still i n place and correctly seated l 4 Repeat the proc...

Page 134: ...laced under the head of the valve will assist considerably i n 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 i n spreading the grinding operation until o dull even matt finish free from any blemishes i s achieved on the valve seat and volve foce On completion the...

Page 135: ...se the new insert will NOT seat fully i n the recess Fig l6 Location of valve seat oversize stamping To Replace 1 Check the combustion chamber adjacent to the respective seat for a C D or E stamping this indicating that that valve seat was fitted oversize in Production If this stamping i s visible then that size or larger seat MUST be used as replacements The letters C D and E referto the prefix l...

Page 136: ...e used as replacements To Remove 1 Remove the cylinder head and dismantle as for decarbonising 2 tieot the whole cylinder head to a temperature of between 100 150 212 303OF and with Special Tool OM knock the gl ides out of the head from the combustion chamber side To Replace ct 1 Heat the cylinder head to a temperature of between 100 150 212 303OF i 2 Locate a new circlip on the new guide and pres...

Page 137: ...A CRANKSHAFT SPROCKET l Set the engine in the timing position 2 Remove the camshafts driving belt toothed belt 3 Remove the crankshaft V belt pulley 4 With the aid of Special Tool 17OA pull off the crankshaft toothed pulley ioiiowed by ihe beii guide iiange I ghten the tooi boits fingertight oniy Fig l7 Using Tool l70A to remove crankshaft sprocket To Replace l Ensure that the engine has not been ...

Page 138: ...ensioners on1y 7 Remove the oil seal from the cover by pushing from its location To Replace 1 Using a new oil seal with Wellseal sealing compound applied to its outer diameter insert into the front cover until flush with the rear face 2 Apply jointing compound to both faces of a new gasket and replace front cover with the aid of Special Tool 09A For manual camshaft belt tensioners ensure that the ...

Page 139: ...ther dismantling i s unnecessary To Replace 1 Measure the distance between the body mouritirig surface and the hub mounting surface of the old water pump see figure 19 2 Apply Loctite RC35 to the front of the bearing shaft or inside pulley hub then press on the V pulley hub to the dimerisiori of the old pump 3 Support the pump shaft while pressing on the hub and also check the impellor to housing ...

Page 140: ... 2 To remove the filter turn i n an anti clockwise towards the cylinder block direction Discord the filter To Replace 1 Clean the mating foce on the oil pump body Pour o small amount of clean engine oil into the filter Then apply a film of engine oil to the new seal ESPRIT Issue 04 78 ...

Page 141: ...ssary tightening the filter further to give on oil tight joint Fig 20 View showing oil pump filter ignition distributor IGNITION DISIRIBWOR ir To Remove 1 Turn engine until at the timing position see figure 15 v h 2 Remove the distributor cap 3 Disconnect the low tension cable 4 Discorinect the vacuum pipes to distributor 5 Release the nut securing the distributor clamp to the oil pump housing and...

Page 142: ... timing i f necessary see TECHNICAL DATA by slackening the distributor clamp and turning the distributor body as necessary 6 After making an adjustment tighten the clamp sufficiently to hold the distributor i n position D O NOT OVERTIGHTEN Remove the timing light OIL PUMP A N D AUXILIARY HOUSING To Remove 1 Set the engine to the timing position and remove camshaft driving belt Mark e position of r...

Page 143: ......

Page 144: ...itted between the oil pump body and the auxiliary housing Flt new outer pump rotor Fit the oil pump body to the housing tightening all bolts to the specified torque loading see TECHNICAL DATA 5 Using a new gasket to which a suitable compound has been added to both faces refit the auxiliary housing _ torthe cylinder block Ensure that the rerainha bolts are replaced in their original locations other...

Page 145: ...ench T o Replace 1 Reverse the removal procedure but use a new gasket Tighten all nub to the specified torque loodings see TECHNICAL DATA OIL SUMP To Remove 1 Gain access to the sump by using a ramp pit or jacks 2 Using a suitable receptacle release the drain plug and allow oil to drain fro the sump Remove the diistick 3 From around the periphery of the sump remove the setscrews and nuts with thei...

Page 146: ...earing shells from both the connecting rod ond the connecting rod cop To Replace 1 Replace the upper and lower big end bearing shells by new parts i n their appropriate locations 2 Fit the cap to the connecting rod and tighten the bolts to the torque looding given in TECHNICAL DATA 3 Replace the remaining big end bearings by repeating the above pmcess 2 f 3 4 Replace the sump L a 4 ENGINE TRANSMIS...

Page 147: ...to the chassis withdraw the righthand mounting brocket ond earthing strap 13 Release the transmission unit mountings from the brackets on the chassis Note number of shims between transmission and chassis mountirrg brackets for e cceme t I ewer the gegrhnx end of the assembly and r e A v e whole assembly from under the rear end of the vehicle 14 Remove all the bolts nuts securing the engine to the ...

Page 148: ...if the flywheel and ring gear only are to be removed Access con be ochieved by removing the transmission unit see TRANSMISSION Section To Remove 1 Remove the clutch assembly from the flywheel see Section Q 2 Release the bolts from the centre OF the flywheel and pull flywheel from Its b locating dowels on the crankshaft 3 Cut between two adjacent teeth on the ring gear with a hacksaw and split the ...

Page 149: ...HNICAL DATA 5 Check the flywheel run out using a proprietary dial gouge The total run out should NOT EXCEED the figure given in TECHNICAL DATA 6 Replace the clutch assembly 7 Refit transmission unit CRANKSHAFT REAR OIL SEAL To Remove 1 Remove the transmission unit from the vehicle 2 Kemove tne riywneei see TL T V V C C L m 1 4 I I Y V v s 3 Remove the rear oil seal housing by releosing ik eight se...

Page 150: ...ation on the cylinder block and main bearing housing with its flange positioned between the two webs on the bearing housing Lightly lubricate the lip of the seal apply Wellseal to both sides of a new gasket and with the aid of Special Tool EM fit the oil seal housing over the flywheel flange of the crankshaft securing with its setscrews Tighten the setscrews to the torque looding given i n TECHNIC...

Page 151: ... aid of Special Tool 83A remove the union screw securing the oil pick up pipe in the cylinder block 7 Remove the ten nuts and woshers to the outside of the sump mounting face followed by the ten large nuts and woshers adjacent to the main ioumalr 4 1 1 nuts should be released i n sequence working diagonally inwards from the outside Remove the oil pick up pipe ond breother pipe from their locations...

Page 152: ...c engines the five main bearings i n the bearing panel are plain without grooves or drilling 1 Fit a new key to the front end of the crankshaft to retoin the sprocket 2 Fit a new spigot bedring and new flywheel dowels in the rear flywheel end of the crankshaft 3 Check the top flanks at the rear of main bearing housing for a 015 stamping this indiating thot oversize bearings were fitted i n Product...

Page 153: ...grooves the copper side are towards the crankshaft Check the end flwt between the crankshaft and the thrustwashers see TECHNICAL DATA If the end flwt is outside this tolerance replace the selective thrust washers 5 Apply Silastic to shoulder or1 the spray shield With the step of the shield facing towards the rear of the cylinder block slide over the crankshaft between flywheel flange and rear of b...

Page 154: ...n sequence diagonally outwards to their specified torque lwdings see TECHNICAL DATA Ensure that the crankshaft connecting rod journals and the connecting rods and caps ore clean then fit new bearing shells Refit the connecting rods and their caps to their respective journals after applying Cylesso to the bearings Tighten the bolts to their specified torque loadings see TECHNICAL DATA The second fr...

Page 155: ... sump and flywheel 1 5 wnen a new cyiinder biock i s being use i t wttt vs I I S G E J U V I I I breather spout at the top rear of the RH side below the inlet manifold F i t the bush with its flange uppermost into its location Tap the breather tube into the bust1until approximately 25mm l Oin i s left protruding Ensure oil gallery and water jacket plugs are also fitted 14 Refit the trnnsrnission u...

Page 156: ...re the rod to the piston with i t s gudgeon pin and circlips 3 The liners are fitted into the cylinder block with their flats in a front to rear line When replacing liners i n the cylinder block they MUST FIRST be fitted clean and dry and pushed fully into their loccttions At this point the liner nip should be checked the nip i s the height of the liners ABOVE the cylinder block face and the heigh...

Page 157: ...ue loading see TECHNICAL DATA 7 Replace the oil sump 8 Replace the cylinder head after removing the cylinder liner clamps 9 Replace engine i n the car NOTE When fitting piston rings proceed as follows A Fit the oil control rings 1 The oil control rings consist of an expander ring and two steel rails which are fitted above and below the expander ring They MUST always be fitted BEFORE the compressio...

Page 158: ...gap and the upper steel roil gap 25mm l Oin to the RIGHT of the expander ring gap B Fit the second compression ring with the step on ring facing down towards piston skirt C Fit the first compression ring Position the oil control ring gap to the rear 0 and the two compression ring gaps 120 an either side of this B Running In When new rings or piston liner sets hove been fitted the rnnning in period...

Page 159: ...t Valve Seat Drift Exhaust Valve Seat Drift For inserting valve seat Front Cover Pilot Camshaft Oil Seal lnserter For inserting oil seal Camshaft Oil Seal Extroctor For extrnr ing oI s s Cylinder Liner Extractor For extracting liners Camshaft Oil Seal Sleeve For locating oil seal Oil Pick Up Pipe Union Spanner For tightening union nut Rear Oil Seal Housing Pilot To locate housing on re assembly Cr...

Page 160: ...ms Crankshaft rear oil seal housing gasket oil sump joint cylinder head gasket and main bearing housing Cylinder liners to cylinder block Manifold studs All push fits All studs not listed elsewhere inc idler pulley to bearing flywheel bolts carburetter trumpet nuts oil sump to main bearing housing studs 6 mm Idler pulley to bearing all push fits corburetter trumpet nuts A036 E 6025V ckhams Q Motor...

Page 161: ...e carburetters fitted ore Zenith 175CD2SE ttie front carburetter C907E0791F and the rear carburetter C907E0792F Exhaust Emission Control Exhaust emissions from the engine are controlled using an air pump and exhaust catalyst converter A vacuum pipe from the corburetters sense the amount the throttle i s opened and this controls the amount of air injected into the exhaust ports The air pump i s dri...

Page 162: ...erature should be 3 5 4 5 S Adjust mixture as necessary After every adjustment run the engine briefly at 2000 r p rn then check the mixture at idle speed This i s to ensure that the piston i n the dash pots have settled correctly For North American vehicles except California with o prefix H on the engine number and fitted with a Lumenition distributor the idle C O level should be less than 1 with ...

Page 163: ...ENGlNE Page 5 2 E S P F Isc ...

Page 164: ...mp Drive Air Filter Hose Air Pump Inlet Hose Clip Hose Air Pump to Diverter Volve Hbse Diverter Valve to Air Roil Air Non return Volve Elbow Air Rail Assembly Mounting Bracket Rear Mounting Bracket Front Bolt Bolt Spocer Air Injector Olive Unian Nut Diverter Valve Screw M6 Inlet Pipe Diverter Valve Vacuum Pipe Assembly ESPRIT Issue 12 78 ...

Page 165: ...posed top of the distributor from strong sunlight I L I W y e 4 l k h m L le A b h l h A a spark should be observed between the EHT lead and the engine casting 2 To Test the Power Module and coil a Uriplug ttie 3 way connector leading to the distributor b Coririect the red wire in ttie Connector to the blue wire to the power module using a piece of wire Brake the wire connection A spark should be ...

Page 166: ...nder no circumstances should o full positive feed be applied to any connection other than the red positive wire Core shoiAd be token not to short the coil terminals as this puts o full feed to the coil brown wire WARNING EHT con be dangerous hondle leods with core when ignition switch i s ON ESPRIT ISSut 12 78 ...

Page 167: ......

Page 168: ...SEMBLY TRANSMISSION ASSEMBLY CLCrrCH BELLHOUSING DRIVE OR I N P U T SHAn GEARBOX REAR HOUSING GEAR SELECTORS REMOVAL GEAR SELECTOR REPLACEldNT PRIMARY SHAFT BEVEL PINION SWAFl DIFFERENTIAL SHAFTS DIFFERENTIAL CROWN WHEEL AND PINION DIFFERENTIAL BEARIWS ADJUSTMENT BACKLASH ADJUSFMNT ESPRIT I Q C M 1 7 R ...

Page 169: ...TRANSMISSDON Page F2 Flg 1 Transmission Assernbiy ...

Page 170: ...RANSMISSION Page F3 KEY TO FIG 1 Gearbox housing Pointer engine tunlng Switch reverse light Gearbox drain tube Speedometer plnlon Speedometer cable Speedometer driveshaft Retaining clip ESPRIT b lle04 70 ...

Page 171: ... the gearbox crw shaft movement of the lever forward and backward moves the cross shaft mdtallyand movemerit from side to side moves the crdss shaft across the gearbox W fhe s r I f t lever I s in nn o vt of gear positinn the gemshift lever wlll take up a neutral centre position irt the gate held there by springs on the gearbox c r s h u f t The left hand lever on the cross shaft i s coupled to th...

Page 172: ...e pull through and pull out the cable from the gearbox end Difficulty may be experienced when pulling the nut and washer through the grommet in the chassis i t is advised to remove the grommet at the same time To Replace 1 Reverse the removal procedure but before fitting the adjustable front tube see Adjustments 2 Before pulling through a new bowden coble ensure the shakeproof washer i s fitted an...

Page 173: ...TRANSMISSION Page F6 ESPRIT Flg 2 Gear Change Mechanism issue 04D8 ...

Page 174: ...forward Gear change tube intermediate Gear chonge tube rear Link adjustable Pivot pin Rubber bush Bearing Gear chonge swing link Pivot pin Stub swing link Nyloc nut Washer Gear change relay lever Cross gate lever Pivot pin Cross gate cable Cross gate cable rod dap tor Washer Clevis Spirol pin Spirol pin ...

Page 175: ...thstand any movement caused by the remowl of parts W Remove both rwr wheel8 and dlrconnect both driverhafta from adaptore Disconnect the battery reverse light switch and remove the starter motor Dmln the eecrrbox of oil Remove the rear gear change tube on the left of the tmnrmiuion unlt together wtth the m r ch e mlng link Ditsonnect the o wble a the lever on the right of the tmrutnlwion unit by r...

Page 176: ...gs 3 Bleed and adjust the clutch 4 Reconnect gear linkage and crossgate cable odjust as necessary 5 Check and top up gearbox oil as necessary 6 Check exhaust system for leaks and rectify if necessary 7 Bleed brakes and adjust handbrake i f necessary CLUTCH BELLHOUSING To Remove 3 1 Remove the transmission assembly and driveshaft bearing housing assemblies 2 From inside the bellhousing remove the f...

Page 177: ...cribed b 2 Remove the tube enclosing the input shaft t ether with the two 0 rlws The tube rhwld pull out from the oil return flange but may come away athrrched to the flange 3 Rernow the oil return flange 4 Remove the clrcllp retaining the front part of the Input shaft In the primary shaft Take core not to loose the spring between the lnput haft and primary shaft If the ctrcllp la very difficult t...

Page 178: ...gage two gears e g 1st gear and reve 4 Remove the locking wire through the screw securing the 5th gear for remove the screw 5 Remove the 5th gear synchro assembly ond the 5th gear fork 6 Remove the speedometer driver gear and connection socket 7 Remove the eight screws securing the rear housing and withdraw the rear housina Fig 4 Rear housing with cover removed To Replace 1 Reverse the removal pro...

Page 179: ...lector c r w C shaft Reveme Gear Selector 1 Slacken the screws securing the fork A and the opemtlng dog B flnt removing the locking wire to the selector rhaft 2 Wlthdmw the aelwtor shaft removing the fork the operating dog and rhaft locking ball and sprlng R h Gear Selector 1 Slacken the screw securing the 5th gear operating dog C after removing the locking wire 0 ESPRIT Issue mm ...

Page 180: ... and position of the plungers NOTE One long plunger between 3rd 4th and 5th selector shafts and shorter plungers between 1st 2nd and 3rd 4th selector shafts and 5th and reverse selector shafts GEAR SELECTOR REPLACEMENT 1st and 2nd Gear Selector a c c F 1 1 Locate the locking ball and spring in position G k g C 2 Compress the spring ond ball assembly using a 6 m m diameter rod C VZ p J T L 3 Insert...

Page 181: ...ly dekribed the 5th gear operating black and into the differential end of the gearbox casting ensuring that the mall interlock plunger is located inside the frdnt end of the selector ahaft 1 0 3 Locate the 5th gear operatlng block on the selector shaft so that the n o k h on the shaft lines up with the screw hole in the block Screw down the grub screw and lock with wire Reverse Gear Selector 1 Pla...

Page 182: ...nterlock plungers with a sealing compound and knock i n the blanking plugs at positions F and G Final Assembly 1 Fit top cover on the gearbox and replace the transmission unit as previously described a PRIMRY SHAFT figure 7 To Remove 1 Remove the Geor Selectors and the Input Shaft as previously described 2 Remove the speedometer drive wheel using spanner 3179 T and pull the 5th r gear rive pinion ...

Page 183: ...TRANSMISSION Page F16 I Fig 6 Gearbox gear train 5 S SPR T Issue 04 78 ...

Page 184: ... 4th and 5th gear synchro rings 34 Circlip 35 Setting pin 36 Spring a 37 Setting pin 5th gear 38 Synchro ball 39 Ball bearing 40 Needle bearing 4th 5th Needle bearing 3rd Double bail bearing Circlip Circlip Reverse gear spindle Screw Reverse gear 1st gear idler pinion 3rd and 4th gear train 2nd gear idler pinion 5th gear driven pinion 1st and 2nd synctiro ring Speedometer driver wheel i s h Washer...

Page 185: ...t towards the bellhousing as deaerlbed under heading Bevel Pinion and allow g T n to rest in the bottom of the casting to provide C additional space to withdraw the primary rhaft 7 The primary shaft can now be moved towards the bellhoualn end until the rear end of the rhaft is clear of the castiag Llft out the p r l m y haft assembly 8 Remove the 1st and 2nd gear selector fork E flgure 5 I P W 5 D...

Page 186: ...Adjustment of this movement i s 5 achieved bGchbnging the circlip Q for one of a different W thickness Withdraw circlip from its groove e Synchro ring D L K7 f 4th gear idler K together with its needle bearing cage smeared with l transmission oil Slide the synchroniser E across to engage the 4th X G gear er 3 Pass the inputishaft end of the assembly through the top opening or he georbox then forwa...

Page 187: ... t a b c d e f s h i k I q p o nrn i Fig 8 Bevel pinion assembly BEVEL PINION SHAFT To Remove I Remove the Primar y Shaft as previously described 2 Withdraw the bevel pinion through the gearbox casting into the differential housing 3 As the bevel pinion i s drawn through the costing remove the gears 1st and 2nd gear synchro needle bearings and the adiusting washers and 3rd 4th gear train NOTE The ...

Page 188: ...oring sleeve 0 Smear the bearing before fitting with transmission oil 7 Finally on the shaft the adiusting washer q and the double pinion r and push the shoft to the rear of the gearbox 8 Fit the rear double bearing c taking core to assembly the double bearing races and beoring ring in the original positions 9 Fit the 5th gear pinion b with the small shoulder on the pinion against the W double bea...

Page 189: ...s so the gauge stem p a w over the ground face of the pinion until the large needle of the dial gauge is about to change direction Lock the needle positions and note the readings Example Totalislng needle between 0and 1 Large needle at 86 4 Remove the Axture and place once again on the surface plate Allow the dial gauge stem to return slowly so the full revolutions can be countad When the gauge st...

Page 190: ... Apply sealing compound to cover rmting surfaces and tighten a l l securing screws to the torque specified i n the TECHNICAL DATA DIFFERENTIAL SHAFTS Drive shafts Dismantle 1 Remove and dismantle the Clutch Bellhousing as previously described 2 Remove the grub screw securing the large nut which locks the bearing to the shaft 3 Using the box spanner 1770 T unscrew and remove the large nut 4 Drive t...

Page 191: ...t hand side of gearbox i s the shorter 1 Fit the bearing 21 in the houslng and tighten the nut 18 to 10 kg m 72 lb ft wing the spanner 1770 T Lock the nut using the grub screw 19 2 Fit the oil seal 20 using the tool 1772 1 3 Position the oil retaining washer on the shaft Fit the spacer 16 and position the mandrel 186P l Centrdlise the oil retaining washer with the mandrel centring bush and fit the...

Page 192: ...e long Satellite spindle short Screw with dowel Crown wheel screw Planet wheel washer Satellite gear washer Crosshead bush Distance piece Distance washer Adjusting washer Crown wheel Roller bearing Spacer Locking nut Nut Grub screw Oil seal Bearing Grub screw Output shaft housing ESPRIT Issue 04 78 ...

Page 193: ... Q f Crowhead 10 g Other planet wheel and thrust washer To Replace 1 Place in the satellite housing o thrust wosher a one planet wheel 3 one fixed thrust washer 9 one satellite gear 3 and the long spindle 4 2 Rotate the planet wheel and check that the point of minimum cleomnce i s 0 1 mm I f this i s not so replace thrust woshers until the minimum clearance i s achieved Remove the satellite and th...

Page 194: ...l and bearings a Place the differential together with bearings in the end of the gearbox costing b Place the adjusting washer 13 and the distance washer 12 with a total thickness of 7 mm against the left hond differential bearing C Secure the differential in place using the two clamps MR630 64 16 tightening the nuts by hand only d Place a new paper gasket on the left hand differential shaft housin...

Page 195: ...Z i l I F i l f f I Average A and B 7 76 7 80 7 78 mm 2 c Add to the ovemge measurements the following items Thickness of the seal 0 10 mm Streu on the bearing 0 30 mm Total 0 40mm Example 7 78 0 40 8 18 mm Select an adlusting washer and o distance wsher w i h a total thlckneu nearest to the calcr lated thickness This wwld be for the example used 8 20 m m the adjusting wosher has a smaller inside ...

Page 196: ...o measure the torque fix and wikd a length of cord around the differential satellite hhosing Attach to the free end of thk card to a spring balance so the satellite housing can be rotated when the spring balance i s pulled b Take a reading from the balance when the satellite housing i s just about to rotate This reading should be within the following limits given for bearings which have previously...

Page 197: ... must be fitted 1 1 Measure the cleoronce between the crown wheel and pinion teeth i e backlash 0 Fit a diol gauge 2437 T to o support fixed to the gearbox castlng b Adjust the position of the diol gouge so that the measuring probe touches the flank of o tooth ot heel outer edge of crown wheel see bi T L L I L d au rn nra z NI riuaimumamer er er l of the crown wheel c Move the crown wheel to the e...

Page 198: ...and 0 24 mm Aim for an average clearance of 0 20 mm b Subtract this average clearance from the minimum reading noted for the example given this will be 0 73 0 20 0 53 mm therefore for this example the clearance must be reduced by 0 53 mm NOTE Moving a 0 15 mm adjusting washer from one side to the other will change the clearance by 0 10 mm For the exomple therefore the thickness of the washers to b...

Page 199: ...TRANSMISSION Page F32 3 I f backlash i s within the tolerance assemble the differential assembly b replace the Clutch Bellhousing and refit Transmission Unit ESPRIT Ice P A 7 7 3 ...

Page 200: ...Description GENERAL DESCRIPTION TYRES SPARE WHEEL FRONT HUBS REAR HUBS MODEL S2 CHARACTERISTICS HUBS WHEEL TYRES Page G1 SECTION G Page G2 G2 G2 G3 G4 G6 ESPRIT Icctso i717R ...

Page 201: ...ICAL DATA Under inflation will cause excessive wear and ropid deterioration of the tyre walls whilst over inflation will have a detrimental effect on the haridling and ride characteristics Pressures should be checked at least once a week or every 1 600 kilometres 1 000 miles In order to obtain the correct handling feel and minimum feedback i t i s very important that tyre uniformity i e radial ari...

Page 202: ...e wheel securing nuts to their specified torque loading see TECHNICAL DATA To Remove 1 Remove the road wheel 2 Detach the brake coliper and attach with straps or string to the chassis taking care NOT to stretch the flexible brake pipe 3 Remove the dust cover A and the split pin B retaining the hub nut C Remove nut washer D and the hub disc assembly E 4 From the rear of the brake disc remove the bo...

Page 203: ...e found i n TECHNICAL DATA REAR HUBS To Remove 1 Remove the road wheel split pin and hub retaining nut 2 Tap loose and remove the cone spacer 3 Using a suitable puller remove the hub from the spline on the driveshaft To Repluce 1 Slide hub on to the driveshaft spline Check that the ground surface of the shaft and the cone iriner bore of the hub the surface of the castellated nut and spacer are ALL...

Page 204: ...ecified torque loading 2 Fit a new split pin to retain the hub nut Do NOT slacken the nut in order to insert the split pin if necessary tighten the nut 3 Fit the road wheel and tighten its securing nuts to the specified torque loading NOTE All Specifications and Torque Lwdings will be found i n TECHNICAL DATA Fig 2 Rear hub ESPRIT IsSlle O A n R ...

Page 205: ...60 ni p ii i100 k p h in the most fovouruhle conditions i s the rei ornniended t i r i speed As a general rule ttrrlvo the speed that wo lcl norrnwli jriven relative to the r w d conditions 2 When folluwing 01 iiii leii L otus recommena rhor you serve rrlo vn iiyhwciy Code or t i t t iu icaiiSafety Council goideiines for vehicle spacing this odvi s t i or ly upplies to spare wheel usage but q w l ...

Page 206: ...STEERING Page til SECTION H Description GENERAL DESCRIPTION STEERING WHEEL INTERMEDIATE COLUMN STEERING COLUMN STEERING COLUMN L OCK IGNITION SWITCH STEERING UNIT ESPRIT Issue 04 78 ...

Page 207: ...SPEERllJG Page H2 ESPRIT ...

Page 208: ...inion end Bush pinion end Steering colurnn assembly Seal plote steering column Gasket seol plote Intermediate steering column assembly Universal joint Spline protection sleeve steering column Spline protection sleeve steering rack Lock ignition switch steering column Steering wheel Collet steering colomn 0 ring Crash pad steering wheel ESPRIT C S t t nnl7R ...

Page 209: ...n are in the straight ahead position then fit steering wheel on to the column also in its straight ahead position ensuring that the splines are fully engaged and that the wheel sits down on the taper 2 Fit the steering wheel plain washers retaining nut and tighten to its specified torque loading see TECHNICAL DATA 3 Replace the steering wheel trim INTERMEDIATE COLUMN To Remove 1 Remove the front w...

Page 210: ...is i s achieved by removing the four small screws two on each side of the shroud and the large screw underneath 4 Disconnect the battery Release the cables from the ignition switch and un screw the bolts securing the multi purpose switches to the column 5 Place a support under the binnacle and unscrew the U1 clamp bracket supporting the bottom front edge of the binnacle remove U clamp cd 6 Remove ...

Page 211: ...5erInarc r n c c h 3 To replace the ignition switch only see Section M ELECTRICAL EQUIP MENT SIEERING UNIT To Remove 1 Support vehicle to allow adequate working space under the front of th vehicle arid remove the front rood wheels 2 Remove the nuts and flat washers and free the ball joints from the stoerirtg arms 3 Remove the intermedicte steering column 4 F r m under the front of the vehicle remo...

Page 212: ... ground so that the front wheels ore clear do NOT move the road wheels quickly from lock to lock as this will cause an hydraulic pressure to build up within the steering unit and may burst or blow off the bellows Toe in 4 r 1 mm 0 156 r 0 031 in Track 1511 mm 59 50 in Steering angles 32 Fig 2 Steering geometry ESPRIT Issue 04 78 ...

Page 213: ......

Page 214: ...YSTEM Page J1 SECTION J Description GENERAL DESCRIPTION FRONT BRAKE PADS REAR BRAKE BLEEDING THE BRAKING SYSTEM MASTER CYLINDER SERVO UNIT PEDAL BOX HANDBRAKE ASSEMBLY Page J4 J4 J8 J l 0 J11 J12 J12 J13 ESPRIT ...

Page 215: ...Fig I Braking system ...

Page 216: ...Way Union Bundy Pipe 131 5 Double Ended Union to Rear 3 Way Union Bundy Pipe 20 01 Front 3 Way Union to Front Hoses Bundy Pipe 26 5 Rear 3 Way Union to Rear Hoses Bundy Pipe 5 5 Front Hose to Front Caliper Handbrake Assy Handbrake Cable Assy Short Handbrake Cable Assy Long Clevis Pin 5 16 X 9 16 Clevis Pin 1 4 X 7 8 Retaining Pin Actuation Rod Handbrake 19 Compensator 20 Hose Servo to Bundy ESPRIT...

Page 217: ...ock to lock as this will cause hydraulic pressure to build up within the steering gear which may cause the rubber bellows to bunt or blow off 2 Remove any accumulated road filth from the area of the brake pads 3 Pull out the pad retaining piri clips A withdraw the retaining pins B antf remove the brake pads C with the stiims Fig 2 Note the position of the dust shield fitted over the brake pads 4 T...

Page 218: ...ehicle to the ground check the brake fluid and top up i f necessary Tighten the wheel nuts to the specified torque loading IMPORTANT After fitting new pads care must be taken when braking brake several times from 50 mph 80 kph to 30 mph 50 kph and only brake fully when system has cooled down If brakes are applied too sharply when new pads have been fitted the surface of the pods will burn and irre...

Page 219: ...BRAKING SYSTEM ESPRIT Issue 04 78 ...

Page 220: ...O FIG 3 Front Coliper RH Front Brake Pads Dust Shield Front Caliper Rear Caliper RH Bolt Primary Bolt Secondory Bushed f Rubber Sleeve Rear Brake Pads Bolts Self Locking Rear Disc Drive Shoft Adaptor Front Disc ESPRIT Issue 04 78 ...

Page 221: ...determined amount of pod wear has taken place a ratchet system extends the mechanical link as the brakes are hydraulically operated keeping the haridbrake system in constant adjustment Resetting the adiustable piston When new pads are fitted i t is necessary to return the mechanically link adjustable piston to its original start position The adjusting mechanism i s a notched spigot onto which four...

Page 222: ...ed and ppds pulled out Support the calipers in such a woy to relieve any strain on the brake hose Before fitting new pads clean the area where the new pods are to be seated but take care nci to damage the dust covers Enst re that the dust covers and retain ing rings are in good condition and fitted securely While pushing primary and c secondary bolts bacc into position check for easy movement and ...

Page 223: ...lb ft Cs Hold the hydraulic housing towards the carrier at a slight angle Then push the r i e ozeinst the snrincr ocd of the C C i etnininc s n t i n lntn the cnrrect nosition enabling the second retaining screw to be fitted Tigthen the retaining screw to torque 4 1 3 9 kpm 30 28 lb ft Operate the brake pedal several tirnes to allow the adiusters to take up the correct brake operating position che...

Page 224: ... 7 Perform the same procedure on the left hand front bleed nipple followed by the right hand rear then the left hand rear WARNING D O NOT USE fluid dispelled during bleeding for tapping up the master cyliner Dispelled fluid contains air and the air contains water there fore contamination would arise if fluid i s re used MASTER CYLINDER To Remove I Place a receptacle under the master cylinder to co...

Page 225: ...der to the servo unit F i C Locate the assembly on the body mounted bracket replace nuts and was he and tighten to the torque specified in the TECHNICAL DATA 3 Reconnect the master cylinder push rod to the brake pedal Check that when the i s held against the stop the holes in the clevis bar and brake pe I are aligned Readjust length of clevis h S necessary and fit clevis pin ond retain with split ...

Page 226: ...the removal procedure Handbrake cable removal 1 Remove the carpet from the s i l l in which the handbrake lever i s fitted 2 Remove the retaining pin in the clevis pin connecting the cable end to the compensator b 3 Disconnect the cable from the lever arm on the rear coliper and withdraw the cable end Release any clips holding down the cable but do not remove complete cable To Replace 1 Tie new ca...

Page 227: ...BRAKlWlG SYSTEM Page J14 Compensator b Fig 5 HondbrakeCable Adiustment i ESPRIT Issue o417a ...

Page 228: ...OLING SYSTEM Page K1 SECTION K Description GENERAL DESCRIPTION COOLING SYSTEM COOLING SYSTEM INHIBITOR RADIATOR THERMOSTAT HEADER TANK MODEL S2 CHARACTERISTICS Page K4 K4 K5 K5 K6 K7 K7 ESPRIT tccpt l nb ...

Page 229: ...ESPRIT lasun nan ...

Page 230: ...al Otter Switch Radiator Fan Thermostat Header Tank Pressure Cap Main Water Pipe Radiator Feed Main Water Pipe Radiator Return Domestic European Main Water Pipe Radiator Return Federal Water Pipe Main to Pump Water Pipe Thermostat to Main Water Pipe Radiator to Main Federal Hose Radiator to Main Pipe Federal 4 off Hose fbdiator to Main Pipe Domestic European Hose Header Tank to Water Pipe Hose A i...

Page 231: ...assis behind the radiator A thermostat switch fitted in the feed pipe from the main thermostat housing corltrols the operation of the electric fans COOLING SYSTEM To Drain 1 Set the air temperature control lower to HOT fully backwards with the engirie running in order to operate the woter tap Switch o fi engine 2 Remove the header tank cop I Turn rcdjntnr Ad i l c v S Tnp in bottom right Domestic ...

Page 232: ...OLING SYSTEM INHIBITOR We recommend a combined antifreeze inhibitor which can be used all year round in the following quantities North America 3 7 litres 6 5 Imp pts 7 8 US pts A l l other territories 2 4 litres 4 3 Imp pts 5 2 US pts Antifreeze inhibiton which are recommended by Lotus Cars Limited are ShelI Shell Safe Union Carbide W 184 4 Antifreeze mix 25 minimum in tempemte climates and in col...

Page 233: ...i s yde rri ed Disconnect the hose frorn the thermostat housiny Remove the two bolts and lift off the thermostat hour Withdraw the thermostat iing Fig 3 Thermostat removal To Rc lace 1 Reverse the removal procedure but note whet refibtin the thermostat the jiggle pin i s located adjacent to the iniet connection to the manifold this ensures the thermostat i s not fouled by the the8l i dt V using ES...

Page 234: ... give an indication that the Otto thennostat has actuated by pulsing momentarily showing that the circuit is functioning correctly Radiator Removal from Vehicles with Air Conditioning NOTE When removing the radiator only i t is not necessary to disconnect the pressurised hoses from the condenser qr l k i n the cooling system 2 Release the clips securing the hoses and disconnect from the mdiotar Di...

Page 235: ...everse the removal procedure but first locate radiator air duct assembly on the side bolts then locate radiator and condenser top bracket screws before tightening all bolts and screws Ensure foam pads are correctly located before finally tightening down ...

Page 236: ...ITH STROMBERG CARBlJRETTERS Description Adjusting Removal Cleaning Overhaul DELLORTO CARBURETTERS Description Adjusting Removal Cleaning 3 Overhaul EVAPORATIVE LOSS CONTROL AIR CLEANER CHOKE CONTROL THROTTLE CABLE CARBURETTER FAULT FINDING MODEL S2 CHARACTERISTICS Poge 14 14 15 16 16 16 18 19 19 114 L18 119 120 L23 123 128 131 134 134 135 135 136 137 138 141 ESPRIT ...

Page 237: ...FUEL SYSTEM Page 2 ESPRIT Issue 04 78 ...

Page 238: ...er Neck Hose Filler Neck to Tank Grommet Filler Neck 0 Ring Cross Feed Pipe Flexible Cross Feed Pipe Tank Vent Pipe Fuel Pump Metalastik Mount Fuel Pipe Tank to Filter Flowlock Fuel Pipe Filter Flowlock to Pump Evapomtive Loss Tank Charcoal Cannister Mounting Bracket inertia Switch Filter Flowlock Valve ESPRIT ...

Page 239: ...ich when operated will need resetting One of two carburation systems are fitted to the engine there i s the twin dual barrel l L L sloe aruugrtl vstiui iu Lutuuget g l t s VI t a w nwt L L I W O L c TECHNICAL DATA or the paragraphs relating to the carburetters i n this section The air cleaner is of the replaceable paper element type where the element is F sandwiched between the two halves of the a...

Page 240: ...ssemblies and replace if necessary Zenith Carburetters 1 Remove the carburetters from the engine 2 Remove and clean the float chambers floats and needle valves with petrol and blow clean with an air line 3 Reploce the needle valves and floats and check the float level Ensure the floats are free to move Using a new gasket reploce the float chambers 4 Using new goskees replace the carburetters on th...

Page 241: ...op of the tank To Replace 1 Fit a new sealing ring and coat the threads of the three retaining screws with Avdelbond A 115 or similar Ensure ali threads are fitted but take care that excess does not fall into tank Tighten screws to 5 to 7 lbs ft only hand tight do not overtGhten as the osket will distort and screw threads may strip 2 Reverse the removal instructions from 4 to 1 FUEL GAUGE Detailed...

Page 242: ...Earthing screw Outlet volve ossembly Vented cover Spring Plastic diophragm barrier 0 ring KEY TO FIG 2 P 16 Perforated diaphragm plate 17 Fuel outlet 18 Deliver chamber 19 Fuel inlet 20 Fuel filter 21 Inlet volve assembly 22 Valve cover 23 Moin diaphragm 24 Main pumping chamber 25 Coil 26 Trunnion 27 Rocker spindle 28 Flexiblewire 29 Tungsten points 30 Non return volve ESPRIT Issue 04 78 ...

Page 243: ...ILTER To Remove 1 The in line filter valve is in the fuel feed pipe from the pump therefore i t i s advisable to hove a new valve available for fitting before removing the existing valve 2 Lift the engine cover to gain access to the valve secured to chassis tubing on the R H side on some vehicles this valve i s situated under the RH engine compartment floor panel 3 Release the two clips securing t...

Page 244: ...e flowlock valve in the clamp on the chassis and reconnect fuel pipes and tighten ZENITH CARBURETTERS DESCRIPTION These carburetters are of the constant depression CD type and opemte on the principle of varying the effective area of choke and jet orifice in accordance with the degree of throttle opening engine speed and engine l w d Fig 3 Cross section of Zenith carburetter ESPRIT I _ _ __ ...

Page 245: ...r at the side of the front corburetter this rotates a disc in the starting device in which a series of holes of different diorneters are drilled In the full rich position all holes will be in communication with the storter circuit and provide the richest mixture A cross teed pipe feeds the rear corburetter Petrol i s drawn from the float chamber via a vertical drilling adjacent to the central main...

Page 246: ...note that there are two positions Winter and Summer on the starting limiting pin This i s the spring loaded knurled headed pin locoted on the side of each starter housing Push down and turn through 90 by the screwdriver slot provided In the Winter position the slot will be horizontol when viewed from the side of the cor whereos in the Summer position the slot will be vertical ESPRIT ...

Page 247: ...djustment of the throttle stop screw which limits the closure of the throttle when the accelerator pedal is released Normal Running The jet needle setting goverrls the correct idle mixture and mixture strength through out the operational range of the engine A feature of the assembly i s the radially located needle which i s biased so that the needle i s i n contact with one side of the jet to ensu...

Page 248: ...etermined by exhaustive tests on bench and rood during original manufacture To maintain correct results i t i s essential that only the recommended needle is vsed Temperature Compensator Testing has shown the need for a temperature compensator operating over a wide range of air valve lift to cater for minor mixture strength variations caused through heat transfer to the carburetter castings An air...

Page 249: ...t is needed when the throttle is suddenly opened To provide this a hydraulic damper i s arranged inside the hollow guide rod of the air valve I he rod itseif i s tiiied with suitable oil engine oil to within a 6 35mm 025in of the end of the rod When the throttle i s suddenly oper ed the immediate upward motion of the air valve i s resisted by the damper For this brief period a temporary increase i...

Page 250: ...vers Rotate the stop screws a further one ond a half complete turns each to open the throttle an equal omount and to provide a basis from which the final idle speed can be set Fig 6 Zenith adjusting screws 2 Ensure fast idle screw i s clear of a m otherwise incorrect synchronisation will result Check olso that the cold start lever i s fully off against the stop with the choke control on the tunnel...

Page 251: ...FUEL SYSTEM age L16 FRONT CARBURETTER ONLY REAR CARBURETTER ONLY Fig 7 Zenith carburetter components ESPRIT ...

Page 252: ...sion nut Lever assembly Nut Washer shakeproaf Washer spacing Lever throttle Bush Lever pick up Washer Throttle spindle rear Butterfly valve Spring throttle return Lever throttle stop Washer Washer shakeproof Nut Screw fost idle Locknut screw Screw throttle stop Bracket starter control Starter control assembly Bracket starter control Clip bracket Gasket starter control Screw cover to body By pass v...

Page 253: ... within the range given in TECHNICAL DATA 1 When correctly set and with the carburetter inverted measure to the hlgb est point of the floats above the main body with the fuel inlet needle on th seating the measurement being 16 17mm Care MUST be taken NOT TO TWIST O R DISTORT the float arms to ensure a constant float level I t I I I I 2 G iidjtst the G C he beiid thcr as wrusn cuniwzir the e n P I ...

Page 254: ... carburetters and carburet ters to airbox backplate CLEANING The carburetters should be cleaned every 12 500 miles 20 000 km using the YELLOW SERVICE PACK one for each curburetter Each pack contains the following items a Float chamber gasket b 0 ring for float chamber plug C Needle valve washer d Adaptor flange carburetter gasket To Clean 1 Remove the carburetters from the engine as previously des...

Page 255: ...re outwards Fit new 0 ring to centre plug and replace tightly i n position Refit carburetters to adaptor flange with 5l l T T S DD Z 10 Top up damper reservoirs with the recommended oil see Section 0 to within in 6 35mm of top of centre rod 11 Refit carburetters and reset controls as described i n ADJUSTING OVERHAUL The carburetters should be overhauled every 25 000 miles 40 000 km using the E 9 S...

Page 256: ...r valve lining up the keyway with the guide screw and gently press into air valve Once strong resistance to further entry i s felt draw the needle in further by turning the needle ad justing screw clockwise Tighten the guide screw ensuring that i t locates i n the keyway in the needle assembly The needle should be drawn into the air valve until its shoulder i s flush with the bottom face of the ai...

Page 257: ...g screw qnd check A S r L I L c n S L valve should return freely Do not strain the bi metal blade or attempt to alter the adiustment Provided the valve i s free replace cover a d flt screws 14 To replace the throttle spindle seals first take off any levers fitted to the spindle ends then carefully prise out the old seals noting how they are fi ted Slide new seals along spindle and press into body ...

Page 258: ...od before fitting Flwt Chamber Removal To prevent the leakage of firel from the float chamber a rubber 0 ring i s situated between the jet cover and the float chamber spigot boss Care should be taken when removing the float chamber to avoid domage to the faces and flats 4 DELLORTO CARBURETTERS DESCRIPTION These carburetters are of the dual barrel side drought type each consisting of two single bar...

Page 259: ...together with their emulsion tubes are accessible after removing the small rectangular cover secured with screws to the top of the f l w t chamber cover A common f l w t chamber is incorporated in each carburetter with twirl floats to reduce the effects of fuel surge actuating o single needle valve which incorporated o damping device to prevent the needle from chattering on its seat The floolh str...

Page 260: ...er with air from hole 5 Arriving at the valve chamber a themixture spreads into the two channels 9 that flow into the main barrels 10 downstream of the throttle butterfly 13 When the starter valve 7 i s closed the communication between the two main barrels and the starter device i s disconnected and by means of the partition 18 the two main barrels are separated 10 Fig 8 Dellorto starting circuit ...

Page 261: ... mixture then passes through the channels 211 to the adiustmerit screws 22 then having been metered to the meln barrels 10 dowr streamof the throttle valves Flg 9 Dellorto idle and progression circuits A t the opening of the throttle valves 13 during the passage from idle to main the mixture arrives at the main barrel8 10 vlo the progression holes 23 ESPRIT ICICIID nr no ...

Page 262: ...s held in position by o spring 30 The diaphragm pumps fuel in two separate circuits through the delivery valves 24 and the pump jets 26 then to the main barrels 10 when the throttle valves are closed the diophrogrn returns to its off position pushed by the spring 3 sucking fuel from the float chamber via volve 25 during this operation Fig l0 Dellorto acceleration circuit The nuts 33 are used to ad...

Page 263: ...ure passes to the main barrels 10 Fig ll Dellorto main circuit ADJUSTING To obtain correct synchrorlisation of the carburetters the following procedure is recommended 1 Ensure the throttle levers are fully returning 2 Release the adiustrnent screw for the throttle valves making contact with the lever 3 Release the screw 3 in the lever 4 to ensure that when pressure i s applied to lever 1 on the re...

Page 264: ...FUEL SYSTEM Page L29 Anti tamper adaptor in poaition on carburettor Sealing Cap Idle Mixture Screw Spring Bras Washer Anti tamper Adaptor y Carburettor Boss Fig l2 Anti tamper Device ...

Page 265: ...gular tunning on all barrels Turning the screw inwards WEAKENS the mixture whereas turning the screw outwards RICHENS the mixture 9 Finally re adjust the engine speed with the screw 2 Anti tamper device I IIU Y S I I V I I V L U I U S I I U S art rtrrea wlrn anrt romper aevtces r o prevenr UnaUtnOrlZecl adjustment of the idle mixture control Fig 12 shows the configuration of the device and to gain...

Page 266: ...Dollorto float chamber level dimension To Remove 1 Remove the air cleaner cover see AIR CLEANER To Remove 2 Disconnect the choke cable throttle coble and return spring 3 Disconnect the breather pipe from the flame trap ot the rear of the cleaner backplate 4 Disconnect the fuel supply pipe to the carburetters 5 Disconnect the vacuum pipe from the carburetters 6 Release the nuts plain woshers and th...

Page 267: ...FUEL SYSTEM Page L32 Fig 15 Dellorto carburetter components ESPRIT ISSM 04 70 ...

Page 268: ...FUEL SYSTEM Page L33 KEY TO FIG 15 Connecting link Fuel filter Needle valve Gosket float chomber Jet slow running Screw idle mixture Gosket pump body Rubber ring throttle screws ESPRIT Issue 04 78 ...

Page 269: ...ARNING Do NOT use a probe or wire to clear the jets as his may I J L 1 C W l l t U l l j S V I UUIIIYtJw 1 1 1 5 1 1 VIIIIba 4 Remove the float chamber covers by releasing their securing screws 5 Remove the remaining jets and clean a e in 2 above Note that the pump et Is concealed beneath a plug on the outside of the carburetter in front of the identification panel Clean the flwts float chambers a...

Page 270: ...catch tank cannot receive petrol via the filler necks of he main tank Petrol vapour obsorbed by the charcwl canister i s Ipurged1by clean air while the engine i s running through throttle edge drillings in the corburetters The system is effectively maintained by renewing the charcoal canister at intervals of every 25 000 miles or 40 000 km AIR CLEANER To Remove d 1 Release the bolts or clips retai...

Page 271: ...pull cable through The outer casing is removed by first releasing i t at the carburetters clamp e 4 then releasing the clamp under the carpet on the tynnel housing and before pulling out outer casing see To Replace To Replace 1 Replacement of the inner cable i s the reversol of the removal procedure cr To replace outer cable first attachthe q new outer cable to the old and then pull through pullin...

Page 272: ...e pulling out the cable see To Replace1 To Replace 1 To replace the cable first attach the new cable to the old and then u l l through under the carpet 2 Attach the clevis at the end of the cable using the pin to the throttle pedal Fixing Studs Accelwetor Pedal A juster Fig 17 Throttle accelerator pedal setting 3 Adjust the inner cable at the carburetters to give the correct free play see below be...

Page 273: ... the MINIMUM AMOUNT N E C E S W to give full throttle openings CARBURETTER FAULT FINDING It i s mssumed that all engine mechanical and or ignition faults have been corrected therefore the ONLY carburetter faults possible ore as follows ZENITH CARBURETTERS Erratic or Poor ldlinq 1 Air valve sticking Check free movement of spring lwded metering needle clean alr valve rod and guides Lubricate air val...

Page 274: ...replaced 6 After reasonable service inspect the throttle spindle seals and thro tle spindle for fracture and wear respectively Replace if necessary 7 Leokage at induction manifold joints Re make joints facing up flanges os required Check that Q rings adoptor flanges to manifold ore correctly located Hesitation or Flat Spot Possible CalJses are as given for Erratic or Poor Idling1 but with the foll...

Page 275: ... Replace cable S starter ler airry Ciean u r r v p o sjr Irregular Firing of Engine 1 incorrect adjustment of mixture screws See DELLOKTO CARBURETTERS ADJUSTING e L jet dirt I IC OCP rlmnn Qn l tighten et 3 Progression holes or idling circuit ducts blocked Thorough1y clean all orifices and ducts 4 Air leak from mounting flange Check mountings are correctly tightened Replace 0 rings if necessary 5 ...

Page 276: ...UNIT To Remove 1 Remove the engine cover 2 Remove RH engine compartment floor p n e l to gain occess to the top of the 81 R H fuel tank 3 Disconnect battery terminals 4 Disconnect sender unit electrical connections 5 Remove clamping ring securing the sender unit in the top of the fuel tank To Replace 1 Fit a new seal replace the clamping ring and tighten with care 2 Reverse the removal instruction...

Page 277: ... C C 8 _ I l L ...

Page 278: ...iption GENERAL DESCRIPTION BULBS AND LIGHT UNIT REPlACEMENT INSTRUMENTS SWITCHES AND CONTROLS COLUMN MOUNTED SWITCHES IGNITION SWITCH RADIO ALTERNATOR BELT ADJUSTMENT RADIO SUPPRESSION FUSES ALTERNATOR MODEL S2 CHARACTERISTICS d ESPRIT issuei2ns ...

Page 279: ...nit Oil pressure Coil Wiper motor Stop light switch Horns two Logic box Fedeml only Flowlock valve Radio speaker Relays a R H of engine compartment uhder rear quarter light b RH rear engine compartment under plastic cover L L _ A 6 V l i Y r UU i erw steering column Left hand front near headlamp motor Top right hand rear corner i n passenger compartment under trim panel Inside glove compartment Ne...

Page 280: ...cedure for remowl is almost identical to that given above sealed beam unit except that after detaching the slotted adaptor the bulb i s removed by dis engagtng the two ends of Its spring retaining clip f r q the tabs on the bulb seating rim 8 4 Replacement of the light unit or bulb i s a reversal of the removal procedure but ensure that the adaptor i s fully entered on the proiections on the bock ...

Page 281: ...ary to remove the four screws securing the rear and stop light lens This lens has lips mauldad along the edges to awl off and secure the inner edges of the other two lenses 2 Unurew the two screws retaining the other lens and lift off 3 Replace the defective bulb s Note that the rear and stop bulb can be fitted one woy only 4 Replace the lenses in the reverse order to above belies li vehicles J go...

Page 282: ...mp assembly from i t s 1x ation to guin access to the bulb 3 Clean off any corrosion which may be on the bulb connection terminals and fit a new bulb lnstrument Panel Warning Lamp see INSTRUMENTS for identification Veglia Instrument Panel 1 Remove the instru ent binnacle see BODY section 2 From the rear tcp of the instrument panel pull out defective bulb a and replace Smlth lnstrument Panel 1 Remo...

Page 283: ...ESPRIT Issue 04 8 Fig 2 Vegiia lnshuments ...

Page 284: ...O FIG 2 Speedometer Tachometer Gauge battery condition Gauge water temperature Gouge oil pressure Gauge fuel Body Warning light panel Printed clnuit Front panel Temperature tmrducer Oil pressure tmncducer 0 1 1pipe Seal ESPRIT ISSW o4ns ...

Page 285: ...instruments become faulty in this instrument panel i t i s necessary to replace the complete panel assembly To Remove 1 Remove the instrument binnacle see BODY section 2 Remove the drive cable from the rear of the speedometer and the electrical conriecioi rrom in CI CLIIT naaro 3 Unscrew and remove complete panel from the mountihg brackets on the scuttle Fitting a new print circuit 1 Cut the circu...

Page 286: ...on from the circuit bmrd To Replace 1 Reverse the removal procedure SWITCHES AND CONTROLS The opemtlon of all inatrument panel 8teerlne column switches and controls is as W followll Comblned ignltlon Starter Swlkh Insert ignltlon key and turn key to position 11 to switch on the ignition circuit and releans the steerfng wheel lock A further turn of the key ogalnst the prlng preuuw 1 to po8 tIon 111...

Page 287: ... motor Direction indicators Headlamps and Horn Switch 1 Horn prah the switch stalk w a r d s the column A of fig 5 to opemte the horn 2 Dlnetion lndlcatm move switch stulk down until it locks to operate the left hand flanhlng indicatola C of fig 5 and lift up stalk fw right hand indlcaton B of flg 5 The switch will cancel autmtically when the steering wheel is returned after executing the turn Fla...

Page 288: ...f the switch stalk E of Fig will give dipped headlights and with the switch pushed forward until i t locks full main beam will be selected These functions are operative only when the lighting switch on the instrument binnacle is in i t s fully down position Fig 6 Windscreen windshield wiper wh her control ESPRIT F ...

Page 289: ... To improve the wiplng o f the screen add 55 cc of solvent Part No A075M6110Z to the reservoir to help remove road dirt and grease Binnacle Illumination Lamps Switch The switch which controls the binnacle illumination is situated i n the bottom left hand corner of the left hand switch panel A resistor is connected across the switch to set the illumination intensity to the correct level Door Window...

Page 290: ...ht hond position on the left hand switch panel When the switch i s actuated all exterior direction indicaton will flash together with the two indicaton on the warning lights panel NOTE it i s illegal to operate the witch when the vehicle i s i n motion Reor Screen Demist Defrost Switch The demist defrost switch is located on the bottom right of the right hand switch panel d The w i t c h when depr...

Page 291: ...rect cable replacement b To Remove 1 The ignttlon switch can only be replaced i n conjunction with the steering lock assembly see Section H To Replace 1 Revens the removal procedure referring to the Wiring Diagromr for correct l cable replacement C RADIO To Remove 1 Rmove the radio control knobs and front ponel 2 Disconnect radio live and earth cables orld oerial lead and withdraw the radio from t...

Page 292: ...bolt B of fig 7 Move the altemator until the correct tension i s achieved then tighten all bolts Run engine briefly switch off and recheck belt tension and readjust if necessory RADIO SUPPRESSION When a radio i s fitted the following suppressors should be fitted to reduce interference COIL 2 microfarad capacitor mounted on bolt with coklt t o positive terminal FUEL PUMP 1 microfarad capacitor moun...

Page 293: ...glove box Access is achieved by prising off the covers exposing four fuses i n each unit with two spares in each All fuses are 35 ampere and protect the following circuits 1 Heoc amp l i f t rnotor s 2 Headlamp full beam Unit 1 3 Right hand sidelights and panel illumination 4 Left hand side 5 Engine cooling fans Unit 2 6 Heater motor indicator flasher and reversing light 7 Horn and hazard flasher ...

Page 294: ...rect c The armature i s free to turn d The battery is fully chorged e The belt tension is correct WARNINGS 7 i Do NOT disconnect the alternator or regulator when the engine i s running ii Do NOT earth the field winding iii Disconnect both terminals to battery when installing or removing the alternator Motorola tlternator 14V 554 a With the ignition turned off connect a C 30V Voltmeter between one ...

Page 295: ...ground The reading should not be greater than 2 volts If reading is more than 2 volts check brushes and if 6 reading i s 0 volts check the regulator connections ignitian lead to switch and indicator lamp d With ignition on and engine not rurining check the regulator circuit by disconnecting the field lead and measuring ftie voltage acrass the field winding The reading should be 2 volts moximum and...

Page 296: ... 19 volts then carry out the following test g g Switch off engine disconnect field winding and connect field terminal to the output terminal B With the 0 30V voltmeter connected between output terminol B ond ground run tne engine at a fast idle speed I f the reading on the voltmeter rises to between 14 and 16 volts then the regulator is deflective and should be re placed I f the reading i s very l...

Page 297: ...NITION ON ENGINE NOT RUNNING V o l t m u rsadlnst Indicate normal mndltlons GULATOR CONNECTED VEHICLE HARNESS a U b T M a FIG 11 WITH IGNITION ON ENGINE RUNNING FASTER THAN IDLE EGUMTOR CONNECTED TO VEHICLE HARNESS All Connections have to be used ...

Page 298: ...ST CIRCUIT b Check the cutput of the alternator using the test circuit shown in fig 12 Adjust the variable resistor for a voltage output of 13 5 wits at a steady engine speed Compare the ammeter reading with the typical octput characteristics graph fig 13 output currant Amp4 Alt r tc Speed Rev Min X 1000 FIG 13 LOAD GRAPH If after checking all leads are connected correctly no output i s obtained f...

Page 299: ...ontrolled from inside the car using the four position joystick and the left and right mirror selector switch Inside each mirror assembly ore motors controlling the vertical and horizdntal planes of the minor Where the wiring loom for the electrical control of the mirrors passes through the body aperture and the inner door panel a grommet Part No X036L6004Z i s fitted A grommet Part No X03686150Z i...

Page 300: ... the screen header rail between the sun visors Although the clock s quartz crystal timing circuit is operational at a l l times when battery connected the display is only l i t when the ignition i s switched on Should the battery ever be disconnected i t will be necessary to reset b the digits on the clock face To reset hours push the rocking bar at the lower edge of the clock on the left hand sid...

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Page 312: ...cription Page GENERAL 02 PRE DELIVERY INSPECTION 02 SCHEDULE OF FREE AFTER SALES SERVICE 500 miles 800 km 03 SCHEDULE OF A SERVICE 5 000 miles 8 000 km 05 SCHEDULE OF B SERVICE 10 000 miles 16 000 km 08 RECOMMENDED LUBRICANTS 011 ESPRIT Issue 04 78 ...

Page 313: ... adiustment Check tightness of wheel nuts Check tyre pressure including spore Check engine idling speed Electrical Check battery electrolyte level Check operation of all lamps Check operation of horns and direction indicators Check operation arid park position of windscreen wiper Check operation of windscreen washer Check operation of all instruments Check operation of headlamps and door windows C...

Page 314: ...ollowing conditions a It i s responsibility of the supplying istributor ik orter dwler to ensure that the car i f delivered to the customer in the best possible condition b A l l cost incurred during the inspection are the responsibility of the supplying distributor importer dealer C Failure to return a signed copy of this inspection to Lotus Cars Limited by the distributor importer dealer may res...

Page 315: ...fuel system for leaks fuel pipe connections on carburetters fuel pump fuel tank and fuel filter for tightness Check entire system for leaks and operation including handbrake and adjust i f necessary Check security of all brake pipes and vacuum pipe connections Top up brake fluid reservoir if law check for cause Check operation of brake fail harid brake warning lamp Check and if necessary top up cl...

Page 316: ... lock Check seat adjustment and operation of seat belts Air Conditioning if fitted Check operation of controls fan speeds and refrigerant for gassing Heater Check operation of controls and fan speeds General W Check engine Transmissfon and drive shafts mounting bolts to specified toque loadings Ensure sbering wheel and upholstery ore free from grease Top up screen washer reservoir SCHEDULE OF A SE...

Page 317: ...dbrake and adjust i f necessary Check security of all broke pipes arid vacuum pipe connections Top up brake fluid reservoir i f low check for cause Check operation of brake fail hand brake warning lamp Check front and rear brake pads for material remaining if down G G L E 3I I MQbA P CCP the y d s Check n i rmn ntlna ho tc nw to their specified torque loading Clutch Ctieck and if necessary top up ...

Page 318: ...s to specified torque locldiilg Check body condition generally including door adjustments Gollrlitt and tuilgclte adjustment opening and closin3 operation of door locks and tailgate lock Check adjustment and operation of secit belts Air Conditioning if fitted Check operation of controls orid fan speeds Check Freon tor gossillg C Heater if fitted Check operation of controls and fun speeds General C...

Page 319: ...n and check mounting bolk for tightness when fitted Check security of all fixings especially engine mounting bolts exhaust manifold arid system and inlet manifold and carbu retter mountings Check carburetters trumpet riuts for tightness Dellorto Check orid adjust slow running mixture orid idle speed Check security and cleanliness of ignition harness joink iricluding alternator and starter motor co...

Page 320: ...e and check condition of bearings and seals Check front disc mounting bolts to their specified toque loodire Electrical Check operation and function of all electrical equipment including headlamps cooling system fans screen wiper screen washer and internal and external lamps Check security of battery terminals and main earth connections Check headlamp alignment and focussing Check electrolyte leve...

Page 321: ...all controls and fan speeds Check engine transmission and drive shafts mounting bolts to specified toque loadicgs Check condition of all moior unit mounting rubbers Ensure steering wheel and u p hoistery are free from grease Top up screen washer reservoir ESPRIT Issue 04 78 ...

Page 322: ...low 2OW 50 lOW 50 Engine below O C Q 10W 40 Havoline Super Uniflow 1ow 40 1OW 30 lOW SO Hypoid 80 12 Multigear Spirax 80EP Esso 6 80 Steering unit Hypoid 90 Multigear Spirax 90EP Gear oil EP90 GX 85W 140 Drive shaft front Duckhams Marfak Shell Esso Hubs LB 10 All purpose Retinox A Multi grease Brake Master Cylinder Reservoir Castrol Girling Universal Brake ond Clutch Fluid Servicing Intervals Afte...

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Page 324: ...HEATING VENTILATION Page P1 SECTION P Description GENERAL DESCRIPTION OPERATION OF CONTROLS HEATER UNIT ASSEMBLY Foge P2 P2 P3 ESPRIT I c r i i n n 70 ...

Page 325: ...ll deliver unheated air at ambient temperature by the ram effect of the vehicle when moving and i s independent of the heater OPERATION OF CONTROLS The air temperature from the heater i s contrilled by the lower lever Air temperature is varied between hot with the lever fully back and external air cold with the lever fully forward Air flow to the screen and footwells i s controlled by the upper le...

Page 326: ...wards to the hot position Select fan speed to suit Cold air to footwell Move upper lever to the forward positionv Move lower lever forwards to the cold position Select fan speed to suit U HEATER UNIT ASSEMBLY To Remove 1 From inside the front compartment remove the twin blower unit side panels to reveal the four screws securing the blower unit 2 Unscrew the four screws securing the twin blower uni...

Page 327: ...de of the b bulkheod and remove the assembly from inside the vehicle To Replace 1 Reverse the removal procedure ond refill the cooling system 2 Check the operation of the heater controls for full movement of the flaps and uniform seating of flops on the seals adjust i f necessary ESPRIT Issue mnn ...

Page 328: ...CLUTCH Page Q1 b SECTION Q Description GfMERbn DESCRIPTION MAINTENANCE ADJUSTMENT CLUTCH ASSEMBLY CLUTCH DRIVEN PLATE RELEASE BEARING ESPRIT Issue 04 78 ...

Page 329: ...agm spring and pressure plate can only be replaced as an assembly The clutch release mechanism i s hydraulically operated through a pendant pedal MAINTENANCE The maintenance required for the clutch system i s confined solely to checking the clutch free play at the specified intervals see Section 0 ADJUSTMENT Fig 2 The clutch i s correctly adjusted when a clearance of 3 mm 0 12 in can be felt at th...

Page 330: ... Tighten each bolt one turn at a time until the specified torque loading is reached see TECHNICAL DATA Remove the dummy input shaft 3 Refit the transmission unit to the engine and check operotion of clutch CLUTCH DRIVEN PLATE d o kemove 1 Remove the clutch ossembly as previous1y described inspea for Wear Check the condition of the pressure plate surface and should i t show any signs of distortion ...

Page 331: ...CbblTCM Page 0 4 ESPRIT Fig 2 Clutch mechanism m ...

Page 332: ...earing 4 Spring retaining release brg fork 5 Release fork 6 Dust cover Fork return spring Ball pivot Adjusting screw fork Fork spring lug Clutch rmster cylinder Clutch slave cylinder Banjo union Banjo bolt Gasket large I D Gasket srmli I D Push rod Flexible pipe ESPRIT I A ...

Page 333: ... may burn off leaving a carbon deposit on the surface of the C facings which will assume a high glaze and produce further slip I nar wiii ne e r h l n n c t h n 0 8 r h n war hin A L I l hides the grain of ttie material b The oil rnay partially burn and leave a resinous deposit on the focings This will produce a tendency for the clutch to be fierce and rnay also cause exterrsive spinning as the su...

Page 334: ... following modification was introduced to improve the durability of the clutch slave cylinder Early Vehicles Gearbox No up to 1164 A modified slave cylinder A075Q4005F with an improved seal and two spacer washers A075W4024F are fitted This slave cylinder is identified by a Red Spot and has its 0 mounting pads machined to give a 4 angle to the horizontal Vehicles Gearbox No 1236 onwards Q Are fitte...

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Page 336: ...EXHAUST SYSTEM Page S1 SECTION S Description GENERAL DESCRIPTION DOWNPIPE SILENCER MANIFOLD Page 54 54 54 55 ESPRIT Issue 04 78 ...

Page 337: ...EXHAUST SYSTEM Page S2 ESPRIT Issue 04 78 ...

Page 338: ...ifold to Head Gasket Manifold to Head Nut Manifold to Head Copperised Stud Manifold to Down Pipe Gasket Manifold to Down Pipe Nut Manifold to Down Pipe Stainless Steel Silencer Heat Shield Fedeml Clamp Strap Heat Shield Federal Plain Washers 8mm Self Lock Nuts Catalyst Heat Shield Assy Federal Cdtal st Heat Shield Clamp Fedeml Screw Shield to Clamp Penny Washer Shakeproof Wosher Down Pipe Heat Shi...

Page 339: ...3 Lift out the twin downpipe and discard the manifold to downpipe gasket To Replace 7 1 Reverse the removal use a new gasket between the downpipe arid manifold A l IC 1 I L 2 A A A V yyl I I L S W U I 1 I U 3 1 1 1 1 1 1 U I I l UYv llt_ll I I I I t I I I I I S U I U I S I Domestic only SILENCER So Remove 1 Unscrew the seven self tapping screws 9 screws on Federal vehicles securing the rear valanc...

Page 340: ...emove 3 Support the engine and release the LII engine mounting bracket i f necessary to enable removal of the manifold 4 Remove the nuts with their plain washers securing the manifold to the cylinder head Remove the manifold and discard the goskets To Replace 1 Reverse the removal instructions but use new gaskets ot the manifold to cylinder head and manifold to downpipe flange joints and new nuts ...

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Page 342: ...S OPERATION Maximum Refrigerated Air Defrost Air to Screen and Footwells Fresh Air from Face Level Vents CHARGING UNlT WITH REFRIGERANT CONDENSER RECEIVER DRIER AIR CONDITIONING UNlT COMPRESSOR RECOMMENDED REFRIGERANT OIL REFRIGERANT LEVEL CHECKING PROCEDlJRE REFRIGERANT QUICK CHECK PROCEDURE Page T4 T4 T5 T5 T5 T6 T6 T7 T9 T9 T9 T10 T10 T11 T12 T13 T15 T17 T17 T18 ESPRIT Issue12 78 ...

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Page 344: ...w Vac Pipe Vacuum Pipe Vacuum Switch Bush and Clip Arsy Opemting Cam Cable Trunnion Binnacle Vent Adaptor Binnacle Vent Demist Outlet Vent Demist Duct Face Level Vent Adaptor Face Level Vent Adaptor Centre Vent Flexible Ducting l Flexible Ducting 1 7 8 Flexible Ducting 24 Fresh Air Flap Recirculation Flap AIR CONDITIONING Page T3 ESPRIT Issue12 78 ...

Page 345: ...acket Receiver Drier Hose Receiver Drier Expansion Valve Hose Expansion Valve Compressor Cowl Condenser Far ABS Fan 10 Fan Motor Fan Cowl and Motor Mounting Vacuum Reservoir Y UUIII r I f J S Elbow l Piece Sleeve Elbow Vacuum Pipe Sleeve Non Return Valve Bracket Vacuum Reservoir Bolt 6mm X 16 Nut Nylac m ...

Page 346: ...AIR CONDITIONING Page T3b ESPRIT Issue12 78 ...

Page 347: ...ans of checking the system is full of refrigerant and operating correctly High pressure liquid enters the expansion valve where i t eqpaqds rapdily changing from high to low pressure liquid As the refrigerant expands in 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 IOW pressure vapourised...

Page 348: ...uid to the core of the evaporotor exceeds requirement the outlet temperature drops this i s sensed via the capillary tube closing down the expansion valve and reducing the flow of liquid refrigerant The expansion volve is pre set internally and has no external adjustment TEMPERATURE CONTROL SWITCH d The air conditioning temperature control switch is located on the right hand side of the instrument...

Page 349: ... a naked flame produces a toxic gas which will also attack metal 6 Do NOT expose the eyes to vapourised or liquid refrigerant ALWAYS wear safety goggles when handling refrigerarit REFRIGERANT PIPEWORK The following precautions should be read carefully before carrying out any work on the refrigerant pipework L 1 When disconnecting any pipe or flexible connection the system MUST FIRST BE DISCHARGED ...

Page 350: ...on structed from aluminium and copper 6 A l l joints should be coated with refrigeration oil BEFORE making any connections as this will aid seating 7 A l l pipes and hoses MUST BE FREE from any kinking The efficiency of the system con be impaired by a single kink or restriction Flexible hoses should not be bent t o o radius which is less thon ten times the diameter of i C4 the hose CONTROLS OPERAT...

Page 351: ...OFWAC COL0 OFF F OFWAC d REFRIGERATED AIR OFWAC v 0 F COL0 AMBIENT F OPWAG v OEF COLD DEFROST Fig 3 Facia Controls ESPRIT lssue 1 Z E e ...

Page 352: ...specially high humidity a white vapour will issue intermittently from the face level vents this i s normal and should cause no concern Defrost Move upper lever backward DEF position Move lower lever backward HOT DEF position Temperature Control Switch to OFF Switch fan speed to Fast Close face level vents for best defrost performance d A i r to Screen and Footwells Move upper lever between the cen...

Page 353: ...C 28 iRChPc Of EtrCgry Ul for NI LESS I A 20 minutes The hold period of 20 minutes will allow any leaks to be seen easily and purge the system of any moisture The system is charged with 1 4kg 31bs of Refrigerant 12 which is made up from Freon 12 and Arcton 12 After charging the system i t must be checked for gassing using the following procedure 1 Start the engine and adjust engine rpeed to 1200 r...

Page 354: ...the leak test be performed in a halogen free atmosphere with no significant droughts of air CONDENSER To Remove 1 Depressurise the air conditioning system by slackening the union nut securing the pipe to the receiver drier Take the necessary precautions described under d the heading Refrigerant Pipework 2 From under the front of the vehicle release the plpes from each side of the condenser Take th...

Page 355: ...nnections on receiver drier To Replace To Replace 1 Reverse the removal proceduis taking care to connect the union end marked IN an the receiver drier to the pipe to the condenser Before connecting pipe unions add one ounce of refrigerant oil into the system Lubricate the flared ends and union threads with refrigerant oil See under heading Refrigerant Lubricants for recommended refrigerant oils DO...

Page 356: ... Remove the small vent flap S ThiDugh the aperture now exposed when small vent flap removed remove the screw securing the water valve to the top of the pedal box Release hose clip on inlet water hose from underneath the vehicle and pull off Inlet water hose Do not removethe other hose on the valve i t i s connected to the unit Disconnect the cantrol cable to the water valve at the solderless nippl...

Page 357: ... the vehicle 15 Remove the bonnet release mechanism lever 1 16 To simplify removal of the wit remove the bottom support bracket cmyletely Remove the two screws securing the bracket to the base of the nozzle wing and remove the two rivets attaching the bracket to the tunnel 17 From the tee connector in the vacuum control piping remove the pipe from the engine This pipe is identified as the pipe whi...

Page 358: ...similar With the engine running and before the bulkhead cover is fitted check that the vacuum actuators operate the flaps correctly Fitting a new air conditioning unit 1 Ensure there i s a clearance between the vacuum control valve assembly and the bonnet release bar The air conditioning unit should be slightly tilted away from the b valve assembly make sure this i s so before marking the position...

Page 359: ...cedure Refill the compressor with the same amount of new oil as that drained during removal plus an additional one fluid ourrce Before assembling the pipework lubricate the flared ends and union threads with refrigerant ail 2 Recharge the system as previously described 3 The compressor drive belt should be correctly tensioned to give a total movement of 9mm 0 35ins on the longest run of belt L To ...

Page 360: ...conditioning unit 3 fluid 02s REFRIGERANT LEVEL CHECKING PROCEDURE J To check the refrigerant oil level during servicing of the Compressor or the system proceed nisr 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 belng careful not to lose any oil 3 Place the angle gauge Sankyo Part No 32448 across the top o...

Page 361: ...cated on the dipstick do not fall between the figures given in the above table odd or subtract oil until the mid range figure i s achieved l 9 Refit oil filler and tighten to 6 to 9 ft Ibs 0 8 to 1 2kg m Ensure the 1 0 ring i s not twisted and that the 0 ring seating i s clean before fitting Do not overtighten if plug leak fit a new 0 ring Re charge the system with refrigerant as previously descri...

Page 362: ... Temperature differential noted at compressor System empty or Switch off engine Re charge nearly empty system with refrigerant and check with leok detector Even though a Check by disconnecting the differential is compressor clutch connection noted there exists at upper front while observing a possibility of the sight glass overcharge A n overcharge filled system will result i n poor cooling Refrig...

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