Lotus Esprit S3 (1980) manual

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Publication Part No. A082T0327Z @ Lotus Cars Ltd June 1986 This publication has been designed primarily for Lotus Dealers, and will be updated by the issue of Service Bulletins to Lotus Dealen when necessary. Lotus policy is one of continuous product improvement an right is reserved to alter specificatiom at any time with01 notice. Whllst every car[...]

CONTENTS TURBO ESPRIT h ESPRIT S3 (Prior '88 M.Y.) Subject Vehicle Identification Technical Data -. Engine - Esprit S3 - Engine - Turbo - Vehicle Body - Paint Procedure - Bodycare & Repair - Body Fittings Front Suspension - Prior to '85 M.Y. - '85 M.Y. onwards Rear Suspension Section See overleaf TDA TDB TDD Engine EB Engine Mana[...]

VEHICLE IDENTIFICATICN NCPMBER @. ', The Vehicle Identification Number WIN) is stamped on a plate fixed to the right or left hand front wheelarch inside the front luggage canpartment. This number is repeated on the right hand side of the chassis front frame, visible fran within the right hand front wheelarch. . . VI N Plate on wheelarch VIN st[...]

DCMESTIC & EXFORT ,a 2= 49 States (USA) 3= California 4= Sweden/ ~ustralia/ Switzerland 5= Japaii 6= 50 States (USA) Engine Type 907= 2 Litre 910= 2.2 Turbo 912= 2.2 N/A I Manufacturer 1dktifier SCC 123 J Vehicle Type 079= Esprit S2 - Year &-80 B= 1981 C= 1982 D= 1983 E= 1984 FZ 1385 G= 1986 H= 1987 I= 1988 I Serial Number I 082= Tu?bo ES[...]

SECTION TD A' TECHNICAL DATA SECTION TD A - ENGINE TYPE 9071912 Engine- Number Engine Specification Cylinder Head Camshafts & Valve Mechanism Crankshaft Main Bearing Configuration Flywheel Connecting Rod Gudgeon Pin Piston & Liner lubrication System Del lorto Carburettors Zenith Carburetton Ignition System Distributor & lgnition Ti[...]

Page 2 SECTION .TD A Before commencing work on any Lotus engine, first check the engine number and prefix letters to establish the engine specification. This number is stamped on the right hand rear of the cylinder block, above the starter motor, and is duplicated on the vehicle identification plate fixed to either the right or left hand inner whee[...]

SECTION TD A Page 3 FIRST PREFIX lJTmm3 (907 X - Danestic Std. W - Danestic A/C Y - Danestic PAS L - Danestic A/C & PAS AML - Danestic A/C, PAS & Auto. (907) P - U.S.A. Std. N - U.S.A. A/C Z - U.S.A. PAS M - U.S.A. A/C & PAS (907 ) C - Esprit D - Elite/Eclat (907 ) A - Esprit B - Elite/Eclat (907) G - Elite/Eclat H - Esprit SECOND PREFI[...]

Page 4 SECTION TD A ENGINE Max. rpm of engine No, of cylinders Firing order Capacity - type 907 - type 91 2 Stroke - type 907 - type 91 2 Bore (nominal) Compression ratio Compression pressure ~n~ine number location 69.2mm (2.72 in.) 76.2mm (3.00 in.) spec. 1,3,5 9.5 : 1 spec.2,4,6,7,8 8.4:1 spec. 9 9.44: 1 0 spec. 10 10.9 : 1 spec. 1,3,5,9 2 11 .2 [...]

SECTION TD A CAMSHAFTS AND VALVE TIMING cam Type Designation Spec.No. 1 groove 1270" 10.350" (110' (red I$II;-I between pulley cam hsg. plain 1 272" ( 0 .34011 ( 110" 1 red plain 2 groove plain 777.. . . 444.... E;~ 1 ;let M.O.P. degrees ATDC* Lift * All cams are symnetrical opening closing VALVES ~arn Pulley Tirning Dot An[...]

Valve seat insert bore (cont .) c 0.025 mm (0.001 in) ' - lnlet - Exhaust F 0.050 mm (0.002 in) - Inlet - Exhaust F 0.127 mm (0.005 in) - Inlet - Exhaust Outside diameter of seat S ta ndard - Inlet t- 0.025 mm (0.001 in) t 0.050 mrn (0.002 in) t 0.127mm (0.005 in) dalve Springs TY pe - Exhaust - lnlet - Exhaust - lnlet - Exhaust - lnlet - Exha[...]

SECTION TD A Page 7 Valve Guider Length - lnlet - Exhaust Internal diameter (to ream after fitting) Bore in head - lnlet and Exhaust Standard + 0.025 mm. (0.001 in.) + 0.050 mm. (0.002 in.) + 0.127 mm. (0.005 in.) Outside diameter of guide 10 Standard + 0.025 mm. (0.001 in.) + 0.050 mm. (0.002 in.) + 0.127 mm. (0.005 in.) Camshafts End float - Dime[...]

Page 8 Crankshaft Balance (inc. flywheel and clutch) Diameter - Main journal (No.1 . to 4 inc.) - Main journal (NO. 5 only) - Crankpin End float - Dimension - Max wear limit - Control I ed by Bearings (main) - Number - Type Static clearance* Max. undersize for regrind Within 15 gr.cm. (0.2 oz. in.) 63.487 - 63.51 3 mm. (2.4995 - 2.5005 in.) 63.500 [...]

SECTION TD A Page 9 Flywheel (fixed) Max run out (lateral) Starter ring gear - run out - lateral - radial Flexplate Flywheel Max. run out (radial) Max. run out (lateral) at clutch face 0.10 mm. (0.004 in.) . . 0.41 mm. (0.016 in.) 0.15 mm. (0.006 in.) 0.18 mm. (0.007 in.) 0.13 mm. (0.005 in.) Connecting Rod ia TY pe 'I' section Material S[...]

Page 70 SECTION TD A . . . .. , , Piston - (Cont .) Identification I 2.0 LITRE 907 %:I C.R 2.0 LITRE 907 8.4:l CR. 2.2 LITRE 912. 944:l CR. 2-2 UTRE 912 10.9:l CR. 2.2 LITRE 910 751 CR. 2.2 LITRE 9l0 Bal CR. - Rings 2 compression,. 1 oil control - Diameter 907 - grade 'A' 95.1 66/95.179 rnrn (3.7467/3.7472 i n) 907 - grade 'B' 9[...]

SECTION TD A ' Piston (cont.) Page 7 7 -Piston ring to groove clearance 907/912 Std - Compression0.038/0.089 mm (0.0015/0.0035 in) - Oil control 0.038/0.064 mm (0.001 5/O.OO25 in) 91 2 H C - compression O.O4O/O. 072 mm (0.001 6/O. 0028 i n) - Oil control 0.020/0.052 mm (0.0008/0.0020 in) Cyl i nder Liner - Type Wet, slip fit - Material - 907/9[...]

Carburettor Type (2 off 1 -US P~NO. (Frmtj, (Rear) Tag No. ~Frmt 1 (Rear)' Paint Spat on 'Dellorto' Chake Main Jet Main Air Corrector Jet Main Rnulsion Tube Idle Jet Idle Jet Holder Float Weight Float Setting Height (mi) Float Needle Valve Pump Jet Starter Jet .: Starter 'Emulsion Tube Paer Jet Sla ~mning Speed (rpn) Idle03Level[...]

Page 73 Zenith Carburetton Type and number Needle Spring Col our Damper Oil Zenith 175/CD SE (two) BIDK Blue SAE 20W/50 Letus part number - Spec 2 front B907E0791 W rear B907E0792W - Spec 4,6,7,8 front C907E0791 F* rear C907E0792F* * Red paint spot on air valve housing. These carbs are'to the same ;a specification as the B pref-ix cork, except[...]

SECTION TD A Page 74 IGNITION SYSTEM TY pe - Spec.1,2,3,4,5,6 Csil and Distributor - Spec 7, 8, 9 (Eprit up Coil and distributor with infra-red solid to 1983. Not Excel) state ' Lumeni tion' system. - Spec 9 (Esprit 1983 on Coil and distributor with Lucas and Excel only) Constant Energy System Number. 1 cyl inder . Toward front Ignition a[...]

SECTION TD A Distributor Page' 75 Direction of rotation (from drive end) Clockwise Drive Offset dog Contact breaker gap (where fitted) 0.35 - 0.40 mm. (0.014 - 0.016 in.) Contact breaker spring tension 0.51 - 0.68 kg.f. (18 - 24 0z.f.) (measured at contact points) Cam dwell angle Firing angles Capacitor value 60° 2 3' changed during 1 97[...]

Page 7.6 SECTION TD A TURQUE LOADING FIGURES ENGINE Cylinder head (tighten cold) both pain (front and rear) nuts (oiled thread) 3 pain (in middle) nuts (oiled threads) Sparking plugs Cams haft coven Camshaft housing Cams haft sprockets Main bearing housing - 907 - 12mm (oiled threads) - 912 - 12mm - 907/912 - 8mm Crank haf t pu l i ey Connecting ro[...]

. . SECTION TD A Page 73 Zenith Carburettors Type and number Zenith 175/CD SE (two) Need 1 e BIDK Spring Col our Damper Oil Letus part nurilber - Spec 2 Blue SAE 20W/50 front B907EO791 W rear B907E0792W - Spec 4,6,7,8 front C907E0791 F* rear C907E0792F" * Red paint spot on air valve housing. These carbs are to the same specification as the 0 p[...]

Page 14 - Spec 1,2,3,4,5,6 Coil and Distributor - Spec 7, 8, 9 (Esprit up Coil and distributor with infra-red solid to 1983. Not Excel) state 'Lumeni tion' system. - Spec 9 (Esprit 1983 on Coil and distributor with Lucm and Excel only) Constant Energy System Number 1 cylinder Toward front lgni tian advance control Fully automa tic Sparkin[...]

Page 75 Distributor - Direction of rotation (from drive end) Clockwise Drive Offset dog Contact breaker gap (where fitted) 0.35 - 0.40 mm. (0.014 - 0.016 in.) Contact breaker spring tension 0.51 - 0.68 kg.f. (18 - 24 0z.f.) (measured at contact points) Cam dwell angle - 25D, 23D 0 - 45D, 43D Firing angles Capacitor value 60° f 3' changed duri[...]

TORQUE LOADING FIGURES ENGINE Cylinder head (tighten cold) both pairs (front and rear) nuts (oiled thread) 3 pain (in middle) nuts (oiled threads) Sparking plugs Camshaft covers Cams haft hous ing Cams haft sprockets Main bearing housing - 907 - 12mm (oiled threads) - 912 - 12mm - 907/912 - 8mm ( Crankshaft pulley ( Connecting rod (big end) ccos (o[...]

TECHNICAL DATA SECTION TD B - ENGINE TYPE 910 i. Engine Number Engine Specification Cyl inder Head Camshafts & Valve Timing Valve Gear Avxil iory Shaft Cranks haft Main Bearing Configuration Flywheel Gnnecting Rod .. Gudgeon Pin Piston & Liner ~ubrlca tion System Del lorto Carburettor Ignition System ~ercpe Settings I DEC 1986 . Page 7 Page[...]

Page 2 SECTION TD B . . Before commencing work on any Lotus engine, first check the engine number and, prefix letters to establish the engine specification. This number is stamped on the right hand rear of the cylinder block, above the starter motor, and is duplicated on the vehicle identification plate fixed to either the right or left hand inner [...]

j. SECTION TD B ENGINE Page 3 Type designation Max. rpm of engine 7,000 No . of cylinders Firing order Capacity Stroke 76.2mm (3.00 in.) Bore (nominal) 95.29mm (3.75 in.) Compression mtio - Std. 7.5 : 1 J. - H.C. Compression pressure - Std. - H.C. 2 8.8 bar (1 30 Ib/in ) minimum 2 9.5 bar (140 Ib/in ) minimum Maximum boost pressure - Std. 2 0.55 ba[...]

Page 4 SECTION TD B *! CAMSHAFTS AND VALVE TIMING * All cams are symmetrical opening/closing VALVES Cam Type Designation Angle of valve seats and faces FDIAAC/~ Spec.No. Domestic & Export USA 1 (Carb) I I USA I (HCI) Head diameter - lnlet - Exhaust Identif. on shank between pulley & 107 107 107 Stem diameter - l nlet Inlet M.O.P. ATDC* Dura[...]

SECTION TD B Page 5 Outside diameter of seat Standard - Inlet - Exhaust + 0.025 mm (0.001 in) - lnlet - Exhaust + 0.050 mm (0.002 in) - lnlet - Exhaust + O.12i'mm (0.005 in) - lnlet - Exhaust 37.325/37,350 mm. (1.4695/1 .4705 in .) 34.380/34.405 mm . (1 .3535/1 .35& in .) 37.350/37.375 mm. (1 .4705/1 .4715 in.) 34.405/34,430 mm . (1 .I 345[...]

Page 6 Cams hafts End float - Dimension - Control led by Running clearance (except front) (front only) Cam Followers Bore in camshaft housings Outside diameter AUXILIARY SHAFT SECTION TD 5 0-1 0.03 - 0.20 mm. (0.001'- 0.008 in.) Sel ec tive thrust washers 0.050 - 0.090 mm (0.0020 - 0.0035 in.) 0.075 - 0.115 mm (0.0030 - 0.0040 in.) 34.925 - 34[...]

SECTION TD B Page 7 - ~ : .. ,, . . . , FLYWHEEL . Max. axial run-out over clutch face 0.05 mm. (0.002 in.) CONNECTING ROD TY ~e 'I' section Material Steel forging 1 Distance between centres 1 39.70 mm . (5.500 in .) + - 0.25 mm. (0.001 in.) Bearings (big end) - Type Steel backed, leaded bronze - Static clearance * 0.025 - 0.081 mm. (0.00[...]

Page 8 ' SECTION TD B - Rf ng gap 91 0 Std . . - top 0.38/0,51 mm (0.015/0.020 in) - second 0.48/0,61 mm (0.019/0.024 in) - scraper (rails) 0.38/1 .I4 mm (0.015/0.045 in). -- - oil control 0.30/0.60 mm (0.01 2j0.024 in) -Piston ring to groove clearance 91 0 Std. - Compression 0,038/0.089 mm (0.001 5/0.0035 in) - Oil control 0 .O38/O .064 mm (0[...]

DELLORTO CARBURETTORS Carburettor Type (2 off) Tag No. - Front - Rear Lotus Part No. - Front - Rear Choke Main Jet Main Air Corrector Jet Main Emulsion Tube Idle Jet Idle Jet Holder Float Weight Float Setting Height Needle Valve Pump Jet Starter Jet Starter Emulsion Tube Slow Running Speed Idle CO Level (hot) Pump Delivery Power Jet Fuel Delivery P[...]

Page 70 SECTION TD B ..-... DISTRIBUTOR & IGNITION TIMING ( all figures + 2" Ignition Timing to be set at Static Idle Ign. Speed Timing Ign. Timing Distributor TVpe Vacuum Capsule crank0 Centrifugal Advance Characteristics Dan/ Export Prior '87 MY 43D Lumeni tion or Lucas Constant En=%' 45m4 Lucas Constant E~ewY Belw 1,000 nil 2,[...]

SECTION TD B Page 11 DEC TORQUE LOADING FIGURES ENGINE Cylinder head (tighten cold) both pain (front and rear) nuts 3 pairs (in middle) nuts Sparking plugs Cams haft covers Cams haft housings Cams haft sprockets Main bearing housing - 12 mm (Dry Sump) Main bearing housing - 12 mm (Wet Sump) - 8 mm Gankhaft pulley Connecting rod (big end) caps Flywh[...]

SECTION' TD D TECHNICAL DATA Page 1 SECTION TD D - VEHICLE, ESPRIT 53 6. TURBO - Page - Dimensions Capacities Suspension Steering Clukh Transmission Cool ing System Brakes Wheels & Tyres Electrical Equipment Torque Settings[...]

Page 2 DIMENSIONS SECTION TD D Overall Length (Series 3) 4225 mm (166.3 in.) (Turbo) 4290 mm (169 in. ) Ge rall Width 1860 mm (73.3 in.) OverallHeight (Series3) 1111 mm (43.7in.) (Turbo - European) 1118 mm (44.0in.) (Turbo - Federal) 1130 mm (44.5 in.) Wheel base 2438 mm (96.0 in.) Front Track (14 in. wheels) 1544 mm (60.8 in.) (15in.CompomotiveWhe[...]

SECTION TD D Page 3 a SUSPENSION Front (Prior to '85 M.Y .); Upper wishbone and lower transverse link with anti-roll. Co-axial coil spring and telescopic damper, Chassis height below chassis-front crossmember 170 mm for checking suspension geometry. Camber 0' 30' negative ' 0' 15' Castor 3' 2 0' 30' ( wi[...]

Page 4 CLUTCH Release mechanism Master cylinder bore diameter (not LHD S3) LHD S3 Sl ave cylinder bore diameter Friction plate - diameter - S3 - Turbo - Number of springs. Free Play at release lever - S3 (prior to '85) - S3 ('85 on) & Turbo Fifth Fourth Third Second First Reverse Final Drive Gear Speedometer gears - Driving gear - Dri[...]

SECTION TD D BRAKES a Type Brake Discs Diameter Page 5 Disc front, inboard disc rear, servo assisted dual hydraulic circuit. Thickness, nomina 1 Up to ,I84 model year Thickness, minimum -I '85 model year Solid Front 265mm . (10.4 in) 12.7mm (0.50 in) Run-out, maximum Ventilated Front 258mm (10.2 in) Solid Rear 275mm (10.8 in) Solid Rear 275mm [...]

Page 6 SEC T/ON TO D 15" Tyre Replacement Cars 1985 Model Year onwards: Goodyear 'NCT' tyres of a new specification were introduced on 1985 Model Year Esprit S3 and Turbo models, together with a revised front suspension. For 1985 M.Y. and later models it is essential that ONLY either the new specification Goodyear 'NCT' tyr[...]

SECTION TD D ELECTRICAL EQUl PMENT Alternator - Series 3 & Dom/Exp Turbo - USA Turbo Starter Motor - type - drive - brush spring tension - light running current - lock torque Battery - type - Dom/Exp prior '85 MY - Dom/Exp '85 &I86 MY - USA prior '86 MY - Dom/Exp '87 MY on - USA '86 MY on 3 - performance - Chloride [...]

Page 8 SECTION TD D Rear Suspension & Drive Shafts kgf .m 1bf.ft. * Radius arm to rubber mounting Radius arm to hub carrier t Top link to chassis t Top link to hub carrier i Lower link to chassis 3) Lower link to hub carrier Drive Shaft bolts Drive shaft adaptor to gearbox Radius arm mounting to chassis x Damper top stem Rear hub nut Wheel nuts[...]

Page 7 BODY -- PAINT PROCEDURE SECTION BA - ALL MODELS Paint Code List Essential Working Practice Preparation for Primer Polyurethane Primer Sprayer Preparation for Colour Coat Nitro- Cellulose Colour Spraying P42O /P42 1 Acrylic Polyurethane Spraying P422 Acrylic Polyurethane Spraying Intercoat Rectification Nitro- Cellulose Paint Rectification Ac[...]

Page 2 SECTION BA BA 1 - PAINT CODES Before commencing any paint work on a Lotus car, first check the paint code number stamped on the lower left hand corner of the vehicle identification plate under the front bonnet. Paint codes with an 'I,' prefix indicate nitro-cellulose paint for which two suppliers reference numbers are sometimes quo[...]

SECTION PAINT CODE COLOUR British Racing Green French Blue Wedgewood Blue Cirrus White Carnival Red Burnt Sand Lotus Yellow Matt Black Royal Blue Bahama Yellow Regency Red Lagoon Blue Pistachio Lime Green Colarado Orange Black Gloss Ford Tawny Renault Mid Green Glacier Blue Sable Indigo Blue SUPPLIER SPEC NO. -- PJ 0170Y2790 ICI PO302854 PJ 6170212[...]

Page 4 SECTION BA PA I NT CODE L 21 L 22 L 23 L 24 L 25 L 26 L 27 L 28 L 29 L 30 L 31 L 32 L 33 L 34 L 35 L 36 L 37 L 38 L 39 L 40 L 41 L 42 L 43 L 44 L 45 L 46 L 47 COLOUR Purple Bitter Green Sepia Brown Firecracker Monaco White Olympic Blue Gunmet a1 Rover Brown Mint Green Garnet Lemon Yellow Oxford Blue Ford Signal Orange Roman Bronze Brazil Sil[...]

SECTION BA Page 5 PAINT CODE COLOUR Gold Laquer Silver Laquer Silver Metallic Jewels S .01 White Repair Cellulose S 02 Signal Red Repair Cellulose S 03 Lemon Yellow Repair Cellulose S 04 Orange Repair Cellulose S 05 Oxford Blue Repair Cellulose Blue Oxford Black Silver Diamond Gold Viper Green Bermuda Blue Roman Bronze Lotus Bronze Martini Green Me[...]

Page 6 SECTION BA PAINT CODE A 13 A 14 A -15 A 16 A 17 A 18 A 19 A 20 A 21 A 22 A 23 A 24 A 25 A 26 A 27 A 28 A 29 A 30 A 31 A 32 A 33 A 34 A 35 A 36 A 37 A 38 A 39 A 40 A 41 A 42 A 43 A 44 A 45 SUPPLIER SPEC. NO. LOTUS PART NO. REMARKS Tabac Altair Green Helleblasl Essex Blue ICI P4229781 ICI P4220182 ICI P4220183 ICI P4220146 IPJ 2 Pack Essex Blu[...]

SECTION BA Page 7 BA 2 - ESSENTIAL WORKING PRACTICE 1. Caution Autocolour 2K hardener P210-760 (used with all ICI two pack P acrylic-polyurethane systems) contains reactive isocyanate, a small portion of which is volatile. Vapour should not be allowed to accumulate in a confined or badly ventilated space. The spray mist is harmful by inhalation and[...]

Page 8 SECTION BA 5. Oven temperatures, and temperatures in the spray booth, Tak Rag booth and main working areas should be checked daily, and periodic measurements of panel temperature carried out. It is absolutely essential that any surface to be sprayed is absolutely clean, dry and free from dust or sludge. After any and each surface covering tr[...]

SECTION BA Page 9 3. Exit oven and allow to air cool. While the mouldings are still warm prick out and mark all defects. When cool rectify the defects with P38 filler. Dry rub down with 80 grade paper (Carborundum)confining flatting to the rectified surface only. Dry flat the entire area with 240 grade paper (Carborundurn). Before polyurethane prim[...]

Page 70 SECTION BA '* 4. Enter the curing oven for a minimum of 20 minutes at 88OC (190°F) panel temperature. Exit oven and allow to air cool. 5. Inspect and rectify any further surface defects with P38 filler. Dry flat the filler with a flat pad of 80 grade paper (Carborundum) confine this to the filled area only. Finally dry flat the entire[...]

SECTION BA Page 11 9. Wet flat with hand blocks using 360 grade paper (Carborundum) removing all traces of orange peel. Do not rub through the polyurethane as this will mean a recycle of the body or component. The wet flatting medium should be 1/8 pint of Finadet No. 1 to 2 gallons clean water for this operation. This solution should be changed fre[...]

Page 72 SECTION B A. BA 6 - BODY & COMPONENT NITRO-CELLULOSE COLOUR COAT Mono Colours: ICI PO30 Type low bake cellulose Metallic colours: ICI PO31 Type low bake cellulose 1. Mix paint as follows:- Mono Colours - ICI PO30 paint 1 part by volume ICI P105 0082 converter thinner 1 part by volume. Viscosity 23 to 27 seconds BS 4 cup at 18 OC (65OF) [...]

SECTION BA Page 73 3. cont..... Spraying should be carried out with a Binks Bhllows 230 gun set up as follows:- Deionised air noxxle - Polonium 210'(to be changed yearly) Material nozzle - 446 Needle valve - 49 Air nozzle - 63PE We film thickness 5 thou. 4. Transfer the body and components to the curing oven and cure for 50 minutes at 8Z°C (1[...]

Page 14 12. Using I.C.1. 2B rubbing compound machine polish the entire painted surfaces. Keep the polishing mop moist, do not allow compound to dry on the mop as scratching may result. Clean the mop frequently, where possible the mop should be moved in a fore and aft direction. 13. Hand polish the body and components using clean woven cloth and mir[...]

SECTION BA Page 75 - Use two operators with guns balanced at 6 ft 'P' test - Blow down interior surfaces with filtered air - Spray a mist coat inside the body to lay remaining dust - Tak Rag to remove all traces of surface dust - Blow down external surfaces with filtered air. - Spray one single coat - Allow to flash off for 10 minutes. Fo[...]

Page 76 SECTION BA 'a 6. Exit oven and allow to air cool. Flat the painted surface using 1200 grade paper (3M). Use 1/4 pint Finadet No. 1 to 2 gallons of clean water as the flatting medium. 7. Using ICI 25 rubbing compound, machine polish the entire painted surface. Keep the polishing mop moist, do not allow polish to dry on the mop as scratc[...]

SECTION BA Page 77 1. Mix 420 Line Monaco White Paint ICI P420 7517 Monaco White 4 parts by volume ICI P210 760 Hardener 2 parts ICI 850 1197 Thinners to 20 sec BS4 cup 1 part N.B. This paint is a curing material with a pot life of 5 hours. 2. Using a pressure pot system & and Binks 230 spray gun: Spray 2 single coats leaving 5 minutes flash of[...]

Page 78 9. Mix clear lacquer as below:- ICI PI90 0379 Clear coat 4 parts by volume ICI P210 0760 Hardener 2 parts by volume ICI P850 1212 Thinner 2 parts by volume Viscosity 23 to 27 seconds BS4 cup at 18OC (65OF) material temperature. If necessary add more P850 - 1212 thinner to achieve this viscosity. 10. Spray one single lacquer coat over all pa[...]

SECTION BA Page 79 BA 9 BODY & COMPONENT INTERCOAT RECTIFICATION PROCEDURES 1. For small area rectification problems remove the gloss from the area to be filled using 400 grade paper (3M) wet. Dry thoroughly and apply cellulose stopper A03686327. This must be left for a minimum period of 30 minutes at shop temperature 16OC (60°F). Wet flat usi[...]

Page 20 SECTION BA 4. Thoroughly dry the body and components after filler/stopper rectification and solvent wipe the rectified areas using Flowline Wax and Grease Remover. Tak Rag these areas to remove all traces of dust. 5. Mix polyurethane primer as below:- P.U. Primer A075B6124 25 parts by volume P.U. Catalyst X036B6137 5 parts by volume P.U. Re[...]

SECTION BA Page 2 1 9. Wash off with clean water (hbse and brush) and remove all traces of rubbing sludge. Dry thoroughly inside and out and ensure that all traces of water is removed from all fixtures and bobbins as this will cause blistering on the 2nd colour pass. Thoroughly Cacuum both inside and outside of the car and components before colour [...]

Page 22 B. Scars or sinkages cont . . . . Ensure the area is dust free and screed the defect with cellulose stopper A036B6327. Allow to cure under infra red heating at 24 inches from the surface at a panel temperature of 60°C, (140°F) for 30 minutes. Allow to air cool and wet flat using soap lubricant, hand block with 400 grade paper (3M). Blow i[...]

SECTION BA Page 23 C. Gel Cracks cont .... The next operation is polyurethane primer spraying. It is important that all cellulose is removed from areas which require polyurethane. Dry the area fully and solvent wipe using isopropanol. Tak Rag thoroughly to remove surface dust. Mix polyurethane primer as follows:- P.U.Primer A075B6124 25 parts by vo[...]

Page 24 SECTION BA E. Chips and Scratches -- Edge/corner chips These should be touched in with an artist brush using paint mixed as follows:- PO30 type paint - 40 parts by volume A036B6385 222 thinner 60 parts by volume Allow to air dry then fully cure using Infra red lamps 24 inches from panel surface giving 60°C (140°F) for 30 minutes allow to [...]

SECTION BA Page 25 BA 11 - ACRYLIC POLYURETHANE PAINT RECTIFICATION A. Orange Peel or scratches caused by compounding These defects should be removed using ICI 2B rubbing compound. Use a machine mop keeping the mop moist and where possible moving the mop in a fore and aft direction. Continue the polishing using 'T-Cut', and a fresh polish[...]

Page 26 Scars or sinkages cont... . Mix colour paint as follows:- ICI P421 paint 4 parts by volume ICI P210 760 hardener 2 parts by volume ICI P850 1212 thinner 2 parts by volume. Viscosity 23-27 seconds BS4 cup at 18OC material temperature. If necessary add more P850-1212 thinner to achieve this viscosity. Mix clear lacquer as follows:- ICI P190-0[...]

SECTION BA Page 27 D. Blisters cont.. .. If the defect extends lower than the paint film it will be necessary to use P38, polyurethane primer, primer/surfacer and paint as for the gel crack defect described in C above. E. Chips and Scratches Where possible these can be treated by respraying both colour and clear lacquer as in B above but if necessa[...]

Page 28 SECTION BA 1. Preparation. Use 400 grit carburundum paper to wet flat the panel and remove all surface irregularities. Do not rub through the primer (A082B4429V, ICI P571/5000). 2. Co1,our Paint Application. For metallic colours: Colour paint P421 5 parts by volume Flex Aid A089B6121V P100/2001 1 part by volume Hardener A076B606 1V P210/076[...]

SECTION BA Page 29 NOTE RRIM components can only be stoved if jig supports are - used to prevent distortion. Where jigs are not available, the paint may be air dried at room temperature for 10 to 12 hours minimum. Parts should not be fitted for 24 hours. BA13 - PEARLESCENT WHITE PAINT PROCEDURE Cars finished in 'Pearlescent Whitef with paint c[...]

Page 30 SECTION BA 2. Pearlescent Finish: A089B6184~ ICI P421-7865 Mixing Ratio : Pearlescent ' 5 pbv Flexaid PlOO 2001 1 pbv Hardener P210 0760 1.5 pbv Thinners P850 1212 to spraying viscosity Spraying viscosity is 16-18 secs. BS4 cup at 18'~ material temperature. Spray 2 single passes to obtain a film thickness of 1 thou. approx. 5 min [...]

BODY -- BODYCARE AND REPAIR SECTION BB - ALL MODELS Owners Handbook Extract; Lotus Composite Body Features Bodycare General Description Accident Damage Assessment Resin Mix Basic Bonds and Joints Headlamp Bowls and Surrounds Pin Holes or Air Voids Distortion or Wrinkling Split Bonds Replacement Sections Positioning Replacement Panels Bobbins (Metal[...]

Page 2 BB 1 - LOTUS COMPOSITE BODY FEATURES (Owners Handbook Extract) Lotus Cars Limited are acknowledgdleaders in the field of composite moulding design and manufacturing techniques, having developed methods which are now used under license throughout the world. These brief notes introduce some features of the construction and service properties o[...]

SECTION BB Page The outer surface of a composite panel is sealed by a thin layer of 'gel coat'. If the panel is deflected beyond its limits of flexibility the gel coat will be overstressed and cracks will result, although the panel will return to its original shape. A steel panel similary treated would become permanently dented. The crack[...]

Page 4 BB 2 - BODYCARE SECTION BB (Owners Handbook Extract) The finish of your Lotus is extremely resistant to all normal forms of atmospheric attack. Provided the simple maintenance procedure summarised below is followed, it will retain its gloss, colour and protective properties throughout the life of the vehicle. However, car finishes are not ch[...]

SECTION BB Page 5 Ventilation Water lying on the paint surface for lengthy periods will penetrate the paint film. Although the effects will not be visible immediately, this will in fact cause a deterioration in the protective properties of the paint film. If a car is garaged, good ventilation must be provided. Otherwise storage outside on a hard st[...]

Page 6 Alloy Wheels It is recommended that these are washed with the preparation as is used to wash the bodywork. Use a brusH having nylon bristles only. During the winter months, particularly when salt has been used on the roads for the dispersal of snow and ice, remove all wheels, including spare, and wash thoroughly to remove all accummulated ro[...]

SECTION 55 Page 7 BB 3 - GENERAL DESCRIPl'ION The basis of the vehicle comprises a one piece moulded composite material bodyshell which straddles a fabricated steel backbone chassis, and is bolted to it via integral alloy bobbins at several widespread mounting points. Whilst the chassis carries all the major structural loads, the body is used [...]

Page 8 A front end impact, for example, at the bulkhead to split without visible. may easily cause the bonds the defect being easily To facilitate a closer examination it may be necessary to remove parts and components to determine the extent of the damage. When determing the size of the replacement panels to be ordered, make sure the new panels, w[...]

SECTION BB Page 9 When the repair has fully cured (hardened), and NOT BEFORE, remove the joining plates from the exterior surface. Sand out the top exposed joint, feathering outwards from the join line, removing any old paint in the process. Fill the depression with rovings and resin, and whilst still wet, lay over a thin layer of chopped-strand ma[...]

Page 70 SECTION BB SUPERFICIAL DEFECT REPAIRS BB 8 - PIN HOLES OR AIR VOIDS - It is difficult to overcome air voids and pin holes when a hand lay-up repair is carried out, but, as all body components 0 0 are heated to 82 C (180 F), the maximum service temperature, before painting, these imperfections will show up. Any air voids located in this mann[...]

SECTION BB . . Page 7 7 they can extend and become serious.' The split.should be peeled open a little further, roughen up the inside flange surfaces with a hacksaw blade and insert the appropriate type of bonding resin before clamping up. Clamping pressure should always be applied evenly, using a small slip of wood or metal if dimpling of the [...]

Page I2 SECTION BB proposed to cut the panels and study these lines thoroughly to see that :- a) any damaged or slightly damaged panel which would be useful in the aligning of another major panel will not be removed or, b) on single skinned areas in particular the proposed outline traverses longitudinal, lateral and horizontal definition points to [...]

SECTION BB Page 73 Bobbins Pulling Out This could be caused by overloading e.g. accident damage. Where the bobbin and its surrounding area is accessible from the rough side of the laminates either naturally or by cutting non-weakening access holes, the remedy is to improvise a local mould in wood or glass fibre of the body surrounding the finished [...]

Page 74 SECTION BB Stripped Threads Whilst their oval section will prevent these bobbins from turning in normal use they may loosen if too much tightening pressure is applied, or when an attempt is made to tap them out to a large diameter. If a thread is damaged or stripped an attempt should be made to drill the thread clear and use a bolt and lock[...]

SECTION BB Page 75 ~ayu~ Around Bobbins a) it is important that build-up around bobbins is as previously described as bobbins by nature of their application are subjected to high loads, and will break out of the surrounding fibre glass if not bonded in correctly. b) Bobbins must be bolted to mould after "mould release agent" has been appl[...]

Page 16 SECTION BB BB 14 - BODY MOUNTING POINTS When mounting the body to the chassis, it may be necessary to use spacing washers between certain mounting points in order to level the.body and/or prevent pre-stressing the body structure, with subsequent distortion and gel crazing. Excel Twelve fixings are used to attach the body to the chassis. All[...]

Page 17 ., , When fitting an old body onto a new chassis, or new body or body section onto an old chassis, care must be taken to attuin computability by one of the following methods. 'Old' body ('laminated in' type bobbins) onto new chassis: Fit 12 x 28 x 2.5 plaln washer A075W9031 F between chassis and body. I Use was her A075W[...]

EXCEL Also anti-roll bar fixing, Access to nut from within head1 amp pod we1 1. n FRONT - REAR - Just ahead of front seat. Just ahead of rear seat. y in position. Drill with body in position. Body Bobbin tapped M10. (Blind fix within rear I seat foam double skin) Drill chassis before Sides of engine bay. fitting body- Below fuel tank in boot. ( RH [...]

SECTION BB Page 79 Esprit. Twelve fixings are used to attach the body to the chassis. All chassis fixing points are plain holes except numbers 13 & 14 (Federal only) which are tapped M10. Holes1 & 2 (8mm) and 3 & 4 (10mm) are drilled with the body in position. Aluminium 'bobbins' are used in the body at all mounting points exc[...]

FRONT ESPRIT REAR - v Front of footwells. Chassis drilled with body in position.[...]

SECTION BD BODY - Page I SECTION BD - ESPRIT S3 & TURBO Operat ion ,Page Windscreen Replacement Tailgate Glass and Finishers Rear Bulkhead Glass Rear Quarter Glass Door Window Frame Door Drop Glass Door Glass External Weatherstrip Door Quarter Light Glass Door Shell Headlamp Pods Front Bonnet Panel Tailgate Front Bumper Rear Bumper and Spoiler [...]

Page 2 BD.l - WINDSCREEN REPLACEMENT. The windscreen is bonded to the body aperture with "Betaseal" adhesive/sealant. The following procedure must be adhered to in detail, paying particular attention to the cleaning and priming operations and using materials supplied with Betaseal Kit, A075B6158J. NOTE: It is likely that the screen bright[...]

- - - SECTION BD Page 3 4. Remove excess Betaseal from the screen aperture with a sharp blade. Note that it is not necessary to remove all traces of the sealant but a uniform surface must be available for bonding the new screen. 5. Dry fit the screen and examine the screen/body joint conformity. If necessary, use props to support the central portio[...]

Page 4 SECTION BD a 11. Cut the Betaseal application nozzle as shown below. A. Cut off top of nozzle at a height of 70 mm as shown. By At a height of 63mm cut horizontally across to the centre line. From the top, cut vertically downwards along the centre line to meet first cut as shown. C. Measure width of horizontal cut from inside surface to the [...]

Page 5 Push in bottom of Betaseal cartridge and remove desiccant Pierce membrane in cartridge thread, screw on application nozzle and insert in cartridge gun. Holding the gun at a right angle to the edge of the glass and leaning slightly inboard, extrude a continuous bead of Betaseal on the perimeter of the glass, using the edge of the glass and sh[...]

Page 6 Dry fit the screen bright finishers and adjust the length and corners of the top finisher if required. Abrade the underside of the finishers to remove the anodised surface and then score to produce a key for the adhesive. Degrease surfaces using acetone or methylated spirit. Adhesive to be used is 3M's 8101 parts A & B, part numbers[...]

Page 7 i ii) iii) iv) v) vi) vii) viii) ix ) x Contents of Betaseal Kit.AO75B6158J. One part adhesive sealant Betaseal 71904 in a 300 cc cartridge, standard viscosity. Cartridge applicator nozzle. Glass primer applicator bottle. Glass primer applicator head. Glass primer applicator felt pad. Glass primer, black, 84132-11. Wipe Cleaner No. 4. Piano [...]

Page 8 SECTION BD BD.3. - REAR BULKHEAD GLASS. The rear bulkhead glass is bonded to its composite surround using either Solbit thermo-electric or Betaseal polyurethane bonding medium. The surround is then screwed to the timber bulkhead. To replace glass. Release both seatbelts from their sill mounting points, and on Federal cars, the tailgate relea[...]

SECTION BD Page 9 Cut a 1.3 metre length of 8 mm Solbit and strip each end to expose 12 mm (0.5 in.) of the internal copper wire. Connect the ends to a variable transformer and apply 9 volts to the Solbit until its surface is tacky. Disconnect Solbit from power source. Starting at the centre top, apply the Solbit around the quarter light aperture a[...]

Page 70 SECTION BD in longitudinal channels on the door beam so that the window frame must be eased off the bolts before it may be withdrawn with glass, from the door. BD.6. - DOOR DROP GLASS. Remove the door window frame from the door (BD.5.) It may prove possible to remove the lift channel from the glass after applying 3 volts to the Solbit therm[...]

SECTION BD Page 7 7 6. Position channel on lower edge of glass with operating arm guide to the inside (carriage plate bracket to rear) and the rear end of channel 120 mm from rear edge of glass.. 7. Reconnect electrical supply to the Solbit and as it starts to flow, push channel fully onto glass. Continue to apply current for a further five minutes[...]

Page 72 SECTION BD Drill out the pop rivets to re.place the rubber seal. When refitting, apply a thin bead of Silastic to the top edge of the door shell before installing the weatherstrip assembly. Ensure the seal lies against the glass before tightening nuts. Overtightening nuts will distort the finisher. BD.8. - DOOR QUARTER LIGHT GLASS. 1. to re[...]

SECTION BD Page 73 window frame. Continue to apply current for a further six minutes whilst keeping the glass central in the frame channel and smoothing out excessive Solbit to leave a smooth surface level with the edge of the window frame . 8. Disconnect power source, cut Solbit ends flush with the corners of the glass and replace door window fram[...]

Page 14 SECTION BD Domestic and ROW cars use a body mounted ball joint on the outboard 0 side, and on the inboard side, a hiilge pin pivotting in bushes moun- ted both in the pod and body, and carrying on its 'overhung' outboard end, the bonnet hinge. Pivot bush Pivot bush Bonnet hinge . Outboard ball joint 0 8 SERIES 3 and Dornestic/Row [...]

SECTION BD Page 75 Always check headlamp beam setting efter any pod adjustment is made since the pod up position will also be altered. BD.ll - FRONT BONNET PANEL. The front bonnet panel is hinged at its front edge by two individual hinges on DOM/ROW cars and by a cross linkage bar on Federal vehicles. The hinge pivots are incorporated with the head[...]

Page anchorage position of the gas struts was changed from the tailgate aperture (early models) to the front engine bay in order to improve opening assistance. apping plate Removal The tailgate is most easily removed by releasing the gas struts and then removing the hinge blade to tailgate bolts. Note that the tapping plate for the hinges is retain[...]

SECTION BD Page 79 The carburettor air box is fed with air via an intake silencer located above the right hand fuel tank and a Venturi hose strapped to the wheelarch. Air is thus drawn from the rear luggage compartment into which is fed fresh air from the left hand luggage compartment vent, connected to the left hand 'ear' intake vent. In[...]

Page 20 BD.16. - DECAL POSITIONING ESPRIT S3 - Early '84 Model Year TA I LG ATE NOSE[...]

SECTION BD Page 2 1 ESPRIT 53 - Prior to '% Model Year (Eucept ~arl~ '84 Model Year) FRONT REAR QUARTER Blend into natural contour (similar at all wheelarches) I NOSE -[...]

Page 22 ESPRIT S3 - '85 Model Year On L REAR QUARTER SECTION BD Waistli ne Fi nisher 1 Stripe NOSE FRONT BUMPER[...]

ESSEX TURBO Waistline finisher 8omm / 85mm 86mm damn 25mm (40mm for Lotus logo opposite side) No lower 12mm chromc stripe behim3 rear wheelarch. I 23mm Nose badge[...]

Page 24 TURBO - Prior to '85 Model Year NOTE On Dom/~oW models, the - size of the 'Turbo Esprit ' decals was reduced during 1987 from an overall decal height of 160mm to 116m as used on Federal cars. SEC JlON BD Left Lib hand! 115mm I side No yap between lower door stripes stripe and joint line. Bonnet shut line 150mm Federal 8Omm ~o[...]

SECT'0N BD TURBO - '85 Model Year On SIDE DECAL Waistline Finisher Page 25 gA 20mm from 7 bottom edge Stripe Wrapped around Wheelarch Stripe Wrapped around Cut Flush to I Cut Flush to emper edges NOSE Nose Badge FRONT BUMPER[...]

Page 26 SECTION BD BD. 17 - GLASS ROOF ABUTMENT In early 1985, a positive stop abutment was added to the glass roof rear catch support brackets, such that the roof is clamped shut against two rubber buffers. An improved 'over centre1 catch action results in mire rigid retention of the roof panel with less liability for rattles and squeaks. The[...]

SECTION CB Page 7 FRONT SUSPENSION SECTION CB - ESPRIT S3 & TURBO : PRIOR TO '85 MODEL YEAR General Description Lubrication Geometry Castor Ad jus tment Front Wheel Alignment Front suspension Disassembly Front Hub Adjustment Wheel Bearing Replacement Operation Page 2/3 4 4 5 6 6 6 7[...]

nt Suspension - General Layout i[...]

Page 3 GENERAL DESCRIPTION The front suspension is fully independent with upper wishbones, single lower links, and an anti-roll bar providing longitudinal location for the lower links. Co-axial coil springs and oil filled telescopic dampers react on the lower link. A stub axle secured in each vertical link, carries the wheel hub on two taper roller[...]

Page 4 CB.1 . - LUBRICATION The only items of the front suspension requiring periodic lubrication, are the front wheel bearings and the lower trunnion swivel ioint. At the recommended service interval, repack the hub with grease, (See Section C and lubricate the lower trunnions. Lower Trunnions: It is ESSENTIAL that a recommended EP90 grade oil is [...]

. SECTION CB Page 5 'a CB.3. - CASTOR ADJUSTMENT Castor adjustment is affected by fitting shims between the anti-roll bar mountings and the chassis. Two types of mounting have been used. i) . Up to Vl N 82/85D 1 262, 82/85 A/E/G/~/s0410 exc . 0399 and 0400 C/F, B/C/F/K 0103. Spacer washers A075W4028Zf 2.5 mm thick, are fitted between the mount[...]

Page 6 CB.4. - FRONT WHEEL ALIGNMENT To adjust the front wheel alignment, slacken the track rod end locknuts and steering rack bellows outer clips. Turn each track rod the same amount, without damaging the surface and after tightening the locknuts check that the same number of threads are left showing at each side. When the adjustment is correct ti[...]

SECTION CB CB.7. - WHEEL BEARING REPLACEMENT Page 7 1 . Remove the road wheel. Release the caliper fixing bolts, and support caliper clear of disc without straining brake hose. 2. Remove hub dust cap (A) split pin (B), nut (C), washer (D) and pull off the hub assembly (E) completewith bearings. Prise out the oil seal from the inboard side of the hu[...]

SECTION CC Page I FRONT SUSPENSI 0,N SECTION CC - ESPRIT S3 & TURBO: 1985 MODEL YEAR ONWARDS General Description Geometry Castor Ad justment Suspension Disassembly Front Wheel Bearings Operation Page - - 2 to4 CCI 4 CC2 4/5 CC3. 5/6 CC4 6/7[...]

Layout of Front Suspension -[...]

1 , Verttcal Link 2. Steering Arm 3. : Setscrew, M12 x 35, Arm/Link 4. Spring -Washer, Arm/Link 5. Bolt, M12 x 45, Arm/Link 6. Nut, Nyloc, MI2 7. Shield, Brake Disc 8. Setscrew, Disc Shield 9. Flat Washer, Disc Shield 10. Front Hub 11 . Inboard Bearing, Front Hub 12. Outboard Bearing, Front Hub 13. Brake Disc, Ventilated 14. Bolt, Brake Disc to Hub[...]

Page 4 GENERAL DESCRIPTION SECTION CC a The front suspension is fully independent with upper and lower wishbones together with concentric damper/spring assemblies and an anti-roll bar. A stub axle, integral with the non-handed vertical link (hub carrier) carries each front hub on two taper roller bearings, adjustable for endfloat. CC. 1 - GEOMETRY [...]

SECTION CC Page 5 Caution in all cases ensure that the top wishbone pivot stud and ball joint bolts have sufficient engagement through their ~~loc nuts. If necessary, replace the pivot bolt front Nyloc and locknut with two iocknuts (i .e. one Nyloc at rear and two locknuts at front). A 5mm longer ball joint outer bolt (M8 x 65) is available part no[...]

Page 6 SECTION CC Suspension Re-assembl y On re-assembly, ensure that the upper and lower wishbone to chassis pivot bolts, and the damper to lower wishbone bolts, are tightened only with the car at ride height. Emure that plastic blanking plug A089U6089F is fitted into the open rear end of the lower wishbone front tube. CC. 4 - FRONT WHEEL BEARINGS[...]

,. SECTION CC a: Page 7 7. lnserttheinboardbearingcentreandretainbypressinginthe inner oil seal . 8. Refit the hub onto the stub axle. Torque spindle nut to 3.0 kgf .m (22 Ibf . ft) whilst rotating the hub to centra lise the bearings. Loosen 'a the nut, and retighten using only your hand on the 30mm socket. With a suitable spring balance, chec[...]

SECTION DB REAR SUSPENSION Page 7 SECTION DB - ESPRIT S3 & TURBO Opera tion General Description - Geometry DBI Rear Wheel Alignment DB2 Rear Suspension Reassembly D B3 Rear Wheel Bearing Removal DM Rear Wheel Bearing Installation DB5 Drive Shaft C.V. Joint Boot Replacement D BC Page[...]

atear Suspension - General Layout[...]

1. Rear Hub 2. Stud, Wheel 3. Nut, HubRetaining 4. Split Pin, Hub Nut 5. Cone, Hub Retention 4. Bearing, Rear Wheel Key to Rear Suspension General Layout Drawing 7. Circl ip, Bearing Retaining 8. . Spacer, Driveshaft/Bearing 9. Drive Shaft, Outboard :- 1'0. Drive Shaft, l ntermediate . . 11 . . . -Adaptor, Driveshaft 1 2. - ff ub Carrier - 13.[...]

Page 4 SECTION DB GENERAL DESCRIPTION a The rear suspension is fully independent with single upper and lower transverse links and box section trailing radius arms. Co-axial coil springs and oil filled telescopic dampers act on the aluminium alloy hub carrier. An outboard drive shaft is carried in each hub carrier on a single sealed for life dual ra[...]

'0 SECTION DB Page 5 Rear wheel alignment is adjusted by transferring shim washers between the inner and outer sides of the radius arm at its front mounting. Spacer plate Shim washers If correct adjustment cannot be obtained by transference of the shim washers, spacer plates may be used between the radius arm mounting and the chassis in the fo[...]

Page 6 SECTION DB DB.4. - REAR WHEEL BEARING REMOVAL 1 . Remove hub carrier assembly from car. 2. Remove split pin and hub retaining nut. Tap loose and remove the conical spacer. 3. Using a suitable puller remove the hub. 4. With the hub carrier on the bed of a press, press out the outboard driveshaft and spacer. 5. Remove circlip retaining bearing[...]

SECTION DB Page 7 with the shoulder in the housing. Apply load to the outer track of the bearing only. Fit a new bearing retention circlip into the housing and allow to cool naturally to ambient temperature. Support the outboard driveshaft on the bed of a press, and fit the spacer over the Shaft,. larger end towards the flange. Press the hub.carrie[...]

Page 8 .7. Fit- new circlip supplied in boot kit and ensure it is iully seated in -shaft groove. 8. Use half grease supplied to pack inboard (rubber boot) side of joint, and fit rubber boot onto joint emuring smaller end of boot is seated in shaft groove. 9. Fit both boot retaining clip as tightly as possible by had before crimping with pliers. i 0[...]

Page I ENGINE SECTION EA - 907/912/910 inc. FEDERAL General Description Lubrication Engine Tune (NOT Federal Turbo) Compression Check Camshaft Covers Camshafts Valve Clearances Toothed Belt Guard Camshaft Driving Belt Driving Belt Yensioner Cylinder Head Valves Decarbonise Cylinder Head and Pistons Valve Seat Inserts Valve Guides Crankshaft 'V[...]

[...]

SECTION EA Page 3 The engine which is inclined at 45' is a die-cast all alloy 4 cylinder, with wet cylinder liners and twin overhead camshaft in a cross flow cylinder head. Pent roof combustion chambers are used with 4 valves (two inlet and two exhaust) having seprate ports, per cylinder. The valves have replacebble guides arid seat inserts an[...]

Page 4 SECTION EA On dry sump Turbo Esprit models a sepemte belt driven oil pump assembly is used, fixed tb the right hand side of the main bearing panel. The assembly consists of two scavenge pump and a pressure pump all mounted on a common axis and supported by the scavenge manifold. The two scavenge pump draw oil out from the sump via the scaven[...]

Page 5 - EA .2. - ENGINE TUNE (NOT Federal Turbo) Pull off the sparking plug leads and remove the plugs. Check the cylinder compressions. Clean the plugs and reset the gaps to the dimensions given in TECHNICAL DATA, or if the electrodes are badly burnt, fit new plugs and re-connect the leads. . . If contact breaker points are fitted: Remove the ign[...]

Page 6 EA.3. - COMPRESSION CHECK SECTION €A Warm the engine t9 its normal operating temperature. Switch 'off' the engine and remove all sparking plugs. Note: before removing spark plugs ensure that plug wells are free of any foreign matter. Set throttles to fully open position. Using proprietary compression testing equipment, place the [...]

SECTION EA a EA.5. - CAMSHAFTS Page 7 . To Remove 1 . Remove upper section of belt guard(Section EA .7 .)(front engined can only) 2. Remove the camshaft covers (Section EA .4.) 3. Check all valve clearances(Secti0n EA .6 .)noting any which require adjustment. Remove the timing be1 t (Section EA .8 .) On engines equipped with air 4* iniection, remov[...]

Page 8 SECTION EA 8. Remove the magnets and release cam followers from their locations. Place them in their respective fitting positions, noting that the cam follower shims are almost always 'stuck' to the underside of the cam follower. If they are not, then they will be 'stuck' to the top of the valve stems. Keep the shim with [...]

SECTION EA Page 9 9. Hold the camshaft sprocket in a vice having fibre protected jaws, and support the carrshaft with the other hand. On engines equipped with an air pump, release the nut, and pull ofthe 'V' pulley with hub, from the rear end of the camshaft. Remove the two bolts and washers which secure the rear cover to the housing, and[...]

Page 70 SEC77ON EA 1. Smear a 1 ittle graphite grease on the bearing surfaces of the camshaft housing; insert camshaft into its housing from the front and fit a new front oil seal . Fig. 8 - Camshaft oil OI L seal fitted SEAL Emure oil seal is flush with outer face of housing. If seal is fitted to the shoulder inside housing the oil drain hole woul[...]

SECTION EA Refit the toothed belt snu!her (where fitted) loosley onto inlet camshaft housing, with the eccentric sleeve fitted on the lower stud, and 'Loctite' applied to the nut threads. If it has been removed, refit the woodruff key to the front end of the camshaft, and replace camhaft sprocket together with its large plain washer sprin[...]

Page 72 SECTION EA On engines from engine number 11276, and earlier engines if fitted with the later camshaft housing with a recess machined around the oil feed for an '0' ring : Seal between the cylinder head and cam housing with Loctite 504 gasket eliminator and an '0' ring fitted over the roll pin dowel. Before applying new g[...]

. - - - SECTION EA Page 7 7 Refit the toothed belt snu!her (where fitted) loosley onto inlet camshaft housing, with the eccentric sleeve fitted on the lower stud, and 'Loctite' applied to the nut threads. If it has been removed, refit the woodruff key to the front end of the camshaft, and replace camshaft sprocket together with its large [...]

Page 72 SECTION EA On engines from engine number 11276, and earlier engines if fitted with the later camshaft housing with a recess machined around the oil feed for an '0' ring: Seal between the cylinder head and cam housing with Loctite 504 gasket eliminator and an '0' ring fitted over the rol l pin dowel . Before applying new [...]

SECTION EA Page 73 Check valve clearances and adjust if necessary (section EA -6 .) Replace camshaft covers (Section EA .4 .) Re-align timing marks on the camshaft sprockets (Fig. 13) Turn the crankshaft back to TDC, and the timing sprocket to align the rotor arm with the previously made reference mark. Fit the toothed belt onto the sprocket with t[...]

Page 74 SECTION EA . . ~a follower and the camshaft heel. The ccrrect clearance is given in TECHNICAL DATA. 3. Check all valve clearances, noting any which require adjustment. To Ad just Remove the camshafts intact in their housings. (refer to Section EA .5 .) Remove each adjusting shim where the clearance requires adjustment . Substitute a shim gi[...]

[...]

-. . SECTION EA Page 1 7. 4. Remove bolt on inlet camshaft cover, securing the belt guard bracket to the engine, and remove upper section. Lower Section 1 . Remove the air duct from between the engine and the radiator (see Section 'K') . 2. Remove the top section of the guard. 3, Remove the alternator drive belt and if fitted, the air con[...]

Page 78 SECTION EA . Fig. 11 - Engine timing marks & Burrouahs wuae in -<itifin[...]

. Page 20 , , ,. . . SECTfON EA '0 t '0 Timing marks in line through centre of pulleys fication. E~~~~ Fig. 13 - Sprocket positions wi th Number 1 cylinder at TDC.[...]

SECTION EA Page 19 Take a further two readings at intervals of 120 crankshaft degrees, turning only a in normal operating direction. The correct belt tension setting for all engines where NO air pump is driven off the back of the belt is: 90 - 95 units, cold. (120 - 125 units hot). If the reading falls outside this range, adjust the temion as follo[...]

SECTION EA Page 2 1 4. a). Release the belt tension by releasing the securing nut on manual tensionen. b). On semi-automatic tensioners, release the alternator and adjusting strap if necessary to gain access to the tensioner adjusting screw. c) . Slacken off locknut and release adjusting screw (spring seat) by turning it anti-clockwise until the ad[...]

Page 22 SECTION €A also applies to engines where the air pump is driven from the back of the toothed belt. Do not under any circumstances attempt to remove locking pin from the tensioner assembly, other than when unit is installed on an engine with timing be1 t in position. 5. Remove toothed be1 t from sprockets. NOTE: Do NOT turn the camshafts w[...]

SECTION EA Page 23 EA.10. - CYLINDER HEAD To Remove (Naturally Aspirated) Disconnect the battery (see Section 'MI). Drain the cooling system (see Section 'Kt). Remove the air duct from in front of the engine (see Section 'K') . (Elite/Eclat). Release the clip securing the air trunking to the airbox and remove airbox outer cover,[...]

SECTION EA a[...]

SECTION EA Page 25 cylinder head and retain the head gasket on 912 engines for reference on @ rebuild. Do NOT lay the cylinder head face down on the bench without first covering the bench with a protective material otherwise the mating face of the cylinder head could be damaged. 14. Do NOT turn the engine without FIRST fitting cylinder liner clamps[...]

Page 26 , . . .. SECTION EA head face down on the bench without first covering the bench with a protective material, otherwise the mating face of the cylinder head could be damaged. Do NOT turn the engine without first fitting cylinder liner clamps, otherwise the linen could be pushed from their locations. To Replace 1. Remove the cylinder liner cl[...]

SECTION EA Page 27 7. Close coolant drain tap on radiator and refill the cooling system, with a inhibitor/anti freeze solution. 8. Check engine oil, start engine and allow to reach its normal operating temperature. Adjust slow running speed and mixture, and ignition timing. Check for oil and coolant leaks while engine is running. Thoroughly check f[...]

Page 28 SECTION EA Remove all carbon deposits from +he cylinder head combustion chamber faces, inlet and exhaust ports, piston crowns and valve heads. A ring of carbon should be left around the periphery of each piston crown. The TOP of the cylinder liners should NOT be touched. Clean each valve thoroughly and carefully examine for pitting. Valves [...]

SECTION EA Page 29 collapse. In the case of a stubborn seat, it is permissable after milling to start the seat on its way to removal by inserting a suitable drift through the appropriate port and gently tapping the seat from its recess. Ensure that the recess in the cylinder head is ENTIRELY FREE OF FOREIG N MATTER, otherwise the new insert willNOT[...]

Page 30 3. With the aid of Special Tool (05A or MA), press the insert into place, ensuring that the seat FACES TOWARDS the combustion chamber. Allow the cylinder head to cool naturally in the air. 4. Re-build and refit the cylinder head. EA.14. - VALVE GUIDES Check the valve spring seat adjacent to each guide bore for a '1 ', '2&apos[...]

SECTION EA Page 3 1 To Replace 1 . Reverse the removal procedure. Torque retaining screw to 7.6 - 9.3 kg .m. (55 - 60 lbs .ft .). Check all 'V' belt tensions after replacing. EA.16. - CRANKSHAFT SPROCKET To Remove 1 . Remove the belt guard(Section EA .-/.)and set the engine in the timing position (Section EA .8.) 2. Remove the camshafts d[...]

Page 32 SECTION EA 2. Remove the camshafts driving belt (toothed belt) (Section EA.8.). 3. Remove the crankshaft sprocket (Section EA .1 6 .). 4. Remove the camshafts driving belt tensioner (Section EA .9 .) .: 5. Release the set-screws with their plain washers from around the periphery of the cover. Pul I off cover and gasket. 6. Remove the oil se[...]

SECTION EA Page 33 EA .18. - WATER PUMP To Remove 1 . Drain the cooling system . 2. Remove the complete belt guard (Section EA -7.) and the water pump 'V' belt. 3. Release the clips and remove all hses from the water pump housing. 4. Where power steering is fitted, remove the power steering pump mounting bracket and secure (with hoses att[...]

Page 34 SECTION EA 0 NOTE: On some engines it may be necessary to first remove the auxiliary shaft pulley, in order to gain access to the water pump refaining bolts. In such cases, take the necessary precautions to ensure that valve and ignition timing are not lost by referring to Section EA "8. Before discarding the water pump, measure the di[...]

SECTfOlV EA Page 34 A 4. Take care when fitting the water pump not to break the bead of Permabond. Fit the water pump fixing bolts and washers and torque tighten to 0.8 - 1 .1 kgf.m. (6 - 8 Ibf.ft) The system may be refilled with coolant immediately after reconnecting hoses . Parts Required. Permabond A1 36 Adhesive A91 2 E6421 Surface Conditioner [...]

Page 34 B EA.19. - OIL FILTER To Remove 1. To remove the filter, us6 a suitable filter removal tool and turn in an anti-clockwise (towards the cylinder block) direction. Discard the filter. Ensure the oil cooler adaptor is not disturbed during this opemtion. To Replace 1. Clean the mating face on the oil pump body. Add a small amount of clean engin[...]

0 All '86 Model Year and some late '85 Model Year cars are fitted with engine oil filter B907E 6000 which differs from filter A907E 6000 in the following respects: i) Provisionof lflats'oncanistertoaidremovalwith oil filter spanner. ii) Slightly shorter canister to provide fitting clearance for spanner. iii) Revised end plate with le[...]

Page 36 2. Note that the driving dog on the distributor shaft is offset, and that it must be turned to match the offset slot in the auxiliary shaft before fitting. Insert the distributor, ensuring that the drive dogs are fully engaged, align the reference marks made previously on the distributor body and auxiliary housing, and secure the clamp. DO [...]

SECIYON EA Page 37 Fig. 23 - Oil pump/auxiiiary housing components[...]

Page 38 To Replace Using a new oil seal, press it into its location.' The lip of the seal should of course be towards the housing. Fit new key to the oil pump end of the shaft and using the new oil pump rotors, fit the inner one to the shaft. Fit a new circl ip to secure. Push the shaft into the housing from the oil pump end so that the shaft [...]

SECTION EA Page 39 Fig. 24 - TDC pasition of distributor rotor arm , 9. Repiace the low tension cable and the distributor cap. Replace oil filter and thl alternator. Replace the carburettws airbox assembly. Re-check ignition timing. EA .22. - l NLET MANIFOLD 8, CARBURETTORS TO Remove (Naturally Aspirated) 1. Drain the cooling system (see Sectio[...]

Page 40 To Remove (Esprit Turbo) 1 . Drain the cooling system. 2. Disconnect throttle and choke cables. 3. Disconnect fuel pipes from pressure regulator. 4. Release water hose(s) from inlet manifold or water mil. 5. Release vacuum connections from inlet manifold or vacuum rail. 6. Disconnect diffuser from turbocharger and seal turbo compressor outl[...]

- - SECTION EA Page 4 1 0 On 91 2 and Wet Sump 91 0 engines, check underside of the sump by clutch housing fixings for shim marking '000' - no shim, '020' - one shim, '040' - two 0.020'' shims. These shims to be fitted between clutch housing and sump. Fit sump and tighten fixings to their specified torque loa[...]

Page 42 SECTION EA 3. Drain the oil from the gearbox (see Section IF'). 4, Disconnect the battery (see Section 'M1). In the engine compartment, disconnect the fol lowing. . . All water hoses, throttle and choke cables; fuel feed pipe to the carburetton; vacuum connections to manifold; cables from altermtor, . . starter motor, ignition dis[...]

SECTION EA 3. Remove the engine campartmen: floor and sidewalls. 4. Dm in the cool ing system. Page 43 5. In the engine compartment, disconnect the following: All water hoses, throttle and choke cables, fuel feed pipe to carburetton (naturally aspirated) or feed and return pipes to fuel pressure regulator (Turbo), vacuum pipes from manifold or vacu[...]

Page 44 SECTION EA 14. On Series Three and Turbo models : Remove the bolts securing the four mountings to the engine/transmission unit, remove the two engine mounting front legs from the cylinder block, and lift out the assembly from the car. * To Replace (all models) Replacement is a reversal of the removal procedure, but the following points shou[...]

SECTION EA Page 43 Remove the engine compartment floor and sidewalls. Drain the cooling system. In the engine compartment, disconnect the following: All water hoses, throttle and choke cables, fuel feed pipe to carburetton (naturally aspirated) or feed and return pipes to fuel pressure regulator (Turbo), vacuum pipes fram manifold 6r vacuum rail, c[...]

Page 44 SECTION EA 14. On Series Three and Turbo models : Remove the bolts securing the four mountings to the engine/transmission unit, remove the two engine mounting front legs from the cylinder block, and lift out the assembly from the car. To Replace (all models) Replacement is a reversal of the removal procedure, but the following points should[...]

SECTION EA Page 45 Parts Required: Heatshield A907E1247F Nyloc nut M8 A075W301 OZ Screw 8m x 20 A075W1038Z Washer 8m x 25 o/d A075W4021 Z 1 off 2 off 2 off 2 off Fig. 25 Heat Shield position on Chassis To Fit Heatshield i) . Remove the existing heatshield. ii). Use the illustration as a guide and place the heatshield over the left hand side engine [...]

Page 46 SECTION EA 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 flyheel from its locating dowels on the crankshaft. 3. Cut between two adjacent teeth on the ring gepr with a hacksaw and split the gear with a chisel. NOTE: Under NO CIRCUMST[...]

SECTION EA Page 47 To Replace . .. a. 1. With the lip of the seal towards tl~e inner machined face of the housing, insert the new seal with the aid of a press, until its inner face is 2.5 mm. . (.I0 . in.) from the .. ' , . .. machined face, ensuring during this operation that the seal . , is . entered , . . . squarely. .-... . . . . .'.[...]

Page 48 SECTION EA Lightly lubricate the lip of the seal, apply 'Wellseal" to both sides of a new gasket, and with the aid of Special Tool (MA), fit the oil seal housing over the flywheel flange of the cmnkshaft, securing with its setscrews. Tighten the setscrews to the torque lading given in TECHNICAL DATA. NOTE: The lower four screws an[...]

SECTION EA Page 49 ,-. . washers adjacent to the main journals ; all nuts should be released in sequence, working diagonally inwards from the outside. Lift off the main bearing housing. If the housing is tight, it is permissable to tap lightly with a rubber mallet to ease removal . Remove the sprayshield from the rear of the cylinder block. 6. Iden[...]

Page 50 SECTION EA . . 8. (NOT Dry Sump Turbo) Remove the ten nuts and washers to the outside of the sump mounting face, followed by the ten large nuts and washen adjacent to the main journals; all nuts should be released in sequence working diagonally inwards from thrs outside. Remove the oil pick-up pipe and breather pipe from their locations in [...]

SECTION EA Page 50 A Remove the main bearing shells, refit the main bearing panel, and measure the main bearing bore diameter. S tandard bore dime ter +0.015" O/D bore diameter 2.6655 - 2.6660 in. (67.704 - 67.716m) 2.6505 - 2.6810 in. (68.085 - 68.097mrn) As a cross check, look for the number stamped on the outside of any main bearing shell w[...]

Page 50 B SECTION EA ii) On all unmodified engines up to No. 20793, remove the main bearing shells from the main bearing panel. (M.B .P .) and modify the panel at No.5 (rear) bearing as shown in the diagram. Using a very fine needle file, carefully form a small chamfer on the right hand corner of the bearing 'cap' from the centre to the r[...]

SECTION EA Page 57 0 Plain (912 Esprit 53, 910 Esprit Turbo) (Std l/D Std O/D ( - 0 .0lOt' I/D (- 0.020" I/D ( Std I/D + 0.015" G/D (- 0.01 0" I/D (- 0.020" 1/D NOTE: Engines from Number 20875, with the revised main bearing panel (without chamfer) do not use the notched bearing she1 I. NOTE: 907 (2 litre) engines'use a[...]

Page 52 cleamnce) compound around the periphery of the ioint. Fit the main bearing housing, using a pair of nuts to pull up the joint over the dowels if necessary. Do not tap the housing, as the bearing shells may be disturbed. Fit the nuts and washers tightening the 8mm nuts first, followed by the 12mm nuts in pain in a sequence outwards from the [...]

SECTION EA Page 53. Coat a new plastic compression olive with engine oil, and from the auxiliary housing chamber, push over the oil pick up pipe/feed pipe and fit the union screw. With the aid of special tool TOOOT0083At tighten the union screw to its specified torque loading (see Technical Data). Ensure spray shield is in its correct location on c[...]

Page 54 Fig, 32 - Usi To Replace 1. The liners are fitted into the cylinder block with their 'flats' in a front-to-rear line. When replacing liners in the cylinder block, they MUST FIRST be fitted clean and dry, and pushed fully into their locations. At this point, the liner 'nip' should be checked; the 'nip' is the he[...]

SECTION EA Page 55 2. When liner nip is correct, withdraw the liners, apply 'Hylomar' on the liner flange to cylinder block mating face and replace liners. 3. If replacement parts are to be fitted, ensure that the pistons and the connecting rods are both balanced sets. Note that all 907 and standard 912/910 engines use cast iron cylinder [...]

Page 56 SECTION EA 0 ii) Fit the lower compression ring: 907: The step on the outer edge is lowermost 912/910 Std: The chamfer on the inner edge is uppermost. 912/910 'HC': The face is tapered towards the side of the ring marked' 'TOP' . iii) Fit the chrome plated top.compression ring 907: May be fitted either way up 912/91[...]

SECTION EA Page 57 EA.30. - CONNECTION OF OIL COOLER THERMOSTAT Oil cooler thermostats are fitted to late dry sump Turbos and all wet sump :nrbos prior to 1986. Early wet sump cabs are fitted with thermostat A910E6550F having 4 5/8" BSP connections, whilst all other cars have thermostat A082E6016F, with 3 x 5/8" BSP connections and 1 x BS[...]

Page 75 Fig. 10 - Belt guard components (early models)' . . ......,- -- . . -... I E714 . . . . >_. .:. .. . , .. .I . (_ . . . . . . A[...]

Page 58 EA i32. - SPECIAL TOOLS TOOO T 00024 TOOO G 0003A TOO0 T 0093A TOOO T '0094A TOOO T 0009A TOOO T 001 0A TOOO T 001 1 A TOOO T 001 2A TOOO T 0072A TOOO T 0083.4 TOOO T 0084A TOOO T 01 70A TOOO T 0242A TOOO T 0290A TOO0 T 0443 Cylinder Liner Clamps to retain cylinder liners Cylinder Liner Nip Gauge To check liner height Valve Guide Drift[...]

a SECTION EA EA -33. - SEALANTS, ADHESIVES Part Number Product A036 E6038V J Silastic RTV 732 (315.5 mi) A907E625NF Loctite 504 Gasket Eliminator A907E6178V Cyl esso A907E6565V Molypaul GP2000 A907 E6119ZA Wellseal A036S6175VH Hylomar PL32 Medium (1 00g) A036B6370V Permabond A1 15 (50 ml) a A074 B60O.9V Permabond A1 38 A91 2 E642 1 V Permabond A1 3[...]

SECTION EMA Page 7 SECTION EMA - U.S.A. ESPRIT TURBO [Prior to '86 M.Y.) Engine Control Components Engine Management System Check/ Set Up Procedure Engine Diagnostic Procedure Operation Page APR 1987[...]

Page 2 SECTION EMA EM4. 1 . - ENGINE CONTROL COMPONENTS Ignition Solenoid Located beneath front of plenum chamber. Function is to advance ignition on operation of choke. A micro-switch operated by the dashboard end of the choke cable (which also operates the choke tell tale lamp) energises the ignition solenoid. The signal to the distributor vacuum[...]

SECTION EMA Page 3 Evaporative Control System Fuel vapour from the fuel tanks is piped into the catch tank, in which the vapour condenses into liquid fuel and residual vapour. The level of liquid fuel in the catch tank is controlled by the catch tank inlet tube. Any increase in level above this tube and the fuel is induced back into the main tanks.[...]

Page 4 SECTION EMA 1 . Remove vacuum tapping screws, fit carburettor balancing tubes and connect to manometer. Connect pressure test gauge kit as shown in diagram. TO VACUUM PUMP UEL SUPPLY TO CARBURElTORS FUEL PRESSURE ADJUSTMENT SCREW AIR FILTER BOX % CONNECT TEST KIT AT THESE POINTS @ 0-3Ohg and 0-15 I? S.1. CENTRE POINT 0 @ FUEL PRESSURE 0-20 t[...]

SECTION EMA COLD Engine Page 5 2. Switch on ignition and check that fuel pressure at fuel regulator gauge is to specification 4.0 - 4.5 p.s .i . - if outside specification contact the Service Department of Lotus Performance Cars, L . P .; 530 Walnut Street, Norwood, New Jersey 07648, quoting VIN and engine numbers. 3. Fully operate choke, open thro[...]

Page 6 SECTION EMA Allow engine to reach normal runniLg temperature i .e. oil and coolant should be stabilised. 5. i) . ii). ... 111). iv) . + Ad just idle speed to 950 - 50 rpm . + 0 Adjust ignition timing to lo BTDC - 1 . Check carburettor balance at manometer. Check that all 4 columns are balanced within 3mm, if not re-balance the carburettors. [...]

SECTION EMA Page 7 7. Fuel regulator micro switch - with the switch set at idle and fuel pressure recorded as in operation 5,open throttle to2500 rprn and thenreturn throttle to idle position. Check that when the engine speed is above 1800 rpm, the micro switch is deactivated allowing fuel pressure to increase to 4.0 - 5.0 psi. Repeat this test and[...]

Page 8 SECTION EMA 10. Flap valve actuator - with all adjustments completed switch off engine and check that the diffuser flap valve closes fully within 15 secs. 11. Hot restart - crank over engine and check that the throttle iack solenoid is operating in the cranking mode. 12. To check maximum vacuum from vacuum pump, clamp off the vacuum hose at [...]

SECTION EMA Page 9 a . . EMA .3. - ENGINE DIAGNOSTIC PROCEDURE Before carrying out detailed diagnostic check, ensure engine management system is within specification. COLD START PROBLEMS Weak battery (recharge or replace) I Possible causes: I ' + 2 v, (3 Fuel pump electrical circuit I Leak in intake manifold Cam timing incbrrect I A Distributo[...]

Page 7 0 ENGINE DIAGNOSTIC PROCEDURE SECTION EMA Before carrying out detailed diagnostic check, ensure engine management system is within a specification. UNEVEN RUNNING Possible causes: 2 POOR PERFORMANCE, LOW TOP SPEED Possible causes: Leak in intake system Air filter clogged I High tension leads I BI Distributor cap High tension leads Cyl i nder[...]

SECTION EMA Page I I SUB GROUP 'A' - Intake Manifold Leaks & Air Filter Inspection -- --- A - 1 . Check for air leaks at the carburettor to manifold joint, The spacer plates and '0' rings used at this joint act as insulators to absorb vibration and prevent frothing of fuel in the float chambers. It is essential that the carb[...]

,. . Page 72 SECT,ON ... 3. Check for air leaks at the inlet manifold to cylinder head joint. 4. Check for air leak from inlet manifold pressure take off adaptor (no. 1 cylinder) and for leak or disconnection of pipe from adaptor to fuel pressure regulator solenoid. 5. Inspect the air filter element. Release the filter cover from the engine bay wal[...]

SECTION EMA Page 13 SUB GROUP B - Ignition System & Cylinder Compressions ---- ------- A). Check for a spark at each plug lead. If all are sparking, remove plugs and check condition. If serviceable, clean and gap to 0.9 mm (0.035"). Before replacing plugs, check cylinder compressions as (B). If no spark at leads, procede as TEST 1 . APR 19[...]

Page 14 SECTION EMA 5 CHECK HT SPARKING - TO IGN SWITCH 7 VISUAL AND HT CABLE CHECKS EXAMINE 1 Distributor Cover 2 6ilTop 3 H.T. Cabla Insulation 4 H.T. Coble Continuity 5 Spark Plugs Should be good HT sparking Repeat with original HT lead Good sparking If engine will not start -* TEST 6 No sparking, replace HT lead If engine will not start --w TE&[...]

SECTION EMA SUB GROUP C - Cold Start System Maladjustment Page 75 1 . Check that operation of the choke control results in full travel of the carburettor cold start levers. With the choke control in the 'off' position both carb levers should contact their closed 'stops' on the carburettor tops. With the choke control operated fu[...]

Page 16 SECTION EMA SUB GROUP D - Check Cam Timing - ----- 1. Turn the engine to No. 1 cylinder TDC with the camshaft toothed pulley timing marks facing EACH OTHER innermost. Note: The engine may beset at TDC by reference to the timing marks on the flywheel, and pointer located at the top of the clutch housing, as shown. 2. Check that the pulley do[...]

SECTION EMA Page 7 7 SUB GROUP E - Fuel Control Pressure ---- 1 . Connect fuel pressure test gauge as shown below. FUEL PRESSURE REGULATOR h--+FL SUPF'LY TO CARWRETTORS , FUEL PRESSURE ADJUSTMENT FUEL SUPPLY FROM ~QUMP SCREW PRESSURE TEST GAUGE KIT LOTUS PART NO. TOOT0500 Switch on ignition and check fuel pressure = 4.0 - 4.5 p.s.i. If outside[...]

Page 7.8' View from front r-7 SECTION EMA If switch adjustment is carried out, open throttle to 2500 rpm and then return throttle to idle position. Check that when engine speed is above 1 800 rpm, the micro-switch is deactivated allowing fuel pressure to increase to 4.0 - 5.0 p.s .i . Repeat this test and check that pressure differences are ma[...]

SECTION EMA . .. : Page . , I9 SUB GROUP F - Carburettor Balance - 1 . Remove vacuum tapping screws, fit carburettor balancing tubes and connect to manometer. + 2. Adjust throttle stop screw to give specified idle speed of 950 - 50 r .p .m. with engine at normal operating temperature. Check that all 4 columns are balanced within 3mm. If not continu[...]

Page 20 SECTION EMA SUB GROUP G - CO Adiurtment ---- 1 . Fit exhaust probe to exhaust outlet pipe of turbocharger and connect to CO/HC analyser (e .g . Sun EPA 75 or equivalent). Exhaust probe connect ion ! Start engine and allow to peach normal running temperature i .e. oil and coolant ' temperatures stabil ised . 2. Switch analyser to sample[...]

SECT/ON EMA Page 2 1 SUB GROUP H - Thermal Switch ------ 1 . In order to test correct operation of the thermal switch, sufficient coolant must fint be drained from the cooling system to permit the removal of the switch from the rear of the inlet manifold. 2. Place the switch bulb in a pan of water, with a battery and bulb connected across the switc[...]

Page 22 SECTfON EMA SUB GROUP J - Battery Re-charging Procedure lnstruc tions for Tungstone Powermaster Maintenance Free Batteries. To determine the state of charge of the battery, apply a brief di's~hir~e of no more than ten seconds duration (e.g. turn on headlights) with the engine off, and then allow to stand on open circuit for two to thre[...]

SECTION EMA SUB SECTION I - Fuel Pump Electrical Circuit - ---- Page 23 1. Checksafetyinertiaswitchhasnotbeenactivated. The switch is located in the ignition box at the rear of the engine bay. To re-set the switch, press down the plunger appearing through the hole in the top of the ignition box. Inertia switch Check for electrical feed at fuel pump[...]

SECTION EMC Page 7 ENGINE MANAGEMENT SECTION EMC - ESPRIT TURBO 1987 MODEL YEAR (Domestic & Export) Operation Page Vacuum Connection Diagram Thermal Iwition Advance Crankcase Breather Valve Cold Enrichment Thermal Valve Plenum Purge Throttle Jack Soleno'id Overboost Switch Idle Speed & Ignition Timing Setting Procedure EMC .I 2/3 EMC .[...]

THERMAL SWITCH OPERATION EMC.1. - ENGINE MANAGEMENT VACUUM CONNECTION DIAGRAM 7 102 TO. CRANKCASE J COLD ENRICHMENT THERHAL VALYE . WHITE @ NON RETURN VALVE @ REAR FRONT CAR R r -I- PLENUM Vacuurn/Pressure Pipe Connections BLACK IWHITE n --- Electrical Connections FUEL REGULATING VALVE I SPEED SENSING I SOLENOID VALVE w IGNmION SOLENOtD TO BOOST PU[...]

.Vacuum Pump: Mounted L.H. si da of crankcase. Driven by 'V' belt from crankshaft. Supplies vacuum for engine management, brake servo and heater/a. c. Thermal Switch: Fitted in thermostat outlet water pipe. M.O.R. 70°C. B.O.F. 60°C. Switches I.S.V. and purge pump. See EMC.2. Ignition Solenoid Valve I.S.V.: Fitted on top of R.H. fuel tan[...]

SECT/ON EMC EMC.2. - THERMAL IGNITION ADVANCE The thermal ignition advance system is designed to provide maximum ignition advance at low engine temperature to aid cold driveability and increase idle speed. The distributor is fitted with a double sided vacuum advance capsule, one side of which is permanently connected to the plenum chamber (boost pr[...]

SECTION EMC Page 5 Water Tem~: inlet manifold below 60'~ TU~DMAI l-4 I VACUUM -. .- -- 1 To aid starting a cold engine, the I.S.V. is de-energised during cranking in order to provide a plenum chamber pressure signal to the distributor for no vacuum advance. IGNITION SOLENOID VALVE CARB. EDGE PORT CARB. PLENUM I Water Temp: inlet manifold above[...]

Page 6 SECTION EMC Water Temp: thermostat pipe above 70'~ In order to safeguard the engine from potentially damaging excessive ignition advance at normal running temperature, should a malfunction of the T.I.V. occur: When coolant temperature (thermostat pipe) reaches 70°C (on rise) the I.S.V. is de-energised, and directs a plenum chamber pres[...]

SECTION EMC Page 7 EMC.4. - COLD ENRICHMENT THERMAL VALVE The cold enrichment thermal valve is designed to enrich fuelling at low engine temperatures to improve driveability. The valve is fitted into the rear of the inlet manifold water rail. Port ID' is connected with port '1' at coolant temperatures below 53OC and with port '2[...]

Page 8 SECTION EMC The solenoid is energised under any of the following conditions: a) Above engine speed of 1400 rpm on fall (1600 rpm on rise) as sensed by the engine speed sensing relay, to prevent complete throttle closure on overun to reduce hydrocarbon. emissions and inhibit stalling. The relay is mounted on the wheelarch alongside the R.H. r[...]

SECTION EMC Page 9 :. Initial Ignition Timing Setting Connected to port 'D' of T.1 .V. Connected n / Posit ion of rotor arm cut-out in distributor shaft ii) Check/Adjust Ignition Timing: Start the engine and run up to normal operating temperature to ensure the T.I.V. switches the distributor capsule to the throttle edge port. Using a stro[...]

' Page 10 SECT/ON EMC To check the centrifugal advance operation, first disconnect and plug, or clamp off the vacuum hose from the distributor capsule. Check centrifugal advance characteristics are as follows: crank rpm Below 1 ,000 2,000 5,000 crank O (+2O) nil 11° 8" iii) Check/Adjust Idle Speed: Start engine and run up to normal opera[...]

SECTION EMD Page 7 ENGINE MANAGEMENT S.ECTION EMD - ESPRIT S3 'HC' 1987 MODEL YEAR (Domestic & Export) Operation Page Vacuum Connection Diagram Thermal Ignition Advance Crankcase Breather Valve Cold Enrichment Thermal Valve Plenum Purge Throttle Jack Solenoid Air Inlet Temperature Control System Idle Speed & Ignition Timing Settin[...]

CRANKCASE BREATER VALVE @ EMD.1. - ENGINE MANAGEMENT VACUUM CONNECTION DIAGRAM qb -".ox THERMAL $. IGNITION @ VALVE TO CRANKCASE COLD ENRICHMENT THERMAL VALVE @ DISTRIBUTOR I 0 VACUUM /PRESSURE PIPE -- - ELECTRICAL CONNECTION I [ARB. 1 I [ARB. 1 WARM AIR INTAKE - FROM EXHAUST SttROUD AIR TEMPERATURE CONTROL VALVE I COOL AIR INTAKE FROM LUGGAGE[...]

1. Thermal Ignition Valve: Fitted to centre of inlet manifold water rail. Below 60°C. -- - directs inlet manifold pressure signal to distributor for full advance to aid cold idle and driveability. See EMD.2. 2. Throttle Jack Solenoid: Fitted to front of ::front carburettor. Controlled bv meed 1 L :sensing relay (item 3) , choke switch and a.c. swi[...]

Page 4 BMD.2. - THERMAL IGNITION ADVANCE The thermal ignition advance system is designed to aid driveability and idle speed when cold and light load economy when warm. The distributor is fitted with a vacuum advance capsule connected via the Thermal Ignition Valve (T.I.V.) to either one of two pressure sensing ports on the carburettors. The T.I.V. [...]

SECTION EMD Page 5 shut off, and enriched fuelling results from the decrease in calibrated airflow past the throttle plates. At higher temperatures the breather line is restored and fuelling returns to normal. EMD. 5. - PLENUM PURGE The purge pump is designed to induce ambient air into the carburettor plenum chamber of a hot engine when switched of[...]

Page 6 SECTION EMD The solenoid is energised under any of the following conditions: a 1 Above engine speed of 1600 rpm on rise (1400 rpm on fall) as sensed by the engine speed sensing relay, to prevent complete throttle closure on overun to reduce hydrocarbon emissions and 'inhibit stalling. The relay is mounted on the wheelarch alongside the [...]

SECTION EMD ,. , , , . . Page ,. .. 7 Intake Hose/ Sidewall . Interface El-- Engine Bay Wall ATC Divertor Grommet Securi ng Ri ng The'ATC flap valve unit consists of a vacuum diaphragm operated flap mounted on the inlet of the carburettor airbox, controlling the air supply thereto. At moderate ambient temperatures the airbox is supplied with c[...]

Page 8 To check that the system is functioning correctly, disconnect the cold air supply trunking from the flap valve and use a mirror to establish the flap position at warm and cold ambient conditions. The flap valve itself may be tested by applying vacuum directly to its vacuum capsule: more than 100 mrn Hg - warm air supply fully open less than [...]

SECTION EMD Using a stroboscope, check/adjust the ignition timing to 10" BTDC at hot idle. Timing marks are provided on the flywheel rim, with an aperture and pointer in the top of the clutch housing, adjuacent to the starter motor. Pull out the protective grommet, and refit after adjustment. Clutch Hous Aperture To check the centrifugal advan[...]

Page lo Use the cable adjuster at the anchor bracket on the cam cover to remove throttle cable slack, and then with the aid of an assistant check that full throttle can be achieved. The throttle pedal downstop should be adjusted such that the carburettor throttle levers may be held against their full throttle stops without allowing the cable to be [...]

Page 1 : SECTION FB - ESPRIT Opera tion -- General Description Gearshift Lever & Gearchange Linkage Transmission Assembly Clutch Bellhousing Clutch Shaft Gearbox Rear Housing Gear Selector Removal Gear Selector Replacement Primary Shbft a Bevel Pinion Shaft Differential Shaft (Drive Shafts) Differential Crownwheel & Pinion Differential Bear[...]

[...]

Gearbox & Clutch Housing. Assembly Level Plug Washer, Level Plug Stop, Speedo Pinion Bracket, Gearbx/Caliper Mounting RH Bolt, Bracket to C~arbox Bolt, Bracket to Gearbox Washer, Flat, Bracket to Gearbox Washer, Spring, Bracket to Gearbox Mounting, . Ehgine/Gearbox rear Washer, Snubber Washer, Flat Nut, Nyloc 7/16" UNF Pointer, Engine Tinu[...]

Page 3 A SECTION FB The transmission is a single unit Comprising a manual 5-speed, all indirect gearbox with integral final drive unit,, and the'clutch,bellhousing containing the clutch release mechanism. The gearbox has five forward gears, all equipped with syncromesh, and a reverse gear of the spur gear type. A clutch shaft transmits the dri[...]

SECTION FB Page 3 B Drain and Level Plug C35 type gearboxes have only one oil drain plug which is situated beneath,the main case. They are not fitted with the additional rear case drain plug as used on previous type gearboxes. The oil level plug (painted yellow) is fitted in the left hand side of the case, as before, and should not be confused with[...]

Page 4 SECTION FB The tubular linkage transmits fore-aft movement of the gear 1 ever into radial movement of the gearbox cross shaft. Crossgate movement of the gearlever is translated into axial cross shaft motion by a bowden cable connected between a bellcrank on the gearshift assembly and a bellcrank on the gearbox casing. To Remove Remove the ce[...]

[...]

Key to Gearchange Linkage Drawing Gear Lever Assembly. Reverse Gate . Knob, Gearlever. Spacer, Gearlever Knob. Spirol Pin, Bellcrank to Yoke. Connector Yoke, Cable to Bellcrank. Spirol Pin, Cable to Yoke. Crossgate Cable. Was her, S hakeproof . Abutment Bracket, Rear. Dust Cover, Cable Rear. Rod, Crossgate Cable Extension. Locknut, Cable Stiffener.[...]

SECTION FB Adjustment Tube Linkage Basic Setting: Page 7 With the linkage connected, and the transmission in neutral, check the position of the ., . . relay lever on the RH engine mounting leg, The lever should be vertical, or leaning very slightly backwards at the top. If necessary, disconnect the rear tube from the , . , relay lever, and adjust l[...]

Page 8 SECTION FB FB.2. - TRANSMISSION ASSEMBLY To Remove Remove engine compartment rear floor and chassis crossmember.. Drain gearbox oil. Remove silencer. Disconnect drive shafts and remove adaptors and brake discs. Release brake caliper mounting bolts and support calipers clear. Support rear of gearbox and rehove gearbox mounting brackets comple[...]

SECTION FB Page 9 FB.3. - CLUTCH BELLHOUSING To Remove 1 . Remove the transmission assembly and driveshaft bearing housing assemblies. 2. From inside the bell housing remove the four nuts and washers on the shds; : : attached to the gearbox casting. 3 . Remove the ten bolts securing the outer edge of the gearbox casting to the bell housing. 4. Hold[...]

Page 70 4. Remove the circlip retaining the clutch shaft in the primary shaft. Take care not to lose the spring between the clutch shaft and primary shaft. If the circlip is very difficult to remove and further dismantling is intended, then remove clutch shaft complete with primary shaft. It will be easier to remove the circlip on the bench. To Rep[...]

SECTION FB Page 7 7 FB .6. - GEAR SELECTORS REMOVAL 1. Remove the transmission unit and gearbox rear housing as previously described Remove the gearbox top cover together with the selector crosshaft. Reverse Gear Selector 1. Slacken the screws securing the fork (A) and the operating dog (B), first removing the locking wire, to the selector shaft. 2[...]

Page 12 2. Remove the shaft, the operating dog and shaft locking ball and spring, and the small interlock plunger inside the front end of the shaft. 3rd and 4th Gear Selector 1. Slacken the screw securing the fork (D) after removing the locking wire. 2. Remove the shaft, the fork, the shaft locking ball and spring, and the small interlock plunger i[...]

SECTION FB Page 73 .,. 3rd and 4th Gear Selector 1. Place the first interlock plunger infrom the opening at (F) figure 5 and locate in the 1st and 2nd selector shaft notch. 2. Insert the gear selector shaft through the gearbox outer casting, fit locking ball and spring as previously described, the operating fork and into the differential end of the[...]

. Page 7 4 SECTION FB Gear Selector Mechanism Top Cover and Cross Shaft Bearing cap Dowel, Top Cover locating. Setscrew, Top Cover to Gearbox. Setscrew, Bearing Cap to Cover. Show ldered Stud . Was her. Filler Plug. Gasket Filler Plug Cross Shaft Spindle Assembly. '0' Ring, Cross Shaft Spindle. Selector Shaft, reverse. Selector Shaft, 5th[...]

SECTION FB Page 75 fork, up against the gauge. Tighten the two locking screws to a torque of 4 kgf.rh (29 Ibf.ft). 4th Gear Stop Adiustment Replace the 'Gearbox Rear Housing' as previously described . Engage the 4th gear. Gently push the slider against the fork. Measure the clearance 'Y' between the slider and the 4th gear pinio[...]

Page 76 SEC7'lON FB 4. Release the rear bearing on the primary shaft using a puller if necessary. Take care not to lose the balls from the race. NOTE: The inner bearing rings are in two halves on the prirriaryshaft rear end and careshould be taken to note where each is fitted. S R Q P M Fig .7 Primary shaft assembly Move the primary shaft towa[...]

SECTION FB Page 7 7 3. Slide off the 3rd gear drive pinion with the synchro ring and the needle bearing cage, 4. If the clutch shaft is fitted, remove the circlip securing the clutchshaft to the primary shaft and remove the clutch shaft and spring. TO Replace 1. If the clutch shaft is disconnected, fit the spring (0), then the clutch shaft (M) and [...]

I a. Gearbox Shafts and Gears a a a[...]

Key to Gearbox Shafts & Gears Drawing Clutch Shaft. Spring, Clutch Shaft endthrust, Circlip, Clutch Shaft retention. Support Tube, Clutch Release Bearing, Sealing Ring, Support Tube. Scroll and Housing. Ball Bearing, Primary Shaft front Primary Shaft. 3rd Speed Drive Pinion. Needle Roller Bearing, 3rd Pinion. Syncroniser Assembly, 3rd and 4th. [...]

Page 20 SECTION FB a the shaft with the grub screw. Smear the threads of the grub screw with a locking compound and tighten screw and lock with nut. 7. Fitthe5thdrivegear(S)togetherwithitsneedlerollercagecoatedwith transmission oil, synchroniser (8) and operating fork assembly on the primary shaft. Secure with the deflector (T) and bolt (A) and tig[...]

SECTION FB To Replace Page 27 Check all parts are clean and there are no abrasive or metal particles adhering to the parts. Fit the front roller bearing (I) on the pinion (k) using a suitable length . , (240 mm) of tubing (inside diameter 44 mm) . Make sure the washer (i) is fitted against the pinion before pressing on bearing. Feed the pinion shaf[...]

Page 22 This distance is different for each bevel pinion and is checked using the distance gauge fixture TOOOT0616 fitted with dial gauge TOOOT0615. The fixture is designed so that the distance between the centre line of the ground contact faces (drive shaft bearing surfaces) and the faces of the probes is 60 mm. This figure is engraved on the fixt[...]

SECTION FB Page 23 8. Measure the thickness of the adjusting washer (q) figure 8 which for this example is: 2.81 mm. Replace this washer by another with a thickness calculated in the following manner: 2.81 - 0.09 ~2.72 mm As washers are available in thickness from 1 .65 mm to 3.1 3 mm in steps of 0 .O4 mm, the nearest to the calculated thickness is[...]

Page 24 I bear 7. Drive out the double bal diameter. 'ing outer ring using a tube of 65 mm external 8. Using a suitable extractor, draw the inner bearing rings from the shaft. Note positions. 9. Removethesealingringfromtheshafthousing. 10. Remove the oil retaining washer and bearing distance bush assembly. from the shaft. Fig .9 Differential a[...]

SECTION FB Page 25 To Assemble NOTE: The differential drive shafton the left-hand side of gearbox is the shorter. 1 . Fit the bearing (21) in the housing and tighten the nut (1 8) to 10 kgf .m (72 Ibf .ft) using the spanner TOOOT0612. Lock the nut using the grub screw (1 9). 2. Fit the oil sed (20) using a suitable tool. 3. Position the oil retaini[...]

Page 26 . , 0.1 mm. If this is not so replace thrust washers until the minimum clearance is achieved. Remove the satellite and thrust washer making a note of the position in the housing. . . Repeat 1 and 2 for each satellite gear, taking care to fit the crosshead bush (1 0) to support the short satellite spindles (5). Fit the dowel pin screws tempo[...]

SECTION FB Page 27 .a locate the drive shaft in tCle planet wheel and align the screw holes. Fit screws, taking care to fit the correct lengths and tighten. (e) Place the gearbox carting on its left-hand side, supporting it in this position. (f) Place against the right-hand differential bearing the adjusting washer (1 3) followed by the distance wa[...]

Page 28 SECTION FB used 8.20 mm (the adiusting washer has a smaller inside diameter). (d) Place the selected rashers on the right-hand bearing, with the adjusting washer next to the bearing. Fit the distance piece and fit the right-hand drive shaft housing with a papergasket betweenthe mating surfaces. IMPORTANT: The thickness of the washers fitted[...]

SECTION FB Page 29 given for bearings which have previously been used and new bearings. (i) Bearings previously used should be within 4 to 6 kg. If the reading is less than 4 kg, increase the thickness of the adjusting washers. For readings inexcess of 6 kg reduce the thickness of the adiusting washers. (ii) New bearings should be within 6 to 9 kg.[...]

Page 30 SECTION FB Fig .l 0 Measuring crown wheel backlash (d) Repeat the procedure on teeth at about 90°, 1 80' and 270° around the crown wheel from the first measurement. The difference between any two measurements should not exceed 0.1 0 mm. If a reading exceeds this figure it will indicate the crown wheel is running out of true or is bad[...]

SECTION FB .; Page 3 1 For the example therefore, thethickness of the washers to be moved (c) Intheexamplechosen,itisnecessarytomovethecrownwheel towards the pinion by a distance of 0.79 mm . To achieve this, the thickness of the washers against the right-hand ... bearing should be reduced to: 8.20 = 0.79 = 7.41 mm, and the thickness of the washers[...]

STEERING SECTION HB - ESPRIT '88 M.Y. Onwards General Description Steering Wheel Upper Steering Column Assembly - Intermediate Steering Column Assembly Track Rod Ends & Toe-in Adjustment Steering Rack Gaiters Rack & Pinion Assembly Sub-section HB. 1 HB.2 HB.3 HB. 4 HB.5 HB. 6 HB.7 Page 5 6 8 15 19 2 0 2 1 Page 1[...]

Steering wheel boss Collets, boss to column Rubber band, collet retention Nut, steering wheel/boss retenti Washer, wheel/boss retention Steering wheel Countersunk screw, wheel to hub Trim pad, steering wheel centre WON-S.I.R. TYPE UPPER STEWING COLUMJ Steering column assembly Fixing, column to scuttle beam 'Break out' insert Clamp bracket[...]

S.1-R. TYPE UPPM STEERING COLUMN 1. Upper column assembly . 2. 'Break out' insert 3. Fixing to scuttle beam 4. Fixing to pedal box 5. Top bearing housing 6. Fixing, housing to column 7. Ball bearing, column top 8. Circlip, top bearing 9. Cushion ring 10. Circlip, cushion ring 11. Column lock 18 12. Shear bolt, column lock 13. Lock barrel [...]

IXEWEDIATE COLUMN & RACK & PINION ASSEMBLY S.I.R. type[...]

Key to Intermediate Column & Rack & Pinion Assembly Drawing 1. Rack & Pinion assembly 2. Gaiter (supplied as kit of 2 , gaiters with clips) 3. Track rod end 4. Locknut, track rod end 5. Rack assembly LH rubber mounting 7. Clamp bracket, LH mounting 8. Rack assembly RH rubber mounting 9. Clamp bracket, RH.rubber mounting 10. Tapping plat[...]

On S.I.R. equipped cars, a shorter upper column assembly requires two short intermediate shafts, the lower of which is supported in a chassis mounted bearing, and three universal joints to connect with the rack assembly. S.I.R. Type Steering System Scuttle beam Upper column Pedal box pivot bracket Intermediat Column/scuttle beam fixing Upper co[...]

=. To Remove Wheel & Hub Assy.: Non-S.I.R. Cars - Pull off the trim pad from the centre of the wheel. - Remove the nut and washer retaining the wheel. - Match mark the relative positions of the steering wheel hub and inner column. - Pull the wheel off the column using minimum force, if necessary using a suitable puller. DO NOT apply excessive a[...]

1. In order to maintain the required bump steer characteristic, it is important to ensure that the steering rack is centralised in the straight ahead position, i.e. both track rods are the same length. Measure the amount of visible thread at each track rod, and if necessary equalise by adjusting an equal and opposite amount at each side. 2. Slide t[...]

inner column is provided with a slot into which the steering lock engages. On S.I.R. equipped cars (primarily USA), a different column is used, but the same principles apply. The same 'break out' fixings are used at the scuttle beam, but the lower end of the column is secured to the pedal box via a hinge bracket and a single fixing bolt. [...]

S.I.R. Cars: i) Remove the column shrouds, loosen the column to scuttle beam fixing bolts and check that the two alloy 'break out' inserts are securely attached to the column flange. ii') Check that the centreline of the u/j at the lower end of the column is within 3 nun of the pivot point of the outer column lower bracket. If greate[...]

column lock shear bolt Switch mounting ~eam/dip/turn/horn switch assembly Switch spacer ring Wiper switch assembly 4. From within the footwell, remove the pinch bolt securing the universal joint to the bottom of the upper column assembly. 5. Slacken the clamp securing the column assembly lower end to the pedal box, and remove the two MI0 bolts fixi[...]

Fit the upper end of the column to the scuttle beam using the two M10 bolts with new shakeproof washers A075W4049Z and existing flat washers. Finger tighten. I 'Break out' insert Upper column Flat washer assembly Shakeproof washer 3. Tighten the lower clamp bracket to the column, to 11 - 16 Nm (8 - 12 1bf.ft) before tighening the upper bo[...]

Scuttle beam Single fixing to pedal box Pedal box I 'break out' insert S.I.R. ~ype Upper Column Assembly Top bearing Indicator cancelling bush Top bearing housing Steering lock Lock barrel Page 13[...]

from the column top bearing carrier. Release the small grub screw at the a bottom left hand rear of the steering lock body, and pull out the ignition switch. If necessary, remove the steering lock mechanism either by unscrewing the two shear bolts using a hammer and punch, or by drilling out the bolt heads. Remove the pinch bolt from the u/j at the[...]

On early cars, the column must be passed beneath the scuttle beam before pulling back onto the scuttle beam platforms. Fit the spacer washers between column flange and beam, and retain with fixings shown but do not tighten. On later cars, tila scuttle beam incorporates two weld studs onto which the upper column flange is fitted from beneath and ret[...]

To Refit Intermediate Steering Column Assembly: Non-S.I.R. cars When refitting the intermediate column, it is most important to follow the correct procedure to 'phase' the upper and lower u/js i.e. orientate the the two joints in a particular manner with respect to each other. This setting provides the optimum steering 'feel', w[...]

(. 5. From this position, turn the steering wheel 30" (3 splines) as follows: RHD - counterclockwise LHD - clockwise before inserting the intermediate shaft into the lower u/j. Fit the pinch bolt and tighten to 22 - 27 Nm (16 - 20 1bf.ft). Turn steering % wheel 30° counterclockwise ( M-ID sert --- . Pinch bolt/ T.,HD car viewed from LH side w[...]

6. Tighten the upper column fixings as follows: Ensure that only a minimal amount of intermediate shaft is allowed to protrude through the upper u/j before tightening the pinch bolt to 22 - 27 Nm (16 - 20 1bf.ft). Column to scuttle beam: 28 - 30 Nm (20 - 22 lbf..ft) Column clamp bolt: 11 - 16 Nm (8 - 12 1bf.ft) 7. Road test and check the alignment [...]

The lower intermediate shaft steady bearing, is an oil impregnated synthetic (Railko) bush pressed into a bracket bolted to the chassis front crossmember. The position of the bracker is set by jig during vehicle manufacture, and should not be disturbed unless the bush is to be replaced. To replace the bush, remove the two screws securing the bracke[...]

specification : Prior VIN 82 D 3582, From VIN 82 D 3582, 85 D 3587 85 D 3887, 82/~ 2728 82/F 2728, 82/~ 5000 Toe-in : 1.6mm each side; to, -1mm 0.1 to 1.9mm overall To adjust the toe-in (front wheel alignment), hold the track rod ends by the flats provided whilst releasing their locknuts. Turn each track rod, an EQUAL amount, either to increase the[...]

the steering unit if necessary. If the assembly is serviceable, clean off any dirt if necessary before lubricating the rack with either EP90 oil (early cars) or, on later cars, Texaco CUP 2 grease or equivalent (lime based, water resistant). 5. At each side, fit the new gaiter and clips over the track rod, locate the large end in the groove on the [...]

- the circlip and spacer tube are fitted onto the pinion shaft. 2. Feed the unit into postion in the chassis from the driver's side and slide the pinion shaft into the u/j with the pinch bolt hole aligned with the flat on the shaft.. 3. Fit the mounting rubbers around the rack housing, and secure the unit with the two clamp brackets, inserting[...]

SECTION JB Page 1 BRAKES SECTION JB - ESPRIT S3 & TURBO: PRIOR TO '85 MODEL YEAR This section is applicable to can up to and including 1984 Model Year which use solid brake discs and Girling calipers front and rear. Section Page - General Description Front Brake Pad Replacement Rear Brake Pad Replacement Handbrake Front Brake Caliper Overh[...]

Page 2 SECTION JB GENERAL DESCRlPTl ON The braking system comists of a Girting Type 28 Supervac servo unit attached to a tandem master cylinder with a bore of 19.05mm (0.75 in ,) operating type GA2, calipers with 250mm (9.7 in.) diameter discs at the front, and type 9CH sliding caliper with 275mm (1 0.82 in .) diameter discs at the rear. The rear b[...]

SECTION JB Page 3 4. Toenablethenewpdstobefitted,pushthepistonsinthecalip4n back into the bores. This action will cause hydraulic fluid to be returned to the master cylinder, which if it has recently been topped- up, my overflow. To avoid this, examine the fluid level andif necessary, remove a quantity of fluid BEFORE pushing the pistons back into [...]

Page 4 SECTION JB 4. Fit new pads and damper spring into the caliper bracket, and refit the caliper body, alighing the stot in the piston with the lug on the brake pad backplate. 5. Fit new self locking bolts to secure the caliper body to the guide pins. Fit the top bolt .first, then compress the pd damper spring and fit the lower bolt. Torque tigh[...]

SECTION JB Page 5 A small amount of lost motion is permitted which prevents over-adjustment, and permits proper relaxation of the pads after each brake application. In order to press the piston back into its bore (necessary when fitting new brake pads) or to eject the piston from the cylinder (during caliper overhaul), the ratchet mechanism must be[...]

Page 6 SECTION JB 3. 4 5. 6. 7. PISTON Turn the piston 45O to disengage the handbrake adjustment ratchet mechanism, before using compressed air to eject the piston from the cylinder. Use rag to protect from brake fluid spray and keep fingers well clear. The handbrake mechanism can be separated from the cylinder body after releasing the three bolts [...]

SECTION JB Page 7 JB. 6 - BRAKE DISCS Check the braking surface on both sides of the brake discs for scoring or corrosion. Replace if in doubt. Measure the disc thickness and run-out. Front - Rear - Thickness, nominal 12.7 mm (0.50 in.) 10.00 mm (0.39 in.) Thickness, minimum 11 .4 mm (0.45 in.) 9.00 mm (0.35 in.) Run-ou t maximum 0.09 mm (0.0035 in[...]

Page 6. 8 SECTION JB Remove the primary plunger spring (1 6), seal refainer (1 7) recuperating 0 seal (1 8) and washer (1 9). Slide off the vacuum seals (34) and spacers (24) and (25). Keep the plunger and its spring together at all times. 7. Check that the breather hole at the rear underside of the cylinder is clear and wash with Girling Cleansing[...]

SECTION JB Page 9 resting centrally in the mouth of the bore. Ensuring the seal is not trupped whilst so doing, GENTLY introduce the plunger with a circular rocking motion as illustrated to ease the seal, then SLOWLY push the plunger down the bore in one continuous movement. 13. Repeat this lubricating and fitting procedure exactly for the primary [...]

Page 70 JB. 8 - BRAKE SERVO UNIT The 'Supervac' brake servo is, with the exception of the air filter and non return valve, a non-servicable sealed unit which must be replaced if found to be faulty. The air filter (surrounds input push rod) should be replaced whenever the brake system is overhauled, and cleaned or replaced more frequently [...]

SECTION JC Page I BRAKES SECTION JC - ESPRIT S3 & TURBO: 1985 MODEL YEAR ONWARDS This section is applicable to 1985 Model Year Esprit variants which use ventilated front disc brake assemblies similar to those used on Excel models and Bendix Series 3 ACG rear disc brake assemblies. General Description Front Brake Pad Replacement Rear Brake Pad R[...]

.,.. SECT,ON' JC Page 2 G ENEWL DESCRIPTION The braking system comprises a Bendix 'Master Vac' servo unit and tandem master cylinder operating single piston sliding calipers on each wheel with ventilated front and solid rear discs. The seperate front/rear hydraulic circuits share a brake fluid reservoir which incorporates a 'Niv[...]

Page 3 - % ~Ati-s~ueol shim Outer pad anti-rattle spring CAUTION The brakes will not work at full efficiency until the new brake pads have bedded-in . if initially, the brakes are used too heavily, the surface of the pads will burn and irregular braking result. Use the brakes gently for the first few miles and gradually build up brake effort. JC.[...]

Page 4 1 . Pull out the locking clips from both caliper retaining plates. 2. Using a pin drift, drive out one retaining plate, and then remove the other. 3. Lift away the caliper, and support clear without stressing flexible hose. 4. Remove the brake pads and anti-rattle sprins . Before fitting new pads, it is necessary to retract the caliper pis t[...]

SECTION JC Page 5 8. Operate the footbrake several times to bring the pads to their correct working position and to take up the handbrake adjustment. JC 3. - HANDBRAKE ADJUSTMENT It is a feature of the Bendix handbrake mechanism that a large amount of handbrake lever travel is required in order for the handbrake to work efficiently and for the auto[...]

Page 6 SECTION JC After verifying this dimension, any slack in the cables may be adjusted out at their forward abutment inside the driver's sill trim panel. For access, slide the driver's seat fully forward and lift the rear end of the sill carpet to expose the trim pnel aperture. After adjustment, re-check the caliper lever 'off&apo[...]

SECTION JC Page 7 10. Install the caliper onto the top slide pin, swing down, and refit the caliper swing release bolt. Torque tighten to 1 .6 - 2.4 kgf.m. (12 - 17 Ibf.ft.). 11. Reconnect the brake hose, and bleed the brakes. JC. 5 - REAR CALIPER OVERHAUL 1. Disconnect the handbrake cable and brake hose 2. Remove the locking clips, slide out the c[...]

Page 8 d) With the tool holding the wings of the carrier apart, slide the new cylinder into the carrier bracket whilst depressing the locking pawl Note Check that the cylinder is fitted the correct way up. e) Ensure that the pawl locks into the carrier bracket locating hole and remove the spreader tool. JC. 6 - BRAKE DISCS Check the braking surface[...]

SECTION JC a 3C. 8 - MASTER CYLINDER OVERHAUL Page 9 Disconnect the fluid level switch leads, release the three brake pipes from the cylinder and remove the two nuts and washers securing the master cylinder to the servo. Remove the master cylinder assembly from the vehicle to a clean workplace before further dismantling. Drain the reservoir and pul[...]

Page 70 SECTION JC Coat the exterior of the projecting primary piston tube, vacuum sealing washers, and guide bush with the silicone grease provided in the repuir kit. Fit a stop washer and one vacuum sealing washer (lip side filst) over the piston tube and insert into the cylinder using a rounded blade. Fit the guide bush, second vacuum sealing wa[...]

SECTION KB Page 7 COOLING SYSTEM SECTION KB - ESPRIT S3 & TURBO Operation Page General Description Drain/Refill Procedure Cooling Fans - Replacement of Early Type Motors Cooling Fans Thermal Trip Cooling Fans Thermal Switch Replacement of Early Type Rad. Duct Stays. KB. 1 1 to 7 KB.2 7/8[...]

Esprit 53 Cooling System[...]

DodRoW Turbo Cooli na System[...]

[...]

codant Circulation ~ia~rnrn - &wit 53 8 U .S .A. Turbo I tor[...]

Heater Take-Off[...]

SECTION Kt3 Page 7 KB.l - GENERAL DESCRIPTION -- A centrifugal water pump is mounted on the front face of the cylinder block and is driven by a single 'V' belt from the crankshaft. Coolant is pumped by the impellor into the front of the block, around the 'wet' cylinder liners and into the cylinder head. Esprit S3 and U.S.A. Turb[...]

Page 8 Fill with coolant until a steady stream flows from the bleed. Close the bleed and add coolant until the system isfully filled. Run the engine a to operating temperature and open the bleed until a continuous stream af water flows out. Close the bleed, allow the engine to cool, and fill to within 50mm (2 in.) of the bottom of the header tank n[...]

. __. . .- ~ - _ ...- - - SECTION KB a' 3. Fit the new fan and motor assembly, using spacers A079K4175 between the motor and shroud legs as shown, and Permabond A136 on the fan motor mounting studs. Page 9 A075W3020 S hakeproof Washer A O75W4 046 4. On Series 3 models, discard the existing reverse polarity connection ---- and connect to loom u[...]

Page 10 SECTION KB thermal trip is open, or any motor fails to rotate at an effective speed. an a earth path or voltage difference is created and the fan failure tell tale will light. Pressing down the red reset button on the trip housing (adjacent to windscreen washer reservoir) will restore any tripped circuit. . -- --_ Cooling Fans Thermal Trip[...]

Page 11 On an earlier car, if inconsistent fan operation is experienced, or if the thermal switch or water-pipe is disturbed for any reason, the elbow pipe should be re-fitted in the 'inverted' position as shown. Esprit 53 cars prior to mid '85 and U.S.A. Turbo models have the switch fitted horizontally into the water pump outlet pip[...]

SECTION LA FUEL SYSTEM SECTION LA - EXCEL & ESPRIT S3 General Description Installation of Revised Fuel Filteration System Carburettor Theory of Operation Float Level Checking Carburettor Balancing Procedure Carburettor Mounting Operat ion LA. 1 LA. 1A LA. 2 LA.3 LA. 4 LA.5 Page 7 Page[...]

Page 2 SECTION LA LA.1 . - GENERAL DESCRIPTION - - Esprit Series 3 Two fuel tanks are fitted, one ahead of each rear wheel arch. A seperate filler neck with lockable cap is provided for each tank, and the two tanks are interconnected by a balance pipe. A single sender unit for the fuel gauge is fitted into the top of the right hand tank. Fuel is fe[...]

Page 2 B SEC T/ON 5 Remove existing fuel pipe from tank to flow lock and flowlock to pump and discard. Disconnect fuel pipe from pump outlet. Fit new banjo bolt /filter assy. (~084~0181 F) using new crush washers and new fuel pipe (AO89L0211F) from tank to pump inlet Torque tighten banjo boltlfilter assy. to 2.8 kgfm (20 lbf. ft.). New Fuel Filter [...]

SECTION LA Page 3 LA.2. - CARBURETTOR THEORY OF OPERATION Carburettor Type - Standard Engines - Dellorto DHLA 45E - 'H.C.' Engines - Dellorto DHLA 45D Fuel Supply Fuel from the union (1) posses through the filter (2) and reaches the needle valve seat (1 8), where the needle valve (1 7) attached to the float (15), controls the fuel flow in[...]

Page 4 SECTION LA With the choke valve (8) partially closed, when a leaner mixture is required, mixfure flows into the vafve chamber (9) through one of the two outlet ports (7), further mixing with air from the two channels (5), which, in this condition, are partially closed. With the choke valve (8) closed, communication between the main barrels a[...]

SECTION LA Page 5 Ptogress ion On first opening the throttle valves (12), that is when passing from idle to full throttle, mixture arrives to barrels (1 1) ' also through progression holes (32) . Acceleration On opening of throttle valves (12), lever (39) attached to spindle (38), by means of the rod (40) and the spring (41) pushes the pump le[...]

Page 6 SECTION LA 0 Full Throttle With the throttle valves (12) opened, fuel from the float chamber (461 metered by the jets (47), enters the well (48) and mixes with air metered by the air corrector (49). The mixture thus formed, passes through the inner venturi (50) where it furthr mixes with air drawn through the main barrel of the carburettor, [...]

SECTION LA Page 7 Power Jet Operation (H . C . engines only) At high engine speeds, an additional amount of mixture flows through the needle jet (52), upstream the inner venturi (50); mixture is composed of fuel drawn from the float chamber through channel (56) and metered by the jet (55), mixed with air metered by the calibrated passage (54) and d[...]

Page 8 SECTION LA lA.3. - FLOAT LEVEL CHECKING Remove the carburettor top complete with float assembly. Ersure the correct weight of 8.5g is indicated on the float, and that the float assembly pivots freely on its pin. Hold the cover vertical with the float hanging downwards and in light contact with the needle. Measure the dimension 'A' [...]

SECTION LA Page 9 Adjust throttle coupling screw to balance lower of mercury columrs 1 and 2 with lower of mercury columns 3 and 4 to within 3 mm. Considering the front carburetton, gradually urscrew the air bleed balancing screw of ONLY the carb. barrel with the highest mercury column, until it is balanced with the lower column to within 3 mrn. Ca[...]

Page 2 A 1 > Disconnect the battery 2) Remove fuel tank board, boot floor and spare wheel Take necessary precautions to avoid fuel spillage, remove banjo bolt/filter assembly and drain tank COMPLETELY. Discard removed banjo bolt /f tlter assy . 4) Use the illustration as a guide and fit the new fuel filter assy. ( A089L6012F) to the body panel o[...]

LH Fuel Tank RH Fuel Tank LH Tank Top Board RH Tank Top Board Bmcket, Board to Bulkhead Studplate, Bracket to Bulkhead Was her Plate Bracket, Board to Wheelarch Washer Plate Washer Plate Foam, Tank Clamping Sender Unit, Fuel Gauge Gasket, Sender Unit LH Filler Neck RH Filler Neck Filler Cap Clamp Ring, Filler Neck Gasket, Clamp Ring Hose, Filler to[...]

- SECTION LB FUEL SYSTEM Page I SECTION LB - ESPRIT TURBO, DOWROW Operation - Page General Description Carburettor Theory of Operation Float Level Checking Carburettor Ba lancing Procedure Carburettor Mounting[...]

[...]

Page 4 LB.l . - GENERAL DESCRIPTION - Two fuel tanks are fitted, one ahead of each rear wheelarch. A seperate filler neck with lockable cap is provided for each tank, and the two tanks are interconnected by a large bore balance pipe. A single sender unit for the fuel gauge is fitted into the top of the right hand tank. Fuel is fed from the left han[...]

SECTION LB Page 5 Starting With the choke valve (8) opened, fuel metered through jet (1 4), passes into the emulsion tube (13), where it mixes with air from the channel (16), communicating with the float chamber top through hole (6). The mixture formed flows, through holes (7), into the valve chamber (9), further -mixing with air from the two chann[...]

Page 6 SECTIONLB With the choke valve (8) partially closed, when a leaner mixture is required, mixtvre flows into the valve chamber (9) through one of the two outlet POIIS (7), further mixing with air from the two channels (5), which, in this condition, are partially closed. With the choke valve (8) closed, communication between the main barrels an[...]

SECTION 1 B Page 7 Progress ion -- On first opening the throttle valves (12), that is when passing from idle to full throttle, mixture arrives to barrels (1 1 ) also through progression holes (32). A Acceleration On opening of throttle valves (12), lever (39) attached to spindle (38), by means of the rod (40) and the spring (41 ) pushes the pump le[...]

Page 8 SECTION LB Full Throttle With the throttle valves (12 opened, fuel from the float chamber (46) metered by the jets (47), enterr the well (48) and mixes with air metered by the air corrector (49). The mixture thus formed, passes through the inner venturi (50) where it further mixes with air drawn through the main barrel of the carburettor, fl[...]

SECTION LB Page 9 LB .3. - FLOAT LEVEL CHECKING Remove the carburettor top complete with float assembly. Ersure the correct weight of 8.5 g is indicated on the float, and that the float assembly pivots freely on its pin. Hold the cover vertical with the float han3ing downwards and in light contact with the needle. Measure the dimension 'A&apos[...]

Considering the balancing screw SECTION LB front carburettor, gradually unscrew the air bleed of ONLY the carburettor barrel with the highest mercury column, until it is balanced with the lower column to within 3 mm. Carry out the same procedure for the rear carburettor, and if necessary re-adjust the throttle coupling screw to balance all columns [...]

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

[...]

Key to Fuel System Diagram - - --- - . LH Fuel Tank RH Fuel Tank LH Tank Top Board RH Tank Top Board GI-acket, Board to Bulkhead Studplate, Bracket to Bulkhead Washer Plate Bracket, Bourd to Wheelurch Washer Plute Washer Plute Foam, Tank Clamping Sender Unit, Fuel Gauge Gasket, Sender Unit LH Filler Neck RH Fit lei- Neck Filler Cap Clamp Ring, Fill[...]

Page 4 SECTION LC LC.1 - GENERAL DESCRIPTION Two fuel tanks are fitted, one ahead of each rear wheelarch. A seperate filler neck with lockable cap is provided for each tunk, and the tvm tunks are interconnected by a large bore balance pipe. A single sender unit for the fuel gauge is fitted into the top of the right hand fank. Fuel is fed from the l[...]

SECTION LC Page 5 Starting With the choke valve (8) opened, fuel metered through jet (1 4), passes into the emulsion tube (13), where it mixes with air from the channel (16), communicating with the float chamber top through hole (6). The mixture formed flows, through holes (7), into the valve chamber (9), further mixing with air from the two channe[...]

Page 6 SEC~/ON LC With the choke valve (8) partially closed, when a leaner mixture is required, mixture flows into the valve chamber (9) through one of the two outlets poris (7); further mixing with air from the two channels (5), which, in this condition, are prtially closed. With the choke valve (8) closed, communication between the main barrels a[...]

SECT/ON LC Page 7 Progression On first opening the throttle valves (12), that is when passing from idle to full throttle, mixture arrives to barrels (1 1 ) also through progression holes (32). Acceleration On opening of throttle valves (1 2), lever (39) attached to spindle (38), by means of the rod (30) and the spring (41) pushes the pump lever (43[...]

Page 8 Whereas on Domestic/RoW Turbo and 912 engine carburetton the volume of fuel delivered by the accelerator pump is adjusted by nut (42), on.Fedeml Turbo DHLA 45M carburettors, the volume delivered is fixed, but the point of delivery commencement is adjustable. The correct setting is such that + with the throttle closed, there is a clearance of[...]

- - - SECTION LC Page 9 Power Jet Operation At high engine speeds, an additional amount of mixture flows through the needle jet (52), upstream the inner venturi (50); mixture is composed of fuel drawn from the float chamber through channel (56) and metered by the jet (55), mixed with air metered by the calibrated passage (54) and drawn from the flo[...]

Page 70 SECTION LC LC.3 - FUEL CONTROL PRESSURE 1 . Connect fuel pressure test gauge as shown below. n FUEL SUPPLY TO CARBURETTORS FUEL PRESSURE REGULATOR SCREW FRES~JRE TEST GAUGE KIT LOTUS PART NO. TOOT0500 Switch on ignition and check fuel pressure = 4.0 - 4.5 p .s .i. If outside specification, remove anti-tamper plug from Fuel pressure regulato[...]

SECTION LC Page 11 View from front If switch adiustrnent is carried out, open throttle to 2500 rpm and then return throttle to idle position. Check that when engine speed is above 1800 rpm, the micro-switch is deactivated allowing fuel pressure to increase to 4.0 - 5.0 p.s.i. Repeat this test and check that pressure differences are maintained. Ad j[...]

Page 72 LC .5 - CARBURETTOR BALANCING PROCEDURE 1 . Ensure ignition timing is correct and the air filter and all trunking etc, fitted. 2. Remove anti-tamper caps from idle CO adjustment screws, air bleed balancing screws, and throttle coupling screws. VACUUM TAPPING SCREW BALANCIN SCREW REAR CARBURETTOR ENGINE IDLE SPEED SCREW IDLE STOP BRACKET THR[...]

SECTION LC Page 73 10. Switch analyser to sample mode and check readings. Note: Do not touch idle adiustment screws until CO reading has stabilised. CO reading should be between 0.2 - 1 .2%. If higher or lower levels are found, move each mixture screw of a turn in or out as the reading dictates. Check the CO reading and repeat procedure until corre[...]

[...]

SECTION LD FUEL SYSTEM Page I SECTION LD - USA ESPRIT TURBO H.C.1 . General Description Fuel Injection System Description Fuel Feed (pump, accumulator, filter) Mixture Control Unit Fuel In jecton Mixture Adaptation Cold Start l n jector Thermal Time Switch Auxiliary Air Valve Warm Up Regulator i High Altitude Compensation Exhaust Emission Control L[...]

[...]

Mixture Control Unit Comprises of the Air Flow Sensor and Fuel Distributor. (LD .4) Air Flow Sersor Measures air flow into the engine and moves fuel distributor control valve accordingly. Fuel Distributor Comprises: i) Rirnary Ressure Regulator to control pressure of fuel delivered by pump. ii) Control valve to regulate fuel delivered to injectors [...]

FUEL ACCUMULATOR FUEL TANK I FUEL PUMPS fp-" '"" FUEL FILTER " & JJ LE 395 FUEL SYSTEM - SCHEMATIC DIAGRAM[...]

a SECTION LD Page 5 LD . 1 -. - GENERAL DESCRIPTION Two fuel tanks are fitted, one ahead of each rear wheelarch. A separate filler neck with lockable cap is provided for each tank, and the two tanks are inter- connected by a large bore balance pipe. A single sender unit for the fuel gauge is fitted into the top of the RH tank. Fuel is fed from the [...]

Page 6 SECTION LD The pump are permanent magnet electric motor roller-cell type, wherein the fuel flows past the motor itself to a roller cell pump chamber. A motor driven disc mounted eccentrically in this chamber, uses rollers contained in slots around its circumference and thrown out by centrifugal force against the wall of the eccentric chamber[...]

Page 7 When the fuel pump are running, the pressure of fuel pshes the diaphragm back against its spring until the storage chamber is filled as in diagram B. When the pumps are switched off, the non-return valve fitted in the outlet of the second pump, prevents fuel returning to the tank, through the pump, and the fuel distributor primary pressure r[...]

Page 8 SECTION LD Air Flow Sensor The air flow sensor consists of a sensor plate mounted on a counterbalanced fever, operating the fuel distributor control valve. The sensor plate is positioned in an air funnel and operates on the suspended body principle such that the greater the quantity of air dmwn in by the engine, the greater the sensor plate [...]

. ... Page 9 When the engine is stopped, the fuel pump are switched off and the pressure drop below injector opening pressure. The primary pressure regulator then seats fully under the action of its spring, and prevents further pressure reduction in the primary system. ii) Fuel Control Valve The fuel control valve is located centrally in the fuel d[...]

Page 7 0 SECTION LD Control Pressure In order to damp any tendency of the control valve and air flow sensor to osillate, and to provide a means whereby the movement of the control valve relative to the airflow may be varied to suit different operation conditions, a 'control pressure' is arranged to act on the top of the control valve and [...]

SECT/ON LD Page I7 Distributor Differential Valves One distributor differential valve for each engine cylinder is incorporated in the fuel distributor to maintain a constant pressure drop across the metering slits regardless of their opening. This is necessary in order to ensure that the fuel flow to the injecton is dependant only on the length of [...]

Page 12 SECTION LD LD. 5. - FUEL INJECTORS The fuel injectors are fitted into the inlet manifold, and continuously inject fuel into the intake parts whilst the engine is running. The injectors have no metering function but open at a specified pressure and inject the fuel allocated to them by the fuel distributor. The injector nozzles are fitted wit[...]

SECTION LD Page 73 LD. 6 - MIXTURE ADAPTATION The system so far described provides a fuel/ air mixture suitable for normal running. Various supplementary devices are required in order to adapt the mixture strength for differing climatic, transient and emissions related conditiom . These components include those providing enriched mixture strength f[...]

Page 14 SECTION LD LD. 8. - THERMALTIME SWITCH The thermal time switch is fitted into the inlet manifold water jacket between tracts 3 & 4. Its function is to control the injection time of the cold start injector dependent on engine temperature, The switch consists of a hollow tube, inside which is mounted an electrical contact controlled by a [...]

SECTION LD Page 15 0- In the cold engine condition the plate adopts a position fully opening the by-pass line. As soon as the ignition is switched on, current flows through the heating coil and gradually causes the bimetal strip to bend and rotate the plate,reducing the by-pass aperture. As the engine warns, and its heat is absorbed by the valve bo[...]

Page 16 SECTION LD LD. 11 . - HIGH ALTITUDE COMPENSATION Operating the engine at high altitude where the air density is lower, requires that some compensation be made by the fuel metering system to prevent the mixture becomi ng too rich. This compensation is achieved by incorporating an aneroic capsule into the base of the warm up regulator. The va[...]

Page 17- .. LD. 13 - UMBDA SENSOR It is possible to determine the excess air factor of the mixture being delivered to the cyllnden by measbring the oxygen content of the exhaust gas before the catalyst. This is achieved by fitting a Lambda sensor into the exhaust system between the turbocharger and =a to1 yst . The Lambda sensor is calibrated such [...]

Page 18 Lowering the pressure beneath the diaphragms will increase the pressure differential across the metering slits and increase fuel delivery to the iniectors. The variable throttle takes the form of a Frequency Valve, which continuously cycles open/clored, with the ratio between open and closed periods being determined by the electronic contro[...]

The E.C.U. sets fixed duty cycles under the following conditiors: i) 75% duty cycle at engine oil temperatures below 35'~ as sensed by the the low temperature switch. ii) 65% duty cycle on engine overun, when fuel by-pass valve (LD.16) is opera ti ng . iii) 65% duty cycle at throttle butterfly openings of more than 30°, as sensed by the throt[...]

Page 20 SECTION LD LD. 18 - VACUUM OPERATED ENGINE MANAGEMENT DEVICES These include the Thermal lgnition Valve, (T. I .V .) lgnition Solenoid, and Throttle Jacking ~a~s"le. Thermal Ignition Valve (T. I .V .) The T.l .V. is fitted into the inlet manifold water rail and controls the vacuum feed to the distributor advance capsule (D .A.C.) . At w[...]

r . . Vacuum Pump, VACUUM SWITCHING DIAGRAM - BELOW 53' C WATER TEMP.[...]

Vacuum Pump I. TO I DISTRIBUTOR CAPSULE I C - Vacuum Pump Feed I- Upstream Throttle Port .- ..." ".". ..". "-.-.' Edge Drilling - Ignition Solenoid VACUUM SWITCHING DIAGRAM - BETWEEN 53' - 70° C WATER TEMP.[...]

THROTTLE EDGE PORT DISTRIBUTOR CAPSULE u[...]

Page 24 SECTION LD LD. 20 - EVAPORATIVE LOSS SYSTEM The fuel evaporative loss system includes a charcoal canister, one way valve, and crankcase breather va he. Charcoal Canister The breather pipes fro-m the fuel tank filler necks are routed via a roll-over valve (to prevent fuel spillage if the car is inverted) to port'~~'on the charcoal [...]

SECTION LD Page 25 In addition, the small depression below the airflow sensor causes a lesser purge to take place through canister port 'C' . At water temperatures above 70° C, with wide throttle openings and high rpm, when turbo boost pressure in developed, inlet manifold pressure becomes positive, and the manifold air rail hose is seal[...]

Page . . 26 SECTION LD LD. 21 - ENGINE WARM UP S1 Engine Cranking As soon as engine cranking takes place, the rpm relay switches on the fuel pump and the system is pressurised to 6.5 bar main primary pressure. Air induced into the engine moves the airflow sensor which opens the fuel control valve and allows fuel to be delivered to the injectors. In[...]

a SECTION LD Page 27 LD 23 ENGINE MANAGEMENT SYSTEM CHECK/SET UP PROCEDURE Tools Required i > ii) iii) iv) 1. Duty Cycle Meter . TOOOT0567 Continuity Meter TOOOT0568 khaust Sample Probe TOOOT0501 Stroboscopic Timing Light (proprietory) Connect the duty cycle meter to the frequency valve: The frequency valve is located ahead of the fuel distribut[...]

Page 28 SECTION LD 0 Connect a strobcscopic timing lamp to No. 1 spark plug lead and remove grommet from clutch bell housing. Start engine and run until normal operating temperature is reached (water temp. above 80O~). 2. Check idle speed. 950 !: 50 rpm. DO NOT ADJUST IDLE SPEED WITHOUT FIRST SLACKENING THROllLE POSIT1 ON SWITCH MOUNT1 NG SCREWS ON[...]

SECTION LD Page 29 3. Check ignition timing at idle: 15O BTDC using the strobe and flywheel timing mark. View of Clutch Housing Timing Aperture Ad just, if necessary, at the distributor clamp. (special Socket TOOOT0503) Check throttle jacking capsule adjustment: Bridge connections to inlet manifold high tempemture switch (use a spre fuse) to activa[...]

Page 30 SECTION LD If the duty cycle or exhaust gas analysis are outside specification, remove the wiring grommet from the LH engine bay wal I, and extract the Lambda sensor electrical connector. Disconnect the single spade connector to obtain an open loop exhaust gas reading. (Larger connector block is Lambda heating coil). If the mixture setting [...]

SECTION LD Page 37' - LD 24 - FUEL INJECTION FAULT DIAGNOSIS Note: When using this chart it is assumed that the general engine condition is sat&factory and ignition system is adjusted correctly. It is also assumed that the electrical system, including the safety cut-out circuit for the petrol iniection system, has been checked and is in go[...]

Page 32 SECT/ON LD A - FUEL PUMPS 1 . Check inertia switch and fuel pump fuses. (LD 26). 2. Remove fuel pump control relays and fit electrical test bridges TOOOT0569. The fuel pump should be heard running. If no sound is heard, refer to LD 26/27/28 for electrical diagnosis. 3. With pumps running, check voltage drop at terminals of both pump. Minimu[...]

Page 33 , .. > . . . . . . . .. . If the quantity is insufficient: . .,. .. .. . ... 5. Check Fuel Delivery Quantity at Secondary hmp Outlet: Fit the test hose to the secondary fuel pump.outlet connection, and place end:.iri ':. .:: graduated flask . Secondary Pump UEL ACCUMULATOR Trip inertia switch and fit electrical test bridges to fuel [...]

Page 34. SECTION LD 0 - FUEL PRESSURES Tools requ Ired: Test Gauge TOOOT0575 Electrical Test Bridges TOOOT0569 1 . Check Prtmary Pressure Trtp inertia switch, remove fuel pump control relays and fit electrical test bridges into relay bases. Fit test gauge to fuel distributor inlet connection with gauge valve toward dtstributor . (see Fuel System Pr[...]

SECTION LD Page 35 3. Adjust Primary Pressure Regulator Remove the pressure regulator from the fuel distributor by unscrewing the hexagonal nut shown (see Fuel System Precautions LD. 22). MIS ITEM SHOULD NEVER REQUIRE ATTENTION UNDER Adjust the shim pack as necessary to correct primary pressure - adding O.lmm shim thickness increases pressure by ab[...]

Page 36 SECTION LD Open gauge valve. With test bridge fitted, see (I), press down inertia swifch and record cold control pressure from gauge. Trip inertia switch. Compare the reading obtained with the graph shown. "Cold" Control Pressure 4,s bar mbar kgf/im 840 4,o 860 880 900 920 3,s 940 a, L 1 E 3 n 3'0 V) w d aJ L f a 0 L . - U 4 [...]

SECTION LD Page 37 The nominal control pressure should be read from the curve in accordance with the air pressure. The effect of the altitude compensation begins at an air pressure of about 933 rnbai, i .e. starting at about 600 m. At higher altitudes it is essential that the exact air pressure is known on the day when the measurements are made. (U[...]

Page 38 Fit the pressure gauge at the fuel distributor inlet connection, and at the secondary fuel pump outlet connection (see Section 'A') and record rate of pressure drop to establish faulty component. Possible causes of control pressure leak: i) Control pressure shut off valve leaking. Replace. Use new sealing washers whenever re-makin[...]

Page 39 D - COLD START INJECTOR a Disconnect the cold stert iniector electrical plug and release injector, with pipe attached, from inlet rnaniflod. Taking care &t to kink the fuel-pipe, lace the injector in a glass jar, or graduate, and fit electrical test lead TOOOT0570. Connect test leads to ignition coil terminals. switch on ignition and pr[...]

Page 40 SECTION LD.. If the sensor plate rest position is too high, the stop pin for the rest position spring may be adjusted by the careful use of a pin punch and light hammer. CAUTION: Take care not to over adjust, as the mixture control unit must then be removed for the pin to be knocked back. Repeated adjustments will loosen Rest position Pin I[...]

SECTION LD See Fuel System Precautions LD . 22 Page 4 1 i> i i) it;) Use a cloth to absorb the small amount of pressurised fuel released when the warm up regulator feed pipe is gradually slackened from the distributor. Release all other fuel pipe connections to the fuel distributor taking all precautions necessary to minimise fire hazard . Relea[...]

Page 42 F - VACUUM SUPPLY Use the vacuum switching diagram and a 0.30 in. Hg vacuum gauge to measure the vacuum available at the ignition solenoid, throttle jacking capsule, thermal ignition valve, and distributor advance capsule under the different engine coolant temperatures. A minimum of 18 in. Hg should be recorded at any point in the vacuum li[...]

Page 43 Vacuum Fhnp Feed - Upstream Throttle Port " ' "" Throttle Edge Drilling Ignition Solenoid i VACUUM SWITCHING DIAGWM - BETWEEN 53O - 70° C WATER TEMP. Vacuum Pump Feed - Upstream Throttle Port - . .'".'.. '" ."" Throttle Edge Drilling -Ignition Solenoid VACUUM SWITCHING DIAGRAM - ABOVE [...]

Page 44 G - FUEL INJECTORS SECTION LD '' Remove the injecto~ from the inlet manifold (seeFuel System Precautions LD 22) and test individually using tool T000T0580 and white spirit. Connect an iniection valve to the valve tester and bleed the discharge tubing by moving the lever back and forth several times with the union nut open. Then ti[...]

SECTION LD Page 45 Open the stopcock and test the opening pressure by moving the lever slowly (about 2 seconds' per stroke). + l njector opening pressure: 3.5 - 0.6 Bar If the opening pressure is outside. tolerance, replace the injection valve. l ndividual valves can be changed within a set. 5. Leakage test. Open the stopcock, build the pressu[...]

Page46 SECTION LO Poor spray formation; replace injection valves. Drop formation a "Cord" spray "Spray in strands "[...]

SECTION LD Refitting fuel injectors: Emure '0' ring are undamaged. Lubricate the manifold injector hole with a silicone spray and carefully slide the injector down the hole pressing it away from the air rail cross-drilling hole. Pvsh the larger '0' ring into its recess using a tube of suitable diameter so, that pressure is appli[...]

Page 48 SECTlON LD Using a 3mn1 allen key, turn the mixture adjustment screw, without ptessing down the airflow sensor, until fuel can i~st be seen to drip from the iniector. Turn the screw f turn cwiterclockwise. rip inertia switch and remove electrical tat bridges. Refit fuel pump conk01 relays, and reset inertia switch. Remove slave injector and[...]

SECTION LO Page 49 L-FUELBY-PASSVALVE With the engine at normal running temperature, remove the valve from the air filter box, and observe the valve action on closed throttle engine overun conditiom . If the valve does 'not open, check electrical feed and refer to electrical sections LD . 26/27/28. Check the closed valve position by blowing do[...]

Page 50 If the throttle position switch requires adjustmen ~t, check first SECTION LD that the warm idle speed a is correct. Slacken the throttle position switch mounting screws before making any idle speed adjustment . When completed, rotate the position switch slowly until continuity is JUST made, and tighten screws. Recheck setting. 0 - AIR LEAK[...]

SECTION LD With engine idling at normal running temperature examine the depression in tracts 2 and 3. Use spanner TOOOT0584 to slacken the coupling locknut and adjust coupling screw, to obtain optimum balance between mercury columns. - Re-tighten locknut and re-check balance. Remove special tools, and return to procedure LD23. If throttle imbalance[...]

Idle Fuel Pump Main Injection C ha ngeover Con fro l Relays ' Fuse 7.5 Amp. Relay I A Fuel Pump Inertia Switch I / Ignition -t-- - -k- Relay Amplifier I Over host I 15 A Fuses Switch . RPM Relay Fuel Pump Idle Up Con~al Relay[...]

SECTION LO Page 53 LD 27 - WIRING DIAGRAM SCHEMATICS - FUEL INJECTION Circuit Descriptions Base Circuit. Ignition Off. Cold Engine (Below 35'~) A positive feed is provided to the RPM relay. Cold Crank. Below 35'~ Oil Temp. When the ignition is switched on, the Lambda sensor heating coil is operated, and the fuel by-pass control relay acti[...]

Page 54 SECTION LD. 5. Normal Idle. Above 70' C Water Temp. Simibr to circuit (4) except: High temp. switch opens and de-energises the fast warm up relay. This relay now provides an earth (vTa the idle up relay) for the idle up solenoid which is energised and closes . The ignition solenoid is de-energised, which de-activates the throttle jacki[...]

SECTION LD , . .' . Page 55 9. Air Conditioning Compressor Operating. At Idle. Above 70° C Water Temp. Similar to circuit (5) except: A feed from the compressor circuit is directed via the idle up control relay to energise the idle up relay. This cuts off the earth circuit for the a/c idle up solenoid, which is de-energised and opened. This c[...]

St u K U KO YK AC.U. YS IDLE - - CHANGEOVER RELAY RELAY RELAY WARM UP RELAY R E LAY A - KS 4 b2 w %LE up ELECTRONIC - BY CONTROL UNIT L SOLENOID G 4) RPM RELAY -'" YO - T FUEL BY-PASS YR SPEED SENSING R 12 8 *-Yy -- - - 31e 7 eYN 31b 6. YB I " 15 KG YG - 4L G +f1gyaEi!i!31 IGNITION AUX. YLG YU IGNITION WS - 5 SOLENOID COI L-ve L-- - [...]

ELECTRONIC CONTROL UNIT n il COLD START &Aso~ L HEATING I L COIL THROTTLE FREQUENCY COLD THERMAL AUX~LIARY WARM UP POSITION VALVE START TIME AIR SWITCH REGULATOR INJECTOR SWITCH VALVE 2. COLD CRANK. BELOW 35'~ OIL TEMP.[...]

COIL THROTTLE FREQUENCY COLD THERMAL AUXILIAKY WARM UP POSITION VALVE START TIME AIR REGULATOR SWITCH INJECTOR SWITCH VALVE 3. COLD RUN & IDLE. BELOW 35'~ OIL TEMP.[...]

IDLE - - ' CHANGEOVER RELAY FUEL BY-PASS CONTROL yp RELAY L I A - I ELECTRONIC CONTROL UNIT n u k SENSOR - HEATING - I COIL THROTTLE FREQUENCY COLD THERMAL POSITION VALVE START TIME SWITCH INJECTOR SWITCH 4. COLD RUN & IDLE. ABOVE 35'~ OIL TEMP. BELOW 70°c WATER TEMP. I WY COLD START AUXILIARY WARM UP A 1.R REGULATOR VALVE[...]

SWITCH 5. NORMAL IDLE. ABOVE 70'~ WATER TEMP. 1 WY COLD START FREQUENCY COLD THERMAL AUX~LIARY WARM UP VALVE START TIME AIR REGULATOR INJECTOR SWITCH VALVE[...]

ELECTROh CONTROL *16 15- 12- 8 - 7- 6- 5 L- -=- 2 - SWITCH - SENSOR - - HEATING COIL THROTTLE POSITION SWITCH I YLG IGNITION AUX. IGNITION' SOLENOID 4 1 Y WY A IGNITION r T I WY COLD START FREQUENCY COLD THERMAL AUXILIARY WARM UP VALVE START TIME AIR REGULATOR INJECTOR SWITCH VALVE 6. NORMAL RUN. ABOVE 700C WATER TEMP. ABOVE 1600 rpm. BELOW 30[...]

VALVE I FUEL PUMP CONTROL p-qL- 1 RELAY ELECTRONIC CONTROL UNIT n FUEL BY-PASS I YG tGN ITION AUX. IGNITION SOLENOID KG YLG YU L 7 Y < b COIL THROTTLE FREQUENC~ COLD THERMAL POSITION VALVE START TIMF IGNITION POSITIVE WY CO-LD START' AUXILIAW WARM UP AIR REGULATOR VALVE - - SWITCH [NJECTOR W~~CH NORMAL RUN. ABOVE 70°C WATER TEMP. OVER 30&a[...]

a K U a K U IGN ITION AUX. so I - HEATING - COIL THROTTLE FREQUENCY COLD THE~MAL POSITION VALVE START TIME SWITCH INJECTOR SWITCH WY COLD START AUXlLlART WARM UP AIR REGULATOR VALVE 'ELAY 8, OVERUN. ABOVE 1400 rpm DECELERATING FROM ABOVE 1600 rpm[...]

LAMBDA,- - SWITCH WY COLD START ISENSOR I - HEATING - COIL THROTTLE FREQUENCY COLD THERMAL AUXILIARY WARM UP POSITION VALVE START TIME AIR REGULATOR SWITCH INJECTOR SWITCH VALVE 9. AIR CONDlTlONl NG COMPRESSOR OPERATING . AT IDLE. ABOVE 70"~ WATER TEMP.[...]

SENSOR SENSOR HEATING LOW I TEMP SWITCH COIL LIGHT THROTTLE, OVER 3250 rpfi THROTTLE POSITION SWITCH, FREQUENCY VALVE COLD THERMAL START TIME INJECTOR SWITCH B POSITIVE = cb - '3 AUXILIARY WARM UP I COLD START & AIR REGULATOR VA LV E[...]

PRIMARY FUEL PUMP RHC LWG-! W FUSE BOX SPLICE ' D ' SEE SHT 27 TO IDLE UP I FAST WARM UP VALVE SEE SHT. 3A I G L-, CBHC rGB ---I RHC CBHC 11 TO TACH0 WS SEE SHT. 2 TO RPM. RELAY 2 SEE SHT. 3A RHC ' b"* I----- wp---+)-WP-.- 1 1, SECONDARY FUEL PUMP WG 70 PUMP KP I FUEL RELAYS I ENGINE WERSPEED I FUEL PUMP KR FAILURE MODULE @ N rr[...]

Page 66 . LD. 28 - ELECTRICAL COMPONENT FUNCTION & FAULT DIAGNOSIS 1 , Idle Change Over Relay Location: Coil box Mating connector colour: Black Change over relay controlled by fuel by-pass speed sensing relay, energised when R.P.M. has exceeded 1600 R.P.M. and de-energised below 1400 R.P.M. Switches pin 7 of electronic control unit to ground, w[...]

SECTION LO Page 67 3. ldle Up Relay Location: Coil box Mating connector colour: Black Change over relay (schimatic as shown item one). Controlled by idle up control relay. De-energises idle up solenoid, when air condition compressor is operating, below 1400 R. P.M. 4. Fast Warm Up Relay Location: Coil box Mating connector colour: Black Changeover r[...]

, Page 68 SECTION LD - 9. High Temperature Switch Location: Water mil, inlet manifold. Additional information see LD 18. - 0 Controls fast warm up relay. Senring coolant temperature goes open circuit on raising temperature at 70' C and closed circuit on falling temperature at 600 C. 10.. Idle Up Solenoid Location: Right hand fuel tank board. A[...]

SECTION LP . < Page 69 13. Low Temperature Switch Location: Oil gallery cover. Additional information see LD 15. Serrses oil temperature, grounds pin 12 of the electronic control unit when closed circuit. 0 Open cicuit on rising temperature at 35 C, closed cicuit on falling temperature at ZOc. 15. Warm Up Regulator Location: Bolted to alternator[...]

.- . Page 70 .,.... SEC.T/ON . LD . 18. Cold Start Injector Loco tion: Cold start adaptor, inlet manifold Mating connector colour:. ~lle. Additional information see LD 7. Electrically controlled iniector. Positive feed supplied from cold start contact of starter motor during cranking, negative supplied by the thermal time switch to control injectio[...]

SECTION LO Page 77 21 . Electronic .Control Unit Location: Inside cabin mounted to the bulkhead behind the dirver's seat Mating connector colour: Black . Additional information see LD 15. Electronic control unit for exhausts emission control . This unit processes information supplied by various sensors/swi tches and controls the opera tion of [...]

Page 72 SECTION LD 24. Engine Ovenpeed/Fuel Pump Failure Module Location: Top of right hand tank board. (Under filler neck) - Mating connector colour: Natural . Additional information see LD 3. The module senses low tension ignition pulses and supplies a negative to the fuel pump control relay winding. In the event of excessive engine speed (7,000 [...]

SECTION MB Page I ELECTRICAL SECTION MB - ESPRIT S3 & TURBO (~om/~ow) Section Circuit Diagrams: MB. 1 S3 - Lumenition & Fused Fan Relay S3 - A/C, Constant Energy & Thermal Trip S3 - A/C, EEC (Symbol) Switches S3 - From VIN 85D2153 (July '85) S3 - '87 M.Y. onwards Turbo - Commemorative, Lumenition Turbo - Constant Energy, Fused[...]

[...]

TURBO ESPRIT WIRING OIAGRAW ( DOMESTIC.RO.W> !rnWIOELlEaR I 1% XI[...]

.. ..- S SLATE U BLUE W WH!TE Y YELLOW " 1-4[...]

TW ESPRIT WIRING MPGRAM I WMESTL . R.O.W. t WIM WNWtil EIERir lGMTlXl8 WQTI WTCR Fffl RELAY LSL 2U[...]

REDSTIT 2 m CENTRE LO*HIE PAN3 UWTL nOul LIGHTER MU[...]

[...]

53 ,ESPRIT WIRING DIAGRAM (DOMESTIC.R.0.W.) WITH KU WTH~aa4nCNmaYIRL(1FIN~~P.IELClSRBCll~ ur tn[...]

53 ESPRIT WIRING DIAGRAM (DOMESTIC.R.0.W.I !mi UMMTIII UO FUYD FN4 WY LSL 2L9[...]

t I S3 ESPRIT WIRING DIAGRAM (DOMEST1C.RO.W) WITH ACU. bllI'mswCrwrrZrwmaC&llbDldmRFPN~W 1% 2%[...]

WINDSCQEEN WASH WMP MOTOR m RADIATOR COOLING RCITDRELAYS FANS mbo (briar 87MY) & S31Rvbo87mm H/L Cantrol H/L Flash H/L Flash H/L Motor Iul H/L Motor RH I WL Motor LH I H/L Motor LH (Grey) Rad Fans (if thermal trip fitted) (Fused) Rad Fans (if no thermal trip) PUMP THERMAL SWITCH ( Water pumpoutlet pipe) For component usage (53 - RAD. FANS I EAR[...]

LOW COOLANT LEVEL MODULE ( TURBO 1 A.C. TEMPERATURE CONTROL UNlT ( TURBO & LATE S3 1 / FAN FAIL RELAY INTERIOR LIGHT DELAY FUSEBOXES AERIAL RELAY 11 HAZARD/TURN FLASHER UNITS INNER HEADLAMP CIGAR LIGHTER WIPE! RELAYS FUSES ( 17A) A.C.U. CO M PARATOR INTERIOR UNIT (TURBO ) FAN RELAY DELAY IT . 'b. A.C. COMPRESSOR Q. RELAY m MB.2. - C[...]

MB.3. - HARNESS ROUTING DIAGRAM[...]

SECTION MB Page 7 7 MB.4. - LUMENITION IGNITION SYSTEM Early Series 3 and Turbo models used Lumenition infra red solid state contact breakerless ignition. On early Turbo models, the Lumenition power module was mounted on the engine bay side of the right hand fuel tank well, but was moved on introduction of the Esprit S3, to the ignition box at the [...]

Page 72 SECTION MB Summary : Power Part Connector Colour Length Compatible Module Number Block o f o f Optical Shape Sea 1 Lead * Switch Mk 16 A075M0335F Rectangular Red or 790 mm A907E6331F (~k 16) (No Black or B907E6331F (MK 17) longer + A083M6305F (convertor) available) Mk 17 ~083~0384~ Oval or White 790 mrn B907E6331F (Mk 17) Rectangular Mk 17 [...]

a/ SECTION MB Page 73 2. Having made certain tags are in locking position, push ,each pin in the correct tunnel of the new connector block until the tag clicks into position. The connector is numbered as illustration w =I Blue a NOTE: On no account must Mk 17 power modules be connected with Mk 16 optical switches. Also, Mk 16 modules must not be co[...]

Page 74 SECTION MB. , wire leading to the power module. As this connection is made a spark is produced at the HT lead. If no spark is produced the power module is suspect. If a weak spark is - produced - the coil may be suspect. 3. To test the optical switch - The optical switch must be connected to a good power module. With a sensitive voltmeter m[...]

,' SECTION MB Page 7 5' a MB.5. - LUCAS CON ISTANT ENERGY IGNITION The Lucas constant energy ignition system is an inductive system in which the energy stored in the coil is maintained constant over a wide range of 'engine speeds, thereby providing consistently high output voltages. The system comprises a distributor model 45 DM, and[...]

Page 16 SECTION MB 3 CHECK AMPLIFIER SWITCHING 4 PICK-UP COIL RESISTANCE 5 CHECK HT SPARKING 7 VISUAL AND HT CABLE CHECKS EXAMINE 1 Distributor Cover 2 Coil Top 3 H.T. Cable Insulation 4 H.T. Cable Continuity 5 Spark Plugr Recommended Test Equipment DC moving coil voltmeter, scale 0 - 20V DC moving coil ohmmeter HT jumper cable Voltage increases wh[...]

[...]

Page 78 SECTION MB MBJ. - DIM-DIP HEADLAMP SYSTEM (U. K. Models) The Motor Vehicles (Dim-Dip Lighting Devices) Regulations 1983 of the Road Traffic Act, decrees that cars manufactured on or after 1st October 1986 for use in the U.K. and first registered on or after 1st April 1987, shall be fitted with Dim-Dip lighting systems. The Dim-Dip system mu[...]

SECTION MB Feed from DIM-DIP MCDIJLE B / Beams - Ignition I I Feed 0 iii) To Headlamp Ignition Mo ton Feed With sidelamps switched on, a feed is supplied to module terminal 1 and the relay is energised. When the ignition is switched on, a feed is supplied through the energised relay to the headlamp motors to raise the pods. In addition, a feed is s[...]

ELECTRICAL SECTION MC -'ESPRIT TURBO U.S.A. (Prior to '86 M.Y.) Circuit Diagrams: Component l ndex Legend Supplies Start, Alternator, lgnition Engine Management & Operation Choke Switch & Fuel Level Radiator Cooling Fans Air Conditioning Internal Fans Headlamp Beam, Dip, Flush a Horns, Beam, Dip & Column Switch Supply Headlamp[...]

- - SECTION MC A . C . U . Compressor A .C .U. Tern. Control A .C .U . Thermistor A Iternator Battery Cigar Lighteis Clock Distributor Engine Speed Limiter Fuel Sender Unit Fuse Box Heated Rear Screen lgnition Amplifier lgnition Coil Intermittent Wipe Unit Instruments - Battery Condition - Fuel Gauge - Tachometer - Temp Gauge Inverter, D. I. Warnin[...]

SECTION MC LEGEND BIN D.H.C. D.I. E.B.C. E.H.C. F.H.C. L.H.. P.H.C. R.H. R.H.C. SOL SD' W/LT . C.C.C. M.H.C. C.F.H.C. B Black G Green K Pink P Purple LTG Light Green N Brown Binnacle Connector Door Harness Connector Direction Indicator Engine Bulkhead Connector Engine Harness Connector Front Harness Connector Left Hand Pumps harness Connector [...]

SHEET 1 TO IGNITION SIW. SEE SHT 2 HEAD LAMP MAINIOIP BEAM CIRCUIT SEE SH1.8 - TO START MOTOR SEE SHT. 2 -TO FUSE BOX FUSE 24 ALARM TO RAD. FAN RELAY SEE SH'I 5 N SPLICE 'A' SEE SHT 25 I -NR-1-NR i w SPLICE . B' SEE SHZ 26 SPLICE 4 'D' SEE SHT. 27 -W+ 4 W IGN SHEET 1 a[...]

TO L.H. DOOR SIW. I BW+-LGW- i/ SEE SHT 12 SHEET 2 IGNITION SIW NR 30 50 P SPLICE'G'+-G SEE SHT 1 o SEE SHT 24 3 -Y--(i-Y A,CY CONTROL TO ENGINE RELAY RELAY SEE SHT 6 ENGINE SPEED LIMITER TO LAMP OELAY UNIT SEE SHT '12 E H C I ALTERNATOR I I I N Y ENGINE BAY VENT CIRCUITSEE StiT21 o+ I RHC 91 I LNya-G- SPLICE '6' SEE SHT 24[...]

SHEET 3A . . TO STARTER MOTOR (COLD START) I SEE SKI. 2 EHC MHC SEE CHOKE SIN 6 FUEL- WU-, 7 , ,;!G ,4 wU LEVEL CIRCUIT ON SHT 4 1 ENGINE RELAYS . . . (CLOSED CIRCUIT WITH THRUTTLE CLOSED 1 THROTTLE MICRO SIW. FUEL PRESS. SOL. CARB. EVA!? SOL. VENT. CIRCUIT ON SHT21 1 I -I THERMAL SIW. ( 7O9C. MAX. BREAK ON RISE I 66~. MIN. MAKE ON FALL.) f SPLICE [...]

IGN. AUX. -Yv YG- SHEET@ . . ' A.1 C. . . . . K U ...... , .. ' , . -., j au. i7.i .<i'$i,,.. KU~T~" - START SOL. YP YP . . . ,.. . '8 told Start. Choke operated & crank~ng la ENGINE MANAG.EMENT CIRCUIT - FEDERAL SHEET 38 ENGINE MANAGEMENT OPERATION A AIC. COMPRESSOR. 8. STARTER MOTOR. C CARB. EVAP SOLENOID: CLOSED W[...]

START SOL. WR IGN. AUX. Y-YG 10A. Cold Run -choke operafed THROTTLE JKK ENGINE MANAG.EMENT' CIRCUIT - FEDERAL SHEET 3c ENGINE MANAGEMENT OPERATION A AlC. COMPRESSOR. . Is B STARTER MOTOR. C CARB. EVAP SOLENOID: CLOSED WHEN IGNITION OFF, OPEN WHEN IGNITION ON. 0 TEMP CHANGE OVER RELAYS: CONTROLLED BY THERMAL SWITCH 'F' E THROTTLE SOLE[...]

IGN. AUX. y-YG- A.1C. K U START SOL. WR THROTTLE JKK IGN. Cold Run ( belo w 70 O C ) ENGINE MANAGEMENT CIRCUIT - FEDERAL SHEET 3~ ENGINE MANAGEMENT 0 RATION A AIC. COMPRESSOR. B STARTER MOTOR, C [ARB. EVAP SOLENOID: CLOSED WHEN IGNITION OFF, OPEN WHEN IGNITION ON. D TEMP CHANGE OVER RELAYS: CONTROLLED BY THERMAL SWITCH 'F' E THROTTLE SOLE[...]

IGN. AUX. Y-Y G- 10A. THROTTLE JACK IGN Hot,Run (above 70°C:) ENGINE MANAGEMENT CIRCUIT - FEDERAL SHEET 3~ e e ENGINE .MANAGEMENT OPERATION A AiC. COMPRESSOR. B - STARTER MOTOR. s 10 C CARB. EVAP SOLENOID: CLOSED WHEN IGNITION OFF, OPEN WHEN IGNITION ON. D TEMP CHANGE OVER RELAYS CONTROLLED BY THERMAL SWITCH 'F' THROTTLE SOLENOID: TO OPE[...]

ENGINE MANAGEMENT OPERATION IGN. AUX. YPYG 10A. 1 Hof Start ENGINE MANAGEMENT CIRCUIT - FEDERAL SHEET 3F A AIC. COMPRESSOR. B STARTER MOTOR. C CARB. EVAP SOLENOID: CLOSED WHEN IGNITION OFF, OPEN WHEN IGNITION ON. D TEMP CHANGE OVER RELAYS: CONTROLLED BY THERMAL SWITCH 'F' E THROTTLE SOLENOID: TO OPERATE WHEN; 1 AIC. COMPRESSOR IS ENERGISE[...]

SHEET 4 CHOKE SIW. RHC EHC >~-wu-+wu-) 7 7 WU SEE ENGINE MANAGEMENT CIRCUIT ON SHT3 . . .. . WU LOW FUEL LEVEL/ I CHOKE WILT. BIN A' 1 SPLICE -G '6' SEE SHT. 24 RHC GO-$--GO-~- CHOKE SIW. & FUEL. LEVEL VOLTAGE STABILISER SEE SHT. 24-SPLICE 'G'- I TO TEMP GAUGE SEE SHT.16 m GAUGE SHEET 4[...]

C F-HC FHC FUSE BOX 5 G--BG- BG 2+=Tl BN BN -RAD. RELAY FAN C FHC FHC FUSE BOX B G ----<- B G -1 3 B N B N BN TO A C U CONT CIK C F H-C FHC RELAY SEE SHT 6 --GK 8 I) CCC BG-(-BG-9- . ...,. .>. . . . . - . . .. .... . BIN 'B' FAN FAIL.WILT POSI 7Q c' POST A.C.U. THERMISTOR CONTROL UNIT I I GK BO - A.C.U. THERMISTOR I K I - LBO u[...]

1 SPLICE 'O' SEE SHT 27 W FUSE BOX 21 TO INT. FAN RELAY TO START MOTOR RAO. COOLING -GK L-r: IGNITION SEE SHT. 2 FANS CIRCUIT SEE SHT. 5 -YG WR S/W. SEE SHT. 2 BIN '0' WR 16 TO BRAKE FAIL 'cWR- SEE SHT. 15 A.C.U. CONTROL RELAY LOGIC BOX SEE SHT 16 RAD. COOLING -nul FANS CIRCUIT RHC EHC SEE SHT. 5 -KU 9 K----+~Ku YP-ENGINE M[...]

FUSE BOX SPLICE '6'-Y SEE SHT 26 B FAN SPEED SIW INT FAN MOTOR 2 FUSE BOX 21 aWdSPLICE '0' 8 SEE SHT 27 A CU CIRCUIT SEE SHT 6 INTERNAL FANS . I,. SHEET 7[...]

SHEET 8 FHC POSITIVE POST NU uwl IIPI MAIN BEAM C COLUMN SIN SEE SHT. 9 I. B FHC U G FUSE BOX 2 BIN 'A' R H HEAD LAMPS NOT USED SEE POWER WASH CIRCUIT -w OUT-BOARD ON SHT. 14 HEAD LAMP MAIN BEAM, DIP BEAM & FLASH SHEET 8 a[...]

MOTOR LH RELAY LH FUSE BOX FHC 16 SPLICE 'A' PA) 5 P A 8 N- SEE SHT 25 FLASH CIRCUIT SEE SHT. 8 NLG UG I MOTOR. RH RELAY RH HEAD 'LAMP MOTOR HORNS HORN RELAY FHC FUSE BOX 9 I TO ALARM SEE SHT 27 AL 7 - - Y HC AL4 DIP1 MAIN BEAM g COLUMN SIW HORNS, DIPIMAIN BEAM & COLUMN S/W SUPPLY SHEET 9~[...]

POSITIVE LH MOTOR l+.sA RELAY HEAO LAMP MOTOR OPERATION m PODS DOWN HEAD LAMP OR CIRCUIT[...]

L H HEADLAMP LH MOTOR MOTOR S RELAY - I , 10A MOTOR .:-. :. ... ... ..-. : ... :;:: .,: .... ... ..... - :::: :.:. $1 .: .. :.. ........ .... ...... .:. : :: :ii I:; :.:. :.: ... ....... ....... 7. ... ...... ... ........ ...... :.:. $ :.> :.: - I= ........ U G ... ... ... ..... ... ...... NLG .,. :. . . .. ... ........ ....... ...... .... . . .[...]

POSITIVE N I HEAD LAMP MOTOR OPERATION HEAD LAMP MOTOR CIRCUIT SHEET 90[...]

HEAD LAMP MOTOR. OP I(h ATION PODS TRAVELLING DOWN NU LIGHT SIW HEAD LAMP MOTOR CIRCUIT SHEET 9~[...]

POSITIVE POST q NLG d HEAD LAMP MOTOR OPERATION HEADLAMP FLASH 1 POD TRAVELLING UP HEAD LA'MP MOTOR CIRCUIT 7[...]

I, SEE SHT. 25 BIN'B' I 20 12 SPLXE '0' GW- 6-1 SEE SHT. 27 B A FUSE TO CLOCK R B- SEE SHT.12 3 R. H. SID MARKER B (RG- FUSE jJ LIGHT S/W '1 F H C 9 R rR+ RO~~RO- R.H. FRONT BOX TO RHC 8 RHC / ~!!GW*B+I' R H REAR 0.1. . .. . . . . .. . .. . SHEET 10. .. D.I. & HAZARD[...]

INSTRUMENT 2 ILLUMINATION 7 TO ALARM BIN%& SHT -N7 FAtU HC 1 27 AL Y AL4 B&B CIRCUIT BAT TACHO. BOOST SPEEDC. TEMF! FUEL L.H. OttC SHT. 12. FIBRE OPTIC 1 ,-~LRO-0.1. 8 HAZ. R N R N RN R N R N -RHC )( CIRCUIT 8T /RO- SEE SHT 10 - R B 1 RB r I RO RO LH. SIDE LICENCE LICENCE R.H. SIDE MARKER NO PLATE NO. PLATE MARKER LT LH LT R H. A " A B[...]

a, LAMP , SHTo FUSE BOX TO RADIO AMP. STARTER CIRCUIT CONNECTOR 3 B A -R B 1 WR CIGAR ;f LIGHTER R. H. DOOR SIW 0.1.1 HAZARD CIRCUIT I SEE SHT.10 P SPLICE 'A' *N SEE SHT. 25 4 FUSE BOX RH. FUSE BOX SPLICE'A-N PANEL LIGHTS SEE SHT 25 0 INTERIOR LAMP _t - RW TO R.H. RHEOSTAT I rRwP SEE SHT. 11 L.H. DOOR SIW 'L.H. KH. oHc STARTER C[...]

SHEET 13 STOP LIGHT RADIO AMP (If fitted) RADIO - SEE CIRCUIT ON SHT 20 REVERSE LIGHT 03 Rl 0 Y SPLICE 'A' SEE SHT 25 6 -N =! STOP LIGHT S/W RHC s 0 STOP LIGHTS LOGIC BOX L H SEE CIRCUIT ON SHT 16[...]

14 -6 W SPLICE '0' SEE SHT. 27 HEAD LAMP WASH I N LG ULG 4" P t -RLG - ,~~LGu@34 1 3 5 POWER LGU PUMP WASH i WIPER MOTOR - -NLG WIPE siw RHc 1. RLG- LGU - ULG- - POWER WASH INTERMITTENT LG B TIMER RELAY WIPE UNIT F H C 8-1 I 01j - LGBLGB FUSE BOX FUSE BOX SCREEN WASH PUMP 2 11 NOT USED- RU AT U PN-S PLIC E 'A' A I3 SEE SHT2[...]

HAND BRAKE S/W BIN 'A' HAND BRAKE WILT BIN TO ACU CONTROL SPLICE'G' RELAY SEE SHT 6 FUSE BOX SEE SHT 24 SPLICE '0' -W G SEE SHT. 27 VAC S/W BIN BIN'B. B S WR--~ WR+-w R 14 ( BINNACLE) J +B-+--BW . SEE SHT: 24 I BRAKE FAIL -WR- W/ LT HAND BRAKE WARNING @ h 0 LOW BRAKE FLUID LEVEL S/W I I BRAKE FAILURE WARNING[...]

SEAT BELT I LOGIC :(n -PLG TO L.H. DOOR SIW +-B VOLTAGE syErGg sTABILIsE:G TEzE BIN 'A' RHC EHC TEMP TRANSMITTER ~EE SHT. GU-1 4 G u-) 3 G U- 24 L--GU--+T~B+ 11 - f 5 LG TO FUEL GAUGE SEE SHT 12 P TO STOP LIGHT SIN SEE SHT 13 SEE SHT.4 1 BATTERY GAUGE LOGICBOX WATER TEMPERATURE & BATTERY GAUGES SHEET. I6 6 5 TO ACU CONT. RELAY 4 3 SEA[...]

SHEET 17 FUSE BOX AQ-WU BIN 'A' HRS eJ1 K-------l SPLICE 'A' -N SEE SHT. 25 A B TAILGATE HINGES HRS S/W SPLICE 'G' SEE SHT.24 HEATED REAR SCREEN (HRS) SHEET 17[...]

L.H. MIRROR R.H. MIRROR L.H. DHC 4 I A FUSE BOX B SPLICE 'B' ' SEE SHT. 26 MIRROR CONTROL -BU b I - 7 YG-TO RADIO AMF! SEE SHT. 20 (If fitted) MIRRORS ( Movement by solenoids) SHEET 19[...]

SHEET 18 L.H. WINDOW LIFT SIN SPLICE 'B' SEE SHT. 26 L.H. WINDOW LIFT MOTOR WINDOW LIFT 7 ----------------SU 8 7 - 6 5 R.H. WINDOW Y-------A - 4 3 LIFTSIW r-- sP 2 1 - R.H. WINDOW LIFT MOTOR R.H. DHC ---4---su 0 % SHEET 1. = 11[...]

MIRROR CONTROL CIRCUIT SPLICE 'B' -Y SEE SHT. 26 TO CLOCK II II Y G SEE SHT 12 ddbdb SPLICE 'A' -N SEE SHT 25 SEE SHT 1.3 RADIO & RADIO AMP (If fitted)[...]

SHEET 20A 1111 1111 REED SW. &U REED SW. S *> G -TO FACIA HC 4 FACIA HC AL3 SEE SHT 24AL P P-+&P--o FUSE BOX I SEE SHT 22AL FACIA HC AL 4 N L>WS- TO BIN 'A'Io TO HORN SEE SHT9AL SEE SHTZAI TO LIGHTS SEE SHT 11AL TO DI &HAZARD SEE SHT lOAL L . FACIA HC FACIAHC AL2 - AL 2 .'I+, LT G WB R I1 R RB I I ? 7 R I %lO,P IN[...]

SHEET ZOO ULTRACOUSTIC DETECTOR (in front of right hand headla-mp motor) SIREN (inside right hand BONNET REED TAILGATE REED SWITCH STANDBY BATTE (below left hand (behind left hand seat) (bottom of 'B' post) tunnel vent)[...]

TO START MOTOR SEE SHT. 2 "'I BATTERY 12 v. - [ THERMAL SWITCH MAKE ON RISE 85:~ * 2:~ BREAK ON FALL 6 8 C + 2 C 1 INHIBIT SWITCH 15 AMP 3 E.H.C. 5 ENGINE MANAGEMENT CIRCUIT SEE SHT. 3 L . LGO .G F I TIMER ENGINE BAY VENTILATION 0 0[...]

1 3 1 SA. I L.H. STDE I TAIL I NO PLATE LAMPS '. 1 4 1 15A. 1 HAZARD LAMPS l INTERIOR LAMP I CLOCK 1 NO. 1 5 FUSE BOX - CIRCUITS 8 RATINGS FUSE RATING 20A. I ! CIRCUIT INTERIOR FANS 15A. CIGAR LIGHTERS 1 DOOR LAMPS 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 2 3 24 10A. 10 A. 5 A. SA. 15A. 25A. 10A. 5 A. 15A. 5A. 10A. 10A. 10A. 10A. 10A. 10[...]

CHANGEOVER DOUBLE CONTACT RELAY CONNECTIONS ELECTRONIC UNIT I@ -l c) SHEET 23[...]

TO ALARM SEE-[. H.R.S. SIW. TACH0 IGN. WILT. SEE SHT17 SEE SHT2 SEE SHT.2 I I I G L H 0.1. WILT. SEE SHT. 10 FUSE BOX SPLICE '0' FACIA H C SEE SHT. 1 -G L -"TG G 4 R H 0.1. WILTG SEE SHT. 10 BRAKE FAIL WARNING . CIRCUIT SEE SHT. 15 G G G HAND BRAKE WILT. LOW FUELI BRAKE FAIL RELAY SEE SHT 15 CHOKE WILT. SEE SHT 15 SEE SHT L SEAT BELT[...]

HEAD LAMP WASH A 11 8 SEE SHT.14 - . P-N A 16 B HEAD LAMP MOTORSp _N SEE SHT 9 I I / . . HORN 8 HEAD LAMP FLASH SEE SHT. 9 - POSITTVE POST P SEE SHT 1 "-P- SEE SHT. 12 A 13 B H.R.S. . STOP LAMPS RADIO SEE SHT. 13 SEE SHT. 20 @ 'm 0 $ - INT. LAMP 8 CLOCK SEE SHT 12 HAZARD LAMPS SEE SHT. 10 NWU SEE SHT.17 SPLICE 'A' SHEET 25[...]

POWER RELAY (AUX.) ' SEE SHT1 ? . ' ' a". ' WINDOW LIFT SEE SHT. 18 5 DOOR MIRRORS rYG- SEE SHT 19 RADIO Y SEE SHT. 20 I INTERNAL FANS I SEE SHT 7 B 22 A ENGINE MANAGEMENT' -YG- SEE SHT. 3 SPLICE '0' SHEET 26[...]

SHEET .27 POWER RELAY (IGN.) SEE SHT 1 ? R HC - A 23 B ENGINE MANAGEMENT - _ START, ALT & IGN. SEE SHT 3 SEE SHT 2 INTERNAL FANS SEE SHT. 7 INDICATORS A20 B G-W SEE SHT. 10 AIR CON0 g RAD FANS- SEE SHT 6 REVERSE LAMPS SEE SHT 19 WIPER MOTOR/ SCREEN WASH NOT USED - SEE SHT 14 G G 1 SPLICE'G I BRAKE FAIL W/LT SEE SHT 24 SEE SHT. 1'5 SPL[...]

[...]

FRONT HARN~S CONNECTORS / / FUSEBOX I. A- HEADLAMP POWERWASH TIMER ( IF FITTED ) C - HEATED REAR SCREEN RELAY D -AIR CONDITIONING ' DROP OUT'RELAY 1 E -INTERIOR FANS RELAY F - RADIATOR FANS RELAY BRAKE FAIL ,WARNING LIGHT RELAY REAR HARNESS[...]

[...]

Page 30 INSTRUMENT BINNACLE REMOVAL The inst~ment binnacle contains a centre panel housing the main instruments, and two side panels housing the tell tale lamps, switches and volt and fuel gauges. The side panels may be removed with the binnacle 'in sib' by removing the four screws securing the centre panel ABS trim, followed by the singl[...]

SECTION MC Page 3 1 The ignition must be switched on for the following checks. Recommended Test Equipment DC moving coil voltmeter, scale 0 - 20V DC moving coil ohmmeter HT jumper cable - - TEST 1 CHECK HT SPARKING J 1 LOW Low 3 CHECK AMPLIFIER ! J SWITCHING Low Low RESULT J J Should be: Regular sparking -* TEST6 No sparking -+ TEST 2 Measure volta[...]

Page 32 SECTION MC . 9 4 PICK-UP COIL RESISTANCE 5 CHECK HT SPARKING I I TEST HT LEAD CRANK 3 ENGINE 7 VISUAL AND HT CABLE CHECKS EXAMINE 1 Distributor Cover 2 CailTop 3 H.T. Cable Inrulafion 4 H.T.CobleContin"ity 5 Spark Plugs Ohmmeter should show 2-5 kQ Correct Change amplifier If engine will not start -- Incorrect Change pick-up If engine.w[...]

SECTION MC Page 33 BATTERY RE-CHARGI NG PROCEDURE Instructions for Tungstone Powermaster Maintenance Free Batteries. To determine the state of charge of the battery, apply a brief discharge of no more than ten seconds duration (e .g. turn on headlights) with the engine off, and then allow to stand on open circuit for two to three minutes. Measure t[...]

ELECTRICAL SECTION ME - USA ESPRIT TURBO, '86 M.Y. ON (H.C.I.) Circuit Diagrams : Component Index Legend Supplies Start, Alternator, Ignition Fuel Injection Management System Fuel .Pumps Fuel Level Radiator Cooling Fans Air Conditioning Interna 1 Fans Headlamp Beam, Dip, Flash Horns, Beam, Dip and Column Switch Supply Head1 amp Motor Operat io[...]

COMPONENT INDEX SECTION ME A.C.U. Compressor A.C.U. Tem. Control A.C.U. Thermistor Alternator Auxiliary Air Valve Battery Cigar Lighters Clock Cold Start Injector Compressor, air horns Distributor Electronic Control Unit (ECU) Engine, OverspeedIFuel Pump failure 3C Sheet / Page 6 5 5 2 3B 2 12 12 3B 9 2 38 ~requency Va 1 ve Fuel Enrichment module F[...]

SECTION ME LEGEND BIN D.H.C. D.I. E.B.C. E.H.C. F.H.C. L.H. P .H .C'. R.H. R.H.C. SOL sm W/LT . C.C.C. M.H.C. C.F.H.C. C.B.H .C. B Black G Green K Pink P Purple LTG Light Green N Brown Binnacle Connector Door Harness Connector Direction Indicator Engine Bulkhead Connector Engine Harness Connector Front Harness Connector Left Hand Pumps Harness[...]

SHEET 1 TO HORNS SEE SHT. 9A HEAD LAMP NU $9 NU MAINIDIP BEAM FHC CIRCUIT SEE SK1.8 - NU- )L~ u TO START MOTOR SEE SHT. 2 TO RAD. FAN N SPLICE 'A' RELAY SEE SHT 5 SEE SHT 25 2 [N R-P---NR TO IGNITION -Y~)LY SIW. SEE SHT. 2 -1 Y SPLICE 1 ' B' SEE SHT 26 '0' I SPLICE SEE SHT. 27 SUPPLIES .[...]

TO L.H. DOOR SIW. a BW-)-LGW- SEE SHT. 12 SEE SHT. 1 0 L RHC w R.-/&-W TO LAMP DELAY WR / POSITIVE POST UNIT SEE SHT 12 SEE SHT. 1 - LNY*--II- SPLICE 6' SEE SHT 24 TACH0 TO ENGINE OVERSPEE01 FUEL PUMP FAILURE SPLICE'G'+G SEE SHT. 24 RHC IGNITION WILT. I TO RPM. RELAY 1 I SEE SHT. 3A START, ALTERNATOR & IGNITION SHEET 2[...]

5 CBHC ' TO THROTTLE POSITION SWITCH SEE SHT. 38 RELAY No. 1 - DECELL CONTROL 2 - IDLE CHANGEOVER 3 - FAST WARM UP 4 - A.C.U. IDLE UP 5 - A.C.U. IDLE CONTROL -4 SHEET 3A CBHC RHC BIN 'A' TO ENGINE OVERSPRD I ECONOMY WlLt FUEL PUMP FAILURE MODULE CBHC fk T T YN YB I TO E.C.U. I SEE SHT. 38 TO ENGINE OVLASPEED I FUEL PUMP FAILURE MODUL[...]

FAST WARM UP RELAY SEE SHT. 3A ELECTRONIC CONTROL UNIT 3?‘8HC I: I I I I I I I SCREENED I CABLE I I I I I I I I t: F I R.PM. RELAY 2 SEE SI-IT. 3A I WATER TEMP SWITCH I DECELL CONTROL I SEE SW. 3A I I I I I CBHC TO START MOTOR YLG CBHC ( IDLE SEE CHANGEOVER SHT. 3A DECELL CONTROL I SEE SHT 3A YLG WY k! FREQUENCY COLD START THERMAL VALVE I INJECTI[...]

1 SHEET 3C I 1 KP FUEL PUMP RELAYS SEE SHT 27 KR N m t) I 1 ] w/5* KR Y N 6 3 I RHC CBHC wp- 4 SECONDARY FUEL PUMP 3 i - TO BATTERY a POSmVE INERTIA FUEL PUMPS a SWITCH 1[...]

VOLTAGE STABILISER LOW FUEL LEVEL Wl tT SEE SHT 24-SPLICE 'G'-G SPtICE -G TO TEMP GAUGE 'G' BIN '0' SEE SHT.16 SEE SHT 24 R H C FUEL SENDER UNIT GO -+GO G o 'I:? RHC BIN 'B' GB-@-GB+ GAUGE FUEL LEVEL SHEET 4[...]

SHEET 5 I FAN MOTOR 1 1 CFHC FHC FUSE BOX P POSITIVE POST SEE SHT. 1 BIN '0' FAN FAIL WILT THERMISTOR OTTER SIW. LOW PRESS. KU A.C.U. CIRCUIT-~~J SEE SHT 6 0 RADIATOR COOLING FANS 0 SHEET 5 .'.[...]

SPLICE '0' I SEE SHT 27 W RAD. COOLING FANS CIRCUIT SEE SHT 5 -YG TO INT. FAN RELAY SEE SHT. 7 I CCC TO START MOTOR rWR SEE SHT. 2 RELAY RAD. COOLING KU 1 FANS CIRCUIT RHC K" ,-el EHC SEE SHT.5 -KU 9 TO A.C.U. IDLE CONTROL RELAY Ku 7)' K SEE SHT. 3A COMPRESSOR a AIR CONDITIONING SHEET 6[...]

SHEET 7 FUSE BOX SPLICE '6'-Y I SEE SHI 26 INT. FAN MOTOR 1 r FUSE BOX FAN SPEED SIW. ----.SPLICE 'D' SEE SHT: 27 INT. FANS RELAY LGS-1 @ CCC BY-) r? C CC INT. FAN MOTOR 2 YG I INTERNAL FANS a G I A CU CIRCUIT SEE SHT. 6[...]

OUT- BOARD 7UB FHC I N-BOARD ,/ @) R H HEAD LAMPS 4 UY OUT-BOARD POSITIVE POST NU uwl HEAD LAMP MAIN BEAM, DIP BEAM & FLASH -UR SEE S HT. 9 DIPIMAIN BEAM &COLUMN SiW (b, h <) BIN Y '3 B 2 J LIGHT S/W L h -8 7 -RG- SEE FRONT 6 5 SIDE TURN SHEET 8[...]

SHEET 9A MOTOR LH RELAY LH FUSE BOX FHC 5 16 SPLICE 'A' P-) P- A 0 N- SEE SHT. 25 FLASH CIRCUIT SEE SHT 8 MOTOR RH RELAY RH HEAD LAMP MOTOR HORNS I HORN RELAY, ! rm 20A N-ii 10 u /I I A 17 B FUSE BOX 1- DIPiMAIN BEAM 8 - COLUMN SIW HORNS, DIPIMAIN BEAM & COLUMN SIW SUPPLY 0 7 0 SPLICE 'A' SEE SHT. 25 SHEET 9A 0[...]

LH MOTOR I Rrw RELAY U G I I NU LIGHT SiW UR s --8 7 h I - TO DIP BEAM 6 5 RELAY COIL -4 37 2 11 d HEAD LAMP MOTOR CIRCUIT[...]

- .... L H HEADLAMP LH MOTOR MOTOR S RELAY HEAD LAMP MOTOR OPERATION PODS TRAVELLING UP - HEAD LAMP YOTOR CIRCUIT Y SHEET 9C[...]

POSITIVE HEAD LAMP MOTOR OPERATION -RS 9- LH MOTOR S RELAY PODS UP TO MAIN BEAM RELAY COIL 1 1 f~] NU LIGHT SIW UR I TO DIP BEAM RELAY COIL HEAD LAMP MOTOR CIRCUIT SHEET 90[...]

NLG A LH HEADLAMP MOTOR POSITIVE TO MAIN BEAM RELAY COIL HEAD LAMP MOTOR OPERATION DS TRAVELLING D OWN TO DIP' BEAM RELAY COIL HEAD LAMP MOTOR CIRCUIT a SHEET 9E[...]

a POSITIVE 11 HEADLAMP FLASH POD TRAVELLING UP I NU LIGHT SIW HEAD LAMP - MOTOR .. .. CIRCUIT SHEET 9~[...]

LH REAR 0.1. DIP,MAIN BEAM g 0.1. SEE SHT. 25 c4 GW- 3 2 1 - rn c) FUSE BOX SEE SHT. 27 D.I. WILT. TO CLOCK .I.lHAZARD UNIT HAZARD WILT. R H REAR 0.1. 0 0.1. & HAZARD . . SHEET 10-[...]

SHEE @ INSTRUMENT 1 ILLUMINATION -I- @ B&B OIL FIBRE BAT. PRESS. TACHO. BOOST SPE EDC TEMP FUEL OPTIC R N R N R N R N R N 0.1. & HAZ.-RB 7 R 0 I CIRCUIT I LICENCE NO. PLATE LT. L.H. LICENCE NO. PLATE LT. R.H. RO RHC CIRCUIT Ro- SEE SHT 10 R.H. SIDE MARKER 03 r? 0 REAR LIGHTS 8 INSTRUMENT ILLUMINATION SHEET 11[...]

SHEET12 I R H DOOR SiW I SEE SHT.10 I I ~ I I TO RH RHEOSTAT STARTER C IRCUTT s w ---.I- L G W I SEE SHT. 2- LOGIC BOX I SEE CIRCUIT ON SHT 16 CLOCK, DOOR WARNING & INTERNAL LAMPS ---' SHEET 12 0[...]

a SHEET 13 a a RADIO AMP. (If fitted) RADIO - SEE CIRCUIT ON SHT 20 SPUCE 'A' SEE SHT 25 -N STOP LIGHT SIW RHC RH G P STOP LIGHTS LOGIC BOX SEE CIRCUIT ON SHT. 16 STOP LIGHT HIGH MOUNTING STOP LIGHT CI, h c, FUSE BOX NOT USED =! SPLICE' D ' 0 SEE SHT 27 --.Q 2 REV LIGHT SIW. RHC (IN GEARBOX) RH s 6--c-G I REV. LIGHTS REVERSE LIG[...]

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

SHE E@ HAND BRAKE SIW BIN 'A' HAND BRAKE WILT 11 ~B-~W-C~SW --@- G A SPLICE 'G' SEE SHT 24 G TO ACU CONTROL G HAND BRAKE WARNING SPLICE '0' -W B A SEE SHT. 27 LOW VAC S/W 1 ob 1 B S LL TO D.I.IHAZARD RELAY SEE SHT. 10 B BS LOW BRAKE FLUID BIN 'A LEVEL SIW L-BS /;. B ,-+I 1. -- BRAKE FAIL WILT BRAKE FAILURE WARNING[...]

SHEET 16 rpLG TO L.H. DOOR SIW. SEE SHT 12 TO STOP LIGHT SIW SEE SHT. 13 LOGIC BOX 6 5 4 3 2 1 w SEAT BELT SIN. TO ACU CONT. RELAY SEE SHT. 6 -WR LpB--------~F+B+l~l BIN A SEAT BELT WILT. Bp'5 SEE SHT. 24 SEAT BELT I LOGIC STABILISER TEMP. GAUGE BIN RHC EHC TEMP TRANSMITTER SEE SHT. 4 2 4 ~u-$------~u-&---~~-----.+~~~~, LG I TO FUEL GAUGE [...]

FUSE BIN 'A' SPLICE 'A' -N SEE SHT. 25 12 3 4 HRS 51W G- SPLICE 'G' = l1 SEE SHT.24 TAILGATE HINGES HEATED REAR SCREEN (HRS) SHEET 17[...]

SHEET 18 SPLICE 'B' SEE SHT. 26 A ~ L.H. WINDOW LIFT SIW. I SN+--J L.H. OH(: s R-----(- L.H. WINDOW LIFT MOTOR R.H. WINDOW LIFT SIN. U R.H. DHC Asu m WINDOW LIFT R.H. WINDOW LIFT MOTOR SHEET 18[...]

MIRROR CONTROL SWITCH CHANGEOVER SWITCH MIRRORS (Movement by motors) SHEET .:I9 '9[...]

SHEET 20 MIRROR CONTROL CIRCUIT RADIO & RADIO AMP (If fitted)[...]

BIN '8' i- yG RG LEVEL Low MODULE OIL LOW OIL LEVEL PROBE LOW OIL WlLt SPUE '0' +,-j SEE SHT. 26 LOW COOLANT EHC Wl Lt 1 LOW COOLANT LEVEL PROBE LOW COOLANT LEVEL MODULE LOW OIL & COOLANT WARNING SHEET 21[...]

SHEET 22 NO. FUSE RATING CIRCUIT 1 15A. INTERIOR FANS ., L 3 5 A- L.H. SIDE I TAIL I NO. PLATE LAMPS 4 15A. HAZARD LAMPS I INTERIOR LAMP 1 CLOCK 5 15A. CIGAR LIGHTERS1 DOOR LAMPS - -- -- - - - - - - 6 10A. RADIATOR FAN NO. 1 7 10A. DOOR MIRRORS 1 RADIO (AUX. RADIO AMP (AUX. [ If fitted 1 -- - - - 8 5A. INSTRUMENTS & WARNING LAMPS I 9 5A. R.H. S[...]

CHANGEOVER DOUBLE CONTACT ELECTRONIC UNIT RELAY CONNECTIONS SHEET 23[...]

SHEET 24 H.R.S. SIW. TACH0 IGN. WILT. SEE SHT.17 SEE SHT.2 SEE SHT.2 L.H. 0.1. WILTG SEE SHT.10 --', FUSE BOX SPLICE 'D-M FACIA H.C SEE SHT. 1 I R.H. 0.1. WILTG SEE SHT. 10 1 BRAKE FAIL WARNING CIRCUIT SEE SHT. 15 G- SEAT BELT WILT. SEE SHT 16 - BATTERY GAUGE SEE SHT. 16 G - VOLTAGE STABILISER SEE SHT. 16 HAND BRAKE WILT. LOW FUELI BRAK[...]

POSITIVE POST ? SEE SHT. 1 A 13 B H.R.S. - N N-WU- A 16 B HEAD LAMP MOTORSp - SEE SHT 9 HEAD LAMP FLASH - A17 B P- N SEE SHT. 9 SEE SHT.17 CIGAR LIGHTERS & DOOR LAMPS SEE SHT. 12 cn h c, 2 0 2 L h INT. LAMP & CLOCK SEE SHT. 12 HAZARD LAMPS SEE SHT. 10 STOP LAMPS RADIO SEE SHT. 13 SEE SHT. 20 SPLICE 'A' SHEET' 25[...]

SHEET 26 POWER RELAY (AUX. 1 SEE SHTl WINDOW LIFT SEE SHT. 18 YG YG I INTERNAL FANS I SEE SHT 7 SPLICE '5' DOOR MIRRORS SEE SHT. 1 9 RADIO SEE SHT. 20 FUEL INJECTION MANAGEMENT SYSTEM SEE SHT. 3A[...]

SHEET POWER RELAY (IGN.) FUEL W JECTION A 23 B MANAGEMENT SYSTEM - G --w SEE SHT. 3A 7 INDICATORS A 20 B G-W SEE SHT. 10 SEE SHT. 1 P W I REVERSE LAMPS SEE SHT. 19 NOTUSED - G I SPLICE'G SEE SHT. 24 R HC START, A LT. & IGN. SEE SHT. 2 INTERNAL FANS rG- SEE SHT. 7 LG-AIR CONO. g RAD. FANS- SEE SHT. 6 w- RAD. COOLING FANS SEE SHT. 5 BRAKE FA[...]

aQADIATOR COOLING FANS WINDSCREEN WIPER MOTOR COMPONENT LOCATION DIAGRAM (1) '-• .u[...]

A BRAKE WIL RELAY B - TURN INDIcAToRS/HAZARD LAMPS FLASHER UNlT C -HEATED REAR SCREEN RELAY' D -AIR CONDITIONING ' DROP OUT'RELAY E - INTERIOR FANS RELAY F-RADIATOR FANS RELAY FUSEBOX LIGHT SWITCH SEAT BELT LOGIC WIPER DELAY AC U CONTROL UNIT UNIT UNIT RELAY COMPONENT LOCATION DIAGRAM(Z)[...]

TI, HEATED REAR MDW HARNESS ROUT!NG DIAGRAM u[...]

SECTION ME Page 30 INSTRUMENT BINNACLE REMOVAL The inst~ment binnacle contains a centre panel housing ihe main instruments, and two side panels housing the tell tale lamps, switches and volt and fuel gauges. The side panels may be removed with the binnacle 'in situ' by removing the four screws securing the centre panel ABS trim, followed [...]

SECTION OB MAINTENANCE & LUBRICATION Page I SECTION OB - ESPRIT 53 & TURBO (Dornertic/Export) Page - Recommended Lubricants Bodywork Defects Sample Sheet Pre-Del ivery Inspection Sample Worksheet Fint After Sales Service Sample Worksheet Maintenance Plan Sample Worksheet[...]

Page 2 SECTION OB RECOMMENDED LUBRICANTS ENGINE: Lotus Cars Ltd.strongly recommend that the following engine lubricants are used at oil changes,and where possible/practical between services. Above O°C Valvoline HP Racing SAE 20W/50 Elf Competition SAE 20W/50 Mobil 1 Rally Formula SAE 5W/50 Below O°C Valvoline XLD SAE 15W/40 Elf Sporti SAE 15W/40 [...]

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

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

SECTION OB Page 5 PRE-DELIVERY INSPECTION - ALL MODELS I MODEL I VI N: ENGINE NO. 1 1 Completely fill fuel tanks and check for leaks. I I I OPEfWTIONS - Tick box if 0 .K . - X box if additional work reqd . - submit defect report 1 L J MECHANICAL I Check clutch ad justrnent. 1 OPERATOR INITIALS I Check tightness of wheel nuts/bdts . 1 1 Check coolan[...]

Page 6 SECTION OB Road Test Carry out brief road test and submit report with any additiorxil attention required. Submit a defect report where necessary. The pre-delivery inspection is subject to the following conditioru: (a) It is the responsibility of the supplying Distributor/importer/dealer to ensure that the car is delivered to the customer in [...]

SECTION OB Page 7 LSL 2468 @ First After Sales Service (NOT) U.A. excel esprit S3 esprit turbo Owner's name ...................... .Date.. ............ Mark as follows: €4 To be carried out at: Adjustments made Registration No. ..................... .Job no. ........... d 500-1 000 miles O.K. (800- 1600 km) V.1.N ......................... Mi[...]

SECTION OB Page 9 LSL 2458 Maintenance Plan (Not USA) excel esprit S3 esprit turbo ................... Owner's name Date .............. Mark as follows: Please tick Service: required: A- 0 . . Adjustments made Registration No. ..................... .Job no. ......... B- O.K. V.1.N ......................... Mileage ................... Repairs d[...]

A SERVICE At 6,000 mIs./10,000 km. or 6 months from Registration (whichever sooner) Mileage: Date: B SERVICE AT 12,000 mls./20,000 km. or 6 months from last Service (whichever sooner) Mileage: Date: A SERVICE At 18,000 mls./30,000 km. or 6 months from last Service (whichever sooner) Mileage: Date: C SERVICE AT 24,000 mls./40,000 km. or 6 months fro[...]

SECTION OC MAINTENANCE & LUBRICATION Page 7 SECTION OC - U .S .A. ESPRIT TURBO Page - Recommended Lubricants Pre-Del ivery l nspection Sample Worksheet Bodywork Defects Sample Sheet Maintenance Schedule - Except California Maintenance Schedule - California a APR 1987[...]

SECTION OC Page 2 RECOMMENDED LUBRICANTS ENGINE: Lotus Cars Ltd.strongly recommend that the following engine lubricants are used at oil changes,and where possible/practical between services. Above O°C Valvoline HP Racing SAE 20W/50 Elf Competition SAE 20W/50 Mobil 1 Rally Formula SAE 5W/50 Below O°C Valvoline XLD SAE 15W/40 Elf Sporti SAE 15W/40 [...]

SECTION OC Page 3 PRE-DELIVERY INSPECTION - ALL MODELS I MODEL I VIN: ENGINE NO. MECHANICAL I I I I OPERATIONS - Tick box if O.K. - X box if additional work reqd , - submit defect report Check coolant l eve1 and check system for leaks. I OPERATOR INITIALS Renew engine oil and filter (Federal only) I I I L Check engine, gearbox and rear axle oil lev[...]

Page 4 SECTION OC Road Test Carry out brief road test and submit report with any additional attention required. Submit a defect report where necessary. Th.e pre-del ivery inspection is subject to the following conditions: (a) It is the responsibil ity of the supplying Distributor/importer/dealer to ensure that the car is delivered to the customer i[...]

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

SEC.TIOIV OC MAINTENANCE SCHEDULE EXCEPT CALIFORNIA The operations listed below should be carried out at the mileage shown. DESCRIPTION OF OPERATION ENGINE Check and if necessary top up coolant. lnspect cooling system hoses and connections. Check valve clearances, adiust if necessary Renew spark plugs. Check operation of engine management Systems. [...]

SECTION OC MAINTENANCE SCHEDULE EXCEPT CALIFORNIA -Continued The operations listed below should be carried out at the mileage shown. a DESCRIPTION OF OPERATION WHEELS AND TYRES Check tyre condition and pressures, including spare. Check torque of all wheel nuts. Check road wheel balance. BODY Check all hinge and lock operations. Check seat belts and[...]

SECTION OC Page 9 0 MAINTENANCE SCHEDULE CALIFORNIA The operations listed below should be carried out at the mileage shown. Recommended Maintenance x Lotus Cars Ltd. urges that these maintenance operations and checks should be made either by you 0r.a qualified technician at the frequencies indicated to help ensure proper safety, emissionsperformanc[...]

Page 7 0 SECTION OC MAINTENANCE SCHEDULE CALIFOR NlA -Continued The operations listed below should be carried out at the mileage shown. DESCRIPTION OF OPERATION ELECTRICAL Check security of battery and earth connections and (if applicable) x x Check operation of all lights. electrolyte level. x x x x Check headlamp alignment. x x Check operation of[...]

SECTION PB Page 7 HEATEWAIR CONDITIONING SECTION PB - ESPRIT S3 & TURBO 'Operation Air Conditioning Operating Principles Aitflow Distribution Refrigerant Ha ndl i ng Refigerant Pipework Precautions Charging Unit with Refrigerant Refrigerant Quick Check Procedure Recommended Refrigera nt Oil Refrigerant Oil Level Checking Procedure Compress[...]

Page 2 SECTION PB PB .I - AIR CONDITIONING OPERATING PRINCIPLES With the air conditioning control 'ON' and engine running, the compressor clutch operates engaging the compressor. Low pressure vapour entering the compressor is converted into high pressure vapour at the output and discharged into a condenser. The vapour is cooled in the con[...]

SECTION PB Page 3 a high pressure liquid. The corstruction of the condenser is similar to the engine radiator but is designed to withstand higher pressures . Receiver-Drier Located in the front compartment on the right hand side iis purpose is to ensure a supply of liquid refrigemnt to the expansion valve in an operational condition. A drier is inc[...]

Page 4 SECTION PB The electronic comparator is fifted to the rear of the temperature confrol.switch; PB2 - AIRFLOW DlSTRlBUTl ON The heater/air conditioning unit is located beneath the fascia and c0ntains.a heater matrix fed with engine coolant via a cable/thermatat operated water valve and a refrigerant evaporator. Two fan motors are contained beh[...]

SECTION PB Page 5 OFF I I In the 'OFF' position, the fresh air vent is closed and the re-circulation vent open. All heater functions are off. - This setting should be used during city driving to avoid drawing traffic fumes into the car. With the air conditioning switched on, this is the haximum refrigerationt setting. Air is drawn by the [...]

Page 6 ': 'SECTIONPB The control cam releases the fresh air/re-circulation flap valve, thus closing the re- circulation vent and opening the fresh air vent. All heater functions remain off. - Fresh air at ambient temperature is supplied to the outer and centre face level, vents. With :the air conditioning switched on this is the 'nor[...]

SECTION PB Page 7 The control cam operates the mode flap valve and starts to move the screen flap link. The mode flap opens the heater matrix and shuts off the centre face level vents. The screen flap moves half way. Withsthe temperature control in the red sector, heated fresh air is supplied by ram effect or fan assisted, to both screen and footwe[...]

Page 8 DEFROST SECTION PB The screen flap is mved full travel to shut off the footwell vent, and direct all air to the windscreen vents. This is the defrost position. With the temperature control in the red sector, heated air is suppl ied solely to the screen. (keep outer face level vents clcsed) . TURBO SERIES 3 HEATER ONLY OFF VENT HEATER DEF E 0[...]

SECTION PB Page 9 PB.3 - REFRIGERANT HANDLING The refrigerant used in the air conditioning system is 'Freon 12' and the following precautiorrs MUST ALWAYS BE OBSERVED. 1 . Do NOT leave refrigerant drums open - always make sure the caps are securely closed. 2. Do NOT transport drums of refrigerant in the passenger compartment of a car. 3, [...]

Page 70 SECTION PB Pipes, flexible end connec tions and components, MUST be capped immedi- ately they are opened to prevent the ingress of moisture and/or dirt. A11 replacement components and flexible end connections are sealed when new, and should only be opened IMMEDIATELY PRl OR TO FITTING, AND AT ROOM TEMPERATURE, to prevent condensation of any[...]

.---- .. - - - SECTION PB Page 7 1 The system is charged with 1.4kg (3 Ibs) of 'Refrigerant 12', which is made up from 'Freon 12' and 'Arcton 12'. After charging the system it must be checked for gassing, using the following procedure: 1 . Start the engine and ad just engine speed to 1200 r.p.m. 2. Turn the air conditi[...]

Page 72 . . SECTION PB PB .6 - REFRIGERANT QUICK-CHECK PROCEDURE The following procedure can be used to quickly determine if the air conditioning system has iis required charge of refrigerant. This check facilitates system diagnosis by pinpointing the problem to the amount of charge in the system, or by eliminating this possibility from the overall[...]

SECTION PB Page 73 PB .7 - RECOMMENDED REFRIGERANT 01 L The refrigerant oil recommended for use in the compressor and to lubricate flared pipe ends and union threads are: Frigidair 525 Shell Clavus Oil 33 Texaco Capella E (Waxfree) Sunisco 5 BP Energol LPT 500 a NOTE: (a) The above oils are not given in any order of preference and all are equally s[...]

Page 74 SECTION PB Insert dipstick (Sankyo tool number 32447) with the angled 'stop' towards highest part of compressor, just inside the plug hole. Align the angled bottom of the 'stop' with the top surface of the oil filler hole, and insert the dipstick until it reaches the 'stop' Remove the dipstick and count the num[...]

Page 15 PB .9 - COMPRESSOR The compressor is factory charged with 6 - + 0.5 fluid ounces (1 75 + 15cc) of refrigerant oil - with a viscosity of 500. Only oils listed under RECOMMENDED REFRIGERANT OIL should be used when adding or changing the oil. To Remove 1 . Depressurise the air conditioning system by slackening the union nut securing the pipe t[...]

Page 76 3. Refill the new compressor with an amount of new oil equal to that drained from the old compressor, plus an additional one fluid ounce (30 cc) of new oil. After a major failure involving total loss of fluid and a replacement compressor; it is necessary to add an extra 2.7 fluid oz. (80 cc) of oil to the 6 fluid oz. (175 cc) of oil suppl i[...]

SECTION PB Page 7 7 Remove the two screws in the passenger footwell securing the lower edge of the bulkhead divider panel. Disconnect the washer tubing and' front wiring harness and feed through the divider panel. With sharp knife, cut round the divider panel sealant, and withdraw the panel into the front luggage compartment. Disconnect the tw[...]

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

CLUTCH SYSTEM DIAGRAM[...]

SECTION QB Key to Clutch System Drawing Page 3 1. Cover/Pressure Plate Assembly. 2. Centre Plate. 3. Release BearingICarrier Assembly. (Cast Type) 4. Spring, Fork to Carrier. 5. Release BearingICarrier Assembly (Fabricated Type) 6. Spring, Fork to Carrier. 7. Release Fork. 8. Pivot, Release Fork, S3 9. Screw, Pivot Ball. 10. Pivot, Release Fork, Tu[...]

Page 4 SECTION QB - Master Cylinder Pushcod Ad justrnent Pedal Upstop Adjustment I 2 - 5mm Free Play Minimal Cle -- - . - RELEASE FORK The side mounted clutch slave cylinder (series 3 after late '84 and all Turbos) is self adjusting, with fluid being returned to ihe master cylinder as the friction plate wears in service and the slave cylinder [...]

SEC Page 5 Series 3 cars up to late '84 with the top mounted slave cylinder, require checking for release fork clearance at service intervals in the following manner: i) At the slave cylinder end, unhook the release fork spring, and measure the free play at the end of the release fork. ii) If necessary, slacken the locknut and adjust to obtain[...]

Page 6 QB 3 - CLUTCH ASSEMBLY The gearbox or engine/gearbox assembly must first be removed from the vehicle before access to the clutch centre plate or spring/pressure plate may be obtained. If the gearbox assembly is to be removed from a Turbo model, it may be found easier if the turbocharger is first removed. Before re-assembly, ensure that the s[...]

SECTION QB Page 7 Turbo Prior to Eng . No. 22728 11 Straight Diaphragm Spring Fingers Turbo After Eng . No. 22728 All Series 3 /I Flat Adaptor Profile Release Bearing and Carrier QB 5 - SPIGOT BEARING The spigot bearing (A907E 6319F) must be fitted into the crank with its identifying numbers facing outwards (i-e. towards gearbox), and pressed in[...]

Page 8 SECTION QB QB 6 - CLUTCH SHAFT The clutch shaft is splined into the gearbox primary shaft and retained by a circlip and spring. Old type clutch shaft A079F 6066F has been replaced by modified shaft B085F 40685 which incorporates a hardened steel sleeve (A089F 0404F), to run inside the spigot bearing. This sleeve is fitted to the shaft using [...]

SECTION VB Cent re Consolc Tunnel Sides INTERIOR TRIM SECTION VB - ESPRIT 53 & TURBO Instrument Binnacle Fascia Cant Rails 'A' Post Covers Windscreen Header Rail Rear Bulkhead Trin Door Trim Panel- Ocerat ion VB 1 Page I[...]

Page 2 SECTION VB VB.l. - CENTRE CONSOLE To remove: 1. Pull off centre tunnel top armrest. 2. Release three screws securing choke/window switch panel and lay aside. 3. Remove radio, or radio blanking panel and release knobs from heater a/c control panel. Remove graphic control panel. 4. On cars prior to VIN 82/85 D2153, release the heater a/c contr[...]

SECTION VB Page 3 0 VB.3. - INSTRUMENT BINNACLE - Domestic & R.O.W. cars . Before the binnacle may be removed, it is necessary to dismantle the instrument/switch panels in order to disconnect the wiring harness, speedo cable, oil and boost pipes, and screen vent ducting. Prior to 1985, Series 3 cars used a binnacle layout similar to that of S2 [...]

Page 4 U.S.A (Federal) Models On these cars it is not necessary to dismantle the instrument panels to remove the binnacle. Release the four bolts beneath the fascia securing the binnacle mounting bracket to the scuttle cross beam. Raise the binnacle sufficiently to enable the wiring connector blocks speedo cable, oil pressure and boost gauge pipes [...]

SECTION VB Page 5 VB.5. - CANT RAILS The cantrails are secured by a single screw at their front end, by two screws from outside the door aperture and, on sunroof models, by the trim material wrapped into the roof aperture. VB.6. -'Af POST COVERS Remove cant rail (VB.5) and pull off door seal from around front of door aperture. Peel off 'A[...]

Page 6 SECTION VB On U.S.A. cars, the tailgate release handle must be released from the bulkhead (see BD.12). Remove the four screws securing the trim panel to the bulkhead, and on sun roof models, the screw,above each roof catch, concealed by the ABS trim. Withdraw the bulkhead trim, unclipping the top edge on solid roof cars from the fixing dowli[...]

[...]

[...]

The Vehicle Identification Nunber WIN) is stamped an a plate fixed to the right or left hand frat wheelarch inside the frat luggage canpartment. This nlmber is rpted a the right hand side oi the chassis frme, visihle fran within the right hand frat wheelarch. This nunber should be quoted in all enquires regarding the vehicle. The seventeen characte[...]

FUnction Contents r - 10.00 BCOYv - 10.01A Bodv Re~alr Sections. Front 10.02A 10.05A 10.07A 10.09A 10.1lA 10. UA 10.19 10.17A 10.23A. 11.00 - 11.01A ll.02A 11.05A 12.00 - 12.0IA 12.05A 12.09A 13.00 - l3.03A 13.09A 13.U U . 27A 14.00 - 14.01A l4.Ol.B 14.05A 14.07A 14.08A 14.10A 14.12A 15.00 - 15.0lA 15.1lA 15.13A l5.lgA 15.24A 15.30A 16.00 - 16.01A [...]

PART NUMBERS All part nwbers carmence with the vehicle type number, indicating the type of mtus rrPdel on which the part was first used: All standard finish bolts, screws, studs, nuts & washers, carry part n&rs including the prefix A075W, B075W etc., EINE PAEIT NUMBERS All engine part nunhers mnce with the engine type nun&er on which th[...]

MID-NOSE SECTION, 28 INCHES FRONT TO REAR. SHUT LINE. TURBO 1o.olA[...]

ILLUS NO. DESCRIPTION Bodyshell (inc. sills) II 11 II 11 n II I1 II II II II n 11 II II Body Section, Mid Nose, Full Width I1 I1 I1 I1 I1 II II Body Section, Mid Nose, RH Half II I1 II I1 I1 I1 I1 Body Section, Mid Nose, LH Half I1 . II II I1 II I1 I1 Body Section, Full Nose, Full Width II II II I1 II II II Body Section, Full Nose, RH Half II II 11[...]

[...]

ILLUS NO. DESC Rl PTl ON Body Section, Short Rear, Full Width Body Section, Short Rear, RH Half Body Section, Short Rear, LH Half Body Section, Full Rear, Full Width Body Section, Full Rear, RH Half Body Section, Full Rear, LH Half Bulkhead, Upper, (Timber) Bulkhead, Upper, (Timber) Wllkhead, Centre, (Timber Bulkhead, mr, (Timber) Speaker Enclosure[...]

1 TURBO I 10.05A[...]

NO. DESCRIPTION Cross Beam, Scuttle, RHD Cross Beam, Scuttle, LHD Setscrew, M8 x 25, Beam to Hinge Post Setscrew, M8 x 20, Beam to ~inge Post Washer, Spring, Beam to Hinge Post Washer, Plain, Beam to Hinge Post Crossbeam, Rear Bulkhead, Seat Belt Mtg. Bolt, Thinhead, Beam End to Door Aperture Washer, Large O/D Nut, M8 Setscrew, M6 x 25, Beam to Bul[...]

I 1 TURBO i 10.07A[...]

NO. DESCRIPTION Headlanp Pod, RH Headlanp Pod, RH Headlanp Pod, LH Headlap Pod, LH Ball Joint, Pod Outer Pivot Pcp Rivet, Ball Joint Fixing Setscrew, M6 x 30, Pod Outer Pivot Washer, Flat, Pod Outer Pivot Washer, Large O/D, Pod Outer Pivot Nut, Nyloc, M6, Pod Outer Pivot Bearing Housing, LH Outer/~H Inner Bearing Housing, RH Outer/LH Inner Pcp Rive[...]

1 TURBO 10.09A[...]

NO. DESCRIPTION Bonnet Panel Seal Bonnet Hinge, Bonnet, IH Hinge, Bonnet, RH Bonnet Panel, Six Slot Bonnet Panel, !I'm Slot Seal, Bonnet Hinge, Bonnet, LH Hinge, Bonnet, RH Stiffener, Bonnet, Front Edge Curvature Stiffener, Bonnet, Front Edge Curvature Shim Plate, Hinge to Bonnet Setscrew, M6 x 18, Hinge to Bonnet Setscrew, M6 x 16, Hinge to B[...]

1 TURBO 10.09A[...]

NO. DESCRIPTION Latch Disc, Bonnet Lack Clevis Pin, Latch Disc to Bracket 'R' Pin, Latch Disc Clevis Washer, Flat, Disc to Bracket Clevis Pin, Latch ~od to Disc Rod, Bonnet Latch Cperating Bush & Clip, Rod to Cross Shaft Cross-Shaft, Bonnet bk, RHD Cross-Shaft, Bonnet Leek, LID Bracket, Cross-Shaft Pivot Setscrew, M6 x 12, Bracket to [...]

[...]

NO. DESCRIPTION Tailgate Panel Foam Seal, Tailgate to Engine Lid Seal, Tailgate to Body Foam Strip, Tailgate to Body Hinge Blade, Tailgate, LH Hinge Blade, Tailgate, RH Bolt, Hinge Pivot Nut, Nyloc, M10, Hinge Pivot Hinge Blade, Tailgate, LH Hinge Blade, Tailgate, RH Bracket, Tailgate Hinge to Body Setscrew, Tailgate Hinge Pivot Washer, Shakeproof,[...]

[...]

0 ILLUS NO. 10.11A Bracket, LH, Gas Strut to Tailgate Bracket, RH, Gas Strut to Tailgate Setscrew, M6 x 30, Bracket to Tailgate Washer, Flat, Bracket to Tailgate Nut, Nyloc, M6, Bracket to Tailgate Bracket, LH, .Gas Strut to Cabin Bulkhead Bracket, RH, Gas Strut to Cabin Wllkhead Studplate, Bracket to Bulkhead Washer, Flat, Bracket Fixing Nut, Nylo[...]

TURBO 10.11A[...]

a ILLUS NO. DESCRIPTION Nut, Nyloc, M6, Latch Upstcp Release Lever, Tailgate Latch Release Lever, Tailgate Latch Screw, Release Lever Pivot Washer, Flat, Release Lever Pivat Nut, Nyloc, M6, Release Lever Pivot Spring, Release Lever Rod, Imk to Release Lever Trunnion, Rod to Release Lever hk Assembly & Keys, Tailgate Lever Arm, Tailgate Lock Lev[...]

TURBO 10.13A[...]

a ILLUS NO. DESCRIPTION Engine Bay Sidewall Engine Bay Sidewall Engine Bay Sidewall Screw, M6 x 25, Sidewall to Body Washer, Flat, sidewall to Body Pulsert, M6, Sidewall to Body Setscrew, M6 x 25, Sidewall to Front Hinge Washer, Large, O/D Nut, Nyloc, M6 Edge Finisher Rear Wall/Floor , Engine Bay Rear ~all/Floor, Engine Bay Rear ~all/Floor, Engine [...]

[...]

NO. DESCRIPTION Hinge, LH, Engine Lid Hinge, RH, Engine Lid Screw, 10 UNF x i", Hinge to Lid Washer, Flat, Hinge to Lid Nut, Nyloc, 10 UNF, Hinge to Lid Catch, Overcentre, Engine Lid Striker, Overcentre Catch Catch, Overcentre, ~ngine Lid Striker, Overcentre, Catch Screw, 4BA, Catch/Striker Fix Washer, Flat, Catch/Striker Fix Nut, 4BA, CatcWSt[...]

[...]

-- a ILLUS NO. DESCRIPTION Spire Clip 'U' Nut, Trim Panel to Body Spire Nut, Flat, Trim Panel to Body Spire Nut, Trim Panel to Engine Ray Screw, Panel to Body & Engine Ray Setscrew, M5 x 20, Panel Rear to Engine Ray Jacknut, M5, Panel Rear to Eng. Ray Washer, Flat, Panel to Engine Ray Undertray, Engine Ray Undertray, Engine Bay Undert[...]

TURBO 10.1SA a[...]

a ILLUS NO. DESCRIPTION Door Shell, Ill Door Shell, LH, RH) Door Shell, LH, IHD Door Shell, RH Door Shell, RH, RHD Door Shell, RH, LFD Door Beam, LH Door Beam, RH Setscrew, M8 x 20, Door Rear to Beam Washer, Large O/D, " It #I I! Washer, Spacing, Door Rear to Beam Setscrew, M6 x 16, Door Front to Beam Washer, Large O/D, Door Front to Beam Fixi[...]

TURBO 10. ISA e[...]

NO. DESCRIPTION Washer, Tie Rod to Hinge Nut, Nyloc, M8, Tie Rod to Hinge Pivot Bush, Door Beam Pivot Pin, Door Beam Nut, Nyloc, Ml2, Pivot Pin Check Strap, Id3 Check Strap, RH Bolt, M8 x 45, Strap to Hinge Brkt. Nut, Nyloc, M8, Strap to Hinge Guide Assy . Check Strap Slider, Id3 Guide Assy. Check Strap Slider, RH Setscrew, M6 x 12, Guide to Bracke[...]

TURBO 10.17A 0 0[...]

ILLUS NO. DESCRIPTION Exterior Door Handle Set (Black) Exterior Door Handle Set (Silver & Black) Door Handle, Exterior, RH, (Black) Door Handle, Exterior, RH, (Silver & Black) Door Handle, Exterior, LH, lack) Door Handle, Exterior, LH, (Silver & Black) Clap Bracket, Handle to Door Nut, 10 UNF, Handle to Clanp Washer, 3/16", Handle [...]

[...]

@ ILLUS NO. DESCRIPTION Plate, Interior Lock Rod Retaining Screw, Plate to Door Spire Nut, Plate to Door Rod, Exterior Release to Latch, RH Rod, Exterior Release to Latch, LH Rod, Exterior LO& to Latch, RH ~od, Exterior LO& to ~atch, LH Rod, Interior Release to Latch Rod, Interior Lock to Latch, LH Rod, Interior Lack to Latch Grarmt, Blanki[...]

[...]

NO. DESCRIPTION Front Bunper, GRP, Inc. Brkts. Front Burrper, GRP, Inc. Brkts. Front Bunper, RRIM Front Bumper, RRIM Front Burrper, RRIM Bracket, GRP Bunper Mtg. Setscrew, Bracket to GFW Wlnper Washer, Spring, Bracket to GRP Bunper Setscrew, M8 x 25, GFW Bunper to Body Washer, Spring, GRP Bunper to Body Washer, Large O/D, GRP Bunper to Body Gram&am[...]

I TURBO[...]

0 ILLUS NO. DESCRIPTION Washer, Flat, Spoiler to Body Washer, Spring, Spoiler to Body Spire Bolt, Spoiler to Rad. Duct Spire Nut, Spoiler to Rad. Duct Washer, 6m, Spoiler to Rad. Duct Grille, Radiator Air Intake Grille, Radiator Air Intake Nut, Nyloc, Intake Grille Fix Washer, 5m, Grille Fix Undershield, Front (Pair) Undershield, Front (Pair ) Spir[...]

I TURBO 10.23A[...]

--- a ILLUS NO. DESCRIPTION Rear Wlnper (GRP) Inc. Brkts. Bracket, GW Bunper Mamting Setscrew, Bracket to GRP Wlnper Washer, Spring, Bracket to GRP Bunper Setscrew, M8 x 25, Wlrtper to Body Washer, Flat, Bunper to Body Washer, Spring, Bumper to Body Seal, Neoprene, Bunper to Body Rear Valance Pulsert, M8, Valance to Body Setscrew, M8 x 25, Valance [...]

[...]

NO. DESCRIPTION "Betaseal" Screen Fitting Kit -rises : Betaseal 71904 in 300cc Cartridge Glass Primer Applicator Bottle Glass Prim Applicator Head and Felt Pad Glass Primr, Black, 84132-11 Wipe Cleaner No. 4 Piano Wire 0.6mn x 120an Special Cleaning Paper Spacing Blocks 10 x 14 x 20mm "Solbi tw , ThemElectr ic Sealer, 9. Smn "So[...]

TURBO 11.01A[...]

NO. DESCRIPTION Finisher, Door Top, External IlI Nut, Plain, 4BA, Finisher Fixing Washer, Flat, Finisher Fixing Weatherstrip, Door Glass, Fxternal Backing Strip, Weatherstr ip/Finisher Pop Rivet, Weatherstr ip/Finisher Finisher/tJeatherstrip Assy. RH Finisherrneatherstrip Assy. LH Seal, Drop Glass, Internal Seal, Door V4 Light, Internal Clip, Seal,[...]

TURBO 11.01A[...]

DESCRIPTION - - Glass, Tailgate, Heated Glass, Tailgate, Unheated Spacer, 4mn, Glass to Tailgate Surround, Tailgate Glass PART NUMBER QUANTITY ALL 1 1 4 1 HAY 199: REMARKS Turbo 11.Ol.A Page 3[...]

TURBO 11.02A[...]

NO. DESCRIPTION Door Window Fran-e, LH Door Window Frame, RH Fixing Strap, Windcrw Frame Top Rear Screw, 10 UNF, Strap to Door Shell Washer, Strap to Door Shell Studplate, M6, Frame to Door Beam Washer, M6 x 25 x 1.4 Washer, M6 x 20 x 2.5 Nut, Nyloc, M6 Silent Channel, Drop Glass Guide Guide Rail, Drop Glass, LH Guide Rail, Drop Glass, RH Fixing Pl[...]

FOR WIND DEFLECTOR. SEE 12.01A TURBO 11. OSA[...]

NO. DESCRIPTION Glass Roof Plinth, Tongue to Roof Glass Tapping Plate, Tongue Plinth Sealing Ring, Tapping Plate Screw, Plinth to Tapping Plate Washer, Plinth to Tapping Plate Tongue, Roof Glass Front Screw, 10 UNF, Tongue to Plinth Washer, Flat, Tongue to Plinth Washer, Shakeproof, Tongue to Plinth Slot Recess, LH, Roof Aperture Front Slot Recess,[...]

[...]

NO. DESCRIPTION Capping Rail, LH Capping Rail, LH Capping Rail, RH Capping Rail, RH Pop Rivet, Capping Rail to Body Finisher, 'A' Post Laer, LH ABS Finisher, 'Ap Post Lower, RH ABS Pop Rivet, Finisher Fixing Drive Fastener, Black Finisher Strip, Capping Rail to Body Pop Rivet, Finisher to Body Air Scoop, IlI, Engine Bay Ventilation A[...]

4 PRIOR TO '85 M.Y. v--. ?7 1905 M.Y. . 22 21 TURBO 12.05A 8 a a[...]

[...]

TURBO 12.OSA /' 16 I w "YE-[...]

NO. DESCRIPTION Single Stripe, 30 mn Wide, Red 11 11 I1 " Gold 11 I1 II " Black 11 In I# Silver Pin Stripe, 3 mn Wide, Red I1 II 11 " Gold I1 11 II Black I$ II I# " Silver Pin Stripe, 3 mn Wide, Red II II 11 " Gold I1 I1 II " Ble 11 II I1 " Silver Black Tape, 8 mn Wide, Spoiler/Wrnper Finisher Strip, Waistband (&a[...]

I TURBO I 12.09A I[...]

- ILLUS NO. DESCRIPTION ~ Door Mirror, RH, Convex Door Mirror, RH, Flat Door Mirror, LH, Convex Door Mirror, LH, Flat Washer, Large OD, Mirror to Door Nut, Nyloc, M6, Mirror to Door Mirror Glass, Convex Mirror Glass, Flat Bezel, Mirror Door Mirror, RH, Less Mirror Glass Door Mirror, RH, Less Mirror Glass Door Mirror, LH, Less Mirror Glass Door Mirr[...]

TURBO l3-03A[...]

0 ruus NO. DESCRIPTION Seat Fram Seat Frm, Reclining, RH Seat Fram, Reclining, LH Spring, Anti-Rattle Seat Recliniq Mechanism, RH Seat Reclining Whanism, LH Nut, Nyloc, M8 Bolt, M8 x 60, Button Head Bolt, M8 x 30, Button Heal Stud, Pawl Pivot Bolt, M8 x 20, Button Heal Spacer Locking Plate, Tilt Pawl Pop Rivet, Lacking Plate Fix Washer, Drive Plate[...]

[...]

ILLUS NO. DESCRIPTION Cushion Fmn Backrest Foam Armrest Foam, RH Armrest Foam, LH Armrest Foam, RH Armrest Foam, LH Insert, Armrest Foam Headrest Foam Suspension Unit, Backrest Suspension Unit, Cushion Flexolator, Backrest, 52h Flexolator, Cushion, 490mn Hogring, Flexolator to Suspension Unit Tube Clip, Trim to Fram Rivet, Rokut, Cushion Unit to Fr[...]

[...]

NO. DESCRIPTION rimmed Seat Assembly, Complete Trimned Seat Assembly, Carplete, RH TrimPTled Seat Assembly, Complete, LH Trim Cover, Seat Ul Flank Trim Cover, Seat Centre Trim Cover, Seat, RH Flank Trim Cover, Seat, Complete Trim Cover, Seat, Carplete, LH Trim Cover, Seat, Complete, RH Collar, Seat Head Restraint Trim Cover, Seat Head Restraint Tri[...]

[...]

NO. DESCRIPTION Seat Belt Assembly Seat Belt Assembly Seat Belt Assembly Finisher, Seat Belt Bulkhead Slot Button, Slot Finisher Fixing Cover, Seat Belt Reel, ABS Screw, Belt Reel Cwer PART NUMBER 0 QUANTITY ALL 2 2 2 2 4 2 8 REMARKS Turbo 13.27A[...]

[...]

ILLUS NO. DESCRIPTION Pedal Box (Uses Threaded Stop Switch) Pedal Box (Uses Push & Twist Stop Switch) Pedal Box (Uses Push & Twist Stop Switch) Setscrew, M8 x 25, Pedal Box to Chassis Washer, Spring, Pedal Box to Chassis Washer, Flat, Pedal Bcx to Chassis Bearing, Throttle Pedal Pivot Washer, Throttle Pedal Pivot Bracket, Throttle Pedal Ups[...]

[...]

NO. DESCRIPTION Pedal Box (Uses Threaded Stop Switch) Pedal Box (Uses Push & Twist Stop Switch) Pedal Box (Uses Push & Twist Stop Switch) Setscrew, M8 x 25, Pedal BcDc to Chassis Washer, Spring, Pedal Box to Chassis Washer, Flat, Pedal Bax to Chassis Bearing, Throttle Pedal Pivot Washer, Throttle Pedal Pivot Bracket, Throttle Pedal Upstop S[...]

[...]

a ILLUS NO. DESCRIPTION Bracket, Throttle Cable Abutment Trunnion Barrel, Carb. Throttle Lever Spacer, Trunnion to Nipple Barrel, Solderless Niple Screw, Solderless Nipple Bracket, Throttle Cable Abutmnt Trunnion Barrel, Carb. Throttle Lever Spacer Trunnion to Nipple Solderless Nipple Setscrew, Abutment Bracket to Plenum Washer, Spring, Abutment Br[...]

[...]

NO. DESCRIPTION Switch, Stop Light Bush, Stop Switch Retentional Bracket, Stop Light Switch Mounting Footrest, Left FootBrake/Clutch Upstop Jacknut, M5, Footrest Fixing Setscrew, M5 x 12, Footrest Fixing Cwer, Footrest Jacknut, M6, Cwer Fixing Setscrew, M6 x 12, Cover Fixing Washer, Shakeproof Cwer Fixing Choke IRver Bracket, Choke Lever Mounting P[...]

TURBO LHD lLOl B[...]

a ILLUS NO. DESCRIPTION Bracket, Throttle Cable Abutmnt Trunnion Barrel, Cab. Throttle Lever Barrel, Solderless Nipple (modify) Screw, Solderless Nipple Bracket, Throttle Cable Abutnwt Trunnion Barrel, Carb. Throttle Lever Spacer, ~runnion to Nipple Barrel, Solderless Nipple Screw, Solderless Nipple Bracket, Throttle Cable Abumnt Trunnion Barrel, C[...]

[...]

NO. DESCRIPTION Setscrew, M8 x 50, Brake/Clutch Upstop lhcknut, M8, ~rake/Clutch Upstop Switch, Stop Light Locknut, Stop Switch Switch, Stop Light Bush, Stop Switch Retention Bracket, Stop Light Switch Mamting Choke lever Bracket, Choke Lever Mounting Pop Rivet l/8" Bracket Fix Pivot Pin, Choke Lever Bush, 'Start01 Ring' Choke Lever [...]

TURBO 1 14.05A ! ![...]

IUUS NO. DESCRIPTION Fascia, Trimmed Fascia, Trid Fascia, Trinmd, Square Choke Cable Aperture Fascia, Trid, 'Dl Shape Cable Aperture Fascia, Trirraned Fascia, Trhmd Fascia, Trid, Square Choke Cable Aperture Fascia, Trid, ID' Shape Cable Aperture Jacknut, M6, Fascia Fixing Bracket, Fascia to 'A' Post Trim Cwer, Screen Landing Tri[...]

TURBO 14.07A[...]

e ILLUS NO. DESCRIPTION Instmnt Mounting Panel, Steel Instmnt Mamting Panel, Steel Inst-t Maunting Panel, Steel Bracket, Instmnt Panel to Binnacle Bracket, Instrument Panel to Binnacle Clip, Instmnt Panel to Bracket Screw, s/t, No. 6 x f " , Panel Fix Spire Nut, Panel Fix Mask, Instrument Panel, ABS Mask, Instmnt Panel, ABS Side Panel, Binnacl[...]

1 , I 1 I 1 I 1 I I I I ! i TURBO I 14.08A I ~ 1[...]

ILLUS NO. DESCRIPTION Centre Console, Trimred, inc. Lever Gaiter ~lanking Panel, TrM, Radio Aperture Light Box, Heater/A/C Controls Spacer, Heater/A/C Controls Clock Muting Panel, ( ABS ) Cassette Storage Bin, (ABS) Centre Console, Trimred, inc. Gaiter & Brkts. Blanking Panel, Trid, Radio Aperture Bracket, Centre Console, Rear Setscrew, M6 x 20[...]

I- -..- -._ TURBO 23 14.08A[...]

NO. DESCRIPTION Mounting Bracket & Light Bax, Heater/s/C Controls Screw, Bracket to Tunnel Top Washer, Flat, Console/Brkt. to Fascia Wing Nut, Console/Brkt. to Fascia Washer, Shakeproof, Console/Brkt. to Fascia Gaiter, Gear Lever Retaining Ring, Gear Lever Gaiter Choke/Window Switch Panel, Trim Window Switch Panel, Trimred PART NUMBER QUANTITY [...]

TURBO 14.10A[...]

ILLUS NO. DESCRIPTION Instrurrrent Binnacle, Trirnrrred Foam Binnacle, Interior, Anti-Rattle Mounting Bracket, Binnacle to Fascia Setscrew, M6 x 18, Binnacle to Brkt. Washer, Large O/D, Binnacle to Brkt. Fascia ~lanking Panel, Trim&, RHD Fascia ~lanking Panel, Trid, LHD PART NUMBER QUANTITY REMARKS I *Prefix Trim Part Number With: A - Leather B[...]

TURBO 14.12A[...]

NO. DESCRIPTION Glwe Box Lid, Trimned Glove Box Inner, RHD Glwe Box Inner, LED Screw, Glwe Box Inner Top Edge Fix Spire Nut, Glwe Box Top Edge Fix Screw, 10 UNF x )", Glwebox to Fascia Nut, Nylm, 10 UNF II II II Hinge, Glovebox Lid, RH Hinge, Glwebox Lid, IH Screw, Hinge to Fascia Beam Latch, Glwebox Lid Bracket, Latch to Fascia Screw, Latch t[...]

j I I ~ TURBO 15.01 A[...]

- - e ILLUS NO. DESCRIPTION Header Rail, Trim& Header Rail, Trinmd Header Rail, Trid Header Rail, Trimtled Header Rail, Trimrred Cant Rail, Trimed, RH Cant Rail, Trim, RH, Cant Rail, Trimred, LH, Cant Rail, Trimred, LH, Bracket, Cant Rail, Fixing Screw, Header & Cant Rail Fixing 'A' Post Trirrm3d Panel, RH 'A' Post Tr- P[...]

! TURBO I 15.11A[...]

ILLUS NO. DESCRIPTION Bulkhead Trimwd Panel Bulkhead Trirm.4 Panel Bulkhead Trirrmed Panel Bulkhead Trimned Panel Bulkhead Trimred Panel Bulkhead Trim Panel Grille, Rear Bulkhead, Air Outlet Screw, Rear Bulkhead Trim Fixing Screw, Rear Bulkhead Top Fixing Map Pocket, Trhmd Map Pocket, Trimned Doweling, Bulkhead Trim Fixing Clip, Bulkhead Trim -ling[...]

TURBO 15.13A a[...]

NO. 15.131 DESCRIPTION Door Trim Panel, Trimned, IH Door Trim Panel, Tr-, LH Door Trim Panel, Trhmd, IH Door Trim Panel, Trirmd, LH Door Trim Panel, Trim&, LH Door Trim Panel, TrimTed, LH Door Trim Panel, Trirrmed, RH Door Trim Panel, Trirnred, RH Door Trim Panel, Trimwd, RH Door Trim Panel, Trimd, RH Door Trim Panel, Trim, RH Door Trim Panel, [...]

TURBO 15.13A 0[...]

NO. DESCRIPTION Door Trim Panel, Trim&, LH Door Trim Panel, Trim&, LH Door Trim Panel, Trim-&, RH Door Trim Panel, Trirnred, RH Stud Plate, Mirror Switch Fixing Bracket, Mirror Control Switch Mounting Nut, Nyloc, M5, Bracket to Stud Plate Flange, Window Weatherstrip Mcunting Flange, Windaw Weatherstrip Mounting Ashtray Assembly (Chrarre[...]

TURBO I 15.19A[...]

ILLUS NO. DESCRIPTION Tunnel Side, Trimned, IH Tunnel Side, Trimwd, RH Setscrew, M6 x 20, Tunnel Side Fixing Washer, Tunnel Side Fixing Rawlnut, M6 x 15, Tunnel Side Fixing Rawlnut, M6 x 15, Tunnel Side Fixing Tunnel Top Armrest, Trimrred Tunnel Top Armrest, Trhmd Clip, Tunnel Armrest Fixing Plate, Gear Lever Aperture Gasket, Aperture Plate to Body[...]

TURBO i 15.24A[...]

ILLUS NO. DESCRIPTION Luggage Bag Assen33ly Fixing Strip, Ehg to Rear Panel Screw, Fixing Strip Spire Nut, Fixing Strip Rear Luggage -t Grey Fleck Carpet Side, LEI Wheelarch, IH Engine Bay Rear Wall Floor Rear Transan Battery Board, Carpeted Button, 'Durable Dot', Carpet Fixing Socket, 'Durable Dot', Carpet Fixing Bracket, Batte[...]

TURBO 15.30A[...]

NO. DESCRIPTION Carpet, Footwell Front Carpet, Front Floor, With Mat, RH Carpet, Front Floor, With Mat, RH Carpet, Front Floor, With Mat, LH Carpet, Front Floor, With Mat, LH Carpet, Underseat Carpet, Front Wheelarch, With Mat, RH Carpet, Front Wheelarch, With Mat, LH Carpet, Sill, RH, (Inc. H/Brake Gaiter) Carpet, Sill, RH Carpet, Sill, RH Carpet,[...]

1 TURBO 16-01 A[...]

ILLUS NO. DESCRIPTION Foam, Front Floor, RH Foam, Tunnel Side, RH Foam, Tunnel Tcp Foam, Tunnel Side, IH Foam, Front Floor, LH Foam, Under seat Foam, Rear Bulkhead Uwer, RH Foam, Rear Bulkhead Upper Foam, Rear Bulkhead Iaer, LH Felt, Wheelarch, LH Felt, Wheelarch, RH PART NUMBER e QUANTITY REMARKS Turbo 16.01A[...]

[...]

ILLUS NO. DESCRIPTION Sound l3arrier Mat, Rear Bulkha Screw, s/t, No. 6 x f ", Mat Fixing Cup Washer, Mat Fixing Screw Faam, Tunnel Top Underside Faam, TUM~ Side, Underside Faam, Pedal Bax Seal Foam, Chassis Front Crossnrember Pad, Anti-Squeak Sound Proofing , Engine Bay Sidewall PART NUMBER QUANTITY ALL 1 14 14 1 2 2 1 1 1 REMARKS '87 M.[...]

[...]

NO. DESCRIPTION Extension Harness, Mirror Main Harness Main Harness Gromrret, Main Harness, Bulkhead & Engine Bay Bush, Grmt Door Mirror Harness Harness, Door Mirror Control Alternator Harness Earth Led, Tailanps Reverse Lanp Lead Door Ajar Iap Harness Rad. Fan Harness Cigar Lighter Earth hs3 Cigar Lighter Harness Air Conditioning Harness Air C[...]

026 010 008 019 018 017 TURBO 17.01A[...]

NO. DESCRIPTION Clip, Loan Fix Clip, Imn Fix Clip, Loan Fix Cable Tie, 312 m Cable Tie, 220 mn Clip, Loan Fixing Clip, Ixxn Fixing Clip, Lnom Fixing Cable Tie, 312 m Cable Tie, 220 m Cable Tie, 455 mn 'PI Clip, Small Screw, No. 6 x 1/4", 'P' Clip Fix Harness, Radio Feed Harness, Aerial Switch Speaker Lrxm, Front Speaker Loan, Re[...]

[...]

ILLUS NO. DESCRIPTION Flasher Unit, Hazard Clip, Hazard Flasher Unit Flasher Unit, Turn Indicators Screw, Flasher Unit Fixing Spire Nut, Flasher Unit Fixing Relay, Double Contact Relay, Changewer, Silver 30 Anp Relay, Changeover, Black 40 Anp Relay, Changeover, Black 40 Anp Fused Relay, 4RA, Radiator Fans 'Cartier' Relay, Interior Fans (O[...]

[...]

ILLUS NO. DESCRIPTION Setscrew, M6 x 25, Horn Brkt. to Body Washer, Flat, Brkt. Fixing Washer, 25mnO/D, Brkt Fixing Nut, Nyloc, M6, Brkt. Fixing Voltage ~tabiliser Diode, Brake Warning Lanp Module, 'DiwDipl Screw, M4 x 30, Unit Fix Bracket, Relay Mounting Pop Rivet, Brkt. Fix Module, I# Coolant Screw, s/t, Module Fix Spire Nut, Module Fix &apo[...]

[...]

ILLUS NO. DESCRIPTION Light Source, Fibre Optics Bulb, 12V W, Light Source Clip, Fibre Optic Carrier to Switch Fibre Optic Light Carrier, 880mn Fibre Optic Light Carrier, 435mn Rheostat, 27W, Binnacle/Switch Illum. Rheostat, 19.8W, Heater/Cigar Illum. Knob, Rheostat, Plain Kncb, Rheostat, with Graphic Heatshield, Rheostat Blanking Plug, Light Sourc[...]

[...]

0 ILLUS NO. DESCRIPTION Switch, Mirror Ad just Switch, Mirror Adjust Nut, 3/4 UNF, Switch Retaining Spacer, Mirror Adjust Switch Bezel, Mirror Adjust Switch Spring Clip, Bezel Retaining Switch, Mirror Select Switch, Mirror Select Switch, ~nterior Fan Speed Switch, Interior Fan Speed Switch, Radio Aerial Knob, Fan Speed Switch Knob, Fan Speed Switch[...]

[...]

ILLUS NO. 4 I DESCRIPTION Clock, Digita1,LED (Rocking Bar Adjustnwt) Clock, Digita1,LED (pin Button Adjustment) Clock, Digital,LED (Rocking Bar Adjustment 1 Clock, Digita1,LCD Screw, M4 x 20, Clock Fixing Washer, Flat, Clock Fixing Nut, Nyloc, M4, Clock Fixing Speedmter, 170 nph, RHD Spedoneter, 170 nph, RHD Speedmter, 265 kph, IlID Speedmeter, 260[...]

[...]

DESCRIPTION Speed0 Cable 'P' Clip, Cable to Chassis Pipe, Oil Pressure Gauge , Nut Fitting pipe, Boost Gauge, Nut Fitting Pipe, Boost Gauge, Plain End Connector Tube, Boost Pipe to Engine Restrictor, Boost Gauge Pipe Washer, Oil/Boost Pipe to Gauge PART NUMBER a QUANTITY WAY is91 REMARKS R/B Items 5,6,7 and Take-Off Elbow A910E6772 (See 4[...]

LUCAS UNEAR UFFUPON PATTERN SIDEITMW INDICATOR LAMP , -[...]

ILLUS NO. DESCRIPTION I Turn Repeater Lanp Turn Repeater Lanp Screw, Lanp Fixing ~idehurn Lanp, IH Side/l?wn Lanp, RH Lens, Sidehurn Lanp Screw, Lanp Fixing Spire Nut, Lanp Fixing Sidemn Lanp, LH Side/lhrn Lanp, RH Lens, Side/l?wn Lanp Washer, Flat, Lanp Fixing Nut, Nyloc, M6, Lanp Fixing Sidehurn Lanp, IH Side/l?wn Lanp, RH Lens, ~idehurn Lanp Set[...]

STRATED[...]

ILLUS NO. DESCRIPTION Head- Assably , Lucas/Hella Headlanp Unit, Lucas/Hella Headlanp Assdly, Lucas/~ella Headlanp Unit , Lucas/Hella Headlanp Assembly, Inboard, Cibie Headlanp Assembly, Outboard, Cibie Headlanp Assembly, Outboard, Cibie Bulb, Halogen H4, -Dip Bulb, Halogen HI, Beam Only Bulb, Halogen, H4, Yellow Screw, Headlanp to Pod Spire Nut, H[...]

[...]

-- a ILLUS NO. DESCRIPTION Motor Assanbly, Headlanp Pod Motor Assembly, Headlarrp Pod Rotary Link Bracket, Head- Motor Mamting Setscrew, 1/4" UNF x 3/4" Brkt/Body Washer, Bracket/Bdy Rawlnut, 1/4" LINE', Bracket/~ody Washer, Flat, Rod End Connecting Link, Pod Actuation Rod End, 1/4" UNF, Connecting Link Locknut, 1/4" L[...]

[...]

ILLUS NO. DESCRIPTION Interior Lanp (with rocking lens switch) Bracket, Interior Lanp Mamting Bulb, Festoon, Interior Lanp, 6W Interior Lanp (with button switch) Bracket, Interior Lanp Mamting Bulb, Festoon, Interior Lanp, 10W Door Switch, Courtesy Lanp Spacer Washer, Fibre, Switch Adjust PART NUMBER QUANTITY ALL 1 1 1 1 1 1 2 rn REMARKS Fran 1986 [...]

[...]

a ILLUS NO. DESCRIPTION Thermal Trip, 3-Way, Rad. Fans Therrml Trip, 3-Way, Rad. Fans Mounting Bracket, Thermal Trip Pq Rivet, rip Connector Mldghrkt. Screw, Mounting Bracket to Body Inertia Switch, Fuel Punp Cut Out Bolt, M5 x 50, Switch Fix Nut, Full, M5, Switch Fix Washer, Shakeproof, Switch Fix Fusebox Screw, 2BA x 1" , Fusebox Fixing Nut,[...]

[...]

-. a ILLUS NO. DESCRIPTION Wiper Motor, 16W Wiper Motor, 29W, Inc. Clap & Pad Clanp & Pad, Motor Mounting Setscrew, M6 x 30, Clanp to Body Washer, 25mn O/D, Motor Mtg. Nut, Nyloc, M6, Motor Mtg. Bundy Tube, Motor to Wheelbarc Bundy Tube, Wheelbox Runlxlt Wheelbox Assembly, Inc. Nuts Bracket, Wheelbox Stabilising Setscrew, Bracket to Body Wa[...]

[...]

NO. DESCRIPTION Radio/Cassette Unit Radio/Cassette Unit Radio/Cassette Unit Radio/Cassette Unit Radio/Cassette Unit Radio/Cassette Unit Radio/Cassette Unit Radio/Cassette Unit Radio/Cassette Unit Fitting Kit, Blaupunkt Units Fitting Kit, Blaupunkt Units Diode, 1 Arrp, Radio Harness Support Bracket, Radio to Tunnel Speaker, 4 ohm, Frontmeat- Grille,[...]

LHD SHOWN[...]

ILLUS NO. DESCRIPTION Locking Plate, Pantograph A~TI I1 I1 II I0 II II I1 II I1 II II II Screw, Locking Plate to Body Screw, Locking Plate to Body Bracket, Downstop Screw, Downstop Fixing Wiper Arm Assgnbly Wiper Arm Assembly Bezel Wiper Arm Assembly Wiper Arm Assgnbly Washer, Wiper Arm Nut Adaptor Plate, Wiper Arm Wiper Arm Assembly Wiper Arm Assg[...]

TURBO 17.27A a LHD SHOWN a[...]

NO. DESCRIPTION Speaker, Rear, 25W Cable, Short, Rear Speaker Cable, Long, Rear Speaker Loan, Rear Speakers Speaker, Rear, Eurotech Grille, Rear Speaker, with Badge Badge, 'Lotus', Speaker Grille Cable Assembly, Rear Speakers Aerial, Electric, External Fit Relay, Electric Aerial Aerial, Electric, Internal Fit Jup Harness, Aerial Junp Harn[...]

[...]

ILLUS NO. DESCRIPTION Earth Bond, IH Door to Scuttle Beam Earth Bond, RH Door to Scuttle Beam Setscrew, M6 x 20, Bond to Door Beam Foil, Screening Earth Bond, Chassis to Bulkhead Earth Braid, Engine to Chassis Capacitor, 2 mE, Ignition Coil Capacitor, 1 mE, Fuel Plmp Capacitor, 1 mE, Stop Switch Capicitor, 1 mE, Voltage Stabiliser Choke, Voltage St[...]

[...]

ILLUS No. DESCRIPTION Tray, Battery Carrier Battery, Chloride, Type 362 Battery, Chloride, Type 385 Battery, Tungstone, Type 065 Maintenance Free Battery, Tungstone, Type 088 Low Maintenance Clanp Plate, Battery Retention Bolt, M8 x 35, Battery Retention Bolt, M8 x 100, Battery Retention Washer, Flat, Battery Retention Clanp Plate, Battery Retentio[...]

[...]

ILLUS NO. DESCRIPTION Heater Assembly Heater Assembly Heater/~ir Conditioning Assmbly Heater/Air Conditioning Assembly Case, WE= Case, Upper Case, Upper Case, Upper Case, Lower Case, Laer Case, Lower Case, Laer setscrew, M6 x 12, Case to Mtg. BI Washer, Flat, Case to Mtg. Brkt. Mmnting Bracket, Case to Tunnel Pop Rivet, Mtg. Brkt. to Tunnel Bush, F[...]

[...]

NO. DESCRIPTION ! Evaporator Evaporator Foam, Open Msh Elbow Adaptor Expansion Valve Flare Gasket, 10.4m~1 Receiver Drier Bracket, Receiver Drier Bracket, Receiver Drier Bolt, M6 x 50, Bracket Clanping Bolt, M6 x 30, Bracket Clanping Nut, Nyloc, M6, Brkt. Clanping Setscrew, M6 x 20, Brkt. to Body Washer, Fht, Brkt. to Body Washer, 25mn OD, Brkt to [...]

TURBO 18.0 3A[...]

NO. DESCRIPTION Screw, Granrrret Plate Fixing Grmt, Fridge Hoses Condenser Foam Strip, Condenser to Radiator Setscrew, M8 x 20, Condenser to Duct Washer, Shakeproof, Condenser to ~uct Washer, 25mn O/D, Condenser to Duct Bracket, Condenser Support Bracket, Condenser Support Setscrew, M6 x 16, Brkt. to Condenser Washer, Flat, Brkt. to Condenser Nut, [...]

[...]

ILLUS NO. DESCRIPTION Heater Matrix Foam, Heater Matrix to Case Water Valve Bracket, Water Valve Mounting, RHD Bracket, Water Valve Mamting, LED Setscrew, Bracket to Water Valve Nut, Bracket to Water Valve Bracket, Cable Abutment Clip, Cable Abutmnt Setscrew, Abutment Bracket to Valve Nut, Abutment Bracket to Valve Clanp, Cable to Water Valve Hose,[...]

I i TURBO 1 18.07A[...]

ILLUS NO. DESCRIPTION Blower Motor & Fan Assembly, Tq Blmer Motor & Fan Assembly, Bottan Clanp, Motor to Housing Setscrew, M5 x 20, Motor Clarrp Washer, Motor Clanp Screw Jacknut, M5, Motor Clarrp Screw PART NUMBER e QUANTITY ALL 1 1 6 6 6 6 CCW Rotation Vie& Motor End CW Rotation Viewed Motor End Turbo 18.07A[...]

TURBO 1 0.0 9A[...]

ILLUS NO. DESCRIPTION Flap, Def rost/Footell Flap, De£rost/Footell Foam, Defrost/Footell Flap Clip, Flap Shaft Ends Lever, Defrost/Footell Flap Shaft Grubscrew, Lever to Shaft Clip, Rod to Lever Rod, De£rost/Footell Flap *rating Control Plate Control Plate Stud, 10 UNF, Cam/Lever Pivot Nut, Plain, 10 W, Pivot Stud Nut, Nyloc, 10 UNF, Pivot Stud C[...]

TURBO 1 0.0 9A 0[...]

ILLUS NO. DESCRIPTION Graphic Control Panel, with A/C Graphic Control Panel, with A/C, Long Graphic Control Panel, with A/C, Long Graphic Control Panel, with 9/C, Short Graphic Control Panel, with A/C, Short Graphic Control Panel, Heater Only, Long Screw, No. 6 x f" s/t, Panel Fix Spire Nut, Panel Fix Kncb, Rotary Controls Knob, Rotary Control[...]

[...]

ILLUS NO. DESCRIPTION Flap, Mode Flap, Mode Foam, Mode Flap Clip, Flap Shaft Ends Mounting Plate, Actuator Brkt. Pop Rivet, Mtg. Plate to Case Bracket, Vacuum Actuator Mtg. Pop Rivet, Brkt to Plate Vacuum Actuator, Modebresh Air Flap Rod, Actuator to Mode Flap Locking Tab, Actuator to Rod Clip, Rod to Mode Flap Lever Lever, Flap Operating Vacuum Sw[...]

[...]

ILL"^ NO. DESCRIPTION Screw, No. 6 x 3/411, Brkt to Bulkhead Spire Nut, Brkt. to Bulkhead Foam Seal, Fresh Air Flap Pivot Bush, Inner Pivot Bush, Outer Vacuum Reservoir Pad, Anti-Vibration, Reservoir Mounting Bracket, Reservoir Fixing Setscrew, M6 x 16, Brkt. Fixing Nut, Nyloc, M6, Brkt. Fixing Screw, s/t, Bracket, Fixing Straight Connector, R[...]

LHD ILLUSTRATED 03 7[...]

ILLUS NO. DESCRIPTION Outlet Adaptor, Centre F.L.V. Outlet Adaptor, Centre F.L.V. Outlet Adaptor, Demist Outlet Adaptor, Outer F.L.V. Pop Rivet, Demist & Outer F.L.V. Adaptors Washer, Pop Rivet Screw, Centre F.L.V. Adaptor Outlet Adaptor, Footell Cwer, Footwell Duct Take Off Screw, No. 8 x 3/8", Cwer to Case Scroll Extension Scroll Extensi[...]

I LHD ILLUSTRATED[...]

NO. DESCRIPTION Plenum Chamber Plenum Chamber Adaptor, Plenum to Drain Tube Cwer, Bulkhead Cwer, Bulkhead Foam Strip, Cwer to Body Screw, No. 6 x t", Bulkhead Cwer Ducting, 1 7/8", Outer F.L.V. Ducting, 2 1/411, Demist Ducting, 2", Centre F.L.V. Ducting, It", Centre F.L.V. Outlet Vanes, Dernist Vent Demist Vent, Passenger Side -[...]

TURBO 1 1 30.01 A I[...]

ILLUS NO. DESCRIPTION 1 Chassis Chassis Chassis Chassis Chassis Chassis Chassis Chassis Rear Crossmnber Clanp, Hose # Clanp, Pipe LJI # Clanp, Pipe RH # PA#T NUMBER QUANTITY RHD LHD MAY 19(11 REMARKS Prior to '85 Model Year* t 1985/'86 Model Year t '87 M.Y. on R/B B082A42345 +(~/~ipe Clanps 1 Prior to '85 Model Year* t 1985/&apo[...]

[...]

ILLUS NO. DESCRIPTION Front Hub Assmbly (With Studs) Stud, Wheel Front Hub Brake Disc Brake Disc Bolt, 3/8" x 7/8" UNF Washer, Spring 3/8" Wheel Bearing, Inner Wheel Bearing, Outer Oil Seal, Front Hub Stub Axle Nut, Nyloc, 9/16" Washer, Plain Nut, Castellated Washer, ID1 Split Pin Hub Cap Vertical Link Vertical Link RH Plug, Lub[...]

[...]

ILLUS NO. DESCRIPTION Bolt 5/16" x 3/4" UNF Washer, Spring, 8 mn Bolt 3/8" x l.l/4" UNF Washer, Spring, 10 mn Bolt, 3/8" x 2.1/411 UNF Nut, Torqloc, 3/8" UNE' Upper Ball Joint Nut, Torqloc, 7/16" UNE' Washer, Plain Bolt, 8 x 100 mn Bolt, 8 x 60 mn Nut, Nyloc, M8 Washer, Plain Wishbone ~rm Pivot Bush, Wis[...]

[...]

NO. DESCRIPTION Bush, Lawer Link Pivot Bolt fn x 6" UNF Nut, Nyloc f " UNF Was her Anti-Roll Bar Anti-Roll Bar Bush, Anti-Roll Bar to Lower Link Distance Tube Washer, Special Washer, Chanter Tuward Front Nut, Nyloc, M12 Mmnting Rubber, A.R.B. to Chassis Clanp Plate Spacer Washer, Castor Adjust Setscrew, M12 x 30, A.R.B. to Chassis Washer,[...]

[...]

NO. DESCRIPTION Danper Assy. (includes A08X6033F) Danper Assy. (includes A082C6033F) Bush Kit, Darrper Top Stem Bush Kit, Danper Top Stem Bush, Danper Lower Eye Washer, Danper/kwer Link/Nut Bolt, $I1 UNF x 23" Nut, Nyloc, 3" UNF Road Spring, Red/Green Road Spring, Redhed Spring Seat, Rubber PART NUMBER a QUANTITY ALL Fny roql REMARKS This[...]

[...]

ILLUS NO. DESCRIPTION Vertical Link Steering Arm RH Steering Arm LH Setscrew, M12 x 35, Arm/Link Washer, Spring, Arm/Link Bolt, M12 x 45, Arm/Link Nut, Nyloc, Ml.2 Arm/Link Shield, Brake Disc, RH Shield, Brake Disc, LH Setscrew, Disc Shieldfiert. Link Washer, Flat, Shielmer-t. Link Hub, Front Bearing, Inboard, Front Hub Bearing, Outboard, Front Hub[...]

[...]

NO. DESCRIPTION Shim Washer, Castor Adjust, 1.- Shim Washer, Castor Adjust, 3.0mn Shim Washer, Castor Adjust, 6.m Ball Joint, Upper Nut, Torqloc, 7/16" UNF Washer, Flat, Ball Joint/Wishbone Bolt, M8 x 100, Ball Joint/Wishbone Bolt, M8 x 60, Ball ~oint/Wishbone Bolt, M8 x 65, " I1 11 II Nut, N~~oc, M8, II 11 II Washer, Plain, In #I )I Shin[...]

[...]

ILLUS NO. DESCRIPTION Nut, Nyloc, M12, ARB to Chassis Ahtmnt Plate, Spring/~anper Top Washer, Abutment ~late/Chassis Nut, M8 11 II II I1 I1 Insulator, Front Spring Top Spring/Darrper Assy. (Parallel Spring) Spring/Danper Assy . (Parallel Spring Road Spring , Parallel, (Purple/Red) Road spring, Parallel, (Yellow/Yellaw) Spring/Darrper Assy . (Conica[...]

[...]

NO. DESCRIPTION Rear Hub Assdly (with studs) Stud, Wheel Rear Hub Nut, Hub Retaining Split Pin, Hub Nut Cone, Hub Retention Bearing, Rear Wheel Circlip, Bearing Retaining Spacer, rive ~haft/Bearing Drive Shaft, Outboard Drive Shaft Assdly, Intermediate Boot Kit, Drive Shaft C.V. Joint Bolt, Allen, M10 x 65 x 1.5 rnn Segment Washer Adaptor, Drivesha[...]

[...]

ILLUS NO. DESCRIPTION Mounting Rubber Plate, Reinforcing Spacer, 0.9mn, Toe-In Adjust Spacer, 1.5mn, Toe-In Adjust Spacer, 6. Omn, Toe-in Ad just Setscrew, M8 x 35 Nut, Nyloc M8 Washer, Plain Bolt, 7/16" x 4.1/2", UNF Nut, Torqloc, 7/16" UNF Washer, Large, 7/16" x If" Washer, Toe-In Ad just Upper Link (Less Bushes) Bush, Up[...]

[...]

NO. DESCRIPTION Bolt, 3" UNF x 5. 1/211 Top Linkkarrier Washer, Bolt/Carrier, Nut/~ink Washer, 31' Hardened, Link/Carrier Nut, Nyloc, 3" UNF Bolt, 3" UNF x 5.1/211 Top Linkkarrier Washer, Bolt Head Washer, x 1.3/4" Nut, Nyloc 3" UNF Lower Link, (Less Bushes) Bush, Lower Link, Outer, Metalastik Bush, Lower Link, Inner, [...]

[...]

ILLUS NO. DESCRIPTION Danper Assy. (Includes A082C6036F) Bush Kit, Danper Top Stan ( 3/8" UNF 1 Bush Kit, Danper Top Stem (3/8" UNF 1 Bush Kit, Danper Top Stan (NO1 Spacer Washer, Danper kmr Fix Washer, Flat Nut, Nyloc, 4" UNF, Danper/Carrier Road Spring , ~reen/Green Road Spring, Green/Green Road Spring, Green Insulator, Rear Spring[...]

TURBO 32.01A i LHD ILLUSTRATED[...]

NO. DESCRIPTION Protective Slewe, Column Spline Intermdiate Steering Colm Assy. Universal Joint, Lower Bolt, M8 x 35, Universal Joint Clanping Washer, Flat, U/J Claq Bolt Nut, Nyloc, M8 U/J Clamp Bolt Protective Sleeve, Pinion Shaft Spacer, Column Lower U/J Circlip, Pinion Shaft/Spacer Rack 6 Pinion Assembly Rack & Pinion Assembly Rack & Pi[...]

[...]

NO. DESCRIPTION Nut, Steering Wheel to Colurm Washer, Steering Wheel Nut Collet, Steering Wheel Thrust Band, Collet Retaining Steering Wheel Assenbly, Black Steering Wheel Assembly, Black Steering Wheel, Black Leather Steering Wheel, Coloured mther Hub, Steering Wheel Roll Pin, Turn Indicator Cancelling Fixing, Wheel to Hub Wheel Centre ('Old&[...]

[...]

NO. DESCRIPTION Caliper Assembly, Front, RH Caliper Assembly, Front, IH Brake Pad Set, Front Pin, Pad Retaining Clip, pin Retaining Bolt, Caliper to Mounting Bracket Washer, Spring, 12 mn Service Kit, Front Caliper Disc, Front Brake Bolt, Disc to Hub Washer, Spring, 3/8" Caliper Assembly, Rear, RH Caliper Assembly, Rear, IlI Brake Pad Set, Rea[...]

[...]

NO. DESCRIPTION Disc, Rear Brake Nut, M12, Disc Fixing Washer, Spring, Disc Fixing PART NUMBER a QUANTITY MAY 1991 i I I REMARKS ! ! This Page Prior to '85 M.Y For '85 M.Y. See 33.01B Turbo (Prior to '85 M.Y.) 33.01A Page 2[...]

1 33.018 TURBO (85 M.Y. ON1[...]

NO. DESCRIPTION Brake Caliper Assembly, RH Front Brake Caliper Assembly, L,H Front Pad Set, Including Anti-Rattle Springs Caliper Repair Kit, Front Bolt, Caliper Swing Release Bush, mr, Caliper Sliding Bleed Nipple, Front Caliper Dust Cap, Bleed Nipple Bolt, Caliper Fixing Washer, Shakeproof, Caliper Fix Brake Disc, Front, Ventilated Bolt, Brake Di[...]

[...]

NO. DESCRIPTION Washer, Spring, Caliper Fix Brake Disc, Rear Nut, M12, Disc Fixing Washer, Spring, Disc Fixing PART NUMBER a QUANTITY ALL MAY f%i REMARKS j This Page '85 M.Y. Onward For Cars Prior to '85 M.Y. See 33.01A White Colour Code or Cast Part Nunher Turbo ('85 M.Y. On) 33.01B Page 2[...]

[...]

NO. DESCRIPTION Servo Assembly, Girling Type 50 Push Rod, Brake Pedal to Servo Clevis Pin, Pushrd to Pedal Clevis Pin, Pushrod to Pedal Spring Clip, Clevis Retaining Service Kit, Brake Servo Non-Return Valve Kit Bracket, Servo to Pedal Bax Bracket, Servo to Pedal Box Spacer, Bracket to Pedal Bax Nut, Bracket to Pedal Box Nut, Servo to Mcunting Brac[...]

[...]

NO. DESCRIPTION Union 3-Way, Front pipe, Brake, 3-Way to Hose Clip, Brake Pipe Screw, Pipe Clip to Chassis Hose, Front Brake Locknut, Front Brake Hose Washer Shakeproof, Front Brake Hose Pipe, Brake, Hose to Front Caliper Bracket, Caliper Pipe Support, RH Bracket, ~ipe/Hose Support IH Pipe, Brake, Rear Feed Pipe, Brake, Rear Feed Union, Double Ende[...]

[...]

NO. DESCRIPTION Pushrcd, Brake Pedal to Servo Clevis Pin, Pedal to Pushrod Spring Clip, Clevis Retaining Locknut, Servo Pushrcd Bracket, Servo & Clutch Wylinder Eltg. Gasket, Servo Bracket to Body Spacer, Bracket to Pedal Box Nut, Nyloc, M8, Brkt. to Pedal Box Washer, Spring, Brkt. to Pedal Box Servo/Brake Master Cylinder Assy . Servo Assgnbly,[...]

[...]

ILLU 4 NO. DESCRIPTION Washer, Flat, Brkt. to Caliper Washer, Shakeproof, Brkt. to Caliper Nut, M6, Brkt. to Caliper pipe, Rear Brake bI/Cyl. to D/E Union Pipe, Rear Brake, M/Cyl. to D/E Union Union, Double Ended Pipe, Rear Brake, D/E Union to 3-Way Union, 3-Way, Rear Bolt, M6 x 40, 3-Way Union to Chassis Washer, Spacer, 3-Way Union Washer, Flat, U[...]

[...]

NO. DESCRIPTION Switch, Low Vacuum Screw, s/t, No.6 x +I1, Switch Fixing Nut, Spire, No.6, Switch Fixing ITt-Piece, Im Vacuum !%itch Take+££ PART NUMBER QUANTITY RHD REMARKS I 1 1'87 M.Y. on 1 1 Turbo ('85 M.Y. On) 33.038 Page 3[...]

[...]

NO. DESCRIPTION Handbrake Lever Assembly Handbrake Lever Assembly Handbrake Lever Assembly Grip, Handbrake Lever Nut, Nyloc, M10, Lever Pivwt Nut, Nyloc, M8, Wer Pivot Washer, Flat, lOmn, Lever Pivot Washer, Flat, 8m, Lever Pivot Mounting Plate, Handbrake Lever Mcunting Plate, Handbrake Lever Mounting Plate, Handbrake Lever Mamting Plate, Handbrake[...]

LHD '85 MY. SHOWN TURBO 33.05A 0 0 a[...]

NO. DESCRIPTION Link, Handbrake to Multiplier Multiplier Lever Multiplier Lwer Washer, Multiplier Lever Pivot Split Pin, Multiplier Lever Pivot Clevis Pin, Multiplier Lever Washer, Multiplier Clevis 'R' Pin, Clevis Retaining Spring, Lever Return Anchor Bracket, Return Spring Pop Rivet, Anchor Bracket to Body Actuating Rod, Handbrake Lever[...]

025' TURBO 34.01 A e[...]

NO. DESCRIPTION Road Wheel & Tyre Assembly, Front Rcad Wheel, Front Tyre, Front, 195/60 VR15 Goodyear Valve, Tyre, Front Rcad Wheel Road Wheel and Tyre Assembly, Rear Road Wheel, Rear Tyre, Rear, 235/60 VR15 Goodyear Valve, Tyre, Rear Rcad Wheel Badge, Wheel Centre Wheel Nut Wheel and Tyre Assembly, Spare Wheel, Spare Tyre, Spare, 175/70 SR14 G[...]

[...]

NO. DESCRIPTION Tyre, Spare, 175/70 SR14, mew Valve, Spare Tyre Wheel Bolt Finisher, Wheel Centre (With 'Old' Badge) Finisher, Wheel Centre (With 'New' Badge) Clanp Bolt, Spare Wheel Securing Clanp Plate '0' Ring, Clanp Bolt Tapping Plate, Clanp Bolt Pcp ~ivet, Tapping Plate to Body PART NUMBER . - a QUANTITY PRIOR 85 [...]

[...]

NO. DESCRIPTION Cylinder Block & Main Bearing Housing Cylinder Block & Main Bearing Housing Cylinder Block & Main Bearing Housing Stud, M12 x 183, Block to MBH Stud, M12 x 183, Block to MIM Stud, M12 x 192, Block to MBH Stud, Ml2, Block to MBH Washer, Flat, Block to MBH Nut, M12, Block to MIM Ring Dad, Block to MBH Stud, M8 x 47 Block t[...]

[...]

NO. DESCRIPTION Gasket, Oil Gallery Bolt, M8 x 35, Oil Gallery Cover Setscrew, M8 x 20, Oil Gallery Cwer Washer, Flat, Oil Gallery Cwer Spout, Crankcase Breather Bush, Breather Spout Pipe, Oil Feed '0' Ring, Oil Feed Pipe/= Pipe, Oil Pick Up Union, Oil Pick weed Pipe Olive, Conpression, Oil Pipe '0' Ring, Dipstick Tube Dipstick [...]

[...]

NO. DESCRIPTION Buffer Washer, Mtg. Brkt. to Rubber Bolt, 7/16'' UNF x 33", Mtg. Brkt/Rubber Washer, Flat, Mtg . ~rkt . /Rubber Nut, Nyloc, 7/16" UNF, Mtg. Brkt./Rubber Setscrew, M8 x 20, Mtg. Rubber/Chassis Washer, Flat, Mtg. ~ubber/Chassis Nut, Nyloc, M8 Mounting Rubber, Engine, RH, Blue ~ounting Rubber, Engine, LH, Pink Buffe[...]

TURBO 4003 A[...]

NO. DESCRIPTION Oil Sup Plug, Surrp Drain Washer, Sup Plug Baffle, Smp Screw, Baffle to Sunp Setscrew, M8 x 25, Sunp to MBH Bolt, M8 x 45, Sunp to MBH Bolt, M8 x 65, Smp to MBH Bolt, M8 x 50, Sunp to MBH Nut, Nyloc, M8, Swrp to MBH Washer, Flat, Sunp to MBH Bolt, M8 x 30, Smp to MBH Bolt, M8 x 80, Sunp to MBH PART NUMBER e QUANTITY REMARKS Turbo 4[...]

1 I 1 TURBO 40.05 A[...]

1LI-u 6 NO. DESCRIPTION Cylinder Head Assembly Cylinder Head Assembly Core Plug, -11 Core Plug, Large, Rear Plug, 1/8" BSP, Socket Pipe, Heater Take-Off Guide, Inlet Valve, O/D Std. Guide, Inlet Valve, O/D + 0.001" Guide, Inlet Valve, O/D + 0.002" Guide, Inlet Valve, O/D + 0. 005°1 Guide, Exhaust Valve, O/D Std. Guide, Exhaust Valve[...]

TURBO 40.05 A[...]

ILLUS NO. DESCRIPTION Stub Pipe, Water Outlet Adaptor, Water Outlet Roll Pin, Cyl. Head to Cam Hsg. '0' Ring, Roll Pin Setscrew, Oil Gallery Plug '0' Ring, Oil Gallery Plug Washer, Flat, Oil Gallery Plug Stud, M8, Cam Hsg. to Head Seat, Valve Spring Spring, Valve, Inner Spring, Valve, Outer Retainer, Valve Spring Collet, Inlet V[...]

TURBO (Prior '87 MY. H.C.) 40.07A[...]

ILLUS NO. DESCRIPTION Camshaft Housing, Exhaust CamMt Housing, Exhaust Camshaft Housing, Inlet Camhaf t Housing, Inlet Camshaft 107 Woodruff Key, Pulley to Canshaft Plug, Camshaft Front Thrust Washer, 0.173 - 0.175" Thrust Washer, 0.175 - 0.177" Thrust Washer, 0.177 - 0.179" Thrust Washer, 0.179 - 0.181" Dowel, Thrust Washer/Car[...]

TURBO (Prior '87 MY. H.C.) 40.07A[...]

NO. DESCRIPTION Cam Cover, Inlet, Without Filler Cam Cover, Inlet, With Filler Cam Cwer, Inlet, With Filler Cam Cover, Inlet, With Filler Cam Cover, Exhaust Cam Cwer, Exhaust Plug, M20, Torx Bolt Access Washer, Fibre, Used With A910E1690F Plug, M20, Tom Bolt Access Washer, 'Dowty', Plug Sealing '0' Ring, Plug Sealing Oil Seal, C[...]

TURBO (Prior '87 MY. H.C.) 40.07A[...]

40 .O7A Item 015 TAPPET SHIMS Shim Part No. Shim Part No. Shim Part No. Shim Part No. Turbo 40 .O7A Page 3[...]

TURBO ('87 MY M.) 40.078[...]

ILLUS NO. DESCRIPTION Camshaft Housing, Inlet Carrshaft ~msing, Exhaust Nut, M8, Cam Hausing to Head Washer, 8mn, Cam Housing to Head Torx Bolt, Cam Housing to Head Plug, M20, Torx Bolt Access '0' ~ing, Access Plug Tappet Shim, Tappet Thrust Washer, 0.173 - 0.175" Thrust Washer, 0.175 - 0.177" Thrust Washer, 0.177 - 0.179" [...]

I I I TURBO 40.0 9A[...]

ILLUS NO. DESCRIPTION Piston & ~iner Assenbly, ( 5mn Oil Control Ring Piston & Liner Assembly, (h Oil Control Ring Piston & Liner Assenbly Gudgeon Pin Gudgeon Pin Circlip, Gudgeon Pin Circlip, Gudgeon Pin Canpression Ring, Top Conpression Ring, Top Canpression Ring, Second Conpression Ring, Second Oil Control Ring (5mm Width) Oil Contro[...]

TURBO 40.1 1 A[...]

ILLUS NO. 4O.lD DESCRIPTION Crankshaft (Including Dowels & Spigot Brg. 1 Crankshaft (Includinq Dowels) -1, Crank to ~l~wfieel Spigot Bearing Flywheel (Integral ring gear 1 Dowel, Flywheel to Clutch Bolt, Shell II ~lywheel to Crank ., Main Bearing, Std. I/D, Std. O/D II I1 II II I1 II Shell, Main Bearing - 0.010" I/D, Std. O/D II II #I II I[...]

TURBO 40.1 1 A[...]

ILLUS NO. DESCRIPTION Shell, Main Bearing, Std. I/D, + 0.015" O/D II II 11 I1 II I1 Shell, Main Bearing, - 11 II II Shell, Main Bearing, - 0.020" I/D + 0.015" O/! I1 II I1 I8 I1 I1 I1 Thrust Washer, Crank, Std. Thrust Washer, Crank, + 0.0025" Thrust Washer, Crank, + 0.0050" Thrust Washer, Crank, + 0.0075" Thrust Washer[...]

13 PRIOR 'b7 N.Y. TURBO 12 40.13A[...]

ILLUS NO. DESCRIPTION Water Punp Assembly, inc. Pulley Water Pwp Assembly, ( less plley 1 Hub, Purrp Pulley Elbow, Heater Return Plug, Blanking Bolt, M6 x 75, Pwp to Block Setscrew, M6 x 25, Punp to Block Washer, Flat, Pwp Fixing Gasket, Purrp to Block Water Pwp Assy. Hub, Water Punp Pulley Elbow Pipe, Heater Return Adaptor Pipe, Themstat Housing G[...]

022 TURBO 4015 A[...]

DESCRIPTION Auxiliary Housing and "Oil Punp" Assgnbly ~uxiliary Hausing and Oil Pump Assembly ~uxiliary Housing and Oil Pq Assgnbly Auxiliary Hausing Auxiliary Housing Auxiliary Hausing Plug, 3/8" BSP, Aw. Hsg. Oilway Blanking Plug, ftt BSP, Aw. Hsg. Oilway Blanking "Oil Punp", Housing, Oil Pump Housing Assembly Stud, Distr[...]

TURBO 40.15 A[...]

NO. DESCRIPTION Setscrew, M8 x 25, Housing to Block Bolt, M8 x 40, Housing to Block Bolt, M8 x 60, Housing to Block Bolt, M8 x 90, Housing to Block Washer, Flat, Aux. Hsg. Fixings Setscrew, M8 x 25, Housing to Block Bolt, M8 x 40, Housing to Block Bolt, M8 x 60, Housing to Block Bolt, M8 x 90, Alt. ~rkt/Housing/Block Bolt, M8 x 100, Alt. ~rM/~ousin[...]

1 TURBO 4015 A[...]

ILLUS NO. DESCRIPTION Extension Union, Oil Filter Sealing Ring, Adaptor/Housing Adaptor, Oil Cooler Union, Oil Cooler Pipes Washer, Union to Adaptor Oil Filter (inc. Sealing Ring) Oil Filter ( inc. Sealing Ring) Pipe, Oil Drain, Turbo to Sunp Pipe, Oil Drain, Turbo to Sunp Pipe, Oil Drain, Turbo to Sunp '0' Ring, Drain Pipe to Sunp Setscr[...]

[...]

ILLUS NO. DESCRIPTION Scavenge Manifold Gasket, Scavenge Manifold to Sunp Stud, M6 x 87, Scavenge Manifold to Sunp Stud, M6 x 67, Scavenge Nanifold to Sunp Nut, M6, Manifold to Sunp Bolt, M6, Manifold to Sunp Washer, 6m, Manifold to Sunp Stud, M6 x 116, Manifold to Punp Stud, M6 x 123, Manifold to Purrp Loctite 501, Studs to Manifold Stud, M6, Oil [...]

[...]

ILLUS NO. DESCRIPTION '0' Ring, pipe to Punp Nut, M6, Nyloc, Pipe to Punp Washer, 6nm Support Bracket, Oil Pipe Setscrew, M6 x 18, Oil Pipe to Bracket Washer, Shakeproof Oil Tank Bracket, Oil Tank Upper Setscrew, M8 x 25, Tank to Bracket Washer, Flat, Tank to Bracket Nut, Nyloc, M8 Tank to Bracket Bracket, Oil Tank Lower Front Bracket, Oi[...]

TURBO 4OA7 A[...]

ILLUS NO. DESC RlPT ION Distributor Assembly, Lumenition (With MK 16 Switch) Distributor Assembly, Lumenition (With Mk 17 Switch) Distributor Assembly, Lucas 'Constant Energyv Distributor Assembly, Lucas 'Constant Energy' '0' Ring, Distributor Spigot Distributor Cap Rotor Ann/kw. Limiter Rotor Am Nut, Nyloc, Dist. Clanp to [...]

[...]

ILLUS NO. DESCRIPTION Nut, Nyloc, M5, Module Fixing Lenition Adaptor, Mkl7 Switch/MK16 Module Fibre Washer, Chopper Blade Height Adjust Lucas 'Constant Energy' Ignition Anplifier (AB 14) Setscrew, M8 x 50, -14 Fixing Washer, Flat, AB14 Fixing Washer, Shakeproof, -14 Fixing Nut, M8, AB14 Fixing Engine Speed Limiter 'Constant Energy&ap[...]

[...]

NO. DESCRIPTION Alternator, 70A Alternator and Pulley Assy. 70A Alter~tor and Pulley Assy. 70A Fan Kit, Alternator Pulley, Alternator Nut, Special, Pulley to Alternator Strap, Alternator Adjusting Setscrew, M8 x 20, Strap to Alternator Washer, Spring, Strap to Alternator Spacer, Adjusting Strap to Belt Tensioner Strap, Alternator Adjusting Setscrew[...]

TURBO 40.1 9A[...]

ILLUS NO. 40.19A DESCRIPTION Clarrp Plate, Ab?rnator to Strap Washer, Flat, Alternator Fixing Nut, Nyloc, M8, Alternator Fixing Steady Bracket, Alternator Bolt, Steady Brkt. to Water Punp Washer, Spring, Brkt. to Water Punp Washer, Flat, Brkt. to Water Punp push, Split, Steady Bracket Stud, Alternator to Aux. Hsg. Washer, Flat, Alt. to Aux. Hsg. Nu[...]

i TURBO tQZl A I I I I I 0[...]

NO. DESCRIPTION Gasket, Exhaust Manifold to Head Gasket, Exhaust Manifold to Head Manifold, Exhaust Manifold, Exhaust Washer, Flat, Manifold to Head Locking Plate, Manifold to Head, Upper Locking Plate, Manifold to Head, Imer Nut, M8, 'Aerotight' Manifold to Head Nut, M8, Special Gasket, Manifold to Adaptor Adaptor, Wastegate Adaptor, Was[...]

I TURBO 1 4Q21 A[...]

ILLUS NO. DESCRIPTION Wastegate Assembly, 2 x !+If3 Stud fixing Wastegate Assembly, 2 x MI0 Stud fixing Wastegate Assmbly, 2 x Ml0 Stud fixing Diaphragm, Wastegate Gasket, Diaphragm Nut, IAcking, Valve Stem Sealing Washer, ~iaphragm Clanping Gasket, Wastegate to Adaptor Gasket, Wastegate to Adaptor Gasket, Wastegate to Adaptor Elbow, Wastegate to B[...]

TURBO 4Q23A a[...]

ILLUS NO. DESCRIPTION Conpressor, Air Conditioning Bracket, Canpressor to Engine Screw, Socket Head, Conpressor to Bracket Nut, Ml0, Carpressor to Bracket Washer, 10mn, Conpressor to Bracket Bush, Carpressor Rear Fix Bolt, M6, Conpressor Mounting Rear Washer, Canpressor Mounting Rear Nut, M6, Conpressor Mounting Rear Idler Pulley/Adjuster Bracket S[...]

1 URBO 6023 A[...]

ILLUS NO. DESCRIPTION Washer, Flat, Idler Pulley Adjust Nut, Nyloc, M8, Idler Pulley Adjust PART NUMBER QUANTITY MAY 1991 REMARKS n=r bo 4O.23A Page 2[...]

I TURBO (737M.Y. H.C.) I 4Q27A[...]

ILLUS NO. 40.27A 001 002 00 3 004 005 006 007 008 009 010 012 013 015 016 017 018 d3p44 DESCRIPTION Vacuum murp / Hub Assembly Carrier Plate, Vacuum Punp Setscrew, M8 x 25, PLmp to Carrier Washer, Spring, Purrp to Carrier Bracket, Pump to Block Setscrew, M10 x 30, Carrier to Brkt. Washer, Spring, Carrier to Brkt. Washer, Flat, Adjusting Slot Setscr[...]

i I C TURBO 60-28A[...]

ILLUS NO. DESCRIPTION Engine Upper Gasket Set Conprising Cylinder Head Gasket Inlet Manifold Gasket Diffuser/~lenum Gasket Exhaust Manifold Gasket Camshaft Cover Gasket Camshaft Cwer Screw Washer Camshaft Front Oil Seal Camshaft Rear Cover '0' Ring Camshaft Housing Oil Feed '0' Ring Carburettor Mounting '0' Ring Engine[...]

TURBO 40-28B[...]

NO. DESCRIPTION Engine Laer Gasket Set Canprising :- Front Cover Gasket Water Punp Gasket Oil Gallery Cwer Gasket Auxiliary Housing Gasket Oil Punp Gasket Rear Seal Housing Gasket Scavenge Manifold Gasket Crankshaft Front Oil Seal Crankshaft Rear Oil Seal Oil Pick Up Pipe Olive '0' Ring, Oil Tank Hose to Punp '0' Ring, Turbo Dra[...]

[...]

ILLUS NO. DESCRIPTION 1 Belt, Camhaft Timing Toothed Pulley, Canshaf t/Auxiliary Shaft Washer, Pulley to Camshaft Washer, Spring, Pulley to Canshaft Bolt, MlO x 35, Pulley to Canshaft Washer, Pulley to Auxiliary Shaft Screw, MlO x 30 C/S, Pulley to Auxiliary Shaft Tensioner Assembly, Timing Belt Tensioner Assanbly, Timing Belt Hasing, Belt Tensione[...]

[...]

ILLUS NO. 41. OLA DESCRIPTION I Spacer, Tensioner to Block Stud, Belt Tensioner to Block Washer, Flat, Tensioner Fixing Nut, Nyloc, M10, Tensioner Fixing Bolt, MLO x 70, Tensioner to Block Washer, Spring, Tensioner Fixing Washer, Flat, Tensioner Fixing Toothed Pulley, Crankshaft, Cam Belt Drive Woodruff Key, Crankshaft to Pulley Flange, Crank Pulle[...]

I TURBO ('87 MY, ON ) 1 I 41.01B[...]

ILLUS. NO. DESCRIPTION lroothed Belt, Camshaft Driving Toothed Pulley, Camshaft/ Aux Shaft -her, Camshaft Pulley Retention Washer, Spring, Cam Pulley Retentian Bolt, MlOx35, Can Pulley Retention Bracket, Belt Tensioner to Block Bolt , MlOx45, Tens ioner brkt/Block Washer, Flat, Tensioner brkt Fixing Stud, NO, Tensioner Fixing Eccentric Hub, Belt Te[...]

PRIoR '87 MY WITH AIC PRIOR 87 MY WITHOUT AIC TURBO 41.03A[...]

ILLUS NO. DESCRIPTION I 'V' Belt, Water Punp 'V' Belt, Water Punpfiacuum Pump 'V' Belt, Alternator 'V' Belt, Alternator 'V' Belt, Alternator 'V' Belt, a/c Carpressor 'V' Belt, (Standard Type), a/c Corrp. 'V' Belt, (Mculded Cog 1, a/c Carp 'V' Pulley, Water Pun[...]

TURBO 4201 A[...]

NO. DESCRIPTION Plenum, RH Air Scocp Screw, Plenum to Body Spire Nut, Plenum Adaptor, Plenum to Hose Pop Rivet, Adaptor to Plenum Trunking, Plenum to Airbox Hose Clip, Trunking Airbox Insulation, Airbox Foam Strip, Airbox to Body Spire Bolt, Airbox to Body Spire Nut, Airbox to Body Cwer, Airbox Adaptor Pipe, Breather to Airbox Clanp, Airbox Cwer to[...]

See 17.0% OOL TURBO 4201 A - see GROUP 10b5[...]

a ILLUS NO. DESCRIPTION Washer, Flat, Durrp Valve to Plenum Elb Union, Boost Gauge, Screw-on pipe Fit. Elb Union, Boost Gauge, Screw-on Pipe Fit. Grub Screw, Elb Union, Danping Elbow Union, Boost Gauge, Push-on Pipe Fit. Elbow Union, Engine bagerrrent Take-Off Bolt, Plenum Cwer to Backplate Washer, Flat, Cwer to Backplate Bolt, Plenum Cwer/~ackplat[...]

[...]

NO. DESCRIPTION Washer, M6 x 12, Adaptor to Sidewall Air Deflector, Engine Sidewall Pop Rivet, Deflector Fix Washer, Deflector Fix Elbow Adaptor, Plenum Purge Pipe, Purge, Elbcrw/Solenoid Valve Pipe, Purge, Solenoid ~alve/Purge Purrp Pipe, Purge, Purge Punp Exhaust Clip, 'Norma', 12-20mn, Pipe Fix Gromnet, Purge -/Sidewall PART NUMBER QUA[...]

[...]

a ILLUS NO. DESCRIPTION Carburettor, Rear, DHLA 40H Carburettor, Front, DHLA 40H Carburettor, Rear, DHLA 45M Carburettor, Front, WILA 45M Throttle Lever Throttle Lever Throttle Lever Spring, Throttle Return Spring, Throttle Return Split Pin, Coil Spring to Lever Anchor Bracket, Coil Spring to Cam Cwer Screw, Anchor Brkt. to Cam Cwer Spring, Throttl[...]

[...]

ILLUS NO. 42.O3A DESCRIPTION Washer, M6, Brkt. Fix Washer, M6, Internal Spring, Brkt. Fix Nut, M6, Brkt. Fix Lever, Throttle Spindle Adjusting Screw, Lever to Solenoid Clip, Adjuster Screw Imking Plug, Anti4%per, CO & Air Bleed Plug, Anti4?amper, & Throttle Coupling Plug, Anti-Tanper, Air Bleed Earth Iead, Carburettor/~ngine PART NUMBER QUA[...]

[...]

ILLUS NO. 42.O3A DESCRIPTION Pipe, Dunlop, PRV to Front Carb. Pipe, Dunlop, PEW to Rear Carb. Hose Clip, Dunlop Fuel Pipes Adaptor, Fuel Pipe to Carb. Washer, Sealing, Adaptor to Carb. Fuel Pressure Regulating Valve(8.5mn S/Spigot Fuel Pressure Regulating Valve(5.Om S/Spigot Cap, Antiqanper, PRV Setscrew, PRV Fixing Washer, Spring, PRV Fixing Hose,[...]

[...]

ILLUS NO. DESCRIPTION Air Corrector Jet, Main, 200 Air Corrector Jet, Phin, 180 Wlsion Tube, Main, 12 Wlsion Tube, Phin, 14 Idle Jet, 40 Idle Jet, 58 Idle Air Tube Idle Air Tube Puq Jet, 48H Special Purr@ Jet, 35 Filter, Punp Jet Starter Jet, 80 Wlsion Tube, Starter Air Bleed Screw '0' Ring, Air Bleed Screw Plug, Vacuum Tapping Orifice Ac[...]

[...]

a ILLUS NO. DESCRIPTION Abutment, Choke Cable Screw, Cable to Almtment Jet Cwer, Cold Start Air Intake Jet Cwer, Cold Start Air Intake Gasket, Jet Cover Gasket, Jet Cwer Gasket, Jet Cwer Top Cwer Gasket, Top Cwer, (Float Chamber) Gasket, Top Cwer, (Float Chamber) Gasket, Top Cwer, (Float Chamber) Screw, Idle CO Adjust '0' Ring, Idle CO Sc[...]

TURBO 4 2.04A[...]

ILLUS NO. DESCRIPTION Inlet Manif old Gasket, Inlet Manifold to Head Stud, Manifold to Carburettors Water Rail Water Rail Hose, Manifold to Water Rail Hose Clip, Manifoldhater Rail Hose Elbow Hose, Cylinder Head to Water Rail Hose Clip, Elbow Hose Stub Pipe, Manifold Water Outlet Nut, Manifold to Head Washer, Manifold to Head Spacer, Manifold to Ca[...]

see TURBO ('87 MY ON ) 4207 B[...]

ILLUS NO. DESCRIPTION - - Inlet Manifold Gasket, Inlet Manifold to Head Nut, Manifold to Head Washer, Manifold to Head Stud, Manifold to Carburettors Spacer, Manifold to Carburettors ' 0' Ring, Mani fold/Spacer/~arb . Nut, Carb. to Manifold Cup Washer, Carb. to Manif old Rubber Washer, Carb. to Manif old PART NUMBER 0 QUANTITY REMARKS Tur[...]

041 060 See 33,038 TO HEATER TURBO('87M.Y HC.) See 18.OSA TO k BRAKE SERVO 43.03A[...]

a ILLUS NO. DESC RlPT ION Thermal Ignition Valve (T.I.V.) The Ignition Valve (T.I.V.) Hose, Vacuum,(T.I.V.) to 1gn.Solenoid Valve Gr<xrmet, Engine Bay Sidewall Hose, Vacuum,(T.I.V.) to Throttle Edge Port Hose, Vacuum,(T.I.V.) to Distributor Restrictor, Pulsation Danping Crankcase Breather Valve (C.B.V.) Adaptor, Crankcase Breather Valve Cold Enr[...]

[...]

ILLUS NO. DESCRIPTION Hose, Vacuum,(I.S.V.) to Boost Gauge Pipe Hose, Vacuum,(I.S.V.) to T-Piece T-P iece Elbow, Heater/= Take-Off Connector Sleeve, T-Piecenacuum Supply Pipes Pipe, Vacuum Supply Gr<rranet, Engine Bay Sidewall, Boostflac .Pipes Connector, Hose T-P iece, Hose Connector Hose Vacuum, T-Piece to Vacuum Pun@ Pipe, (C.B.V.) to Airbax [...]

TURBO 64.01A[...]

ILLUS NO. DESCRIPTION Filler Cap Assanbly, Luckable Filler Cap Cover Filler Cap Shutter Filler Cap Base, (Inc. Lock & Keys) Clanp Ring, Filler Neck Gasket, Clanp Ring to Body Screw, No. 6 x 3'' Clanp Ring Fuel Filler Neck, Id-l Fuel Filler Neck, RH Fuel Filler Neck, LH Fuel Filler Neck, RH Hose, Filler Neck to Tank Hose Clip, Filler H[...]

002 .b TURBO 4601A[...]

ILLUS NO. DESCRIPTION Pipe, Crosswer Hose, Clip, Crosswer Pipe Hoses Hose, Mculded, Tank to Crosswer Pipe Grmt , Crosswer Pipe/Chassis Sender Unit, Fuel Gauge Sender Unit, Fuel Gauge Gasket, Sender Unit Screw, 10 UNF x +'I, Sender Fixing Washer, Spring, Sender Fixing Washer, Flat, Sender Fixing Capscrew, 10 UNF x f", Sender Fix Washer, Fi[...]

TURBO 44.03A[...]

ILLUS NO. DESCRIPTION Banjo, lOmn, LH Tank Fuel Feed Banjo, lhn, LH Tank Fuel Feed Copper Washer, Banjo Crush Washer, i", Banjo Bolt, Banjo Pipe, Steel Braided, LFl Tank to mmp Pipe, Dunlop, Ul Tank to Punp Pipe, Dunlop, LH Tank to Plmp Clip, Fuel Pipe to Tank and Punp Clip, Fuel Pipe to Tank and Pump Graranet, Pipe Thro' Bcdy -1 Punp Cla[...]

TURBO b4.03A[...]

a ILLUS NO. DESCRIPTION Banjo, 10m-1, LH Tank Fuel Feed Banjo, lh, IH Tank Fuel Feed Copper Washer, Banjo Crush Washer, +", Banjo Bolt, Banjo Pipe, Steel Braided, LH Tank to Pwp Pipe, Dunlop, LH Tank to Punp Pipe, Dunlop, LH Tank to Purrp Clip, Fuel Pipe to Tank and Punp Clip, Fuel Pipe to Tank and Purrp Grmt, Pipe Thro' Body Fuel Purrp C[...]

1 TURBO I I 4 LO3A[...]

ILLUS NO. 44.03A DESCRIPTION Bolt, M6 x 60, Filter Clanping Washer, Flat, Filter Clarrp Nut, Nyloc, M6, Filter Clarrp Studplate, Filter Clarrp to Body Pipe, Filter to Bundy Pipe, Filter to Bundy Clip, Oetiker, 9/16" Bundy Pipe, F'uel Feed 'PI Clip, Bundy Fixing Screw, s/t, P Clip Fix Spire Nut, P Clip Fix Pipe, Steel ~raided, Bundy t[...]

TURBO 4L.05A[...]

NO. DESCRIPTION Breather Hose, Filler Neck to Anti Surge Valw Breather Hose, Filler Neck to Anti Surge Valvc Clip, Breather Hose to Filler Neck Clip, Breather Hose to Valve Valve, Anti Surge 'PI Clip, Valve Fixing 'PI Clip, Valve Fixing Pop Rivet Washer Breather Hose, 200 mn, Anti Surge to IT1 Piecc Breather Hose, 2 m, Anti Surge to IT&ap[...]

~ TURBO 45.03A I i[...]

a ILLUS NO. DESCRIPTION Exhaust Pipe, Main Ekhaust Pipe, Wastegate Bolt, Pipes to Silencer Nut, Pipes to Silencer Silencer & Tail Pipes Silencer & Tail Pipes Clanp, Silencer to Channel Setscrew, M8, Silencer Clanp Nut, M8, Silencer Clanp Channel, Silencer Writing Nut, M10, Channel to Bracket Washer, Channel to Bracket Bracket, Silencer Moun[...]

TURBO 4505A[...]

ILLUS NO. 45.05A DESCRIPTION Heatshield, Body & Tyre, (Aluminium) Jacknut, M6, Heatshield Screw, S/T, Alum. Shield Joining Pop Rivet, 3/16", Shield to Body Washer, Pop Rivet Heatshield Assy. Body & Tyre (Ferrobestos) Heatshield, Body, (Ferrobestos 1 Setscrew, M6 x 12, (Ferro.) Shield Fix Washer, Shakeproof, (Ferro.) Shield Fix Washer, [...]

TURBO 4505A 0[...]

a ILLUS NO. DESCRIPTION Heatshield, Radius Arm Mounting Setscrew, M6 x 20, Heatshield Fix Heatshield Setscrew, M6 x 20, Heatshield Fix Washer, Flat, M6 x 15, Heatshield Fix Washer, Spring, M6, Heatshield Fix Nut, M6, Heatshield Fix Heatshield, Vacuum Punp Setscrew, M6 x 20, Heatshield Fix Washer, Flat, M6 x 15, Heatshield Fix Heatshield, Engine Mou[...]

[...]

ILLUS NO. DESCRIPTION I Radiator Duct Radiator IXIct Radiator Duct Radiator Duct Setscrew, M6 x 25, Duct to Body Washer, Large O/D, Duct to Body Nut, Nyloc, M6, Duct to Body Screw, s/t, Duct to Body Spire Nut, Duct to Body Support Stay, Radiator Duct 'L' Bracket, Stay to Chassis Support Stay, Rad. Duct, RH Support Stay, Rad. Duct, LH Supp[...]

[...]

ILLUS NO. DESCRIPTION Washer Bush, Rad. to Duct Jacknut, M6, Rad. to Duct Cwl, Radiator Fans, ABS Cwl, Radiator Fans Edge Clip, Cwl to Radiator Fan Shroud & Motor t4mnting Fan Shroud & Motor Mmting Fan Motor, Rad. Cooling (for metal fan) Fan, Radiator Cooling, Metal Fan Mor and Blade Assy. (plastic fan) Fan Motor, Rad. Cooling (for plastic [...]

[...]

DESCRIPTION Hose, Rad. Main Feed Pipe, Rear Hose Clip, 32-50mn Pipe, Rad. Main Feed, Thro' chassis Hose, Reducer, Feed Pipe Front Hose Clip, 32-50 Elbow Pipe, Radiator Inlet Rad; -Fan Themswitch ( 'Otter' 1 (82/72 1 Blue Coded Rad. Fan Them. Switch ( 'Otter ' 1 ( 86/76 1 Rad. Fan Them. Switch ( 'Otter' 1 ( 92/82 1[...]

[...]

ILLUS NO. DESCRIPTION Junction Pipe, Return Hose, Junction Pipe to Reducer Hose Clip, 32-50 Pipe, Reducing, Punp Inlet Hose, Water Purtp Inlet Hose Clip, 32-50 Hose, Rad. Main Return Pipe Rear Hose Clip, 32-50 Pipe, Rad. Main Return, Thro' Chassis Sheathing, Chassis Strut Pipe Protection Snapper Clip, Sheathing to Chassis Hose, stepped, Return[...]

[...]

ILLUS NO. DESCRIPTION Cooling System Modification Kit Carprising :- Header Tank Blanking Cap, Header Tank Sensor Grarmet, Sensor Mamting Hose, Header Tank to Expansion Tank Clip, Hose Expansion Tank Pressure Cap, Expansion Tank Setscrew, M6 x 25, Expansion Tank Fix Setscrew, M6 x 18, n II el Washer, Flat, M6 x 16, " @I !I Washer, Flat, M6 x 12[...]

[...]

ILLUS NO. DESCRIPTION Radiator Duct Spacer, Radiator Duct Front to Body Bolt, M8 x 127, Radiator Duct Front Mounting Nut, Nyloc, M8, Radiator Duct Front Mounting Washer, Flat, Radiator Duct Front Mounting Setscrew, M6 x 25, Duct to Body Washer, 25 O/D, Duct to Body Nut, Nylcc, M6, Duct to Body Screw, s/t, Duct to Body Spire Nut, Duct to Ekdy Suppor[...]

[...]

ILLUS NO. DESCRIPTION Pop Rivet, Shroud to Cowl Washer, Pop Rivet Fan Motor, Radiator Cooling Fan, Radiator Cooling Washer, Fan to Mor Shaft Spring Clip, Fan to Motor Shaft Washer, Flat, Motor Mcunting Nut, Nyloc, M6, Motor Mounting Hose, Radiator Outlet Hose Clip, Outlet Hose Pipe, Water Feedheturn, thraugh Chassis Sheathing, Chassis Strut, Pipe P[...]

[...]

ILLUS NO. DESCRIPTION Clip, Thermal Switch Retention Hose, Outlet Pipe to Chassis Pipe Hose Clip, Elbow Hose & Water Pipe to Brkt. Hose, Reducing Hose Clip Elbaw Pipe, Radiator Inlet & Thermal Switch Hose, Radiator Inlet Hose Clip, Radiator Inlet Hose Bracket, Water Pipe to Chassis Screw, Bracket, to Chassis Hose Clip, Pipe to Bracket Edge [...]

[...]

e ILLUS NO. DESCRIPTION I Oil Hose Assdly, Scavenge Pup to Cooler Oil Hose Assembly, Scavenge Punp to Themstat Themstat, Oil Cooler Bracket, Thenmstat Wnting Setscrew, M6 x 16, Bracket to Body Washer, 6 rrm, Bracket to Body Nut, Nyloc, M6, Bracket to Body Oil Hose Assembly, Thermostat to Cooler Oil Hose Asdly, Cooler to Themstat Oil Hose Assembly, [...]

TURBO 46.03 A[...]

ILLUS NO. 46.O3A DESCRIPTION Connector Union, Oil Hose, Eng. to Cooler Connector Union, Oil Hose, Cooler to Eng. Mcunting Brkt. Connector Unions CLanp Plate, Unions to Brkt. Spacer, Union Locking Nut, Nyloc, M8, CLanping & Fixing Washer, 25 O/D, Brkt. to Chassis Oil Hose Assembly, Cooler/Stat Ul Oil Hose Assanbly, Cooler/Stat RH Oil Hose Assemb[...]

TURBO 47.01A a[...]

ILLUS NO. 47.01A DESCRIPTION Master cylinder, Clutch Clevis Pin, Clutch Pedal to Clevis 'R' Pin, Clutch Pedal to Clevis Pressure Washer, Clutch Pedal to Clevis Washer, Master Cylinder Fix Nut, Nyloc, M8, Master Cyl. Fix Service Kit, Master Cylinder Filler Cap Pipe, Flexible, Master to Slave Cylinder Pipe, Flexible, Master to Slave Cylinde[...]

PREVIOUS TYPE I TURBO 47.0 2A I 'C35' TYPE --I +. ' -. . . .. . 1- Gearbox Number Locati (DO not remove) I - 4 Oil Level Plug Revised Rear Cover Shape[...]

INTRODUCTION OF TYPE C35 GEARBOX ASSEMBLY From early 1984, all Esprit models were fitted with the type 'C35' gearbox. All Esprit gearboxes are stamped with a Lotus serial number, repeated on its matched clutch housing. All gearboxes stamped with a 'C' prefix to the serial number are type C35. Gearboxes with the following serial [...]

[...]

a ILLUS NO. DESCRIPTION Gearbox & Clutch Housing Assy. Gearbox b Clutch Housing Assy. Gearbox 6 Clutch Housing Assy. Clutch Housing Clutch Housing Rubber Mounting, Engine/G.Box Fear Bolt 7/16", Mtg. to G/.Box Brkt. Washer, Snubber, Mtg. to G./Box Brkt. Washer, Flat, Mtg. Bolt Nut, Nyloc, 7/16" Mtq. Bolt Setscrew, M8 x 20, Mtg. to Chas[...]

[...]

ILLUS NO. DESCRIPTION Bolt, M10 x 75, Clutch Housing/Engine Nut, Nyloc, M10, Clutch Housing/Engine Washer, Flat, Clutch Hatsing/Engine Shim, Clutch Housing to Sunp Cwer, Timing Aperture Switch, Rwerse Light Washer, Rwerse Light Switch Drain Plug Drain Plug Washer, Drain Plug Level Plug Blanking Plug Washer, Imel/Blanking Plug Air Vent, Breather End[...]

[...]

a ILLUS NO. DESCRIPTION stop, Speedo Pinion Nut, Speedo Pinion Stop Nut, Speedo Pinion Stq Screw, M9 x 30, Rear Cover/Main Case Screw, M9 x 25, Rear Cover/Main Case Outflow Plate Outflow Tube Oil Deflector Oil Deflector Stud, M12 x 73, ~/Bax to Clutch Hsg. Stud, M12 x 58, G/B~ to Clutch Hsg. Washer, 12mn, G/Box to Clutch Hsg. NU^, m2, G/B~ to clutc[...]

[...]

ILLUS NO. DESCRIPTION Gear Lever Assembly Roll Pin, Gear Lever, M5 x 40 Gear Uver Assembly Gear Lever Assembly Gear Lever Knob, Gear Lever, M7 Knob, Gear Lever, MI3 Spacer, M7 Gear Knob Lock Ring, M8 Gear Kn& Rwerse Gate Rwerse Gate Spirol Pin, 5 x 14, Bellcrank to Cable Yoke Spirol Pin, 3/16" x 14 Yoke, Lever Assy . to Crossgate Cable Spi[...]

[...]

e ILLUS NO. DESCRIPTION I Washer, Bellcrank Pivot Nut, Nyloc, M10, Bellcrank Pivot Bolt pivot Pin, Gearchange Tubes Pivot Pin, Gearchange Tubes Rubber Bush, Tube End Bearing, Nylon, Tube End Nut, pivot Pin Nut, Pivot Pin Washer, 8mn, Gear Lever to Front Tube Tube, Gearchange, Front Tube, Gearchange, Rear Tube, Gearchange, Rear Adjustable End, Rear [...]

TURBO ///[...]

0 ILLUS NO. DESCRIPTION I Top Cwer & Cross Shaft Bearing Cap Top Cover & Cross Shaft Bearing Cap Dowel, Top Cwer Locating Setscrew, M7 x 35, Top Cover Setscrew, M7 x 25, Top Cwer Setscrew, M7 x 28, Top Cover Setscrew, M7 x 50, Top Cwer Shouldered Screw Shouldered Screw Washer, Top Cover Screw Filler Plug Gasket, Filler Plug Cross Shaft Asse[...]

[...]

ILLUS NO. DESCRIPTION I Adjusting Washer, 3.00 Adjusting Washer, 3.05 Adjusting Washer, 3.10 Adjusting Washer, 3.15 Adjusting Washer, 3.20 Adjusting Washer, 3.25 Adjusting Washer, 3.30 Adjusting Washer, 3.35 Crown Wheel and Pinion Roller Bearing PART NUMBER QUANTITY ALL .:: , ; .; , . j ' 85; REMARKS Turbo 47.11. Page 2[...]

TURBO 47.1 5A 0[...]

ILLUS NO. DESCRIPTION I Housing Planet Wheel Satellite Wheel Satellite Spindle, Long Satellite Spindle, Short Lacking Screw, Satellite Wheel Locking Screw, Satellite Wheel Locking Screw, Crown Wheel Planet Wheel Washer 1.52 Planet Wheel Washer 1.58 Planet Wheel Washer 1.64 Planet Wheel Washer 1.70 Planet Wheel Washer 1.76 Planet Wheel Washer 1.82 S[...]

TURBO 67.11 A a[...]

ILLUS NO. DESC RlPT ION Spacer Washer, 2.61 Spacer Washer, 2.65 Spacer Washer, 2.69 Spacer Washer, 2.73 Spacer Washer, 2.77 Spacer Washer, 2.81 Spacer Washer, 2.85 Spacer Washer, 2.89 Spacer Washer, 2.93 Spacer Washer, 2.97 Spacer Washer, 3.01 Spacer Washer, 3.05 Spacer Washer, 3.09 Spacer Washer, 3.13 Driven Pinion, 3rd/4th Secondary Shaft Double [...]

1 TURBO 47.11 A[...]

ILLUS NO. DESCRIPTION Driven Pinion, lst, Secondary Shaft Driven Pinion, 2nd, Secondary Shaft Driven Pinion, 2nd, Secondary Shaft Needle Roller Bearing, lst/2nd Pinion Sleeve, lst/2nd Pinion Bearing Synchroniser Assembly, 1st & 2nd Synchroniser Assenbly, 1st & 2nd Synchro Ring, 1st & 2nd Spacer Washer, 1.65 Spacer Washer, 1.69 Spacer Wa[...]

TURBO 47-07A[...]

ILLUS No. DESCRIPTION Spring, Clutch Shaft Endthrust Circlip, Clutch Shaft Retention Support Tube, Clutch Release Bearing '0' ~ing, Support Tube Sealing Scroll and Housing Ball Bearing, Primry Shaft Front Primary Shaft Drive Pinion, 3rd, Primary Shaft Drive Pinion, 3rd, Primary Shaft Needle Roller Bearing, 3rd Pinion Needle Roller Bearing[...]

[...]

ILLUS NO. DESCRIPTION Relay Dog, 5th Selector Shaft Selector Fork, 5th Selector Fork, 5th Selector Fork, 3rd & 4th Selector Fork, 1st & 2nd Locking Screw, Forkhelay to Shaft Locking Wire, Forkhelay Screw Screw, 5th Fork to Shaft Spring Washer, 5th Fork Screw Setscrew, M9 x 25, Fork Clanping Interlock Plunger, Short Interlock Plunger, Long B[...]

[...]

ILLUS NO. DESCRIPTION Housing, Diff. Output Shaft, RH Housing, Dif f . Output Shaft, RH Housing, Diff. Output Shaft, Ill Housing, Dif f . Output Shaft, IH Gasket, Output Shaft Housing Drain Hose, Output Shaft Hausing Bolt, M7 x 20, Output Hsg.hrans. Bolt, MI x 25, Output Hsg.hrans. Bolt, M7 x 70, Output Hsg./Trans, Bolt, M9 x 30, Output Hsg.firans.[...]

TURBO 60.01 A[...]

ILLUS NO. DESCRIPTION Toolkit & Roll Toolkit & Roll Roll, Toolkit Spanner, OD, 8 x 10 Spanner, O/E, 10 x 13 Spanner, OD, 13 x 17 Screwdriver, Posidrive no. 2 Pliers 'TI Bar, Sliding Extension, 5 in., 3/8 in. Drive Spark Plug Socket, 13/16 in. Socket 1% Socket, 17mn Toolkit & Plastic Case Strap, Tool Case Retention Hook, Tool Case S[...]

TURBO 60.02A[...]

d ILLUS NO. DESCRIPTION Engine Special Tool Kit Assanbly Cylinder Liner Clanps* Cylinder Liner Extractor* Cylinder Liner Nip Gauge* Drift, Inlet Valve Seat* Drift, Exhaust Valve Seat* Inserter, Spigot Bearing* Drift, Valve Guide* Inserter, Camshaft Oil Seal* Spanner, Oil Pick-Up Pipe Union* Extractor, Camshaft Oil Seal* Sleeve, Camshaft Oil Seal* P[...]

[...]

LOTUS PAINT CODES & TOUCH-IN PAINT/STICK NUMBERS LOTUS LOTUS LOTUS LOTUS PAINT COLOUR TOUCH-IN PAINT TOUCH-IN * TOUCH-IN KIT, CONTAINING (PAINT/LACQUER STICKS) LOTUS PAINT CODES & TOUCH-IN PAINT/STICK NUMBERS 80.20A[...]

ID. ILLUS NO. DESCRIPTION I Transmission Tool Kit, Carprises Spanner, Bearing to Shaft Nut Spanner, Bearing to Housing Lock Ring Dial Gauge Support Dial Gauge Pinion Setting Fixture Spanner, Speedo Drive Nut Syncro Gauges (set of 6 ) Reverse Selector Gauge Circlip Pliers, 3rd/4th Syncro Hub PART NUMBER QUANTITY ALL 1 1 1 1 1 1 1 1 1 1 REMARKS lst/2[...]