User manual LOTUS ESPRIT SERVICE MANUAL

[. . . ] Turbo 93-96 10. 00 11. 00 12. 00 13. 00 14. 00 15. 00 16. 00 17. 00 18. 00 19. 00 30. 00 31. 00 Body Structure Glazing, Door Weatherstrips, Window Lift Exterior Hardware & Trim Seat & Seat Belts Pedal Box & Fascia Interior Trim Sound Insulation Electrical Heater/Air Conditioning Labels & Literature Chassis Suspension 32. 00 33. 00 34. 00 40. 00 41. 00 42. 00 43. 00 44. 00 45. 00 46. 00 47. 00 60. 00 80. 00 Steering Brakes Wheels & Tires Engine Belts & Pulleys Induction System Emission Equipment Fuel System Exhaust System Cooling System Transmission Tools Bulk Items Body Structure 10. 01A 10. 02A 10. 03A 10. 04A 10. 05A 10. 07A 10. 09A 10. 11A 10. 13A 10. 15A 10. 17A 10. 23A 10. 23B 10. 31A Bodyshell & Front Body Repair Sections Rear Body Repair Sections Body to Chassis Fixings Body Attachment 'Bobbins' Body Crossbeams, Jacking Plates Headlamp Pods & Pivots Front Bonnet & Release Mechanism Tailgate & Release Mechanism Engine Compartment, Undertray Door Shell, Beam, Hinges, Hinge Post Door Handles, Lock Mechanism, Striker Posts S4: Bumpers, Sills, Valances, Spoilers Sport 300: Bumpers, Sills, Valances, Spoilers Towing Eye & Fixings Glazing, Door Weatherstrips, Window Lift 11. 01A 11. 02A 11. 05A 11. 05B Glass, Finishers, Door Weatherstrips Door Window Frames, Window Lift Mechanism Glass Roof Composite, Fixed Composite Roof Exterior Hardware & Trim 12. 01A 12. 02A 12. 05A 12. 07A 12. 09A Capping Rails, Air Scoops, Wind Deflector Fuel Filler Flaps & Release Mechanism Decals & Badges License Plate Plinths Door Mirrors Seats & Seat Belts 13. 03A 13. 09A 13. 11A 13. 27A Seat Frames, Runners, Recline Mechanism Seat Foams, Suspension, Lumbar Support Trimmed Seats, Covers Seat Belts & Reel Covers Pedal Box & Fascia 14. 01A 14. 05A 14. 05B 14. 07A 14. 08A 14. 10A 14. 12A Pedal Box & Pedals, Throttle Cable Except Dual S. I. R. : Fascia Trim, Knee Bolster Dual S. I. R. : Fascia Trim, Knee Bolster Binnacle Instrument Panel & Masks Centre Console, Climate Controls Mtg. Trimmed Instrument Binnacle Glovebox Interior Trim 15. 01A 15. 11A 15. 13A 15. 19A 15. 24A 15. 30A Roof Trim, Interior Mirror, Sun Visors Rear Bulkhead Trim, Bulkhead Pocket Door Trim Tunnel Trim, Gear Level Gaiters Luggage Compartment Carpet Passenger Compartment Carpet, Handbrake Gaiter Sound Insulation 16. 01A 16. 02A S4: Passenger Compartment Sound Insulation Body Underside Sound Insulation Electrical 17. 01A 17. 03A 17. 03B 17. 03C 17. 03D 17. 05A 17. 06A 17. 06B 17. 06C 17. 07A 17. 09A 17. 11A 17. 13A 17. 15A 17. 21A 17. 27A 17. 29A 17. 31A 17. 33A Harnesses, Leads & Fuses Prior VIN*: Relays, Modules & Horns From VIN*: Relays, Modules & Horns Prior VIN*: Engine Bay Relay Box & Inertia Switch From VIN*: Engine Control Relays & Inertia Switch Driver Operated Switches & Cigar Lighter Engine Management ECM & Sensors S. I. R. : Inflator Modules, D. E. R. M. & Sensors ABS: ECM & Sensors Instruments, Senders, Tell Tales, Clock S4: Speedo Cable Lamps (except headlamps), Door Switches Headlamps, Carriers & Masks Headlamp Pod Motors & Lift Mechanism Windscreen Wiper Mechanism & Washers Audio Equipment, Speakers, Aerial Earth Braids & Suppression Devices Battery & Battery Cable Alarm System Controller & Sensors Heater/Air Conditioning 18. 01A 18. 03A 18. 05A 18. 07A 18. 09A 18. 11A 18. 13A Heater/Air Conditioning Assembly, Casings Condenser, Evaporator, Rec. Drier, Hoses Heater Matrix, Water Valve & Plumbing Interior Blower Motor Rotary Controls, Graphic Panel, Screen Flap Mech. [. . . ] Withdraw the solenoid. Page 57 Pressure relief valve Reservoir Low fluid level sensor Reservoir gasket Rear solenoid RH front solenoid LH front solenoid Bleed nipple \ , Bleed nipple 3. Before refitting the solenoid, check that both `0' rings on the lower end of the solenoid are in place and in good condition. Check the condition of the solenoid top seal, and replace any seal if in doubt. Lubricate the `0' rings with clean DOT 4 fluid before inserting the solenoid into its bore in the master cylinder/booster assembly. 4. IMPORTANT: Ensure that the correct solenoid is fitted into the correct position - the two front solenoids (identical, with black connector sockets) are fitted in the right hand and left hand front positions, and the rear solenoid (tan or grey connector) is fitted in the left hand rear position. Retain the solenoid with the two Torx screws, and tighten to 4 - 5 Nm (33 - 45 lbf. in). Refit reservoir (see section JF. 15) and bleed brake system (JF. 8). JF. 17 - MASTER CYLINDER/BOOSTER ASSEMBLY Servicing of the master cylinder/booster- assembly is limited to the fluid reservoir components, and the solenoid valves as previously described. . The master cylinder, displacement cylinders and isolation valves are not serviceable, and if found to be faulty, must be rectified by fitting a replacemnt master cylinder/booster assembly. Depressurise the accumulator by turning off the ignition and FIRMLY applying the brake pedal up to 40 times. A noticeable change in pedal feel (to a hard pedal) will occur when the accumulator is completely discharged. Release the reservoir cover, and use a syringe to remove as much fluid as possible from the reservoir. Protect the surrounding area of bodywork and any electrical equipment from fluid drips during the course of unit removal. Unplug the harness from the low fluid level switch and the three solenoids. Use a suitable container or shop towel to catch fluid, and disconnect from the reservoir the fluid supply hose from reservoir to pump assembly. Ensure that the accumulator has been fully depressurised before disconnecting the high pressure pipe from pump/accumulator to master cylinder/booster (MlOthread). NOTE: After disconnecting any brake pipes, always plug both the pipe end and the port to prevent dirt ingress and reduce fluid spillage. Disconnect the two front brake pipes (Ml2 and Ml3 thread) and the single rear brake pipe (Ml4 thread) from the master cylinder/booster. From within the driver's footwell, remove the clevis pin connecting the brake pedal to the pushrod. Remove the two bolts securing the unit to the bulkhead mounting bracket, and withdraw the master cylinder/booster assembly and pushrod from the car. Slacken the pushrod locknut, and screw the pushrod off the pushrod nose. if fitting a replacement master cylinder/booster assembly), the plastic retaining clip will be damaged during removal and must be renewed. If necessary, fit the pushrod nose into the master cylinder/booster assembly, and retain with a new plastic circlip. Fit the boot carrier plate over the pushrod and locate the boot and plate correctly against the master cylinder/booster assembly. Fit the master cylinder/booster assembly to the bulkhead mounting bracket, passing the pushrod through the bulkhead gasket. [. . . ] Washer, spring, M8 Washer, flat, M8 Bolt, M8 x 60, cap hd. , clutch to flywheel Clutch Fork Clutch Fork Snap Ring, clutch release bearing Clutch Assembly, twin pate Clutch Assembly, twin pate, retro fit kit Pin fixing kit Pivot, clutch fork Screw, M8 x 35, flg, skt. Spring, clutch fork Pop Rivet, spring to clutch fork Release Bearing, twin plate clutch Heatshield, flexpipe coil, clutch pipe protection Not illustrated Not illustrated Not illustrated For stiff alloy clutch housing For stiff alloy clutch housing V8, V8-GT, `98 MY on V8, prior to `98 MY V8, prior to `98 MY V8, prior to `98 MY V8, prior to `98 MY V8, prior to `98 MY Twin plate clutch V8, prior to `98 MY V8, V8-GT, `98 MY on 1 2 2 2 6 1 1 1 1 1 1 1 V8, V8 GT V8 Twin plate clutch V8, V8-GT, `98 MY on B082Q0718F A082Q0720S A0824071 9S A082Q4061 F A91 0W7121 F A082Q4062F A082W6302F A082Q4041 H V8, V8-GT, `98 MY on V8, V8-GT, `98 MY on V8, V8-GT, V8, V8-GT V8, V8-GT, `98 MY on `98 MY on 1 1 1 A082Q4070F TOOT1 402F Clutch alignment tool, twin plate clutch Service kit, slave cylinder 1 V8, prior to `98 MY A082Q6024F Function Code: 47. 01, Page: 3 3 1, 8 9 ESPRIT 47. 03 Service Parts List Function Code 47. 03 Transmission Assembly Dep P a r t Description 01 Remarks Type UN1 027 Type UN1 027 Type UN1 026 Type UN1 028 Single plate clutch Single plate clutch Twin plate clutch Twin plate clutch, includes release fork Single plate clutch -- Option V8, prior to `98 MY V6, V8-GT, `98 MY on Part Number A082F41 50F A082F4186F A082F6522F A082F4187F B082F4153J B082F4153J A082Q4073J A082Q4064F A082F4146S A082F6570S A082F6553S A082F B907E6181 A082F6358F A082F0766K A082F0767K A075W4024Z F m Transmission Assembly Transmission Assembly Transmission Assembly Transmission Assembly Clutch (Bell) Housing. alloy Clutch (Bell) Housing, cast iron Clutch (Bell) Housing Assembly, alloy Clutch (Bell) Housing Assembly, alloy Clutch (Bell) Housing Rear Casing Assembly Rear Casing Assembly Rear Casing Assembly Dowel, clutch hsg. Washer, flat, Ml 0 x 20, bracket t o gearbox. Ola 01 b 01 c 02 02a 02b 02c 02d 03 03a 03b 04 05 06 07 08 1 1 1 1 1 1 1 1 1 GT3, prior to VIN: W2272 GT3, VIN: W2272 on V8, B918E0150K V8 . . V8, prior to `98 MY V8, V8-GT, GT3 V8, prior to `98 MY GT3 V8, V8-GT, , 98 MY on, GT3, VIN W2272 on `98 MY on R/B 1 2 2 1 1 6 Function Code: 47. 03, Page: 1 Function Code 47. 03 Transmission Assembly Dep 09 IO 11 Part Description Remarks Option Part Number A082W7057F A075W2061Z A075W2056F A075W2059Z A075W1049Z Qty 1 1 1 Screw, Ml0 x 45, button hd. , bracket to gearbox. [. . . ]