Lotus Esprit Series Manuel d'instructions

~@#US

iUP9

i%@d

Norwich, Norfolk, N~f4

8EZ.

England.

Jelegrants; Lotus

Norwich.

relex,

Si"4E)i

Telephone; Wymondha'm

(0953)

602674

lotus

Cars

Lid

1982

INTROBIJGTIOM

Page

This

Workshop Manual

produced primarily for Lotus Dealers to give repair and

maintenance information on the Lotus Esprit car. It

divided into sections giving

comprehensive information insome sections on the main

sub-assemblies

and in others

cover.only the features which will require maintenance.

special tools are

required these will be shown at the end of the relevant section. Service Bulletins

andParts Bulletins will be ussued when necessary to update the manual.

MANUAL

FORMAT

.",..

2.:

.-.

...

:+,

;-S.,

The manual is divided into sections which are identified by letters. These letters are

-9.-

:..

...

r?...

'CA~;:.-C

P,,+,

t;t'

.TZ;!

+C:=

S-_hedv!e'. %here

the

numbers

(e.g.

A907E or ~079~)carry the identifying letters for the

ENGINE,

lktter

.:,:

'E'

andTRANSMISSION, letter 'F'. The sections in this monual are as follows:

INTRODUCTION

TECHNICAL DATA

CHASSl

BODY

FRONT SUSPENSION

REAR

SUSPENSION

ENGINE

. .

TRANSMISSION

.:'

HUBS, WHEELS, TYRES

STEERING

BRAKING SYSTEM

COOLING

SYSTEM

FUEL

SYSTEM

ELECT

CAL

HEATING/VENTlLATION

WCH

EXHAUST SYSTEM

ESPRIT

Issup

M178

INTRODUCTION

Page

VEHICLE IDENTIFICATION

All cars are identifiedby a Chassis (Cor) Number, and this number will be found on

the Identification Plate which

located in the front compartment on the rear bulk

head. The engine nvmber

duplicated on the right

hand rear of the cylinder block,

above the starter motor. Inall communication with the Factory, the Chassis Number

MUST

QUOTED

FULL.

An example of the Chassis (Car) Number

given below, to

ether with the full

identification breakdown.

100

Chassis (Car) Number

05 Denotes year and month of manufacture (1976, May)

100 Denotes the number

Denotes the Territory the car

destined for

Deomestic and Eurpean

North America

Rest of World

ESPRIT

Issue

W178

TECHNICAL DATA

Page

CONTEN'TS

Description

DIMENSIONS

CAPACITIES

ENGINE

Generol

Engine

Belt

Tensions

linder Heod

Valves

Valve

Seat

inserts

,:.:i:$

.?>V

~;.::!a,j;d:,

valve

springs

.-..!

.c!.-

....

;:+~,cf..-

;:>.;

Poge

Valve Guides

Camshafts

Cam Followers

Auxiliary Shaft

Crankshaft

Flywheel

Connecting Rod

Gudgeon Pin

Piston and Liner

Lubrication System

FUEL SYSTEM

IGNITION SYSTEM

DISTRIBUTOR

COOLING SYSTEM

CLUTCH

TRANSMISSION

FRONT SUSPENSION

STEERING

REAR SUSPENSION

BRAKES

ELECTRICAL EQUIPMENT

TORQUE LOADING FIGURES

MODEL

CHARACTERISTICS

PECHWIBCAL

DATA

'age

DIMENSIONS

Wheelbase

Track

Front

Rear

Overall Length (European Spec.)

Overall Length (North American Spec.)

Overall Width

Overall Height

Ground Clearance

Turning Circle (Between Kerbs)

Kerb Weight (European Spec.)

-A

\AI-:-LL

lR1-JL

A-.-.:rlr

K-.-.+

..-.-

..-.

-...

(96 ins)

(59.50 ins)

(165 ins)

(167.71 ins)

(73.25 ins)

(43.75 ins)

ins)

(38 ft)

(2012.82 lbs)

><>Cl

1heI

..,A>

a'.;,.

I.Ai.

CAPACITIES

';'

Engine (Inc. Filter)

Dty

5.95 litres (10.5 imp pts., 12.6 US pts)

,.....

Refill 4.83litres (8.5imppts., 10.2USpts)

ntcr

.-..--.

L-..

L?-L

--.a

-...

J:-..:-I.

-I...

vltrr;lrv,Ls

uw1nrr;w88

su~ts

U*~U

IVW

US~BS~R

IIIUU~..

0.85 litres (1.5 imp pts., 1.8 US pk)

,W:%

Transmission 2.25 litres (4 imp pts., 4.8

pts)

Cooling System 10.8 litres (19 imp pts., 22.8 US pts)

C.-

Fuel Tank

litres (14.75 imp gal, 17.7 US

gal)

ESPRIT

Issue

04/78

TECHNICAL

DATA

Page

ENGINE

GENERAL

Engine Type

907,

Twin overhead camshafts

Number of cylinders

Firing order

Capacity

1973

cc.

(120.4

cu ins)

Stroke

69.2

(2.72

ins)

Bore (nominal)

95.2

(3.75

ins)

Compression-rqio

European Spec.

9.5:l

<!,

North American Spec.

8.4:l

Corppression

Pressure (At sea level)

..,

,..

. .

...,,;

European Spec.

11.65/12.65

kg cm sq

(160/180

ibs insq.)

North Americon Spec.

10.55/11.95

kg cm sq

(150/170

lbs insq.)

'r-

Engine number location on top rear of cylinder block adjacent to

starter mounting

BELT TENSIONS

Toothed timing belt

(133

teeth)

..$-C

):c;

With

both

iypes

of belt tensioners set the belt tension to an average reading of

unitscold

(120

125

units hot). Check to6thed belt tension between

1,'

auxiliary and inlet camshaft pulley, with Burroughs Gauge

Type

BT-33-86b

20.

IMPORTANT: Check the belt tension with number

cylinder at TDC after

rotating

engine at least one full turn clockwise (norrml running direction). Repeat

.,,

,.,..

:,$A;:&

."'.Lii:'

thls

operation twice to obtoin specified average reading.

..:,

.l:<

G*;'"..

,..,..i.

.,.:.,.

.,,

beltcompre~sor

(0.35

ins) Deflection

Other V

belts

(0.50

ins) Deflection

ESPRIT

Issue

04/78

TECHNICAL

DATA

'age

CYLINDER HEAD

Material Aluminium alloy

Gasket Steel asbestos DV

Head depth 82.04+ .254

(3.23

.O1

ins)

Combustion chamber depth 12.192/12.573

(0.480/0.495 ins)

Max. permissiblemetal

removal

Nil

(To correct warping)

Valve Timing

Inlet opens

Inlet closes

Exhaust opens

Exhaust closes

European Spec. NorthAmerican Spec.

30°B.T.D.C. 26OB.T.D.C.

Valve

.P.

(Maximum

openinn

noin?!

European Spec. Inlet

~O~.~~A.T.D.C.

Exhaust 102.5'

NorthAmerican Spec.

.,:

Inlet

~OO~A.T.D.C.

Exhaust lloOB.T.D.C.

Angle of valve

seats

45O

..,-

VALVES

,j_

.<;

.Z2..$

...

:,.

.,.

...

.<<$::+.,

..:

.S::

Head diameter -,;,inlet 35.56

(1.40 ins)

exhaust

30.86

(1.215 ins)

Stem diameter

inlet/exhaust 7.137 mm (0.281 ins)

Stem clearance inguide

inlet 0.0076/0.0457

(0.0003/0.00 18 ins)

exhaust 0.0076/0.0584

(0.0003/0.0023 ins)

Valve clearance (cold)

inlet 0.127/0.178

mm,

0.005-0.007 ins

-yxhaust

. .

0.254/0.305

mm,

0.010

0.012 ins

ESPRIT

Issue

04\78

TECHNICAL

DATA

Page

Valve Seat Inserts

Bore

in head:

Standard

Inlet

Exhaust

+0.0254

(0.001

in)

lnlet

Exhaust

+0.0508

(0.002

in)

lnlet

Exhaust

+O.

127

(0.005

in)

lnlet

Exhaust

37.2364/37.2618

(1.466/1.467

ins)

34.29/34.3154

(1.350/1.351

ins)

37.2618/37.2872

(

.467/1.468

ins)

34.3154/34.3408

(1.351/1.352

ins)

37.2872/37.3126

(1.468/1.469

ins)

34.3408/34.3662

(1.352/1.353

ins)

37.3634/37.3888

(

.471/1.472

ins)

34.417/34.4424

(1.355/1.356

ins)

Outside diameter

seats

Standard

Inlet

37.2813/37.3507

(

.4695/1.4705

ins)

Exhaust

34.3789/34.4043

(1 .3535/1.3545

ins)

+0.0254

(0.001

ins)

Inlet

37.3507/37.3761

(l .4705/1.4715

ins)

Exhaust

34.4043/34.4297

1345/1.3555

ins)

+0.0508

(0.002

in)

Inlet

37.3761/37.4015

(1 .4715/1.4725

ins)

Exhaust

34.4297/34.4551

(1 .3555/1.3565

ins)

+O.

127

(0.005

in)

Inlet

37.4523/37.4777

(1 .4745/1.4755

Exhaust

34.5059/34.5313

(1.3585/1.3595

Valve Springs

Dual

Free length

Inner

37.465

(1.475

in)

46.863

(1.845

in)

.::*;,>*,'<,i:<~

Outer

.z-?,.:...$2

.....-

L.,::.

....

Rate

Inner (Compressed

mm;

13.6

kg;

ibs)

. .

.:;

Outer (Compressed

mm;

28.57

kg;

lbs)

Valve Guides

,,:;;v:

Length

Inlet

53.34

(2.100

in)

'<.

::.;::.:,

..,;#c;,

,'l7.

Exhaust

53.34

(2.100

in)

Internal diameter (to ream after fitting)

7.1450fl.1704

(0.2813/0.2823

in)

ESPRIT

Issue

04/78

PECHIMIICAL.

DAn

'age

Valve Guides (cont.)

Bore in head

Standard

+.0254

(.001

in)

0508

(

.002

in)

127

(.005

in)

lrilet

Exhaust

11.9126/11.9253

(.4690/.4695

in)

.938/11.9507

4700/.4705

in)

11.9634/11.9761

(.4710/.4715

in)

12.0396/12.0523

(

.4740/.4745

in)

Outside diameter of guide

Standard

1.938/11.9507

4700/.4705

in)

+.0254

(.001

in)

11.9634/11.9761

(.4710/.4715

in)

0508

002

in)

1.9888/12.0015

(.4720/.4725

in)

127

(.005

in)

12.065/12.0777

(

.4750/.4755

in)

CAMSHAFTS

End float

Dimension

.0254/.2032

(.001/.008

in)

Controlled by Selective thrust washers

Running clearance

.0254/.0635

(.001/.0025

in)

.;E

..>.

CAM FOLLOWERS

..,#$,

...

Bore in camshaft housings

34.925/34.9402

(1.3750/1.3756

in)

Outside diameter

34.904/34.912

(1.3742/1.3745

in)

AUXILIARY

SHAFT

Running Clearance

End float

.025/.065

(.000P/.0025

in)

.0127/.0381

(.0005/.0015

in)

Balance (inc. flywheel

clutsh)

,.,,

Within

14.42

gr. cm.

(.2

oz in)

Diameter

Main journal (No.

inc.)

63.487/63.513

(2.4995/2.5005

in)

Mainjournal(No,5only)

63.500/63.513mm (2.500/2.5005in)

Crankpin

50.73q50.762

(1.995/1.9985

in)

End float

Dimension

.076/.203

(.003/.008

in)

ESPRIT

Issue

04/78

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