Lotus Manual

Publication Part No.
A082T0327Z
@ Lotus Cars Ltd June 1986
This publication has been designed primarily for Lotus Dealers,

and w i l l be updated by the issue of Service Bulletins to Lotus
Dealen when necessary.
Lotus policy i s one of continuous product improvement an

right i s reserved to alter specificatiom at any time with01
notice.
Whllst every care has been taken to ensure correctness o f

i t Is impossible to guatuntee complete freedom from error!
or to accept liability arising from such erron or omissions
herein contained shall affect your statutory rights.
CONTENTS
TURBO ESPRIT h ESPRIT S3 ( P r i o r '88 M.Y.)
Subject Section
Vehicle I d e n t i f i c a t i o n See o v e r l e a f
T e c h n i c a l Data -. Engine - E s p r i t S3 TDA

- Engine - Turbo TDB
- Vehicle TDD
Body - P a i n t Procedure
- Bodycare & R e p a i r
- Body F i t t i n g s
F r o n t Suspension - P r i o r t o ' 8 5 M.Y.

- '85 M.Y. onwards
Rear Suspension
Engine EB
Engine Management - USA Turbo, c a r b u r e t t o r ( P r i o r t o ' 8 6 M.Y.) EMA

- Turbo HC, Dom/Exp '87 M.Y. onwards EMC
- E s p r i t HC, ' 8 7 M.Y. onwards EMD
Transmission FB
Steering HB
Brakes - P r i o r t o ' 8 5 M.Y.

- ' 8 5 M.Y. onwards
a Cooling System
F u e l System - E s p r i t S3
- Turbo, ~ o m / ~ x p o r t
- USA Turbo, C a r b u r e t t o r
- USA Turbo, F u e l I n j e c t i o n (Bosch K J e t r o n i c )
Electrical - E s p r i t S3 & Turbo, Dom/~xport

- USA Turbo, P r i o r ' 8 6 M.Y.
- USA Turbo, '86 M.Y. onwards
Maintenance & L u b r i c a t i o n - E s p r i t S3 & Turbo, Dom/Export

- USA Turbo
Heater & A i r Conditioning
Clutch
I n t e r i o r Trim
VEHICLE IDENTIFICATICN NCPMBER @.',
The Vehicle I d e n t i f i c a t i o n N u m b e r WIN) is stamped on a p l a t e f i x e d to the
r i g h t or l e f t hand f r o n t wheelarch i n s i d e the f r o n t luggage canpartment. This
number is repeated on the r i g h t hand side of the c h a s s i s f r o n t frame, v i s i b l e
f r a n w i t h i n t h e r i g h t hand f r o n t wheelarch.
. .
VI N Plate on wheelarch
V I N stamped on chassis
This number, together with t h e engine numkr (see TDA or TDB) should be
quoted i n a l l e n q u i r i e s regarding t h e vehicle.
There are two v a r i a t i o n s of t h e V I N , one k i n g f o r Danestic and export
markets o t h e r than f o r t h e USA, which c a n p l i e s w i t h European Econanic C m u n i t y
(EEC)d i r e c t i v e s , and one f o r the USA which canplies with requirements laid
d m by t h e National Highway T r a f f i c S a f e t y Association ( W S A ) .
The seventeen c h a r a c t e r s of t h e VIN are coded as follws:
1. =A V I N c h a r a c t e r 6:
501 = Basic E l i t e 521 = Basic E c l a t 701 = Basic Esprit

502 = Elite A/C 522 = E c l a t A/C 702 = E s p r i t A/C
503 = E l i t e A/C & PAS 523 = E c l a t A/C &PAS 701 Ccmn = Esprit Cmunanerative
504 = E l i t e Auto 524 = E c l a t Auto 702 C m = E s p r i t C m . A/C
A/C & PAS A/C & PAS
2. S e x r a t e serial number sequences a r e used f o r t h e f o l l m i n g groups of

c h a s s i s m r k e t ( c h a r a c t e r -12 1 ;
D
A, ErGr HrS
B,CiF,K
3. For change p o i n t i d e n t i f i c a t i o n i n S e r v i c e Notes, P a r t s L i s t s and Service

B u l l e t i n s , t h e f o l l m i n g VIN c h a r a c t e r s ONLY w i l l be quoted;
Danestic & Export - 5,6,12,14 t o 17
- 4,12,14 to 1 7
,
USA
Example A t y p i c a l change p o i n t could be listed as folluws;

82 D 1100 (Danestic Turbo 1100)
82q/~/G/H/S0341 (ExportTurbo0341)
F B/c/F/K 0265 (USA Turbo 0265 1
Note that t h r e e numbers are needed to i d e n t i f y the s i n g l e change point due
to t h e d i f f e r e n t serial n m b e r sequences o u t l i n e d i n n o t e 2. 'a
I f a dash is used i n p l a c e of the c h a s s i s m r k e t letter code (e.g.
- -
.82 0341 or F 02651, t h i s is t h e change p o i n t f o r . a l 1 markets i n that
s e r i a l numker sequence n o t otherwise l i s t e d .
--- - - -- - -. -.
1992 1 0 1
DCMESTIC & EXFORT
,a
\
2= 49 S t a t e s (USA)
3= C a l i f o r n i a
4= Sweden/
I
Engine Type ~ustralia/
907= 2 L i t r e Switzerland
Manufacturer 910= 2.2 Turbo 5= Japaii
1dktifier 912= 2.2 N/A 6= 50 S t a t e s (USA)
S C C
1 2 3
J
Vehicle Type
079= E s p r i t S2
-
Year I S e r i a l Number
I
082= Tu?bo ESp &
80- J
083= E l i t e S2 B= 1981 M r k e t (Chassis)
084= E c l a t S2 C= 1982 *Australia G = E x p r t (hot)
085= E s p r i t S3 D= 1983 B= 49 States RHD
089= Excel E= 1984 ( USA H= Export ( h o t )
FZ 1385 C= C a l i f o r n i a LHD
G= 1986 D= Dcfnestic J= Japan
H= 1987 E;= Europe (cold)K= Canada &
I= 1988 F 50 S t a t e s P u e r t o Rico
( USA L= Saudi ~ r a b i a
S= Sweden
-
(also Daestic & Export up t o serial nos.;
E l i t e i 7 1 8 (Dan) 0236 (Exp), E c l a t 1034 (Dan) 0205 (Exp), E s p r i t 0934 (Dan) 0.307 (Exp))
Model Year Market ( C h a s s i s

/+ 1980 B= 1981 C= 1982 A= A u s t r a l i a H= I3mort
B= 49 S t a t e s ( h i t LHD
(USA) J= Japan
I series
A = Series 1
11 C=
D=
California
Danestic
K= Canada &
P u e r t o Rico
.a B = Series 2
C = Series 3
Restr-
E=
S
Europe (cold)L= Saudi
50 S t a t e s
( USA )
Arabia .
S= Sweden
aint G= Export ( h o t
RHD
Active
1
Option Check S e r i a l Number
1=501/521/701 Diqit
B = Eclat 2= 502/522/702 Market (Enqine)
C = Esprit 3= 503/523/701 Ccmn Plant 1=Damestic
F 4 Turbo E s p r i t 4= 504/524/702 Cunn
4=504/524/702 H=Hethel 2 = 4 9 States (USA)
I
5= 501 PAS/521 PAS 3= C a l i . f o r n i a
6= 501 Auto/521 Auto I 4= S w d e n / ~ u s t r a ia/
l
7= 501 PAS ~ u t o / 5 2 1 PAS Auto Swit zer l a n d
8= 502 Auto/522 Auto 5= Japan
6= 50 S t a t e s (USA)
DEC 1986
SECTION TD A ' Page 7
TECHNICAL DATA
SECTION TD A - ENGINE TYPE 9071912
-
Page
Engine-Number
Engine Specification
Cylinder Head
Camshafts & Valve Mechanism
Crankshaft
M a i n Bearing Configuration
Flywheel
Connecting Rod
Gudgeon Pin
Piston & Liner
lubrication System
Del lorto Carburettors
Zenith Carburetton
Ignition System
Distributor & lgnition Timing
Cool ing Systern
Torque Loading Figures
0 APR 1987
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 i s stamped on the right hand rear of the cylinder block,
above the starter motor, and i s duplicated on the vehicle identification
plate fixed to either the right or left hand inner wheelarch under
the front bonnet.
I Example
For the purpose of clarification i n the TECHNICAL DATA SECTION ONLY,

a specification number i s allocated to various specifications as listed below.
In some countries, prefix letters may differ from those listed, i n which case
reference should be made to the Lotus Distributor of that country for the
relevent specification.
.. .
FIRST!PREFIX SECOND PREFIX REMARKS TECHNICAL
LmTER LETrER DATA SECTION
SPEC. NO.
Single Prefix
D -(907)
D a n e s t i c Std. Letter hly.
G - D a n e s t i c A/C 1974
J - Danestic A/C & PAS
(907 Single Prefix

F - U.S.A. Std. Letter Only.
I - U.S.A. A/C U.S.A. 1974
K - U.S.A. A/C & PAS
APR 1987
SECTION TD A Page 3
FIRST PREFIX SECOND PREFIX TECHNICAL

lJTmm3 LETTER DATA S E T I ~
SPEC. NO.
(907 Single Prefix

X - Danestic Std. Letter mly .
W - Danestic A/C
Y - Danestic PAS
L - Danestic A/C & PAS
AML - Danestic A/C, PAS
& Auto.
(907) Single Prefix

P - U.S.A. Std. Letter Cnly .
N - U.S.A. A/C U.S.A. 1975
Z - U.S.A. PAS
M - U.S.A. A/C & PAS
(907) C - Std.
C - Esprit D - A/C
D - Elite/Eclat z - PAS
L - A/C & PAS EUROPEAN
R - Auto. 1976 - ' 80 5
S - Auto. & A/C
T - Auto. & PAS
M - Auto, A/C & PAS
(907) Ct Dt ZtLt CALIFORNIA ' 76-' 79
A - Esprit RtStTtMt 49-STATES '76-'77 6
B - Elite/Eclat as for Spec. 5
1
(907) Ct Dt ZrLr 49-STATES
G - Elite/Eclat Rt StTIMI 1978- ' 80 7
H - Esprit as for Spec. 5
-
J
K -
Esprit
Elite/Eclat
(912
Rt StTIMI
as for Spec. 5
1980 CALIFORNIA
1
- Esprit
D - Elite/Eclat/btcel
A - H.C.
;.
B - H.C. PAS EUROPEAN
N - H.C. PAS & A/C HIGH CDPRESSION 10
P - H.C. & A/C Excel 86 MY @tion
Y - H.C. PAS & A/C Esprit Feb. 1987
& Auto.
Page 4 SECTION TD A
ENGINE
Max. rpm of engine

No, of cylinders
Firing order
Capacity - type 907
- type 912
Stroke - type 907 69.2mm (2.72 in.)
- type 912 76.2mm (3.00 in.)
Bore (nominal)
Compression ratio spec. 1,3,5 9.5 : 1
spec.2,4,6,7,8 8.4:1 0
spec. 9 9.44: 1
spec. 10 10.9 : 1
Compression pressure spec. 1,3,5,9 11 .2 - 12.6 bar (165 - 185 Ib/in 2)
spec. 2,4,6,7,8 10.2 - 1 1 .6 bar (150 - 170 lb/in2)
2
spec. 10 11 .5 - 13.0bar (170 - 190 Ib/in )
~ n ~ i number
ne location O n top of cylinder block adjacent
to starter mounting
Engine belt tensions - Toothed timing belt, using Burroughs gauge part number
TOOOT0025J, 90 - 95 units cold ( 6 0 ~ ~ / 2 0See
~ ~Section
) EA -8.
( - Alternator 'V' belt 12 mm (0.5 in.) (& in.)

Talal movement
rnodamte (
(
- Compredsor 'V' be1t 9mmt0.35in.) (3/8in.)
finger pressure I WC)
- .
on longest i - Power steering pump 12 mm ( 0 5 in) (jin.)

be1t run.
( 'V' be1t
CYLINDER HEAD
Material Aluminium alloy

Gasket Steel / Asbestos
Combustion Chamber Depth (nos. 1 & 4) 12.32-1 2.57mm(0.485-0.500 in)
APR 1987
SECTION TD A Page 5
CAMSHAFTS AND VALVE TIMING
cam Type I$II;-I

Designation between
pulley
E
degrees
1
; ~;M.O.P.
let
ATDC*
~arn
l3xhi3ust 1
M.0.P
Pulley BTDC*
Tirning
Cam
Pulley
Timing
Spec.No. cam hsg. Lift Dot Dot
1 groove 1270" 10.350" (110' (red 110" red
plain 1 ( (
272" 0 .34011 110" 1 red 110° red
plain 100" blue 110" red
2 groove 1023" yellw 1023" yellow
plain 1023" yellw 110" red
777.. .. 104" green

444.... 104" green
* All cams are symnetrical opening closing

VALVES
Angle of valve seats and faces 45O

Head diameter - lnlet 35.47 - 35.65 mrn (1 .396 - 1 .404 in .)
- Exhaust 30.73 -30.91 rnm (1 .210 - 1 .217 i n . )
Stem diameter - lnlet & Exhaust 7.125 - 7.137 mm (0,2805 - 0.2810 i n .
Stem clearance in guide - lnlet & exhaust 0.008 - 0.046 mm (0.0003 - 0.0018 in.
Valve clearance (cold)

Spec. 1 . (ID' Cams) - lnlet 0.10 - 0.15 mm (0.004 - 0.006 in.)
- Exhaust 0.20 - 0.25 mm (0.008 - 0.010 in.)
Spec 2,3,4,5,6,7,8,9 - lnlet 0.13 - 0.18 mm (0.005 - 0.007 in.)
1b
- Exhaust 0.25 - 0.31 mm (0.010 - 0.012 in.)
Valve Seat lrserts
Bare in head:
S ta ndard - Inlet 37.235/37.260 mm . (1I/&. .467 in. )
- Exhaust 34.290/34.315 mm. (1.350/1 .351 in.)
Valve seat insert bore (cont .)
c 0.025 mm (0.001 in) ' - lnlet 37.260/37.285 mm. (1.467/1 . a 8 in.)
- Exhaust 34.315/34.340 mm. (1,351/1 .352 i n .)
F 0.050 mm (0.002 in) - Inlet 37.285/37.315 mm. (1 .468/1 . a 9 in.)
- Exhaust .
34. 340/34.365 mm (1 .352/l ,353 i n .)
F 0.127 mm (0.005 in) - Inlet 37.365/37.390 mm. (1.471/1 .472 in.)
- Exhaust 34.415/34.440 mm. (1 .355/1 .356 in.)
Outside diameter of seat
S ta ndard - Inlet 37.325/37.350 mm. (1.4695/1 .4705 in .) -:

- Exhaust 34.380/34.405 .
mm (1.3535/1 .3545 in .)
t- 0.025 mm (0.001 in) - lnlet .

37.350/37.375 mm (1.4705/1 .4715 i n ) .
- Exhaust 34.405/34.430 mm. (1 .l345/l .3555 in.)
t 0.050 mrn (0.002 in) - lnlet 37.375/37.400 mm. (1.4715/1 .4725 in.)
- Exhaust .
34.430/34.455 mm (1 .3555/l .3565 i n .)
t 0.127mm (0.005 in) - lnlet 37.450/37.475 mm ..(1 .4745/1 .4755 in .)
- Exhaust 34.505/34.530 mm. (1 .3585/1 .3595 in.)
dalve Springs
TYpe Dual
Free Length Rate

Inner 1 Outer Inner Outer
I I
A l l 907 engines plus 37.5mn 4 6 . 9 ~ 1 1 10.7kg/an 22.4kg/d
912up'toeng.no.18104 (1.48in) ( 1 . 8 5 i n ) (601b/in) (1261b/in)
912 engines 18105 on 42.2mn 48.5mn ll.Okg/an 22.5kg/an

(1.66 i n ) (1.91 i n ) (61.5 lb/in) (126 lb/in)
FDlAAA/2
APR 1987
SECTION TD A Page 7
Valve Guider
Length - lnlet 53.34 mm. (2.100 in.)

- Exhaust 53.34 mm. (2.100 in.)
Internal diameter (to ream after fitting) 7.145 - 7.170 mm. (0.2813 - 0.2823 in.)
Bore in head - lnlet and Exhaust
Standard 11.915 - 11.925 - 0,4695 in.)
mm. (0.4690
+ 0.025 mm. (0.001 in.) 11.940 - 11.950 mm. (0,4700 - 0,4705 in.)
+ 0.050 mm. (0.002 in.) 11 .965 - 11,975 mm. (0.4710 - 0.4715 in.)
+ 0.127 mm. (0.005 in.) 12,040 - 12.050mm. (0,4740 - 0.4745 in.)
Outside diameter of guide
10 Standard 11.940 - 11.950 mm. (0.4700 - 0.4705 in .)
+ 0.025 mm. (0.001 in.) 11 .965 - 11 .975 mm. (0.4710 - 0.4715 in.)
+ 0.050 mm. (0.002 in.) 11.990 - 12.000 mm. (0.4720 - 0.4725 in.)
+ 0.127 mm. (0.005 in.) 12.065 - 12.080 mm. (0.4750 - 0,4755 in.)
Camshafts
End float - Dimension 0.03 -0.20 mm. (0.001 - 0.008 in.)
- Controlled by Selective thrust washers
Running clearance (except front) 0.050 - 0.090 rnm (0.0020 - 0.0035 in.)
(front only) 0.075 - 0.115 mm (0.0030 - 0.0040 in)
Cam Followen .
Bore in camshaft housings 34.925 - 34.940 mm. (1.3750 - 1 .3756 in .)

Outside diameter 34.904 - 34.912 mm. (1.3742 - 1,3745 in .)
Auxiliary Shaft
Running clearance 0.025 - 0.065 inm. (0.0009 - 0.0O%in.)
End float 0.013 - 0.038 mm. (0.0005 - 0.0015 in.)
'0
APR 1987
Page 8
Crankshaft
Balance (inc. flywheel and clutch) Within 15 gr.cm. (0.2 oz. in.)
Diameter - Main journal (No.1 .to 4 inc.) 63.487 - 63.51 3 mm. (2.4995 - 2.5005 in.)
- Main journal (NO. 5 only) 63.500 - 63.51 3 mm , (2.5000 - 2.5005 i n .)
- Crankpin 50.736 - 50.762 mm. (1.9975 - 1.9985
..
in.)
End float - Dimension 0.08 - 0.20 mm. (0.003 - 0.008 in.)
- Max wear l i m i t 0.30 mm. (0.012 in.)
- ControlIed by Selective thrust washers on rear main
bearing
Bearings (main) - Number 5
- Type Steel backed, leaded bronze
Static clearance* 0.013 - 0.056 mm. (0.0005 - 0.0022 in.) 0.'
Max. undersize for regrind 0.508 mm. (0.0200 in.)
* Bearing clearance i s measured with Plastigage.
MAIN E W K l N G SHELL CONFIGURATICN
ENGINE MAIN BEARING NUMBER

TYPE FRONT '1 I CENTRE 1 1 REAR
1 2 3 4 5
107 ~ l i t e / E c l a t UPPER G r o o v e / H o l e Groove/Hole G r o o v e / ~ o l e Grocwe/~ole Groare/Hole

107 Esprit w i t h
ION X - d r i l l e d
rank
I07 Esprit w i t h UPPER

idrilled crank
112 Esprit I
m Plain Plain Plain Plain
112 E l i t e / E d l a t UPPER Groove/Hole Groave/Hole ~lain/Hole Groove/Hole

112 Excel w i t h
KIN X - d r i l l e d
xank Groove/Hole Groave/Hole Plain Groove/Hole
112 Excel w i t h UPPER G r o o v e / H o l e Groove/Hole Plain/Hole Groove/Hole

:-drilled crank
112 E s p r i t HC
Plain
. .
SECTION TD A Page 9
Flywheel (fixed)
0.10 mm. (0.004 in.) ..
Max run out (lateral)
Starter ring gear - run out - lateral 0.41 mm. (0.016 in.)
- radial 0.15 mm. (0.006 in.)
Flexplate Flywheel
Max. run out (radial) 0.18 mm. (0.007 in.)
Max. run out (lateral) at clutch face 0.13 mm. (0.005 in.)
ia Connecting Rod
TYpe 'I' section

Material Steel forging
Distance between centres .
1 39 -70 rnm (5.500 i n .)
-4- 0.25 mm. (0.001 in.)
Bearings (big end) - Type Steel backed, leaded bronze
- Static clearance * 0.025 - 0.081 mm.(0.0010- 0.0032 in.)
.. . - End float on crankpin 0.10 - 0.25 rnm. (0.004 - OD10 in.)
Small end bore (bushed) 25.405/25,410 mm (1.0002 . - 1 ,0004 in .)
Permissable weight variation between rods 2 gramrnes (in any set)
* Bearing clearance i s measured with Plastigage
'a Gudgeoc (Piston) Pin
TYpe Fully floating

Locatiori Circl ips
Diameter 25.40 mm. (1 .OO in.)
Class of f i t Finger push f i t at 2 0 ' ~ (68' F)
Piston and Liner
Piston - Type Sol.id skirt
a - Material - 907/912 Die-cast aluminium al loy

Forged al umi nium al loy
APR 1987
Page 70 SECTION TD
. ..
A .. , ,
Piston - (Cont .) Identification
2.0 LITRE 907 2.0 LITRE 907 2.2 LITRE 912.

%:I C.R 8.4:l CR. 944:l CR.
2-2 UTRE 912 2.2 LITRE 910 2.2 LITRE 9 l 0

10.9:l CR. 751 CR. B a l CR.
- Rings 2 compression,. 1 oil control

- Diameter 907 - grade 'A' 95.1 66/95.179 rnrn (3.7467/3.7472 in)
907 - grade 'B' 95 . I 79/95 . I 92 rnm (3.7472/3.7477 in)
912 Std - grade 'A ' 95.148/95.161 rnrn (3.7460/3.7465 in)
912 Std - grade 'B' 95.161/95.174 mm (3.7465/3.7470 in)
912 HC - grade ' A ' 95.205/95.219 mm (3.7482/3.7488 in)
912 HC - grade 'B' 95.21 7/95.231 mm (3.7487/3.7493 in)
- Grade diameter - 907/912 Std 15 mm (0.6 in) up from skirt edge
- 912 HC 10.2mm (0.4 in) up fromskirt edge 900
pinaxis 1
- Gudgeon pin bore offset 907/912 Std 1 .52 mm (0.060 in) towards thrust face
912 HC 1 .50 mm (0.059 in) towards thrust face
- Permissable weight variation
betweenpistons. 907/912~td 3.5 grammes
912 HC 3.0 grammes
- Ring gap 907/912 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 .14 mm (0.015/0,045 in)
912 HC - top&second 0.40/0.65 mm (0.016/0.026 in)
APR 1987 -oil control 0.30/0.60 mm (0.f 12/0.024 in)

SECTION TD A Page 7 7
' Piston (cont.)

-Piston ring to groove clearance
907/912 Std - Compression0.038/0.089 mm (0.0015/0.0035 in)
- O i l control 0.038/0.064 mm (0.001 5/O.OO25 in)
912 HC - compression O.O4O/O. 072 mm (0.001 6/O. 0028 in)
- O i l control 0.020/0.052 mm (0.0008/0.0020 in)
Cyl inder Liner - Type Wet, slip f i t
- Material - 907/912 Std Cast Iron
-91 2 HC Nikosil coated, forged aluminium alloy
- Internal diameter
- 907/912 Std Measured 50mm from top across thrust axis
Grade 'A' 95.275/95.288 mm (3.751 0/3 .751 5 in)
Grade 'B' 95.288/95.308 mm (3.7515/3.7520 in)
- 912 HC Measured 70mm from top across thrust axis
.. a Grade 'A'
Grade 'B'
95.255/95.269 nim (3.7502/3 .7507 in)
95.267/95.281 mm (3.7507/3.7512 in)
- Fitted height above block - 907/912 Std 0.1 O/O.l5 mm (0.004/0.006 i n 1
('nip') up to engine number 12477
0.025/0.13 mrn (0.001/0.005 in) O O I / Q ~ ~
from engine number 12478
- 912 HC minus 0.025 to + 0.050mm
(minus 0.001 to + 0.002 in)
- Permissable variation between linen 0.03 mm (0.001 in) J
- Piston clearance in cylinder liner 907 0.?8[0.13mm (0.004/0.005 in)
912 Std 0.11/0.15mm (0.005/0.006 in)
912 HC 0.05/0.08mm (0.002/0.003 in)
Lubrication System
a Oil pressure under normal running condition (hot)

a). Not below 5 Ib/sq .in. (0.35 kg ./sq .cm .) at idle speed
b), N0tbel0~35Ib/s~.in.(2.5kg./s~.cm.)at3,500rpm
C); Not below 45 Ib/sq .in. (3.2 kg ./sq .cm .) at 6,500 rpm
Filter Full-flow, disposable canister

type with anti-flow back valve)
Pump - type Eccentric rotor
- Drive Toothed belt
- Rotor /annulus tip clearance 0.05 - 0.15 mm (0.002 - 0.006 in)
- Annulus end float 0.03 - 0.08 mm (0.001 - 0.003 in)
- Rotor end float - 0.09
,- a - Annulus to housing clearance
0.06
0.18 - 0.30
mm (0.0025
mm (0.007 -
- 0.0035
0.012 in)
in)
APR 1987 Dipstick tube standout from M. B P ..

Dellorto Carburettors
E l i t e1 E l i t e1 Ekcel HC Excel HC. Esprit

E c l a t )m. E c l a t )auto m u a l auto S3 HC
Excel Std. Esp.S3 S t d
spec 1 spec 3 Spec 9 Spec 9 spec 1 0 spec 1 0 spec 1 0
C a r b u r e t t o r Type ( 2 off 1 DHLA 45E DHLA 45E DHLA 45E DHLA 45E DHLA 45D DHlA45D
-US P ~ N O . (Frmtj, D907EO789W E907E0789F A912E0789F A912E094OJ A912E9207F A912E2336F
(Rear) D9O 7EO 790W E90 7E0790W A912EO790F A912E094LJ A9l2E92O8F A912E2337F
Tag No. ~ F r m1t - 5295A 5324A . . 5324A 5382 5395A
(Rear)' - 5294P 5323P 5324P 5381P 5394P
P a i n t S p a t on 'Dellorto' - Green BluekBlack Blue Black Black
Chake 35 mn 36 m 37 mn 37 m 37 mn 37 mn
Main Jet 130 160 160 160 135 135
Main A i r C o r r e c t o r Jet 110 230 230 230 150 150
Main Rnulsion Tube 7772-5 7772-8 7772-8 7772-8 7772-8 7772-8
Idle Jet 56 50 58 55 55 56
Idle Jet Holder 7850-6 7850-7 7850-9 7850-9 7850-9 7850-9
F l o a t Weight log log 8.5g 8.5g 8.5g 8.5g
F l o a t Setting Height (mi) 16.5-17.0 16.i5-17.0 14 .5-15 .O 14.5-15 .O 14.5-15 .O 14.5-15 .O
F l o a t Needle Valve 170 170 170 170 170 170
Pump Jet 45 38V 42H 50H 50H 45H 45H
S t a r t e r Jet .: 70 70 95 95 9 5 ( R / ~80) 80
S t a r t e r 'Emulsion Tube 7482-1 7482-1 7482-3 7482-3 7482-3 7482-3
P a e r Jet - - - - 70 70
S l a ~ m n i n gSpeed (rpn) 900-1000 900-1000 850-950 850-950 900-1000 900-1000
Idle03Level ( h o t ) 2.0-3.0% 2 -0-3.0% 0.7-1.5% 0.7-1.5% 0.5-1.5% 0.5-1.58
fdlaas/I
Page 73
Zenith Carburetton
Type and number Zenith 175/CD SE (two)
Needle BIDK
Spring Colour Blue
Damper O i l SAE 20W/50
Letus part number - Spec 2 front B907E0791W
rear B907E0792W
- Spec 4,6,7,8 front C907E0791F*
rear C907E0792F*
* Red paint spot on air valve housing. These carbs are'to the same
;a specification as the B pref-ix cork, except for the inclusion of internal/

external flaat vent valves.
Fast idle setting (engine warm)

- Spec 2 . -
2.16 2.41 rnm. (0.085 - 0.095 in.)
between starter cam and screw
head i n 'off' pasition
- Spec 4,6,7,8 1 .27 mm. (0.050 in.)
Sl ow running speed 950 - 1000 rpm
Idle CO level (normal running tempemture)

- Spec 2 (without air injection) 2.5 - 4.0 % CO
- Spec 4, 6 This must be checked with the air injection
disconnected and a reading taken via a
sample pipe before the catalyst. To
disconnect the air injection remove the air
outlet hose (between outlet and non-return
valve) from the air pump, and blank off
the hose. Adaptor and sample pipe -
Part NO.TOOOT0321A. Blanking plug
-
(for air hose) Part No. TOOOT0322A
-
Setting 3.5 4.5% CO
- Spec 7 with air pump (and no catalyst)
-
Tailpipe idle check less than 1 .O%
C.O. with air en, 2.0 - 3.5% C.O.
with air off.
- Spec 7 With pulse air injection system
Upstream of catalyst 0.2 -
1 .O%.C.O.
SECTION TD A Page 74
IGNITION SYSTEM
TYpe - 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 ' Lumenition' system.
- Spec 9 (Esprit 1983 on Coil and distributor with Lucas
and Excel only) Constant Energy System
Number. 1 cyl inder . Toward front

Ignition advance control Fully automatic
Sparking plugs:
- spec 1,3,5
With Lucas ignition leads NGK BP6ES
- spec 2,4,6,7 NGK BP5ES
With NGK ignition leads - spec 1,3,5,9 NGK BPR6ES
-spec 2,4,6,7,8 NGK BPR5ES
- spec 10 NGK BPR7ES
Spark plug gap - with contact breaker 0.6 mm. (0.023 in.)
- with high energy ignition 0.9 rnm. (0.035 in.)
DISTFSBVPOR & IGNITIaJ TIMING ( A l l figures + 2")
C e n t r i f u g a l Advance
Characteristics
(vacuum disconnected
B e l w 1,000
2,000
3,000
nil
8" I
28" BTDC @
3.500 - 4.000 run
16" ( & c u m disconn;?cted)
Spec 2 25D 8O 8' 0" as Spec 1 24" BTDC @
( 41584 ) Retard 3,500 - 4,000 rpn
I (vacuum d i s c o n n e c t e d )
Spec 3 25D blanked 16" 16' as Spec 1 ( 3 2 - 34" BTDC @
(41584 ) off
Spec 4 , 6 25D 8" 8' 0"

( 41634A) Retard 2,000
45D 4,000 (vacuum d i s c o n n e c t e d )
( 41626 ) 5,000
Spec 5 23D4 ar 43D - 9" -

( 41623 1
Spec 7,8 45D (41626) 8" 10" .2" Spec 4,6
with Retard
Livnenition (vacuum disconnected)
- -
'
I I I I
spec 9 43D with :go .,

Lumenition 3,500 - 4,000
Ehergy Iqn.
Spec 1 0 45D (41946 1 w 10" lo0
Ccostant Advance (hot 950 2 50 rpn
APR ,1987
SECTION TD A 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
60° 2 3' changed during 1978 to
&$O -+ 30
52O 2 4' changed during 1978 to
60°? 3' -
Firing angles oO, 90°, 180°, 270o, -+ 1o

Capacitor value 0.1 8 - 0.23 Microfarad
Cool ing System

TYpe Centrifugal pump and electric fan
2 2 2 2
Header tank cap relief valve pressure 0.7kg/crn (IOIb/in ) o r 1 .lkg/cm (15lb/in )
Thermos tat - (Temperate climates) 82'~
- (High ambient temperatures) 74Oc
lmpellor vanes to water pump housing 907 : 0.50 - 0.75 mm (0.020 - 0.030 in)
clearance 912 : 0.25 - 0.40 rnm (0.010 - 0.016 in)
Cooling system anti-freeze/inhibitor 'Shell Safe'or Union Carbide 'UT 184'
(year round) minimum 25% maximum 60%
:a
APR 1987
Page 7.6
TURQUE LOADING FIGURES
ENGINE
Cylinder head (tighten cold)

-
SECTION T D A
kgf .m -
Ibf .ft
.
"
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 puli ey
Connecting rod (big end) caps (oiled thread)
Fixed Flywheel - 907/912
Flexplate flywheel (inc. auto flexplate)
Clutch assembly
Torque convertor to flexplate
O i l sump to main bearing housing - 907
O i l sump to main bearing housing - 912
Auxil iary housing to cyl inder block
.Auxiliary shaft sprocket
O i l pick-up pipe union
Retaining nut (be1t tensioner)
A l l other 6mm nuts or setscrews
Stud - -
Cylinder head to cylinder block 12mm
- Main bearing housing - 8mm
- Camshaft housing to cylinder head 8mm -
-- -
Sump to main bearing housing 6mm
- A l l other non-specified 8mm studs
Exhaust manifold to cylinder head
Inlet maniflod to cylinder head
Banjo bolt (fuel line to carburetton)
Purge pump thermal switch
APR 1987
. . SECTION TD A Page 73
Zenith Carburettors
Type and number Zenith 175/CD SE (two)
Need1 e BIDK
Spring Col our Blue
Damper O i l SAE 20W/50
Letus part nurilber - Spec 2 front B907EO791W
rear B907E0792W
- Spec 4,6,7,8 front C907E0791F*
rear C907E0792F"
* Red paint spot on air valve housing. These carbs are to the same
specification as the 0 prefix carbs, except for the inclusion of internal/
external flout vent valves.
Fast idle setting (engine warm)

- Spec 2 2 . l 6 - 2.41 mm. (0.085 - 0.095 in.)
between starter cam and screw
head in 'off' pssi tion
- Spec 4,6,7,8 1 .27 mm. (0.050 in.)
Slow running speed 950 - 1000 rpm
Idle CO level (normal running temperature)
- Spec 2 (withour air injection) 2.5 - 4.0 % CO
- Spec 4, 6 This must be checked with the air injection
disconnected and a reading taken via a
sample pipe before the catalyst. To
disconnect the air injection remove the air
outlet hose (between outlet and non-return
valve) from the air pump, and blank off
the hose. Adaptor and sample pipe -
Part No. TOOOT0321A. Blanking plug
-
(for a ir hose) Part No. TOOOT0322A
-
Setting 3.5 4.5% CO
- Spec 7 with air pump (and no catalyst)
-
Tailpipe idle check less than 1.0%
C.O. with air on, 2.0 - 3.5% C.O.
with air off.
- Spec 7 With pulse air injection system
Upstream of catalyst 0.2 -1 .Ph C.O.
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

lgnitian advance control Fully automa tic
Sparking plugs:
With Lucas ignition leads - spec 1,3,5 NGK BP6ES
- spec 2,4,6,7 NGK BP5ES
With NGK ignition leads - spec 1,3,5,9 N G K BPR6ES
-spec2,4,6,7,8 NGKBPRSES
- spec 10 NGK BPR7ES
Spark plug gap - with contact breaker 0.6 mm. (0.023 in.)
- with high energy ignition 0.9 mm. (0.035 in.)
DISTRIBUTOR & IGNITICN TIMING ( A l l f i g u r e s + 2")

Idle Centrifugal Fdvance
Static Speed Characteristics
Vacuum Ignition Ignition ( vacuum dis m e c t e d )
Distributor
WP
CaPsae
(crank0
Timing
m
Timing
BTCC crank rpn
crank0 I g n i t i o n Timing
- 2" t o be s e t a t
+ I
8" 12" 40 I elm ~ , O O O nil
Retard
8" 8"
Retard
blanked 16O 16" as Spec 1
off
8" 8' Below 1,000

Retard 2,000 3,000 rpn
( vacum disconnected
5,000
I 26"
w
Spec 5 1 23D4 or 4313 - 9" as Spec 1
1 (41623)
Spec 7,8 145D (41626) 8O lo0 as Spec 4,6
Retard 3,000 rpn
(vacumdisconnected)
Spec 9 43D with - 9"
&\wkb ,-,
Lmition
22" 10
Advance
Page 75
Distributor
-

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 60° f 3' changed during 1978 to
6d0 2 3O
- 45D, 43D 52O f 4O changed during 1978 to
0 60° f 3'
o + o
Firing angles oO, 90°, 180°, 270 ,- 1
Capacitor value 0.18 - 0.23 Microfarad
Cool ing System

TYpe Centrifugal pump and electric fan
2 2 2 2
Header tank cap relief valve pressure 0.7kg/cm (lOlb/in ) or 1 .lkg/cm (15ib/in )
Thermostat - (Temperate climates) 82'~
- (High ambient tempemtures) 74Oc
lmpellor vanes to water pump housing 907 : 0.50 - 0.75 mrn (0.020- 0.030 i n )
clearance 912 : 0.25 - 0.40 rnm (0.010 - 0.016 i n )
-0 Cooling system anti-freeze/inhibitor

round)
'Shell Safe'or Union Carbide 'UT 184'
minimum 25% maximum 60%
0
APR 1987
TORQUE LOADING FIGURES
ENGINE kgf .m -
Ibf .ft
both pairs (front and rear) nuts (oiled thread)

3 pain (in middle) nuts (oiled threads)
Sparking plugs
Camshaft covers
Camshaft hous ing
Cams haft sprockets
Main bearing housing - 907 - 12mm

(oiled threads) - 912 - 12mm
- 907/912 - 8mm
(
Crankshaft pulley
(
Connecting rod (big end) ccos (oiled thread)
Fixed Flywheel - 907/912

F!explate flywheel (inc . auto flexplate)
Clutch assembly
Torque convertor to flexplate

O i l sump t o main bearing housing - 907
O i l sump t o main bearing housing - 912
Auxiliary housing to cylinder block
Auxii iary shaft sprocket
O i l pick-up pipe union
Retaining nut (bet t tensioner)
A l l other 6mm nuts or setscrews

Stud - Cylinder head to cylinder block - 12mm
- M a i n bearing hovs ing - 12mm
- Camshaft homing to cylinder head - 8mm
- Sump to main bearing housing - 6mm
- A l l other non-specified 8mm studs
Exhaust manifold to cylinder head
Inlet maniflod to cylinder head
Banjo bolt (fuel line to carburettors)
Purge pump thermal switch
APR 1987
. Page 7
TECHNICAL DATA
SECTION TD B - ENGINE TYPE 910
i. -
Page
Engine Number 2
Engine Specification
Cyl inder Head
Camshafts & Valve Timing
Valve Gear
..
Avxil iory Shaft
Cranks haft
M a i n Bearing Configuration
Flywheel
Gnnecting Rod
Gudgeon Pin
Piston & Liner
~ubrlca
tion System
Del lorto Carburettor
Ignition System
~ e r c p eSettings
DEC 1986
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 i s 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
wheelarch under the front bonnet.
Example
Market
A = Japan
C = Europe
F = Swedey'AustraI ia/Swi tzerland
H = Canada/49 States N. America
J = California
L = 50-States N. America
C = Standard
D = Air Conditioning
A = High Compression
P = High Compression / Air Conditioning
Wet Sump Introduction
From 1980 until late 1 981/early 1982, a11 Turbo Esprit engines (type 91 0) were built with
a 'dry sump' lubrication system. Cars not fitted with air conditioning were changed to
a 'wet sump' configuration i n late 1981, followed by air conditioned can i n early 1982.
Wet sump introductory VIN's are as follows:
Domestic heater 82 D l 193

Domestic air conditioning 82Dl261
ROW (air conditioning) 82 A/E/G/H/S 0399
A l l Federal cars are wet sump.
IEC 1986
SECTION TD B Page 3
.j
ENGINE
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
- H.C.
. J 2
Compression pressure - Std. 8.8 bar (130 Ib/in ) minimum
2
- H.C. 9.5 bar (140 Ib/in ) minimum
2
Maximum boost pressure - Std. 0.55 bar (8.0 Ib/in )
2
- H.C. 0.65 bar (9.5 lb/in )
Engine number location On top rear of cylinder block near
starter mounting
Engine belt tensions - Toothed timing belt, using Burroughs gauge part number
TOOOG0025J, 90 - 95 units cold (60°~/200c) See Section W .9.
( - Alternator 'V' belt 12 mm (0.5 in.) (4in.)
Total movement ( -
Compressor 'V' belt )
using moderate (
finger pressure ( A/C )
- Vacuum Pump 'V' belt ) 9 rnm (0.35 in.) (3/8 i n .)
on longest (
be1t run. ( - A i r Pump 'V' belt )
1
(
CYLINDER HEAD
Material A1umi nium a1loy

Gasket Steel/asbestos
Combustion chamber depth (nos. 1 & 4) 12.19 - 12.57 mm (0.485 - 0.500 in.)
.!
DEC 1986
Page 4 SECTION TD B *!
CAMSHAFTS AND VALVE TIMING
Identif. Duration Inlet Exhaust

Cam Type on shank (crank M.O.P. Cam M.0.P Cam
Designation between degrees 1 ATDC* Pulley BTDC* Pulley
pulley & Timing Timing
Spec.No. cam hsg . ' Lift Dot Dot
Domestic 107 777.. .. 252O 0.378" 104O green 104O green

& Export
USA 107 777.... 252O 0.378" 110' red 104" green

1 (Carb)
I
I
I
USA
(HCI)
107 777 .... 252' 0.378" 110' red 100" blue
FDIAAC/~
* All cams are symmetrical opening/closing
VALVES
Angle of valve seats and faces 45O

Head diameter - lnlet 35.47 - 35.65 mm (1 .396 - 1 .404 in.)
- Exhaust 30.70 - 30.90 mm (1.209 - 1.217 in.)
Stem diameter - lnlet 7.125 - 7.137mm (0.2805 - 0.2810 in.)
- Exhaust 7.955 - 7.970 mm (0.31 32 - 0.31 38 in.)
Stem clearance in guide - lnlet 0.008 - 0.046 mm (0.0003- 0.001 8 in.)
- Exhaust 0.030 - 0.070 mm (0.001 2 - 0.0027 in.)
Valve clearance (cold) - lnlet 0.13 - 0.18 mm (0.005 - 0.007 in.)
- Exhaust 0.25 - 0.31 mm (0.010 - 0.012 in.)
'Valve Seat 1nserts

Bore i n head:
Standard - Inlet .
37.235/37.260 mm (1.466/1 .467 i n .)
- Exhaust 34.290/34.315 mm. (1.350/1 .351 in.)
+0.025 mm (0.001 in) - Inlet 37.260/37.285 .
mm (1.467/1 .468 i n .)
- Exhaust 34.315/34.340 mm. (1.351/1 .352 in.)
+ 0.050 mm (0.002 in) - Inlet 37.285/37.315 mm. (1.468/1 .469 i n .)
- Exhaust 34.340/34.365 mm. (1 .352/1 .353 in.)
+ 0,127 mm (0.005 in) - Inlet 37.365/37.390 mm. (1.471/1 .472 in.)
0:
- Exhaust .
34.41 5/34.440 mm (1.355/1 -356i n .)
DEC 1986
SECTION TD B Page 5
Outside diameter of seat
Standard - Inlet 37.325/37,350 mm. (1.4695/1 .4705 in .)

- Exhaust 34.380/34.405 .
mm (1 .3535/1 .35& in .)
+ 0.025 mm (0.001 in) - lnlet 37.350/37.375 mm. (1 .4705/1 .4715 in.)
- Exhaust .
34.405/34,430 mm (1 .I345/i .3555 i n .)
+ 0.050 mm (0.002 in) - lnlet .
37.375/37.400 mm (1.471 5/1 .4725 in .)
- Exhaust 34.430/34.455 .
mm (1.3555/1 .3565 i n .)
+ O.12i'mm (0.005 in) - lnlet 37.450/37.475 mm ..(1 .4745/l ,4755 in .)
- Exhaust 34.505/34.530 mm. (1 .3585/1 .3595 in .)
ia Valve Springs
Dual
I
Inner
F r e e Length
I Outer Inner
Rate
I Outer
I
1
1 42.2 mm
(1.66 i n . ) ( 4 8 . 5 mm
(1.91 i n . )
Valve Guides
0 Length - lnlet and Exhaust 53.34 mm. (2.100 in.)

Internal diameter (to ream after fitting) - Inlet 7.145 - 7.1 70 mm. (0.281 3 - 0.2823 i n .)
- Exhaust8.000 -8.025 mm. (0.3150 - 0.3159 in.)
Bore i n head - lnlet and Exhaust
Standard 11.915 - 11.925 mm. (0.4690 - 0.4695 in.)
+0.025 mm. (0.001 in.) 11.940 - 11.950 mm . (0.4700 - 0,4705 in. )
+ 0.050 mm. (0.002 in.) 11 ,965 - 11 .975 mm. (0.4710- 0.4715 in.)
i.
+ 0.127 rnm. (0.005 in.) 12.040 - 12.050mm. (0 A740 - 0.4745 in.)
Outside diameter of guide
Sta ndard 11.940 - 11.950 mm. (0.4700 - 0.4705 in.)
+O.025 mm. (0.001 in.) 11 ,965 - 11.975 mm. (0.4710 - 0,4715 in.)
+ 0.050 mm. (0.002 in.) 11 .W0 - 12.000 mm. (0.4720 - 0.4725 in.)
+ 0.127 mm, (0.005 in.) 12.065 - 12.080 mm. (0.4750 - 0.4755 in.!
'I DEC "186

Page 6 SECTION TD 5
Camshafts
0-1
End float - Dimension 0.03 - 0.20 mm. (0.001'- 0.008 in.)
- Controlled by Sel ec tive thrust washers
Running clearance (except front) 0.050 - 0.090 mm (0.0020 - 0.0035 in.)
(front only) - 0.115 mm (0.0030 - 0.0040 in.)
0.075
Cam Followers
Bore i n camshaft housings 34.925 - 34.940 mm . (1 ,3750 - 1.3756 in ;)
Outside diameter 34.904 - 34.912 rnm. (1 ,3742 - 1.3745 in.)
AUXILIARY SHAFT
Running Clearance 0.025 -0.065 mm. (0.0009 - 0.0025 in.)
End Float 0.013 - 0.038 mm. (0.0005 - 0.0015 in.)
;
CRANKSHAFT
Balance (inc. f l y h e e l and clutch) Within 15 gr .cm. (0.2 oz .in.)

Diameter - Main journal (No .l .to 4 inc .) - 63.51 3 mm.
63 .LC87 (2.4995 - 2.5005 in.)
- Main journal (No. 5 only) 63.500 - 63.51 3 mm. (2.5000 - 2.5005 i n .)
- Crankpin 50.736 - 50.762 rnm. (1,9975 - 1.9985 in .)
End float - Dimension 0.08 - 0.20 mm. (0.003 - 0.008 in.)
- Controlled by Selective thrust washers on rear main bearing
Bearings (ma in) - Number 5
- Type Steel backed, leaded bronze
- Static clearance* 0.013 - 0.056 mm. (0.0005 - 0.0022 in.)
0
Mac i undenize for regrind 0 .SO8 mm. (0.0200 in .)
* Bearing clearance i s measured with Plastigage.
MAIN BEARING CONFIGURATION -
I TYPE I 1 1 1 2 1 3
I Upper
910 IurboHole /
Groove/
I 1 Groove/
Hole I Plain/
Hole
I Dflet Sump I Lower I Plain I Plain I Plain

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
Distance between centres
1
.
139.70 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. (0.0010 - 0.0032 in.)
- End float on crankpin 0.10 - 0.25 mm. (0.004 - 0.010 in.)
Small end bore (bushed) 25.405/25.410 mm. (1.0002 - 1.0004 in.)
Permissable weight variation between rods 2 grammes (in any set)
* Bearing clearance i s measured with Plastigage
GUDGEON PIN
Type Fully floating

Location Circl ips
Diameter 25.40 mm. (1.00 in.)
Class of fit Finger push f i t at20°c (68'~)
PISTON AND LINER
-
Piston Type Sol id skirt
- Material Aluminium alloy
- Rings 2 compression, 1 oil control
- Diameter 91 0 Std - grade 'A' 95 .148/95.161 mm (3.7460/3 .7465 in)
910 Std - gmde '8' 95 .16 l/95.l74 mm (3.7465/3 .747O in)

- grade 'A'
910 HC 95.205/95.219 mm (3.7482/3.7488 in)
91 0 HC - gmde 'B' 95.21 7/95.231 mm (3.7487/3.7493 in)
- Grade diameter - 910 Std 15 mm (0.6 in) up from skirt edge
- 910 HC 10.2mm (0.4 in) up from skirt edge pin axis 1
- Gudgeon pln bore offset - 910 Std 1.52 mm (0.060 in) towards thrust face
- 910 HC Zero
DEC 1986 - Permtssable weight variation

between plstom 3 grammes
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
910 Std. -
Compression 0,038/0.089 mm (0.001 5/0.0035 in)
-
O i l control 0 .O38/O .064 mm (0.001 5/0.0025 in)
91 0 HC -
Compression O,O40/O .O72 mm (0.001 6/0.0028 in)
-
O i l control 0.020/0.052 mm (O.OOO8/O .0020 f n)
Cyl inder Li ner TY pe- Wet, slip f i t
- Material - 910 Std. Cast Iron
- Internal diameter
Nikosil coated, forged aluminium alloy
.a
- 91 0 Std. Measured 50mm from top across thrust axis
Gmde 'A' 95.275/95.288 mm (3.751 0/3.7515 in)
Grade '0' 95.288/95.308 mm (3.751 5/3.7520 in)
- 910 HC Measured 70mm from top across thws t axis
Grade 'A' 95.255/95 -269 mm (3.7502/3.7507 in)
Grade '8' 95.267/95.281 mm (3.7507/3 .El2 in)
- Fitted height above block - 91 0 Std. 0.025/0.13 mm (0.001/0.005 in)
('nip')
- 910 HC minus 0.025 to + O.05Omm
(minus 0.001 to -t 0.002 in)
- Perrnissable variation between liners 0.03 mm (0.001 in)
- Piston clearance i n cylinder liner 91 0 Std . 0.1 1/0.15 rnm (0.005/0.006 in)
910 HC 0.048/O.O76 mm (O.OM/O.O03 in)
LUBRICATION SYSTEM
Minimum o i l pressure under normal working conditiom (hot);
Wet Sump Dry Sump
2
- at idle speed Slb/in2(0.35kg/cm2) 5lb/in2(0.35kg/cm)
.. .
- at 3,500 rpm
- at 6,500 rpm
Filter Full flow disposable canister type
with anti-flow back valve
Dry Sump
Pump - VPe Eccentric rot~r,.:2.scavenge & 1 pressure
pvmp i n common unit driven by toothed be1t
Wet Sump
.Pump
-
t y Pe
rotor/annulus tip clearance
Eccentric rotor. Drtven by cam be1t
0.05/0.15 mm (0.002/0.006 in) a.
- annulus end float 0.03/0.08 mm (0.001/0.003 in)
- rotor end float 0.06/0 .O9 mm (0 ,.OO??/Ot 0035 in),
- annulus to housing clearance 0.18/0.30 mm (Q1007/0..012
.. in) " :
DEC 1986
Page 9
DELLORTO CARBURETTORS DomesticJ ~omestic/ I USA

Export 'Stdl Export 'HC'
Carburettor Type ( 2 off) DHLA 4 0 ~ DHLA 45M DHLA 45M

Tag No. - Front 5322A 5390A
- Rear 5321P 5389P
Lotus Part No. - Front B910E0926F A91OE6855F A910E6633
- Rear B910E0925F , A91OE6856F A910E6632
Choke 36 mm 35 mm 37 mrn
Main Jet 185 160, 165
Main Air Corrector Jet 200 180 230
Main Emulsion Tube 7772-12 7772-14 7772-13
Idle Jet 40 58 .52
Idle Jet Holder 7850-7 7850-9 7850-9
Float Weight 8.5g 8.5g 8.5g
Float Setting Height 14.5-15.Omm 14.5-15.Omm 14.5-15 .Omm
Needle Valve 200 200 200
Pump Jet 48H (special) 35 38H
Starter Jet 80 80 80
Starter Emulsion Tube 7482-3 7482-3 7482-3
Slow Running Speed 850 rpm 850-950 rpm 950 rpm
Idle CO Level (hot) 1.0 + 0.5 % 1.0 + 0.5 % 0.8 %
Pump Delivery 7cc/T0 stks. 8cc/?0 stks. 8cc/20 stks.
Power Jet - Blank 110
Fuel Delivery Pressure + 0.5 psi
4.0 - 4.0 -+ 0.5 psi 4.0 - 4.5 psi
(at idle speed)
I G N I T I O N SYSTEM
Type - Domestic/ROW 1980 - early 1983 Coil anddistributor with infra-red solid ;
state 'Lumenition' system I

I
- 1983 on +- Federal Coil anddistributor with Lucas 'Constant r

Energy' ignition system
Number 1 cylinder Toward front
Sparking Plugs - ~omestic/RoW (Std .) N G K BPR 6ES

- Federal & 'HC' NGK BPR 6EY
Spark Plug ~ a p 0.9 mm (0.035 in.)
Distributor

Drive Offset dog
Page 70 SECTION TD B ..-...
DISTRIBUTOR & IGNITION TIMING ( all f i g u r e s + 2"
Distributor Vacuum S t a t i c Idle C e n t r i f u g a l Advance I g n i t i o n

TVpe Capsule Ign. Speed C h a r a c t e r i s t i c s Timing
Timing Ign. t o be
crank0 Timing set a t
Dan/ 43D B e l w 1,000 nil

Export Lumenit i o n 2,000 8
'
Prior or Lucas 3,000 16"
'87 MY Constant
En=%'
LEA 45m4 1 8O 1" 1" B e l w 1,000 nil Idle

Prior Lucas pdvance BTDC BTDC 1,500 3O (950rpn)
'86 MY Constant 2,100 12"
(Carb) E ~ e w Y 2,800 15"
5,000 16"
LEA 45m4 28O 15O 15" 2,500 minus 3" Idle

'86 MY Lucas Advance BTDC BTDC 5,000 minus 6" (900 -
onward Constant 1ooorpn
(HCI Ener9-Y
m/ 45DM4 28" Belm 1,000 n i l Hot Idle

Export Lucas Advance 2,000 11" (850 -
'87 MY Constant 5,000 8" 950 rpn)
onward Energy
(fdla4
DEC 1986
SECTION TD B Page 1 1
TORQUE LOADING FIGURES
ENGINE kgf .m -
Ibf .ft

both pain (front and rear) nuts 9 07
3 pairs (in middle) nuts 10.4
Sparking plugs 2.5
Camshaft covers 0.40-0.55
Cams haft housings 1 .9-2.2
Camshaft sprockets 3 *5
Main bearing housing - 12 mm (Dry Sump) 10.4
Main bearing housing - 12 mm (Wet Sump) 9 .O
- 8 mm 1 .9-2.2
Gankhaft pulley 8.0-8.3
Connecting rod (big end) caps 11 .6-11 .9
Flywheel 7.6
Clutch Assembly 2.3-2.6
Oil sump to main bearing housing (all) 2.2-2.5
Auxiliary housing to cylinder block 1 .8-2.1
Auxiliary shaft sprocket 3.5
Oil pick-up pipe union 7.6
Retaining nut (be1t tensioner) 3.5-4.2
A l l other 6 mrn nuts or setscrews 1 .o-1 .1
Stud - Cylinder head to cylinder block - 12 mm 5.5
- Main bearing housing - 8 mm 1.7
- Main bearing housing - 12 mm 5.5
- Camhaft housing to tylinder head - 8 mrn 1.7
- Sump to main bearing housing 0.7
- Was tegate to adaptor (1 Omm) 4.8
A l l other non-specified 8mm studs 1 .7
Exhaust manifold to cylinder head 1 .9-2.2
Wastegate to adaptor 4.8
Inlet manifold to cylinder head 1.9-2.2
Engine mounting legs to rubbers 5.5-6.2

Mounting rubbers to chassis 3.5
DEC 1986
SECTION' TD D Page 1
TECHNICAL DATA
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 SECTION TD D
DIMENSIONS
Overall Length (Series 3) 4225 mm (166.3 in.)

(Turbo) 4290 mm (169 in. )
G e 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.CompomotiveWheels) 1536 mm (60.5in.)
(15 in. BBS Wheels) 1524 mm (60.0 in.)
Rear Track 1554 mm ( 6 1 .2 in.)
Ground Clearance, Federal Spec. 146 mm ( 5.8in.)approx.
Below rod. duct with
driver only
-
Turning Circle (between kerbs) 10.6 m (34 f t 9 in) --+\--
Kerb Weight (Series 3 prior to '85 MY) 1 100 kg (2425 Ib
(with a / ~ ) (Series 3 '85 MY on) 11 30 kg (2492 Ib)
&+ybb
FE\%
(Turbo Dom/Exp prior '85 MY)
(Turbo Dom/Exp '85 MY on)
(Turbo USA)
*
,
1200 kg (2645 Ib)
1225 kg (2701 lb)
1226 kg (2703 Ib)
p;ot&wLp ~ r
@- 308
,
Gross Weight (Series 3) 1340 kg (2955 Ib)

(Turbo Dom/Exp prior to '85 MY) 1389 k g (3063 Ib)
(Turbo Dom/Exp '85 MY on) 1452 kg (3202 Ib)
(Turbo USA) 1453 kg (3200 Ib)
1 crlc *w
CAPACITIES
E x c e ~ Drv
t sum^ Turbo
Engine (inc. fllter) - Dry 6.51itre(11.41mp.pt.13.7U.S.pt.)

- Refill 5.4 litre ( 9.4 imp. pt. 11 .4 U.S. pt,)
Difference between high and low 0.85 litre (1.5 imp. pt. 1 -8 U .S. pt ,)
dipstick marks
Dry Sump Turbo
Engine (inc. filter) - Dry

- Refill
6.5 litre (11 .4 imp. pt. 13.7 U.S. pt.)
5.0 litre ( 8.8 imp. pt. 10.6 U.S, pt,)
Difference between high and low 1.Olitre ( 1 . 8 imp. pt. 2.1 U.S. pt.)
dipstick marks
Transmission 2.25 litre (4.8 U.S. pt.)

Coaling System - Series 3 10.8 litre (19 imp. pt. 22.8 U.S. pt.)
- Turbo 121itre (21 imp.pt..25 U.S.pt.)
Fuel System - Series 3 67 litre (14.8 imp. gall. 17.7 U.S. gal\.,
- Turbo 86 litre (18.9 imp. gall. 22.7 U.S. gall.)
DEC 1986
SECTION TD D Page 3
a SUSPENSION
Front (Prior to '85 M.Y .);
Upper w i s h b o n e a n d l o w e r t r a n s v e r s e l i n k w i t h a n t i - r o l l .
Co-axial c o i l s p r i n g and t e l e s c o p i c damper,
C h a s s i s h e i g h t below c h a s s i s - f r o n t crossmember 170 mm

f o r checking suspension geometry.
Camber 0' 30' negative ' 0' 15'
Castor 3' 2 0' 3 0 ' ( w i t h i n 0' 30' s i d e

to side)
Toe . - i n 2mm o v e r a l l
+- Imm
S t e e r i n g A x i s I n c l i n a t i o n ( K .P .I. ) 9' nominal
- -
a F r o n t Hub E n d f l o a t
Front ('85 M.Y. on);

0.08 0 . 1 3 mm ( 0 . 0 0 3 0,005 i n , )
Upper and l o w e r w i s h b o n e s . Co-axial c o i l s p r i n g and t e l e s c o p i c

damper.
Anti-roll bar.
C h a s s i s h e i g h t below c h a s s i s f r o n t crossmember 170 mm

f o r checkLng s u s p e n s i o n geometry
Camber 0' 30' negative f 0' 30'
Castor min l o 45; max 3'

(within 0 30' s i d e t o s i d e )
Toe i n 1.6mm e a c h s i d e , + 0 - 1 mm
S t e e r i n g A x i s I n c l i n a t i o n ( K .P . I . ) 9' 23' nominal
F r o n t Hub E n d f l o a t 0.05mm ( 0 . 0 0 2 i n . ) maximum

Rear: U p p e r a n d l o w e r t r a n s v e r s e l i n k w i t h box s e c t i o n t r a i l i n g
r a d i u s arm.
C o - a x i a l c o i l s p r i n g and damper
C h a s s i s h e i g h t below r e a r l o w e r l i n k c h a s s i s 1 7 0 mm
b r a c k e t s f o r checking geometry
Camber 0' 30' negative 0' 15'
Toe i n 1.5mm e a c h s i d e -
+ 0 . 5 mm
STEERING
Manual r a c k a n d . p i n i o n w i t h e n e r g y
absorbing collapsible steering
column
Turns, lock t o lock
DEC 5986
Page 4 SECTION TD D
a
CLUTCH
Single dry plate,

Diaphragm spring
Release mechanism Hydraul ic
Master cylinder bore diameter (not LHD S3) 15.88 mm (0.625 in.)
LHD S3 17.78 mm (0.700 in.)
S l ave cylinder bore diameter 22.23 mm (0.875 in.)
-
Friction plate diameter S3 - 216 mm (8.5 in.)
-
Turbo 241 mm (9.5 i n .)
-
Number of springs. 6
-
Free Play at release lever S3 (prior to '85) 3 mm (0.12 in.)
-
S3 ('85 on) & Turbo Self adjusting slave cylinder
Manual. 5 forward gears (all

syncromesh) and reverse
Gear l nternal Speed i n mph ( k ~I) per 1000 rpm
Ratio 14 i n wheels 15 i n wheels
Fifth
Fourth
Third
Second
First
Reverse
Final Drive
Speedometer gears - Driving gear 5 teeth

- Driven gear 17 teeth
COOLING SYSTEM
-- ~ - ~ -
Type Centrifugal water pump. Electric

cooling fam with ther?lal switch.
Header Tank Cap Relief Valve Pressure 2 2
, 0.7 kg/cm2 (1 0 Ib/i n2)
or 1 .lk -.d c m (15 Ib/in )
Thermostat nominal opening temperature 7 4 ' ~S3 hot climate7
8 2 ' ~ S3 temperate climates and Turbo
- -
Impellor Vanes to water pump
houring clearance
Cooling system anti-freeze/corrosion inhibitor
0.25 0.40'mm (0.01 0 0 .016 in.)
:a
Minimum 25% strength.
Up to 60% in cold climates.
D EC 1986
SECTION TD D Page 5
BRAKES
a Type Disc f r o n t , i n b o a r d d i s c r e a r , s e r v o a s s i s t e d
dual hydraulic c i r c u i t .
-I
B r a k e Discs Up t o ,I84 m o d e l y e a r ' 8 5 model y e a r

Solid Solid Ventilated Solid
Front Rear Front Rear
Diameter 265mm 275mm 258mm 275mm

. (10.4 i n ) (10.8 i n ) (10.2 i n ) (10.8 i n )
Thickness, 12.7mm 10.0mm 20.0mm 12.0mm

nomina 1 (0.50 i n ) (0..39 i n ) (0.79 i n ) (0.47 i n )
Thickness, 11.4mm 9.0mm 19.0mm 1l.Omm

minimum (0.45 i n ) (0.35 i n ) (0.75 i n ) (0.43 i n )
Run-out,
maximum I 0.09mm
0.0035 i n ) I 0( -00. 90 m I
0 3m5 i n ) (0.006)
..
1 0.2mm
(0.008 i n )
Handbrake - Mechanical o p e r a t i o n o f r e a r pads. Self adjusting
WHEELS & TYRES
S e r i e s 3 w i t h 14" wheels
Wheels - -I ype Light alloy Speedline

- Size - front 7JKx14
- rear 7.5 JK x 14
Tyres - Type Goodyear 'NCT' or 'Eagle NCT'
- Size - front 205/60 VR14
- rear 205/70 VR14
- spare (if fitted) 185/70 HRl?
- Pressure - front 2
1 .40 kg/cm2 (1 .35 bar, 20 lb/in2)
- rear 1.90 kg/cm2 (1.85 bar, 27 lb/in2)
- spare 2.10 kg/cm (2.05 bar, 30 Ib/in )
S e r i e s 3 w i t h 15" w h e e l s , and Turbo
Wheels - Type - early Turbo 3-piece, Iight alloy Cornpamotive

- a I i others Light alloy BBS
- Size - front 7Jx15
- rear 8Jx15
Tyres - Type Goodyear 'NCT' or 'Eagle NCT'
- Size - front 195/60 VR 15
- rear 235/60 VR 15
- spare (if fitted) 175/70 SRl4
Page 6 SEC T/ON TO D
15" T y r e Replacement
C a r s 1985 Model Year onwards: Goodyear ' N C T ' t y r e s of a new

s p e c i f i c a t i o n were i n t r o d u c e d on 1985 Model Y e a r E s p r i t S3 a n d
Turbo m o d e l s , t o g e t h e r w i t h a r e v i s e d f r o n t s u s p e n s i o n . For
1985 M.Y. a n d l a t e r models it i s e s s e n t i a l t h a t ONLY e i t h e r
t h e new s p e c i f i c a t i o n Goodyear 'NCT' t y r e s o r Goodyear
' E a g l e NCT' t y r e s a r e f i t t e d . T h e s e two t y r e s d i f f e r i n name o n l y
a n d may b e s a f e l y mixed, b u t t y r e s made t o t h e p r e ' 8 5
s p e c i f i c a t i o n should - n o t be used. For i d e n t i f i c a t i o n of t y r e
s p e c i f i c a t i o n see below.
Tyre P r e s s u r e s - front 1.45bar (21 l b / i n 2 )

- rear 1.70 b a r (25 l b / i n 2 )
- spare 2 .05 b a r (30 l b / i n 2 )
C a r s P r i o r t o 1985 Model Year: I f t y r e s t o t h e p r e '85 s p e c i f i c a t i o n

a r e n o t a v a i l a b l e , t h e l a t e r t y p e Goodyear 'NCT' o r ' ~ a g 1 eNCT'
may b e u s e d b u t o n l y i n a x l e s e t s , and w i t h t h e t y r e p r e s s u r e s
o f o'nly t h e l a t e r s p e c . t y r e s i n c r e a s e d a s below.
'a
Tyre P r e s s u r e s -
P r e ' 8 5 M.Y. c a r w i t h P r e '85 c a r with

P r e ' 8 5 spec. t v r e ' 8 5 onwards s p e c . t y r e
f r o n t 1.45 b a r ( 2 1 l b / i n 2 ) f r o n t 1.60 b a r ( 2 3 l b / i n 2 )
r e a r 1.70 b a r ( 2 5 l b / i n 2 1 rear 1.90 b a r ( 2 7 l b / i n 2 )
s p a r e 2.05 b a r (30 l b / i n 2 ) s p a r e 2 - 0 5 b a r (30 l b / i n 2 )
I d e n t i f i c a t i o n of t y r e spec.
Embossed i n t h e s i d e w a l l of e a c h t y r e , on one s i d e o n l y ,
a r e t h e l e t t e r s D.O.T. f o l l o w e d by a s e r i e s of numbers and
l e t t e r s . T h i s f o r m a t i s t h e d a t e c o d i n g employed by t y r e
m a n u f a c t u r e r s t o i d e n t i f y t h e t i m e and p l a c e of b u i l d o f e a c h
tyre. Goodyear a l s o i n c l u d e a c o d i n g which i d e n t i f i e s t h e make
up o f each t y r e .
a
R e f e r e n c e need o n l y be made t o t h e l a s t t h r e e d i g i t s .
week Year
of of
Build Build
Any t y r e m a n u f a c t u r e d on o r a f t e r week number 38 of y e a r

4 i s t o 1985 s p e c i f i c a t i o n .
Unused 1985 s p e c . t y r e s a l s o have i n t h e t r e a d a r e a 2

i d e n t i f y i n g c i r c u m f e r e n t i a l y e l l o w c o l o u r bands.
DEC 1986
SECTION TD D Page 7
ELECTRICAL EQUl PMENT
Alternator - Series 3 & Dom/Exp Turbo Motorola 70 amp

- USA Turbo Motorola 90 amp
Starter Motor - type Lucas 2M100
- drive pre-engaged
- brush spring tension 1 .02 kgf (36 ozf)
- light running current 40 amp @ 6,000 rpm
- lock torque 1 .99 kgf.m (14.4 Ibf.ft)
@ 463 amps
Battery - type - Dom/Exp prior '85 MY Chloride type 385
- Dom/Exp '85 &I86 MY Tungstone type 065
- USA prior '86 MY
- Dom/Exp '87 MY on
- USA '86 MY on 3 Tungstone type 088
- performance - Chloride type 385 55 amp hr

- Tungstone type 065 255 amp cold start*
- Tungstone type 088 330 amp cold start*
* 1 min @ -1 8 ' ~to 1.4 VPC
TORQUE S E T T I N G S
Front Suspension (Prior to '85 M.Y .)
k g f .m lbf. ft.
Stub axle t o vertical link 11.0-15.0 80-110
*Upper wishbone t o c h a s s i s
Upper b a l l j o i n t t o wishbone
Ball j o i n t t o v e r t i c a l l i n k
S t e e r i n g arm t o v e r t i c a l l i n k
C a l i p e r mounting p l a t e t o
vertical link
*Lower l i n k t o c h a s s i s 5.5-6.2 40-45
Lower l i n k t o t . r u n n i o n 4.4-4.7 32-34
Anti-Poll bar t o lower l i n k 0.8-1.4 6-10
Anti r o l l bar t o chassis 6.9-8.3 50-60
*Damper t o l o w e r l i n k 6.9-8.3 50-60
xDamper t o p stem t o c h a s s i s see below
Wheel n u t s o r b o l t s
Front Suspension (1 985 M.Y. onwards)
*Upper wishbone t o c h a s s i s 6.9 50

Upper b a l l j o i n t t o wishbone 2.1 15
Upper b a l l j o i n t t o v e r t i c a l l i n k 5.5 40
S t e e r i n g arm t o v e r t i c a l l i n k 9.0 65
"ower wishbone t o c h a s s i s 6.9 50
Lower b a l l j o i n t t o v e r t i c a l l i n k 9.0 65
Anti-roll-bar t o chassis 9.0 65
*Damper t o l o w e r w i s h b o n e 6.9 50
xDamper t o p stem t o s p r i n g p l a t e see b e l o w
Spring top plate t o chassis 2.1 15
Wheel b o l t s - - 9.0 65
DEC 1986
Page 8 SECTION TD D
Rear Suspension & D r i v e S h a f t s kgf .m 1bf.ft.

* R a d i u s arm t o r u b b e r m o u n t i n g 5.5-6.2 40-45
R a d i u s arm t o h u b c a r r i e r 4.2-4.8 30-35
t Top l i n k t o c h a s s i s 6.9 50
t Top l i n k t o h u b c a r r i e r 6.9- 50
i Lower l i n k t o c h a s s i s 6.9 50
3) Lower l i n k t o h u b c a r r i e r 6.9 50
Drive Shaft b o l t s 8.3 60
Drive s h a f t adaptor t o gearbox 8 . 3 - 1 1 .O 60-80
Radius arm mounting t o c h a s s i s 3.5 25
x Damper t o p stem See below
Rear h u b n u t
Wheel n u t s o r b o l t s
it Tighten only with suspension a t r i d e height.
c
x Nut i s ' n i p p e d 1 t o s h o u l d e r o n s t e m , h o l d i n g t o p o f s t e m w i t h
spanner, then locknut tightened.
I S p r i n g must be i n compressed c o n d i t i o n d u r i n g t h i s o p e r a t i o n . ]
Steering kgf .m 1bf.ft.
S t e e r i n g rack assembly t o c h a s s i s 1 . 7 - 1 .9 12-14
Upper column l o w e r b o l t s 1.1-1.7 8, 12
S t e e r i n g column l o c k b o l t s "Break o f f t 1 t y p e .
S t e e r i n g wheel t o column 4 .2-4 .'8 30-35
U n i v e r s a l j o i n t clamp b o l t s 2.2-2.8 16-20
T i e rod locknuts 6.9-8.3 50-60
T i e r o d e n d t o s t e e r i n g arm 4.2-4.8 30-35
B r a k e s (Prior to '85 MY)
k g f .m 1bf.ft.
Front b r a k e c a l i p e r mounting
Rear b r a k e c a l i p e r m o u n t i n g
Rear c a l i p e r mounting b r a c k e t t o
transmission
B r a k e s e r v o t o p e d a l box
Master c y l i n d e r t o s e r v o
F r o n t b r a k e d i s c t o hub
10 mm p i p e n u t s - male
- female
10 mm h o s e e n d
7 mm b l e e d screw
Rear c a l i p e r p i p e a d a p t o r
B r a k e s (1985 MY onwards)
k g f .m lbf. ft
Front b r a k e c a l i p e r mounting
Rear b r a k e c a l i p e r m o u n t i n g
Brake s e r v o t o mounting b r a c k e t
Master.cylinder t o servo
Front b r a k e d i s c t o hub
Chassis k g f .m lbf. f t
Rear c r o s s m e m b e r 4.2 - 4.8 30 - 35
Page 7
BODY
--
PAINT PROCEDURE
SECTION BA - ALL MODELS
-
Page
P a i n t Code L i s t 2 to 6
E s s e n t i a l Working P r a c t i c e 7/8
P r e p a r a t i o n f o r Primer 8 19
Polyurethane Primer Sprayer 9 t o 11
P r e p a r a t i o n f o r Colour Coat 11
Nitro- C e l l u l o s e Colour Spraying 12 t o 14
P42O /P42 1 A c r y l i c Polyurethane Spraying 14 t o 16
P422 A c r y l i c Polyurethane S p r a y i n g 16 t o 18
Intercoat Rectification 19 t o 21
Nitro- C e l l u l o s e P a i n t R e c t i f i c a t i o n 21 t o 24
A c r y l i c Polyurethane P a i n t R e c t i f i c a t i o n 25 t o 27
R R I M P a i n t Procedure 27 t o 29
P e a r l e s c e n t White P a i n t Procedure BA 13 29 130
P a i n t Removal BA 14 30
Tne p a i n t procedure c o n t a i n e d i n t h i s s e c t i o n is based on t h a t

used i n t h e manufacture o f Lotus Cars and commences w i t h t h e
b a r e composite b o d y s h e l l . It is i n c l u d e d h e r e o n l y f o r g e n e r a l
g u i d a n c e i n r e p a i r work, and i t s h o u l d be n o t e d t h a t d i f f e r e n t
oven t e m p e r a t u r e s and t h i n n e r s may be n e c e s s a r y dependant on
t h e l e v e l o f t r i m of t h e body, and t y p e of oven etc..
JUL 1985
Page 2 SECTION BA
BA 1 - PAINT CODES
B e f o r e commencing any p a i n t work on a L o t u s c a r , f i r s t

check t h e p a i n t code number stamped on t h e lower l e f t
hand c o r n e r o f t h e v e h i c l e i d e n t i f i c a t i o n p l a t e u n d e r
t h e f r o n t bonnet.
P a i n t c o d e s w i t h an ' I , ' p r e f i x i n d i c a t e n i t r o - c e l l u l o s e
p a i n t f o r which two s u p p l i e r s r e f e r e n c e numbers a r e
sometimes q u o t e d - International Paint (formerly Pinchin
and Johnson) and I C I .
'A' p r e f i x p a i n t codes a r e used f o r c a r s f i n i s h e d i n

ICI 2K two pack a c r y l i c p o l y u r e t h a n e p a i n t s o f t h e
P420/421/422 line.
'S' p r e f i x p a i n t c o d e s were used f o r a s h o r t p e r i o d o n l y

(1976/77) and i n d i c a t e t h a t t h e body was moulded w i t h
i n t e g r a l c o l o u r u s i n g ICI 2 K two pack p o l y u r e t h a n e p a i n t
of t h e P407 l i n e . These c a r s may b e r e p a i r e d u s i n g
ICI PO30 l i n e n i t r o - c e l l u l o s e .
ICI P a i n t R e f e r e n c e Number
I C I p a i n t r e f e r e n c e number p r e f i x groups i n d i c a t e t h e
following p a i n t types.
P 030 Mono c o l o u r n i t r o - c e l l u l o s e
P 031 Metallic n i t r o cellulose
P 407 2 pack a c r y l i c p o l y u r e t h a n e
P 420 Mono c o l o u r 2 pack a c r y l i c p o l y u r e t h a n e
P 421 M e t a l l i c 2 pack a c r y l i c p o l y u r e t h a n e
P 422 B a s e c o a t / c l e a r 2 pack a c r y l i c p o l y u r e t h a n e
JUL 1985
SECTION Page 3
PAINT SUPPLIER LOTUS

CODE COLOUR -NO.
SPEC
- PART NO. REMARKS
B r i t i s h Racing Green P J 0170Y2790

ICI PO302854
French Blue PJ 617021280
ICI PO307210
Wedgewood Blue P J 617021290
C i r r u s White PJ 6170x0540
ICI PO309049
C a r n i v a l Red P J 6170x5350
ICI PO308385
Burnt Sand P J 6170x4570
ICI PO306853
Lotus Yellow PJ 6170x3940
ICI DO309547
Matt Black PJ 0235X9050RZ
ICI Non G l o s s
Royal Blue PJ 617021920
ICI PO307557
Bahama Y e l l o w PJ 6170Y3140
ICI PO306854
Regency Red PJ 6170Y5960
ICI PO309053
Lagoon Blue PJ 6170A1130
ICI PO314339
P i s t a c h i o Lime Green P J 6170W2230Rl
ICI PO309052
Colarado Orange P J 617025980RJ
ICI PO309055
Black G l o s s ICI PO30122
Ford Tawny P J 6170A4330
ICI PO313626
R e n a u l t Mid Green P J 6170A2580
G l a c i e r Blue I C I PO794403
Sable ICI PO307604
I n d i g o Blue
Page 4 SECTION BA
P A I NT SUPPLIER LOTUS
CODE COLOUR SPEC. NO PART NO. REMARKS
L 21 Purple I C I PO314963
L 22 B i t t e r Green P J 6170x2097
I C I PO309501
L 23 S e p i a Brown P J 6170Y4817
I C I P030TW25028
L 24 Firecracker PJ 6170x5150
I C I PO308662
L 25 Monaco White ICI PO307517
L 26 Olympic B l u e I C I PO309257
L 27 Gunmet a 1 I C I PO313141
L 28 Rover Brown
L 29 Mint Green I C I P030DC27
L 30 Garnet I C I PO314984
L 31 Lemon Yellow ICI PO300455
L 32 Oxford Blue I C I PO30113
L 33 F o r d S i g n a l Orange I C I DA 21
L 34 Roman Bronze ICI PO315050
L 35 Brazil I C I PO314563
L 36 Silver I C I PO315699
L 37 J u p i t e r Basecoat ICI PO31 9235
L 38 Garnet Basecoat ICI PO319142
L 39 V e r s a i l l e s Red
L 40 Midnight Blue I C I PO304647
L 41 C r y s t a l Blue
L 42 C a l y p s o Red I C I P030GJ23
L 43 M a r t i n i Green
L 44 Essex Blue I C I PO31 9176
L 45 B r i t i s h R a c i n g Green I C I PO3OCC43
L 46 B r i t i s h Racing Green I C I PO308120
L 47 B r i t i s h R a c i n g Green I C I PO308461
SECTION BA Page 5
CODE COLOUR .
SPhC NO. PART NO. REMARKS
Gold Laquer PJ 6170A3130 A036B6345V Elan s p r i n t

bumpers
S i l v e r Laquer PJ 6170A8020 A036B6313V E l a n bumpers
Silver A036B6355V + 2 s roof
M e t a l l i c Jewels
S .01 White ICI P407701 A076B6024V

Repair Cellulose ICI PO30101
S 02 S i g n a l Red ICI P407717 A076B6025V
Repair C e l l u l o s e ICI PO30437
S 03 Lemon Yellow ICI P407783 A076B6026V
S 04 Orange ICI P407720 A076B6034V
S 05 Oxford Blue ICI P407738
Blue Oxford ICI P420113 A076B6060 + clear

Black ICI P420122 A089B6151V + clear
S i l v e r Diamond ICI P4229167 A076B6067
Gold ICI P4229638 A076B607 1
Viper Green ICI P4229289
Bermuda Blue ICI P4229288 A076B6072
Roman Bronze ICI P4229468 A076B6075
L o t u s Bronze ICI P4229756 A076B6076
M a r t i n i Green IPJ
M e t a l l i c Black ICI P4229719
M a r t i n i Green ICI P422 9890
Onyx ICI P4229809
Page 6 SECTION BA

CODE SPEC. NO. PART NO. REMARKS
A 13 Tabac I C I P4229781
A 14 A l t a i r Green ICI P4220182
A -15 Helleblasl I C I P4220183
A 16 Essex Blue ICI P4220146
A 17 Essex Blue IPJ 2 Pack
A 18 T i s s o t Blue
A 19 Copper F i r e M e t a l l i c ICI P4220311
A 20 Gold S i k k e n s F158979
A 21 Monaco White ICI P4207517
A 22 L o t u s Yellow ICI P4200455 + clear
A 23 C a l p y s o Red ICI P420GJ23 + clear
A 24 Gunmet a 1
A 25 New Gold ICI P4220628B
A 26 Copper
A 27 T o y o t a Red ICI P4220691
A 28 Ruben Red ICI P4229373
A 29 Copper ICI P421 5031 -t, c l e a r
A 30 J u p i t e r Red ICI P4216056 + clear

A 31 Copper ICI P4217222 + clear
A 32 Mediterranean Blue ICI P4217215 + clear
A 33 I c e Blue ICI P4217220 -t clear
A 34 Dark B l u e ( E s s e x ) ICI P4217219 + clear
A 35 Silver ICI P4217379 + clear
A 36 New Gold ICI P4217221 + clear
A 37 F i a t Grey ICI P4214491 + clear
A 38 C h r y s l e r S t e e l Grey I C I P4215310 + clear
E x c e l bumpers
and s i l l s
A 39 I c e Blue I C I PO32 + clear
A 40 Silver I C I P032-918 + clear
A 41 Silver
A 42 B r i t i s h R a c i n g Green I C I P4216490 + clear
A 43 Gold ( O y s t e r ) ICI P4215888
A 44 G l a c i e r Blue ICI P4210757 + clear
A 45 Silver Frost ICI P4217805 + clear
a
SECTION BA Page 7
BA 2 - ESSENTIAL WORKING PRACTICE
1. Caution
A u t o c o l o u r 2K h a r d e n e r P210-760 ( u s e d w i t h a l l ICI two p a c k
P
acrylic-polyurethane systems) c o n t a i n s r e a c t i v e i s o c y a n a t e ,
a s m a l l p o r t i o n of which i s v o l a t i l e . Vapour s h o u l d n o t be
allowed t o accumulate i n a confined o r badly v e n t i l a t e d space.
The s p r a y m i s t i s h a r m f u l by i n h a l a t i o n and c o n t a c t w i t h s k i n
and e y e s .
A u t o c o l o u r 2 K s h o u l d o n l y be u s e d i n a w e l l v e n t i l a t e d a r e a ,
p r e f e r a b l y a s u i t a b l e spray booth with e f f i c i e n t exhaust
ventilation. S p r a y o p e r a t o r s s h o u l d wear a i r l i n e b r e a t h i n g
a p p a r a t u s t o BS4467 P a r t 3 , m a i n t a i n e d a c c o r d i n g t o BS4275.
People e n t e r i n g t h e s p r a y i n g a r e a f o r s h o r t p e r i o d s (up t o
1 5 m i n s ) s h o u l d wear a r e s p i r a t o r t o BS2091 w i t h t y p e CC
canister.
B e f o r e s p r a y i n g 4 u t o C o l o u r 2K, o p e r a t o r s s h o u l d r e f e r t o ICI
H e a l t h and S a f e t y I n f o r m a t i o n S h e e t PV1. Store thinners i n
a c c o r d a n c e w i t h t h e P e t r o l e u m ( C o n s o l i d a t i o n ) Act 1928 and t h e
P e t r o l e u m M i x t u r e s O r d e r 1 9 2 9 ; and i n a c o o l p l a c e . Store
p a i n t , h a r d e n e r and c l e a r c o a t i n a c c o r d a n c e w i t h t h e H i g h l y
I n f l a m m a b l e L i q u i d s and L i q u i f i e d P e t r o l e u m Gas R e g u l a t i o n s
1972. Use o n l y a non-smoking a r e a , and away from a l l s o u r c e s
of i g n i t i o n . Take p r e c a u t i o n a r y m e a s u r e s a g a i n s t s t a t i c
aischarge. I n c a s e o f f i r e , u s e foam o r d r y a g e n t e x t i n g u i s h e r s .
Contain any s p i l l a g e w i t h sand o r e a r t h . Do n o t a l l o w t o e n t e r
a drain o r water course.
2. A l l a i r u s e d f o r s p r a y i n g o r blow down s h o u l d b e f i l t e r e d b e f o r e
use.
3. A l l p r e c a u t i o n s s h o u l d b e t a k e n t o e n s u r e t h e r e i s no o i l o r
w a t e r c o n t a m i n a t i o n i n t h e p a i n t c o n t a i n e r s and a i r s u p p l y l i n e s .
4. A h i g h s t a n d a r d o f c l e a n l i n e s s must b e m a i n t a i n e d w i t h a l l s p r a y
e q u i p m e n t , f r e q u e n t c l e a n i n g o f g u n s and t h e s u r r o u n d i n g a r e a
and b o o t h i s n e c e s s a r y .
Page 8 SECTION BA
5. Oven t e m p e r a t u r e s , and t e m p e r a t u r e s i n t h e s p r a y b o o t h , Tak
Rag b o o t h and main working a r e a s s h o u l d b e checked d a i l y , and
p e r i o d i c measurements o f p a n e l t e m p e r a t u r e c a r r i e d o u t .
I t i s a b s o l u t e l y e s s e n t i a l t h a t any s u r f a c e t o b e s p r a y e d i s
a b s o l u t e l y c l e a n , d r y and f r e e from d u s t o r s l u d g e .
A f t e r any and e a c h s u r f a c e c o v e r i n g t r e a t m e n t i n c l u d i n g P38

f i l l e r , c e l l u l o s e stopper, polyurethane primer, primer/surfacer,
c o l o u r p a i n t and c l e a r l a q u e r , i t i s e s s e n t i a l t h a t t h e s e b e
f u l l y c u r e d u s i n g a bank o f i n f r a r e d l i g h t s g i v i n g a 60°C
panel temperature f o r t h e duration specified f o r t h e
operation. T h i s t h e n must be a l l o w e d t o a i r c o o l b e f o r e
f u r t h e r work.
8. P o l y u r e t h a n e p r i m e r must n o t b e s p r a y e d o n t o p o f a c o l o u r
c o a t and l e f t t o form a sandwich o f p a i n t / p r i m e r / p a i n t .
BA 3 - BODY AND COMPONENT PREPARATION FOR PRIMER COATING
1. Dry f l a t t h e e n t i r e s u r f a c e a r e a u s i n g 240 g r a d e p a p e r
(Carborundum t y p e ) t o e n s u r e t h a t t h e r e i s no t r a c e o f wax
or gloss. The o p e r a t i o n i s a c l e a n i n g p r o c e s s i n o r d e r t o
provide a s u i t a b l e surface f o r painting. The f l a t t i n g i s
f o r t h e r e m o v a l o f p r o t r u s i o n s and must p r e s e n t a c o m p l e t e l y
s c r u b b e d s u r f a c e t o key t h e p o l y u r e t h a n e . F l a t t i n g should
b e c a r r i e d o u t w i t h a n o r b i t a l s a n d e r o n f l a t s u r f a c e s and
a f l a t p a d i n more r e s t r i c t e d a r e a s . During t h i s o p e r a t i o n
a l l d i s t o r t i o n s must b e removed. Extra c a r e is necessary t o
a v o i d g e l c o a t r u b t h r o u g h on s h a r p c o r n e r s .
2. E n t e r t h e body s t o v i n g o v e n . Stove cure t o give a panel

t e m p e r a t u r e o f 1 0 0 W (210°F) f o r a minimum o f 1 0 m i n u t e s .
E n s u r e t h a t t h e e x t e r n a l o v e n t e m p e r a t u r e gauge r e a d s 93OC
(200°F) minimum b e f o r e body e n t r y and close t h e o v e n d o o r
i m m e d i a t e l y a f t e r ' body e n t r y .
SECTION BA Page 9
3. E x i t oven and a l l o w t o a i r c o o l . While t h e mouldings a r e

s t i l l warm p r i c k o u t and mark a l l d e f e c t s . When c o o l
r e c t i f y t h e d e f e c t s w i t h P38 f i l l e r . Dry r u b down w i t h
8 0 g r a d e paper (Carborundum)confining f l a t t i n g t o t h e
r e c t i f i e d surface only. Dry f l a t t h e e n t i r e a r e a w i t h 240
g r a d e p a p e r (Carborundurn). Before polyurethane primer
s p r a y i n g t h e c a r must b e t h o r o u g h l y vacuum c l e a n e d and
a l l f o r e i g n b o d i e s must be removed.
BA 4 - BODY A N D COMPONENT POLYURETHANE PRIMER
1. Ensure t h a t t h e body and components a r e f u l l y vacuum c l e a n e d .

E n t e r t h e Tak Rag booth and t h o r o u g h l y s o l v e n t wipe t h e
e n t i r e c a r and component s u r f a c e s t o b e p a i n t e d . The s o l v e n t
t o be used i s F l o w l i n e Wax and Grease Remover.
Ensure t h a t new c l o t h s of woven m a t e r i a l a r e used and t h a t

t h e y a r e changed f r e q u e n t l y d u r i n g u s e s o a s t o e n s u r e
s u r f a c e c l e a n l i n e s s , remove a l l t r a c e s o f r u b b i n g down
sludge.
2. Thoroughly Tak Rag a l l s u r f a c e s t h a t a r e t o b e p a i n t e d t o

remove a l l t r a c e s of d u s t .
3. Spray one s t r a i g h t c o a t and one c r o s s c o a t o f p o l y u r e t h a n e

mixed a s below: -
P.U. Primer A075B6124 25 p a r t s by volume
P.U. C a t a l y s t X036B6137 5 p a r t s by volume
P.U. R e t a r d e r ~O75B6172 2 p a r t s by volume
T h i n t o 45 seconds B.S.4. Cup a t 18-20°C (64-68OF) using

t h i n n e r A075B6125. Spray u s i n g a Binks Bullows p r e s s u r e
p o t gun w i t h m a t e r i a l n o z z l e 2059, n e e d l e 59 and p r e s s u r e
c a p 6 3 PB.
A l l o w t o f l a s h o f f f o r 1 0 m i n u t e s a t 21°C (709F). .
Wet f i l m t h i c k n e s s 6 t h o u .
Page 70
4. E n t e r t h e c u r i n g oven f o r a minimum o f 20 m i n u t e s a t 88OC

SECTION BA
'*
(190°F) p a n e l t e m p e r a t u r e . E x i t oven and a l l o w t o a i r
cool.
5. I n s p e c t and r e c t i f y any f u r t h e r s u r f a c e d e f e c t s w i t h P38

filler. Dry f l a t t h e f i l l e r w i t h a f l a t pad o f 80 g r a d e
p a p e r (Carborundum) c o n f i n e t h i s t o t h e f i l l e d a r e a o n l y .
F i n a l l y d r y f l a t t h e e n t i r e p o l y u r e t h a n e s u r f a c e w i t h 240
grade paper t o provide a scrubbed s u r f a c e f o r t h e second
p a s s of polyurethane. Where p o s s i b l e t h e p r i m e r c o a t s h o u l d
remain unbroken, r u b t h r o u g h s b e i n g k e p t t o a minimum.
6. Loosen d u s t u s i n g an a i r l i n e and t h o r o u g h l y vacuum c l e a n

t o remove a l l d u s t from t h e i n s i d e and o u t s i d e o f t h e body
and i t s components. E n t e r t h e booth and Tak Rag t h e body
and components f u l l y removing a l l t r a c e s o f d u s t and
s l u d g e from t h e s u r f a c e s t o be s p r a y e d .
7. Immediately a f t e r t h e Tak Rag o p e r a t i o n e n t e r t h e s p r a y b o o t h

and s p r a y o n e s t r a i g h t c o a t and one c r o s s c o a t o f g r e y
p o l y u r e t h a n e p r i m e r mixed a s below:-
P.U. Primer A075B6124 25 p a r t s by volume

P.U. Catalyst X036B6137 5 p a r t s by volume
P.U. Retarder A075B6172 2 p a r t s by volume
T h i n t o 45 s e c o n d s BS 4 Cup a t 18-20°C (64-6S°F) using ,
P.U.Thinner A075B6125. Spray u s i n g a Binks Bullows p r e s s u r e

p o t gun w i t h m a t e r i a l n o z z l e 2059, n e e d l e 59 and p r e s s u r e
c a p 63PB.
Allow t o f l a s h o f f f o r a minimum of 1 0 m i n u t e s a t 21°C (70°F).
8. T r a n s f e r t h e body and components i n t o t h e c u r i n g oven f o r a

minimum o f 20 m i n u t e s a t 88OC (190°F) p a n e l t e m p e r a t u r e .
Exit oven and a l l o w t o a i r c o o l .

SECTION BA Page 1 1
9. W e t f l a t w i t h hand b l o c k s u s i n g 360 grade p a p e r (Carborundum)

removing a l l t r a c e s o f orange p e e l . Do n o t r u b through t h e
p o l y u r e t h a n e a s t h i s w i l l mean a r e c y c l e o f t h e body o r
component. The w e t f l a t t i n g medium should be 1/8 p i n t of
F i n a d e t No. 1 t o 2 g a l l o n s c l e a n w a t e r f o r t h i s o p e r a t i o n .
T h i s s o l u t i o n s h o u l d be changed f r e q u e n t l y s o a s t o a v o i d
sludge contamination.
10. Wash o f f a l l r u b b i n g s l u d g e u s i n g c l e a r r u n n i n g w a t e r ( h o s e
and b r u s h ) . Do n o t a l l o w s l u d g e t o d r y on t h e body s u r f a c e
a s t h i s w i l l s e r i o u s l y impair i n t e r c o a t a d h e s i o n .
11. The f i n a l wash down must be c a r r i e d o u t w i t h d e - i o n i s e d w a t e r .

Dry o f f t h o r o u g h l y .
12. B e f o r e c o l o u r c o a t i n g i t i s e s s e n t i a l t h a t t h e body and components

have a p r o p e r l y c u r e d , smooth, unbroken and c l e a n p o l y u r e t h a n e
s u r f a c e , and t h a t t h e y a r e k e p t d r y , under c o v e r , and o u t o f
direct rainfall.
BA 5 - BODY & COMPONENT PREPARATION FOR COLOUR COATING
1. Thoroughly vacuum t h e i n s i d e and o u t s i d e o f t h e body and i t s

components. Ensure t h a t t h e body and a l l components a r e
completely d r y b e f o r e e n t e r i n g t h e Tak Rag Booth.
2. E n t e r t h e Tak Rag b o o t h and s o l v e n t wipe t h e e n t i r e s u r f a c e

t o be p a i n t e d u s i n g F l o w l i n e Wax and Grease Remover.
Remove t h e s o l v e n t w i t h c l e a n woven c l o t h and g i v e a l l

s u r f a c e s a thorough Tak Rag t o remove d u s t .
Page 72 SECTION B
A.
BA 6 - BODY & COMPONENT NITRO-CELLULOSE COLOUR COAT
Mono Colours: I C I PO30 Type low bake c e l l u l o s e

Metallic colours: ICI PO31 Type low bake c e l l u l o s e
1. Mix p a i n t a s f o l l o w s : -
Mono Colours - ICI PO30 p a i n t 1 p a r t by volume
ICI P105 0082 c o n v e r t e r t h i n n e r 1 p a r t
by volume.
V i s c o s i t y 23 t o 27 seconds BS 4 cup a t 18 O C (65OF) m a t e r i a l

temperature. I f n e c e s s a r y add more P105 0082 c o n v e r t e r
t h i n n e r t o achieve t h i s v i s c o s i t y .
Metallic colours -
1st p a s s - ICI PO31 p a i n t / t h i n n e r s 1:l a s above
2nd p a s s - ICI PQ31 p a i n t 1 part
Low Bake c o n v e r t o r c l e a r P017-708 1 p a r t
Thin r e s u l t a n t m i x t u r e 1:l w i t h c o n v e r t e r t h i n n e r s P105-0082.
V i s c o s i t y 23 t o 27 seconds BS 4 cup a t 1 8 O C (65OF) m a t e r i a l
temperature. I f n e c e s s a r y , add more P105 0082 c o n v e r t e r t h i n n e r
t o achieve t h i s v i s c o s i t y .
2. Immediately a f t e r t h e Tak Rag o p e r a t i o n e n t e r t h e p a i n t s p r a y

booth and s p r a y a l i g h t m i s t c o a t i n s i d e t h e body. With s p r a y
gun a i r o n l y , blow down t h e o u t s i d e s u r f a c e s .
3. Spray one s i n g l e c o a t , a l l o w s o l v e n t s t o f l a s h o f f t h e 1 0
m i n u t e s , one c r o s s c o a t and a f i n a l s i n g l e c o a t . Leave i n
t h e f l a s h b o o t h f o r 30 minutes t o a l l o w s o l v e n t f l a s h o f f .
During s p r a y i n g c a r e s h o u l d be t a k e n t h a t p a i n t c o v e r s a l l
areas, i n p a r t i c u l a r those areas of a defect nature; apertures,
door s h u t s , body and bonnet edges e t c . . The booth t e m p e r a t u r e
should be 20-21°C (68-70°F). Spray gun s e t t i n g s s h o u l d be
a i r pressure 65 - 70 p s i and m a t e r i a l p r e s s u r e 1 2 - 15 p s i to
g i v e a 7 ' 6 " throw P t e s t . Ensure t h a t t h e mixing p o t f i l t e r s
a r e f i t t e d and c l e a n ( t h e s e a r e t o be c l e a n e d d a i l y and as
required).
SECTION BA Page 73
3. cont.....
Spraying should be c a r r i e d o u t w i t h a Binks Bhllows 230

gun s e t up a s f o l l o w s : -
Deionised a i r noxxle - Polonium 2 1 0 ' ( t o be changed y e a r l y )

Material nozzle - 446
Needle v a l v e - 49
A i r nozzle - 63PE
We f i l m t h i c k n e s s 5 thou.
4. T r a n s f e r t h e body and components t o t h e c u r i n g oven and c u r e

f o r 50 minutes a t 8Z°C (180°F) p a n e l t e m p e r a t u r e .
5. E x i t oven and i n s p e c t . R e c t i f y a s d e s c r i b e d i n s e c t i o n BA - 8.
6. E n t e r s p r a y booth and s o l v e n t wipe u s i n g Isopropanol mixed

1:l with c l e a n w a t e r . Remove s o l v e n t w i t h c l e a n new Kimwipes,
changing r e g u l a r l y . Tak Rag t h o r o u g h l y t o remove a l l t r a c e s
of s u r f a c e d u s t .
7. Mix p a i n t a s i n ( 2 ) and t h i n t o t h e recommendation.
8. Apply one c o a t of p a i n t o v e r a l l r e c t i f i c a t i o n a r e a s , wheel

a r c h e s and a p e r t u r e s , and allow 10 minutes f l a s h o f f .
Continue t o c o v e r a l l s u r f a c e a r e a t o be p a i n t e d w i t h one
single coat. Allow 10 minutes f l a s h o f f and spray one c r o s s
c o a t t o a l l s u r f a c e s of body and components.
9. Allow 30 m i n u t e s f o r s o l v e n t f l a s h o f f i n t h e f l a s h b o o t h .
10. E n t e r c u r i n g oven f o r 50 mins a t 80°C (176OF) p a n e l t e m p e r a t u r e .
11. E x i t oven and a l l o w t o a i r c o o l t o room t e m p e r a t u r e . Flat the

p a i n t e d s u r f a c e u s i n g Wet 1200 grade paper (3M). The f l a t t i n g
medium f o r t h i s o p e r a t i o n i s 1/4 p i n t F i n a d e t No. 1 t o 2 g a l l o n s
of clean water. F l a t t i n g i s o n l y n e c e s s a r y i n a r e a s where
normal compounding w i l l n o t r e c t i f y i . e . t h e t o p h a l f o f t h e
car.
Page 14
12. Using I . C . 1 . 2B rubbing compound machine p o l i s h t h e e n t i r e
painted surfaces. Keep t h e p o l i s h i n g mop m o i s t , do n o t
a l l o w compound t o d r y on t h e mop a s s c r a t c h i n g may r e s u l t .
Clean t h e mop f r e q u e n t l y , where p o s s i b l e t h e mop s h o u l d be

moved i n a f o r e and a f t d i r e c t i o n .
13. Hand p o l i s h t h e body and components u s i n g c l e a n woven c l o t h

and m i r r o r g l a z e MGM8 p o l i s h .
BA 7 - BODY COMPONENT P420/421 ACRYLIC POLYURETHANE COLDUR COAT & CLEAR.
1. E n t e r t h e Tak Rag booth and s o l v e n t wipe u s i n g I s o p r o p a n o l

mixed 1 : 1 w i t h d e - i o n i s e d w a t e r . Remove s o l v e n t w i t h
a
c l e a n new woven c l o t h s - changing r e g u l a r l y .
2. Mix c o l o u r p a i n t a s below:-
For Mono c o l o u r s :
ICI P420 P a i n t 4 p a r t s by volume

I C I P210/0760 Hardener 2 p a r t s by volume
ICI P850/1196 Thinner 1 p a r t by volume
For M e t a l l i c colours:
I C I P421 P a i n t 4 p a r t s by volume
ICI P210/0760 Hardener 2 p a r t s by volume
I C I P850/1196 Thinner 2 p a r t s by volume
S p r a y i n g v i s c o s i t y i s 17-21 seconds BSB4 cup a t 18OC m a t e r i a l

temperature.
If found n e c e s s a r y , d u r i n g h o t w e a t h e r r e p l a c e P850/1196
t h i n n e r w i t h P850/1212 t o overcome s o l v e n t b o i l .
3. Spray u s i n g a Binks Bullows gun set up a s f o l l o w s : -

A i r Nozzle 63 PB
F l u i d Nozzle 446
Needle 18.01.00
Fluid Pressure 30 p . s . i .
A i r Pressure 70 p . s . i .
Fan Angle 35 O
SECTION BA Page 75
- Use two o p e r a t o r s w i t h guns b a l a n c e d a t 6 f t 'P' t e s t

- Blow down i n t e r i o r s u r f a c e s w i t h f i l t e r e d a i r
- Spray a m i s t c o a t i n s i d e t h e body t o l a y remaining d u s t
- Tak Rag t o remove a l l t r a c e s o f s u r f a c e d u s t
- Blow down e x t e r n a l s u r f a c e s w i t h f i l t e r e d a i r .
- Spray one s i n g l e c o a t
- Allow t o f l a s h o f f f o r 10 m i n u t e s .
For s o l i d c o l o u r s :
Spray second s i n g l e c o a t
Allow 10 minutes f l a s h o f f
Spray t h i r d s i n g l e c o a t
For m e t a l l i c c o l o u r s :
Spray second s i n g l e c o a t
Spray double d u s t c o a t
4. Mix c l e a r c o a t a s f o l l o w s : -
ICI P190/0379 C l e a r Coat 4 p a r t s by volume
I C I P210/0760 Hardener 2 p a r t s b y volume
ICI P851/0727 R e t a r d e r 3 p a r t by volume
I C I P850/1212 Thinner 1* p a r t s by volume
Spraying v i s c o s i t y i s 14 t o 1 6 seconds BSB4 cup a t 18O m a t e r i a l

temperature.
Spray one s i n g l e l a q u e r c o a t o v e r a l l p a i n t e d a r e a s , wet f i l m

t h i c k n e s s , 5 thou.
Allow 10 minutes t o f l a s h o f f
Spray second s i n g l e c o a t , w e t f i l m t h i c k n e s s 5 t h o u .
Allow 30 minutes f l a s h o f f i n t h e f l a s h o f f a r e a .
5. T r a n s f e r body and components t o t h e p a i n t c u r i n g oven and c u r e

f o r 50 minutes a t 180°F (80°C).
Page 76 SECTION BA
'a
6. E x i t o v e n and a l l o w t o a i r c o o l . F l a t t h e painted surface

u s i n g 1 2 0 0 g r a d e p a p e r (3M). Use 1 / 4 p i n t F i n a d e t No. 1 t o
2 g a l l o n s o f c l e a n w a t e r a s t h e f l a t t i n g medium.
7. U s i n g I C I 2 5 r u b b i n g compound, machine p o l i s h t h e e n t i r e
painted surface. Keep t h e p o l i s h i n g mop m o i s t , do n o t a l l o w
p o l i s h t o d r y on t h e mop a s s c r a t c h i n g may r e s u l t . Clean t h e
mop f r e q u e n t l y , where p o s s i b l e t h e mop s h o u l d b e u s e d i n a f o r e
and a f t d i r e c t i o n .
8. M a t t b l a c k and hammerite t o c u r r e n t s p e c i f i c a t i o n .
9. Hand p o l i s h t h e body and components u s i n g c l e a d woven c l o t h

a n d M i r r o r g l a z e MGM8 p o l i s h .
BA 8 - P422 LINE,2 PACK ACRYLIC POLYURETHANE SPRAYING
I f a c a r f i n i s h e d i n I C I P422 l i n e a c r y l i c p o l y u r e t h a n e i s t o b e
t o t a l l y r e s p r a y e d , e i t h e r P422 o r P421 l i n e p a i n t s y s t e m s may b e u s e d ,
t h e l a t t e r h a v i n g a n improved r e s i s t a n c e t o p a i n t c h i p p i n g .
I f P421 i s t o b e u s e d , f i r s t s t r i p t h e l a c q u e r and b a s e c o a t P422

c o m p l e t e l y down t o t h e Monaco White ' u n d e r c o a t ' , and t h e n f l a t
t h o r o u g h l y w i t h P800 g r a d e p a p e r . C o n t i n u e w i t h P421 p a i n t
p r o c e d u r e BA 7 .
F o r P422 l i n e p a i n t a p p l i c a t i o n , p r o c e e d as f o l l o w s : -
SECTION BA Page 77
1. Mix 4 2 0 L i n e Monaco White P a i n t
ICI P420 7517 Monaco White 4 p a r t s by volume

ICI P210 760 Hardener 2 parts
ICI 850 1197 T h i n n e r s t o 20 s e c BS4 c u p 1 p a r t
N.B. This paint i s a curing material with a pot l i f e of 5 hours.
2. U s i n g a p r e s s u r e p o t s y s t e m & and B i n k s 230 s p r a y gun:

S p r a y 2 s i n g l e c o a t s l e a v i n g 5 m i n u t e s f l a s h o f f between c o a t s .
Leave 30 m i n u t e s , f l a s h o f f .
Oven 5 0 m i n u t e s a t 80-85OC.
Allow t o c o o l .
3. I n s p e c t and r e c t i f y a s d e s c r i b e d i n BA 9 .
4. Wet f l a t u s i n g 360 g r i t p a p e r t o l e a v e a s c r a t c h f r e e s u r f a c e .
S p e c i a l c a r e must be t a k e n i n -
a l l areas a s the basecoat c l e a r
s y s t e m a c c e n t u a t e s any s c r a t c h marks.
5. E n t e r s p r a y b o o t h and s o l v e n t w i p e u s i n g I s o p r o p a n o l mixed 1:l

with clean water. Remove s o l v e n t w i t h c l e a n new woven c l o t h s
c h a n g i n g r e g u l a r l y . Tak Rag t h o r o u g h l y t o remove a l l t r a c e s o f
surface dust.
6. Basecoat
ICI 422 Colour P a i n t 2 parts
ICI 8 5 0 1197 Thinners 3 parts
To g i v e 1 8 s e c s BS 4 .
7. Spray t h r e e s i n g l e c o a t s l e a v i n g 5 - 10 minutes, f l a s h o f f
between c o a t s .
Apply a d u s t c o a t t o remove a l l p a t c h i n e s s .
8. Inspect.
Leave 20 m i n u t e s t o f l a s h o f f b e f o r e a p p l y i n g c l e a r c o a t .
Page 78
9. Mix c l e a r l a c q u e r a s below:-
ICI PI90 0379 C l e a r c o a t 4 p a r t s by volume
ICI P210 0760 Hardener 2 p a r t s by volume
ICI P850 1212 Thinner 2 p a r t s by volume
V i s c o s i t y 23 t o 27 seconds BS4 cup a t 18OC (65OF) m a t e r i a l
temperature. I f n e c e s s a r y add more P850 - 1212 t h i n n e r t o
achieve t h i s v i s c o s i t y .
10. Spray one s i n g l e l a c q u e r c o a t o v e r a l l p a i n t e d a r e a s . Wet

f i l m t h i c k n e s s 5 thou.
11. Allow 1 0 m i n u t e s t o f l a s h o f f i n t h e s p r a y booth.
12. Spray second s i n g l e l a c q u e r c o a t .

13. Leave t o f l a s h o f f f o r 30 minutes i n t h e f l a s h booth.
14. T r a n s f e r body and components t o t h e p a i n t c u r i n g oven and

c u r e f o r 50 m i n u t e s a t 80°C (176OF) p a n e l t e m p e r a t u r e .
15. E x i t oven and allow t o a i r c o o l t o room t e m p e r a t u r e . Flat the

p a i n t e d s u r f a c e u s i n g wet 1200 grade paper (3hi). The f l a t t i n g
medium f o r t h i s o p e r a t i o n i s 1L4 p i n t F i n a d e t No. 1 t o 2 g a l l o n s
of clean water.
a
16. Using I . C . I . 2B r u b b i n g compound, machine p o l i s h t h e e n t i r e
painted surface. Keep t h e p o l i s h i n g mop m o i s t , do n o t a l l o w
compound t o d r y on t h e mop a s s c r a t c h i n g may r e s u l t .
Clean t h e mop f r e q u e n t l y , where p o s s i b l e t h e mop should be
moved i n a f o r e and a f t d i r e c t i o n .
17. Hand p o l i s h t h e body and components u s i n g c l e a n woven c l o t h

and m i r r o r g l a z e MGM 8 p o l i s h .
SECTION BA Page 79
BA 9 BODY & COMPONENT INTERCOAT RECTIFICATION PROCEDURES
1. F o r s m a l l a r e a r e c t i f i c a t i o n problems remove t h e g l o s s from

t h e a r e a t o be f i l l e d u s i n g 400 g r a d e p a p e r (3M) w e t . Dry
t h o r o u g h l y and a p p l y c e l l u l o s e s t o p p e r A03686327. T h i s must
b e l e f t f o r a minimum p e r i o d of 30 m i n u t e s a t shop
t e m p e r a t u r e 16OC ( 6 0 ° F ) . Wet f l a t u s i n g a b l o c k and 400
g r a d e p a p e r (3M). Confine f l a t t i n g t o t h e r e c t i f i c a t i o n
and immediate s u r r o u n d i n g s o n l y . F l a t t i n g medium i s 1/4
p i n t F i n a d e t No. 1 t o 2 g a l l o n s c l e a n w a t e r .
2. L a r g e r d e f e c t s must be f i l l e d u s i n g P38 f i l l e r X036B6203.

P 38 must n e v e r be used t o f i l l on t o p of c o l o u r c o a t s .
Remove t h e d e f e c t and s u r r o u n d i n g a r e a of c o l o u r c o a t s u s i n g
240 g r a d e p a p e r (3M) w e t . Dry t h o r o u g h l y , mix f i l l e r and
h a r d e n e r and a p p l y t o t h e d e f e c t . Allow t h e f i l l e r t o g e l
and become h a r d t o t h e t o u c h (10-15 m i n u t e s ) . Apply i n f r a
r e d lamps t o c u r e t h e f i l l e r f o r 30 m i n u t e s a t 24 i n c h e s from
t h e panel s u r f a c e . When c o o l wet f l a t t h e r e p a i r e d a r e a
u s i n g 240 g r a d e p a p e r (3M) and s m a l l hand b l o c k s . Confine
f l a t t i n g t o the f i l l e d area only. F l a t t i n g medium i s 1/4
p i n t F i n a d e t No. 1 t o 2 g a l l o n s c l e a n w a t e r .
3. G e l c r a c k d e f e c t s , where p o s s i b l e s h o u l d b e r e t u r n e d t o t h e
body p r e p a r a t i o n a r e a . I f g e l c r a c k s become a p p a r e n t a f t e r
t h e f i r s t colour p a i n t pass i n t h e p a i n t shop, t h e following
p r o c e d u r e must b e a d o p t e d . The c r a c k mark and an a r e a o f 4
i n c h s u r r o u n d i n g t h e mark must be removed w i t h a r o u t e r down t o
t h e base of t h e g e l c o a t . With an a i r l i n e blow o u t d u s t t r a c e s
and check t h a t no d u s t r e m a i n s . Using P38 f i l l e r mixed w i t h
hardener f i l l t h e d e f e c t . Allow t h e f i l l e r t o g e l and become
h a r d t o t h e t o u c h (10-15 m i n u t e s ) .
Apply i n f r a r e d lamps t o c u r e t h e f i l l e r f o r 30 m i n u t e s a t 24
i n c h e s from t h e p a n e l s u r f a c e . When c o o l wet f l a t t h e r e p a i r e d
a r e a u s i n g 240 g r a d e p a p e r (3M) and s m a l l hand b l o c k s . Confine
f l a t t i n g t o the f i l l e d areas only. F l a t t i n g medium i s 1 / 4 p i n t
F i n a d e t No. 1 t o 2 g a l l o n s c l e a n w a t e r .
Page 20 SECTION BA
4. Thoroughly d r y t h e body and components a f t e r f i l l e r / s t o p p e r

r e c t i f i c a t i o n and s o l v e n t wipe t h e r e c t i f i e d a r e a s u s i n g
F l o w l i n e Wax and G r e a s e Remover. Tak Rag t h e s e a r e a s t o
remove a l l t r a c e s o f d u s t .
5. Mix p o l y u r e t h a n e p r i m e r a s below:-
P.U. P r i m e r A075B6124 25 p a r t s by volume
P.U. Catalyst X036B6137 5 p a r t s by volume
P.U. Retarder A075B6172 2 p a r t s by volume
T h i n t o 45 s e c o n d s BS4 cup a t 18-20°C (64-68OF) m a t e r i a l

t e m p e r a t u r e u s i n g PU T h i n n e r A075B6172. Spray with A . I . D .
L2 p r e s s u r e p o t gun w i t h m a t e r i a l No. 6 , n e e d l e No. 6 , and
p r e s s u r e c a p No. 8 . .
6. Spot prime s p r a y t h e r e c t i f i e d a r e a s t o b l e n d i n w i t h
s u r r o u n d i n g body s u r f a c e s . Allow t o f l a s h o f f f o r 1 0 m i n u t e s
and a p p l y i n f r a r e d lamps t o c u r e t h e p r i m e r f o r 30 m i n u t e s
a t 24 i n c h e s from t h e p a n e l s u r f a c e . \Vet f l a t t h e r e c t i f i e d
a r e a s u s i n g 400 g r a d e p a p e r (3M). Do n o t r u b t h r o u g h t h e
polyurethane.
7. Mix p r i m e r s u r f a c e r a s below:-
S u r f a c e r 22 w h i t e A036B6396 and t h i n n e r 222 A036B6385 t o 25-
28 s e c o n d s BS4 cup a t 18-20°C, (64-68OF), m a t e r i a l temperature.
Spray with I.A.D. L2 gun w i t h m a t e r i a l n o z z l e N o . 6 , n e e d l e
No. 6 . and p r e s s u r e c a p No. 8 . B u i l d up 2 t o 3 f u l l c o a t s
allowing 10 - 1 5 m i n u t e s d r y i n g t i m e between e a c h c o a t a t
18 OC (65OF).
8. Apply i n f r a r e d lamps t o c u r e t h e r e c t i f i e d a r e a f o r 30 m i n u t e s
a t 24 i n c h e s from t h e p a n e l s u r f a c e . Allow t o c o o l and w e t
f l a t u s i n g 400 g r a d e p a p e r (3M). U s e 1/4 p i n t F i n a d e t No. 1
t o 2 g a l l o n s c l e a n water, change t h i s s o l u t i o n f r e q u e n t l y t o
avoid sludge contamination. A l l f l a t t i n g must b e done i n a f o r e
and a f t d i r e c t i o n u s i n g hand h e l d b l o c k s . C a r e must b e t a k e n
t o avoid rubbing through e i t h e r t h e c o l o u r f i l m o r t h e polyurethane
repair.
SECTION BA Page 2 1
9. Wash o f f w i t h c l e a n w a t e r ( h b s e and b r u s h ) and remove a l l

t r a c e s of rubbing s l u d g e . Dry t h o r o u g h l y i n s i d e and o u t
a n d e n s u r e t h a t a l l t r a c e s o f water i s removed from a l l
f i x t u r e s and b o b b i n s a s t h i s w i l l c a u s e b l i s t e r i n g o n t h e
2nd c o l o u r p a s s . T h o r o u g h l y Cacuum b o t h i n s i d e and o u t s i d e
o f t h e c a r and components b e f o r e c o l o u r c o a t i n g .
BA 1 0 - NITRO-CELLULOSE PAINT RECTIFICATION
A. Orange P e e l o r s c r a t c h e s c a u s e d by compounding
I f t h e s e d e f e c t s a r e heavy t h e y s h o u l d b e removed by w e t
f l a t t i n g u s i n g 1200 g r a d e p a p e r (3M). F l a t t i n g medium i s
1 / 4 p i n t F i n a d e t No. 1 t o 2 g a l l o n s o f c l e a n w a t e r . Always
f l a t i n a f o r e and a f t d i r e c t i o n . T h o r o u g h l y wash down t h e
f l a t t e d s u r f a c e u s i n g r u n n i n g water ( h o s e a n d b r u s h )
removing a l l t r a c e s o f r u b b i n g s l u d g e and d u s t . When
c o m p l e t e l y d r y u s i n g ICI 2 B r u b b i n g compound machine p o l i s h
t h e panels. Keep t h e p o l i s h i n g mop m o i s t and do n o t a l l o w
t h e compound t o d r y on t h e mop a s s c r a t c h i n g may r e s u l t . Clean
t h e mops f r e q u e n t l y , where p o s s i b l e t h e mop s h o u l d b e moved i n
a f o r e and a f t d i r e c t i o n . U s i n g a c l e a n d r y mop l i g h t l y b u f f
t o complete.
Continue p o l i s h i n g t h e panel u s i n g ' T - c u t ' . Using a f r e s h

p o l i s h i n g mop a g a i n k e e p i n g t h e mop m o i s t a n d moving i n a
f o r e and a f t d i r e c t i o n . F i n a l l y hand p o l i s h t h e c a r u s i n g
c l e a n c l o t h s and M i r r o r g l a z e MGM8 p o l i s h .
B. Scars o r sinkages
Normally t h e s e c a n b e d e a l t w i t h u s i n g t h e f l a t and p o l i s h
procedures d e t a i l e d i n 'A' above. I f t h e y a r e heavy however,
t h e s u n k e n s u r f a c e must b r b r o u g h t up t o t h e l e v e l o f t h e
surrounding paintwork with c e l l u l o s e s t o p p e r . Remove t h e g l o s s
from t h e d e f e c t u s i n g 400 g r a d e p a p e r (3M) hand f l a t t i n g .
Page 22
B. Scars o r sinkages cont . . ..

Ensure t h e a r e a i s d u s t f r e e and s c r e e d t h e d e f e c t w i t h
c e l l u l o s e s t o p p e r A036B6327. Allow t o c u r e under i n f r a
r e d h e a t i n g a t 24 i n c h e s from t h e s u r f a c e a t a p a n e l
t e m p e r a t u r e o f 60°C, (140°F) f o r 30 m i n u t e s . Allow t o
a i r c o o l and wet f l a t u s i n g s o a p l u b r i c a n t , hand b l o c k
w i t h 400 grade p a p e r (3M). Blow i n t h e r e c t i f i e d a r e a
w i t h p r i m e r s u r f a c e r 22 A036B6396 t o b r i n g t h e d e f e c t
s u r f a c e l e v e l up t o t h a t o f t h e s u r r o u n d i n g paintwork.
I f s e v e r a l c o a t s a r e n e c e s s a r y a l l o w 10-15 m i n u t e s d r y i n g
t i m e between e a c h c o a t a t 18OC (65OF). Allow a f u r t h e r
30 m i n u t e s d r y i n g t i m e p r i o r t o a p p l y i n g i n f r a r e d h e a t i n g
f o r 1 5 m i n u t e s a t 24 i n c h e s from t h e p a n e l g i v i n g a s u r f a c e
t e m p e r a t u r e of 60°C (140°F). Allow t o a i r c o o l and w e t
f l a t t h e a r e a u s i n g hand b l o c k , l u b r i c a n t and 600 g r a d e
p a p e r (3M) t o complete.
Mix p a i n t a s f o l l o w s : -
PO30 t y p e mono p a i n t 40 p a r t s by volume
A036B6385 222 t h i n n e r 60 p a r t s by volume
t o g i v e 22 s e c s BS4 cup a t 21°C (70°F). This t o be sprayed
u s i n g a Binks Bullows p r e s s u r e pot gun. Spray l i g h t c o a t s
t o o b t a i n d e s i r e d c o l o u r matching. Continue t o complete a s
i n 'A' above.
Gel Cracks
Remove t h e p a i n t , p r i m e r and g e l c o a t o v e r t h e c r a c k e d a r e a
and 1 / 2 i n c h s u r r o u n d i n g t h i s f e a t h e r i n g back t o t h e p a i n t
s u r f a c e o v e r a f u r t h e r 1/2 i n c h . Use a machine r o u t e r and
d i s c s a n d e r f o r t h i s purpose. Blow o u t d u s t , mix P38 f i l l e r
and f i l l t h e d e f e c t back t o s u r f a c e l a y e r . Allow t h e f i l l e r
t o cure u n t i l dry t o t h e touch, approximately 15 minutes a t
20°C (80°F). Apply i n f r a r e d lamps t o f u l l y c u r e t h e f i l l e r
f o r 30 m i n u t e s a t 24 i n c h e s from t h e p a n e l g i v i n g a s u r f a c e
t e m p e r a t u r e o f 60°C (140°F). Allow t o a i r c o o l , w e t f l a t
t h e f i l l e d a r e a u s i n g s m a l l hand b l o c k s , l u b r i c a n t and 320 g r a d e
paper (3M) c o n f i n i n g f l a t t i n g t o t h e f i l l e d a r e a o n l y .
SECTION BA Page 23
C. G e l C r a c k s c o n t ....
The n e x t o p e r a t i o n i s p o l y u r e t h a n e p r i m e r s p r a y i n g . I t is
i m p o r t a n t t h a t a l l c e l l u l o s e i s removed from a r e a s w h i c h
require polyurethane. Dry t h e a r e a f u l l y and s o l v e n t w i p e
using isopropanol. Tak Rag t h o r o u g h l y t o remove s u r f a c e
dust.
Mix p o l y u r e t h a n e p r i m e r a s f o l l o w s : -
P.U.Primer A075B6124 25 p a r t s by volume

P.U.Catalyst X036B6137 5 p a r t s by volume
P.U.Retarder A075B6172 2 p a r t s by volume
T h i n t o 45 s e c o n d s BS4 cup a t 18-20°C (64-6B°F) u s i n g P.U.
t h i n n e r A075B6125. S p r a y u s i n g a B i n k s Bullows p r e s s u r e p o t
gun w i t h m a t e r i a l n o z z l e 2 0 5 9 , n e e d l e 59 and p r e s s u r e c a p
6 3 PB. Allow t o f l a s h o f f t h e 1 0 m i n u t e s a t 21°C (70°F)
and t h e n a p p l y I n f r a r e d lamps t o o b t a i n p a n e l t e m p e r a t u r e
o f 60°C (140°F) f o r 20 m i n u t e s . Allow t o a i r c o o l and wet
f l a t t h e r e c t i f i e d a r e a u s i n g hand b l o c k s , l u b r i c a n t a n d
400 grade paper (3M). Do n o t r u b t h r o u g h t h e p o l y u r e t h a n e .
I f t h e p o l y u r e t h a n e s u r f a c e i s p i e r c e d i t w i l l be n e c e s s a r y
t o r e p e a t t h e priming procedure. Dry t h o r o u g h l y d e g r e a s e
u s i n g F l o w l i n e wax and g r e a s e r e m o v e r , and p r o c e e d on t o
primer/surfacer p a i n t i n g and p o l i s h i n g t r e a t m e n t s d e t a i l e d
i n A & B above.
D. Blisters
Rout o u t t h e b l i s t e r j u s t d e e p enough t o e x p o s e t h e b l i s t e r
cavity.
I f t h e defect is contained within t h e paint film thickness
i t w i l l b e n e c e s s a r y t o u s e c e l l u l o s e s t o p p e r f o l l o w e d by
primer/surfacer and p a i n t a s d e t a i l e d i n B a b o v e .
I f t h e d e f e c t e x t e n d s down t o t h e p o l y u r e t h a n e i t w i l l b e
n e c e s s a r y t o u s e P38, p o l y u r e t h a n e p r i m e r , p r i m e r / s u r f a c e r
a n d p a i n t a s i n C above.
I f t h e d e f e c t e x t e n d s i n t o t h e g e l c o a t it w i l l b e n e c e s s a r y
t o u s e P 3 8 , p o l y u r e t h a n e p r i m e r , p r i m e r / s u r f a c e r and p a i n t
as i n C above.
Page 24 SECTION BA
E. Chips and S c r-
a t c-
hes
Edge/corner c h i p s
These s h o u l d be touched i n w i t h a n a r t i s t b r u s h u s i n g p a i n t
mixed a s f o l l o w s : -
PO30 t y p e p a i n t - 40 p a r t s by volume
A036B6385 222 thinner 60 p a r t s by volume
Allow t o a i r d r y t h e n f u l l y c u r e u s i n g I n f r a r e d lamps 24
i n c h e s from p a n e l s u r f a c e g i v i n g 60°C (140°F) f o r 30 m i n u t e s
a l l o w t o a i r c o o l and w e t f l a t u s i n g 800 grade p a p e r (Norton)
with lubricant. Dry t h o r o u g h l y and c a r r y on t o r u b b i n g
compound and p o l i s h i n g t r e a t m e n t s a s i n A above.
Panel Chips
I f t h e s e c h i p s a r e down i n t o t h e g e l c o a t i t i s n e c e s s a r y t o
u s e P38, p o l y u r e t h a n e p r i m e r , p r i m e r / s u r f a c e r and p a i n t a s
d e s c r i b e d i n C above.
Scratches-minor
These s h o u l d be t r e a t e d a s f o r edge and c o r n e r c h i p s above
i . e . touched i n w i t h an a r t i s t b r u s h , wet f l a t t e d and
polished.
Scratches-major
These s h o u l d be t r e a t e d w i t h c e l l u l o s e s t o p p e r , p o l y u r e t h a n e
p r i m e r , p r i m e r s u r f a c e r and p a i n t a s i n B above.
SECTION BA Page 25
BA 11 - ACRYLIC POLYURETHANE PAINT RECTIFICATION

A. Orange P e e l o r s c r a t c h e s c a u s e d by compounding
T h e s e d e f e c t s s h o u l d b e removed u s i n g ICI 2B r u b b i n g compound.

Use a machine mop k e e p i n g t h e mop m o i s t and where p o s s i b l e
moving t h e mop i n a f o r e and a f t d i r e c t i o n .
Continue t h e p o l i s h i n g u s i n g 'T-Cut', and a f r e s h p o l i s h i n g

mop, a g a i n k e e p i n g t h e mop m o i s t a n d moving i n a f o r e and
a f t direction. F i n a l l y hand p o l i s h t h e c a r u s i n g c l e a n
c l o t h s and M i r r o r g l a z e MGM8 p o l i s h .
B. Scars o r sinkages
T h e s e d e f e c t s s h o u l d b e removed by wet f l a t t i n g t h e l a c q u e r
u s i n g hand b l o c k s , l u b r i c a n t and 1200 g r a d e p a p e r (3M). Great
c a r e must b e t a k e n n o t t o f l a t t h r o u g h t h e l a c q u e r c o a t . If
t h i s t r e a t m e n t i s s u c c e s s f u l t h e p a n e l c a n b e compounded and
p o l i s h e d a s above. I f t h e problem i s s u c h t h a t i t c a n n o t b e
removed by f l a t t i n g t h e n t h e a r e a s h o u l d be t h o r o u g h l y d r i e d
and Tak Rag p r e p a r e d . C l e a r l a c q u e r s h o u l d be mixed a s
follows: -
I C I P190-0379 Clear coat 4 p a r t s by volume
I C I P210-0760 Hardener 2 p a r t s by volume
ICI P850-1212 Thinner 2 p a r t s by volume
V i s c o s i t y 2 3 t o 27 s e c o n d s BS4 cup a t 18OC (64OF), m a t e r i a l
tetoperature. I f n e c e s s a r y add more P850-1212 t h i n n e r t o
achieve t h i s viscosity. Mask o f f a r e a i m m e d i a t e l y s u r r o u n d i n g
t h e f a u l t y a r e a and b u i l d up t h e minimum number o f c o a t s o f
lacquer required t o disguise t h e defect. 1 0 minutes should
b e a l l o w e d between c o a t s f o r f l a s h o f f a t lS°C ( 64OF). Leave
t h e f i n a l c o a t t o f l a s h o f f f o r 30 m i n u t e s a t 18OC (64OF), t h e n
a p p l y I n f r a r e d lamps t o f u l l y c u r e t h e l a c q u e r f o r 3 0 m i n u t e s
a t 60°C ( 1 4 0 ° F ) . The r e c t i f i e d a r e a can t h e n b e wet f l a t t e d
compounded and p o l i s h e d a s above.
I f by e r r o r t h e metallic p a i n t u n d e r t h e l a c q u e r i s b r o k e n
i n t o by f l a t t i n g t h e n it w i l l b e n e c e s s a r y t o s p r a y f r e s h
c o l o u r c o a t and l a c q u e r o v e r t h i s a r e a . W e t f l a t the area
u s i n g 400 g r a d e p a p e r (3M), l u b r i c a n t and hand b l o c k . Dry
t h o r o u g h l y a n d Tak Rag.
Page 26
Scars o r sinkages c o n t . . . .
Mix c o l o u r p a i n t a s f o l l o w s : -
ICI P421 paint 4 p a r t s by volume

ICI P210 760 hardener 2 p a r t s by volume
I C I P850 1212 thinner 2 p a r t s by volume.
V i s c o s i t y 23-27 seconds BS4 cup a t 18OC m a t e r i a l t e m p e r a t u r e .
I f n e c e s s a r y add more P850-1212 t h i n n e r t o a c h i e v e t h i s
viscosity.
Mix c l e a r l a c q u e r a s f o l l o w s : -
ICI P190-0379 c l e a r coat 4 p a r t s by volume

ICI P210-0760 hardener 2 p a r t s by volume
ICI P850-1212 thinner 2 p a r t s by volume
V i s c o s i t y 23-27 seconds BS4 cup a t 18OC (64OF) m a t e r i a l

temperature. I f n e c e s s a r y add more P850-1212 t h i n n e r t o a c h i e v e
t h i s viscosity. Mark o f f t h e a r e a immediately s u r r o u n d i n g
t h e faulty area. Spray one s i n g l e c o a t o f c o l o u r p a i n t and
a l l o w 30 m i n u t e s t o f l a s h o f f a t 18OC (64OF). Spray one
s i n g l e c o a t of c l e a r l a c q u e r a l l o w 15 m i n u t e s t o f l a s h o f f
a t 18OC (64OF) and s p r a y t h e f i n a l l a c q u e r c o a t . Leave t o
f l a s h o f f f o r 30 m i n u t e s a t lS°C (64OF) and t h e n a p p l y i n f r a
r e d h e a t i n g f o r 30 m i n u t e s a t a p a n e l t e m p e r a t u r e of 60°C ( 1 4 0 ° F ) .
Allow t o a i r c o o l and t h e n wet f l a t u s i n g 1200 g r a d e p a p e r
(3M) f o l l o w e d by compound and p o l i s h i n g a s i n A above.
Gel Cracks
Remove t h e p a i n t , p r i m e r and g e l c o a t o v e r t h e c r a c k e d a r e a
and 1/2 i n c h s u r r o u n d i n g t h i s , f e a t h e r i n g back t o t h e p a i n t
s u r f a c e over a f u r t h e r 1/2 inch. Apply P38, p o l y u r e t h a n e
p r i m e r and p r i m e r / s u r f a c e a s d e s c r i b e d i n BA 10 - P a r t C , and
c o n t i n u e t o p a i n t and f i n i s h a s i n A & B above.
Blisters
Rout o u t t h e b l i s t e r j u s t d e e p enough t o expose t h e b l i s t e r
cavity.
I f t h e d e f e c t is contained within t h e p a i n t f i l m t h i c k n e s s
i t w i l l be necessary t o r e s p r a y l o c a l l y both c o l o u r p a i n t
and c l e a r l a c q u e r a s d e s c r i b e d i n B above.
SECTION BA Page 27
D. Blisters cont.. ..
I f t h e d e f e c t e x t e n d s lower t h a n t h e p a i n t f i l m it w i l l be
n e c e s s a r y t o u s e P38, p o l y u r e t h a n e p r i m e r , p r i m e r / s u r f a c e r
and p a i n t a s f o r t h e g e l c r a c k d e f e c t d e s c r i b e d i n C a b o v e .
E. C h i p s and S c r a t c h e s
Where p o s s i b l e t h e s e c a n be t r e a t e d by r e s p r a y i n g b o t h c o l o u r
a n d c l e a r l a c q u e r a s i n B above b u t i f n e c e s s a r y t h e f u l l
.., body s u r f a c i n g t r e a t m e n t must b e g i v e n a s i n C a b o v e .
BA 1 2 - PAINT PROCEDURE FOR RRIM COMPONENTS
E c l a t E x c e l f r o n t a n d r e a r bumpers, s i l l s a n d r e a r v a l e n c e s a r e
R e i n f o r c e d R e a c t i o n I n j e c t i o n Mouldings (RRIM) a n d a r e s u p p l i e d
only i n primer f o r f i n i s h i n g i n t h e colour r e q u i r e d . Refer t o
t h e p a i n t code stamped on t h e v e h i c l e i d e n t i f i c a t i o n p l a t e .
1982/83 model y e a r E x c e l s .
R R I M p a r t s a r e p a i n t e d i n S t e e l Grey m e t a l l i c L o t u s p a r t n o .
A089B6113V , I C I P421/5310 and c l e a r l a q u e r , u s i n g a f l e x a i d
a d d i t i v e i n b o t h c o l o u r and c l e a r c o a t s .
1984 model y e a r E x c e l s .
On m e t a l l i c c a r s , R R I M p a r t s a r e p a i n t e d i n t h e same P421 l i n e
p a i n t a s i s t h e body, t o g e t h e r w i t h a c l e a r l a q u e r and f l e x a i d
additive.
On mono c o l o u r cars finished i n nitro cellulose ('L' p a i n t code
p r e f i x ) t h e R R I M p a r t s a r e p a i n t e d u s i n g P420 l i n e 2-pack a c r y l i c
polyurethane paint with a f l e x a i d additive, but -
NO c l e a r l a q u e r .
P a i n t p a r t numbers a s f o l l o w s : -
V I N P l a t e Body Colour RRIM P a i n t P a r t Numbers

P a i n t Code Lotus ICI
L31 Lemon Yellow A089B6148V P420/0455

L25 Monaco White A089B6149V P420/7517
L42 C a l y p s o Red A089B6150V ~ 4 2 0 / ~ ~ 2 3
L15 Black A089B6151V P420/0122
On mono c o l o u r c a r s finished i n a c r y l i c polyurethane

( ' A ' p a i n t c o d e p r e f i x ) , R R I M p a r t s a r e p a i n t e d i n t h e same
P420 l i n e p a i n t a s i s t h e body, t o g e t h e r w i t h a c l e a r l a q u e r
and f l e x a i d a d d i t i v e .
JUL
Page 28 SECTION BA
1. Preparation.
Use 400 g r i t carburundum p a p e r t o wet f l a t t h e p a n e l and

remove a l l s u r f a c e i r r e g u l a r i t i e s . Do n o t r u b t h r o u g h t h e
p r i m e r (A082B4429V, ICI P571/5000).
2. Co1,our P a i n t A p p l i c a t i o n .
For m e t a l l i c c o l o u r s :
Colour p a i n t P421 5 p a r t s by volume
F l e x Aid A089B6121V P100/2001 1 p a r t by volume
Hardener A076B606 1 V P210/0760 3 p a r t s by volume
Thinner A076B6077V P850/1212 To s p r a y i n g V i s c o s i t y
F o r mono c o l o u r s :
Colour p a i n t P420 5 p a r t s by volume

Hardener A076B6061V P210/0760 3 p a r t s by volume
For e i t h e r s y s t e m , s p r a y one s i n g l e c o a t , a l l o w 1 0 minutes t o

f l a s h o f f , and s p r a y one c r o s s c o a t . Allow 30 m i n u t e s f l a s h o f f
b e f o r e s t o v i n g a t 80°C f o r 50 m i n u t e s . R e c t i f y minor b l e m i s h e s
w i t h c e l l u l o s e s t o p p e r and p r e p a r e f o r s p r a y i n g second c o a t .
S p r a y second c o a t a s a b o v e , and i f n e c e s s a r y w i t h m e t a l l i c c o l o u r s ,
a d u s t c o a t t o rninimise s h a d i n g . For mono c o l o u r s , a l l o * 30
m i n u t e s f l a s h o f f b e f o r e s t o v i n g a t 80°C f o r 50 m i n u t e s .
3. C l e a r Coat A p p l i c a t i o n . (Not used on 'L' p a i n t code c a r s )
C l e a r Coat A076B6069V P190/0379 5 p a r t s by volume

Hardener A076B6061V P210/0760 3 p a r t s by volume
S p r a y one s i n g l e c o a t o f c l e a r c o a t , a l l o w 1 0 m i n u t e s t o f l a s h o f f ,
and s p r a y one d o u b l e c o a t . Allow 30 m i n u t e s t o f l a s h o f f b e f o r e
s t o v i n g a t 80°C f o r 50 m i n u t e s .
JUL 1985
SECTION BA Page 29
-
NOTE R R I M c o m p o n e n t s c a n o n l y b e s t o v e d i f
used t o prevent d i s t o r t i o n . Where j i g s a r e
j i g s u p p o r t s are
not available, the
p a i n t may b e a i r d r i e d a t room t e m p e r a t u r e f o r 10 t o 1 2 h o u r s
minimum. P a r t s s h o u l d n o t be f i t t e d f o r 24 h o u r s .
BA13 - PEARLESCENT WHITE PAINT PROCEDURE
Cars f i n i s h e d i n ' P e a r l e s c e n t W h i t e f w i t h p a i n t c o d e PO2

should be painted a s follows:
1. F o l l o w p r o c e d u r e s BA2, BA3 BA4 a n d B A 5 t o a p p l y p o l y u r e t h a n e
0 p r i m e r and t o p r e p a r e f o r t h e c o l o u r coat.
2. F o l l o w p r o c e d u r e BA7 s t a g e s 1 , 2 a n d 3 t o a p p l y Monaco
w h i t e , L C 1 P420-7517, and a l l o w 45 min. f l a s h o f f b e f o r e
appiying t h e pearlescent coat.
3. P e a r l e s c e n t F i n i s h : A089B6184V I C I ~ 4 2 1 - 7 8 6 5
Mixing R a t i o : P e a r l e s c e n t 4 p a r t s by v o l u m e
Hardener P2 10-760 1 p a r t s by v o l u m e
T h i n n e r s P850-1212 4 p a r t s by v o l u m e
S p r a y i n g v i s c o s i t y i s 16-18 s e c s . BS4 c u p a t 1 8 ' ~ material

temperature. P r e s s u r e a t t h e gun 60 p s i .
S p r a y 2 s i n g l e p a s s e s t o o b t a i n a f i l m t h i c k n e s s of 1 t h o u .
a p p r o x . 5 min. f l a s h o f f between c o a t s .
F l a s h o f f 30-45 min. b e f o r e c l e a r c o a t a p p l i c a t i o n .
4. F o l l o w p r o c e d u r e BA7 s t a g e s 4 t o 9 t o a p p l y c l e a r c o a t a n d
to polish.
R R I M COMPONENTS I N PEARLESCENT WHITE
1. F o l l o w p r o c e d u ' r e BA12 t o a p p l y a c o l o u r c o a t of R o n a c o
W h i t e I C I P420-7517.
a
JUL 1985
Page 30 SECTION BA
2. Pearlescent Finish: A 0 8 9 B 6 1 8 4 ~ I C I P421-7865

Mixing Ratio : Pearlescent ' 5 pbv
Flexaid PlOO 2 0 0 1 1 pbv
Hardener P210 0 7 6 0 1 . 5 pbv
Thinners P850 1 2 1 2 t o s p r a y i n g v i s c o s i t y
S p r a y i n g v i s c o s i t y i s 1 6 - 1 8 s e c s . BS4 c u p a t 1 8 ' ~ m a t e r i a l
temperature.
Spray 2 s i n g l e passes t o obtain a film thickness of 1 thou.
a p p r o x . 5 min f l a s h o f f between c o a t s .
F l a s h o f f 30-45 m i n s b e f o r e c l e a r c o a t a p p l i c a t i o n .
3. F o l l o w p r o c e d u r e BA12 t o a p p l y a c l e a r c o a t o f I C I
P190-0379.
BA 1 4 - PAINT REMOVAL
Under n o c i r c u m s t a n c e s m u s t " P a i n t S t r i p p e r " be u s e d t o remove

p a i n t from g l a s s f i b r e r e i n f o r c e d p l a s t i c (G.F.R.P.) bodies as
t h i s w i l l attack the gel-coat, w h i c h MUST o f c o u r s e r e m a i n i n t a c t .
The recommended p r o c e d u r e f o r r e m o v i n g p a i n t is:-
1. Wash o f f w i t h a slow t h i n n e r ,
or
2. Wet f l a t w i t h a n a p p r o p r i a t e g r a d e of p a p e r d e p e n d e n t
o n t h e a m o u n t of p a i n t t o b e r e m o v e d .
a
P a p e r h e a v i e r t h a n 1124011g r a d e m u s t n o t b e u s e d .
JUL 1985
Page I
-BODY
-
BODYCARE AND REPAIR
SECTION BB - ALL MODELS
Operation Page
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 Inserts)
Body Mounting Points
Page 2
BB 1 - LOTUS COMPOSITE BODY FEATURES
(Owners Handbook E x t r a c t )
L o t u s C a r s L i m i t e d a r e a c k n o w l e d g d l e a d e r s i n t h e f i e l d of
c o m p o s i t e moulding d e s i g n and m a n u f a c t u r i n g t e c h n i q u e s ,
h a v i n g d e v e l o p e d methods which a r e now u s e d u n d e r l i c e n s e
throughout t h e world.
T h e s e b r i e f n o t e s i n t r o d u c e some f e a t u r e s o f t h e c o n s t r u c t i o n
and s e r v i c e p r o p e r t i e s o f c o m p o s i t e s a s a p p l i e d t o v e h i c l e
bodies.
Composite m a t e r i a l s have major a d v a n t a g e s f o r s p e c i a l i s t

vehicle bodies;-
Composites w i l l n o t c o r r o d e . The s t r e n g t h of c o m p o s i t e
components i s r e t a i n e d r e g a r d l e s s o f a g e , u n l e s s p h y s i c a l
damage i s s u s t a i n e d .
The M a n u f a c t u r i n g p r o c e s s e n a b l e s t h e t h i c k n e s s o f c o m p o s i t e
mouldings t o be v a r i e d t h r o u g h o u t t h e b o d y s h e l l and components
t o p r o v i d e e f f i c i e n t s t r u c t u r e s , of h i g h s t r e n g t h and low
weight.
The p a s s e n g e r compartment i n a l l L o t u s models i s e n c l o s e d by

p r o t e c t i v e s t r u c t u r a l beams, b u i l t i n t o t h e b o d y s h e l l and
d o o r s which combine t o p r o v i d e maximum o c c u p a n t p r o t e c t i o n .
Composites h a v e t h e a b i l i t y t o a b s o r b h i g h i m p a c t l o a d s by
p r o g r e s s i v e c o l l a p s e and impact damage i s l o c a l i s e d . In
a c c i d e n t s i t u a t i o n s t h i s p r o t e c t s d c c u p a n t s from i n j u r i o u s
shock l o a d s and g r e a t l y r e d u c e s t h e d a n g e r o f e n t r a p m e n t by
d e f o r m a t i o n o f body p a n e l s , o r jammed d o o r s . T h i s behaviour
a l s o f a c i l i t a t e s r e p a i r by i n t e g r a t i n g r e p l a c e m e n t body
s e c t i o n s w i t h t h e undamaged p a r t , u s i n g r e c o g n i s e d approved
methods which w i l l r e s t o r e t h e body t o o r i g i n a l c o n d i t i o n
without residual s t r a i n o r d i s t o r t i o n .
cont .. . . .
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 cracking may be confined to the surface gel coat, with no
reduction in panel strength, but if damage is more severe the
composite structure below the gel coat may be weakened.
Localised repairs can be made in either case. Gel cracks may
not appear immediately after overstressing because the effect
can be masked by the flexibility of the paint finish which
covers the gel coat. In some instances gel cracks can take
as long as three months to appear.
Gel cracks can be caused by, for example:-
Sitting or leaning heavily on the bonnet or any other

flexible panel.
Knocking doors against obstructions when opening.
Dropping a sharp or heavy object on a panel.
Allowing unsecured items to slide about in the boot (trunk).
Closing bonnet (hood) or boot (trunk) onto projecting objects,

e.g. luggage or tools.
Attempting to deflect or remove, by force, parts attached to

composite panels e.g. mirrors, locks, aerial etc., (action by
vandals or even some mechanical car washes).
Incorrect jacking.
Collision with heavy rigid object.
Note that bumpers are sacrificial members which will absorb

shock loads, thus protecting body panels. Exceeding bumper
load factor may cause gel crazing of body panels.
Page 4 SECTION BB
BB 2 - BODYCARE
(Owners Handbook E x t r a c t )
The f i n i s h o f your L o t u s i s e x t r e m e l y r e s i s t a n t t o a l l
normal forms o f a t m o s p h e r i c a t t a c k . Provided t h e simple
m a i n t e n a n c e p r o c e d u r e summarised below i s f o l l o w e d , it
w i l l r e t a i n i t s g l o s s , c o l o u r and p r o t e c t i v e p r o p e r t i e s
t h r o u g h o u t t h e l i f e of t h e v e h i c l e .
However, c a r f i n i s h e s a r e n o t c h e m i c a l l y r e s i s t a n t . Severe
l o c a l c o n t a m i n a t i o n of a n a c i d o r an a l k a l i n e c h a r a c t e r
can occur. I f it is l e f t i n contact with t h e paint film
f o r any l e n g t h of t i m e , i t may c a u s e p i t t i n g and c o l o u r
change.
Washing
Many c o n t a m i n e n t s which w i l l a t t a c k a p a i n t f i l m a r e w a t e r
soluble. They w i l l be removed b e f o r e any harm o c c u r s by
thorough washing w i t h p l e n t y of w a t e r , t o which i s added a
few d r o p s of l i q u i d d e t e r g e n t . F r e q u e n t washing i s t h e b e s t
s a f e g u a r d a g a i n s t unseen c o n t a m i n a n t s ; a t t h e same t i m e
e n s u r i n g t h e r e g u l a r removal of d i r t , d u s t and t r a f f i c f i l m .
I f washing w i t h c o l d w a t e r i s n o t e f f e c t i v e , warm w a t e r and

d e t e r g e n t w i l l remove t h e gummy d e p o s i t s exuded by some t r e e s
i n t h e summer months. P e t r o l o r w h i t e s p i r i t w i l l remove s t a i n s
of t h e t a r , bitumen and g r e a s e t y p e .
Polishing
E v e n t u a l l y some l o s s of g l o s s , and an a c c u m u l a t i o n o f t r a f f i c
f i l m , w i l l occur. A t t h i s s t a g e , a f t e r t h e normal washing, a
p o l i s h w i t h a good q u a l i t y . 1 . i q u i d p o l i s h w i l l r e s t o r e t h e
o r i g i n a l l u s t r e of t h e p a i n t f i l m .
Higher g l o s s of t h e p a i n t f i l m , and added p r o t e c t i o n a g a i n s t

c o n t a m i n a t i o n , c a n b e o b t a i n e d by wax p o l i s h i n g . But i t must
b e remembered t h a t a wax p o l i s h c a n o n l y b e u s e d s u c c e s s f u l l y
on a c l e a n s u r f a c e , and t h a t t h e p r e v i o u s a p p l i c a t i o n must
f i r s t be removed w i t h w h i t e s p i r i t o r a l i q u i d p o l i s h c l e a n e r
b e f o r e re-waxing.
SECTION BB Page 5
Ventilation
Water l y i n g on t h e p a i n t s u r f a c e f o r l e n g t h y p e r i o d s w i l l
penetrate the paint film. Although t h e e f f e c t s w i l l n o t b e
v i s i b l e i m m e d i a t e l y , t h i s w i l l i n f a c t cause a d e t e r i o r a t i o n
i n t h e p r o t e c t i v e p r o p e r t i e s of t h e p a i n t f i l m .
I f a c a r i s g a r a g e d , good v e n t i l a t i o n must b e p r o v i d e d .
O t h e r w i s e s t o r a g e o u t s i d e on a h a r d s t a n d i n g o r u n d e r a
c a r p o r t is preferable.
Summary
1. Wash f r e q u e n t l y , u s i n g c o l d w a t e r w i t h a few d r o p s
o f l i q u i d d e t e r g e n t added
2. I n s p e c t a f t e r a normal w a s h i n g , and remove any l o c a l

c o n t a m i n a t i o n w i t h warm w a t e r , p e t r o l o r w h i t e s p i r i t
a s appropriate.
3. U s e a good q u a l i t y l i q u i d p o l i s h i n f r e q u e n t l y - say,
t w i c e a y e a r - t o r e s t o r e h i g h g l o s s and t o remove
a c c u m u l a t e d t r a f f i c f i l m and scum.
4. P a r k on a h a r d s t a n d i n g , and u n d e r c o n d i t i o n s o f good
v e n t i l a t i o n i f a covered a r e a i s used.
Windscreen
When washing t h e w i n d s c r e e n , t h e w i p e r b l a d e may o n l y b e
l i f t e d away from t h e s c r e e n a s m a l l d i s t a n c e , t o a v o i d
damaging t h e p a n t o g r a p h mechanism. Wash t h e w i p e r b l a d e
with c l e a n water.
B r i g h t Metal
The a t t r a c t i v e a p p e a r a n c e o f b r i g h t metal c a n b e p r e s e r v e d i f
i t i s cleaned r e g u l a r l y .
Each week wash w i t h a s o a p and w a t e r s o l u t i o n , r i n s e t h o r o u g h l y

w i t h c l e a n w a t e r and d r y o f f . For f u r t h e r p r o t e c t i o n , apply a
good q u a l i t y wax p o l i s h .
Page 6
Alloy Wheels
I t i s recommended t h a t t h e s e a r e washed w i t h t h e p r e p a r a t i o n
a s i s used t o wash t h e bodywork. Use a brusH h a v i n g nylon
b r i s t l e s only. During t h e w i n t e r months, p a r t i c u l a r l y when
s a l t h a s been used on t h e r o a d s f o r t h e d i s p e r s a l o f snow and
i c e , remove a l l w h e e l s , i n c l u d i n g s p a r e , and wash t h o r o u g h l y
t o remove a l l accummulated r o a d f i l t h from wheels and t y r e s .
Upholstery and roof l i n i n g

Normal c l e a n i n g c o n s i s t s of an o c c a s i o n a l l i g h t wipe o v e r
w i t h a c l o t h dampbned i n a m i l d soap and w a t e r s o l u t i o n ;
i t i s i m p o r t a n t t h a t t h e c l o t h i s o n l y dampened, n o t
soaked.
Leather Upholstery
The l e a t h e r s h o u l d be wiped o v e r o c c a s i o n a l l y w i t h a c l o t h
dampened i n warm soapy w a t e r . Repeat t h e o p e r a t i o n u s i n g
a f r e s h c l o t h and w a t e r only - avoid f l o o d i n g t h e l e a t h e r -
f i n i s h by d r y i n g and p o l i s h i n g w i t h a s o f t dry c l o t h .
I t i s i m p o r t a n t t o u s e a m i l d , non c a u s t i c s o a p of t h e t o i l e t
kind ( o r 'Lux' s o a p f l a k e s ) and t o avoid t h e u s e o f p e t r o l o r
d e t e r g e n t s , f u r n i t u r e creams and p o l i s h e s .
An o c c a s i o n a l u s e of C e e Bee Hide Food is recommended a f t e r

t h e l e a t h e r h a s been i n u s e f o r a y e a r o r two.
Seat Belts cleaning

The most s u i t a b l e c l e a n e r f o r s e a t b e l t s i s a m i l d s o a p and
w a t e r s o l u t i o n s i n c e t e r y l e n e does n o t a b s o r b w a t e r t o any
e x t e n t and t h e r e f o r e w i l l d r y q u i t e q u i c k l y .
F l u i d s which are harmful t o t e r y l e n e are t h o s e c o n t a i n i n g

m i n e r a l a c i d s and MUST NOT b e used.
SECTION 55 Page 7
BB 3 - GENERAL DESCRIPl'ION
The b a s i s o f t h e v e h i c l e comprises a o n e p i e c e
moulded composite m a t e r i a l b o d y s h e l l which s t r a d d l e s
a f a b r i c a t e d s t e e l backbone c h a s s i s , and i s b o l t e d
t o i t v i a i n t e g r a l a l l o y bobbins a t s e v e r a l widespread
mounting p o i n t s .
Whilst t h e c h a s s i s c a r r i e s a l l t h e major s t r u c t u r a l
l o a d s , t h e body i s used t o c a r r y o r t r a n s f e r t h e
r e m a i n d e r , and when t h e body and c h a s s i s a r e mounted
t o g e t h e r each c o n t r i b u t e s t o t h e s t r e n g t h and t o r s i o n a l
s t i f f n e s s of each o t h e r . The b o d y s h e l l i s moulded i n
two major s e c t i o n s , a t o p s h e l l and u n d e r t r a y which
a r e bonded t o g e t h e r around t h e ' w a i s t l i n e ' .
S p e c i f i c p r o p e r t i e s , where r e q u i r e d , a r e i n c o r p o r a t e d
w i t h i n t h e moulded s e c t i o n s by u t i l i z i n g t h e h i g h
t e n s i l e and s t r e n g t h c h a r a c t e r i s t i c s o f t h e v a r i o u s
t y p e s of f i b r e r e i n f o r c e m e n t used.
BB 4 - ACCIDENT DAMAGE ASSESSMENT
A l l damage t o t h e body must be c l a s s e d a s s t r u c t u r a l .

However, i n s i d e t h i s broad c l a s s i f i c a t i o n t h e damaged a r e a
" can be f u r t h e r d e f i n e d a s e i t h e r : -
a ) High s t r e s s e d , b ) Moderate s t r e s s e d , o r =) Low s t r e s s e d ,
and on t h a t d e f i n i t i o n depends t h e o r i g i n a l c o n s t r u c t i o n and
t h e r e f o r e t h e r e p a i r method t o b e employed.
A s a g e n e r a l r u l e t h e r e should be a bond wherever two p a n e l s

t o u c h , o r wherever t h e y c l o s e on i m p o r t a n t p o i n t s . It is
u s u a l l y p o s s i b l e t o check t h e s e bonds b o t h v i s u a l l y and
physically f o r f r a c t u r e s o r breaks. A s c e r t a i n t h e c a u s e of
damage and t h e d i r e c t i o n o f impact and examine a l l p a n e l s o r
bonds which may have been a f f e c t e d .
Page 8
A f r o n t end i m p a c t , f o r example, may e a s i l y c a u s e t h e bonds

a t t h e bulkhead t o s p l i t w i t h o u t t h e d e f e c t b e i n g e a s i l y
visible.
To f a c i l i t a t e a c l o s e r examination i t may b e n e c e s s a r y t o
remove p a r t s and components t o d e t e r m i n e t h e e x t e n t o f t h e
damage. When d e t e r m i n g t h e s i z e of t h e replacement p a n e l s
t o be o r d e r e d , make s u r e t h e new p a n e l s , when c u t - i n , w i l l
be a t t a c h e d t o f i r m GFRP m a t e r i a l ; avoid badly crazed a r e a s
and badly b u r n t a r e a s .
F i r e damage i s t h e most d i f f i c u l t t o a s s e s s b u t g e n e r a l l y o n l y
t h e o b v i o u s l y b u r n t o r c h a r r e d s e c t i o n s w i l l need t o be
replaced o r reinforced.
BB 5 - RESIN M I X ( A c c e l e r a t e d Hand Lay-Up)
Resin - P a r t Number X036 B 6206V

C a t a l y s t - P a r t Number X036 B 6344V (Butinox M50)
Mix h a r d e n e r ( c a t a l y s t ) i n t o t h e r e s i n i n t h e p r o p o r t i o n s o f
1 5 c c of c a t a l y s t t o 1 kg (21b) o r r e s i n . Mix r a t i o (1:150)
For Gel c o a t s mix 20cc of c a t a l y s t w i t h 1 kg ( 2 l b ) of g e l .
BB 6 - BASIC BONDS AND JOINTS
Cut o f f t h e damaged p o r t i o n a f t e r marking f o r r e - p o s i t i o n i n g

of t h e new p a n e l . Clean and p r e p a r e b o t h e x i s t i n g and new
p a n e l s , removing a l l r o a d f i l t h and u n d e r s e a 1 from t h e
e x i s t i n g panel. Cut t h e new p a n e l t o f i t , l i n i n g up w i t h t h e
p r e v i o u s l y marked p o s i t i o n i n g l i n e s . Mate t h e two p a r t s t o
be j o i n e d , u s i n g packing a s n e c e s s a r y t o a c h i e v e a p e r f e c t
match. J o i n i n g p l a t e s (of a n g l e d s e c t i o n ) should b e a t t a c h e d
t o t h e e x t e r i o r of t h e p a n e l w i t h t h e a i d of s e l f - t a p p i n g s c r e w s .
Using chopped-strand g l a s s f i b r e mat of 302 w e i g h t , t o g e t h e r
w i t h t h e r e s i n and h a r d e n e r , lay-up by hand from t h e u n d e r s i d e
o f t h e j o i n t , e n s u r i n g an o v e r l a p o f 3 - 4 i n (8-10 cm), and
0
l e a v e t o harden i n a t e m p e r a t u r e o f n o t less t h a n 1 5 C.
SECTION BB Page 9
When t h e r e p a i r h a s f u l l y c u r e d ( h a r d e n e d ) , and NOT BEFORE,

remove t h e j o i n i n g p l a t e s from t h e e x t e r i o r s u r f a c e . Sand o u t
t h e t o p exposed j o i n t , f e a t h e r i n g outwards from t h e j o i n l i n e ,
removing any o l d p a i n t i n t h e p r o c e s s . F i l l t h e depression
w i t h r o v i n g s and r e s i n , and w h i l s t s t i l l w e t , l a y o v e r a t h i n
l a y e r of chopped-strand mat and apply more r e s i n and h a r d n e r
( 1 oz w e i g h t ) . Allow t o d r y and f u l l y c u r e . Sand down and
f i l l any i m p e r f e c t i o n s w i t h f i l l e r ( P a r t No. A036B 6203V), and
allow t o d r y . F i n a l l y , sand down with carborundum paper t o
prepare f o r painting.
BB 7 - HEADLAMP BOWLS AND SURROUNDS
Where s e v e r e damage t o t h e headlamp bowl and surround has

occured i t i s g e n e r a l l y found more economical t o f i t a
replacement bowl and s e c t i o n . I t is essential for the correct
o p e r a t i o n of t h e headlamp assembly t h a t t h e replacement s e c t i o n
is c o r r e c t l y p o s i t i o n e d , t h e bowl being a t t a c h e d t o t h e p i v o t
bobbins of t h e new s e c t i o n and t e s t e d f o r c l e a r a n c e i n t h e
up-and-down p o s i t i o n b e f o r e b e i n g bonded t o t h e c a r .
The bowl should be f i x e d i n t h e most c o n v e n i e n t p o s i t i o n by t a p i n g

i n p l a c e b e f o r e l a m i n a t i n g i n t h e new s e c t i o n . Accessibility is
r e s t r i c t e d i n t h i s a r e a and i t may be found more advantageous t o
work through t h e a c t u a l lamp u n i t hole.
A l t e r n a t i v e l y where a l e s s s e r i o u s impact has o c c u r r e d and

t h e lamp surround can be s a t i s f a c t o r i l y r e p a i r e d without
r e s o r t i n g t o a replacement s e c t i o n i t i s recommended t h a t
a s m a l l j i g be made t o embrace b o t h p i v o t mounting b o l t s
of t h e bowl w i d t h . These can be screwed i n t o t h e body
bobbins s e r v i n g t o c o r r e c t l y l o c a t e them w h i l s t p r o v i d i n g
s u f f i c i e n t a c c e s s t o bond them i n and perform t h e d e s i r e d
repair.
Page 70 SECTION BB
SUPERFICIAL DEFECT REPAIRS
BB 8 - PIN HOLES OR AIR VOIDS

-
I t i s d i f f i c u l t t o overcome a i r v o i d s and p i n h o l e s when a

hand lay-up r e p a i r i s c a r r i e d o u t , b u t , a s a l l body components
0 0
a r e h e a t e d t o 82 C (180 F), t h e maximum s e r v i c e t e m p e r a t u r e ,
b e f o r e p a i n t i n g , t h e s e i m p e r f e c t i o n s w i l l show u p . Any a i r
v o i d s l o c a t e d i n t h i s manner c a n b e opened up from t h e s u r f a c e
and f i l l e d w i t h a s t o p p e r o r f i l l e r .
The a i r v o i d s and p i n h o l e s can b e opened up u s i n g one o r b o t h

of t h e f o l l o w i n g methods:
a) E n l a r g i n g t h e h o l e by gouging o r ' p i c k i n g - o u t '

b) D r i l l i n g o r routing o u t , leaving a l a r g e hole with near
parallel sides.
I f a f t e r r e p a i r i n g pin holes t h e p a i z t s u r f a c e s i n k s over t h e
r e p a i r , t h i s may have been caused by t h e f i l l e r s h r i n k i n g .
When c e l l u l o s e p a i n t s t o p p e r i s u s e d , o v e r f i l l a s t h i s s t o p p e r
h a s a h i g h r a t e of s h r i n k a g e . Depressions i n t h e p a i n t s u r f a c e
t o o soon a f t e r t h e r e p a i r .
.
when u s i n g a p o l y e s t e r s t o p p e r a r e u s u a l l y caused by p a i n t i n g
T h e r e f o r e , befoi-e r u b b i n g down and
p a i n t i n g make s u r e t h e s t o p p e r h a s c u r e d c o m p l e t e l y , l e a v e f o r
a s l o n g a s p o s s i b l e b e f o r e r u b b i n g down. S e e S e c t i o n BA.
BB 9 - DISTORTION OR WRINKLING
D i s t o r t i o n o r w r i n k l i n g a r e u s u a l l y caused by e x p o s u r e t o
severe heat. T h i s can cause t h e r e s i n t o s o f t e n s l i g h t l y
and i n d o i n g s o g i v e way t o any i n b u i l t o r a s s o c i a t e d
stresses. I n a l l s u c h cases t e c h n i c a l a d v i c e s h o u l d be
s o u g h t from L o t u s C a r s L i m i t e d .
Small s p l i t s i n b o n d s , s u c h as t h o s e around t h e d o o r c a n
o c c u r and a r e c a u s e d mainly by e x c e s s i v e f l e x i n g o f t h e
p a n e l s o r by v i b r a t i o n ; t h e s e should be a r r e s t e d b e f o r e
SECTION BB . . Page 7 7
t h e y can e x t e n d and become s e r i o u s . ' The s p l i t . s h o u l d be

p e e l e d open a l i t t l e f u r t h e r , roughen up t h e i n s i d e f l a n g e
s u r f a c e s w i t h a hacksaw b l a d e and i n s e r t t h e a p p r o p r i a t e
t y p e of bonding r e s i n b e f o r e clamping up. Clamping p r e s s u r e
s h o u l d always be a p p l i e d e v e n l y , u s i n g a small s l i p o f wood
o r metal i f dimpling of t h e p a n e l s u r f a c e i s t o b e avoided.
Where p o s s i b l e , a l l s p l i t s s h o u l d be laminated from t h e
. .
inside.
BB 11 - REPLACEMENT SECTIONS
Where t h e r e p a i r of a damaged v e h i c l e c a l l s f o r replacement

s e c t i o n s o r p a n e l s i t i s recommended t h a t t h e s e be o b t a i n e d
d i r e c t from Lotus Cars L i m i t e d .
S t a n d a r d s e c t i o n a 1 , r e p a i r moulds c a t e r f o r t h e r e p a i r o f damage
i n any a r e a of t h e body u n i t . These a r e s o d e s i g n e d t h a t t h e y
can be used i n d i v i d u a l l y o r connected t o g e t h e r f o r t h e
manufacture o r t h e r e q u i r e d s e c t i o n of t h e body. These a r e
a l s o used f o r l o c a t i n g new s e c t i o n s c o r r e c t l y r e l a t i v e t o t h e
existing panels. These moulds a r e d e l i b e r a t e l y l e f t unframed
s o a s t o accommodate s l i g h t d i s c r e p a n c i e s and have been made
on a s t a n d a r d p a i n t e d body s h e l l t o allow f o r a v e r a g e p a i n t
thickness.
Due t o t h e m a t e r i a l used i n c o n s t r u c t i o n of t h e body u n i t ,
c a s e s of s e v e r e damage can o f t e n be economically r e p a i r e d
i . e . where damage h a s been s e v e r e enough t o d e s t r o y v i r t u a l l y
t h e whole f r o n t end of t h e v e h i c l e , a s f a r a s t h e bulkhead f o r
i n s t a n c e , i t i s p o s s i b l e t o g r a f t on a new complete s e c t i o n .
Before c u t t i n g away t h e damaged p a r t s o r o r d e r i n g replacement

s e c t i o n s , t h e proposed method o f r e p a i r , p o s i t i o n i n g of j o i n t
l i n e s , o v e r l a p s e t c . , s h o u l d be a s c e r t a i n e d . Determine a
method f o r t h e c o r r e c t p o s i t i o n i n g of r e p l a & e n t sections
and b e f o r e c u t t i n g away d a m a g e d ' p a r t s check ' i n any prominent
f e a t u r e s from which measurements, c a n b e made a i ~ ds c r i b e t h e s e
c l e a r l y on t o t h e p a n e l s . which a r e t o , b e l e f t i n t a c t . Use
masking t a p e o r c h a l k t o d e f i n e t h e l i n e s on which i t i s
Page I2 SECTION BB
proposed t o c u t t h e p a n e l s and study t h e s e l i n e s thoroughly

t o s e e t h a t :-
a) any damaged o r s l i g h t l y damaged panel which would be
u s e f u l i n t h e a l i g n i n g of another major panel w i l l
n o t be removed o r ,
b) on s i n g l e skinned a r e a s i n p a r t i c u l a r t h e proposed
o u t l i n e t r a v e r s e s l o n g i t u d i n a l , l a t e r a l and
h o r i z o n t a l d e f i n i t i o n p o i n t s t o a s s i s t easy l i n i n g
up of t h e new panel i n a l l t h r e e p l a c e s .
When r e p a i r s have been c a r r i e d o u t i n t h e v i c i n i t y of t h e f r o n t
wheelarches, ensure t h e t y r e s do not f o u l t h e f r o n t lower f l a n g e
when t h e wheels a r e on f u l l l o c k .
Undersea1 t h e wheelarch a r e a t o a depth of 1 / 8 t h i n (3mm)

u s i n g "3M" m a t e r i a l , o r i t s e q u i v a l e n t i n c o n s i s t e n c y , t o
prevent gel-coat c r a z i n g caused by small s t o n e s e t c . ' , thrown
up by t h e wheels.
BB 12 - POSITIONING REPLACEMENT PANELS
a) Line up f l a t s u r f a c e (e.g. undertray o r f l o o r a r e a )

u s i n g long wooden beams b o l t e d t o undamaged a r e a .
b) Line up main c o n t o u r s (e.g. wing s e c t i o n s ) u s i n g
s p l i n t s and b o l t i n t o p o s i t i o n with f l a t o r curved
steel straps.
BB 1 3 - BOBBINS ( METAL INSERTS)
Considerable u s e i s made of d i e - c a s t metal i n s e r t s , which

a r e o v a l i n c o n f i g u r a t i o n and commonly known a s 'bobbins'.
These a r e designed t o c a r r y high l o a d s i n most d i r e c t i o n s

and a l s o o f f e r t h e advantage of being a c c u r a t e l y l o c a t e d i n
t h e mountings.
Two b a s i c forms a r e employed a s follows:-

Large ( s t r u c t u r a l ) bobbins - with 3/8 i n o r 7/16 i n h o l e s
(plain o r threaded).
Small ( s e m i - s t r u c t u r a l ) bobbins - with 1/4 i n o r 5/16 i n

holes (plain o r threaded).
The f o l l o w i n g advice i s given on d e a l i n g with bobbin f a i l u r e s : -
SECTION BB Page 73
Bobbins P u l l i n g Out
T h i s c o u l d be c a u s e d by o v e r l o a d i n g e . g . a c c i d e n t damage.
Where t h e bobbin and i t s s u r r o u n d i n g a r e a i s a c c e s s i b l e from
t h e rough s i d e of t h e l a m i n a t e s e i t h e r n a t u r a l l y o r by
c u t t i n g non-weakening a c c e s s h o l e s , t h e remedy i s t o i m p r o v i s e
a l o c a l mould i n wood o r g l a s s f i b r e of t h e body s u r r o u n d i n g
t h e f i n i s h e d s i d e of t h e bobbin.
D i f f i c u l t y may be e x p e r i e n c e d i n temporary r e - l o c a t i n g t h e
bobbin and i t s s u r r o u n d i n g l a m i n a t e i n i t s o r i g i n a l p o s i t i o n .
A l o c a l mould of t h e smooth s i d e of t h e s u r r o u n d i n g a r e a
( f o r example 6 i n (15 c m ) beyond i n a l l d i r e c t i o n s ) s h o u l d
eliminate t h i s trouble. R e - r e g i s t e r i n g can be a c h i e v e d by
d r i l l i n g h o l e s t h r o u g h mould and body and t h r o u g h t h e bobbin
b e f o r e removing t h e r e p a i r mould.
A d d i t i o n a l 4 i n (10 cm) s q u a r e p a t c h e s t o make t o up:-

1 / 4 i n and 5/16 i n b o b b i n s : t h e e q u i v a l e n t of 5 x 1$ oz
layers.
3/8 i n and 7/16 i n b o b b i n s : t h e e q u i v a l e n t of 7 x 1 . 4 o z

1a y e r s .
NOTE: Number of p a t c h e s t o be determined from t h e above.
The bobbin can t h e n be d i r e c t l y l a m i n a t e d on t h e o l d

mounting by u s i n g t h e t e c h n i q u e s d e s c r i b e d and o v e r l a p p i n g
t h e new l a m i n a t e on t o t h e o l d by s e v e r a l i n c h e s
( c e n t i m e t r e s ) whenever p o s s i b l e .
The l a r g e r b o b b i n s a r e used o n l y where t h e l o a d i n g s a r e

known t o be h i g h , e . g . body mountings, s e a t a t t a c h m e n t s ,
etc .. S m a l l e r b o b b i n s a r e u s e d as a l o c a t o r y p o i n t or a
b l i n d attachment p o i n t .
T y p i c a l i n s t a n c e s such a s n o n - s t r u c t u r a l applications are

headlamp p i v o t s . I n t h e s e c a s e s l o o s e bobbins can b e
r e p a i r e d by more l o c a l i s e d and less e x a c t i n g means, e . g .
f o r c i n g i n a dough m i x t u r e around and b e h i n d t h e b o b b i n ;
winding t a p e around i t , e t c . .
Page 74 SECTION BB
S t r i p p e d Threads
W h i l s t t h e i r o v a l s e c t i o n w i l l p r e v e n t t h e s e bobbins from
t u r n i n g i n normal u s e t h e y may l o o s e n i f t o o much t i g h t e n i n g
p r e s s u r e i s a p p l i e d , o r when an a t t e m p t i s made t o t a p them
out t o a l a r g e diameter. I f a t h r e a d i s damaged o r s t r i p p e d
an a t t e m p t s h o u l d b e made t o d r i l l t h e t h r e a d c l e a r and u s e
a b o l t and l o c k n u t o r d r i l l o v e r s i z e and f i t h e l i c o i l i n s e r t .
When f i t t i n g an i n i t i a l check should be made w i t h e a c h b o l t
before tightening. Only U . N . C . bobbins a r e employed and
p a r t i c u l a r c a r e s h o u l d be p a i d t o f i t o n l y U.N.C. bolts t o
them. Where t h e b o l t s a r e p a r t i c u l a r l y t i g h t t h i s may b e
due t o r e s i n w i t h i n t h e t h r e a d e d p o r t i o n o f t h e bobbin which
can be remedied by t a p p i n g o u t .
Only t h e c o r r e c t l e n g t h of t h e b o l t s h o u l d be u s e d , i . e . t h o s e
whose t h r e a d engages w i t h t h e f u l l d e p t h o r t h e bobbin. No
a t t e m p t s h o u l d b e made t o p u l l i t e m s up under heady l o a d w i t h
a s m a l l engagement of t h r e a d . To avoid t i g h t e n i n g up o n t o
t h e p l a i n shank of t h e b o l t i s i s recommended t h a t o n l y
s e t s c r e w s be u s e d , i . e . t h o s e t h r e a d e d a l l t h e way up t o t h e
head.
Laminating New Bobbin
F i r s t l y t h e l a m i n a t e s from t h e b a s i c mounting s u r f a c e must

o v e r l a p and i n t e r l e a v e w i t h t h e l a m i n a t e s around t h e bobbins.
Secondly t h e l a m i n a t e must b e w e l l b u i l t up under t h e bobbin
t o p r e v e n t t h e bobbin from p u l l i n g o u t i n a downward d i r e c t i o n .
T h i s s u r r o u n d i n g l a m i n a t e s h o u l d i n i t s e l f comprise a t i g h t
r i n g around t h e bobbin t o p r e v e n t it from b u r s t i n g o u t under
d i a g o n a l l o a d s b u t i f i n doubt one o r two l a y e r s of t a p e o r
c l o t h s h o u l d b e wound round t h e w a i s t of t h e bobbin. Finally
p l a s t i c i n e o r s i m i l a r p l u g s s h o u l d b e used d u r i n g l a m i n a t i n g
t o keep t h e r e s i n o u t of t h e bobbin t h r e a d s . When p r o p e r l y
l a i d t h e v i s i b l e rough s i d e w a l l w i l l b e n e a r l y v e r t i c a l i n
l i n e w i t h t h e bobbin t o p p r o f i l e . I n effect a s t r o n g
r e i n f o r c i n g r i n g of l a m i n a t e s u r r o u n d s t h e bobbin and t h i s
r i n g must b e p r o p e r l y connected t o t h e b a s i c l a m i n a t e .
SECTION BB Page 75
~ a y Around
u ~ Bobbins
a) i t i s i m p o r t a n t t h a t b u i l d - u p around b o b b i n s i s a s
p r e v i o u s l y d e s c r i b e d a s bobbins by n a t u r e o f t h e i r
application are subjected t o h i g h l o a d s , and w i l l
b r e a k o u t of t h e s u r r o u n d i n g f i b r e g l a s s i f n o t
bonded i n c o r r e c t l y .
b) Bobbins must be b o l t e d t o mould a f t e r "mould r e l e a s e
a g e n t " h a s been a p p l i e d and p r i o r t o Gel-coat a p p l i c a t i o n .
C a r e must b e t a k e n t o e n s u r e t h a t i t s i t s w e l l down on t o
t h e mould, and t h a t t h e bobbin i s p o s i t i o n e d c o r r e c t l y
i n a c c o r d a n c e w i t h t h e s p e c i f i c a t i o n concerned.
DO NOT a p p l y G e l - c o a t t o t h e bobbin s u r f a c e o r s i d e s .
I t i s e s s e n t i a l t o keep t h e Gel-coat t o a minimum t h i c k n e s s
t o p r e v e n t " c r a z i n g " and d e s i r a b l e t h a t t h e g e n e r a l l a y u p
t h i c k n e s s . t a p e r s g r a d u a l l y away from t h e b o b b i n s .
Remember t h a t t e n s i l e a p p l i c a t i o n s a r e t h e most demanding
and r e q u i r e c o n t i n u i t y of l a y - u p , t h a t t h e above
i n s t r u c t i o n s be s t r i c t l y adhered t o , t h a t t h e s a f e t y of
t h e v e h i c l e may be dependent upon t h e c o r r e c t n e s s of
t h e a p p l i c a t i o n of t h e s e o p e r a t i o n s .
Page 16 SECTION BB
BB 1 4 - BODY MOUNTING POINTS
When m o u n t i n g t h e body t o t h e c h a s s i s , i t may b e n e c e s s a r y t o

u s e s p a c i n g w a s h e r s between c e r t a i n m o u n t i n g p o i n t s i n o r d e r
t o l e v e l t h e . b o d y a n d / o r p r e v e n t p r e - s t r e s s i n g t h e body
s t r u c t u r e , w i t h subsequent d i s t o r t i o n and g e l c r a z i n g .
Excel
Twelve f i x i n g s a r e u s e d t o a t t a c h t h e body t o t h e c h a s s i s . A l l
chassis fixingpoints a r e plain holes, those along t h e centre
backbone l o w e r f l a n g e b e i n g d r i l l e d w i t h t h e body i n p o s i t i o n .
Aluminium ' b o b b i n s ' a r e u s e d i n t h e body a t a l l m o u n t i n g p o i n t s .
A l l h a v e p l a i n h o l e s e x c e p t f o r numbers 9 and 1 0 . T h e s e b o b b i n s
a r e t a p p e d MI0 and must have t h e h o l e s i n t h e c h a s s i s d r i l l e d
b e f o r e t h e body i s f i n a l l y f i t t e d .
A f t e r l o w e r i n g t h e body o n t o t h e c h a s s i s , l o c a t e t h e body
u s i n g f i x i n g s 1 , 2 , 3 , 4 , 11, 1 2 . Use w a s h e r s where n e c e s s a r y
t o a v o i d s t r a i n i n g any o f t h e m o u n t i n g s a n d d r i l l t h e c h a s s i s
f i x i n g h o l e s a t p o i n t s 5 , 6 , 7 , and 8 by u s i n g a d r i l l t h r o u g h
t h e body b o b b i n s a t t h e s e p o i n t s . R a i s e t h e body o f f t h e
c h a s s i s o n c e a g a i n , a n d , on t h e o l d c h a s s i s , m e a s u r e t h e p o s i t i o n
of f i x i n g h o l e s 9 & 10 r e l a t i v e t o holes 7 & 8. T r a n s f e r t h i s
d i m e n s i o n o n t o t h e new c h a s s i s , and d r i l l f i x i n g h o l e s 9 & 1 0 .
R e f i t t h e body and t i g h t e n a l l f i x i n g s . Note t h a t f i x i n g s

1 & 2 a l s o s e c u r e t h e a n t i - r o l l b a r c l a m p s . F i x i h g s 1, 2 , 5 ,
6 , 7 , 8 , 11 & 12 s h o u l d have t h e n u t s f i t t e d on t h e i n s i d e o f
the car.
The body t o c h a s s i s mounting b o b b i n s i n t h e body r e a r s e c t i o n , f r o n t o f
b o o t , were changed i n 1984 from t h e ' l a m i n a t e d i n ' t y p e t o t h e ' b i f u r c a t e d '
t y p e . The body mounting t u b e s o n t h e c h a s s i s r e a r crossmember w e r e a l s o
changed t o s u i t .
O l d body o n old chassis New body o n new chassis

(for r e f e r e n c e only) (for reference o n l y )
'bifurcated '
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:

F i t 12 x 28 x 2.5 plaln washer A075W9031 F between chassis
and body. I
Use was her

A075W9031 F
b) New body or body section (bifurcated bobbins) onto old chassis:

Cut 5 mm from the rear end of the crossmember tubes, and f i t a
12 x 28 x 2.5 plain washer A075W9031 F between chassis and body.
use was her

A075W9031F
New body
on old chassis
EXCEL
Also a n t i - r o l l bar
f i x i n g , Access t o n u t
from w i t h i n head1 amp
n
pod w e 1 1.
-
FRONT
-
REAR
Just ahead of f r o n t seat. J u s t ahead of r e a r s e a t .

y i n position. D r i l l with body i n p o s i t i o n .
Body Bobbin tapped M10.

(Blind fix w i t h i n r e a r I
s e a t foam double s k i n )
D r i l l chassis before
f i t t i n g body-
Below f u e l
S i d e s o f engine bay. tank i n boot.
( RH ahead of
fuel pump)
SECTION BB Page 79
Esprit.
T w e l v e f i x i n g s a r e u s e d t o a t t a c h t h e body t o t h e c h a s s i s . All
c h a s s i s f i x i n g p o i n t s a r e p l a i n h o l e s e x c e p t numbers 1 3 & 1 4
( F e d e r a l o n l y ) w h i c h a r e t a p p e d M10. H o l e s 1 & 2 (8mm) a n d 3 & 4
(10mm) a r e d r i l l e d w i t h t h e body i n p o s i t i o n .
Aluminium ' b o b b i n s ' a r e u s e d i n t h e body a t a l l m o u n t i n g p o i n t s

e x c e p t 9 & lowhich h o l e s are d r i l l e d t h r o u g h t h e t i m b e r /
composite r e a r bulkhead.
A f t e r l o w e r i n g t h e body o n t o t h e c h a s s i s , c h e c k t h a t t h e p e d a l
box m o u n t i n g b o s s e s a r e n o t f o u l i n g t h e b o d y . Locate t h e
body by i n s e r t i n g f i x i n g s 11 & 1 2 ( 1 3 & 1 4 o n F e d e r a l c a r s )
but do not t i g h t e n .
I n s e r t s p a c e r s i f n e c e s s a r y b e t w e e n t h e body a n d c h a s s i s a t
p o i n t s 1 & 2 and d r i l l c h a s s i s a t t h e s e p o i n t s t h r o u g h t h e
body b o b b i n s . Insert fixing bolts.
S i m i l a r l y d r i l l c h a s s i s a t p o i n t s 3 & 4 and i n s e r t f i x i n g s
using s p a c e r washers i f necessary. I n s e r t remaining f i x i n g s
and t i g h t e n from t h e f r o n t o f c a r r e a r w a r d s .
FRONT ESPRIT
-
REAR
v
Front of footwells.
Chassis drilled with
body in position.
SECTION BD Page I
-
BODY
S E C T I O N BD - E S P R I T S3 & TURBO
O p e r a t ion ,Page
Windscreen Replacement BD. 1

Tailgate G l a s s a n d F i n i s h e r s BD.2
Rear Bulkhead Glass BD.3
.- ,
Rear Quarter Glass BD. 4
D o o r Window F r a m e BD. 5
Door Drop Glass BD.6
Door Glass External Weatherstrip B D . ~
Door Quarter Light Glass BD.8
Door S h e l l BD. 9
Headlamp Pods BD. 10
Front B o n n e t P a n e l BD. 11
Tailgate BD. 1 2
Front B u m p e r BD . I 3
R e a r Bumper a n d Spoiler BD. 1 4
-
Eneine Bav V e n t i l a t i o n BD. 15
D e c a l Positioning BD. 16
G l a s s R o o f Abutmen* ED. 17
Page 2
BD.l - WINDSCREEN REPLACEMENT.

The windscreen is bonded t o t h e body a p e r t u r e w i t h " B e t a s e a l "
adhesive/sealant. The f o l l o w i n g procedure must be adhered t o
i n d e t a i l , p a y i n g p a r t i c u l a r a t t e n t i o n t o t h e c l e a n i n g and
priming o p e r a t i o n s and u s i n g m a t e r i a l s s u p p l i e d w i t h B e t a s e a l
K i t , A075B6158J.
NOTE: I t i s l i k e l y t h a t t h e s c r e e n b r i g h t f i n i s h e r s w i l l
have t o be renewed on s c r e e n replacement.
1. Remove t h e i n t e r i o r ' A ' p o s t f i n i s h e r s , and s c r e e n header

rail. (see section 'V')
2. Remove windscreen e x t e r i o r b r i g h t t r i m and wiper arm.
Bore a s m a l l h o l e t h r o u g h t h e B e t a s e a l and i n s e r t a
l e n g t h of p i a n o w i r e o r s i m i l a r ( s u p p l i e d i n B e t a s e a l '
K i t ) approx. 1 metre l o n g , through t h e h o l e . With t h e
a i d of an a s s i s t a n t i n s i d e t h e c a r , use a sawing a c t i o n
t o c u t through t h e B e t a s e a l and f r e e t h e s c r e e n from
t h e c a r . A l t e r n a t i v e l y , use c u t t i n g o u t t o o l A075B6169
Take g r e a t c a r e n o t t o damage t h e i n t e r i o r t r i m o r
paintwork d u r i n g t h i s o p e r a t i o n .
SECTION BD Page 3
4. Remove e x c e s s B e t a s e a l from t h e s c r e e n a p e r t u r e w i t h a
sharp blade. Note t h a t i t i s n o t n e c e s s a r y t o remove a l l
t r a c e s of t h e s e a l a n t b u t a uniform s u r f a c e must be
available f o r bonding t h e new s c r e e n .
5. Dry f i t t h e s c r e e n and examine t h e screen/body j o i n t

c o n f o r m i t y . I f n e c e s s a r y , use p r o p s t o s u p p o r t t h e c e n t r a l
p o r t i o n of t h e a p e r t u r e t o p f l a n g e . Mark any a r e a s o f
s i g n i f i c a n t non-c'onformity i n o r d e r t h a t a n a d d i t i o n a l
bead of B e t a s e a l may be a p p l i e d t o t h e body f l a n g e i n
t h a t l o c a l area only, before screen fitment.
6. Make up t h e two s p a c e r s t o s u p p o r t t h e s c r e e n i n i t s
a p e r t u r e and p r o v i d e a 6 - 7 mm gap between s c r e e n t o p edge
and body.
7. Clean up t h e l a m i n a t e d edge o f t h e g l a s s w i t h a s h a r p k n i f e .
8. Cut t h e s p e c i a l p a p e r provided i n t h e B e t a s e a l K i t i n t o two.

With one h a l f u s e Wipe C l e a n e r No. 4 t o c l e a n t h e p e r i m e t e r
o f t h e g l a s s and t h e whole bonding a r e a of t h e body f l a n g e .
With t h e o t h e r h a l f , wipe d r y t h e s u r f a c e s c l e a n e d .
9. Remove t h e grooved s e c t i o n s from t h e primer a p p l i c a t o r g u i d e

t o o b t a i n a 20 mm width band. ( i . e . f u l l a p p l i c a t o r w i d t h . )
Cut here
10. Shake g l a s s p r i m e r . c o n t a i n e r f o r a t l e a s t 30 seconds

b e f o r e opening. Pour g l a s s primer i n t o ~ l a s t i cb o t t l e
and f i t a p p l i c a t o r guide and f e l t pad. Apply primer around
p e r i m e t e r and l a m i n a t e d edge o f g l a s s . Algo; prime whole of
body a p e r t u r e f l a n g e .
Page 4 SECTION BD
a
11. Cut t h e B e t a s e a l a p p l i c a t i o n nozzle a s shown below.
A. Cut o f f t o p of n o z z l e a t a h e i g h t
o f 70 mm a s shown.
By A t a h e i g h t of 63mm
cut horizontally across
t o the centre line.
From t h e t o p , c u t
v e r t i c a l l y downwards
along t h e c e n t r e l i n e
t o meet f i r s t c u t a s
shown.
C. Measure width of
h o r i z o n t a l c u t from i n s i d e
s u r f a c e t o t h e p l a n e of t h e
vertical cut. If t h i s
dimension i s less than 5mm
c u t f u r t h e r a c r o s s ( a t 63mm
h e i g h t ) and t h e n downwards
a s i n b) u n t i l a width of
5mm i s achieved.
D- Cut a 'V' notch a s shown by

continuing one s i d e of t h e
v e r t i c a l c u t downwards t o a
height of 52mm, and i n t e r s e c t
with a diagonal c u t from t h e
p o i n t of maximum width.
Page 5
Push i n bottom o f B e t a s e a l c a r t r i d g e and remove d e s i c c a n t

P i e r c e membrane i n c a r t r i d g e t h r e a d , screw on a p p l i c a t i o n
n o z z l e and i n s e r t i n c a r t r i d g e gun.
Holding t h e gun a t a r i g h t a n g l e t o t h e edge of t h e g l a s s

and l e a n i n g s l i g h t l y i n b o a r d , e x t r u d e a c o n t i n u o u s bead of
B e t a s e a l on t h e p e r i m e t e r of t h e g l a s s , u s i n g t h e edge of
t h e g l a s s and s h a p e o f t h e n o z z l e a s a g u i d e . T h i s method
w i l l g i v e t h e bead t h e c o r r e c t dimensions and a l s o make t h e
t o p of t h e bead c o l l a p s e i n b o a r d , r e d u c i n g t h e amount of
m a t e r i a l squeezed o u t of t h e j o i n t om assembly.
Push e i g h t 4 mm s p a c e r b l o c k s A075U0588Z i n t o t h e B e t a s e a l
from t h e i n s i d e o f t h e bead i n t h e p o s i t i o n s shown.
F i t t h e s c r e e n o n t o t h e body and u s e t h e two s p a c e r s made

i n paragraph 6 t o s u p p o r t t h e g l a s s w h i l s t t h e B e t a s e a l
c u r e s . P r e s s g e n t l y a l l round t h e edge o f t h e g l a s s t o
e n s u r e uniform compression of t h e j o i n t .
Water t e s t b e f o r e f i t t i n g b r i g h t t r i m . I f any l e a k a g e i s
found, mark t h e s p o t and d r y t h e bead w i t h a blow d r y e r o r
s i m i l a r . Extrude a s m a l l amount of B e t a s e a l from t h e o u t s i d e
on t h e s u s p e c t e d a r e a i n o r d e r t o e n s u r e t h e v e h i c l e i s
waterproof.
Do n o t f i t s c r e e n b r i g h t t r i m u n t i l t h e B e t a s e a l i s
s u f f i c i e n t l y c u r e d n o t t o be d i s t u r b e d . T h i s may t a k e up
t o 6 h o u r s depending on atmospheric c o n d i t i o n s .
Page 6
Dry f i t t h e s c r e e n b r i g h t f i n i s h e r s and a d j u s t t h e l e n g t h
and c o r n e r s o f t h e t o p f i n i s h e r i f r e q u i r e d . Abrade t h e
u n d e r s i d e o f t h e f i n i s h e r s t o remove t h e a n o d i s e d s u r f a c e
and t h e n s c o r e t o produce a key f o r t h e a d h e s i v e . Degrease
s u r f a c e s u s i n g acetone o r methylated s p i r i t .
A d h e s i v e t o b e u s e d i s 3M's 8 1 0 1 p a r t s A & B , p a r t numbers

A075U6073F and A075U6074F r e s p e c t i v e l y .
Mix p a r t s A & B o f a d h e s i v e i n e q u a l p a r t s u n t i l a u n i f o r m
c o l o u r . Apply a s h o r t bead o f a d h e s i v e a p p r o x i m a t e l y 40 mm
l o n g i n 1 0 p l a c e s . a s shown.
F i t t h e t h r e e s e c t i o n s of t r i m and t a p e f i r m l y i n position.
Wipe o f f e x c e s s a d h e s i v e . The a d h e s i v e w i l l c u r e w i t h i n one
h o u r t o . p r o v i d e h a n d l i n g s t r e n g t h a t 73OF, w h i l s t 8 hours is
r e q u i r e d f o r f u l l c u r e . Curing w i l l be slower a t cooler
temperatures.
NOTE: Under no c i r c u m s t a n c e s must s i l i c o n , d u s t , wax e t c . be

p r e s e n t i n t h e atmosphere d u r i n g bonding.
A f t e r c u r i n g apply b l a c k " S i l a s t i c " around t h e b r i g h t t r i m

o u t e r e d g e t o s e a l , and b l a c k s t r i p A082U6072V t o t h e l o w e r
e d g e o f t h e g l a s s . R e f i t w i p e r arm and i n t e r i o r t r i m .
S p i l l a g e of m a t e r i a l .
Any s p i l l a g e o f B e t a s e a l o n t o unprimed g l a s s c a n b e r e a d i l y
peeled o f f a f t e r it has cured.
Any s p i l l a g e o n t o t h e body c a n b e removed w i t h e i t h e r Wipe

C l e a n e r No. 4 , o r w h i t e ' s p i r i t .
Shelf l i f e .
B e t a s e a l h a s a s h e l f l i f e o f o v e r 6 months a t a m b i e n t t e m p e r a t u r e
i n t h e o r i g i n a l unopened p a c k a g e .
.Glass p r i m e r becomes spongy. a f t e r a p e r i o d o f t i m e when

e x p o s e d t o t h e . a i r . I f t h e m a t e r i a l i s spongy DO NOT USE.
Always u s e g l a s s p r i m e r i m m e d i a t e l y on o p e n i n g , a n d r e p l a c e
l i d a f t e r use.
Page 7
C o n t e n t s o f B e t a s e a l Kit.AO75B6158J.
i One p a r t a d h e s i v e s e a l a n t B e t a s e a l 71904 i n a 300 cc c a r t r i d g e ,

standard viscosity.
ii) Cartridge applicator nozzle.
iii) Glass p r i m e r a p p l i c a t o r b o t t l e .
iv) G l a s s p r i m e r a p p l i c a t o r head.
v) Glass primer a p p l i c a t o r f e l t pad.
vi) G l a s s p r i m e r , b l a c k , 84132-11.
vii) Wipe C l e a n e r No. 4.
viii) Piano w i r e 0 . 6 mm d i a m e t e r x 120 cm l o n g .
ix) Special cleaning paper.
x 4 o f f r u b b e r s p a c i n g b l o c k s , a p p r o x i m a t e s i z e 1 0 x 14 x 20 mm.
BD.2 - TAILGATE GLASS.
Series 3.
The t a i l g a t e g l a s s i s f i t t e d u s i n g B e t a s e a l i n a s i m i l a r
manner t o t h e w i n d s c r e e n .
To r e p l a c e a t a i l g a t e g l a s s and f i n i s h e r s , f o l l o w t h e
windscreen r e p l a c e m e n t p r o c e d u r e BD.l. b u t p o s i t i o n t h e
s p a c e r b l o c k s A075U0588Z a s f o l l o w s .
7 6 5
Turbo.
The t a i l g a t e g l a s s i s f i t t e d u s i n g B e t a s e a l i n a s i m i l a r
manner t o t h e w i n d s c r e e n . To r e p l a c e a t a i l g a t e g l a s s , f o l l o w
t h e windscreen p r o c e d u r e B D . l . w i t h t h e f o l l o w i n g n o t e s .
i) The ABS moulding around t h e i n s i d e of t h e a p e r t u r e i s . s e c u r e d

using black S i l a s t i c .
ii) S i x s p a c e r b l o c k s , A075U0588F a r e u s e d around t h e p e r i p h e r y

of t h e g l a s s .
Page 8 SECTION BD
BD.3. - REAR BULKHEAD GLASS.
The r e a r bulkhead g l a s s i s bonded t o i t s c o m p o s i t e s u r r o u n d

using e i t h e r S o l b i t thermo-electric o r Betaseal polyurethane
bonding medium. The s u r r o u n d i s t h e n screwed t o t h e t i m b e r
bulkhead.
To r e p l a c e g l a s s .
R e l e a s e b o t h s e a t b e l t s from t h e i r s i l l mounting p o i n t s , and

on F e d e r a l c a r s , t h e t a i l g a t e r e l e a s e h a n d l e assembly.
P u l l o f f t h e door s e a l s from t h e t o p r e a r o f e a c h d o o r
a p e r t u r e , r e l e a s e t h e s c r e w s s e c u r i n g t h e rear bulkhead t r i m
p a n e l , and remove t h e p a n e l , d i s c o n n e c t i n g t h e i n t e r i o r lamp.
R e l e a s e t h e screws s e c u r i n g t h e g l a s s s u r r o u n d t o t h e b u l k h e a d ,
and remove.
I t may p r o v e p o s s i b l e ( d e p e n d a n t on l e n g t h o f s e r v i c e ) t o push
o u t t h e g l a s s from t h e s u r r o u n d a f t e r r e - h e a t i n g t h e S o l b i t by
applying 1 9 v o l t s t o t h e S o l b i t ends f o r s e v e r a l minutes.
A l t e r n a t i v e l y use 'piano' w i r e t o c u t out t h e g l a s s .
Remove r e m a i n i n g bonding medium from s u r r o u n d and g l a s s .
Follow t h e B e t a s e a l p r o c e d u r e d e t a i l e d i n B D . 1 . t o c l e a n ,
prime and bond t h e g l a s s t o i t s s u r r o u n d , u s i n g s i x s p a c e r
b l o c k s A075U0588Z around t h e p e r i p h e r y o f t h e g l a s s .
R e f i t t h e surround t o t h e bulkhead, using black S i l a s t i c

t o seal.
Refit t r i m panels, seat b e l t s , e t c .
BD.4. - REAR QUARTER LIGHT GLASS.
The r e a r q u a r t e r windows a r e f i t t e d u s i n g ' S o l b i t ' thermo-

e l e c t r i c bonding medium.
To r e p l a c e .
C a r e f u l l y remove t h e ABS f i n i s h e r which i s s t u c k t o t h e

g l a s s w i t h double s i d e d t a p e .
I t may prove p o s s i b l e (dependant on l e n g t h of s e r v i c e ) t o

push o u t t h e g l a s s a f t e r r e - h e a t i n g t h e S o l b i t by a p p l y i n g
9 v o l t s t o t h e S o l b i t ends f o r s e v e r a l minutes. A l t e r n a t i v e l y
u s e ' p i a n o ' w i r e t o c u t o u t t h e g l a s s , b u t f i r s t remove t h e
a i r s c o o p / e x t r a c t o r and t a k e p r e c a u t i o n s a s n e c e s s a r y t o
p r o t e c t t h e paintwork.
Remove r e m a i n i n g S o l b i t from t h e body and g l a s s .
C l e a n t h e i n s i d e p e r i p h e r y of t h e g l a s s , and t h e whole of
t h e body bonding a r e a w i t h m e t h y l a t e d s p i r i t , and wipe d r y .
Apply S o l b i t P r i m e r t o t h e a r e a s c l e a n e d i n 4 .
SECTION BD Page 9
Cut a 1 . 3 metre l e n g t h o f 8 mm S o l b i t and s t r i p each end

t o expose 1 2 mm (0.5 i n . ) of t h e i n t e r n a l copper w i r e . Connect
t h e ends t o a v a r i a b l e t r a n s f o r m e r and apply 9 v o l t s t o
t h e S o l b i t u n t i l i t s s u r f a c e i s t a c k y . Disconnect S o l b i t
from power s o u r c e .
S t a r t i n g a t t h e c e n t r e t o p , a p p l y t h e S o l b i t around t h e
q u a r t e r l i g h t a p e r t u r e and c r o s s o v e r a t t h e end. F i t two
s p a c e r b l o c k s A075U0588F i n t o t h e t o p of t h e S o l b i t s t r i p
a l o n g t h e a p e r t u r e lower edge.
F i t t h e g l a s s o n t o t h e a p e r t u r e and r e c o n n e c t t h e S o l b i t t o
t h e 9 v o l t power s o u r c e . Apply g e n t l e p r e s s u r e t o t h e g l a s s .
A f t e r about two minutes, t h e S o l b i t w i l l s t a r t t o flow and
t h e g l a s s w i l l b e f e l t t o move s l o w l y inwards. When t h e lower
edge of t h e g l a s s i s f e l t t o c o n t a c t t h e s p a c e r s and t h e rest
of t h e S o l b i t i s s i m i l a r l y compressed STOP a p p l y i n g p r e s s u r e
b u t c o n t i n u e t o a p p l y c u r r e n t f o r a f u r t h e r t e n minutes w h i l s t
s u p p o r t i n g t h e g l a s s u s i n g t a n k t a p e . Smooth o f f o r remove
excess extruded S o l b i t .
Clean t h e o u t s i d e p e r i m e t e r of t h e g l a s s , and i n s i d e s u r f a c e
o f t h e ABS f i n i s h e r w i t h m e t h y l a t e d s p i r i t . . Wipe d r y .
Apply S o l b i t Primer t o t h e i n s i d e s u r f a c e o f t h e ABS f i n i s h e r ,

and when d r y , apply double s i d e d t a p e B075U6070V. P e e l o f f
t h e backing paper and f i t t h e f i n i s h e r t o t h e g l a s s .
Refit the a i r scoop/extractor.
BD.5. - DOOR WINDOW FRAME.
To remove:- P e e l back t h e t r i m m a t e r i a l i n s i d e t h e i n t e r i o r
door h a n d l e and l o o s e n t h e t h r e e screws s e c u r i n g t h e handle
assembly t o t h e door. S l i d e o u t t h e upper and lower h a l v e s
of t h e door handle p l a s t i c s u r r o u n d .
Remove t h e screw s e c u r i n g t h e lower f r o n t and lower r e a r of

t h e t r i m p a n e l , and unhook t o p l i p of p a n e l from door t o p
edge.
Remove PVC s h e e t i n g from door s h e l l . Disconnect window motor

w i r e s , r e l e a s e t h e f o u r n u t s , s e c u r i n g motor b r a c k e t t o door
beam and remove window motor , s l i d i n g i t s o p e r a t i n g arm from
t h e drop g l a s s c h a n n e l .
Release t h e two M 6 n u t s securing.:,t h e c a r r i a g e p l a t e , t o ,, . t h e

d r o p g l a s s channel and .separate..: :Tape t h e drop g l a s ~.to..; :.
t h e window frame. . . . ..,. . .....

, . ..
. . . . t, :.:,:. -.
Remove t h e f i v e n u t s s e c u r i n g . t h e . window channel. t o . .t h e :,door
beam and t h e two screws s e c u r i n g t h e c h a n n e l t o t b e u p p e r : .
r e a r of t h e door s h e l l . Note t h a t t h e b o l t heads a r e r e t a i n e d
Page 70 SECTION BD
L Washer
Window
Frame
i n l o n g i t u d i n a l c h a n n e l s on t h e door beam s o t h a t t h e window

frame must be e a s e d o f f t h e b o l t s b e f o r e i t may be withdrawn
w i t h g l a s s , from t h e door.
BD.6. - DOOR DROP GLASS.
Remove t h e door window frame from t h e door (BD.5.)
I t may prove p o s s i b l e t o remove t h e l i f t channel from t h e

g l a s s a f t e r applying 3 v o l t s t o t h e S o l b i t thermo-electric
bonding medium f o r s e v e r a l m i n u t e s .
Before f i t t i n g a l i f t c h a n n e l t o t h e g l a s s , thoroughly c l e a n
t h e lower edge and s i d e s of t h e g l a s s and i n s i d e c h a n n e l , w i t h
methylated s p i r i t .
Apply S o l b i t Primer t o t h e lower edge and b o t h lower s i d e s of

g l a s s i n a band 12 mm ( a i n . ) wide. Also apply t o whole
i n s i d e s u r f a c e o f c h a n n e l . Allow t o d r y .
S t r i p b o t h ends of a 450 mm (18 i n . ) l e n g t h of 10 mm
d i a m e t e r S o l b i t t o expose 12 mm (3 i n . ) of i n t e r n a l
copper w i r e . Connect t o a v a r i a b l e t r a n s f o r m e r and apply
3 v o l t s t o t h e S o l b i t u n t i l i t s s u r f a c e becomes t a c k y
(10 - 13 secs.) . Disconnect s u p p l y and p l a c e S o l b i t i n t o
l i f t channel.
SECTION BD Page 7 7
6. P o s i t i o n c h a n n e l on l o w e r e d g e o f g l a s s w i t h o p e r a t i n g
arm g u i d e t o t h e i n s i d e ( c a r r i a g e p l a t e b r a c k e t t o r e a r )
and t h e r e a r e n d o f c h a n n e l 120 mm from r e a r e d g e o f g l a s s . .
7. Reconnect e l e c t r i c a l s u p p l y t o t h e S o l b i t and a s i t s t a r t s
t o flow, push channel f u l l y o n t o g l a s s . Continue t o apply
c u r r e n t f o r a f u r t h e r f i v e m i n u t e s w h i l e removing o r
smoothing o u t e x t r u d e d S o l b i t . D i s c o n n e c t s u p p l y .
8. F i t d r o p g l a s s i n t o frame and r e f i t door window f r a m e i n t o

d o o r . A d j u s t c a r r i a g e p l a t e t o o b t a i n smooth r i s e and
f a l l o f t h e d r o p g l a s s b e f o r e i n s t a l l i n g window m o t o r .
Ref i t d o o r t r i m .
BD.7. - DOOR GLASS EXTERNAL WEATHERSTRIP.
To remove w e a t h e r s t r i p , f i r s t remove t h e d o o r i n t e r i o r
t r i m panel ( s e e s e c t i o n B C . 5 . ) t o gain access t o t h e t h r e e
nutso1:amping t h e w e a t h e r s t r i p a s s e m b l y t o t h e d o o r s h e l l .
Loosen t h e n u t s and e a s e t h e assembly away from t h e d o o r .
- Nut clamping weatherstrip

assembly to door shell
Page 72 SECTION BD
D r i l l o u t t h e pop r i v e t s t o r e . p l a c e t h e r u b b e r s e a l .
When r e f i t t i n g , a p p l y a t h i n bead o f S i l a s t i c t o t h e t o p edge

of t h e door s h e l l b e f o r e i n s t a l l i n g t h e w e a t h e r s t r i p assembly.
Ensure t h e s e a l l i e s a g a i n s t t h e g l a s s b e f o r e t i g h t e n i n g
nuts. Overtightening nuts w i l l d i s t o r t t h e f i n i s h e r .
BD.8. - DOOR QUARTER LIGHT GLASS.
1. t o remove: Remove t h e door window frame from t h e d o o r

( S e c t i o n BD.5.). I t i s n o t n o r m a l l y p o s s i b l e t o remove
t h e q u a r t e r g l a s s from t h e f r a m e w i t h o u t b r e a k a g e .
2. Remove r e m a i n i n g g l a s s and S o l b i t from i n s i d e t h e

q u a r t e r glass channels.
3. To r e p l a c e : C l e a n t h e f r o n t and r e a r e d g e s and p e r i p h e r y
o f new g l a s s w i t h m e t h y l a t e d s p i r i t . A l s o i n s i d e window
frame channel.
4. Apply S o l b i t P r i m e r t o t h e e d g e o f t h e g l a s s and a 6 mm ( 1 / 4 i n . )
wide band on b o t h s i d e s o f t h e f r o n t and r e a r e d g e o f t h e
g l a s s . Apply S o l b i t P r i m e r t o a l l s u r f a c e s i n s i d e t h e f r a m e
channel .
5. S t r i p b o t h e n d s o f a 1 . 4 mm (4 f t 6 i n ) l e n g t h o f 1 0 mm
S o l b i t t o e x p o s e 1 2 mm ( & i n . ) of i n t e r n a l c o p p e r wire
and c o n n e c t t o a v a r i a b l e t r a n s f o r m e r o r 6v b a t t e r y .
Apply 6 v o l t s t o t h e S o l b i t u n t i l i t s s u r f a c e becomes t a c k y .
D i s c o n n e c t t h e power s o u r c e and p o s i t i o n t h e S o l b i t on
t h e primed e d g e o f t h e g l a s s . I n t r o d u c e g l a s s and
S o l b i t i n t o t h e window frame and p u s h home, u n t i l t h e
S o l b i t c o n t a c t s t h e window f r a m e .
7. C o n n e c t t h e S o l b i t t o t h e 6 v o l t power s o u r c e a n d a p p l y
p r e s s u r e t o t h e lower edge of t h e g l a s s , and a s t h e
S o l b i t s t a r t s t o f l o w , push t h e g l a s s f u l l y i n t o t h e
SECTION BD Page 73
window f r a m e . C o n t i n u e t o a p p l y c u r r e n t f o r a f u r t h e r
s i x minutes w h i l s t keeping t h e g l a s s c e n t r a l i n t h e
f r a m e c h a n n e l and s m o o t h i n g o u t e x c e s s i v e S o l b i t t o
l e a v e a smooth s u r f a c e l e v e l w i t h t h e e d g e o f t h e window
frame .
8. D i s c o n n e c t power s o u r c e , c u t S o l b i t e n d s f l u s h w i t h t h e
c o r n e r s of t h e g l a s s and r e p l a c e d o o r window f r a m e .
BD.9. - DOOR SHELL.
The GRP d o o r s h e l l i s s e c u r e d t o t h e a l l o y d o o r beam

by f o u r b o l t s a s shown and may b e removed from t h e c a r
by s l i d i n g o f f t h e d o o r beam ( i n s i t u ) a f t e r removing
t h e d o o r window f r a m e (BD.5) and l a t c h mechanism.
-.\\?fy- - --- - - - - - -
"fie
BD.10 - HEADLAMP PODS.
Pivot.
F e d e r a l c a r s u s e a pod p i v o t b a l l j o i n t a t e a c h s i d e
o f e a c h pod, t h e o u t b o a r d b a l l j o i n t b e i n g r i v e t t e d t o
t h e body, w h i l s t t h e i n b o a r d b a l l j o i n t i s f i x e d t o t h e
pod. The i n b o a r d p i v o t b o l t p a s s e s t h r o u g h t h e pod b a l l
j o i n t and t h e n t h r o u g h t h e b o n n e t b a l l j o i n t ( f i x e d
t o t h e body) b e f o r e t h r e a d i n g i n t o t h e b o n n e t h i n g e b a r .
Bonnet p i v o t b a l l Inboard ball j o i n t Outboard ball j o i n t

j o i n t ...r i. v e t t e d t o body r i v e t t e d t o pod r i v e t t e d t o body
- FEDERAL CARS
Page 14 SECTION BD
D o m e s t i c a n d ROW c a r s u s e a body mounted b a l l j o i n t on t h e o u t b o a r d
0
s i d e , and on t h e i n b o a r d s i d e , a hiilge p i n p i v o t t i n g i n b u s h e s moun-
t e d b o t h i n t h e pod a n d b o d y , and c a r r y i n g on i t s ' o v e r h u n g ' o u t b o a r d
end, t h e bonnet hinge.
P i v o t bush P i v o t bush Bonnet

.
hinge Outboard
i n body i n pod ball joint
0 8
SERIES 3 and
.-'U.\luu _) a,,u
D o r n e s t i c / R o w TURBO
To remove.
To remove a headlamp p o d , u n p l u g t h e b u l b c o n n e c t o r s
and release t h e pod a c t u a t i n g l i n k . R e l e a s e t h e pod
o u t b o a r d p i v o t b o l t and s u p p o r t t h e b o n n e t p a n e l b e f o r e
r e l e a s i n g t h e i n b o a r d p i v o t b o l t ( F e d e r a l ) o r removing
t h e s p l i t p i n and s l i d i n g o u t t h e h i n g e p i n (DOM/ROW).
On r e f i t t i n g e n s u r e t h a t t h e pod i s l o c a t c d c e n t r a l l y ' u s i n g
s p a c e r w a s h e r s if n e c e s s a r y , a n d t h a t t h e pod p i v o t s f r e e l y
before connecting t h e actuating link.
Adjustment
The pod down p o s i t i o n is a d j u s t e d by a l t e r i n g t h e a c t u a t i n g l i n k

l e n g t h . S l a c k e n t h e l o c k n u t a t e a c h end o f t h e a c t u a t i n g l i n k a n d
t u r n t h e l i n k r o d t o change i t s e f f e c t i v e l e n g t h a s r e q u i r e d .
Tighten locknuts.
SECTION BD Page 75
Always check headlamp beam s e t t i n g e f t e r any pod a d j u s t m e n t
i s made s i n c e t h e pod up p o s i t i o n w i l l a l s o be a l t e r e d .
BD.ll - FRONT BONNET PANEL.
The f r o n t bonnet p a n e l i s h i n g e d a t i t s f r o n t edge by two

i n d i v i d u a l h i n g e s on DOM/ROW c a r s and by a c r o s s l i n k a g e
b a r on F e d e r a l v e h i c l e s . The h i n g e p i v o t s a r e i n c o r p o r a t e d
w i t h t h e headlamp pod i n b o a r d p i v o t s . ( s e e s e c t i o n BD.8.)
The s t r i k e r hoops f i t t e d a t e a c h r e a r c o r n e r o f t h e bonnet

panelengage w i t h two c a t c h d i s c s mounted on t h e b u l k h e a d .
The c a t c h d i s c s a r e c o n n e c t e d v i a a d j u s t a b l e l i n k r o d s
t o a c r o s s b a r w i t h a r e l e a s e h a n d l e on t h e d r i v e r s s i d e .
Adjustment .
The s h u t gap and h e i g h t of t h e bonnet f r o n t edge may be
a d j u s t e d v i a h i n g e s l o t s and s p a c e r p l a t e s . The sideways
f i t o f t h e p a n e l i s c o n t r o l l e d by s p a c e r washers a t t h e
hinge p i v o t s .
A t t h e r e a r e d g e , t h e c a t c h d i s c p o s i t i o n s h o u l d be
s i m i l a r on both s i d e s w i t h t h e s l o t p o i n t i n g s l i g h t l y
upwards i n t h e ' r e l e a s e d ' s e t t i n g . S t r i k e r p l a t e s p a c e r s
and s l o t s a r e used t o a d j u s t t h e bonnet r e a r edge h e i g h t
and c a t c h engagement r e s p e c t i v e l y .
BD.12. - TAILGATE
The t a i l g a t e p a n e l i s hinged a t each t o p c o r n e r ( e x c e p t on sun r o o f

models) t o a bobbin bonded i n t o t h e roof s t r u c t u r e . On sun r o o f models
each h i n g e p i v o t t a k e s t h e form of a b r a c k e t b o l t e d ' t o t h e r o o f .
Three t y p e s o f t a i l g a t e l a t c h i n g system have been employed.

Domestic/R.O.W. Turbo models have a k e y l o c k a b l e e x t e r n a l r e l e a s e knob
o n t h e r e a r s p o i i e r , which i s connected v i a a l i n k rod t o t h e r i g h t hand
t a i l g a t e l a t c h . Right and l e f t hand l a t c h e s a r e i n t e r c o n n e c t e d by a
c r o s s b a r and when r e l e a s e d a l l o w t h e t a i l g a t e t o be opened, a s s i s t e d by
two g a s s t r u t s . On e a r l y c a r s , t h e s t r u t s were anchored i n t h e t a i l g a t e
a p e r t u r e , b u t l a t e r c a r s used an anchor p o s i t i o n a t t h e f r o n t of t h e
e n g i n e bay f o r g r e a t e r opening a s s i s t a n c e .
S e r i e s 3 models u s e a c a b l e o p e r a t e d r e l e a s e a c t i v a t e d v i a a p u l l h a n d l e
i n t h e d r i v e r s door 'B' p o s t . P r i o r t o 1985, a s p r i n g p l u n g e r a l o n g s i d e
e a c h c a t c h , r a i s e d t h e t a i l g a t e on r e l e a s e s u f f i c i e n t l y t o e n a b l e i t t o
b e opened f u l l y by hand. From 1985, t h e s p r i n g p l u n g e r s were d e l e t e d and a
r e c e s s p r o v i d e d i n t h e t a i l g a t e lower edge and body t o permit a handhold
U.S.A. Turbo models u t i l i s e a c a b l e r e l e a s e a c t i v a t e d v i a a p u l l l e v e r

i n t h e d r i v e r s . s i d e r e a r bulkhead. T h i s i s connected, t.o a, c a t c h p l a t e
i n e a c h lower c o r n e r of t h e t a i l g a t e a p e r t u r e . Two g a s 8 t r u t s . a r e used
t o a s s i s t t a i l g a t e opening and s u p p o r t i t i n t h e f u l l y open p o s i t i o n .
The r e l e a s e l e v e r p i v o t i s s e c u r e d by a n u t and i n t e e r a l s t u d which p a s s e s

t h r o u g h t h e bulkhead j u s t o u t b o a r d o f t h e s e a t b e l t r e e l .
Page
anchorage p o s i t i o n of t h e gas s t r u t s was changed from t h e
t a i l g a t e a p e r t u r e ( e a r l y models) t o t h e f r o n t e n g i n e
bay i n o r d e r t o improve opening a s s i s t a n c e .
Removal The t a i l g a t e is most e a s i l y

removed by r e l e a s i n g t h e g a s s t r u t s and
t h e n removing t h e h i n g e b l a d e t o
t a i l g a t e b o l t s . Note t h a t t h e t a p p i n g
p l a t e f o r t h e hinges i s r e t a i n e d i n t h e
t a i l g a t e by a t h i r d f i x i n g f u r t h e r a l o n g
( g a s s t r u t anchor S3 and e a r l y Turbo).
On no account should a l l t h r e e f i x i n g s
be removed a t t h e same t i m e s i n c e t h e
p l a t e is captive within t h e t a i l g a t e
d o u b l e s k i n and may n o t e a s i l y be
repositioned .
Removal o f t h e h i n g e b l a d e p i v o t b o l t s
w i l l ( e x c e p t on g l a s s roof models)
n e c e s s i t a t e removal of t h e e x t e r i o r
c a p p i n g r a i l and i n t e r i o r r e a r bulkhead a
trim. The capping r a i l i s f i x e d by
screws and S i l a s t i c a l o n g i t s lower edge
and r e t a i n e d a l o n g i t s t o p edge by t h e
l i p of t h e b r i g h t f i n i s h e r s t r i p . A f t e r
apping p l a t e
removing t h e capping r a i l and r e a r bulkhead
t r i m panel ( V B . 8 ) t h e Nyloc p i v o t b o l t
n u t s may be r e l e a s e d and t h e p i v o t b o l t s
withdrawn.
Note t h a t t h e h i n g e s a r e used t o t r a n s m i t
c u r r e n t t o t h e heated r e a r screen, with
one w i r e on each s i d e being f i t t e d
beneath t h e p i v o t b o l t nut and t h e n t a k e n
from t h e t a i l g a t e t a p p i n g screw t o t h e
screen.
On'glass roof' c a r s a pivot bracket i s bolted t o the

roof on each s i d e s o t h a t a f t e r removal of t h e t a i l g a t e
and p i v o t b r a c k e t s t h e hinge p i v o t b o l t may be removed
without d i s t u r b i n g t h e capping r a i l .
Latch a d j u s t m e n t .
On S e r i e s 3 t a i l g a t e s , s l o t s and shim p l a t e s a r e provided

f o r a d j u s t i n g s t r i k e r p o s i t i o n and d e p t h . The h e i g h t
of each c a t c h assembly hay b e a d j u s t e d a f t e r s l a c k e n i n g
t h e c a t c h t o body screws and c a t c h b r a c k e t t o r e a r p a n e l
s u p p o r t s t r u t screws. A s i n g l e c a b l e is used t o
r e l e a s e b o t h c a t c h e s and i s a d j u s t e d t o remove s l a c k by
means o f a s o l d e r l e s s n i p p l e a t t h e l e f t hand c a t c h .
F e d e r a l Turbo models u s e s t r i k e r p i n s i n t h e t a i l g a t e
panel a d j u s t a b l e f o r h e i g h t a f t e r s l a c k e n i n g t h e l o c k n u t .
The c a t c h a s s e m b l i e s i n e a c h r e a r c o r n e r o f t h e t a i l g a t e
aperture are adjustable f o r position a f t e r slackening
t h e i r two mounting s c r e w s . The s i n g l e r e l e a s e c a b l e
a b u t s a g a i n s t t h e l e f t hand c a t c h b e f o r e b e i n g r e t a i n e d
a t t h e r i g h t hand c a t c h by a s o l d e r l e s s n i p p l e .
SECTION BD Page 79
The c a r b u r e t t o r a i r box i s f e d w i t h a i r v i a an i n t a k e
s i l e n c e r l o c a t e d above t h e r i g h t hand f u e l t a n k and a
V e n t u r i h o s e s t r a p p e d t o t h e w h e e l a r c h . A i r i s t h u s drawn
from t h e r e a r luggage compartment i n t o which i s f e d f r e s h
a i r from t h e l e f t hand l u g g a g e compartment v e n t , connected

t o t h e l e f t hand ' e a r ' i n t a k e v e n t . I n t h i s way an
a i r f l o w i s m a i n t a i n e d t h r o u g h t h e l u g g a g e compartment,
aiding'demisting of t h e t a i l g a t e g l a s s .
Turbo.
On Turbo models, t h e l o u v e r e d t a i l g a t e p a n e l s e a l s around

t h e e n g i n e l i d a p e r t u r e and draws a i r o u t from t h e e n g i n e
bay when t h e c a r i s moving. Cool a i r i s f e d i n t o t h e
bottom o f t h e e n g i n e bay v i a t h e NACA d u c t i n e a c h s i l l .
The e n g i n e a i r b o x is f e d from t h e r i g h t hand i n t a k e v e n t
' e a r ' b e h i n d t h e r e a r q u a r t e r window.
On F e d e r a l c a r s t h e l e f t hand i n t a k e ' e a r ' i s u s e d t o

supply a d d i t i o n a l c o o l i n g a i r t o t h e c a r b u r e t t o r a r e a
v i a a d u c t w i t h i n t h e e n g i n e c o v e r l i d . The e n g i n e bay
cooling fan f i t t e d i n t h e engine cover l i d i s designed
t o a i d c o o l i n g a f t e r t h e e n g i n e h a s been s w i t c h e d o f f , by
blowing a i r down o v e r t h e c a r b u r e t t o r s . The f a n w i l l
o p e r a t e during a period of 1 5 minutes a f t e r switching o f f
t h e i g n i t i o n i f e n g i n e bay t e m p e r a t u r e e x c e e d s 85OC
( t h e r m a l s w i t c h f i t t e d t o l e f t hand f r o n t u n d e r s i d e o f
e n g i n e c o v e r l i d ) . An i n h i b i t o r s w i t c h f i t t e d i n t o t h e
t o p o f t h e i g n i t i o n box i s o l a t e s t h i s c i r c u i t when t h e
engine l i d is raised.
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 ~ a r '84
l ~ Model Year)
FRONT REAR QUARTER
Blend i n t o n a t u r a l
contour ( s i m i l a r a t
a l l wheelarches)
I
NOSE
-
Page 22 SECTION BD
ESPRIT S3 - '85 Model Year On
Waistli ne Fi nisher
L REAR QUARTER
1
Stripe
NOSE
FRONT BUMPER
ESSEX TURBO
Waistline f i n i s h e r
8omm / 85mm 86mm damn

25mm (40mm f o r L o t u s
logo opposite s i d e ) N o l o w e r 1 2 m m chromc
s t r i p e behim3 r e a r
wheelarch.
I 23mm
Nose badge
Page 24 SEC JlON BD
TURBO - Prior to '85 Model Year
-
NOTE On Dom/~oW m o d e l s , t h e
s i z e of t h e 'Turbo E s p r i t '
d e c a l s was r e d u c e d d u r i n g 1987
f r o m an o v e r a l l d e c a l h e i g h t
Left
hand!
side
Lib 115mm I
of 160mm t o 1 1 6 m a s u s e d o n
Federal cars.
No yap b e t w e e n l o w e r I
door stripes N o gap b e t w e e n lower
s t r i p e and j o i n t l i n e . s t r i p e and j o i n t l i n e .
Bonnet s h u t l i n e
150mm F e d e r a l
8Omm ~ o m e s t i c / ~ o ~
Not f i t t e d on
F e d e r a l cars
SECT'0N BD TURBO - '85 Model Year O n Page 25
SIDE DECAL Waistline Finisher
g A 20mm from
7 bottom edge
Stripe
Wrapped around
Stripe
Wrapped around
Wheelarch
Cut Flush to
I
Cut Flush to
emper edges NOSE
Nose Badge
FRONT BUMPER
Page 26 SECTION BD
BD. 17 - GLASS ROOF ABUTMENT
I n e a r l y 1 9 8 5 , a p o s i t i v e s t o p abutment was added t o t h e g l a s s r o o f r e a r

c a t c h s u p p o r t b r a c k e t s , s u c h t h a t t h e r o o f i s clamped s h u t a g a i n s t two
r u b b e r b u f f e r s . An improved ' o v e r c e n t r e 1 c a t c h a c t i o n r e s u l t s i n m i r e r i g i d
r e t e n t i o n o f t h e r o o f p a n e l w i t h l e s s l i a b i l i t y f o r r a t t l e s and s q u e a k s .
The shimming o f t h e r e a r c a t c h s u p p o r t b r a c k e t s t o t h e body may t h e n be
a d j u s t e d f o r optimum p a n e l h e i g h t and s e a t c o m p r e s s i o n .
The r e v i s e d c a t c h s u p p o r t b r a c k e t s (D082U4974F) a n d r u b b e r b u f f e r s
(X046B6113Z) a r e d i r e c t l y i n t e r c h a n g e a b l e w i t h t h e e a r l i e r b r a c k e t s .
Glass Roof Abutment Buffer
<
SECTION CB Page 7
FRONT SUSPENSION
SECTION CB - ESPRIT S3 & TURBO : PRIOR TO '85 MODEL YEAR
Operation Page
General Description 2/3

Lubrication 4
Geometry 4
Castor Ad jus tment 5
Front Wheel Alignment 6
Front suspension Disassembly 6
Front Hub Adjustment 6
Wheel Bearing Replacement 7
-
i nt Suspension General Layout
Page 3
GENERAL DESCRIPTION
The front suspension i s f u l l y independent with upper wishbones, single lower links,
and an anti-roll bar providing longitudinal location for the lower links. Co-axial
c o i l springs and o i l f i l l e d telescopic dampers react on the lower link.
A stub axle secured i n each vertical link, carries the wheel hub on two taper
roller bearings, adjustable for endfloat.
Key to Front Suspension General Layout Drawing
Front Hub Lower Trunnion
Brake Disc Bush Kit, Lower Trunnion
Wheel Bearing, inner Seal, Trunnion Top
Wheel Bearing, outer Bolt, Trunnion to Lower Link
Oil Seal, Front Hub Lower Link Assembly.
Stub Axle Bush, Lower Link Pivot
Dust Cap Anti- Roll Bar
Vertical Link Bush, Anti-Roll Bar to Lower Link
Steering Arm Distance Tube
Caliper Mounting Plate Washer, A n t i Roll Bar to Lower Link Bush
Dust Shield Mounting Rubber, A n t i Roll Bar to Chassis
Upper Ball Joint Clamp Plate
Wishbone Arm Damper Assembly
Pivot Bush, Wishbone Bolt, Damper to Lower Link
Stud, Wishbone Pivot Road Spring
Spring Seat
0
DEC 1984
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.
A t the recommended service interval, repack the hub with grease, (See Section C
and lubricate the lower trunnions.
Lower Trunnions: I t i s ESSENTIAL that a recommended EP90 grade oil i s used to

lubricate the trunnions, and NOT grease. Remove the plug shown arrowed, and
fit a threaded grease nipple into the vertical link. Apply an o i l filled grease gun
to the nipple, and pump until o i l exudes from the trunnion top seal.
.ing Plug
CB .2. - GEOMETRY
Under normal service conditions, i t should only be necessary to check the front
wheel alignment. A full geometry check i s only necessary following front
suspension repair, or i f excessive tyre wear i s evident, or steering difficulties
experienced. Both wheel a1ignment and castor angle are adjustable, but camber
and steering axis inclination (K .P. I.) are set during manufacture, and are non-
adjustable.
A t ride height of 170mm :- Measured at front chassis box section
Camber minys f30' -+ 0

0 15'
Castor 3' - 0 30' (within
o+ 0
o0
30' side to side)
K.P.I. 9 - 0 30'+
Toe-in 2mm overall - 1 mm
. SECTION CB Page 5
'a CB.3. - CASTOR ADJUSTMENT

Castor adjustment i s 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 1262, 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
mounting and chassis, on both upper and lower bolts. O n each side
o f the car, an equal number o f washers must be used top and bottom,
up to a maximum thickness of three washers.
Spacer washers
ii). From V l N 82/85D 1263, 82/85 A/E/G/H/S 041 1 ~ l u s0399 and 0400
c,/F B/C/F/K 01 04.
Shim plates A082C4052, 2mm thick, may be slid i n behind the mountings
after slackening the bolts. Up to four shims may be used on each side.
Shim plates
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
i s correct tighten the bellows clamps.
CB .5. - FRONT S U S P E N S I ~ NDISASSEMBLY

-.--
CAUTION: Because the upper and lower road spring abutments are the chassis
and lower link respectively, i t is ESSENTIAL that spring compressors are used
before disconnecting either end of the damper, or the lower link from the chassis.
Failure to do so could result i n personal injury.
A l l suspension rubber bush pivots, must be tightened only at ride height (1 50 and
175 mm at front and rear of chassis centre box section).
On the anti-roll bar to lower link bush fixing, note that a sp,ecial chamfered
washer i s fitted between the anti-roll bar and the lower link front bush, i n
order to provide for fillet clearance. Ensure this washer i s fitted the correct
way round.
L
Chamfered Washer Distonce Tube
Note when fitting the damper thataflat washer is used on both sides of thedamper
lower bush inside the lower link.
CB .6. - FRONT HUB ADJUSTMENT

Adjustment: Remove the road wheel followed by the hub dust cover (A) and
split pin (B).
- -
Tighten the hub nut to 0.7 0.8 kgf .m. (5 6 1bf.ft.) whilst rotating the hub
to ensure bedding of the taper roller bearings. Slacken the nut sufficiently to
-
obtain a hub endfloat of 0.O8 - 0.1 3 mm (0 .OO3 0.005 i n .) measured with a
dial gauge. Insert the split pin and refit the hub dust cover.
SECTION CB Page 7
CB.7. - WHEEL BEARING REPLACEMENT
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 o i l seal from the inboard side of the hub, and remove the
inboard inner race and roller assembly. Both outer race:; may now be
driven from the hub using a soft metal drift at alternate sides of each
race.
F i t new outer races into the hub wing a press.
Pack the new bearings with an approved Lithium based wheel bearing
grease, and work well into the roller cages. Coat the inside o f the hub
outer races and cap with grease.
l nsert the inboard bearing roller assembly and inner race, and retain
with new o i l seal.
Mount the hub assembly onto the spindle and fit the outboard roller
assembly and race, retaining washer and nut, and adjust the bearings
(see above) before fitting split pin and dust cap.
Refit brake caliper, torque tightening fixing bolts to 8.3 kgf .m. (60 Ibf .ft .)
and road wheel.
Torque wheel retaining bolts to 9.0 kgf.m (65 1bf.ft.).

SECTION CC Page I
FRONT SUSPENSI 0,N
SECTION CC - ESPRIT S3 & TURBO: 1985 MODEL YEAR ONWARDS
Operation -
Page
General Description - 2 to4

Geometry CCI 4
Castor Ad justment CC2 4/5
Suspension Disassembly CC3. 5/6
Front Wheel Bearings CC4 6/7

Layout of Front Suspension
-
C/,
nl I
--
Key to Suspension Layout Diagram
C)
1, Verttcal Link Locking Cap, Bearing Nut Ball Joint, Lower

83
2. Steering Arm Grease Cap, Hub Bearing Nut, Nyloc, M I 4 0 8
3. : Setscrew, M12 x 35, Arm/Link Arm, Upper Wishbone Pivot Bolt 3" UNF x 6 " 0
4. Spring -Washer, Arm/Link Pivot &sh;Upper Wishbone Nut, Nyloc, 4" UNF
5. Bolt, M12 x 45, Arm/Link Stud, Upper Wishbone Pivot Pivot Bolt, 3" UNF x 23"
6. Nut, Nyloc, M I 2 Buffer Wusher, Pivot Bush Nut, Nyloc, 3" UNF
7. Shield, Brake Disc Nut, Nyloc, 3" UNF Anti-Roll Bar
8. Setscrew, Disc Shield Locknut, +I1UNF Bush, A RB/Chass i s
9. Flat Washer, Disc Shield Shim Washer, Castor Adjust Clamp, ARB/Chassis
10. Front Hub Ball Joint, Upper Setscrew, M12 x 35
11 . Inboard Bearing, Front Hub Nut, torqloc, 7/16" UNF Washer
Nut, Nyloc, M12
12. Outboard Bearing, Front Hub Bolt, M8 x 100, Ball Joint
13. Brake Disc, Ventilated Bolt, M8 x 60/65, Ball Joint Abutment Plate, Spring/Damper
14. Bolt, Brake Disc to Hub Nut, Nyloc, M8 Was her, Plate/Chass is
15. Washer, Disc to Hub Washer, Plain Nut, M8 Plate Chassis
16. Grease Seal, Front Hub Shimplate, Castor Adjust Insulator, Spring Top
17. .Claw Washer, bearing Retaining Lower Wishbone Road Spring
18. . Nut, eari in^, Retaining Pivot Bush, Wishbone Rear Damper
19. Split Pin, ' ~ o c k i Cap
n~ Pivot Bush, Wishbone Front Bolt, 3" UNF x 33"
Bush, ARB/Wishbone Nut, Nyloc, &'I UNF
Bush Kit, Damper Top Stem
Blanking Plug, Plastic
Page 4 SECTION CC
GENERAL DESCRIPTION a
The front suspension i s fully independent with upper and lower wishbones
together with concentric damper/spring assemblies and a n 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
Under normal service conditions, i t should only be necessary to check the front
wheel alignment. A f u l l geometry check i s only necessary following front
suspension repair or i f excessive tyre wear i s evident, or steering difficulties
experienced.
The recommended method of measuring front wheel a1ignment i s by the use of

parallel bars as described i n section DB so that the rear wheel alignment may.
be checked a t the same time.
Before measuring suspension geometry set car to ride height o f 170mm below
chassis front cross member, 170mm bklow rear lowei l i n k chassis brackets.
Camber O0 30' negative 5 O0 30'

Castor min lo 45' rnax 3O
(Within O0 30' side to side)
K .P.I. 23' nominal
Toe- i n 1 .6mm each side +0- 1mm
CC. 2 - CASTOR ADJUSTMENT
.
Cars prior to V l N 82/85 D 1937 (Dom) FF 0602 (U S .A .) may be fitted with
.
castor adjustment shims 'A' and '8' as illustrated These shims are available
i n various thicknesses:
Shim Washer 'A' 1 .5mm A082C4091
'I II
'A' 3.0mm A082C4092
'I I1
'A' 6.Omm A 082C4093
Shim Plate '8' 1 .5mm A082C4090
1' 'I
'B' 3.0mm A082C4089
Shins may be fitted up t0.a max;mum thickness of 6.0mm to correct castor i f

necessary.
Important The same thickness shim pack must be used a t location 'A' and 'B'.
As a r o i- h guide,
- fitment of 3.0rnm shim a t 'A' and 'B' wit1 result i n a n increase
. ,.
i n castor of approx 2
10. '
Can from and including Vl N 82/85 D 1937 ( ~ b m FF0602) (USA) have a shortened
chassis fixing tube for the top wishbone pivot stud, and 6rnm o f shim washers 'A'
distributed between the front and rear of the-chassis a t this poifit .
I n extreme
cases, these cars may be fitted w i t h additional shims 'A' and 'B' as detailed above.
SECTION CC Page 5
Caution i n a l l cases ensure that the top wishbone pivot stud and ball joint bolts
have sufficient engagement through their ~ ~ l nuts. o c I f necessary, replace the pivot
bolt front Nyloc and locknut with two iocknuts (i.e. one Nyloc a t rear and two
locknuts a t front). A 5mm longer ball joint outer bolt (M8 x 65) i s available part
no. A OEW2044.
CC. 3 - SUSPENSION DISASSEMBLY
See exploded diagram for general layout
Caution The road spring lower platform is integral with the damper lower body, while ,
the spring top pla tform/damper abutment i s bolted to the chassis. Under no c i r c u m tances
therefore may the damper top stem nuts be removed unless the spring/damper assembly
i s removed from the vehicle and the spring compressed i n an hydraulic press or similar.
Spring/damper removal : These two components must be removed from the vehicle as an
a assembly. Release the damper to lower wishbone fixing, and the four nuts securing the
spring top platform to the chassis, and remove assembly to bench.
Spring Lower Platform

Spring Top PI a tform/
Note that early '85 MY cars used parall el coil springs, which were superceded by conical
springs with the greater diameter fitted lowerma t. The dianieter of the spring seat on the
damper body i s correspondingly increased for use with conical springs. If replacing a
spring or a damper o f the earlier 'parallel spring' type, then the later 'conical spring' type
components should be fitted us an assembly.
Before the spring/damper assembly may be further dismantled, i t i s necessary to

compress the spring. Conventional spring compressor clamps may not be suitable
due to the close coiled nature of the compressed spring. Use special tool TOO0
or hydraulic press with suitable adaptors to compress the spring before removing the
damper top stem nuts and rubber bush, After unloading the spring, the individual
components may be replaced.
The anti-roll bar fixing into the lower wishbone i s by push f i t only. Use rubber grease
on assembly. If replacing the lower wishbone anti-roll bar bush, ensure that the larger
portion (in relation to its location groove) i s fitted towards the front.
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
1 . The brake caliper must first be removed. In order to extract the caliper
uppermost fixing bolt, i t i s necessary f i n t to remove the cylinder swing
release bolt, and swing up the cylinder until the brake pipe clean the
caliper top fixing bolt.
2. Remove the hub nut and pull off the hub complete with brake disc.
3. Prise out the inner oil seal and remove the centre assembly of the inboard
.
bea r i ng
4. The outer races of both bearings may be removed from the hub wing a drift
as shown a t alternate sides of the race.
5, Using a press, f i t the outer mces into the hub.
6. Pack the new bearing with a Lithium base wheel bearing grease and
work well into the roller cages. Coat the irside of the hub, outer
races, and cap with grease.
APR 1987.
,.
SECTION CC Page 7
a:
7. lnserttheinboardbearingcentreandretainbypressinginthe
.
inner o i l 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, check the force needed to rotate the hub.
Preload:
With new oil seal 350 - 8759

(0.8 - 1.9 Ib)
With used o i l seal 50 - 500g

0 - 1 .l lb)
9. Using a dial gauge, measure the hub end float.

Maximum = 0.05mm (0.002 in.).
lmtall the lock ring and split pin, I f necessary tightening the hub nut further by
by the smallest amount required.
Refit brake caliper and torque bolts -

Caliper to vertical link 9.0kgf. m e (65 Ibf .ft)
Cylimler swing release 1 .6 - 2.4 kgf .me (12 - 17 Ibf .ft)
SECTION DB Page 7
REAR SUSPENSION
SECTION DB - ESPRIT S3 & TURBO
Opera tion Page
General Description -
Geometry DBI
Rear Wheel Alignment DB2
Rear Suspension Reassembly DB3

Rear Wheel Bearing Removal DM
Rear Wheel Bearing Installation DB5
Drive Shaft C.V. Joint Boot Replacement DBC
-
a t e a r Suspension General Layout
Key to Rear Suspension General Layout Drawing
1. Rear Hub Bolt, Radius Arm to Mounting
2. Stud, Wheel Nut, Nyloc, Radius Arm to Mounting
3. Nut, HubRetaining Washer, Large
4. Split Pin, Hub Nut Washer, Toe- In Adjustment
5. Cone, Hub Retention Top Link
4. Bearing, Rear Wheel Rubber Bush, Top Link
7. Circl ip, Bearing Retaining Bolt, Top Link to Hub Carrier
8. . Spacer, Driveshaft/Bearing Lower Link
9. Drive Shaft, Outboard Stud, Lower Link to Hub Carrier
:-1'0. Drive
..
Shaft, l ntermediate Split Spacer, Hub Carrier
11. . -Adaptor, Driveshaft

. Damper Assembly
1 2 . - ff ub Carrier Bush Kit, Damper Top Stem
- 13. R~diusArm 31 . Spacer Washer, Damper to Hub Carrier
1 4 . Bolt, Radius Arm to Hub Carrier 32. Washer, Plain, Damper to Hub Carrier
- 15. Nut, Nyloc, Arm to Hub Carrier 33. Nut, Nyloc, Damper to Hub Carrier
16. .. Mounting Rubber, Radius Ann Front 34. Road Spri ng

. .. .
171. &inforcing Plate, Radius Arm Mounting 35. Insulator, Road Spring
.. .. ,. .
18. - Spacer, Radius Arm Mounting
Page 4 SECTION DB
GENERAL DESCRIPTION
The rear suspension i s fully independent with single upper and lower transverse links
a
and box section trailing radius arms. Co-axial coil springs and o i l filled telescopic
dampers act on the aluminium alloy hub carrier.
A n outboard drive shaft i s carried i n each hub carrier on a single sealed for l i f e dual
race angular contact ball bearing.
DB .I . - GEOMETRY
A t ride height ( 170mm below rear lower link chassis brackets);
Camber :
+ 0
minus 0 ~ 3 0 ' - 0 15'
Toe-In : 1.5rnm each side
DB.2. - REAR WHEEL ALIGNMENT

It i s essential that rear wheel alignment i s checked using equipment which measures
individual wheel alignment. The most reliable and accurate method i s considered to
be the use of para1lel bars, as used on production.
Two ban which are longer than the overall length of the car, and 4 axle stands are
required. The bars should be obtained locally and should be of 'T' or square section
and be sufficiently rigid to avoid significant bending or sagging between supports.
Set up the two ban on each side o f the car.at wheel centre height as shown i n the
diagram, so that A equals A, B equals B and C equals C.
A A
REAR
FRONT
[
B C
1
1
Measure the distance from the bar to the RIM of the wheel concerned at front and rear
of the centre line o f the wheel. If the front dimension i s greater than the rear dimension,
the wheel has TOE-IN. If the rear dimension is greater than the front dimension, the
wheel has TOE-OUT. The difference between the two measurements i s the amount the
wheel has TOE- IN or TOE-OUT.
SECTION DB Page 5
'0
Rear wheel alignment i s 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 i n the following combinations,
in order to bring the correct setting within the range of adjustment afforded by the shim
was hers.
EITHER - One 2mm spacer A079D4051 K
OR - Two 2mm spacer A079D4051 K
OR - One 6rnrn spacer B079D4051K
OR - (One 2mm spacer A079D4051 K)

(Plus One 6mm spacer B079D4051K)
Ensure at a l l times that the mounting to chassis fixing bolts are of sufficient length to ensure
full engagement of the nyloc fixing nuts.
NOTE : O n final assembly, use a new nyloc nut on the bolt securing the radius arm to the
rubber mounting, and torque tighten to 5.5 -
6.2 kgf .m (40 - 45 Ibf .ft.) with the car at
ride height.
DB.3. - REAR SUSPENSION REASSEMBLY

O n reassembly of the rear suspension after component replacement or overhaul, check the
rear wheel toe-in and ad just i f necessary.
Tighten a l l upper and lower link pivot boltr and h d i u s arm bolt o n l.y.'k i t h t h e car
. .. , . . .
at ride height. . ..
Note positions and assembly sequence of a l l pivot bolt washers before dismantling. Check
0 geneml layout drawing at front of this section for damper to hub carrier fitment.
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 o f a press, press out the outboard driveshaft and spacer.
5. Remove circlip retaining bearing i n hub carrier, and press out the bearing.
DB,5. - REAR WHEEL BEARING INSTALLATION

1. Thoroughly d e g r e a s e hub carrier ( b e a r i n g
. . h o u s i n g ] a n d o u t e r s u r f a c e o f new h u b b e a r i n g .
2. B e f o r e f i t t i n g t h e new b e a r i n g i n t h e h o u s i n g ,
p r e h e a t t h e h u b c a r r i e r t o a p p r o x . 10oO C a n d
s o a k a t t h a t t e m p e r a t u r e f o r 5 t o 10 m i n s . A
c o n v e n i e n t m e t h o d i s t o immerse t h e c a s t i n g f o r
1 0 m i n u t e s i n b o i l i n g water. Do n o t e x c e e d a
t e m p e r a t u r e o f 150° C ,
3. Allow m o i s t u r e t o e v a p o r a t e f r o m t h e h u b
c a r r i e r , t h e n a p p l y a t h i n c o a t o f Permabond
A148 ( P a r t No. A082V6107) t o t h e m a t i n g s u r f a c e s
o f t h e b e a r i n g a n d h o u s i n g . 'Do NOT c o n t a m i n a t e
a n y moving p a r t s o f t h e b e a r i n g .
4. P r e s s i n t h e new b e a r i n g f r o m t h e h u b s i d e o f
t h e h o u s i n g , u n t i l t h e b e a r i n g is i n c o n t a c t
SECTION D B Page 7
w i t h t h e s h o u l d e r i n t h e h o u s i n g . Apply l o a d
t o the outer track of the bearing only.
F i t a new b e a r i n g r e t e n t i o n c i r c l i p i n t o t h e
h o u s i n g a n d a l l o w t o cool n a t u r a l l y t o a m b i e n t
temperature.
S u p p o r t t h e o u t b o a r d d r i v e s h a f t on t h e bed of
a press, a n d f i t t h e s p a c e r o v e r t h e S h a f t , .
larger end towards t h e f l a n g e .
Press t h e h u b . c a r r i e r a s s e m b l y o n t o t h e
driveshaft, applying load to t h e inner
t r a c k of t h e . b e a r i n g o n l y . .
F i t t h e nub o n t o t h e d r i v e s h a f t s p l i n e s .
Check t h a t t h e m a t i n g f a c e s of t h e c o n i c a l
washer and hub are s c r u p u l o u s l y c l e a n b e f o r e
f i t t i n g t h e washer and hub n u t . ~ i g h t e nt h e
n u t t o 28 k g f - m ( 2 0 0 1 b f . f t . ) a n d t h e n i f
necessary tighten further t o enable t h e s p l i t
p i n t o be f i t t e d . It i s most i m p o r t a n t t h a t
t h e n u t is n o t s l a c k e n e d t o i n s e r t t h e p i n .
R e f i t t h e h u b c a r r i e r a s s e m b l y t o c a r . TIGHTEN
ALL BOLTSiNUTS TO T H E I R SPECIFIED TORQUE L O A D I N G
(Refer t o S e r v i c e Notes Technical Data)
DB.6. - DRIVE SHAFT C.V. JOINT BOOT -

REPLACEMENT
--
Remove drive shaft assembly from vehicle.
Remove the two boot retaining c l i p and tap off

end closure plate.
Remove and discard circlip ietainihg ball hub

on shaft. Slide boot along shaft, away from
joint.
Support ball hub with suitable distance piece and

knock or press drive shaft f h n joint. Remove boot 6
Wash out ioint with degreasing fluid and dry off.
itnew b o d onto shaft. Drive ball hub carefully

onto shaft up to limit position.
Page 8
.7. Fit- new circlip supplied i n boot k i t and ensure i t is

iully seated i n -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 i s seated i n shaft
groove.
9. F i t both boot retaining c l i p as tightly as possible

by h a d before crimping with pliers.
i0. Ensure that crimp position of larger clip does not

interfere with bolt hole access .
11 . Pack outer end of ioint with remaining grease.
12.' F i t new end closure plate,ensuring bolt holes are

, ,
.
aligned .
13. Refit driveshaft ossembly to vehicle, toque laadt
a l l driveshaft socket head bolts to 80 Nm (8.3 kg).
60 Ibf .ft .).
Page I
ENGINE
SECTION EA - 907/912/910 i n c . FEDERAL
Operati o n Page
General D e s c r i p t i o n -
Lubrication EA 1
E n g i n e Tune (NOT F e d e r a l Turbo) EA 2
Compression Check EA 3
Camshaft Covers EA 4
Camshafts EA 5
Valve C l e a r a n c e s EA 6
Toothed B e l t Guard EA 7
Camshaft D r i v i n g B e l t EA 8
Driving B e l t Yensioner EA 9
C y l i n d e r Head EA 10
Valves EA 11
D e c a r b o n i s e C y l i n d e r Head and P i s t o n s EA 12
Valve S e a t I n s e r t s EA 13
Valve G u i d e s EA 14
Crankshaft ' V 1 Pulley EA 15
Crankshaft Sprocket EA 16
F r o n t Cover & O i l S e a l EA 17
Water Pump EA 18
O i l Filter EA 19
Ignition Distributor EA 20
O i l Pump and A u x i l i a r y Housing EA 21
I n l e t M a n i f o l d and C a r b u r e t t o r s EA 22
O i l Sump EA 23
C o n n e c t i n g Rod (Big-End) B e a r i n g s EA 24
E n g i n e Assembly EA 25
F l y w h e e l and Ring Gear EA 26
Crankshaft Rear O i l Seal EA 27
Crankshaft EA 28
P i s t o n s , P i s t o n R i n g s , C o n n e c t i n g Rods
& Cylinder Liners EA 29
C o n n e c t i o n o f O i l C o o l e r T h e r m o s t a t (Turbo) EA 30
L u b r i c a t i o n System P r e c a u t i o n s EA 31
S p e c i a l Tools EA 32
S e a l a n t s , Adhesives EA 33
APR 1987
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
and are at an inclusive angle of 38'. They are operated by the camshafts bcting directly
on the cam followers (tappets), the camshafts being driven at half engine speed by a
toothed belt. The camshafts end float i s taken by a thrust washer at the rear end of each
shaft. The toothed driving belt also drives the auxiliary shaft, this i n turn driving the
oil pump and ignition distributor.
The crankshaft, of cast iron construction and dynamically balanced, runs i n 5

steel-backed leaded bronze lined main bearings, end float beingcontrolled by split
thrust washers located in the cylinder block on either sideof the rear main bearing.
The connecting rods of 'I' section forgings have steel backed bronze l i t t l e end
bushes and steel-backed leaded bronze lined big-end bearings, the big-end bearing
caps being located by dowels and retained by bolts. Solid skirt aluminium alloy pistons
with two compression and one oil control ring, situated above the gudgeon pin, are used.
The gudgeon pins are retained i n position by circlips installed i n groovesat each end of
the gudgeon pin bore.
A cast iron flywheel incorporating a steel ring driving gear for the starter, i s located
on the crankshaft flange and retained by two dowels and six bolts fitted -
without
-
lockwashers.
EA.1 , - LUBRICATION
General
The lubrication system i s of the forced feed type, the o i l being circulated by a
mechanically driven o i l pump. The pump, of the eccentric bi-rotor type which
incorporates a non-ad justable plunger type relief valve, i s driven by an auxiliary
shaft thls being contained i n the auxiliary housing bolted to the right-hand side of
the cylinder block.
Oil i s drawn from the sump up a pick-up pipe and into the pump. When the relief
valve opens, o i l i s passed back into the inlet side of pump. From the pump the
pressurised o i l flows through the o i l cooler and full-flow filter to the o i l gallery.
The o i l gallery passes along the right-hand side of theengine, from where o i l i s
taken to feed the crankshaft main bearings and through drillings i n the webs of the
crankshaft, to the big-end bearings. The o i l gallery also takes o i l forward to the
auxiliary shaft, then subsequently to the camshaft bearings and valve gear. Lubrication
of the l i t t l e end bushes, the gudgeon pins and the non-thrust sides of the cylinder
linen i s by o i l mist.
An oil gallery cover opposite fourth main bearing provides take offs for the
oil pressure gauge, turbocharger oil feed and low temperature switch (H.C. I.)
Page 4 SECTION EA
On dry sump Turbo Esprit models a sepemte belt driven o i l pump assembly i s used, fixed
tb the right hand side of the main bearing panel.
The assembly consists of two scavenge pump and a pressure pump a l l mounted on a
common axis and supported by the scavenge manifold.
The two scavenge pump draw o i l out from the sump via the scavenge manifold, one pump
drawing from ducts 1 and 3, the other from duetr 2 and 4. The oil/air mixture i s pumped
through the o i l cooler and into the o i l tank oil/air seperator. The pressure pump draws
o i l from the tank and feeds i t via a cylinder block passage into the auxiliary housing.
A pressure relief valve i s incorporated into the scavenge manifold and bleeds o i l back
into the inlet side of the pump on opening.
The auxiliary housing passageways are modified to direct the o i l into the o i l filter, (by-
passing the pump housing) and thehce into the o i l gallery.
All Esprit models (except early Series 1) use a 'cross drilled' crankshaft to enable plain
lower main bearing shells to be fitted and increase load capacity.
Oil Level
NOT Dry Sump Turbo: Before checking o i l level, allow a full five minutes for o i l to
returh to sump. The correct o i l level i s to the upper mark on the dipstick with the car
on a level surface. Add o i l i f netesiary through the filler neck on the inlet camshaft
cover. Do NOT overfill. Replace filler ~ a securely.
p
The engine o i l should be changed and a new filter fitted at the recommended service
intervals. Sump capacity is listed i n TECHNICAL DATA, and should be drained when
the o i l i s warm and impurities are held i n suspension.
Dry Sump Turbo: Check the o i l level i n the tank at the right hand side of the engine
bay WITHIN TWO MINUTES of switchingoff. Oil w i l l drain back from the tank into
0
the sump when left standing and i f the level is checked before the scavenge pumps
have returned this o i l to the tank, overfilling w i l l result.
The o i l should be changed and a new filter fitted at the recommended service intervals.
The tank drain plug i s located i n theright hand rear wheelarch reached after removal
of the road wheel. Drain the tank when the o i l is warm and impurities are held i n
suspension. F i l l the tank with new o i l to the top mark on the dipstick and run the
-
engine for 2 3 minutes at 1500 rpm. Switch off and check level within 2 minutes,
topping up if necessary.
Oil Filter
A full flow filter of the 'throw-away' canister type, incorporating an anti-drain back
valve, i s screwed onto the rear of the auxil iary housing.
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 i n TECHNICAL DATA, or if
the electrodes are badly burnt, fit new plugs and re-connect the leads.
. .
I f contact breaker points are fitted:
Remove the ignition distributor and examine the contact-breaker points. Replace the
points if badly burnt, or excessive metal transfer is evident. Adjust the points gap to
the dimension given i n TECHNICAL DATA and refit the distributor.
Remove the a i r cleaner element and clean (or replace if necessary).
Disconnect the fuel feed pipe at the carburetten and check the fuel flow.
2
Fuel pressure on Turbo e'ngines = 4.5 Ib/in above boost pressure.
~ I Carburetters -
D lorto Remove float chamber cover. Withdraw the float assembly.
Remove a l l jets and blew them clear with the assistance of an air line. Do NOT use wire
as this w i l l enlarge the jet orifice. Remove the needle valve and valve body and blow
clean with an a i r I ine. Clean the float and float chamber using clean petrol. Replace
a l l jets, needle valve body and needle valve. Using a new gasket, fit to float chamber
cover, replace float assembly. Check float setting. Refit float chamber cover.
Zenith-Stromberg Carburetten - Remove carburetters from the engine to a clean bench.
Release centre-plug from the base of each carburetter. Remove float chamben by
releasing the retaining screws and withdrawing i n a vertical motion to avoid damage
to the float mechanism. Remove float chamber gasket and take out floats.
Remove needle valve from float chamber cover. Remove '0'
ring from base centre-
plug. Thoroughly wash a l l removed parts i n clean petrol. Refit needle valve into
float chamber cover using a new washer. Replace float assembly ., Refit float
chamben with a new gasket. F i t new '0' ring t o base centre-plug and replace
securely. Refit carburetters t o engine using new gaskets. Top up damper reservoirs
with oil.
Re-connect the fuel pipes at the carburetters.
Check valve timing, toothed belt tension and condition, valve clearances, adjust
as necessary.
Check the ignition timing, adjusting ifnecessary.
Adjust the engine slow-running speed and mixture (see TECHNICAL DATA).
Page 6 SECTION €A
EA.3. - COMPRESSION CHECK

Warm the engine t9 i t s normal operating temperature. Switch 'off' the engine and
remove a l l 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 gauge i n a
convenient position t o be observed and insert the conical-ended rubber tube i n
the No.1 sparking plug orifice. The normal compression pressure with an
engine that has been 'run-in' correctly i s given i n TECHNICAL DATA. A t
altitudes above sed-level, proportionally lower pressures will be obtained.
Compression i s checked with the starter motor turning the engine at
appboximot,ly 200 r.p.m. Battety and starter motor must of course, be in
g o d condition.
Test the iemaitGng cylinders i n a similar manner.
~ e ~ i a sparking
ca plugs and re-connect the sparking plug leads.
EAe4. - CAMSHAFT COVERS

Three d i f f e r e n t types of camshaft cover have been used:
A l l 907 engines, and n a t u r a l l y aspirated 912 engines p r i o r t o 1986, use
a 'saddle' type cover with a curved j o i n t face. When ref i t ting t h i s type
of cover, i t i s e s s e n t i a l t o use S i l a s t i c RTV 732 on the j o i n t face of
both housing and cover together with a new gasket. Do not overtighten
the f i x i n g s ( s e e Torque loadings) On some models i t may be necessary t o
place the b o l t s i n t o the cover before f i t t i n g t o the engine.
Turbo 910 engines p r i o r t o mid '86 and e a r l y '86 M.Y. Excel engines, use
f l a t type cam covers with a t h r e e eared f i l l e r cap a t t h e f r o n t of t h e
i n l e t cover. Use Hylomar i f necessary t o r e t a i n the gasket whilst f i t t i n g .
tighten the three s l o t head retaining nuts with t h e i r rubber washers.
U.S.A. Turbo H.C.I. a n d - o t h e r engine v a r i e n t s a t l a t e r d a t e s , use covers
s i m i l a r t o (2) but with t h e o i l f i l l e r a t the r e a r of the i n l e t cover.
the gaskets on these engines a r e retained by s p i r o l pins and the covers
by socket head screws and '0' r i n g s .
SECTION EA Page 7 .
a
EA.5. - CAMSHAFTS
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 a l l valve clearances(Secti0n EA .6 .)noting any which require adjustment.

Remove the timing be1t (Section EA .8.) On engines equippedwith air
4* iniection, remove the air injection mil from the cylinder head.
5. Insert small bar magnets across each of two cam followers, to hold the cam followers
i n their respective bores. Note: Use magnets only for removal.
Fig. 1 - View showing cam followers held by magnets
6. Remove the ten nuts and washers (release the nuts diagonally inwards from the
outside) securing the camshaft housing. Care MUST be taken to avoid drbpping
any nuts or washers down the inside front of the camshaft housing. Remove the
housing and discard the gasket. (if fitted).
O n Turbo engines, i t i s necessary t o remove the socket head access plugs and then
to use 'Torx' socket TOOT0443 on the cam housing bolts.

7. Repeat the process for the other housing. On front engined cars, release the
cooling system header tank before removing the exhaust cum haft housing.
On engines equipped with an air pump, remove the air pump belt guard and
be1t before removing the exhaust camshaft housing.
Page 8 SECTION EA
8. Remove the magnets and release cam followers from their locations. Place them i n
their respective fitting positions, noting that the cam follower shims are almost
always 'stuck' t o the underside of the cam follower. If they are not, then they
w i l l be 'stuck' to the top of the valve stems. Keep the shim with its respective
cam follower.
shims
SECTION EA Page 9
9. Hold the camshaft sprocket i n 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 remove cover with its '0' ring. Release the thrust washer retaining bolt
and washer, or 'V' pulley adaptorspindle, and remove thrust washer. Remove
bolt and washers securing the toothed sprocket to the camshaft.
Fig. 4 - Camshaft thrust washer & '0' ring
WASHER
10. Remove the assembly from the vice, and pull off the camshaft sprocket.
1 Remove the toothed belt snubber (where fitted) from the front of the inlet camshaft
housing, by releasing the two M8 nuts, noting the eccentric sleeve fitted on the
lower stud.
12. Withtlieaidofatwo-leggedpuller,
attached to the rear of the camshaft . . .. .3.
.
housing, screw i n the centre bolt to ,'
push out the camshaft towards the front -'
of housing, together with its oil seul

. .
. .
13. Repeat the process for the other camshaft

. .
and sprocket.
Fig. 5 - Releusing the camshaft

Page 70 SEC77ON EA
1. Smear a 1ittle graphite grease on the bearing surfaces of the camshaft housing;
insert camshaft into its housing from the front and fit a new front o i l seal .
Fig. 8 - Camshaft oil seal fitted

OI L SEAL
Emure oilseal i s flush with outer face of housing. If seal is fitted to the
shoulder inside housing the o i l drain hole would be blocked. ,a
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 i t has been removed, refit the woodruff key to the front end of the camshaft,
and replace camhaft sprocket together with its large plain washer spring
washer and retaining bolt. It i s ESSENTIAL that the sprockets are fitted
-
the correct way round on each camshaft, i.e. "IN coloured dot' facing
-
forward on inlet camshaft and "EX coloured dot" facing forward on
exhaust camshaft. See 'TECHNICAL DATA' for correct specification.
O n engines without air pump: fit the selective thrust washer with i t s retaining
bolt, and spring washer, ensuring that i t i s located on the dowel protruding
from the rear end of the camshaft. Hold the camshaft sprocket i n the vice
(fig.3.). Tighten thrust washer and sprocket retaining bolt tospecified
loading (see TECHNICAL DATA). Replace rear cover with new 'O'ring,
tightening the bolts to their specified torque loading. Check the Camshaft
end-float (see TECHNICAL DATA). If the end-float i s outside this tolerance,
replace the selective thrust washer.
O n engines equipped with an air pump: apply Permabond A1 38 thread locking

compound to the .threads of the 'V' pulley adaptor spindle, and screw into the
rear of the camshaft securely. Fit the selective thrust washer over its locating
dowel, and f i t the rear seal housing using a new '0' ring andoil seal. Apply
Silastic RTV 732 into the inside of the 'V' pulley hub, and fit onto the adaptor
spindle, ensuring that the dowel engages into thehub correctly. Fit the 'V'
pulley onto the hub with the drive line inset towards theengine, f i t the M8
washer and self locking nut and torque tighten (see TECHNICAL DATA). Check
- -
the camshaft end float 0.03 0.20 mm (0.001 -0.008 in.). If outside of
tolerance, replace selective thrust washer.
F i t the four washers and setscrews securing the 'V' pulley to the pulley hub
and tighten.
Replace cam follower shims onto the ends of the valve stems, these being
greased (with graphogen grease) on the valve stem side. Replace the cam
followers into their respective bores i n the camshaft housing, after an
application of graphogen grease.
I n order to avoid damaging the.valves when thecamshaft housings are replaced,

i t is ESSE NTlAL that the crankshaft is turned BACK 'apjirokimately 90' from
its TDC position, to bring the pistons half way down the cylinders. Do not
turn the crankshaft more than 90O back a?this may also cause the valves to
. . . . . .. . . .
be damaged. . ..
O n engines up to engine number 11276, using a new gasket, which is DRY

and kept FREE OF OIL, replace the'carnshaft housing with its securing
washers and nuts. Tighten the..nutsto.their specified loadings. diagondly. '
outwards from the centre.

Page 72 SECTION EA
O n engines from engine number 11276, and earlier engines i f 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 gasket eliminator ensure a l l old gasket elimiminator i s removed from
the mating surfaces of the cylinder head and cam housing. Take care not
to scratch sealing surfaces - use a blunt scraper such as the flat end of a
steel rule. Degrease and clean the mating surfaces using methylated spirit
or similar. Lay a thin continuous bead of gasket eliminator (approx 1/16
to 3/32 in. wide) i n the middle of the sealing surface on the cam housing,
following the outer surface around the stud holes. F i t '0'
ring on cyl inder
head dowel and carefully place cam housing on cylinder head studs and
secure with washers and nuts. Tighten the nuts tb the specified torque
loading diagonal iy outwards from the centre.
. - - -
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 i t has been removed, refit the woodruff key to the front end of the camshaft,
and replace camshaft sprocket together with i t s large plain washer spring
washer and retaining bolt. I t i s ESSENTIAL that the sprockets are fitted
-
the correct way round on each camshaft, i .e. "IN coloured dot' facing
-
forward on inlet camshaft and "EX coloured dot'' facing forward on
exhaust camshaft. See 'TECHNICAL DATA' for correct specification.
On engines without air pump: f i t the selective thrust washer with its retaining
bolt, and spring washer, ensuring that i t i s located on the dowel protruding
from the rear end of the camshaft. Hold the camshaft sprocket i n the vice
(fig.3.). Tighten thrust washer and sprocket retaining bolt tospecified
loading (see TECHNICAL DATA). Replace rear cover with new '0'ring,
tightening the bolts to their specified torque loading. Check the Camshaft
end-float (see TECHNICAL DATA). If the end-float i s outside this tolerance,
replace the selective thrust washer.
On engines equipped with an air pump: apply Permabond A1 38 thread locking

compound to the threads of the 'V' pulley adaptor spindle, and screw into the
rear of the camshaft securely. Fit the selective thrust washer over its locating
dowel, and f i t the rear seal housing using a new '0' ring andoil seal. Apply
Silastic RTV 732 into the inside of the 'V' pulley hub, and f i t onto the adaptor
spindle, ensuring that the dowel engages into the hub correctly. F i t the 'V'
pulley onto the hub with the drive line insettowards theengine, f i t the M8
washer and self locking nut and torque tighten (see TECHNICAL'DATA). Check
- -
the camshaft end float 0.03 0.20 mm (0.001 -0.008 in.). If outside of
tolerance, replace selective thrust was her.
Fit the four washers and setscrews securing the 'V' pulley to the pulley hub
and tighten.
Replace cam follower shims onto the ends of the valve stems, these being
greased (with graphogen grease) on the valve stem side. Replace the cam
followers into their respective bores i n the camshaft housing, after an
application of graphogen grease.
I n order to avoid damaging the valves when thecamshaft housings are replaced,
I t i s ESSENTIAL that the crankshaft i s turned BACK approximately 90' from
i t s TDC position, to bring the pistons half way down the cylinders. Do not
turn the crankshaft more than 90' back as this may also cause the valves to
be damaged.
On engines up to engine number 11276, using a new gasket, which i s DRY

and kept FREE OF OIL, replace the camshaft housing with its securing
washen and nuts. Tighten the nuts to their specified loadings diagonally '
outwards from the centre.

Page 72 SECTION EA
O n engines from engine number 11276, and earlier engines i f 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 gasket eliminator ensure a l l old gasket elimiminator i s removed from
the mating surfaces of the cyl inder head and cam housing . Take care not
to scratch sealing surfaces - use a blunt scraper such as the flat end of a
steel rule. Degrease and clean the mating surfaces using methylated spirit
or similar. Lay a thin continuous bead of gasket eliminator (approx 1/16
to 3/32 in. wide) i n the middle of the sealing surface on the cam housing,
following the outer surface around the stud holes. F i t '0'
ring on cylinder
head dowel and carefully place cam housing on cylinder head studs and
secure with washers and nuts. Tighten the nuts t o the specified torque
loading diagonally outwards from the centre.
Cont1mro.s bead of Loctite 504 Gasket Ellminotor.

, .
SECTION E A Page 73
Check valve clearances and adjust ifnecessary (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 the shafts i n this position.
Pull the belt sufficiently to force the pulley wheel towards the tensioner
body. Remove the locking pin and release pressure on the belt. Re-check
all the reletive sprocket positions. Check toothed belt tension (Section EA .8.)
Check ignition timing and adjust i f necessary.
Adjust the inlet pulley snubber (where fitted) for a clearance of 0.50 -
0.75 mm (0.020 - 0.030 in.)..between the back of the toothed belt and
the snubber bracket. Tighten the securing nuts via the pulley holes to
2.2 - 2.5 kg.m. (15 - 18 1bs.ft.).

Replace 'V' belts and belt guard (Section EA .7.)
EA.6. - VALVE CLEARANCES

To Check
1 . Remove both camshaft coven (Section EA .4 .)

2. Turn engine until heel of camshaft i s on the cam follower (of the valve to be
checked). Using a feeler gauge, determine the clearance between the cam
Fig. 9 - Checking cam follower clearances.

Page 74 SECTION EA . .
follower and the camshaft heel. The ccrrect clearance i s given i n

~a
TECHNICAL DATA.
3. Check a l l valve clearances, noting any which require adjustment.
To Ad just
Remove the camshafts intact i n their housings. (refer to Section EA .5 .)

Remove each adjusting shim where the clearance requires adjustment .
Substitute a shim giving the correct clearance, which has been greased on
i t s face abuting the valve stem. O N L Y use ONE shim t o each valve. I
NOTE: A Thinner shim w i l l increase the valve clearance, whereas a thicker

shim w i l l decrease the clearance.
!
Replace the carnshafts(Section EA .5 .)after adjustment and recheck the
clearance. If the clearance i s s t i l l incorrect, then the whole o f the above
procedure MUST be carried out again.
NOTE: Do 'NOT turn the camshafts with No.1 piston at T .D .C., as this w i l l
cause the valves t o be bent. Turn the crankshaft back through 90° to bring
the pistons half-way down the cylinders. Do NOT turn the crankshaft
BEYOND 90' back, as this w i l l also cause the valves to be bent whilst
the camshaft driving belt i s off.
If, on the later type of camshaft housings (with '0' ring and no gasket)
the valve clearances are to be verified before application of Loctite 504
gasket eliminator, allow 0.0015 in. for this thickness.
EA.7. - TOOTHED BELT GUARD (front engined cars - early type)

To Remove
Upper Section:
..
1. Releasethe bolt, plain andspring

. .
washer on RH side..
2. Release bolt, plain and spring washer on inner of LH side, securing the guard
to i t s mounting bracket.
3. Release nyloc nut and plain washer i n centre of section, taking care NOT t o
;misplacethe distanee piece between &aid and engine when removing the
guard.
-. . 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 i f fitted, the air conditioning
compressor pump be1t, and power-assisted steering pump drive be1t .
4, Release the bolt securing the guard bracket to the thermostat housing,
5, Remove the nyloc nuts and plain washers from both sides at the bottom of the
guard, taking care NOT to misplace the distance pieces (one on eachstud).
To Replace
1, Replacement of both upper and lower sections of the belt guard is a reversal of
the removal instructions, NOT forgetting the distance pieces i n their correct
locations.
EA .8, - CAMSHAFT DRlVl NG BELT (TOOTHEDBELT)

Prior to '86 M.Y. all engines use a trapeziodal (nearly squarej tooth profile
belt with originally, a mannually adjusted eccentric belt tensioner, and later
a semi-automatic spring loaded tensioner. 1986 M.Y. Excel and U.S.A. Turbo
H.C. I. models and other engines at a later date use an H.T.D. (~ighTorque rive)
t
cam belt and ulley set, having a rounded tooth profile. A manually adjusted
eccentric be1 tensioner is generally used with the H.T.D. belt, and no snubbers
are necessary A
Do -
NCYT attempt to tension a hot engine. Only carry out,this adjustment at an
engine (ambient) temperature of between 15' 25'~. -
Use cantilevered Burroughs Gauge TOOOG0025J between the auxiliary and inlet
camshaft.pulleysin the following manner, removing the belt guard
upper section and such ancillary equipnent as may be necessary to gain access.
Fully extend the hoak by pushing the handle completely down before inserting
the belt between the noae piece and hook, ,ensuring that'the hmk i s between
the belt teeth. Release the handle with a rapid ackon. A slow release w i l l
result i n a HIGH reading owing t o the small amount of internal friction
present stopping the hook f r m fully returning. Note the indicator dial
readi*
;is . .-. Repeat action several times to 'get the feel '.
Page 78 SECTION EA
. Fig. 11 - Engine timing marks & Burrouahs wuae in -<itifin

, ,
. Page 20
., .. SECTfON EA
'0
'0
Timing marks in line through centre of pulleys
fication.
E~~~~ Fig. 13 - Sprocket positions w i th Number 1 cylinder at TDC.

SECTION EA Page 19
Take a further two readings at intervals of 120 crankshaft degrees, turning only a
i n normal operating direction.
The correct belt tension setting for a l l 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 follows with No. 1 piston
at TDC after rotating the crankshaft a minimum of one turn clockwise
Manual tensioner:
--- Slacken the nut securing the pulley, and b y means of the
hexagoh on the front of the pulley, adjust the tension of the belt. Tighten
the securing nut. After adjustment, re-check the tension with the
Burroughs gauge.
I
Semi-automatic
- tensioner : Where no air pump is driven off the back of the
toothed belt, slacken the locknut, and screw the spring seat (adjusting screw)
i n or out to obtain the correct Burroughs gauge reading. Tighten the locknut.
e'
On Federal engines where an air pump i s driven off the back of the toothed belt,
first slacken off the air pump fixings. Screw the spring seat (adjusting screw)
clockwise until only one or two threads are showing above the locknut, and
tighten locknut. Tension the air pump to 5.5 kg .m (40 Ibs .ft .) using special
tool part number TOOOT0320A and a dial torque wrench. Entirely release load
on air pump and then re-torque to a final tension of 2.8 kg.m (20 Ibs-ft.) and
tighten all air pump mountings i n that position.
To Remove
Remove both upper and lower sections of the belt guard (Section EA .7.)
Remove all 'V' belts.
Set the engine i n the timing position with No. 1 piston at T. D .C. Align
the timing mark on the crankshaft 'V' pulley with the mark on the front cover.
At this point f i e marks on the camshaft sprockets should also be aligned with
each other. Remove the crankshaft 'V' pulley. (Section EA .15 .)
Mnk the p a i t i o n of the auxiliary shaft sprocket against the belt snubber,
(or as with the belt removed, the shaft w i l l almost certainly turn,
thus losing the correct ignition timing.
SECTION EA Page 2 1
4. a). Release the belt tension by releasing the securing nut on manual
tensionen.
b). O n 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 i t anti-clockwise until the adjusting screw i s protruding a
MAXIMUM of 12 mm (3 in) from the tensioner housing.
Adjuster Screw
\
4mm Locking Pin to be
inserted after looseni ng
fig. 14. tens h e r .
d). Force idler towards tensioner body (merely tension timing belt
by hand) until groove an piston.alignr with locking pin hole i n
housing, and i k e r t a 4mm diameter pin. This locking pin hole
may be located on the lower side of the piston bore, or on the
upper side, '&&red by the upper fixing bolt/nut' washer, which
must therefore be removed.
The pinsisinserted to prevent the springs pushing the assembly apart
and consequently lasing a l l the ~ a r t s .
IMPORTANT: The locking pin must be fitted to the tensioner housing
every time the toothed

.. belt i s being removed,or slackened off. This
. .
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 i s installed on an engine with
timing be1t i n position.
5. Remove toothed be1t from sprockets.
NOTE: Do NOT turn the camshafts with No.1 piston at T.D.C. as this w i l l
cause the valves to be bent. Turn the crankshaft back through 90' to bring the
pistons half-way down the cylinders. Do not turn the crankshaft BEYOND 90°
back whilst the camshaft driving (toothed) belt i s OFF otherwise there i s danger
of the pistons contacting any valves which may be off their seats.
TO Replace
1. Reverse the removal procedure. Before f i t t i ng bet t, ensure correct position

of crankshaft, camshafff and auxiliary shaft sprocket (fig -13).
2. After fitment, adjust belt tensibn, and check ignition timing. If a new belt
has been fitted, run the engine for a minimum of two minutes, switch off and
recheck tension.
EA .9.
----- - DRIVING BELT TENS! ONER
To Remove
Carry out the procedure detailed i n S e c t i o n s .8.for removing the camshaft drive belt,
although i t w i l l not be necessary to actually remove the belt. Release the bolts or
bolt and nut securing the tensioner assembly, making careful note of a l l the bracket
positions and spacer washers. Remove the tensioner.

O n some can (i.e. air conditioned) with two bolts securing the tensioner, i t
may not be necessary to remove the. crankshaft .'V'pulley,

,
To Replace
. . .
;Rkvene the remo&l procedure checking the valve timing, i&i'&n timing and
. , ..; . : '
belt t e n i i a n ' a ~ dnddjusting as necessary. ~ d i u r the

t pd'ley snubber for
4- C
a clearance of 0.4 - 0.1 mm (0.016 - 0.004 in.) between the pad and toothed
. belt.
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 i n front of the engine (see Section 'K') .
(Elite/Eclat).
Release the c l i p securing the air trunking to the airbox and remove airbox
outer cover, together with the air cleaner element, after releasing i t s
securing bolts and washers, or fastening clips.
Remove the complete belt guard (Section EA .7.) (front engined cars).
Disconnect the water hwes from their connections an the cylinder head and on
the inlet manifold.
Remove the inlet manifold together with the carburetten (Section EA .22).
Remove the spark plug leads from the plugs and secure out of the way of
cylinder head removal .
Release the exhaust downpipe from the exhaust manifold and remove
manifold, (see Section 'St) .

Some engines, fitted with the non air conditioning type water pump may
require removal of the water pump before the cylinder head may be 1 ifted .
Remove the cam covers and check the valve clearances (Section EA .6 .)
noting any which require adjustment.
Remove the camshaft housings with cams (Section EA .5 .)
Release the cylinder head nuts evenly and progressively, working diagonally
inwards from outside. Remove the nuts with their washers. Remove the
- Cylinder head nut tightening/releasing sequence
-.
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
otherwise the liners could be pushed from their locations.
To Remove (Esprit Turbo)
NOTE: O n Turbo rnodels cylinder head removal i s more easily carried out with
the engine removed from the car (Section EA .25 .)
1 . Remove the inlet manifold and carburetters assembly (See Section EA -22 .)
2. Remove the o i l feed and drain pipes from the turbocharger, and remove the
exhaust manifold complete with wastegate and turbo. O n air injection
engines, remove the a i r pump 'V' belt guard, and air injection rail.
3. Remove the cam covers and check the valve clearances (Section EA .6 .)
noting any which require adjustment .

4. Remove the camshaft housings with cams (Section EA.5.)
5. Release the cylinder head nuts evenly and progressively, working
diagonally inwards from outside. Remove the nuts with their washers.
Remove the cylinder head with i t s gasket. Do NOT lay the cylinder
. ...
,
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 clamps. Thoroughly clean both the cylinder block
and cylinder head mating faces (use Trichtorethelene or petrol).
2. Fit new cylinder head gasket. The gasket i s fitted with lWellseall applied
around the periphery of both sides of the oil pressure hole.
912 Head Gasket Selection
m e n replacing the head gasket on a 9.44:l CR 912 engine ( i e : NOT H.C.) , note I
the type of gasket f i t t e d , ( i e . count laminations) o r the p a r t number stamped

thereon, and replace with the same type.
If the cylinder linen, crankshaft or reciprocating components have been

changed, the piston standout above the liner flange must be measured. If
the standout i s measured at right angles to the gudgeon pin, the height on
both sides of the piston must be measured and then averaged
Select a gasket from the following table based on the highest standout.
-.Standout
- Description Part No
Less than 0.014 in. N o extra laminations A907E0026

0.014 - 0.023 in. One extra lamination 891 1 E l 291
0.023 - 0.032 in. Two extra laminations 891 1 E l 292
3. Fit the cylinder head assembly, plain washen and nuts . Tighten a l l nuts i n
stages to the specified torque loading working diagonally outward from the
centre.
4. Replace both camshaft carrier housings. Check valve clearances. (Section
EA.5. and EA.~.).

5. Replace camshaft drive (toothed) belt, spark plug leads and set static ignition
timing (Section EA .8 .)
6. Refit ancillaries i n reverse order to dissassembly ,

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 o i l and coolant leaks while engine is running. Thoroughly
check fuel system for leaks and security of joints.
EA.11. - VALVES
To Remove
1 . Remove the cylinder head (Section €4.1 0.)

2. Using a suitable valve spring compressor, compress the valve springs and
extract the split collets. Release the valve spring compressor, and remove
the valve spring retainer, valve springs and spring seat from each valve.
Remove the valve .

3. Repeat the process for the remaining valves. Label each valve with its
Ioca tion.
To Replace
1 . Check the valve seats for condition, re-cutting as necessary, and check
condition of valve guides. Grind i n all valves.

2. Lightly lubricate the stem of the valve and insert into i t s guide.
3. Fit spring seat, valve springs, spring retainer. Place the valve spring
compressor i n position and compress the valve springs sufficiently to f i t
the split collets. Release the valve spring compressor.
4. Repeat the process for the remaining valves.

5. Replace the cylinder head followed by the cams haft housings. Re-check the
valve clearances .
6. Replace ancillaries .
EA.12. - DECARBONISE CYLINDER HEAD & PISTONS
TO Remove
1 . Remove cylinder head t o a clean covered bench . (Section EA .I 0.)

2. Remove the valves (Section EA.11 .)
Page 28 SECTION EA
Remove a l l 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 i n a
pitted condition should be refaced with a suitable grinder or new valves should
be fitted. If the valve seats show any signs of pitting, or uneveness, they shduld
be trued by the use of service cutting tools. When using a cutting tool take care
to remove only as much metal as i s necessary to ensure a true surface. The removal
of too much metal could cause difficulty i n achieving the required valve
clearance.
When grinding a valve onto its seating the valve should be smeared lightly
with 'fine' or 'medium' carborundum paste and then lapped i n with a suction
type grinder after oiling the valve stem. Avoid the use of excessive quantities
of grinding paste and ENSURE that i t remains i n the region of the valve seating
only. A light coil spring placed under the head of the valve w i l l assist
considerably i n the process of grinding. The valve should be ground to its
seat with a semi-rotary motion and occasionally allowed to rise by the pressure of
the light coil spring. This action assists i n speeding the grinding operation until
a dull, even, matt finish, free from any blemishes i s achieved on the valve seat
and valve face. On completion, the valve seats, guides and ports, should be
cleaned with petrol then blown dry and clean with compressed air. The valves
should be washed i n petrol and a l l traces of grinding paste removed. Ensure that
no grinding paste has entered the valve guides.
Lightly oilthe valve stems, and re-assemble the valves to cylinder head.
Refit cylinder head, camshaft housings not forgetting to check the valve
clearances, camshaft coven, inlet and exhaust manifolds, carburetters, etc .,
EA.13. - VALVE SEAT INSERTS
To Remove
1 . Remove the cylinder head and dismantle as for decarbonising (Section EA .12 .)
2. Remove the valve seat inserts by milling through, or almost through (dependant
upon the skill of the operator), the edge of the insert, whereupon the seat should
SECTION EA Page 29
collapse. In the case of a stubborn seat, i t 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 i t s recess. Ensure that the
recess i n the cylinder head i s ENTIRELY FREE OF FOREIGN MATTER, otherwise
the new insert willNOT seat fully i n the recess.
To Replace
1 . Check the combustion chamber adjacent to the respective seat for a '1 ', '2',
or '5' stamping, (or alternatively 'C', 'Dl, or 'E') this indicating that an
oversize valve seat was fitted i n production (0.001 in, 0.002 i n and 0.005 i n
respectively).
Fig . l 8 - Location of valve seat oversize stamping

If this stomping is visible then that size (or larger) seat MUST be used as
replacements. The letters 'C', 'Dl, or 'El refer to the prefix fetters of the
respective part numbers.

2. Heat the whole cylinder head to a temperature NOT EXCEEDING 200'~. and
0
freeze the insert with dry ice to a temperature NOT LESS THAN minus 80 C.
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 i n 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' or
'5' stamping. This refers to the amount of oversize of the guide (.001 in, .002 in,
and ,005 in. respectively).
If this stamping i s visible, then that size or larger guide MUST be used as replacements.
To Remove
I
1 . Remove the cylinder head and dismantle as for decarbonising. (Section EA,12.)
2. Heat the whole cylinder head to a temperature of between 100/150~ C. (212/303'~ .) .

and, with Special Tool (MA), knock the guides out of the head frdm the combustion
chamber side.
To Replace
1 . . z / ~ o ~ ' F.)
Heat the cylinder head to a temperature of between 1O O / I ~ O ~ C(21 .
2. Locate a new circlip on the new guide and press the guide into its bore from the top,
until the circlip seats completely in its recess. Care must be taken that the guides are
NOT driven i n further than this point. See TECHNICAL DATA for fitted height.
3. Ream the guide AFTER fitting, to the dimension given i n TECHNICAL DATA. Recut
the valve seat to ensure that it i s concentric with the valve stem bore.
4. Re-build and refit the cylinder head to the engine.
EA.15. - CRANKSHAFT 'V' PULLEY-

TO Remove
1 . Remove a l l the 'V' belts.

2. Remove the set screw, and special washerfrom the centre of the pulley.
Pull off pulley, using a proprietary .puller if necessary.
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 a l l 'V' belt tensions after replacing.
EA.16. - CRANKSHAFT SPROCKET

To Remove
1 . Remove the belt guard(Section EA .-/.)and set the engine i n the timing
position (Section EA .8.)

2. Remove the camshafts driving be1t (toothed belt) (Section EA .8 .)
3. With the aid of Special Tool TOOOTOl7OA, pull off the crankshaft toothed pulley
followed by the belt guide flange. Tighten the tool bolts finger-tight only.
NOTE: O n dry sump Turbo models f i r s t remove the oil pump drive sprocket.
Fig. 19 - Using To01 TOOOTOI 70A to remove crankshaft sprocket w

To Replace
1. Ensure that the engine has nat been turned from the timing position.
2. Reverse the removal procedure.
EA.17. - FRONT COVER & OIL SEAL
To Remove
1 . Remove the belt guard (Section EA .7.) and set the engine i n the timing position
(Section EA .8 .)
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 seal from the cover by pushing from its location.
To Replace
1 . Using a new o i l seal, with 'Wellseal' sealing compound applied to its outer
diameter, insert into the front cover until flush wifh the rear face,
2. Apply jointing compound to both faces of a new gasket and replace front cover,
with the aid of Special Tool TOOOT0009A. O n early engines, ensure that the
stud which retains the camshafts driving belt tensibner i s centralised i n the hole
of the front cover. Secure cover with its set-skrews and lain washers,
tightening the screws to the specified torque loading (see TECHNICAL DATA).
3. Replace the remainder of the removed parts by reversing the removal procedure.
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 a l l hses from the water pump housing.
4. Where power steering i s fitted, remove the power steering pump mounting
bracket and secure (with hoses attached) clear of water pump.
5. Release the water pump fixing bolts, and remove bolts and washers together with
the water pump housing and gasket. Discard the gasket.
Fig. 21 Impellor/Housing Clearance

Page 34 SECTION EA
0
NOTE: O n some engines i t may be necessary to first remove the auxiliary shaft
pulley, i n 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 dimension from pulley mounting
face on hub, to pump body mounting face, i n order that the new pump may be
assembled correctly.
TO Replace
1 . If fitting a new water pump to a 907 engine, press a new pulley hub onto the
shaft to achieve the dimension measured inEA .I 8. Press only on the hub and
opposite end of the shaft (NOT impellor). Check impel lor/housing clearance
i s to dimension showti i A Fig.21 .

2. Using a new gdsket, to which a suitable jointing compound has been used on both
sides, refit the housing msembly to the engine, tightening a l l bolts to their
specified torque loddihgs (see TECHNICAL DATA).
3. Replace a l l ancillariei .
4. Refill the coaling system, and check for wdter leaks with the engine running.
FXXL,MDDEIS - 1985 MODEL YEAR ONWARD

On these c a r s , no gasket i s f i t t e d , but Permabond A136 i s used i n the following
0
manner.
1. Clean the joint faces on both water pump and cylinder block.
2. Spray both p i n t faces with Permabond A905 Surface b n d i t i o n e r

(A912E6759)
3. Apply a 3-4 mm wide bead of Permbond A1 36 (A912E6421) to

the water pump joint face as shown i n the diagram.
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 A905 A91 2 E6759
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 i s not disturbed during this opemtion.
To Replace
1. Clean the mating face on the oil pump body. Add a small amount of clean
engine oil into the filter then, apply a film of engine oil to the new seal
(supplied with the new filter) which i s in contact with the oil pump body,
locate filter on its adaptor and screw on by HAND i n a clockwise direction.
a
When the filter 'seats' continue turning the filter for a further two-thirds
to three-quarters of a turn to ensure am o i l tight joint.
. .. . .
.% '
Fig. 22 0 V i w ' j h c i w i n i iii pump, filter b ignition distributor
Where an oil cooler i s fitted, ensure that the adaptor i s not disturbed from
i t s seating on the auxiliary housing during this opemtion.

2. Start the engine and check for oil leaks at the filter to o i l pump joint,
if necessary tightening the filter further to give an oil tight joint.
a
0 All '86 Model Year and some late '85 Model Year cars are
f i t t e d with engine oil f i l t e r B907E 6000 which d i f f e r s from
f i l t e r A907E 6000 in the following respects:
i) Provisionof l f l a t s ' o n c a n i s t e r t o a i d r e m o v a l w i t h
o i l f i l t e r spanner.
i i ) Slightly shorter canister t o provide f i t t i n g
clearance for spanner.
i i i ) Revised end p l a t e with less thread protrusion
In order t o provide sufficient thread engagement as a result
of i i i above, the o i l f i l t e r u n i o n extension has been
increased in l e n g t h by 3mm.
a) 1986USATurboH.C.I.modelsshouldonlybefitted
w i t h B907E 6000 due t o the restricted access.
b) All other 1986 Model Year cars may be f i t t e d with

either ' A 1 or ' 0 ' prefix f i l t e r s .
c) A L L CARS PRIOR TO '86 M.Y. MUST BE FITTED WITH

FILTER A907E 6000.
Fitment of ' B 1 f i l t e r t o these cars may result
i n insufficient thread engagement w i t h consequent
danger of the f i l t e r working loose.
I n order to avoid any confusion i n the U.K. i t i s recommended
t h a t U.K. dealers stock o n l y ' A ' prefix f i l t e r s which are
suitable for a l l cars.
EA.20. - IGNITION DISTRIBUTOR
To Remove
1 . Turn engine until at the timing psition. (Section EA .8 .)
2. Remove the distributor cap.
3. Disconnect the low tension cable (points) or trigger lead cannector block
(electronic)
4. Disconnect the vacuum pipe to distributor (if fitted)
5. Mark the position of the distributor body against the o i l pump housing,
release the nut securing the distributor clamp to the o i l pump housing,
and withdraw distributor.
Note: Special socket spanner required on 1983 on Federal cars - TOOOT0503.

6. Emure the spring is retained i n the dog drive slot.
To Replace
1 . Before fitting the distributor, ensure that the contact breaker points (if fitted)
are i n good condition and correctly adjusted (see Technical Data).

Page 36
2. Note that the driving dog on the distributor shaft is offset, and that i t must
be turned to match the offset slot i n 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 NUT OVERTIGHTEN.

3. Reconnect the vacuum pipe, (iffitted) the low tension lead or trigger lead,
and the distributor cap. Check the static ignition timing at the coil negative
terminal.
4. Run the engine and check/adjust the ignition timing as specified in

TECHNICAL DATA.
EA.21. - OIL PUMP &AUXILIARY HOUSING

To Remove
- -
Set the engine to the timing position and remove camshaft driving belt (Section
EA .8 .)
Remove the carburetten airbox backplate or plenum chamber (Turbo).
Remove distributor (SectionE A .20.)
Remove the oil filter, and alternator.
Where applicable, remove the compressor rear mounting bracket.
Fully release a l l the bolts securing the housing to the cylinder block, noting
the position of the various bolts (some are longer than others) and remove
housing together with its gasket. Discard the gasket.
With the assembly on a clean bench, remove the auxiliary shaft sprocket by
releasing its central retaining bolt and washer.
Remove the bolts and washers retaining the oil pump body to the auxiliary
housing and remove body with i t s gasket. Take care that the spring i n the
end of the auxiliary shaft, and the annulus (not fitted i n Dry Sump Turbo
models) i s not misplaced during this operation. Discard the o i l pump body
gasket .
Remove the spring from the o i l pump end of the auxil iary shaft. Remove the
circlip securing the inner rotor of the oil pump to the shaft. Rernove the
circlip from the forward end of the shaft. Push shaft out of housing from the
front end. Using a suitable drift, remove the front oil seal. Dry Sump Turbo
models are also fitted with a rear oil seal.
SECIYON E A Page 37
Fig. 23 - Oil pump/auxiiiary housing components

Page 38
To Replace
Using a new o i l seal, press i t into i t s location.' The l i p 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. F i t a new circl i p to secure.

Push the shaft into the housing from the o i l pump end so that the shaft
protrudes through the oil seal at the front end. Fit circlip.
Insert the ignition distributor shaft loading spring into the oil pump end of
the auxiliary shaft. F i t a new oil pump annulus (outer rotor) into the pump
body (Except dry sump Turbo). Fit the o i l pump to the auxiliary housing
using a NEW gasket which i s fitted DRY. Tighten a l l bolts to the specified
torque loading (see Technical Data).
Using a new gasket to which a suitable compound hcis been added to both
faces, refit the auxiliary housing to the cylinder block. On engines fitted
with tin 'adaptable' type auxiliary housing with seperate alternator bracket
(i.e. with air conditioning) note that the mating faces between the alternator
mounting brackkt and auxiliary housing are not tnuching, and MUST be
sealed with " ~ i l a s t i c y Apply a bead of "Silastic" to either one mating face,
enough to form an approximate 0.5mm thick gasket when'the parts are fitted.
Ensure that the retaining both are replaced in their original locations, and that
the spacer i s fitted between the alternator bmcket and auxiliary housing on the
lower front bolt. Tighten bolts to torque loading given i n TECHNICAL DATA.
Replace the auxiliary shaft sprocket on the shaft using a new key and with the
relevant timing mark facing forward (see fig. 13). Apply thread locking
compound to the special securing bolt, and fit with special washer, torque
tightening to specified figure (see TECHNICAL DATA).
Replace the ignition distributor.

Ensure that the crankshaft and camshafts are s t i l l at the timing position,
rotate the auxiliary shaft sprocket to align the reference mark, and replace
the camshaft drive belt (Section EA .8 ,)

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. - lNLET MANIFOLD 8, CARBURETTORS
TO Remove (Naturally Aspirated)
1. Drain the cooling system (see Section 'K').
2. Remove the airbox outet cover (see Section 'L').

3. Disconnect the water hoses from the manifold.
4. Disconnect the breather pipe from the flame trap a t the rear end of the
airbox backplate. Disconnect the throttle and choke cables, and the
vacuum pipes.
5. Disconnect the fuel feed pipe to the carburettnn, and fit plug t o main fuel
pipe to prevent fuel draining from the tank.
6. Release the nuts and washen securing the manifald, and remove manifold.
7. Further dismantling of the manifold, such as removing the carburettors,

may be carried out as desired on the bench.
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 m i l .
5. Release vacuum connections from inlet manifold or vacuum rail.
6. Disconnect diffuser from turbocharger and seal turbo compressor outlet immediately.
7. Release fuel pressure regulator from plenum chamber. Release evaporative loss
hose from front of plenum, and also electrical connections and vacuum pipes as
necessary.
8. Release heater water transfer pipe from plenum chamber.
9. Remove manifold to head nuts and washers and remove complete assembly to bench.
To Replace
1 . Reverse the removal procedure, but use a new gasket. Tighten a l l nuts to the
specified torque loadings (see TECHNICAL DATA).
EA .23. - OIL SUMP (NOT Dry Sump Turbo)

To Remove
On front engined cars i t i s necessary to disconnect the downpipes from the manifold,
-
release the engine mountings and raise the engine 2 3 inches (5 - 8 cm) to gain
sufficient sump to crossmember clearance.
1. Using a suitable receptacle, release the drain plug and allow oil to drain from
the sump. Remove the dipstick.
2. From around the periphery of the sump, remove the setscrews and nuts with their
plain washers securing the sump to the main bearing housing. Release the clutch
housing to sump bolts, noting any shim washen fitted, @
Remove the sump by tilting i t slightly towards the exhaustside of the engine i n order
to clear the o i l strainer and pick up pipe assembly.
To Replace
..
-1 . Thoroughly remove any sludge which may havecollected i n the sump, BEFORE
replacing the sump.
2. On 907 engines, use a new gasket with jointing compound applied to both
faces. No gasket i s used on 912 engines but Perma Bond A 136 (A912E6421)
. -
.,should,be used i n the following~manner. Apply a 1 .O 1 .5 mm bead of
Perma Bond to the joint face on both the sump and main bearing housing,
with the bead passing to the inside of the fixing holes. Also, on 912
: .. . engines, check that the .'O1.ring i s fitted over the dipstick tube inside the
I
mai n bearing, housing,o
'
SECTION EA Page 4 1
--
On 91 2 and Wet Sump 91 0 engines, check underside of the sump by clutch
0 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 loadings (see TECHNICAL
DATA).
3. Refill the engine with the recommended oil.

NOTE: If a new sump i s to be fitted on a 912 or Wet Sump 91 0 engine, carry out the
-
following Sump Alignment Procedure .
i) With the clutch housing fitted to the engine, fit the sump to the main
bearing housing, but do not tighten fixings. Pull the sump rearwards,
towards the clutch housing, and measure the clearance between sump
bosses and clutch housing.
ii) If less thanO.O1O" torqueupsumpbolts withsump inrearmost position.

0 If clearance i s greater than 0.010", f i t shims at the two fixing points
as follows.
Clearance -
Shim
0.0'1 0"-0 .030" one 0.020"
0.030"-0 .O5OH two 0.020'' (0.040")
EA .24. - CONNECT! NG ROD (BIG-END) BEARINGS (Dry Sump Turbo see Section EA . - 28
To Remove
1 . Remove the sump. (Section EA .23.)
2. Commenciiig with NO. 1 (from front end) connecting rod, turn the crankshaft to
facil itate removal of cap. Mark cap and rod.
3. Release the bolts by two or three turns and tap themto release the cap. Fully
release the bolts and remove the cap.
0 4. Remove the upper and lower big-end bearing shells from both the connecting
rod and the connecting rod cap.
To Replace
1 . Replace the upper and lower big-end bearing shells by new parts in their
appropriate locations.
2. F i t the cap to the connecting rod and tighten the bolts to the torque. loading
given i n TECHNICAL DATA.
3. Replace the remaining big-end bearings by repeating the above process.
4. Replace the o i l sump assembly.
EA.25. - ENGINE ASSEMBLY

The engine and gearbox should be removed as a complete assembly.
To Remove - Front engined cars
1 . Remove the bonnet (see Section 'B').
2. Dmin the cooling system (see Section 'Kt) .

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.

. .
A l l water hoses, throttle and choke cables; fuel feed pipe to the
carburetton; vacuum connections to manifold; cables from altermtor,
. .
starter motor, ignition distributor and tempertaure sender unit;
oil pressure pipe, o i l cooler pipes.
O n can fitted with air conditioning equipment DO NUT discennect the pipes
from the compressor, but remove the compressor complete with pipes from its
mounting bracket and secure away from the engine.
O n can fitted with paver steering, disconnect the hoses from the pump, and
collect the oil i n a clean container.
6. Remove the airflow duct from i n front of engine.
7. Disconnect air trunking and remove airbox.
8. From beneath the car, disconnect the clutch cable at its mounting on the
bell housing, together with i t s bpcket on the main bearing housing or remove
clutch slave cylinder from gearbox. Remove the speedometer cable from the
gearbox. Disconnect the downpipe from the exhaust manifold (see Section 'S').
Disconnect the engine earth strap. Release the reverse lamp switch cables at
the gearbox. Release the propshaft from the final drive.
9. For a l l cars except Elite/Eclat Series Two with Getrag gearbox : Remove
gear lever assembly (See section 'F ').
With Getrag gearbox : Remove gear lever knob and gaiten only.
10. Fit slings and support the weight .of the engine/gearbox assembly.
11 Remove the gearbox mounting crossmember. Remove the engine mountings
and right hand engine mounting leg, and withdraw the engine/gearbox unit
from the car.
To Remove - mid engined can

, , ' .
On Series CJne and Two Esprit models, the engine/tmnsmission unit i s removed from the
car from underneath, whilst on Series Three and Turbo models, the unit i s removed
from above.
1. ~ i & o n n e c ithe battery.
2. Remove the tailgate.

SECTION EA Page 43
3. Remove the engine campartmen: floor and sidewalls.
4. Dmi n the cool ing system.

5. I n the engine compartment, disconnect the following:
A l l 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

vacuum ra it, cables from a1ternator, starter motor, ignition
distributor and temperature sender unit. Disconnect air trunking
and remove airbox. Disconnect engine earth strap. Remove cool ing
system header tank. Disconnect crankcase breather to o i l tank
(Dry Sump Turbo).
On Federal Turbb disconnect divertor valve hoses, plenum chamber emissions hose,
air pump inlet pipetemissions system vacuum pipes.
6. Remove the clutch slave cylinder from the clutch housing. Disconnect the
crossgate cable from the gearbox and clutch houisng.
7. Disconnect the gearshift linkage from the selector lever on the transmission,
and both links from the gearchange relay lever. Disconnect the speedo cable
from the transmission.
8. Remove the rear valance, silencer and downpipes.
9. Disconnect the driveshafts, and handbrake cables and remove the rear
calipers and brake discs.
10, Disconnect oil cooler hcses. O n Dry Sump Turbo disconnect the scavenge
pump outlet pipe (to cooler) and the o i l supply pipe from tank to pump.
Remove A/C compressor (where fitted) from engine without disturbing pipes,
and secure away from engine.
11. On Series Three and Turbo models, remove the chassis rear crossmember.
12. F i t slings and support the weight of the engine/transmission unit on
suitable tackle.
13. On Series One and Two models ;release the transmission unit mountings
from the brackets on the chassis. Note the number of shims between
transmission and chassis mounting brackets for replacement.
Remove the bolts/nuts securing the ehgine mountings t o the chassis, and
remove the right hand engine mounting leg from the engine. Lower the
gearbox end of the assembly and remove whole assembly from under the
rear end of the vehicle.
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 l i f t out the assembly from the car.
*
To Replace (all models)
Replacement is a reversal of the removal procedure, but the following points should be
observed:
On 912 and Wet Sump 91 0 engines, check underside of sump by clutch housing
fixings for shim marking. '000' - -
no shim, '020' one0.020" shim, '040' -
two 0.020" shims. These shims to be fitted between clutch housing and sump.
On Series One and Two Esprit models ; Insert the same number of shims
between the transmission and chassis mounting brackets as noted on removal.
Connect the front engine mountings first, and shim the rear mountings if
necessary to avoid preloading the mountings.
(Not Turbo models) Adjust clutch release mechanism to clearance given i n

'Technical Data'.
Close the radiator drain tap, and refill the cooling system.
Check security of gearbox drain plug. Refill gearbox if necessary with

recommended o i l and replace filler/level plug.
Check security of sump drain plug. Refill engine with one of the
recommended oils i f necessary. Replace filler cap securely (double notch),
otherwise an o i l loss could occur.
Esprit models : Check the gear linkage and cross-gate cable adjustments
for correct selection of a l l gears, and adjust if necessary.
Check security of a l l fuel pipe connections.
Check and adjust ignition timing, slow running speed and idle mixture.
Check tension o f a l I 'V' be1t s .

check engine/gearbox ass &bly for oil, water and exhaust leaks,
rectifying where necessary.
Road test car and check operation of a l l engine/gearbox ancillaries and

instruments, including operation of the headlamp.
NOTE: . .
Elite/Eclats manufactured from the beginning of September 1978 with chassis number 7809
onwards have a revised left hand engine mounting heat shield fitted, which should be
fitted to a l l vehicles when the opportunity arises.
This
improved heatshield i s fitted to the chassis as shown, instead of to the engine a
mounting bracket as formerly.
SECTION EA Page 43
Remove the engine compartment floor and sidewalls.
Drain the cooling system.
In the engine compartment, disconnect the following:

A l l water hoses, throttle and choke cables, fuel feed pipe t o
carburetton (naturally aspirated) or feed and return pipes to
fuel pressure regulator (Turbo), vacuum pipes fram manifold 6r

vacuum rail, cables from alternator, starter motor, ignition
distributor and temperature sender unit. Disconnect air. trunking
and remove airbox. Disconnect engine earth strap. Remove cooling
system header tank. Disconnect crankcase breather to o i l tank
(Dry Sump Turbo).
On Federal Turbb disconnect divertor valve hoses, plenum chamber emissions hose,
air pump inlet pipe,emissions system vacuum pipes.
Remove the clutch slave cylinder from the clutch housing. Disconnect the
crossgate cable from the gearbox and clutch houisng.
Disconnect the gearshift linkage from the selector lever on the transmission,
and both l inks from the gearchange relay lever. Disconnect the speed0 cable
from the transmission.
Remove the rear valance, silencer and downpipes ,
Disconnect the driveshafts, and handbrake cables and remove the rear
cal ipers and brake discs.
Disconnect o i l cooler hoses. O n Dry Sump Turbo disconnect the scavenge
pump outlef pipe (to cooler) and the o i l supply pipe from tank to pump,
Remove A/C compressor (where fitted) from engine without disturbing pipes,
and secure away from engine.
On Series Three and Turbo models, remove the chassis rear crossmember.
F i t slings and support the weight of the engine/trarrsmission unit on
suitable tackle.
O n Series One and Two models ;release the transmission unit mountings
from the brackets on the chassis. Note the number of shims between
transmission and chassis mounting brockets for replacement.
Remove the bolts/nuts securing the engine mountings to the chassis, and
. . . .
. .. .
remove the right hand engine mounting leg from the engine.. Lower the
gearbox end ef the assembly and remwe whale assembly frnm under the
rear end of the vehicle.
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 l i f t out the assembly from the car.
To Replace (all models)
Replacement i s a reversal of the removal procedure, but the following points should be
observed:
On 912 and Wet Sump 910 engines, check underside of sump by clutch housing
fixings for shim marking. '000' - -
no shim, '020' one0.020" shim, '040' -
two 0.020" shims. These shims to be fitted between clutch housing and sump.
I
On Series One and Two Esprit models ; Insert the same number of shims
between the transmission and chassis mounting brackets as noted on removal.
Connect the front engine mountings first, and shim the rear mountings i f
necessary to avoid preloading the mountings.
(Not Turbo models) Adjust clutch release mechanism to clearance given i n

e
'Technical Data' .
Close the radiator drain tap, and refill the coolingsystem.
Check security of gearbox drain plug. Refill gearbox i f necessary with

recommended o i l and replace filler/level plug.
Check security of sump drain plug. Refill engine with one of the
recommended oils i f necessary. Replace filler cap securely (double notch),
otherwise an o i l loss could occur.
Esprit models : Check the gear linkage and cross-gate cable adjustments
for correct selection of a l l gears, and ad just i f necessary,
Check security of a l l fuel pipe connections.
Check and adjust ignition timing, slow running speed and idle mixture.
Check tension of a1I 'V' be1ts .

Check engine/gearbox a s embly for o'il, water and exhaust leaks,
rectifying where necessary ,.
Road test car and check operation of a l l engine/gearbox ancillaries and

instruments, including operation o f the headlamps.
NOTE:
~lite/Eclats manufactured from the beginning of September 1978 with chassis number 7809
onwards have a revised left hand engine mounting heat shield fitted, which should be
fitted to all vehicles when the opportunity arises.
This improved heatshield is fitted to the chassis as shown, instead of to the engine 0
mounting bracket as formerly.
SECTION EA Page 45
Parts Required:
Heatshield A907E1247F 1 off

Nyloc nut M8 A075W301OZ 2 off
Screw 8m x 20 A075W1038Z 2 off
Washer 8m x 25 o/d A075W4021Z 2 off
Fig. 25 Heat Shield position on Chassis

To F i t Heatshield
i) . Remove the existing heatshield.
ii). Use the illustration as a guide and place the heatshield over the left hand
side engine mounting on to the chassis. Once i n the correct position use
the shield as a template and drill two 8mm clearance holes into the chassis.
...
111). Secure the heutshield with two bolts, large plain washers and nyloc nuts i n
the following order : Bolt head on outside - large o/d plain washer -
heatshield - chassis - nyloc nut.
EA.26. - FLYWHEEL & RING GEAR (Manual Transmission)
Since shortly after its introduction, 912 engines have been fitted with a 'flexplate'
flywheelt which incorporates a flat steel disc bolted to the crankshaft,' the flywheel
itself bolting to the outside of the disc. The disc/flywheel assembly i s balanced
as a unit, and the bolts securing the two parts should never be disturbed.
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 f l y h e e l from i t s
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 CIRCUMSTANCES must pressure be applied i n attempting
t o remove the gear for re-positioning the gear on the flywheel.
Check the face of the flywheel for signs of damage from the clutch driven plate.
I f evident, fit a new flywheel.
Heat the new ring gear evenly, to a temperature N O T EXCEEDING 315 C
0
.
. NOT heat beyond this point, otherwise the wear resistance
( 6 0 0 ~ ~ )Do
properties of the gear w i l l be destroyed. Fit the gear to the flywheel with the
chamfers on the leading face of the teeth relative to the normal direction of
rotation . Allow the ring gear to coal naturally i n the air. D O NUT QUENCH.
Locate the flywheel squarely on the cmnkshaft flange and upon the locating
dowels.
Apply the Loctite 'AV' to threads i n crankshaft, then insert the securing bolts and
tighten to the specified torque loading (see TECHNICAL DATA).
Check the flywheel run-out using a proprietary dial gauge. The total run-out
should NOT EXCEED the figure given i n TECHNICAL DATA.
Replace the clutch assembly.
EA .27. - CRANKSHAFT REAR OIL SEAL

Te Remove
1. One front engined cars, remove the engine/gearbox assembly from the car
(Section EA .25 .I part gearbox from engine, and mount engine on a
suitable stand. On mid engined cars, remove the transmission from the car.
2. Remove the flywheel (Section EA .26 .)
3. Remove the rear o i I seal housing by releasing i t s eight securing setscrews .
4. Remove seal from the housing. Discard the gasket.
SECTION EA Page 47
To Replace
. ..
a. 1. With the lip of the seal towards t l ~ einner 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 l i p 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 i t s setscrews. Tighten the setscrews to the
torque l a d i n g given i n TECHNICAL DATA.
NOTE: The lower four screws and washers (into main bearing panel) are special,
having a 'thinner' head.
Fig. 28 - Using Tool ' M A ' to f i t rear oil seal housing
3. Replace the flywheel .

4. Re-dssemble the gear box t o the engine, and replace engine/gearbax assembly
i n the car.
EA.28. - CRANKSHAFT
To Remove
1 . Remove the engine/gwrbox assembly frm the cur(Section EA .25 ,)part

gearbox from engine, and mount engine on a suitable stand.
2. Remove the surnp(Secti0n EA023.)(NOT Dry Sump Turbo).
3. Remove the front cover (Section EA - 17.) a

4. Remove the rear o i l seal housing (Section EA .27.)
5. Dry Sump Turbo Only. Remove the 8rnm nuts and washen from around the , .
outside of the main bearing panel, fol lowed by the ten large nuts and
- - -- -
SECTION EA Page 49
,-.. washers adjacent to the main journals ;a l l nuts should be released i n

sequence, working diagonally inwards from the outside. Lift off the main
bearing housing. If the housing i s tight, i t i s permissable to tap lightly
with a rubber mallet to ease removal . Remove the sprayshield from the
rear of the cylinder block.
6. Identify each connecting rod bearing cap with its rod, and then unscrew
the connecting rod bearing cap bolts by two or three turns, and tap them
to release the caps. Push the pistons up into the cylinder liners.
7. Remove the auxiliary housing (Section EA .21 .)With the aid of Special
Tool (83A) remove the union screw securing the oil pick-up pipe i n the
cylinder block.
Fig. 29 - O i l pick-up pipe and union spanner

APR 1987
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;
a l l nuts should be released i n sequence working diagonally inwards from thrs

outside. Remove the oil pick-up pipe and breather pipe from their locations
i n the main bearing housing and cylinder block. Lift off the main bearing
housing. If the housing i s tight, it i s permissable t o tap lightly with a

rubber mallet to ease removal. Remove the spray shield from the rear of
the cylinder block.
9. Lift out the crankshaft. Remove the main shell bearings from both the
bearing housing and the cylinder block. Remove the thrust washen from
the rear main bearing locations i n the cylinder block.
To Replace
1 . Fit a new key to the front of the crankshaft to retain the sprocket.
2. F i t a new spigot bearing and new flywheel dowels i n the rear (flywheel)
end of the crankshaft.
Cross-dril led crankshafts
The 'standard' or non cross drilled crankshaft as fitted to all front engined cars prio;
to engine no. 23749 (March 1987) has drillings from main bearings 1,2,4 & 5 through
to crankpins 1,2,3 & 4 to provide big end lubrication. Both upper and lower shells
for these main bearings are provided with a hole to admit oil from a drilling i n the
block, and a groove to provide an oil channel around which oil may flow to the big
end feed drilling i n the journal .
l h e 'cross-drilled' crankshaft is'similar i n the above respect, but diffen as follows:
I n order to permit the use of plain lower main bearing shells with their increased
load bearing area, crank journals 1,2,4 & 5 are also 'cross-drilled' diametrically
across from the point where the big end feed drilling emerges. One end of this cioss
drilling i s therefore always i n communication with the oil supply channel i n the
grooved upper main bearing shell, maintaining big end lubrication throughout 360'
crankshaft rotation.
This 'cross-drilled' crankshaft i s fitted to a l l Esprit variants from engine no. 13277
(1976), and to Excel models from engine no. 23749 (1987). It i s MOST IMPORTANT
to refer to the table i n section TDA (N/A) or TDB (Turbo) for the correct main
bearing shell configuration.
Oversize outside diameter main bearing shells
Whenever main bearing shells are to be replaced on any 907/912/910 engines,

it is most important to check whether the block assembly has been bored to accept
M.015 oversize outside diameter mainbearing shells on production.
0
APR 1987
SECTION EA Page 50 A
Remove the main bearing shells, refit the main bearing panel, and measure the
main bearing bore diameter.
Standard bore d i m eter 2.6655 - 2.6660 in.
(67.704 - 67.716m)
+0.015" O/D bore diameter 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 with a GROOVE and HOLE
'5690' = Standard Outside Diameter
'5946' = +0.015" Outside Diameter
Block assemblies bored +0.015" oversize on production are normally identified
as follows: -
907 Engines
'+015' stamped externally on flank at rear of main bearing housing, together
with red paint.
912 and 910 Wet Sump Engines

'15' stamped on 4th or 5th main bearing 'cap' (along with another 4 or 5 digit
number). Block may also be 'stamped in the region of engine number (above
starter motor) .
910 Drv sum^ Eneine
Stamped externally on side of M.B.P. above rear of scavenge manifold.
Undersize inside diameter shells to suit reground crankshafts are available
for both standard and +0.015" overbored blocks. See Parts List.
MODIFICATION OF 910/912 WIN BEARING PANEL, PRIOR TO ENG. NO 20875
A l l 912 (natuml.ly aspirated 2.2 Iitre) and 910 (turbocbarged

2.2 litre) engines from engine number 20875, incorporate a
revised main bearing panel casting ta enable the rear face of
No. 5 main bearing to be fully machined i n order to reduce
o i l drain off from the thrust washer face. This pane1 does not
have the chamfer on No .5 main bearing as detailed below.
A l l engines prior to 20875 should have the following modification

carried out ONLY i f stripped for any other reason, and show
evidence of crankshaft thrust collar wear.
i) Engines with numbers 20793 to 20874 inclusive have been

modified i n accordance with these instructions at the factory,
a together with approximately thirty engines prior to 20793.

These engines require no further action but care should be
AP R 1987 taken to order the axrect m i n bearing s he1Is (see paragraph 3).
Page 50 B SECTION EA
ii) On a l l unmodified engines up to No. 20793, remove the main

bearing shells from the main bearing panel.(M.B .P .) and modify
the panel a t No.5 (rear) bearing as shown i n 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 rear edge, until $e width of the chamfer i s 1 1 .5mm
and i s approximately 45 to.the ioint face. iuke care not to
mark any other M.B.P. face with the file.
Thoroughly clean a l l swal-F from the panel.
/' No. 5 Main Bearing
Notch in Shell
iii) On reassembly, ensure that the correct notched shell i s fitted

to No.5 (rear).main bearing i n the prier
Part Numbers for the notched bearing shell (ONLY fifted to

No .5 bearing LOWER half) are as follows:
(Std ID
Std O/D -
( 0 .Ol Ol' I/D
( - 0.020" 1/D
( Std I/D A91 2E1990S

+ 0.015" O/D ( - O.Ol0l1 l/D A912 El 991S
( - 0.020" I/D A912El992S .
APR 1987
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 she1I.
NOTE: 907 (2 litre) engines'use a main bearing panel similar to the revised 912 panel and
are therefore unaffected by this bulletin.
3, Ensure the correct bearing shell configuration is fitted by referring to the

0 table in Technical Data.
Ensure that both the cylinder block and the main bearing housings are clean,
then fit new bearing shells. Apply a small amount of graphogen grease to the
bearing she1Is.
4. Ensure that the crankshaft main journals are clean, then f i t the crankshaft. Spin
the crankshaft to ensure even distribution of th3 gmphogen grease. F i t new
selective thrustwashen to the rear main bearing so that the oil grooves
(the 'copper' side) are towards the crankshaft. Check the end-float
between the crankshaft and the thrustwashers (see TECHNICAL DATA). If
a 5.
the end-float is outside this tolerance, replace the selective thrust washers.
Dry Sump Turbo Only : Ensure the crankshaft connecting rod journals and the
connecting rods and caps are clean then fit new bearing shells. Refit the
connecting rods and their caps to their respective iournals after appiying
gaphogen weuse t o the bearings. Tighten the bolts to their specified
torque loading (see TECHNICAL DATA).
Ensure the scavenge manifold and sump ducts are fitted and the stud locknuts
retained with thread locking compound and their locktabs. Insert the oil
feed pipe into the block with a 'new ring fitted en i t s lower end. Oil
'0'
the '0' ring.
a 6. Ensure a l l the main bearing panel to black locating dowels are i n place, and
clean the ioint face on both parts before applying only 'WELLSEAL' (zero
APR 1987
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 i n pain i n a sequence outwards from the centre. For torque figures
see Technical Data.
(Not Dry Sump Turbo)

Ensure that the crankshaft connecting rod journals and the connecking rods and
caps are clean, then fit new bearing shells. Refit the connecting rods and
their caps to their respective journals, after applying Graphogen grease to the
bearings. Tighten the bolts to their specified torque loadings (see TECHNICAL
DATA).
(Not Dry Sump Turbo)
To enable the oil pick up pipe, and the crankcase breather pipe (all 907
and early 912) to be fitted, it i s necessary to remove both 12mm nuts from
main bearing No. 4. Fit the breather pipe by pushing into i t s drilling
at the rear of the MBH, a d refit the 12mm nut end washer to retain. Push
the oil pick up pipe into i t s drilling at the front of the MBH and retain with
the main bearing nut and washer. Torque tighten the two main bearing nuts.
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 i t s specified torque loading (see Technical Data).

Ensure spray shield i s i n its correct location on cylinder block and main
bearing housing, with its flange positioned between the two webs on the main
bearing housing. Replace -the crankshaft rear oil seal (Section EA .27.)
Replace the front cover, crankshaft sprocket, sump and flywheel.

When a new cylinder block is being used, it will be necessary to f i t the
breather spout at the top of the right hand side below the inlet manifold.
Fit the bush, with its flange uppermost, into its location. Tap the breather
tube into the bush until approximately 25mm. (1 .0 in.) is left protruding.
Ensure oil gallery and water jacket plugs are also fitted.
Re-assemble the gearbox to the engine, and replace engine/gearbox assembly
i n the car.
EA.29. - PISTONS, PISTON RINGS, CONNECTING RODS 8, CYLINDER LINERS
To Remove
1 . Remove engine/gearbox assembly (Section EA .25 .)
2. Remove cylinder head (Section EA .10 .)
3. Remove the oil sump (Section EA .Z3.)
4. Remove the connecting rod bearing caps. Remove the ring of carbon from the top
of liner wall. Push the piston up and out of the cylinder liner, by i t s
connecting rod. Remove the assembly to a bench.
5. Remove the piston rings. Extract the gudgeon pin circlips and push the pin
out of the piston, thus releasing the connecting rod. Mark all companents in
relation t o each other, and to the cylinder from which they were removed.
6. UsingSpecialTool TOOOT0012ZA,withdrawthelinersfromthecylinderblock.
a
APR 1987
Page 54
Fig, 32 - Usi
To Replace
1. The liners are fitted into the cylinder block with their 'flats' i n a front-to-rear
line. When replacing liners i n the cylinder block, they MUST FIRST be fitted
clean and dry, and pushed fully into their locations. A t this point, the liner
'nip' should be checked; the
'nip' i s the height of the
liners ABOVE the cylinder
block face and the height
of the l i n e n i n relation t o
each other (see TECHNICAL
DATA).
-
Fig. 33 Using Tool TOOOT0003A
to check cylinder liner height
1987
SECTION EA Page 55
2. When l i n e r n i p i s c o r r e c t , w i t h d r a w t h e l i n e r s , a p p l y
'Hylomar' o n t h e l i n e r f l a n g e t o c y l i n d e r b l o c k m a t i n g f a c e a n d
replace liners.
3. I f r e p l a c e m e n t p a r t s a r e t o be f i t t e d , e n s u r e t h a t t h e p i s t o n s
and t h e c o n n e c t i n g r o d s a r e b o t h b a l a n c e d s e t s .
Note t h a t a l l 907 and s t a n d a r d 912/910 e n g i n e s u s e c a s t i r o n

c y l i n d e r l i n e r s w i t h c a s t aluminium a l l o y p i s t o n s . 912/910
' h i g h c o m p r e s s i o n ' e n g i n e s u s e f o r g e d aluminium a l l o y c y l i n d e r
l i n e r s with a 'Nikosil' coated bore, together with
f o r g e d aluminium a l l o y p i s t o n s . The a l l o y l i n e r s h a v e a
l a r g e r s p i g o t d i a m e t e r a n d c a n n o t be f i t t e d t o s t a n d a r d
engines.
P . i s t o n s and l i n e r s a r e o n l y s u p p l i e d t o g e t h e r a s matched p a i r s .
Two *grade d i a m e t e r s a r e u s e d , ' A ' and ' B ' w i t h ' A ' p i s t o n
(marked a s crown) f i t t e d i n t o ' A ' l i n e r s (marked on l i n e r
t o p r i m o r on s i d e f l a t ) and ' B ' i n t o ' B ' . Pistons a r e a l s o
w e i g h t g r a d e d i n 3 . 5 gram ( c a s t p i s t o n s ) o r 3.0 gram ( f o r g e d
. p i s t o n s ) i n c r e m e n t s , a n d a r e marked i n t h e f o l l o w i n g manner:
C a s t p i s t o n s ; c o l o u r e d p a i n t s p o t on crown, w i t h c o r r e s p o n d i n g
i n i t i a l l e t t e r ( s ) , e n g r a v e d on gudgeon p i n b o s s u n d e r s i d e .
Forged p i s t o n s : stamped on crown w i t h 2+, 1 t , 0 , 1- o r 2- .

Each e n g i n e u s e s 4 p i s t o n s o f t h e same w e i g h t g r a d e b u t may m i x
' A ' and ' B ' p i s t o n / l i n e r a s s e m b l i e s . S i m i l a r l y , connecting
r o d s a r e w e i g h t g r a d e d i n t o 2 gram matched s e t s , and i d e n t i f i e d
by a l e t t e r c o d e e t c h e d o r p a i n t e d below t h e f o r g e d 'FRONT'
mark on t h e r o d .
I f o r d e r i n g an i n d i v i d u a l c o n n e c t i n g r o d o r p i s t o n / l i n e r , t h e
w e i g h t g r a d e symbols must be q u o t e d .
F i t each connecting rod t o i t s p i s t o n w i t h both ' f r o n t ' marks
f a c i n g t h e same way ( f o r g e d p i s t o n s have a r r o w stamped on crown
p o i n t i n g f o r w a r d s ) and i n s t a l l t h e gudgeon p i n a n d c i r c l i p s .
i) F i t the o i l control rings:

907/910/912 S t d : The o i l c o n t r o l r i n g s c o n s i s t o f a n e x p a n d e r
r i n g and two s t e e l r a i l s which a r e f i t t e d above a n d below
t h e e x p a n d e r r i n g . They FUST a l w a y s b e f i t t e d BEFORE t h e
c o m p r e s s i o n r i n g s , working downwards from t h e p i s t o n
crown. F i t t h e e x p a n d e r r i n g on t h e p i s t o n a n d e n s u r e t h a t
t h e c o l o u r e d e n d s a r e b u t t i n g . F i t o n e end o f a s t e e l r a i l
i n t o t h e g r o o v e below t h e e x p a n d e r r i n g , h o l d i n g t h e r a i l
end w i t h a thumb w h i l s t e a s i n g t h e r a i l o v e r t h e p i s t o n
and i n t o i t s l o c a t i o n , and r e p e a t t o f i t t h e o t h e r s t e e l r a i l
above t h e e x p a n d e r . P o s i t i o n t h e g a p s i n t h e two r a i l s ,
25mm e a c h s i d e o f t h e e x p a n d e r g a p .
912/910 'HC': F i t t h e e x p a n d e r s p r i n g f i r s t , f o l l o w e d by
t h e one p i e c e o i l c o n t r o l r i n g , a n d p o s i t i o n t h e e n d s o f
e a c h t o be d i a m e t r i c a l l y o p p o s i t e
APR 1987
Page 56 SECTION EA
0
ii) F i t t h e l o w e r compression r i n g :
907: The s t e p on t h e o u t e r edge i s lowermost
912/910 S t d : The chamfer on t h e i n n e r e d g e i s uppermost.
912/910 'HC': The f a c e i s t a p e r e d t o w a r d s t h e s i d e o f t h e
r i n g marked' 'TOP' .
iii) F i t t h e chrome p l a t e d t o p . c o m p r e s s i o n r i n g
907: May be f i t t e d e i t h e r way up
912/910 S t d : The chamfer on t h e i n n e r edge i s uppermost
912/910 'HC': May be f i t t e d e i t h e r way up
i v ) P o s i t i o n t h e o i l c o n t r o l r i n g gap t o t h e r e a r , and t h e
two c o m p r e s s i o n r i n g g a p s 120" t o e i t h e r s i d e .
Running In:
When new rings, or pistadliner sets have been fitted, the running-in
period must be 800 kilometres (500 miles), (see Section '0').
4. Using a pisten ring compressor, insert the piston into the liner with tk
'FRONT' mark towards the front of the cylinder block. F i t cylinder liner
clamp after replacing the pistons in the liners.
5. F i t new bearing shells to both connecting rod c a p securing with their bolts.
Tighten all bolts to the specified torque loading (see TECHNICAL DATA).
6. Replace the oil sump.
7. Replace the cylinder head, after removing the cylinder liner clamp.
8. Replace engine/gearbox assembly (Section EA .25 .)
APR 1987
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 BSP connection.
The large BSP connection is always the inlet connection from the engine,
ie from either the scavenge pump (dry sump) or upper connection on oil filter
sandwich plate (wet sump)
Thermostats with 4 x 5/8" BSP connections must be viewed down each port and
the diagram used below to identify the connections.
Unions clamping the mounting bracket to be coated:wTth 'Ornni-Fit ' thread lock
and torque tightened to 11 kgf .m. (80 1bf.ft) (Dry sunp bracket shown)
Inlet from Cooler
Outlet to Cooler
€14.31 . - LUBRICATION SYSTEM PRECAUTIONS .

In the event of engine failure involving the possibility of debris entering the
lubrication systen, it is essential that the following precautions are taken
before re-assembly:
i clean and inspect all eigine oilways inblock, crankshaft, cylinder head
etc.
ii) Clean and inspect oil pump, pick up pipe and strainer and auxiliary housing.
iii) On 'dry sump' Turbo models, clean and inspect the oil tank and strainer.
iv) Thoroughly flush out oil cooler hoses and clean and inspect oil cooler
thermostat.
v) In view of the difficulty of ensuring no debris is retained in.the oil.

cooler, this item must always be replaced in such circurnstances.
APR 1987
Page 75
Fig. 10 - Belt guard components (early models)'

. . . . ......,-
. . .:\.
>_. .. . , .. . I . .
(_
. . .
--
. .. .-... A I E714
Page 58 SECTION EA .
EA i32. - SPECIAL TOOLS

TOOO T 00024 Cylinder Liner Clamps
to retain cylinder liners
TOOO G 0003A Cylinder Liner N i p Gauge

To check liner height
Valve Guide Drift

To assemble/remove guides
TOO0 T 0093A Inlet Valve Seat Drift
TOOO T '0094A Exhaust Valve Seat Drift
For inserting valve seat
TOOO T 0009A Front Cover Pilot

To locate front cover
TOOO T 0010A Camshaft O i l Seal Inserter

For inserting o i l seal
TOOO T 001 1A Camshaft O i l Seal Extractor

For extracting o i l seal
TOOO T 0012A Cylinder Liner Extractor

For extracting liners
TOOO T 0072A Camshaft O i l Seal Sleeve

For locating o i l seal
TOOO T 0083.4 O i l Pick-Up Pipe Union Spanner
For tightening union hut
TOOO T 0084A Rear O i l Seal Housing Pilot
To locate housing on
re-assembl y
TOOO T 0170A Crankshaft Sprocket Remover
For removal of sprocket
TOOO T 0242A Spigot Bearing Inserter

For inserting spigot b e a r i n d
aligning clutch assembly
Magnet Assembly To retain cam followers during
(4 off x 2 i n long) dismantling
TOOO T 0290A Borroughs Gauge For checking timing belt
tension
TOO0 T 0443 'Tom' socket Turbo cam housing bolts
APR 1987
SECTION EA Page 59
a
EA -33. - SEALANTS, ADHESIVES
Part Number Product Application
A036 E6038VJ Silastic RTV 732 (315.5 mi) 907 Cam Covers
A907E625NF Loctite 504 Gasket Eliminator Cam Housings
A907E6178V Cyl esso Crank Journals
A907E6565V Molypaul GP2000 Cam Followers & Shims
A907 E6119ZA Wellseal Crank Rear Seal Housing Gasket
Sump Joint, Cylinder Head Gasket
Main Bearing Housing
A036S6175VH Hylomar PL32 Medium (100g) Cylinder Liners to Block
A036B6370V Permabond A1 15 (50 ml) Thread locking
a A074 B60O.9V
A91 2 E6421V
Permabond A1 38
Permabond A1 36 (200 ml)
Push fits
91 2 Sump Joint
A907E6252V Permabond A1 21 Pipeseal (50ml) Dipstick Tube
Note
Do NOT apply thread locking compound to the following studs:
a. Cylinder Head to Block (12 mm)

b. MainBearing Housing (12mm)
c. Main Bearing Housing ( 8 mm)
do . Cam Housing to Cylinder Head ( 8 mm)
, a
APR 1987
SECTION EMA Page 7
SECTION EMA - U.S.A. ESPRIT TURBO [Prior t o '86 M.Y.)
Operation Page
Engine Control Components

Engine Management System Check/
Set Up Procedure
Engine Diagnostic Procedure
APR 1987
Page 2 SECTION EMA
.
EM4. 1 - ENGINE CONTROL COMPONENTS
Ignition Solenoid
Located beneath front of plenum chamber. Function i s to advance ignition on operation

o f choke. A micro-switch operated by the dashboard end o f the choke cable (which also
operates the choke t e l l tale lamp) energises the ignition solenoid. The signal to the
distributor vacuum advance capsule (normally connected to N o . 1 cylinder throttle
edge drilling) i s then switched to the vacuum pump, and thus f u l l ignition advance i s
achieved, together with an increase i n engine idle speed.
Fuel Pressure Solenoid
Located beneath rear of plenum chamber. Function i s to reduce fuel pressure on 'overun'
and idle. A micro-switch, mounted on the front of the front carburettor, and cperated by
the throttle lever i n i t s fully closed position, energises the fuel pressure solenoid. The
signal to the fuel pressure regulator (normally connected to boost pressure i n the plenum
chamber) i s then switched to No. 1 cylinder inlet manifold depression, thus reducing
0-
fuel pressure to the carburettors and mixture strength under closed throttle 'overun'
conditions.
Throttle Jack Solenoid
Located on the front o f the front carburettor. Function i s to increase engine idle speed
when engine i s cold or air conditioning switched on, and also to open throttle on hot
start cranking mode. A thermostatic switch fitted into the rear o f the i n l e t manifold
0
water rail, makes contact at water temperature below 70 C, and energises the throttle
jack solenoid. To aid cold starting the solenoid i s de-energised whilst i n the cranking
mode, A t water temperature above 70°c, the solenoid i s energised O N L Y whilst
cranking to a i d hot starting. The solenoid i s alsoenergised when the ACU i s switched on.
Air Pump & Divertor Valve
d he a i r pump i s mounted on the rear of the engine and driven by 'v' b e l t from the exhaust
0
cdmshaft. The divertor valve i s fitted on the outside of the ehgine bay left hand wall.
Their function i s to provide additional air into eitherthe exhaust ports, or the exhaust
catalyst, and reduce engine emissions.
The a i r pump draws a i r from a filter located on the right hand rear wheel arch and supplies
it to the divertor valve. The divertor valve i s spring loaded so as to supply a i r to the
exhaust ports via a non-return valve, and air injection manifold.
0
When engine coolant temperature reaches.70 C, a solenoid on the divertor valve i s
energised, and connects a diaphragm chamber on the valve with vacuum supplied by
the engine driven pump. This vacuum is used to overcome spring pressure and divert
a i r flow via a non return valve to the exhaust catalyst.
APR 1987
SECTION EMA Page 3
Evaporative Control System
Fuel vapour from the fuel tanks i s piped into the catch tank, i n which the vapour condenses
into liquid fuel and residual vapour. The level of liquid fuel i n the catch tank i s
controlled by the catch tank inlet tube. Any increase i n level above this tube and the
fuel i s induced back into the main tanks. The vapour outlet pipe from the catch tank i s
routed via a rol lover valve to connection 'TI on the vapour .(charcoal) canister.
With the ignition switched off, the carburettors are vented via the plenum chamber and
.
carb vent valve to connect ion 'C' on the vapour canister. When the ignition i s switched
on, the carb vent valve solenoid is energised and the pipe i s sealed.
The purge connection on the vapour canister (port 'PI) i s piped to a venturi IT' piece fitted
between the air pump and filter. I n this way, when the engine is running air is drawn in
a through the bottom of the canister, to replace gasoline vapoun corsumed by the air pump
and fed into the exhaust system for oxidation. .
E N . 2. - ENGINE MANAGEMENT SYSTEM CHECKAET UP PROCEDURE
Special Tools Rewired
Lotus Part No:

1. Carburettor Balance Tubes TOOOT0496
2. Carburettor Idle Mixture Adjuster TOOOT0497
3. Carburettor Float Setting Bar TOOOT0498
4. Carburettor Manometer TOOOT0499
a 5.
6.
Pressure Test Gauge Kit
Exhaust Sample Probe
TOOOT0500
TOOOT0501
7. Throttle Damper Setting Bar. TOOOT0502
8. Special Socket for anti-tamper TOOOT0503
Distributor Clsmp
a
APR 1987
Page 4 SECTION EMA
1 . Remove vacuum tapping screws, f i t carburettor balancing tubes and connect

to manometer.
Connect pressure test gauge k i t as shown i n 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? S.I.
PRESSURE TEST GAUGE KIT
LOTUS PART NO. TOOT0500 @ 0-30hg
Fit exhaust probe to exhaust outlet

pipe of turbo charger and connect to
CO/HC analyser (e.g. Sun EPA 75
or equivalent). Connect stroboscopic
timing lamp to number one spark plug
lead.
Exhaust probe connection
APR 1987
SECTION EMA Page 5
COLD Engine
2. Switch on ignition and check that fuel pressure at fuel regulator gauge i s
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 throttle fully and release. Start engine and
check the following ,
i). Vacuum at pump gauge. Minimum = 20" Hg .

ii). Vacuum at ignition solenoid gauge. Minimum 20" Hg.
iii). Position of diffuser flap valve. Should be fully open.
iv). Engine speed rises to approximately 2,500 rpm.
4. -
Return choke fully after 20 100 seconds (dependant on temperature) and
adjust idle speed at the throttle lever on the front of the carburetton, bearing
on the throttle jack solenoid, to 1000 rpm (basic setting).
r-x' ACU throttle iack solenoid
M- Throttle iack idle
speed adjusting screw

U_J
VIEW FROM FRONT
Disconnect the hose to the air rail pulse valve and check that air i s supplied
from the hose and reconnect hose.
When a water temperature of 7 0 ' ~i s attained, "check that. the throttle iack
-sofenaid is deactivated and switches out and check that the air supply to the
0' injection mil hose ceasesby temporarily disconnecting hose to the air mil
pulse valve. (i.e. air supply i s diverted to catalyst).
. .
APR 1987
Page 6 SECTION EMA
Allow engine to reach normal runniLg temperature i .e. o i l and coolant should
be stabilised.
5. i) . Ad just idle speed to 950

+
- 50 rpm .
BTDC - 1
ii). Adjust ignition timing to lo
+ 0
.
...
111). Check carburettor balance a t manometer. Check that a l l 4 columns
are balanced within 3mm, i f not re-balance the carburettors. (see
Carburettor Balancing Procedure).
iv) . -
Check fuel pressure at the regulator this should be lower than 3.5 psi
at idle. If the pressure i s higher the micro switch position on the front
.
carb bracket w i l l require adjustment Rotate the switch down towards the
lever until switch contact i s made. Manifold pressure w i l l now be
connected to the fuel regulator via the regulator solenoid.
6. -
Mixture setting with the carbs balanced and rpm and fuel pressure set, the idle
mixture can be sampled and adjustment made if required.
i). Switch analyser to sample mode and check readihgs.
NOTE: Do not touch idle adjustment screws until CO reading has

.
stabil ised The carburetton have been flow tested and only minor
adjustment w i l l be required, i f any.
ii) . CO reading should be within 0.2 to 1 -2%. If higher or lower levels are
4
found, remove anti-tamper plugs and move each mixture screw a of a
turn i n or out as the reading dictates, check the C O reading and repeat
until the tune specification i s reached. A balance between CO and HC
i s required and the hexane level should be below 550 ppm for a 'new
engine' and below 350 ppm for a run-in engine. When adjustment i s
complete f i t anti-tamper plugs .
CROSS SECTION THROUGH AN71 TAMPER IDLE CO A Y v S T E R
IDLE CO ADJUST'
FRONT
OF
VEHICLE
CARBURETTOR I L
ENGINE IDLE
SPEED SCREW-
IDLE S l W BRACKET
SECTION EMA Page 7
7. -
Fuel regulator micro switch with the switch set at idle and fuel pressure recorded
as i n operation 5,open throttle to2500 rprn and thenreturn throttle to idle position.
Check that when the engine speed i s above 1800 rpm, the micro switch i s deactivated
-
allowing fuel pressure to increase to 4.0 5.0 psi. Repeat this test and check that
pressure differences are maintained.
NOTE (1). Failure to change pressure i s a serious malfunction. Check

pipework and electrical circuit for defects. Rework the
defective items before further testing.
(2). The throttle w i l l be delayed i n returning to the idle position

due to the action of t k damper valve (see number 8).
8. -
Damper valve with adjustments 1-7 carried out the throttle damper can now be
adjusted. With the engine at i d k rprn rotate the damper until a distance between
damper body and lever i s 0.55 - .05 in. Lock up the retaining nut, open throttle
to 2500 rprn and release. Idle rprn should be attained within0.8 to 2.0 seconds.
Damper valve adjustment
TO
ENGINE
VIEW FROM REAR
9. ACU throttle jack solenoid - with adjustments 1 - 8 carried out,switch on

air conditioning and then disconnect red wire from compressor where i t joins
the p i n w l u e at the right hand front of the engine bay. Note engine rpm.
Initial adjustment CIS

completed i n paragraph 4. The engine speed should
.
rise to 1 100 rpm ( - 25 rpm) If further adjustment i s required, ad just on the
front carburettor lever. After completion, reconnect compressor. lead.
Page 8 SECTION EMA
10. -
Flap valve actuator with a l l 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 i n the cranking mode.
12. To check maximum vacuum from vacuum pump, clamp off the vacuum hose a t
air box to 'TI-connection and note increase i n pump vacuum. This should rise
by approximately 3 " Hg.
13. O n completion disconnect pressure test gauge k i t from components and re-connect
fuel and vacuum pipes securely. When connecting vacuum pipes spray connections
w i t h a "silicone" aerosol and push on connections firmly. Disconnect manometer,
remove balancing tubes and replace vacuum tapping screws securely. Fit new anti-
tamper plugs to both throttle coupling screws, 4 balancing screws and 4 mixture
screws.
APR 1987
SECTION EMA Page 9
a E M A .3. - ENGINE DIAGNOSTIC PROCEDURE . .
Before carrying out detailed diagnostic check, ensure engine management system i s within
specification.
COLD START PROBLEMS

I HOT START PROBLEMS
Possible causes: + 2'
I
Possible causes:
v, (3
Weak battery (recharge

or replace) I Fuel pump electrical
circuit
Fuel pump electrical I Leak in intake

circuit manifold
Leak i n intake manifold A Spark plugs
Distributor cap I Cold start maladjustment

High tension leads
B Cam timing incorrect
Rotor
Control pressure
Spark plugs
incorrect
Cold start maladjustment C Fuel system,
external leakage
Cam timing incbrrect
I Fuel system
internal leakage
Control pressure, too
low
I C O maladjustment ,
Fdel pump capakity

unsatisfactory I Thermal switch incorrect
Fuel lines (filter)

clogged
C O misadjustment I
Thermal switch incorrect I . H
a APR 1987
. .
Page 7 0 ENGINEDIAGNOSTIC PROCEDURE SECTION EMA
Before carrying out detailed diagnostic check, ensure engine management system i s within
specification.
a
UNEVEN RUNNING POOR PERFORMANCE,
LOW TOP SPEED
Possible causes: 2
Possible causes:
Leak i n intake system
I High tension leads

I B I
Air filter clogged
I Cylinder compression
I I
Distributor cap
I Spark plugs
I I High tension leads
Cyl inder compress ion
Cold start maladjustment
Spark plugs
Cam timing incorrect Ignition timing incorrect
I Incorrect control pressure I

I Fuel l ines (filters) clogged
Cam timing incorrect

Fuel pump capacity ~- - -
unsatisfatoty '
Control pressure
maladjustment
Throttle or throttle
linkage misadjustment Fuel lines (filters) clogged
Incorrect balance Fuel pump capacity
unsatisfactory
C O maladjustment
Incorrect vacuum control
of the control pressure
Throttle or linkage
ENGINE STALLS-
maladjustment
Possiblecauses:
C O malodjustment
II Fuel pump electrical

circuit
I
Leak i n intake system
I A l EXCESSIVE
- -----
CONSUMPTI
----
FUEL
ON
I = a
Distributor cap Possible causes: 9
m0
2
High tension leads
Cylinder compression B
-++
Fuel lines- (filters) clogged
Fuel pump capacity unsatisfacto
I c l
Control pressure incorrect
CO maladjustment G
Ignition timing incorrect
C O maladjustment ' G
APR 1987
SECTION EMA Page I I
-S-UB 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 o f fuel in the float chambers.
It i s essential that the carburettor mountings are not overtightened,
as the '0' rings may be displaced with a resultant a i r leak.
A uniform gap between spacer plate and carburettor, and between

spacer plate and inlet manifold must be maintained as shown below.
spacer plate/manifold
1.9 mm (0.075")
2. Check for air leaks at carburettor balance pipe connections, and a t

cold start air intake pipe connections to carbs anddiffuser.
Check torque of banjo bolts : 2.2 kgf .m (1 6 Ibf .ft)
APR 1987
SECT,ON , . .
...
Page 72
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 o f pipe from adaptor
to fuel pressure regulator solenoid.
5. Inspect the air filter element.
Release the filter cover from the engine bay wall, leave the hoses
attached and pull open. Remove the cleaner element and inspect
condition.
If necessary, remove the rubber seal, and discard the element. Ensure
the seal is i n good condition (replace i f necessary) and f i t i n position
on the new element.
Note: The seal joint must be at the centre top. Clean the inside o f the
---
a i r cleaner body and cover, keeping dust out o f the intake trunking .
F i t new element with its metal face towards the carburettors and replace
cover.
APR 1987
SECTION EMA Page 13
SUB GROUP B - Ignition----
System & Cylinder
------- Compressions
A). Check for a spark at each plug lead. If a l l are sparking, remove plugs and
check condition. I f 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 .
TEST RESULT
1 CHECK HT SPARKING
Should be:
Regular sparking *
-
TEST6
No sparking
+ -
TEST 2
Measure voltages at 1 4 incl

should be :
1-More than 11.W
2 - l V max. below V at 1
j - 1 V max. below V at 1
-
4-ov-0.1 v
All correct -
v
TEST 3
Incorrect reading(s)
SEE CHART
SUSPECT
J Battery discharged
J lgnit~onswitch andlor wiring
J 1 J 1 Low J Coil or amplifier
HIGH Amplifier earth (ground)
3 CHECK AMPLIFIER SWITCHING

Voltage increases
CRANK i while cranking
7
-
ENGINE
TEST 5
doltage does not increase

~ h i l cranking
e
TEST 4
-
4 PICK-UP COIL RESISTANCE Ohmmeter should show
2-5 kn
Correct
-
Ehange amplifier
f engine w i l l not start
TEST 5
ncorrect
:hange pick-up
If engine w i l l not start
TEST 5
APR 198'
Page 14 SECTION EMA
5 CHECK HT SPARKING Should be good HT sparking
Repeat with original HT lead
-
Good sparking
-
*
If engine will not start
TO IGN TEST 6
SWITCH No sparking, replace HT lead
If engine will not startw
--
TE& 6
-
No sparking
Replace coil
If engine will not start *
-
Should be:
No sparking
-
TEST 7
HT sparking
Replace rotor armlrotorvane
TEST 7
7 VISUAL AND HT CABLE CHECKS

EXAMINE Should be:
1 Distributor Cover
1 Ciean, dry, no tracking marks
2 6ilTop
2 Clean, dry. no tracking marks
3 H.T. Cabla Insulation 3 Must not be cracked, chafed
or perished
4 H.T. Coble Continuity 1 Must not be open circuit
5 Spark Plugs 5 Clean, dry, and setto correct gap
B). Check cylinder compressions: Remove spark plugs. Gnnect a remote control
'
switch to battery and starter motor solenoid.
Use a compression tester to measure cylinder compressions with throttle fully

open.
Check that cylinder compressions are fairly even.
Cold engine (dry bores) - .

120 p .s .i minimum (at sea level)
Hot engine - .
130 p .s .i minimum (at sea level)
C). Check ignition timing:
Nominal static and idle: lo BTDC ( - lo)

+
0 4,000 rprn with vacuum pipes disconnected from capsule: 17O BTDC
+
( - 2 )
0
APR 1987
SECTION EMA Page 75
SUB GROUP C - Cold Start System Maladjustment
1 . Check that operation of the choke control results i n full travel of the
carburettor cold start levers.
With the choke control i n the 'off' position both carb levers should contact
their closed 'stops' on the carburettor tops. With the choke control operated
fully, check that both levers are against their fully open stops. Adjust the
choke cable at the carburettor, tmd linkage if necessary.
CHOKE FULLY OPEN CHOKE FULLY CLOSED

STOP STOP
. aAPR 1987
Page 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 dots (red on inlet, green on exhaust) are aligned with a
line through the camshaft pulley centres. These dots may be viewed from either
the front side (using a mirror) or the rear side.
If the engine i s running, the rear side of the pulleys may be viewed with a
stroboscope set a t TDC or No. 1 cylinder. .
Note: I t i s most important that each camshaft toothed pulley isfitted the correct
way round, i.e. 'IN' facing forward on inlet camshaft and 'EX' facing forward
on exhaust camshaft. Marks on the reverse side of the pulley w i l l be reversed.
Belt tension Pulley
Cmnkshaft Sprocket
a
SECTION EMA Page 7 7
SUB GROUP E - Fuel Control
--- Pressure
-
1 . Connect fuel pressure test gauge as shown below.
h+-FL SUPF'LY TO CARWRETTORS
,FUEL PRESSURE ADJUSTMENT SCREW
FUEL PRESSURE
REGULATOR
FUEL SUPPLY
FROM
~QUMP
PRESSURE 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 regulator adjustment screw, and adjust as
necessary .
If the pressure reading i s too high, and cannot readily be adjusted to specification, a
restriction i n the return line i s indicated. Rectify as necessary.
If the pressure reading i s too low, and cannot readily be adjusted to specification, a
restriction i n the supply line, or faulty fuel pump i s indicated.
Check for an unrestricted supply.to the fuel pump, and for fuel filter restriction.
Test fuel pump
2, Start engine and allow to .reach normal running temperature.
Check fuel pressure at the regulator. This should be lower than 3.5 p.si. at idle
+
(950 - 50 rpm). If above specification., check that the micro-switch on the front
of the front carburettor is activated. If not, rotate theswitch down towcrds the
lever until switch contact i s made.
0
APR 1987
Page 7.8' SECTION EMA
r-7
View from front
If switch adjustment i s carried out, open throttle to 2500 rpm and then return
throttle to idle position. Check that when engine speed i s above 1 800 rpm, the
micro-switch i s deactivated allowing fuel pressure to increase to 4.0 -5.0 p.s .i .
Repeat this test and check that pressure differences are maintained. Adjust switch
position i f necessary but always ensure that idle pressure requirements are met.
If switch contact i s made at idle, but fuel pressure remains above 3.5 p.s .ischeck
fuel pressure regulator solenoid pipework and wiring for leakage or disconnection.
If no fault i s found, replace fuel pressure regulator solenoid valve.
If pressures are found to be correct, remove caiburettor tops and check fuel inlet
fil ten, cleaning if necessary. Remove float needle valves and inspecf seating.
Replace i f necessary. Check float height setting = 14.5 - 1 5.0 mm .
Float height with

APR 1987 gasket i n position
SECTION EMA . ..: Page I9
. ,
SUB GROUP F -
- Carburettor Balance
1 . Remove vacuum tapping screws, f i t 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 a l l 4 columns
are balanced within 3mm. If not continue balancing procedure.
VACUUM TAPPING SCREW
FRONT
OF
VEHICLE
'L
FRONT
- CARBURETTOR
IDLE STOP BRACKET THROTTLE COUPLING

SCREWS
Remove anti-tamper plugs to gain access to the throttle coupling and
balancing screws.
Emure that a l l balancing screws are closed. (do not graunch).
Whilst maintaining idle speed, adjust throttle coupling screws to balance

lower of columns 1 , 2 with lower of column 3,4.
NOTE: Ensure that both clamping screws on the balance lever are i n
secure contact with thebalance arm.
Considering the carburettor barrels i n pairs (1, 2 and 3,4) note which of
the two mercury columns for each pair i s higher and gradually move only
the corresponding balancing screw until the two mercury columns of each
.pair are balanced within 3mm. Maintain correct idle speed arid ensure that
a l l 4 mercury columns are within 3mm.
On completion disconnect manometer and remove balancing tubes and

replace vacuum tapping screws securely. Fit new anti-tamper plugs
to both thmttle coupling screws, 4 balancing screws and 4 mixture screws.
Ensure that fuel pipe connections are secure.
APR 1987
Page 20 SECTION EMA
SUB GROUP G - CO Adiurtment
----
1 . Fit exhaust probe to exhaust outlet pipe o f 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. o i l and coolant
!
' .
temperatures stabil ised
2. Switch analyser to sample mode and check readings.
Note: Do not touch idle adjustment screws until C O reading has stabilised.
-
CO reading shquld be betwben 0.2 1.2%. I f higher or lower ievels are found
ensut-e carburettors are balanced (see Sub Group F) beforecontinuing. .
Remove anti-tamper plugs and move each mixture screw $ o f a turn i n or out as
the reading dictates. Check the CO reading and repeat procedureuntil correct
specification i s achieved. A balance between C O and HC i s required, and the
Hexane level should be below 550 ppm for a 'new' engine and below 350.ppm for
a 'run-in' engine.
a
3. When adjustment i s complete, fit anti-tamper plugs.
SECT/ON EMA Page 2 1
----- GROUP H - Thermal

-SUB Switch
1 . I n order to test correct operation o f the thermal switch, sufficient coolant must
f i n t be drained from the cooling system to permit the removal of the switch from
the rear o f the i n l e t manifold.
2. Place the switch bulb i n a pan of water, with a battery and bulb connected across
the switch terminals and a thermometer measuring water'temperature. Heat the
water and check make and break temperatures meet specification.
Maximum break on rise = 70°c

Minimum make on fall = 60°c
APR 1987
Page 22 SECTfON EMA
SUB GROUP J - Battery Re-charging Procedure
lnstruc tions for Tungstone Powermaster Maintenance Free Batteries.
To determine the state of charge o f the battery, apply a brief d i ' s ~ h i r ~

o fe 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 the terminal voltage o f the battery.
If steady voltage is below 12.4 Volts, recharge battery as follows.
Note: The battery -

must
-not be boost charged.
If necessary, f i t
a replacement battery to the vehicle, whilst original
battery i s charged as fol lows.
Remove battery from vehicle.
Constant Current: The battery must be charged at a maximum o f 5 amps until

the battery terminql voltage (on charge) has stabil ised over a one hour period,
at which time the voltage w i l l be i n the range 16.0 -
16.5 V. Atthis &age
the battery must be taken off charge IMMEDIATELY, to prevent excess gassing
with resulting water loss which w i l l ultimately reduce the guaranteed service
iife.
Constant Voltage: The battery may be charged at avoltage up to a maximum

of 15.8V providing the current i s carefully monitored and the charge terminated
when the current has tapered off and changes by less than 0.1 amp over a period
of one hour. If i t is not possible to monitor the current during charging, then
the voltage must be restricted to 14.4 V maximum.
Battery access
APR 1987
SECTION EMA Page 23
-
SUB SECTION I Fuel
- Pump Electrical
---- Circuit
1. Checksafetyinertiaswitchhasnotbeenactivated.
The switch i s located i n the ignition box at the rear o f the engine bay. To re-set
the switch, press down the plunger appearing through the hole i n the top o f the
ignition box.
Inertia switch
Check for electrical feed at fuel pump terminals with ignition switched on.
I ' a
. APR 1987
SECTION EMC Page 7
ENGINE MANAGEMENT
SECTION EMC - ESPRIT TURBO 1 9 8 7 MODEL YEAR ( D o m e s t i c & E x p o r t )
Operation Page
Vacuum C o n n e c t i o n D i a g r a m EMC . I 2/3

T h e r m a l I w i t i o n Advance EMC . 2 4 to 6
Crankcase B r e a t h e r Valve EMC . 3 6
Cold Enrichment Thermal Valve EMC . 4 7
Plenum P u r g e EMC . 5 7
T h r o t t l e J a c k Soleno'id EMC . 6 7/8
Overboost Switch EMC .7 8
I d l e Speed & I g n i t i o n Timing
S e t t i n g Procedure EMC . 8 8 t o 10
., a
APR 1987
THERMAL SWITCH OPERATION
EMC.1. - ENGINE MANAGEMENT VACUUM CONNECTION DIAGRAM
7
TO. CRANKCASE
1 0 2
J COLD ENRICHMENT
THERHAL VALYE @
. WHITE
NON RETURN
VALVE @
Vacuurn/Pressure
BLACK IWHITE REAR FRONT Pipe Connections
n
r
CAR R
--- Electrical Connections
FUEL
I SPEED
SENSING REGULATING
VALVE
-I-
PLENUM
w IGNmION
SOLENOID VALVE
SOLENOtD
TO BOOST
PURGE
PUMP p i n k towards plenum
A
.Vacuum Pump: Mounted L.H. s i da
of
a
Non R e t u r n V a l v e : Fitted i n line,
a C/>
crankcase. D r i v e n by ' V ' b e l t from between t h e r m a l v a l v e and c a r b s . fm
crankshaft. S u p p l i e s vacuum f o r P r e v e n t s boost p r e s s u r e blowing
S e e EMC.3.
cj
e n g i n e management, b r a k e s e r v o and o f f through thermal valve.
h e a t e r / a . c. 3
h
Cold E n r i c h m e n t Thermal V a l v e : Fitted into
Thermal Switch: F i t t e d i n t h e r m o s t a t r e a r of i n l e t manifold water r a i l . At Z
o u t l e t water pipe.
B.O.F. 60°C.
M.O.R. 70°C.
S w i t c h e s I.S.V. and
w a t e r temps below 5 3 ° C , v a l v e s h u t s o f f rn
p u r g e pump. S e e EMC.2.
crankcase breather bleed,to e n r i c h f u e l l i n g .
S e e EMC.4. L
C)
I g n i t i o n S o l e n o i d Valve I . S . V . : Crankcase Breather Valve: Fitted a t top rear
F i t t e d on t o p o f R.H. f u e l t a n k of c r a n k c a s e . Vents c r a n k c a s e e m i s s i o n s t o
board. C o n t r o l l e d by t h e r m a l s w i t c h airbox with bleed t o carbs. S e e EMC.3.
( i t e m 2 ) . Removes vacuum s i g n a l t o
d i s t r i b u t o r during cold cranking,
( a i d s s t a r t u p ) and a t w a t e r temps. Thermal I g n i t i o n V a l v e : F i t t e d t o c e n t r e o f
a b o v e 70°C, ( s a f e g u a r d i n c a s e o f i n l e t manifold water r a i l . Below 60°C
T.I.V. f a i l u r e ) S e e EMC.2. d i r e c t s vacuum pump s i g n a l t o d i s t r i b u t o r
f o r f u l l advance t o a i d c o l d i d l e and
Overboost Switch: F i t t e d on t o p of driveability. S e e EMC.2.
R.H. f u e l t a n k board. Cuts o u t
i g n i t i o n i f overboost i s detected T h r o t t l e Jack S o l e n o i d : Fitted t o front
( w a s t e g a t e f a i l u r e ) . S e e EMC.7. of f r o n t c a r b u r e t t o r . C o n t r o l l e d by
speed s e n s i n g r e l a y ( i t e m 7 1 , choke
P u r g e Pump: Fitted t o tailgate s w i t c h and a . c . s w i t c h . Energised
a p e r t u r e R.H. s t i f f e n e r b r a c k e t . a b o v e 1400 rpm t o r e d u c e e m i s s i o n s
C o n t r o l l e d by t h e r m a l s w i t c h ( i t e m 2) on o v e r u n and when c h o k e / a . c .
O p e r a t e s a t w a t e r temps. above 70°C. operated t o raise/maintain i d l e
with ignition o f f , t o aid hot re-start. speed. S e e EMC.6.
S e e EMC.5.
F u e l P r e s s u r e R e g u l a t i o n V a l v e : Mounted t o
S h u t Off S o l e n o i d Valve: F i t t e d a d j a c e n t r e a r o f c a r b . plenum. Adds b o o s t p r e s s u r e
t o p u r g e pump. S h u t s o f f p u r g e pump t o f u e l d e l i v e r y p r e s s u r e f r o m pump t o
l i n e with i g n i t i o n . on t o prevent l o s s maintain f u e l delivery t o carbs. a t
o f b o o s t p r e s s u r e t h r o u g h p u r g e pump. 0.27 f 0.02 b a r ( 4 . 0 f 0.25 l b / i n 2 ) a b o v e
S e e EMC.5. boost pressure. S e e LB.l.
E n g i n e Speed S e n s i n g R e l a y : Fitted inside
R.H. w h e e l a r c h i n r e a r l u g g a g e compartment
E n e r g i s e s t h r o t t l e j a c k above 1400 rpm o n
f a l l (1600 rpm o n r i s e ) t o r e d u c e e m i s s i o n s
on overun. S e e EMC.6.
SECT/ON EMC
EMC.2. - THERMAL I G N I T I O N ADVANCE

The t h e r m a l i g n i t i o n advance system i s d e s i g n e d t o p r o v i d e
maximum i g n i t i o n advance a t low e n g i n e t e m p e r a t u r e t o a i d c o l d
d r i v e a b i l i t y and i n c r e a s e i d l e speed.
The d i s t r i b u t o r i s f i t t e d w i t h a double s i d e d vacuum advance
c a p s u l e , one s i d e of which i s permanently connected t o t h e plenum
chamber ( b o o s t p r e s s u r e ) . The o p p o s i t e s i d e of t h e c a p s u l e
i s c o n n e c t e d , v i a t h e Thermal I g n i t i o n Valve ( T . I . V . ) and I g n i t i o n
S o l e n o i d Valve (I.S.V.) t o e i t h e r t h e vacuum pump o r t h r o t t l e edge
drilling.
The T.I.V. i s f i t t e d i n t o t h e c e n t r e of t h e i n l e t manifold
w a t e r r a i l , and a t c o o l a n t t e m p e r a t u r e s below 60°C, connects
p o r t s ID' and ' 1 ' . Above 60°C, p o r t s 'D' and ' 2 ' a r e connected.
The I.S.V. i s mounted on t o p of t h e r i g h t hand f u e l t a n k board

and i s c o n t r o l l e d by a t h e r m a l s w i t c h f i t t e d i n t o t h e t h e r m o s t a t
h o u s i n g o u t l e t p i p e a t t h e f r o n t of t h e e n g i n e bay. A t c o o l a n t
t e m p e r a t u r e s below 70°C (on r i s e ) t h e I . S . V . i s e n e r g i s e d and
c o n n e c t s p o r t s ' 2 ' and ' 3 ' . Above 70°C t h e s o l e n o i d i s de-energised
and c o n n e c t s p o r t s ' 1 ' and ' 3 ' .
The I.S.V. i s de-energised d u r i n g e n g i n e c r a n k i n g r e g a r d l e s s
of coolant temperature.
Vacuum C i r c u i t s
Water Temp: inlet manifold below 6 0 ' ~
A t coolant temperatures
( i n l e t manifold) below 60 O C ,
t h e T.I.V. and ( e n e r g i s e d )
I.S.V. d i r e c t a vacuum
pump s i g n a l t o t h e d i s t r i b u t o r
advance c a p s u l e t o provide
o v e r 30°C i g n i t i o n advance
t o a i d c o l d d r i v e a b i l i t y and
i n c r e a s e i d l e speed.
SECTION EMC Page 5
Water Tem~:inlet manifold below 6 0 ' ~ TU~DMAI l-4 I VA-.CU
.-U--
M 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.
EDGE PORT
CARB. CARB.
PLENUM I
IGNITION
SOLENOID
VALVE
Water Temp: inlet manifold above 6 0 ' ~ ~~ERM*L

thermostat pipe below 7 0 ' ~
When the coolant temperature

(inlet manifold) reaches 6 0 ° C ,
the T.1.v~ changes over and
directs a throttle edge
drilling +acuum signal to the
distributor for normal
running ignition advance.
IGNITION
SOLENOID
VALVE
Page 6 SECTION EMC
Water Temp: thermostat pipe above 70'~ THERMAL

IGNITION
VALVE 2
I n o r d e r t o safeguard t h e
e n g i n e from p o t e n t i a l l y
damaging e x c e s s i v e i g n i t i o n
advance a t normal r u n n i n g
temperature, should a
malfunction of t h e T . I . V .
o c c u r : When c o o l a n t
temperature (thermostat
p i p e ) r e a c h e s 7 0 ° C (on r i s e )
t h e I.S.V. i s de-energised,
and d i r e c t s a plenum chamber
p r e s s u r e ( i n s t e a d o f vacuum
pump) s i g n a l t o t h e T . I . V .
IGNITION
SOLENOID
VALVE
EMC.3. - CRANKCASE BREATHER VALVE
A one way b r e a t h e r v a l v e i s c o n n e c t e d between t h e c r a n k c a s e

b r e a t h e r s p i g o t a t t h e r e a r of t h e b l o c k , and t h e a i r b o x .
C r a n k c a s e e m i s s i o n s d e v e l o p e d d u r i n g normal r u n n i n g a r e
a b l e t o v e n t t h r o u g h t h e one way v a l v e i n t o t h e a i r b o x .
I n o r d e r t o p r e v e n t t h e s e fumes, under low a i r f l o w e n g i n e i d l e
c o n d i t i o n s , e s c a p i n g t h r o u g h t h e i n l e t t r u n k i n g t o atmosphere
t h e v a l v e is a l s o connected v i a a small bore hose t o t h e
c a r b u r e t t o r s . This enables t h e small q u a n t i t y of crankcase
fumes a t i d l e t o p a s s d i r e c t l y i n t o t h e c a r b u r e t t o r s and i n t a k e
t r a c t and s u p r e s s e s o p e n i n g o f t h e b r e a t h e r v a l v e .
The c a r b u r a t i o n i s c a l i b r a t e d t o compensate f o r
t h i s d e g r e e o f a i r f l o w by-passing t h e v e n t u r i s .
A o n e way ( n o n - r e t u r n ) v a l v e i s . f i t t e d between t h e b r e a t h e r v a l v e
and c a r b s . t o p r e v e n t r e v e r s e f l o w when b o o s t p r e s s u r e e x c e e d s
c r a n k c a s e p r e s s u r e . The b l a c k s i d e o f t h e v a l v e must b e
f i t t e d towards t h e c a r b u r e t t o r s .
SECTION EMC Page 7
EMC.4. - COLD ENRICHMENT THERMAL VALVE
The c o l d e n r i c h m e n t t h e r m a l v a l v e i s d e s i g n e d t o e n r i c h f u e l l i n g
a t l o w e n g i n e t e m p e r a t u r e s t o improve d r i v e a b i l i t y .
The v a l v e i s f i t t e d i n t o t h e r e a r o f t h e i n l e t m a n i f o l d w a t e r
rail. P o r t ID' i s c o n n e c t e d w i t h p o r t ' 1 ' a t c o o l a n t t e m p e r a t u r e s
below 53OC and w i t h p o r t ' 2 ' a b o v e 5 3 ' .
The s m a l l b o r e c r a n k c a s e b r e a t h e r p i p e b e t w e e n b r e a t h e r v a l v e
and c a r b u r e t t o r s i s c o n n e c t e d t o t h e t h e r m a l v a l v e v i a p o r t s
'Dl a n d ' 2 ' , w i t h p o r t ' 1 ' b e i n g b l a n k e d o f f . Thus a t low e n g i n e
t e m p e r a t u r e , t h e b r e a t h e r c i r c u i t t o t h e c a r b s i s s h u t o f f , and
e n r i c h e d f u e l l i n g r e s u l t s from t h e d e c r e a s e i n c a l i b r a t e d a i r f l o w
past the throttle plates. A t higher temperatures t h e breather
a l i n e i s r e s t o r e d and f u e l l i n g r e t u r n s t o n o r m a l .
EMC.5. - PLENUM PURGE
The p u r g e pump i s d e s i g n e d t o i n d u c e a m b i e n t a i r i n t o t h e
c a r b u r e t t o r plenum chamber o f a h o t e n g i n e when s w i t c h e d o f f .
T h i s improves h o t s t a r t i n g of t h e e n g i n e .
The pump i s f i t t e d on t h e t a i l g a t e a p e r t u r e R . H . s u p p o r t b r a c k e t ,
b e h i n d t h e q u a r t e r window t r i m p a n e l i n t h e r e a r l u g g a g e
compartment, and i s o p e r a t i v e o n l y when t h e . i g n i t i o n i s s w i t c h e d
o
- ff. A thermal switch i n t h e thermostat o u t l e t p i p e ( a l s o used
f o r t h e i g n i t i o n s o l e n o i d v a l v e ) e n e r g i s e s t h e p u r g e pump
a t w a t e r t e m p e r a t u r e s above 70°C ( o n r i s e ) u n t i l c o o l a n t
t e m p e r a t u r e f a l l s t o 60°C.
A S o l e n o i d v a l v e mounted j u s t below t h e p u r g e pump, i s e n e r g i s e d

' w i t h t h e i g n i t i o n o n , t o s h u t o f f t h e purge l i n e , and p r e v e n t
b o o s t p r e s s u r e b l o w i n g o f f t h r o u g h t h e pump.
EMC.6. - THROTTLE J A C K SOLENOID
The t h r o t t l e j a c k s o l e n o i d i s d e s i g n e d t o
i) p r e v e n t c o m p l e t e t h r o t t l e c l o s u r e on o v e r u n t o r e d u c e
e m i s s i o n s and i n h i b i t s t a l l i n g .
ii) i n c r e a s e i d l e s p e e d when t h e c h o k e c o n t r o l i s o p e r a t e d
i i i ) m a i n t a i n i d l e s p e e d when t h e a i r c o n d i t i o n i n g ( i f f i t t e d )
is o p e r a t i n g
The s o l e n o i d i s f i t t e d t o t h e f r o n t o f t h e f r o n t c a r b u r e t t o r
and o p e r a t e s a l e v e r a t t a c h e d t o t h e f r o n t end o f t h e t h r o t t l e
spindle.
,a
Page 8 SECTION EMC
The s o l e n o i d i s e n e r g i s e d u n d e r any o f t h e f o l l o w i n g c o n d i t i o n s :
a) Above e n g i n e s p e e d o f 1400 rpm o n f a l l ( 1 6 0 0 rpm on r i s e )

a s s e n s e d by t h e e n g i n e s p e e d s e n s i n g r e l a y , t o p r e v e n t
complete t h r o t t l e c l o s u r e on overun t o reduce hydrocarbon.
e m i s s i o n s and i n h i b i t s t a l l i n g . The r e l a y i s mounted o n
t h e w h e e l a r c h a l o n g s i d e t h e R . H . r e a r o f t h e e n g i n e bay.
b) When t h e choke c o n t r o l i s o p e r a t e d , t o i n c r e a s e i d l e s p e e d .
The choke m i c r o - s w i t c h i s i n t e g r a l w i t h t h e choke c a b l e
a s s e m b l y a t t h e f a s c i a e n d , and i s a l s o u s e d t o o p e r a t e t h e
choke t e l l t a l e . T h i s s w i t c h o p e r a t e s a t h r o t t l e j a c k
r e l a y l o c a t e d a d j a c e n t t o t h e engine speed sensing r e l a y .
c.) When t h e a i r o c n d i t i o n i n g ( i f f i t t e d ) c o m p r e s s o r i s
o p e r a t i n g , i n o r d e r t o maintain i d l e speed.
To s e t up: With t h e e n g i n e a t normal r u n n i n g t e m p e r a t u r e , w i t h o u t

t h e a i r conditioning switched on, check/adjust i d l e speed a t
t h e normal s t o p screw o n t h e f r o n t o f t h e r e a r c a r b u r e t t o r .
C o r r e c t s e t t i n g 850-950 rpm.
E n e r g i s e t h e s o l e n o i d w i t h 1 2 v o l t s and a d j u s t t h e l e v e r screw
( a g a i n s t which t h e s o l e n o i d b u t t o n o p e r a t e s ) t o o b t a i n a n
e n g i n e s p e e d o f 1200 rpm and t h e n d e - e n e r g i s e .
T e s t e a c h o f t h e t h r e e a c t i v a t i n g s y s t e m s and o b s e r v e t h e a c t i o n
of t h e solenoid.
EMC.7. - OVERBOOST SWITCH
The o v e r b o o s t s w i t c h i s f i t t e d t o s a f e g u a r d t h e e n g i n e a g a i n s t
e x c e s s i v e boost p r e s s u r e i n t h e e v e n t of wastegate f a i l u r e
by c u t t i n g o u t t h e i g n i t i o n .
The s w i t c h i s mounted o n t h e r i g h t hand f u e l t a n k b o a r d and

i s connected t o t h e crankcase b r e a t h e r bleed/cold enrichment
s y s t e m i n o r d e r t o m o n i t o r t h e b o o s t p r e s s u r e s i g n a l downstream
of t h e t h r o t t l e b u t t e r f l i e s . I f a p r e s s u r e g r e a t e r t h e n 0.71 b a r
(10.5 l b / i n 2 ) i s s e n s e d , t h e s w i t c h c u t s o u t t h e f e e d t o t h e
i g n i t i o n coil.
EMC.8. IDLE SPEED & I G N I T I O N T I M I N G SETTING PROCEDURE
i I g n i t i o n Timing I n i t i a l S e t t i n g :
I f t h e e n g i n e h a s been r e b u i l t , o r t h e d i s t r i b u t o r
replaced, an i n i t i a l s e t t i n g of t h e i g n i t i o n timing
must b e made t o e n a b l e t h e e n g i n e t o r u n . S e t t h e
c r a n k s h a f t t o 10' BTDC u s i n g t h e t i m i n g marks o n t h e
f l y w h e e l and c l u t c h h o u s i n g w i t h t h e r o t o r arm p o i n t i n g
t o w a r d s no.1 t e r m i n a l on t h e d i s t r i b u t o r c a p . P u l l
o f f t h e r o t o r arm a n d p l a s t i c s h i e l d and t u r n t h e
d i s t r i b u t o r body t o a l i g n t h e p i c k up s e n s o r w i t h
t h e a d j a c e n t p r o j e c t i o n on t h e r e l u c t o r (equivalent
t o t h e cam o n a c o n t a c t b r e a k e r s y s t e m ) . The e n g i n e
may now b e s t a r t e d and r u n up t o normal o p e r a t i n g
temperature.
SECTION EMC Page 9
Connected to
Initial Ignition Timing Setting port 'D' of T.1 .V.
.:
Connected n /
Position of rotor
arm cut-out i n
distributor shaft
ii) Check/Adjust I g n i t i o n Timing:
S t a r t t h e e n g i n e and r u n up t o normal o p e r a t i n g
temperature t o ensure t h e T.I.V. switches t h e d i s t r i b u t o r
c a p s u l e t o t h e t h r o t t l e edge p o r t .
Using a s t r o b o s c o p e , c h e c k / a d j u s t t h e i g n i t i o n t i m i n g t o
l o 0 BTDC a t h o t i d l e . T i m i n g m a r k s a r e p r o v i d e d on t h e
f l y w h e e l r i m , w i t h a n a p e r t u r e a n d p o i n t e r i n t h e t o p of
t h e c l u t c h housing, a d j a c e n t t o t h e s t a r t e r motor. Pull
o u t t h e p r o t e c t i v e grommet, a n d r e f i t a f t e r a d j u s t m e n t .
' Page 10 SECT/ON EMC
To c h e c k t h e c e n t r i f u g a l a d v a n c e o p e r a t i o n , f i r s t
d i s c o n n e c t a n d p l u g , o r c l a m p o f f t h e vacuum h o s e f r o m
t h e d i s t r i b u t o r capsule.
Check c e n t r i f u g a l a d v a n c e c h a r a c t e r i s t i c s a r e a s f o l l o w s :
c r a n k rpm crank O (+2O)
Below 1 , 0 0 0 nil
2,000 11°
5,000 8"
iii) Check/Adjust I d l e Speed:
S t a r t e n g i n e and r u n up t o normal o p e r a t i n g t e m p e r a t u r e .
Check t h a t t h e a i r c o n d i t i o n i n g ( i f f i t t e d ) i s s w i t c h e d
off.
A d j u s t i d l e s p e e d , a t t h e s t o p screw, o n t h e f r o n t
o f t h e rear c a r b u r e t t o r , t o 900 +
50 rpm.
U s e t h e c a b l e a d j u s t e r a t t h e anchor b r a c k e t on t h e
c a m c o v e r t o remove t h r o t t l e c a b l e s l a c k , a n d t h e n
w i t h t h e a i d o f a n a s s i s t a n t check t h a t f u l l t h r o t t l e
can be achieved. The t h r o t t l e p e d a l d o w n s t o p s h o u l d
be a d j u s t e d such t h a t t h e c a r b u r e t t o r t h r o t t l e l e v e r s
may b e h e l d a g a i n s t t h e i r f u l l t h r o t t l e s t o p s w i t h o u t
allowing t h e cable to be overstrained,
To a d j u s t t h r o t t l e j a c k s o l e n o i d , s e e EMC.6.
SECTION EMD Page 7
E N G I N E MANAGEMENT
S.ECTION EMD - ESPRIT S3 'HC' 1987 MODEL YEAR (Domestic & E x p o r t )
Operation Page
Vacuum C o n n e c t i o n Diagram EMD . 1

T h e r m a l I g n i t i o n Advance EMD . 2
C r a n k c a s e B r e a t h e r Valve EMD . 3
Cold E n r i c h m e n t Thermal Valve EMD . 4
Plenum P u r g e EMD . 5
T h r o t t l e Jack Solenoid EMD .6
A i r I n l e t T e m p e r a t u r e C o n t r o l System EMD . 7
I d l e Speed & I g n i t i o n Timing
S e t t i n g Procedure EMD .8
- ENGINE MANAGEMENT VACUUM CONNECTION DIAGRAM
qb
CRANKCASE BREATER VALVE @
ox."-
EMD.1.
THERMAL
IGNITION @
THERMAL SWITCH OPERATION
ru
$.
TO CRANKCASE
VALVE
COLD
ENRICHMENT DISTRIBUTOR
THERMAL
VALVE @
I 0
VACUUM /PRESSURE PIPE

-- - ELECTRICAL CONNECTION
I [ARB. 1 I [ARB. 1
TO A T
COMPRESSOR
JACK
SOLENOID
WARM AIR INTAKE

FROM EXHAUST
- THERMAL SWITCH 1
SttROUD AIR TEMPERATURE

ENGINE
CONTROL VALVE SPEED
I
COOL AIR INTAKE
FROM LUGGAGE COMPARTMT.
C/,
h
0
1. Thermal I g n i t i o n Valve: Fitted t o centre 6. A i r Temperature C o n t r o l (ATC) S e n s o r :
of i n l e t manifold w a t e r r a i l . Below 60°C. -
- - R e g u l a t e s vacuum s u p p l y t o ATC v a l v e d e p e n d e n t ?
d i r e c t s i n l e t manifold p r e s s u r e s i g n a l t o on a i r b o x t e m p e r a t u r e . See EMD.7.
d i s t r i b u t o r f o r f u l l advance t o a i d c o l d
rn
i d l e and d r i v e a b i l i t y .
See EMD.2. 7. Purge Pump: F i t t e d t o t a i l g a t e a p e r t u r e R . H . b
s t i f f e n e r bracket. C o n t r o l l e d by t h e r m a l
s w i t c h ( i t e m 4 ) O p e r a t e s a t w a t e r temps
2. T h r o t t l e J a c k S o l e n o i d : F i t t e d t o f r o n t of above 70°C w i t h i g n i t i o n o f f , t o a i d h o t
::front c a r b u r e t t o r . C o n t r o l l e d bv m e e d
1 L
re-start. See EMD.5.
: s e n s i n g r e l a y ( i t e m 3 ) , choke s w i t c h and
a . c . switch. E n e r g i s e d above 1 4 0 0 rpm t o
r e d u c e e m i s s i o n s on overun and when choke/ 8. Cold Enrichment Thermal Valve: F i t t e d
a.c. operated t o r a i s e / m a i n t a i n i d l e speed. i n t o r e a r of i n l e t m a n i f o l d w a t e r r a i l .
S e e EMD.6. A t w a t e r temps. below 35"C, v a l v e s h u t s
off crankcase breather bleed t o e n r i c h
fuelling. See EMD.4.
3. Engine Speed S e n s i n g Relay: Fitted inside
R.H. whee.larch i n r e a r luggage compartment
E n e r g i s e s t h r o t t l e j a c k above 1 600- rpm 9. Crankcase B r e a t h e r Valve: F i t t e d a t
' ( o n 'r:ise) and d e - e n e r g i s e s below 1 4 0 0 rpm t o p r e a r of c r a n k c a s e . Vents c r a n k c a s e
'.,(on f a l l ) t o r e d u c e e m i s s i o n s on overun fumes t o a i r b o x w i t h b l e e d t o c a r b s .
.'( see EMD ;6 ..I. See EMD. 3 .
4. Thermal Switch: F i t t e d i n thermostat o u t l e t

w a t e r pipe. M.O.R. 70°C B.O.F. 60°C.
S w i t c h e s a i r b o x p u r g e pump. See EMD.5.
5. A i r Temperature C o n t r o l (ATC) Valve:

S w i t c h e s a i r i n t a k e t o w a r m a i r s u-..
p ~ l vfrom
A
e x h a u s t downpipe s h r o u d a t low a i r b o x temps.

f o r improved c o l d r u n n i n g . See EMD.7.
Page 4
BMD.2. - THERMAL I G N I T I O N ADVANCE
The t h e r m a l i g n i t i o n a d v a n c e s y s t e m i s d e s i g n e d t o a i d
d r i v e a b i l i t y a n d i d l e s p e e d when c o l d and l i g h t l o a d
economy when w a r m .
The d i s t r i b u t o r i s f i t t e d w i t h a vacuum a d v a n c e c a p s u l e
c o n n e c t e d v i a t h e Thermal I g n i t i o n Valve ( T . I . V . ) t o
e i t h e r o n e o f two p r e s s u r e s e n s i n g p o r t s on t h e c a r b u r e t t o r s .
The T . I . V . i s f i t t e d i n t o t h e c e n t r e of t h e i n l e t m a n i f o l d '
water r a i l and s e n s e s engine c o o l a n t temperature..
A t c o o l a n t t e m p e r a t u r e s below 60°C, t h e T . I . V . connects

p o r t I D ' (connected t o d i s t r i b u t o r ) t o p o r t ' 1 ' (connected
t o c a r b u r e t t o r p o r t s downstream o f t h r o t t l e p l a t e s ) t o
d i r e c t an i n l e t manifold depression s i g n a l to t h e d i s t r i b u t o r
capsule. T h i s p'rovides o v e r 30" i g n i t i o n advance a t c o l d
i d l e t o r a i s e i d l e s p e e d a n d improve d r i v e a b i l i t y .
A t c o o l a n t t e m p e r a t u r e s a b o v e 60°C t h e T . I . V . connects p o r t
'Dm w i t h p o r t ' 2 ' ( c o n n e c t e d t o t h r o t t l e e d g e d r i l l i n g on
c a r b u r e t t o r b a r r e l no. 1 ) t o p r o v i d e i g n i t i o n a d v a n c e a t
p a r t t h r o t t l e f o r improved l i g h t l o a d economy.
EMD.3. - CRANKCASE BREATHER VALVE
A o n e way b r e a t h e r v a l v e i s c o n n e c t e d between t h e c r a n k c a s e
b r e a t h e r s p i g o t a t t h e rear o f t h e b l o c k , and t h e a i r b o x .
C r a n k c a s e e m i s s i o n s d e v e l o p e d d u r i n g normal r u n n i n g a r e able
t o v e n t t h r o u g h t h e o n e way v a l v e i n t o t h e a i r b o x .
I n o r d e r t o p r e v e n t t h e s e f u m e s , u n d e r low a i r f l o w e n g i n e i d l e
c o n d i t i o n s , escaping through t h e i n l e t t r u n k i n g t o atmosphere,
t h e valve is a l s o connected v i a a small bore hose t o t h e
carburettors. This enables t h e small quantity of crankcase
fumes a t i d l e t o p a s s d i r e c t l y i n t o t h e c a r b u r e t t o r s and i n t a k e
t r a c t and s u p r e s s e s o p e n i n g o f t h e b r e a t h e r v a l v e .
The c a r b u r a t i o n i s c a l i b r a t e d t o c o m p e n s a t e f o r t h i s d e g r e e
of a i r f l o w by-passing t h e v e n t u r i s . . .
The c o l d e n r i c h m e n t t h e r m a l v a l v e i s d e s i g n e d t o e n r i c h f u e l l i n g
a t l o w e n g i n e t e m p e r a t u r e s t o improve d r i v e a b i l i t y .
The v a l v e (brown) i s f i t t e d i n t o t h e r e a r o f t h e i n l e t m a n i f o l d
water r a i l . P o r t ' D l i s 'connected with p o r t , ' 1 ' a t coolant
t e m p e r a t u r e s below 35OC : a n d w i t h p o r t ' 2 ' a b o v e 35°C.
, .
The s m a l l b o r e c r a n k c a s e b r e a t h e r p i p e between b r e a t h e r
v a l v e and c a r b u r e t t o r s i s c o n n e c t e d t o t h e t h e r m a l valve v i a
p o r t s ' D l a n d ' 2 ' , w i t h p o r t ' 1 ' b e i n g b l a n k e d o f f . Thus a t
l o w engine temperature, t h e breather c i r c u i t t o t h e carbs is
SECTION EMD Page 5
s h u t o f f , and e n r i c h e d f u e l l i n g r e s u l t s from t h e d e c r e a s e i n
calibrated airflow past the throttle plates. A t higher
temperatures t h e b r e a t h e r l i n e i s r e s t o r e d and f u e l l i n g r e t u r n s
t o normal.
EMD. 5. - PLENUM PURGE
The p u r g e pump i s d e s i g n e d t o i n d u c e a m b i e n t a i r i n t o t h e
c a r b u r e t t o r plenum c h a m b e r o f a h o t e n g i n e when s w i t c h e d o f f .
T h i s improves h o t s t a r t i n g o f t h e e n g i n e .
The pump i s f i t t e d o n t h e t a i l g a t e a p e r t u r e R . H . s u p p o r t
b r a c k e t b e h i n d t h e q u a r t e r window t r i m p a n e l i n t h e r e a r l u g g a g e
c o m p a r t m e n t , a n d i s o p e r a t i v e o n l y when t h e i g n i t i o n i s s w i t c h e d
off.
- A thermal switch i n t h e thermostat o u t l e t pipe energises
t h e p u r g e pump a t w a t e r t e m p e r a t u r e s a b o v e 70°C ( o n r i s e )
u n t i l c o o l a n t t e m p e r a t u r e f a l l s t o 60°C.
EMD.6. - THROTTLE J A C K SOLENOID
The t h r a t t l e j a c k s o l e n o i d i s d e s i g n e d t o
i) p r e v e n t c o m p l e t e t h r o t t l e c l o s u r e on o v e r u n t o r e d u c e
e m i s s i o n s and i n h i b i t s t a l l i n g .
ii) i n c r e a s e i d l e s p e e d when t h e c h o k e c o n t r c l i s o p e r a t e d
iii) m a i n t a i n i d l e s p e e d when t h e a i r c o n d i t i o n i n g ( i f f i t t e d )
i s operating.
The s o l e n o i d i s f i t t e d t o t h e f r o n t o f t h e f r o n t c a r b u r e t t o r
and o p e r a t e s a l e v e r a t t a c h e d t o t h e f r o n t e n d of t h e t h r o t t l e
spindle.
Carburettor
Adjuster
Screw
I
Throttle Jack Lever

Page 6 SECTION EMD
The s o l e n o i d i s e n e r g i s e d under any of t h e f o l l o w i n g c o n d i t i o n s :
a1 Above e n g i n e speed of 1600 rpm on r i s e ( 1 4 0 0 rpm on f a l l )

a s s e n s e d by t h e e n g i n e s p e e d s e n s i n g r e l a y , t o p r e v e n t
c o m p l e t e t h r o t t l e c l o s u r e on overun t o r e d u c e hydrocarbon
e m i s s i o n s and ' i n h i b i t s t a l l i n g . The r e l a y i s mounted on
t h e w h e e l a r c h a l o n g s i d e t h e R.H. r e a r of t h e e n g i n e bay.
b1 When t h e choke c o n t r o l i s o p e r a t e d , t o i n c r e a s e i d l e s p e e d .
The choke micro-switch i s i n t e g r a l w i t h t h e choke c a b l e
assembly a t t h e f a s c i a e n d , and i s a l s o u s e d t o o p e r a t e t h e
choke t e l l t a l e . T h i s s w i t c h o p e r a t e s a t h r o t t l e jack r e l a y
l o c a t e d a d j a c e n t t o t h e engine speed s e n s i n g r e l a y .
c When a i r c o n d i t i o n i n g ( i f f i t t e d ) compressor i s o p e r a t i n g
i n o r d e r t o maintain i d l e speed.
To set up: With t h e e n g i n e a t normal r u n n i n g t e m p e r a t u r e , w i t h o u t

t h e a i r c o n d i t i o n i n g switched on, check/adjust i d l e speed a t
t h e normal s t o p screw on t h e f r o n t of t h e r e a r c a r b u r e t t o r .
C o r r e c t s e t t i n g 9 5 0 c 5 0 rpm.
E n e r g i s e t h e s o l e n o i d w i t h 1 2 v o l t s and a d j u s t t h e l e v e r screw
( a g a i n s t which t h e s o l e n o i d b u t t o n o p e r a t e s ) t o o b t a i n an e n g i n e
speed of 1100 rpm and t h e n d e - e n e r g i s e .
T e s t e a c h of t h e t h r e e a c t i v a t i n g s y s t e m s and o b s e r v e t h e a c t i o n
of t h e s o l e n o i d .
EMD.7. - A I R INLET TEMPERATURE CONTROL SYSTEM
The ~ i I rn l e t Temperature C o n t r o l ( A T C ) system c o m p r i s e s an

ATC f l a p v a l v e u n i t on t h e a i r b o x i n l e t and a n ATC s e n s o r f i t t e d
i n t o t h e bottom of t h e a i r b o x .
Vacuum
Proportioning
To Carburet.tor Ports Valve
Vacuum
L. I
Air ~ i h e r
Element
Shroud
SECTION EMD ,., , . Page
,. , . .. 7
Intake Hose/
Sidewall . Interface
El- Engine Bay W a l l
ATC Divertor
Grommet Securi ng R i ng
The'ATC f l a p v a l v e u n i t c o n s i s t s o f a vacuum d i a p h r a g m o p e r a t e d
f l a p mounted on t h e i n l e t o f t h e c a r b u r e t t o r a i r b o x , c o n t r o l l i n g
t h e a i r supply t h e r e t o . A t moderate ambient t e m p e r a t u r e s t h e
a i r b o x i s s u p p l i e d w i t h c o o l a i r from t h e r e a r l u g g a g e compartment
via .the intake silencer. I n c o l d a m b i e n t c o n d i t i o n s , when
a i r t e m p e r a t u r e i n s i d e t h e c a r b u r e t t o r a i r b o x i s below 2 0 ° C ,
t h e ATC f l a p v a l v e i s moved t o a d m i t a p r o p o r t i o n o f warm a i , r
drawn from a s h r o u d a r o u n d t h e e x h a u s t downpipe. The c o l d e r
t h e a i r b o x t e m p e r a t u r e , t h e g r e a t e r t h e p r o p o r t i o n o f warm air
directed t o the airbox.
The ATC s e n s o r mounted by a r u b b e r grommet i n t o t h e b o t t o m o f t h e

a i r b o x i s a t h e r m o s t a t i c a l l y c o n t r o l l e d vacuum p r o p o r t i o n v a l v e
c o n n e c t e d between t h e c a r b u r e t t o r p o r t s downstream o f t h e
t h r o t t l e p l a t e s , a n d t h e ATC f l a p v a l v e . A t a i r b o x t e m p e r a t u r e s
above 2 0 ° C t h e v a l v e i s s h u t , b u t a t lower t e m p e r a t u r e s a
p r o p o r t i o n of t h e i n l e t m a n i f o l d d e p r e s s i o n i s d i r e c t e d t o t h e
ATC f l a p v a l v e t o open t h e warm a i r s u p p l y . The s e n s o r c o n n e c t i o n
w i t h t h e l a r g e r h o l e must b e c o n n e c t e d t o t h e f l a p v a l v e .
Connect to carb. ports
Connect to flap valve

Page 8
To c h e c k t h a t t h e s y s t e m i s f u n c t i o n i n g c o r r e c t l y , d i s c o n n e c t
t h e c o l d a i r s u p p l y t r u n k i n g from t h e f l a p v a l v e a n d u s e a
mirror t o e s t a b l i s h t h e f l a p p o s i t i o n a t w a r m a n d c o l d a m b i e n t
c o n d i t i o n s . The f l a p v a l v e i t s e l f may be t e s t e d by a p p l y i n g
vacuum d i r e c t l y t o i t s vacuum c a p s u l e :
more t h a n 100 mrn Hg - warm a i r s u p p l y f u l l y open

less t h a n 30 mm Hg - warm a i r s u p p l y f u l l y c l o s e d .
EMD.8. - IDLE SPEED & IGNITION T I M I N G SETTING PROCEDURE
i) I g n i t i o n Timing I n i t i a l S e t t i n g :
I f t h e e n g i n e h a s been r e b u i l t , o r t h e d i s t r i b u t o r
replaced, an i n i t i a l s e t t i n g of t h e i g n i t i o n timing
m u s t b e made t o e n a b l e t h e e n g i n e t o r u n . Set the
c r a n k s h a f t t o 1 0 " BTDC u s i n g t h e t i m i n g marks a n d p o i n t e r
o n t h e f l y w h e e l a n d c l u t c h h o u s i n g w i t h t h e r o t o r arm
p o i n t i n g t o w a r d s n o . 1 t e r m i n a l on t h e d i s t r i b u t o r c a p .
P u l l o f f t h e r o t o r arm and p l a s t i c s h i e l d a n d t u r n t h e
d i s t r i b u t o r body t o a l i g n t h e p i c k up s e n s o r w i t h t h e
a d j a c e n t p r o j e c t i o n on t h e r e l u c t o r ( e q u i v a l e n t t o
distributor shaft
t h e c a m on a c o n t a c t b r e a k e r s y s t e m ) . The e n g i n e may
now b e s t a r t e d a n d r u n up t o normal o p e r a t i n g t e m p e r a t u r e
b e f o r e a d j u s t i n g i g n i t i o n t i m i n g a s i n ii)
ii) ~ h e c k / A d j u s t I g n i t i o n Timing:
S t a r t t h e e n g i n e a n d r u n up t o normal o p e r a t i n g
t e m p e r a t u r e t o e n s u r e t h e T.I.V. switches t h e d i s t r i b u t o r
c a p s u l e t o t h e t h r o t t l e edge p o r t .
SECTION EMD
Using a s t r o b o s c o p e , c h e c k / a d j u s t t h e i g n i t i o n t i m i n g
t o 1 0 " BTDC a t h o t i d l e . Timing marks a r e p r o v i d e d on
t h e flywheel r i m , w i t h an a p e r t u r e and p o i n t e r i n t h e
t o p o f t h e c l u t c h h o u s i n g , a d j u a c e n t t o t h e s t a r t e r motor.
P u l l o u t t h e p r o t e c t i v e grommet, and r e f i t a f t e r a d j u s t m e n t .
Clutch Hous Aperture
To c h e c k t h e c e n t r i f u g a l a d v a n c e o p e r a t i o n , f i r s t d i s c o n n e c t
and p l u g , o r clamp o f f t h e vacuum h o s e between d i s t r i b u t o r
c a p s u l e and T.I.V.
Check c e n t r i f u g a l a d v a n c e c h a r a c t e r i s t i c s a r e a s f o l l o w s :
crank rDm crank " (+2")

Below 1 , 0 0 0 nil
2,000 8"
16" (max)
iii) Check/Ad j u s t I d l e Speed
S t a r t e n g i n e and r u n up t o normal o p e r a t i n g t e m p e r a t u r e s .
Check t h a t t h e a i r c o n d i t i o n i n g ( i f f i t t e d ) i s s w i t c h e d
off.
A d j u s t i d l e s p e e d , a t t h e s t o p screw, on t h e f r o n t o f t h e
r e a r c a r b u r e t t o r , t o 950 +
5 0 rpm. S t o p e n g i n e .
Page l o
U s e t h e c a b l e a d j u s t e r a t t h e a n c h o r b r a c k e t on t h e cam
c o v e r t o remove t h r o t t l e c a b l e s l a c k , and t h e n w i t h t h e
a i d o f a n a s s i s t a n t c h e c k t h a t f u l l t h r o t t l e c a n be
achieved. The t h r o t t l e p e d a l downstop s h o u l d b e a d j u s t e d
s u c h t h a t t h e c a r b u r e t t o r t h r o t t l e l e v e r s may b e h e l d a g a i n s t
t h e i r f u l l t h r o t t l e s t o p s without allowing t h e cable
t o be overstrained.
To a d j u s t t h r o t t l e j a c k s o l e n o i d , see EMD.6.
Page 1 :
SECTION FB - ESPRIT
Opera
- - tion Page
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 Bearings Adjustment
Backlash Adiustrnent
Gearbox & Clutch Housing.Assembly Level Plug
Pointer, Engine Tinuing Washer, Level Plug
Switch, Reverse Light Stop, Speedo Pinion
Speedo Driven Gear Bracket, Gearbx/Caliper Mounting RH
Nylon Bush, Speedo Driven Gear B o l t , Bracket t o C ~ a r b o x
Right Angle Drive, Speedo B o l t , Bracket to Gearbox
Air Vent, Breather Washer, Flat, Bracket t o Gearbox
End Housing Washer, Spring, Bracket t o Gearbox
Mounting, .Ehgine/Gearbox rear
Stud, Silencer/Gearbox Mounting Bracket Washer, Snubber
Bolt, Silencer Mounting Bracket Washer, Flat
Drain Plug N u t , Nyloc 7/16" UNF
Washer, Drain Plug

Page 3 A SECTION FB
The t r a n s m i s s i o n is a s i n g l e u n i t Comprising a manual 5-speed, a l l i n d i r e c t

g e a r b o x w i t h i n t e g r a l f i n a l d r i v e u n i t , , and t h e ' c l u t c h , b e l l h o u s i n g c o n t a i n i n g
t h e c l u t c h release mechanism.
The g e a r b o x h a s f i v e f o r w a r d g e a r s , a l l equipped w i t h syncromesh, and a

r e v e r s e gear of t h e spur gear type.
A c l u t c h s h a f t t r a n s m i t s t h e d r i v e from t h e c l u t c h t o t h e , g e a r b o x p r i m a r y
s h a f t , which i s s u p p o r t e d by a b a l l b e a r i n g a t i t s f r o n t and a d o u b l e b a l l
bearing at t h e rear. The primary s h a f t c a r r i e s t h e 3 r d / 4 t h s y n c r o n i s e r a s s e m b l y ,
and o n i t s overhung r e a r e n d , t h e 5 t h g e a r s y n c r o n i s e r assembly. The l o w e r ,
s e c o n d a p y , s h a f t i n c o r p o r a t e s t h e f i n a l d r i v e p i n i o n g e a r on i t s f r o n t e n d , i s
s u p p o r t e d by a r o l l e r b e a r i n g a t t h e f r o n t , and a d o u b l e b a l l b e a r i n g a t t h e
r e a r , and c a r r i e s t h e l s t / 2 n d s y n c r o n i s e r assembly. A r e v e r s e i d l e r g e a r on
a s e p e r a t e s p i n d l e may b e engaged w i t h s p u r g e a r s i n t e g r a l w i t h t h e p r i m a r y
s h a f t and w i t h t h e l s t / 2 n d s y n c r o n i s e r assembly.
The f i n a l d r i v e assembly i s c o n t a i n e d between . t h e a i u t c h h o u s i n g and g e a r b o x .

Two s h o r t o u t p u t s h a f t s s u p p o r t e d by t h e i r own h o u q i h g s , b o l t e d t o e a c h s i d e of
t h e t r a n s m i s s i o n , u s e a d o u b l e b a l l b e a r i n g on t h e i r b u t b o a r d e n d s , and a t a p e r
r o l l e r b e a r i n g a t t h e i n b o a r d e n d s , where t h e y c a r r y t h e crownwheel and
d i f f e r e n t i a l assembly.
Four s e l e c t o r s h a f t s a c r o s s t h e t d p o f t h e gearbox, c ? n t r o l l s t / Z n d , 3rd/4th

5 t h and r e v e r s e g e a r s and a r e o p e r a t e d by a c r o s s s h a f t which may be r o t a t e d and
moved a x i a l l y by t h e remote g e a r l e v e r .
'C35' I n t r o d u c t i o n
I n e a r l y 1 9 8 4 , t h e 'C35' t y p e gearbox assembly was i n t r o d u c e d . T h i s d i f f e r s o n l y

i n d e t a i l from t h e e a r l i e r t y p e , w i t h most i n t e r n a l components b e i n g unchanged
o r improved and d i r e c t l y i n t e r c h a n g e a b l e w i t h t h e e a r l i e r p a r t . See p a r t s l i s t
for details.
-
A l l E s p r i t g e a r b o x e s a r e stamped w i t h a L o t u s s e r i a l number, r e p e a t e d on i t s
matched c l u t c h h o u s i n g . A l l g e a r b o x e s stamped w i t h a 'C' p r e f i x t o t h e
s e r i a l number a r e t y p e C35.
Gearboxes w i t h t h e f o l l o w i n g s e r i a l numbers ( w i t h o u t 'C' p r e f i x ) are a l s o t y p e
2914 to 2920
2954 to 2974
3023 and 3024
3028 to 3029
3044 to 3152
A l l numbers a r e i n c l u s i v e and are t o b e found o n t h e t o p f r o n t o f t h e g e a r b o x

and ' a d j a c e n t s u r f ace o f t h e c l u t c h h o u s i n g .
SECTION FB Page 3 B
D r a i n and L e v e l P l u g
C 3 5 t y p e g e a r b o x e s have o n l y o n e o i l d r a i n p l u g which i s s i t u a t e d b e n e a t h , t h e
main c a s e . They a r e n o t f i t t e d w i t h t h e a d d i t i o n a l r e a r c a s e d r a i n p l u g a s
u s e d on p r e v i o u s t y p e g e a r b o x e s .
The o i l l e v e l p l u g ( p a i n t e d y e l l o w ) i s f i t t e d i n t h e l e f t hand s i d e o f t h e c a s e ,
a s b e f o r e , and s h o u l d n o t b e c o n f u s e d w i t h a s i m i l a r p l u g ( b l a n k i n g ) p o s i t i o n e d
h i g h e r up o n t h e same s i d e o f t h e g e a r b o x .
The d i f f e r e n t r e a r c o v e r s h a p e n e c e s s i t a t e s a r e v i s e d s i l e n c e r mounting b r a c k e t
and t h e c l u t c h r e l e a s e b e a r i n g assembly on S e r i e s 3 c a r s i s changed. See
Parts List for details.
PREVIOUS TYPE NEW ' C35 ' TYPE
..--)
j .!,)
-+\. : /------- Gearbox Number Locatio
(Do n o t remove)
I f
Oil Level Plug
I
Revised Rear Cover Shape
FB.1. - GEARSHIFT LEVER AND GEAR CHANGE LINKAGE

The gearshift lever operation controls two functions on the gearbox cross-shaft;
movement of the lever forward and backward rimves the cross-shaftmdi~llyand
movement from side-to-side moves the cross-shaft across the gearbox.
When the cross-shaft is i n an out o f gear position the gearshift lever w i l l take up
0 a neutral centre position i n the gate, held there by springs on the gearbox cross-shaft.
Page 4 SECTION FB
The tubular linkage transmits fore-aft movement of the gear 1ever into radial movement
of the gearbox cross shaft. Crossgate movement o f the gearlever i s 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 centre tunnel top assembly.
Unscrew the sixscrews securing the cover plate covering the recess i n the
chassis, which contains the gearshift assembly.
Remove the spirol pin connecting the bowden cable to the cross-gate lever
clevis on the gear shift lever assembly.
Unscrew the four bolts holding down thegearshift lever assembly to the
chassis .
a
Lift the assembly sufficiently to enable the front linkage tube to be disconnected
from the lever assembly .
Release the front tube from therelay lever, and withdraw tube from chassis.
Release rear tube from relay lever and cross shaft lever.
Remove the spring clip and clevis pin, securing the crossgate cable extension
to the crossgate bellcrank lever. Remove the nut and washer securing the
crossgate cable to the bell housing.
To the gear lever endof the cable, attach a ~ i r e ' ~ u 1
throughlto
l aidreassembly.
Remove the nut and washer securing the cable i n the gearshift lever recess, and
withdraw cab1e .
To Replace
Reverse the removal procedure, noting the following points:
1 . When fitting the crossgate cable at its front end into the chassis abutment, ensure
that the two cable nuts with shakeproof washers, are locked i n a position such
that the minimum amount ofouter cable protrudes forwards o f the front lock nut.
Otherwise, contact with the gearlever bellcmnk lever may b a dk selection o f
fifth and reverse gears.
2. O n can with a 0.86:l ratio relay lever, ensure that the longest a n of the lever
i s *positioneduppermost. Later cars have a 1:1 relay lever.
Key to Gearchange Linkage Drawing
Gear Lever Assembly. Be1lcrank Lever, Cross-shaft .

Reverse Gate . Pivot Pin, Bel lcrank .
Knob, Gearlever. Washer, Pivot Pin.
Spacer, Gearlever Knob. Nut, Nyloc, Pivot Pin.
Spirol Pin, Bellcrank to Yoke. Tube, Gearchange, Front.
Connector Yoke, Cable to Bellcrank. Tube, Gearchange, Rear.
Spirol Pin, Cable to Yoke. Adjuster, Gearchange Tube.

Crossgate Cable. Locknut, Gearchange Adjuster.
Was her, S hakeproof . Pivot Pin, Gearchange Tubes.
Abutment Bracket, Rear. Nut, Pivot Pin.
Dust Cover, Cable Rear. Bush, Rubber, Tube End.
Rod, Crossgate Cable Extension. Bearing, Plastic, Tube End.
Locknut, Cable Stiffener. Relay Lever.

Locknut, Plain. Washer, Relay Lever Pivot.
Clevis Pin, Rod to Bellcrank. Split Pin, Relay Lever Pivot.
Spring Clip, Clevis Pin.
SECTION FB Page 7
Adjustment
Tube Linkage Basic Setting:

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 a t the top. If necessary, disconnect the rear tube from the , . ,
relay lever, and adjust length to suit. Tighten the locknut after adjustment, but before
reconnecting to relay lever, check that full travel of the gear lever both fore and aft
provides movement at the relay lever exceeding that required by the rear tube for
c'omplete selection of gears.
Crossgate Cable Basic Setting:
0 The crossgate cable, outer casing should be fitted at its rear end into the clutch housing
abutment with the adiustment at its mid position. Tighten the locknuts.
With the transmission i n neutral and the cable connected, check the position of the gear
lever. The lever should be vertical orleaning very slightly to the right. If necessary,
disconnect the cable extension rod from the cross shaft bellcrank lever and after slackening
the locknut, screw the extension rod on or off the cable to achieve t h correct setting.
Tighten locknut.
Before finally connecting extension rod to the bzllcrank lever, check that full travel of
the gear lever side to side provides movement of the extension rod exceeding that required
by the bellcrank for full axial cross shaft movement.
0 NOTE: On cars up to 1983 fitted with a 240mm crossgatecable extension rod, a special
stiffening locknut (A082F4066F) may be fitted inplace of the plain nut to
increase stiffness o f the crossgate cable.
Later cars, and Federal cars have a shorter crossgate cable and 442 mm
extension rod.
Page 8 SECTION FB
FB.2. - TRANSMISSION ASSEMBLY

To Remove
Remove engine compartment rear floor and chassis crossmember..

Drain gearbox o i l .
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 complete with
rubber mountings.
Disconnect the gearbox linkage from the gearbox and clutch housing.
Remove the turbochai-geroil drain pipe and boost sensing pipe. (Turbo only).
Release the reverse light switch wires,
Disconnect the speedo drive cable.

Release the lower clutch housing to engine bolts,
Remove the air pump (Federal cars).

Release the Turbo air inlet hose and adaptor (Turbo only).
Release the clutch slave cylinder.

Remove the starter motor.
Support the engine and releasethe remaining clutch housing to engine bolts.
Carefully withdraw the gearbox assembly rearwards to disengage the clutch
shaft and lift out.
To Replace
Reverse the removal procedure, noting the following:

.
.
a). (NOT Dry Sump Turbo) - Check underside o f engine sump by clutch housing
fixings for shim marking. '000' - no shim, '020' - one 0.020" shim,
'040' - two 0.020" shims. These shims to be fitted between clutch
housing and sump.
b). Adjust gearchange linkage as i n FB .I .

c). Check/refill with gearbox o i l as necessary.
d) . Pump brake pedal to restore rear brake pad position.

Page 9
SECTION FB
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
b e l l housing.
4. Hold the differential i n position against tb,e bellhousing and pull away from
a the gearbox casting. Place the bell housing on the bench with the differential
uppermost and l i f t out the differential.
Dismantl ing
1. Slide off the fork arm the rubber dust excluder.
2. From inside the bellhousing remove the retaining spring and the thrust bearing
assembly.
3. Remove the p i n securing the fork to the bc'li joint and withdraw the fork.
1. Reverse the dismantling and removal procedures for the clutch bell housing.
Seal the mating faces with "Silastic" . Tighten a l l bolts tospecified torque.
FB.4. - CLUTCH SHAFT

To Remove
1 . Remove khe clutch bellhousing as previously described.
2. Remove the tube enclosing the clutch shaft together w i t h the two '0' rings.
The tube should pull out from the o i l return flange, but may come away
attached to the flange.
3. Remove the o i l return flange.
a
Page 70
4. Remove the circlip retaining the clutch shaft i n the primary shaft. Take care
not to lose the spring between the clutch shaft and primary shaft. If the
c i r c l i p i s very difficult to remove and further dismantling i s intended, then
remove clutch shaft complete with primary shaft. It w i l l be easier to remove

the c i r c l i p o n the bench.
To Replace
1 . Reverse the removal procedure for the clutch shaft and clutch bellhousing.
Note: When replacing the release bearing guide tube, that the chamfered end i s fitted
towards the clutch housing.
FB.5. - GEARBOX REAR HOUSING

To Remove
Remove the transmission unit as previously described.
Remove the rear and top cover o n the gearbox.
Remove the bolt securing the 5th gear synchro assembly together with the
deflector. To assist i n the removal of the bolt, slacken the screws securing
the reverse gear forkand engage two gears, e.g. 1st gear and reverse gear.
Remove the locking wire through the screw securing the 5th gear fork and
remove the screw.

Remove the 5th gear synchro assembly and the 5th gear fork.
Remove the speedometer driven gear and connection socket ..

Remove the eight screws securing the rear housing and withdraw the rear
housing.
1 . Reverse the removal procedure taking care to fix a lockingwire to the 5th
gear fork fixing screw. Tighten retaining bolt for the synchro assembly to
14.5-16.5 kgf.m (105-120 1bf.ft). Seal a l l mating faces with "Silastic".

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 . Withdraw the selector shaft, removing the fork, the operating dog and shaft
locking ball and spring.
5th Gear Selector
1, Slacken the screw securing the 5th gear operating dog (C), after removing
the locking wire.
Fig .5 Gear selectors

Page 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 inside the front end of the shaft.
1 s t and 2nd Gear Selector
1. Slacken the screws securing the fork (E).

2. Remove the shaft and the shaft locking ball and spring; the fork cannot be
removed at this stage.
Interlock plungers
To Remove
1. Prise out the blanking plugs at positions (F) & (G) and pushout the interlock
plungers, taking care to note the order and position of the plungers .
NOTE: One long plunger between 3rd/4thand 5th selector shafts and
shorter plungers between 1st/2nd and 3rd/4th selector shafts and
5th and reverse selector shafts.
-
FB .7. GEAR SELECTOR REPLACEMENT
1 s t and 2nd Gear Selector
1 . Locate the locking ball and spring i n position.
2 . Compress the spring and ball assembly, using a 6mm diameter rod.
3. Insert the gear selector shaft through the gearbox outer casting, the
operating fork and into the differential end of the gearboi .casting'up to,the
neutral position. . .
4. Using a set of 1st and2nd synchro gauges TOOOT0618 locate the fork i n the
neutral position. The sets of gauges are available i n different thicknesses,
select a set of gauges giving the least movement of the fork.
5. Tighten the two screws securing the fork to a torque of 4kgf .m (29 Ibf. ft)
and remove the gauges.

SECTION FB Page 73 .,.
3rd and 4th Gear Selector
1. Place the first interlock plunger infrom the opening at (F) figure 5 and
locate i n the 1st and 2nd selector shaft notch.
2. Insert the gear selector shaft through the gearbox outer casting, f i t locking
ball and spring as previously described, the operating fork and into the
differential end of the gearbox casting, taking care to correctly locate the
small plunger inside the front end of the selector shaft.
3. Locate the operating fork onthe selector shaft so that the notch on the shaft
lines up with the screw hole and screw down the grubscrew, lock with wire.
5th Gear Selector
1. Place the long interlock plunger i n from the opening at (G) figure 5 and
ensure that the fitted selector shafts are located i n the 'neutral' position.
This w i l l allow the 5th gear selector shaft to be' inserted into the differential
end of the gearbox.
2. Insert the gear selector shaft through the gearbox outer casting, f i t the locking
ball and spring as previously described, the5th gear operating block and into
the differential end of the gearbox casting, emuring that the small interlock
plunger i s located inside the frontend of the selector shaft.
3. Locate the 5th gear operating block on the selector shaft so that the notch
on the shaft lines up with the screw hole i n the block. Screw down the grub
screw and lock with wire.
Reverse Gear Selector
1 0 Place the. last interlock plunger infrom the opening a t (G) figure 5 and
ensure that the fitted selector shafts are located i n the 'neutral ' position.
2. Insert the gear selector shaft through the gearbox outer casti,ng, f i t the locking
ball and spring as previously described, the operating dog, the reverse gear
fork and into the differential end of the gearbox casting.
3. Locate the reverse operating dog on the selector shaft so that the notch on
the shaft lines up with the screw hole i n the operating dog. Screw down
the grub screw and lock with wire.
4. Position the reverse selector shaft i n the neutral position with the notch i n
the operating dog vertical. Place the gauge TOOOT0619 (3rnrn) against the 1st
gear idler and move the reverse intermediate gear, together with the reverse
. Page 7 4 SECTION FB
Gear Selector Mechanism
Top Cover and Cross Shaft Bearing cap Relay Dog, Reverse Selector Shaft.
Dowel, Top Cover locating. Selector Fork, reverse.
Setscrew, Top Cover to Gearbox. Relay Dog, 5th Selector Shaft.
Setscrew, Bearing Cap to Cover. Selector Fork, 5th.
.
Show ldered Stud Selector Fork, 3rd and 4th.
Was her. Selector Fork, 1st and 2nd.
Filler Plug. Locking Screw, ~ o r k / ~ e ltoa ~
Shaft.
Gasket Filler Plug Setscrew, Fork Clamping.
Cross Shaft Spindle Assembly. lnterlock Plunger, short.
'0' Ring, Cross Shaft Spindle. lnterlock Plunger, long.
Selector Shaft, reverse. Blanking Plug, Interlock Bore.
Selector Shaft, 5th. Detent Ball, Selector Shaft.
Selector Shaft, 3rd and 4th. Spring Detent Bal I.
Selector Shaft, 1st and 2nd.
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 pinion, using feeler gauges.
Place a shim of thickness 'Y' tO.5 mm between the pinion and slider. Tighten
the screw of the stop (J i n fig.5) until i t bean against theshaft of the 3rd
and 4th gear fork.
Tighten the locknut on the stop and check the clearance.
Interlock PI ungers
To Replace
1 . Smear the bores of the interlock plungers with a sealing compound and knock
i n the blanking plugs at positiom (F) and (G).
Final Assembly
a 1 . Fit top cover on the gearbox and replace the transmission unit as previously
described.
FB.8. - PRIMARY SHAFT

To Remove
1 . Remove the Gear Selecton and the clutch shaft us previously described.
2. Remove the speedometer drive wheel using spanner TOOOT0617 and pull the 5th
gear driven pinion off the splined pinion shaft.
3. Release the forward bearing (bellhousing end) on the primaryshaft by gently
tapping the rear end-o f the primary shaft.

Page 76 SEC7'lON FB
4. Release the rear bearing on the primary shaft using a puller i f

necessary. Take care not to lose the balls from the race.
NOTE: The inner bearing rings are i n two halves on the prirriaryshaft
rear end and careshould be taken to note where each i s fitted.
S R Q P M
Fig .7 Primary shaft assembly
Move the primary shaft towards the bellhousing, seperdting the 4th gear drive
pinion to gain access to the synchro hub assembly retaining circlip. Remove the
circlip from the shaft using circlip pliers 3253-T, taking care to note the direction
i n which i t i s fitted.
Move the pinion shaft towards the bellhousing as described under heading
'Bevel Pinion' and allow gears to rest i n the bottom of the casing to provide
additional space to withdraw the primary shaft.
The primary shaft can now be moved towards the bellhousing end until the
rear end of the shaft i s clear of the casing. Lift out the primary shaft
assembly.
Remove the 1s t and 2nd gear selector fork, (E) figure 5,
Dismantling
1 . Slide off the 4th gear drive pinion with the synehro.ri.ngcind the needle bearing.
cage.
2, Remove the s ync hro niser .

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 i s 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 secure with the circlip (J).
2. Fit the following onto the primary shaft inthe order shown.
(a). 3rd drive gear (P) together with its needle bearing cage coated
with transmission oil.
(b) . Sync hro ring (F) .

(c). Synchroniser (E) ensuring that the collar with a groove i s towards
the 3rd drive gear (P).
(d). Using the circlip pliers TOOOT0620 f i t the circlip (Q). Make sure circlip
is fitted i n the direction noted when removed.
IMPORTANT: The maximum movement of the synchroniser(E) on the shaft

must not exceed 0.1 0 rnm. Adjustment of this movement i s
achieved by changing the circlip (Q) for one of a different
thickness.
(e) . Synchro ring (D) .

(f). 4th drive gear (R) together with its needle bearing cage coated with
transmission oil. Slide the synchroniser (E) across to engage the 4th
drive gear.
3. Pass the input shaft end ofthe assembly through the top openingof the
gearbox, then forward through the bearing opening into the differential
compartment and locate circlip i n i t s groove. It may be necessary to remove

the pinion shaft to provide additional space to move the primary shaft down
into the casing. See under heading 'Bevel Pinion Shaft'.
4. F i t the double rear bearing (C) and the front bearing (H) using a tube 30 mrn
internal diameter, 300 mm long.
5. Replace the bevel pinion, see 'Bevel pinion Shaft'.
6. Place the reverse gear wheel down into the gearbox with the fork groove
towards the differential. Insert the intermediate shaft and line up'the recess i n
I
Gearbox Shafts and Gears

a a. a a
Key to Gearbox Shafts & Gears Drawing
Clutch Shaft. Circl ip, 5th syncroniser ,

Spring, Clutch Shaft endthrust, Screw, 5th Hub to Primary Shaft.
Circlip, Clutch Shaft retention. Roller Bearing, Secondary Shaft front.
Support Tube, Clutch Release Bearing, 1 st Speed Driven Pinion.
Sealing Ring, Support Tube. 2nd Speed Driven Pinion.
Scroll and Housing. Needle Rol-Ier Bearing.
Ball Bearing, Primary Shaft front Sleeve, lst/2nd Pinion Bearing,
Primary Shaft. Syncroniser Assembly 1st/2nd.
3rd Speed Drive Pinion. Syncroniser Ring, 1st and 2nd.
Needle Roller Bearing, 3rd Pinion. Spacer Washer, Selective.
Syncroniser Assembly, 3rd and 4th. 3rd and 4th Speed Driven Pinion.
Syncroniser Ring, 3rd, 4th and 5th. Double Ball Bearing, Secondary Shaft rear.
Stop Ring, 3rd and 4th, Syncro. 5th Speed Driven Pinion.
4th Speed Drive Pinipn. Nut/Speedo Drive Gear.
5th Speed Drive Pinion. Reverse ldler Gear,
Needle Roller Bearing, 4th and 5th Pinion. Spindle, Reverse ldler Gear.
Double Ball Bearing, Primary Shaft rear Screw, Reverse Gear Spindle.
Syncroniser Assembly, 5th. Nut, reverse spindle screw.
Page 20 SECTION FB
the shaft with the grub screw. Smear the threads o f the grub screw with a
a
locking compound and tighten screw and lock w i t h nut.
7. Fitthe5thdrivegear(S)togetherwithitsneedlerollercagecoatedwith
transmission oil, synchroniser (8) and operating fork assembly on the primary
shaft. Secure w i t h the deflector (T) and bolt (A) and tighten to
14.5 - 16.5 kgf.m (105 - 119 Ibf.ft).
FB.9. - BEVEL PINION SHAFT

To Remove
1 . Remove the Primary Shaft as previously described.
2. Withdraw the bevel pinion through thegearbox casing into the differential
housing.
3. As the bevel pinion i s drawn through the casing, remove the3rd & 4th driven
gear pair, adjusting washer, 1s t and 2nd syncro hub assembly with gears and
needle roller bearings.
NOTE: The two rear b a l l races and the innerbearing rings must be replaced
i n the same order, f i x labels to indicate positions.
r q P 0 n m l k I
Fig .8 Bevel pinion assembly
SECTION FB Page 27
To Replace
Check a l l parts are clean and there are no abrasive or metal particles
adhering to the parts.
F i t 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 shaft through the opening i n the gearbox casing from the
differential end.
Onto the shaft inside the gearbox casting first place the 1st speed driven
pinion (h), together with its needle bearing cage (m) and inner bearing
sleeve (n). Coat the bearing before fitting with transmissionoil.

Next place onto the shaft the syncro ring (g), the synchroniser (f) with
the reverse gear teeth towards the back o f the gearbox and the syncro ring
(4
Now slide on the 2nd speed driven pinion (d) togetherwith its needle bearing
cage (p) and inner bearing sleeve (0). Coat the bearing before fitting with
transmission o i l .
Finally place on the shaft the adjusting washer (q)and the double pinion (r)
and push the shaft to the rearof the gearbox.
Fit the rear double bearing (c), taking care to assemble the double bearing
races and bearingring i n the original positions.
F i t the 5th gear pinion (b) with the small shoulder on the pinion against the
double bearing.
Using spanner TOOOT06 17, Lock the shaft and tighten the threaded
speedometer drive wheel (A) to a torque of 20 to 22 kgf .m (145 to 160 Ibf .ft) .
If both shafts are fitted, then the shafts can be locked by selecting the
reverse gear and any other gear. Do not lock nut a t this stage.
Before fitting the primary shaft and covers to the gearbox, check the pinion
cone setting as detailed i n "Adjustments".
Adjustments
On the ground face of the bevel pinion i s engraved a figure i n mil Iimetres . This
figure represents the distance, which must be maintained after adjustment, between
the differential centre line and the ground face of the bevel pinion.
Page 22
This distance i s different for each bevel pinion and is checked using the distance
gauge fixture TOOOT0616 fitted with dial gauge TOOOT0615. The fixture i s designed so that
the distance between the centre line of the ground contact faces (drive shaft bearing
surfaces) and the faces of the probes i s 60 mm. This figure i s engraved on the fixture
between the probes.
First calibrate the fixture.

(a). Clean the bearing surfaces and the ground contact faces of the
fixing.
(b). Place the fixture on a surface plate.
(c). Zero the dial gauge with the large needle on 0.
(d). Note the position of the totalising needle.

Totalising needle between 4and 5.
Large needle a t 0.
Offer the fixture up to the bearing surfaces of the drive shafts with the dial
gauge stem not i n contact with the ground face of the bevel pinion, uhlock
the gauge stem.
Rotate the fixture i n the bearing sr~rfaces,so the gauge stem passes over the
ground face of the pinion, until the large needle ofthe dial gauge i s about
to change direction. Lock the needle positions and note the readings.
Example: Total king needle between 0 and 1 .

Large needle at 86.
Remove the fixture and place once again on the surface plate. Allow the
dial gauge stem to return slowly, so the full revolutions can be counted.
When the gauge stem comes torest on the surface plate the measurement of
the part revolution can be made.

If the measurements for the examples are:
Conic distance 60 + 3.86 = 63.86 mm.
If the dimension engraved on the pinion for this example i s 63.95 mm then
the bevel pinion must be moved away from the differential centre line by:
63.95 - 63.86 = 0.09 mm.

To adjust the bevel pinion remove the rear housing, the speedometer drive
wheel and the 5th gear pinion.

Remove the bevel pinion as previously described.
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 i n the following manner:
2.81 - 0.09 ~ 2 . 7 2mm

As washers are available i n thickness from 1 .65 m m to 3.1 3 mm i n steps of
0 .O4 mm, the nearest to the calculated thickness i s 2.73 mm.
9. F i t the new adiusting washer (q) and replace the bevel pinion as previously
described.
10, Check the adiustment, repeat irstructions 1 to 4.
11. If adjustment is within thetolerance

+
- 0,02 mmfit the 1st and 2nd gear
a operating fork.
Final Redacement
1 . Replace the primary shaft as previously described, tighten speedometer drive

wheel nut to specified torque as described i n "bevel pinion shaft" and lock
nut by peening it to the pinion.
2. Check that the pinions rotate freely when out of gear.
3. Apply sealing compound to cover mating surfaces and tighten a l l securing

screws to the torque specified i n the TECHNICAL DATA.
FB .lo. - DIFFERENTIAL SHAFTS (Drive Shafts)
Dismantle
1 . Remove and dismantle the 'Clutch Bellhousing' as previously described.
2. Remove the grub screw securing the large nut which locks the bearing to the
shaft.
3, Using the box spanner TOOOT0612 unscrew and remove the large nut
4. Drive the shaft out through the bearing.
5. Remove the grub screw i n the top o f the shaft housing and using the special
spanner TOOOT0613, remove the locking ring securing the bearing to the shaft
housing .
6. Gently twp aut the two bal 1 races.
' NOTE: The two ball races must be replaced i n the save order, f i x labels
to indicate positions.
Page 24
7. Drive out the double bal I bear'ing outer ring using a tube of 65 mm external
diameter.
8. Using a suitable extractor, draw the inner bearing rings from the shaft.
Note positions.
9. Removethesealingringfromtheshafthousing.
10. Remove the o i l retaining washer and bearing distance bush assembly. from
the shaft.
Fig .9 Differential assembly
Satellite housing Adjusting was her

Planet wheel Crown wheel
Satellite gear Roller bearing
Satellite spindle, long Spacer
Satellite spindle, short Locking nut
Screw with dowel Nut
Crown wheel screw Grub screw
Planet wheel washer Oil seal
satellite gear washer Bearing
Gosshead bush Grub Screw
Distance piece Output shaft housing
Distance was her
SECTION FB Page 25
To Assemble
NOTE: The differential drive shafton the left-hand side of gearbox i s the shorter.
1 . Fit the bearing (21) i n 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 o i l s e d (20) using a suitable tool.
3. Position the o i l retaining washer on the shaft. Fit the spacer (16), and ensuring
that the washer i s centralised, press on the spacer.
4. F i t the differential shaft into the housing and position using a tube o f 30 mm
a inside diameter under a press.
15 kgf.m (1 08 1bf.ft).
Tighten the bearing locking nut (17) to
Tighten the grub screw (22) i n the locking nut.
5. Assemble and replace the 'Clutch Be1lhousing' as previously described.
FB.11 . - DIFFERENTIAL CROWNWHEEL & PINION

To Remove
1 . Dismantle the 'Differential Shafts' as previously described.
2. Using a suitable extractor remove the tapered roller bearings from each end
of the crown wheel assembly.
3. Remove the eight screws (6) securing the crown wheel to the housing and
a remove the following:
(a) Crown wheel (14)

(b) Satellite spindle (4)
(c) Planet wheel (2) and thrust washer (8)
(d) Two satellitespindles (5)

(e) Sate1Ii t e gears (3) and stop was hers (9)
(f) Crosshead (1 0)
(g) Other planet wheel and thrust washer.
To Replace
1 . Place in the satellite housing a thrust washer (8), one planet wheel (2), one
a 2.
fixed thrust washer (9),one satellite gear (3) and the long spindle (4).
Rotate the planet wheel and check that the point of minimum clearance is
Page 26
. ,
0.1 mm. I f this i s not so replace thrust washers until the minimum clearance
i s achieved. Remove the satellite and thrust washer making a note of the
position i n the housing. . .
Repeat 1 and 2 for each satellite gear, taking care to f i t the crosshead bush
(1 0) to support the short satellite spindles (5). F i t the dowel p i n screws
temporarily to locate the short satellite spindles.
F i t a l l the satellite gean and thrust washes.

Place the second planet wheel with thrust washer i n the crown wheel .
Locate the satellite housing i n recess i n the crown wheel and fit the eight
screws. Take care the dowel screwsare fitted i n the correct holes.
Gradually tighten the screws, checking the pinions rotate freely, to a
torque of 1 1 .5 to 13 kgf .m (83 to 94 Ibf .ft),

Check the minimum clearanceof thesecond planet wheel and this should be
0.1 mm. Change the thrust washer to achieve this clearance.
Using an o i l gun, inject gearbox o i l into the satellite housing lubricating
a l l parts inside.
F i t the bearings on the satellite housing and crown wheel using a suitable
mandrel.
FB.12. - DIFFERENTIAL BEARINGS ADJUSTMENT

There are two methods by which adiustments can be made to the differential bearings.
The f i n t method uses a dial gauge to measure the thickness of the adjusting washers,
which i s directly related to the bearing stress. Thesecond method measures the torque
required to rotate the differential usinga spring balance.
Method 1
1 . Position the differential and bearings.
(a) Place the differential together with bearings i n the end o f the gearbox
casing.
(b) Place the adiusting washer (13) and the distance was her (12 ) , with a
total thickness o f 7 mm, against the left-hand differential beciring .

(c) Secure the differential i n place using clamps as necessary.
(d) Place a new paper gasket o n the left-hand differential shaft housing,
SECTION FB Page 27
.a locate the drive shaft i n tCle planet wheel and align the screw holes.
Fit screws, taking care to f i t the correct lengths and tighten.
(e) Place the gearbox carting on i t s left-hand side, supporting i t i n this
position.
(f) Place against the right-hand differential bearing the adjusting washer
(1 3) followed by the distance washer (12) and the distance piece (1 1) .

The total thickness (12) and (1 3) should not be less than 9 mm.
(g) Locate the right-hand differential drive shaft i n the planet wheel and
align the screw holes. Without a gasket fitted on housing, fit the
assembly i n position and tap lightly on the differential shaft.
(h) Remove the right-hand drive shaft, adjusting washers and distance
piece.
2. Adjust the pre-load on the differential bearings.
NOTE: The bearings must be fitted with a specified pre-load,

(a) Place gauge support TOOOT0614, fitted with dial gauge TOOOTO615, on the
collar of the right-hand drive shaft housing. Allow the probe of the
gauge to touch the bearing faceof the housing. Bring the zero of the
movable dial o f the gauge i n line with the large needle. Note the
position of the needle.

Example: Large needle reading = 0
Small needle reading = 0
(b) Place the d i a l gauge and support on the gearbox castingwith the probe
bearing on the distance piece. Take two measurements,
Example: Measurement A = 7.76mm

Measurement B = 7.80mm
Average A and B = 7.76+7.80
= 7.78 mm
2.
(c) Add to the average measurements the following items:
Thickness o f the seal = 0 .I0 rnm

Stress on the bearing = 0.30 mm
Total = 0.40 mm
Example: 7.78 + 0.40 = 8.18mm

.. Select an adjusting washer and a distance washer with a total thickness
nearest to the calculatedthickness. This would be for the example

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 f i t
the right-hand drive shaft housing with a papergasket betweenthe
mating surfaces.
IMPORTANT: The thickness of the washers fitted against the left-hand

and right-hand bearings corresponds to the setting of
the bearing stress only.
To adjust the backlash these washers must be redistributed to the left

and to the right, without changing the overall thickness.
Example: Left- hand bearing washers = 7.00mm

Right-handbearingwashers = 8.20mm
Overall thickness = 15,20 mm
Method 2
1 . Fitting the differential assembly.
(a) Place the differential, fitted with bearings, i n the end of the gearbox
casting.
(b) Secure the differential i n place using clamps as necessary.
(c) Place new paper gaskets on the left-hand and right-hand drive shafts
assemblies, together with any shims removedduring dismantling.
Locate the drive shafts i n the planet wheel andalign the screw holes.
'
Fit screws, taking care t i f i t the correct lengths and tighten.
2. Adjust the pre-load on the bearings.

NOTE: The bearings must be fitted with a specific pre-load . This can be
checked by measuring the torque required to turn the differential .
(a) To measure the torque f i x and wind a length of cord'around the
differential satellite housing, Attach to thefi-ee end of'the cord to
a spring balance so the satellite housing canbe rotated when the
spring balance i s pulled.
(b) Take a reading from the balance when the satellite.hous~ngi s just
about to rotate. This reading shduld be within the following limits

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 i s less than 4 kg, increase the thickness of the adjusting
washers. For readings inexcess of 6 k g reduce the thickness of

the adiusting washers.
(ii) New bearings should be within 6 to 9 kg. If the reading i s less

than 6 kg, increase the thickness o f the adjusting washers. For
readings i n excess o f 9 k g reduce the thickness o f the adjusting

was hers .
NOTE: A n adjusting washer 0.1 0 mm thick corresponds approximately to a
bearing stress of: 0.250 k g for new bearings
0.500kg for used bearings
IMPORTANT: The thickness of the was hers fitted against the left- hand and
right-hand bearings corresponds to the setting o f the bearing
stress only.
To adjust the backlash these washers must be redistributed to the left and
right, without changing the overall thickness.
FB,13. - BACKLASH ADJUSTMENT

a To check the backlash adjustment both drive shaft housings must be fitted.
1. Measure the clearance between the crown wheel and pinion teeth i .em
backlash.
(a) F i t a dial gauge TOOOT0615 to a support, fixed to the gearbox casting.
(b) A d just the position of the dial gauge so that the measuring probe
touches the flank o f a tooth a t heel (outer edge o f crown wheel) see
figure 10. This should be achieved somewhe& near maximum diameter
o f the crown wheel .
(c) Move the crown wheel to the extent o f the backlash several times
and measure the difference on the dial gauge.

Page 30 SECTION FB
Fig .l 0 Measuring crown wheel backlash
(d) Repeat the procedure on teeth a t 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. I f a reading
exceeds this figure i t w i l l indicate the crown wheel is running out o f
true or i s badly fitted .

(e) Make a note o f the minimum clearance.
Example clearance = 0.73 mm
Adjust the backlash.
IMPORTANT: The clearance between the teeth i s adjusted by redistributing

the adjusting washers against the left-hand and right-hand
bearings. Under no circumstances must the overall thickness
o f the washers be altered, see DIFFERENTIAL BEARINGS
ADJUSTMENT.
The clearance must be adjusted towithin the limits 0 .I 6 mm and
0.24 mm. Aim for an .average

.
clearance
. , .
o f 0,20 mm.
Subtract this average clearance from the Ainimum reading noted; for
the example given, this w i l l be:
therefore, for this example the clearance must be reduced by 0.53 mm.
NOTE: Moving a 0.15 mm adjusting washer from oneside to the
other, w i l l change the clearance by 0.1 0 mrn.
SECTION FB Page 3 1
.; For the example therefore, thethickness o f 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 against the left-hand bearingshould
be increased by the same amount.
7.00 + 0.79 = 7.79mm
(d) Recheck the backlash measurement to verify t hat the difference
between any two measurements, around the crown wheel, does not
exceed 0.10 mm.
3. I f backlash i s within the tolerance, assemble the differential assembly,
replace the Clutch Bell housing and refit Transmission Unit.

STEERING
SECTION HB - ESPRIT '88 M.Y. Onwards
Sub-section Page
General Description HB. 1 5
Steering Wheel HB.2 6
Upper Steering Column Assembly HB.3 8

-
Intermediate Steering Column Assembly HB. 4 15
Track Rod Ends & Toe-in Adjustment HB.5 19
Steering Rack Gaiters HB. 6 20
Rack & Pinion Assembly HB.7 21
Page 1
WON-S.I.R. TYPE UPPER STEWING COLUMJ
Steering column assembly

Fixing, column to scuttle beam
'Break out' insert
Clamp bracket, column to pedal box
Fixing, bracket to pedal box
Sealing gasket, column to bulkhead
Seal plate
Fixings, seal plate
Steering lock .
Shear bolt, steering lock fixing
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
S.1-R. TYPE UPPM STEERING COLUMN
1.
2.
Upper column assembly
'Break o u t ' i n s e r t
.
3 . F i x i n g t o s c u t t l e beam
4. F i x i n g t o p e d a l box
5. Top b e a r i n g housing
6 . F i x i n g , housing t o column
7. B a l l b e a r i n g , column t o p
8. C i r c l i p , t o p b e a r i n g
9. Cushion r i n g
10. C i r c l i p , cushion r i n g
11. Column l o c k
12. Shear b o l t , column l o c k

13. Lock b a r r e l & keys
14. I g n i t i o n switch
15. Turn c a n c e l l i n g s l e e v e
16. SIR r o t a r y connector
17. F i x i n g , r o t a r y connector
18 18. - S t e e r i n g wheel
19. Nut, wheel t o column
20. Washer, wheel t o column
21. SIR i n f l a t o r module
22. F i x i n g , i n f l a t o r module
IXEWEDIATE COLUMN & RACK & PINION ASSEMBLY
S.I.R.
type
Key t o I n t e r m e d i a t e Column & Rack & P i n i o n Assembly Drawing
1. Rack & P i n i o n assembly Circlip, spacer tube s t o p

2. Gaiter ( s u p p l i e d as k i t o f 2 Clip, spacer tube f i x
, g a i t e r s with c l i p s ) Lower u n i v e r s a l j o i n t ( u / j )
3 . T r a c k r o d end P i n c h b o l t , lower u / j
4. Locknut, t r a c k r o d e n d Non-SIR i n t e r m e d i a t e s h a f t
5. Rack assembly LH r u b b e r mounting SIR lower i n t e r m e d i a t e s h a f t
7. Clamp b r a c k e t , LH mounting Steady bracket, i n t . s h a f t
8 . Rack assembly RH r u b b e r mounting Bush, s t e a d y b r a c k e t
9 . Clamp b r a c k e t , RH.rubber mounting Shim ( i f f i t t e d ) , s t e a d y b r a c k e t
1 0 . Tapping p l a t e , r a c k a s s y mounting Fixing, steady bracket
11. S p a c e r t u b e , lower u / j SIR u p p e r i n t e r m e d i a t e s h a f t
HB.l - GENERAL DESCRIPTION
A r a c k and p i n i o n s t e e r i n g system i s used on t h e E s p r i t , w i t h t h e s t e e r i n g

r a c k assembly clamped t o t h e t h e c h a s s i s f r o n t crossmember behind t h e f r o n t a x l e
line. On c a r s w i t h o u t a Supplementary I n f l a t a b l e R e s t r a i n t ( S I R . ) , t h e
c o l l a p s i b l e u p p e r s t e e r i n g column assembly i s c o n n e c t e d w i t h t h e r a c k p i n i o n
s h a f t via a s h o r t i n t e r m e d i a t e s h a f t and two u n i v e r s a l j o i n t s .
Non-S.I.R. Type S t e e r i n q System

S c u t t l e beam
Intermediate
a
Pedal box mounting boss
S t e e r i n g r a c k assembly
a
Page 5
On S . I . R . equipped c a r s , a s h o r t e r upper column assembly r e q u i r e s two s h o r t
i n t e r m e d i a t e s h a f t s , t h e lower of which i s supported i n a c h a s s i s mounted
b e a r i n g , and t h r e e u n i v e r s a l j o i n t s t o connect with t h e r a c k assembly.
S.I.R. Type S t e e r i n g System S c u t t l e beam

Upper column \
Pedal box pivot bracket
\
Intermediat
Column/scuttle
beam f i x i n g
Upper column
L o w e r intermediate
.' S t e e r i n g r a c k assembly
HB.2 - STEERING WHEEL
On non-S.I.R. (Supplementary I n f l a t a b l e R e s t r a i n t ) c a r s , t h e . t h r e e spoke

s t e e r i n g wheel i s s e c u r e d t o an a l l o y hub by s i x countersunk screws. The hub is
s p l i n e d t o t h e i n n e r s t e e r i n g column, a n d a tongue on t h e back of t h e b o s s s e r v e s
t o o p e r a t e t h e c a n c e l l i n g mechanism f o r t h e t u r n i n d i c a t o r s w i t c h .
On S.I.R. equipped c a r s ( p r i m a r i l y U S A ) , . t h e t h e s t e e r i n g wheel and hub are
i n t e g r a t e d i n t o a s i n g l e u n i t which houses an i n f l a t o r module ( a i r bag) a t its
c e n t r e , concealed beneath a moulded t r i m c o v e r . ~ h & padded cover is d e s i g n e d t o
s p l i t open when t h e i n f l a t o r module i s deployed ( a i r bag i n f l a t e d ) . The spokes
of t h e s t e e r i n g wheel a l s o i n c o r p o r a t e a p a i r o f horn b u t t o n s .
WARNING: Any work on, or removal of the s t e e r i n g wheel on 3.I.R. cars r e q u i r e s

t h a t r i g o r a u s s a f e t y precautions be taken i n o r d e r t o safeguard a g a i n s t
u n i n t e n t i o n a l deployment o f t h e i n f l a t o r module. Do not attempt any
work on t h e s t e e r i n g wheel of an S.I.R. equipped car without r e f e r r i n g
t o S u b s e c t i o n WA.3 - J i n t h e s e p a r a t e manual 'Section WA', part no.
EO82TO327J.
Page 6
=.
To Remove Wheel & Hub Assy.: Non-S.I.R. C a r s
- P u l l o f f t h e t r i m pad from t h e c e n t r e o f t h e wheel.
- Remove t h e n u t and washer r e t a i n i n g t h e wheel.
- Match mark t h e r e l a t i v e p o s i t i o n s of t h e s t e e r i n g wheel hub and i n n e r column.
- P u l l t h e wheel o f f t h e column u s i n g minimum f o r c e , i f n e c e s s a r y u s i n g a
s u i t a b l e p u l l e r . DO NOT a p p l y e x c e s s i v e a x i a l f o r c e t o t h e s t e e r i n g wheel,
or i n n e r o r o u t e r columns w i t h o u t t h e u s e o f a p u l l e r , o r t h e mechanism
r e t a i n i n g t h e t e l e s c o p i c l e n g t h o f t h e column may b e o v e r r i d d e n ,
n e c e s s i t a t i n g column r e p l a c e m e n t .
- Take c a r e n o t t o m i s p l a c e t h e s p l i t t h r u s t c o l l a r from t h e t o p of t h e column.
% Tapered e n d t o w a r d s hub
S t e e r i n g wheel
, fk i n g thread
Retaining nut
S t e e r i n g wheel hub
To R e f i t Wheel & Hub A s s y . : Non-S.I.R. C a r s

- Apply a small amount o f PBC g r e a s e t o t h e column s p l i n e s t o a i d s u b s e q u e n t
s t e e r i n g wheel removal, b u t e n s u r e t h a t t h e t h r e a d e d s e c t i o n is t h o r o u g h l y
degreased;
- Check t h a t t h e s p l i t t h r u s t c o l l a r i s h e l d i n p o s i t i o n (by a r u b b e r band) i n
t h e g r o o v e i n t h e column j u s t below t h e s p l i n e s , w i t h t h e t a p e r e d f a c e s
t o w a r d s t h e s t e e r i n g wheel as shown;
- Taking c a r e n o t t o damage t h e t u r n i n d i c a t o r s w i t c h c a n c e l l i n g f i n g e r s , r e f i t
t h e s t e e r i n g wheel assembly w i t h t h e match marks a l i g n e d , f i t t h e washer a n d
r e t a i n i n g n u t and t i g h t e n t o 4 1 - 47 Nm ( 3 0 - 35 1 b f . f t ) .
To Remove & R e f i t Wheel & Hub Assy.: S.I.R. C a r s

S e e Sub-Section WA.3 - J i n s e p a r a t e manual ' S e c t i o n WA' p a r t no. E082T0327J.
S t e e r i n g Wheel Alignment
I f t h e s t e e r i n g wheel a l i g n m e n t r e q u i r e s r e - s e t t i n g , o r i f t h e r e are no w h e e l
t o column r e f e r e n c e marks a v a i l a b l e when f i t t i n g a s t e e r i n g wheel, p r o c e e d as
Page 7
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 the steering wheel onto the column splines in an approximate straight
ahead position. Rotate the wheel to full left hand lock and then to right
hand lock, and check that the two extreme steering wheel positions are the
mirror image of each other. If necessary, reposition the wheel on the column
until this is achieved. Fit and tighten the steering wheel nut as above.
Typical 'full lock' steering wheel positions
3. Road test the car to check steering wheel alignment. It should not be
necessary to reposition the wheel by more than one spline to achieve
alignment to within 5". Complete alignment is achieved by adjustment at the
track rod ends, an equal and opposite amount at each side to maintain the
toe-in setting.
4. Check front wheel toe-in.
HB.3 - UPPER STEERING COLUMN ASSEMBLY
On non-S.I.R. (Supplementary Inflatable Restraint) cars, the upper steering

column assembly comprises inner and outer columns, both of which are telescop-
ically collapsible if an axial load above a specified figure is applied to the
column in the course of an accident. The lower end of the outer column is
secured to the pedal box via a clamp bracket, and the top end of the column is
secured to the scuttle beam via two fixing bolts and 'break out' inserts, which
are retained in slots in the column brackets by nylon pins. These pins are
designed to shear in an accident, and allow the upper half of the column to break
free of the scuttle beam and telescope downwards, this movement being accornrn-
odated by the deformation of an open mesh crumple section (covered by a rubber
sleeve) at the bottom of the column.
The telescopic inner column assembly is supported in ball bearings and
provided with splines at the top end for the steering wheel, and splines at the
bottom end for connection with the intermediate column. The upper part of the
Page 8
i n n e r column i s p r o v i d e d w i t h a s l o t i n t o which t h e s t e e r i n g l o c k engages.
On S . I . R . e q u i p p e d cars ( p r i m a r i l y USA), a d i f f e r e n t column i s u s e d , b u t t h e
same p r i n c i p l e s a p p l y . The same ' b r e a k o u t ' f i x i n g s a r e u s e d a t t h e s c u t t l e
beam, b u t t h e lower end o f t h e column i s s e c u r e d t o t h e p e d a l box v i a a h i n g e
b r a c k e t and a s i n g l e f i x i n g b o l t . The two p a r t s o f t h e o u t e r column are
c o n n e c t e d by g r i p c o l l a r s and t h e assembly must b e r e p l a c e d i f c o l l a p s e d . The
two p a r t s of t h e i n n e r column are c o n n e c t e d by a t e l e s c o p i c j o i n t , t h e l e n g t h of
which i s f i x e d by p l a s t i c b u t t o n s l o c a t i n g i n g r o o v e s , which may b e o v e r i d d e n b y
a s p e c i f i e d f o r c e . The assembly must b e r e p l a c e d i f c o l l a p s e d .
WARWING: Any work o n , ' o r removal of t h e s t e e r i n g column o n S.I.R. cars r e q u i r e s

t h a t r i g o r o u s s a f e t y p r e c a u t i o n s be t a k e n i n o r d e r t o s a f e g u a r d a g a i n s t
u n i n t e n t i o n a l deployment of t h e i n f l a t o r module. D o n o t a t t e m p t any
work o n t h e s t e e r i n g column o f an S.I.R. e q u i p p e d car w i t h o u t r e f e r r i n g
t o S u b s e c t i o n WA.3 - L i n t h e separate manual ' S e c t i o n WA', part no.
EO82TO327J.
P o s t Accident I n s p e c t i o n
I f t h e v e h i c l e h a s been i n v o l v e d i n an a c c i d e n t , o r i f t h e r e i s any o t h e r
r e a s o n t o s u s p e c t t h a t t h e upper column assembly may have c o l l a p s e d , c a r r y o u t
t h e following inspection:
Non-S.I.R. Cars: Remove t h e s t e e r i n g wheel (see a b o v e ) , remove t h e column

s h r o u d s , and s e p a r a t e t h e lower end of t h e column from t h e i n t e r m e d i a t e s h a f t
universal joint.
i) Loosen t h e column t o s c u t t l e beam f i x i n g b o l t s and check t h a t t h e two a l l o y

' b r e a k o u t ' i n s e r t s a r e s e c u r e l y a t t a c h e d t o t h e column f l a n g e .
i i ) Measure t h e o v e r a l l l e n g t h of t h e i n n e r column a s shown i n t h e diagram.

S p e c i f i c a t i o n = 7 5 8 . 5 - 7 5 9 . 5 mm
Replace t h e column i f o u t s i d e s p e c i f i c a t i o n .
i i i ) Measure t h e o v e r a l l l e n g t h of t h e o u t e r column t u b e , e x c l u d i n g t h e b e a r i n g
h o u s i n g f l a n g e s as shown i n t h e diagram.
S p e c i f i c a t i o n = 611 - 612 rnm
R e p l a c e t h e column i f o u t s i d e s p e c i f i c a t i o n .
i v ) I f t h e r e i s any d i s c e r n i b l e a x i a l p l a y i n t h e column ( a l o n g t h e d i r e c t i o n of
t h e column), t h e i n n e r column t e l e s c o p i c r e t e n t i o n mechanism h a s been
o v e r r i d d e n , and t h e column assembly s h o u l d b e r e p l a c e d .
O u t e r column 611 - 612 nun

L
C o l l a p s i b l e mesh s e c t i o n
-
\..'
.
a I n n e r column 758.5 759.5 mn
Page 9
S.I.R. Cars:
i ) Remove t h e column s h r o u d s , l o o s e n t h e column t o s c u t t l e beam f i x i n g b o l t s and
c h e c k t h a t t h e two a l l o y ' b r e a k o u t ' i n s e r t s are s e c u r e l y a t t a c h e d t o t h e
column f l a n g e .
ii') Check t h a t t h e c e n t r e l i n e o f t h e u / j a t t h e lower e n d o f t h e column i s w i t h i n

3 nun of t h e p i v o t p o i n t o f t h e o u t e r column lower b r a c k e t . I f g r e a t e r t h a n
3 nun, r e p l a c e t h e column assembly.
i i i ) Measure t h e l e n g t h o f t h e lower p a r t o f t h e o u t e r column as shown i n t h e

diagram.
S p e c i f i c a t i o n = 105.4 + 1 mrn
I f o u t s i d e s p e c i f i c a t i o n , r e p l a c e t h e column assembly.
i v ) I f t h e r e i s a n y d i s c e r n i b l e a x i a l p l a y i n t h e column ( a l o n g t h e d i r e c t i o n o f
t h e c o l u m n ) , t h e i n n e r column t e l e s c o p i c r e t e n t i o n mechanism h a s been
o v e r r i d d e n , a n d t h e column a s s e m b l y s h o u l d b e r e p l a c e d .
To Remove Upper S t e e r i n q Column Assembly: Non-S.I.R. c a r s

1. Remove t h e s t e e r i n g w h e e l ( s e e S u b - s e c t i o n H B . 2 ) .
2. Remove t h e column s h r o u d s : R e l e a s e t h e two screws a t e a c h s i d e , s e c u r i n g t h e

u p p e r t o t h e l o w e r s h r o u d . Release t h e s i n g l e screw a n d washer from b e n e a t h ,
s e c u r i n g t h e l o w e r s h r o u d t o t h e column l o c k .
3. Remove t h e column s w i t c h e s : From b e n e a t h t h e f a s c i a , d i s c o n n e c t t h e column

s w i t c h a n d i g n i t i o n s w i t c h c o n n e c t o r b l o c k s , a n d a l l t i e wraps s e c u r i n g
w i r i n g a n d h e a t e r d u c t i n g t o t h e column. R e l e a s e t h e two s c r e w s s e c u r i n g t h e
'
wiper c o n t r o l s w i t c h a n d remove b o t h column s w i t c h a s s e m b l i e s . S l i d e o f f t h e

s w i t c h s p a c e r r i n g from t h e column.
Page 10
column l o c k s h e a r bolt
Switch
mounting
~eam/dip/turn/horn
s w i t c h assembly Switch
spacer
ring Wiper s w i t c h assembly
4. From w i t h i n t h e f o o t w e l l , remove t h e p i n c h b o l t s e c u r i n g t h e u n i v e r s a l j o i n t
t o t h e b o t t o m o f t h e u p p e r column a s s e m b l y .
5. S l a c k e n t h e clamp s e c u r i n g t h e column a s s e m b l y l o w e r e n d t o t h e p e d a l b o x ,
a n d remove t h e two MI0 b o l t s f i x i n g t h e column u p p e r e n d t o t h e s c u t t l e beam.
Withdraw t h e c o m p l e t e column a s s e m b l y t h r o u g h t h e f a s c i a .
6. C a r e f u l l y d r i l l o u t t h e s h e a r b o l t h e a d s s e c u r i n g t h e column l o c k a s s e m b l y t o
t h e column and remove t h e l o c k . Remove a n d d i s c a r d t h e s h e a r b o l t t h r e a d s .
TO Ref it Upper S t e e r i n g Column Assembly: Non-S. I.R . c a r s

1. F e e d t h e column t h r o u g h t h e f a s c i a a n d i n t o t h e p e d a l b o x c l a m p b r a c k e t a n d
i n t e r m e d i a t e column u p p e r u / j . Take care t o a l i g n t h e f l a t o n t h e column
with t h e pinch b o l t hole i n t h e u / j .
E n s u r e t h a t o n l y a m i n i m a l amount o f s h a f t i s a l l o w e d t o p r o t r u d e t h r o u g h t h e
j o i n t yoke a s shown i n t h e d i a g r a m . F i t a n d t i g h t e n t h e p i n c h b o l t u s i n g a
new M 8 ' P I t y p e Nyloc n u t (A907E6284F) t o 22 - 27 Nm (16 - 20 1 b f . f t ) .
Intermediate
~m
column
upper u / j
assembly Minimal
protrusion
Page 11
F i t t h e u p p e r e n d o f t h e column t o t h e s c u t t l e beam u s i n g t h e two M10 b o l t s
w i t h new s h a k e p r o o f w a s h e r s A075W4049Z and e x i s t i n g f l a t w a s h e r s . F i n g e r
tighten.
I
'Break o u t '
insert
Upper
column
F l a t washer assembly
Shakeproof w a s h e r
3. T i g h t e n t h e lower clamp b r a c k e t t o t h e column, t o 11 - 16 Nm ( 8 - 1 2 1 b f . f t )

b e f o r e t i g h e n i n g t h e u p p e r b o l t s t o t h e s c u t t l e beam t o 28 - 30 Nm ( 2 0 - 22
lbf . f t ) .
4. F i t t h e s t e e r i n g column l o c k / i g n i t i o n s w i t c h assembly t o t h e column u s i n g new

s h e a r b o l t s A079H6008F a n d t i g h t e n u n t i l s h e a r e d .
5. F i t t h e s w i t c h s p a c e r r i n g t o t h e t o p of t h e column w i t h t h e s p l i t on t h e
l e f t hand s i d e , and clamp t h e two column s w i t c h e s i n t o p o s i t i o n w i t h t h e p i p
on t h e i n d i c a t o r s w i t c h l o c a t e d i n t h e s p a c e r r i n g s l o t . Mate t h e c o n n e c t o r
b l o c k s from t h e column s w i t c h e s and i g n i t i o n s w i t c h , and f i t t i e wraps as
n e c e s s a r y t o s e c u r e h a r n e s s e s and h e a t e r d u c t i n g t o t h e column.
6. F i t t h e column lower s h r o u d w i t h screw a n d washer t o t h e column l o c k , and

then t h e upper shroud w i t h its f o u r screws.
7. R e f i t t h e s t e e r i n g wheel ( s e e Sub-Section H B . 2 ) .
To Remove Upper S t e e r i n g Column Assembly: S . I . R . C a r s

WARNING: Any work o n , or r e m a v a l of the s t e e r i n g column o n S . I . R . cars r e q u i r e s
that r i g o r o u s s a f e t y p r e c a u t i o n s be t a k e n i n order t o safeguard a g a i n s t
u n i n t e n t i o n a l deployment of t h e i n f l a t o r module. Do n o t a t t e m p t a n y
work on t h e s t e e r i n g column of an S . I . R . equipped car w i t h o u t r e f e r r i n g
t o Sub-Section WA.3 - L i n t h e separate manual ' S e c t i o n WA', p a r t no.
EO82T0327J.
1. Refer t o s e p a r a t e manual ' S e c t i o n WA' t o :

- remove t h e i n f l a t o r module ( S u b - s e c t i o n WA.3 - I )
- remove -
t h e s t e e r i n g w h e e l ( S u b - S e c t i o n WA.3 J)
- remove -
t h e r o t a r y c o n n e c t o r ( S u b - S e c t i o n WA.3 K)
- remove t h e k n e e b o l s t e r (Sub-Secion WA.3 - C)
2. Unplug t h e b l o c k c o n n e c t o r s a n d r e l e a s e t h e h a r n e s s e s f o r t h e column
s w i t c h e s . D e p r e s s t h e r e t a i n i n g p r o n g s , and s l i d e o u t t h e column s w i t c h e s
Page 12
Scuttle Single fixing Pedal box
beam to pedal box I
S.I.R. ~ y p eUpper
Column Assembly
'break out' insert
Top bearing
Indicator
cancelling
bush
Top bearing housing
Steering lock
Lock barrel
Page 13
from t h e column t o p b e a r i n g c a r r i e r . Release t h e small g r u b screw a t t h e
a
b o t t o m l e f t hand r e a r of t h e s t e e r i n g l o c k body, and p u l l o u t t h e i g n i t i o n
switch.
I f n e c e s s a r y , remove t h e s t e e r i n g l o c k mechanism e i t h e r by u n s c r e w i n g t h e two

s h e a r b o l t s u s i n g a hammer and punch, o r by d r i l l i n g o u t t h e b o l t h e a d s .
Remove t h e p i n c h b o l t from t h e u / j a t t h e b o t t o m end o f t h e s t e e r i n g column,

and remove t h e b o l t s e c u r i n g t h e column lower mounting b r a c k e t t o t h e p e d a l
box.
Remove t h e two n u t s and b o l t s s e c u r i n g t h e t o p end o f t h e column t o t h e

s c u t t l e beam, and withdraw t h e column assembly from t h e u p p e r i n t e r m e d i a t e
shaft .
I f n e c e s s a r y , t h e column assembly may b e d i s m a n t l e d :
- Remove t h e c i r c l i p from t h e t o p e n d o f t h e column, f o l l o w e d b y t h e c u s h i o n
r i n g , and withdraw t h e i n n e r column from t h e b o t t o m e n d o f t h e o u t e r
column.
- If n e c e s s a r y , remove t h e t h r e e b o l t s s e c u r i n g t h e t o p b e a r i n g h o u s i n g t o
t h e o u t e r column. Remove t h e c i r c l i p , and p r e s s o u t t h e b a l l b e a r i n g
assembly.
T o R e f i t Upper S t e e r i n g Column Assembly: S . I . R . c a r s

1. I f n e c e s s a r y , r e a s s e m b l e t h e column assembly:
- F i t t h e b a l l b e a r i n g i n t o t h e t o p b e a r i n g h o u s i n g u s i n g a p r e s s , and f i t
t h e r e t a i n i n g c i r c l i p . F i t t h e b e a r i n g h o u s i n g t o t h e t o p o f t h e column,
and r e t a i n w i t h t h e t h r e e M6 s e t s c r e w s and s p r i n g w a s h e r s . T i g h t e n t h e
t h r e e screws.
- F i t t h e i n n e r column i n t o t h e o u t e r , and f i t t h e c u s h i o n r i n g o v e r t h e t o p
end, f o l l o w e d by t h e r e t a i n i n g c i r c l i p .
2. F i t t h e u p p e r column assembly i n t o p o s i t i o n .
- Engage t h e u p p e r i n t e r m e d i a t e s h a f t i n t o t h e u p p e r column u / j , w i t h t h e
f l a t on t h e s h a f t a l i g n e d w i t h t h e p i n c h b o l t h o l e . F i t t h e s p r i n g washer
t o t h e s p e c i a l MI0 p i n c h b o l t , and t h r e a d i n t o t h e u p p e r u / j b u t d o n o t
tighten a t t h i s stage.
- Two v a r i a t i o n s o f s c u t t l e beam mounting p l a t f o r m h a v e been u s e d :
Early C a r s L a t e r Cars
'Break out'
insert
\ 633I
pin
Scuttle beam
beam
Column
Column
bracket
Page 14
On e a r l y c a r s , t h e column must b e p a s s e d b e n e a t h t h e s c u t t l e beam b e f o r e
p u l l i n g back o n t o t h e s c u t t l e beam p l a t f o r m s . F i t t h e s p a c e r washers
between column f l a n g e and beam, and r e t a i n w i t h f i x i n g s shown b u t do n o t
tighten.
On l a t e r c a r s , tila s c u t t l e beam i n c o r p o r a t e s two weld s t u d s o n t o which t h e
u p p e r column f l a n g e i s f i t t e d from b e n e a t h and r e t a i n e d w i t h w a s h e r s and
Nyloc n u t s . Do n o t t i g h t e n .
3. S e c u r e t h e column assembly lower b r a c k e t t o t h e p e d a l box w i t h t h e s i n g l e M 8

b o l t w i t h shakeproof and f l a t washer.
4. ~ i g h t e nt h e s t e e r i n g column f i x i n g s i n t h e f o l l o w i n g o r d e r :
- column t o p e d a l box; 24 Nm ( 1 7 . 5 1 b f . f t ) .
- column t o s c u t t l e beam ( 2 o f f ) ; 1 5 Nm ( 1 1 1 b f . f t ) .
- u p p e r column u / j t o upper i n t e r m e d i a t e s h a f t ; 40 Nm (30 1 b f . f t ) .
5. F i t t h e s t e e r i n g l o c k t o t h e t o p b e a r i n g h o u s i n g u s i n g new s h e a r b o l t s , and
t i g h t e n u n t i l t h e b o l t heads s h e a r .
6. F i t t h e i g n i t i o n s w i t c h and r e t a i n w i t h t h e g r u b s c r e w . S l i d e t h e two column

s w i t c h e s i n t o t h e column t o p b e a r i n g c a r r i e r and p l u g i n t h e i r b l o c k
connectors.
7. R e f e r t o s e p a r a t e manual ' S e c t i o n WA' (E082T0327J) t o :

- r e f i t t h e knee b o l s t e r (Sub-Secion WA.3 - C)
- r e f i t t h e r o t a r y c o n n e c t o r (Sub-Section WA.3 - K )
- r e f i t t h e s t e e r i n g wheel ( S u b - S e c t i o n WA.3 - J )
- r e f i t t h e i n f l a t o r module ( S u b - S e c t i o n WA.3 - I )
HB.4 - INTERMEDIATE STEERING COLUMN ASSEMBLY
On non-S.I.R. c a r s , a s i n g l e i n t e r m e d i a t e column i s u s e d t o g e t h e r w i t h two

u n i v e r s a l j o i n t s t o t r a n s m i t t h e motion of t h e upper s t e e r i n g column t o t h e
s t e e r i n g r a c k p i n i o n s h a f t . When r e f i t t i n g t h e i n t e r m e d i a t e column, it i s most
i m p o r t a n t t h a t t h e two j o i n t s a r e c o r r e c t l y phased w i t h r e s p e c t t o e a c h o t h e r .
On c a r s f i t t e d w i t h S . I . R . (Supplementary I n f l a t a b l e R e s t r a i n t ) , t h e s h o r t e r
u p p e r s t e e r i n g column assembly n e c e s s i t a t e s t h e u s e o f t w o i n t e r m e d i a t e columns
and t h r e e u n i v e r s a l j o i n t s , w i t h t h e lower i n t e r m e d i a t e column s u p p o r t e d i n a
c h a s s i s mounted b e a r i n g . The d e s i g n o f t h e i n t e r m e d i a t e column s y s t e m i s s u c h as
t o p e r m i t assembly o n l y w i t h t h e c o r r e c t p h a s i n g of t h e t h r e e u n i v e r s a l j o i n t s .
To Remove I n t e r m e d i a t e S t e e r i n g Column Assembly: Non-S.I.R. c a r s

1. Remove t h e p i n c h b o l t s e c u r i n g t h e u p p e r u / j t o t h e u p p e r column.
2. Remove t h e t w o n u t s and b o l t s s e c u r i n g t h e upper column assembly t o t h e

s c u t t l e beam, and s l a c k e n t h e clamp b o l t s e c u r i n g t h e lower end o f t h e column
t o t h e p e d a l box. Draw t h e u p p e r column assembly i n t o t h e car o n l y
s u f f i c i e n t l y t o d i s e n g a g e t h e i n n e r column from t h e u p p e r u / j .
3. From b e n e a t h t h e c a r , remove t h e p i n c h b o l t s e c u r i n g t h e lower u / j t o t h e

i n t e r m e d i a t e column and withdraw t h e i n t e r m e d i a t e column i n t o t h e c a r .
4. I f n e c e s s a r y , remove t h e p i n c h b o l t s e c u r i n g t h e lower u / j t o t h e s t e e r i n g
r a c k p i n i o n s h a f t , a n d remove t h e lower u / j .
To R e f i t I n t e r m e d i a t e S t e e r i n g Column Assembly: Non-S.I.R. c a r s
When r e f i t t i n g t h e i n t e r m e d i a t e column, it i s most i m p o r t a n t t o f o l l o w t h e
c o r r e c t p r o c e d u r e t o ' p h a s e ' t h e u p p e r and lower u / j s i . e . o r i e n t a t e t h e t h e t w o
j o i n t s i n a p a r t i c u l a r manner w i t h r e s p e c t t o e a c h o t h e r . This s e t t i n g provides
t h e optimum s t e e r i n g ' f e e l ' , w i t h minimum c y c l i c a l f o r c e v a r i a t i o n a s t h e w h e e l
is t u r n e d .
I n o r d e r t o e n s u r e t h a t t h e lower u / j i s n o t s l i d too f a r o n t o t h e p i n i o n
s h a f t , w i t h t h e c o n s e q u e n t d a n g e r o f t h e s h a f t end f o u l i n g t h e u / j s p i d e r , or
of t h e u / j fouling t h e chassis, a c i r c l i p is f i t t e d onto t h e pinion s h a f t
followed by a rubber s p a c e r tube.
A l i g n t h e p i n c h b o l t h o l e i n t h e lower u / j w i t h t h e f l a t o n t h e p i n i o n s h a f t
a n d f i t t h e u / j o n t o t h e s h a f t t o a b u t t h e s p a c e r t u b e , or u n t i l t h e s h a f t
e n d i s f l u s h w i t h t h e i n s i d e o f t h e u / j yoke. F i t t h e p i n c h b o l t a n d t i g h t e n
t o 22 - 27 Nm (16 - 20 1 b f . f t ) .
From i n s i d e t h e c a r , f e e d t h e i n t e r m e d i a t e column t h r o u g h t h e b u l k h e a d seal

( b u t n o t i n t o t h e lower u / j ) b e f o r e s l i d i n g o n t o t h e ( u n f i x e d ) u p p e r column
a s s e m b l y , w i t h t h e p i n c h b o l t h o l e a l i g n e d w i t h t h e column f l a t . F i t t h e
p i n c h b o l t b u t do n o t t i g h t e n a t t h i s s t a g e .
Turn t h e f r o n t w h e e l s u n t i l t h e a x i s o f t h e p i n c h b o l t h o l e i n t h e u p p e r p a r t
of t h e lower u / j i s i n a v e r t i c a l f o r e / a f t p l a n e a s shown i n t h e d i a g r a m .
Turn t h e s t e e r i n g wheel u n t i l t h e p i n c h b o l t s e c u r i n g t h e u p p e r column t o t h e

u p p e r u / j i s h o r i z o n t a l , and t h e u p p e r and lower u / j s are a l i g n e d ' b a c k t o
b a c k ' as shown.
RHD car viewed f r o m

RH side w i t h j o i n t s
i n aliqnment
LHD car
symmetrically
opposite
When j o i n t s are DO NOT INSERT

aligned, pinch a t t h i s stage
bolt i s h o r i z o n t a l
P i n c h bolt
vertical plane
Page 16
(.
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 RHD car viewed
( M-ID from RH side
with joints phased
sert
Pinch
--- .
bolt/
horizontal
Check pinch bolt

hole is still in
vertical plane
before assembly
T.,HD car viewed clockwise

from LH side
with joints phased
horizontal
Check pinch bolt

hole .is- still in
vertical plane
before a s s d l y
Page 17
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 of the steering wheel. Realign if
necessary as detailed in sub-section HB.2.
To Remove Intermediate Steerinq Column Assembly: With S.I.R.

WARNING: Any work on, or removal of t h e s t e e r i n g column on S . I . R . cars r e q u i r e s
t h a t r i g o r o u s s a f e t y p r e c a u t i o n s b e taken i n o r d e r ' t o safeguard a g a i n s t
u n i n t e n t i o n a l deployment of t h e i n f l a t o r module w i t h consequent r i s k of
p e r s o n a l i n j u r y o r unnecessary S . I . R . system r e p a i r s . Follow t h e
procedures.below i n t h e o r d e r l i s t e d t o temporarily d i s a b l e t h e S . I . R .
system and prevent f a l s e codes from s e t t i n g .
a) Turn o f f i g n i t i o n .
Disconnect t h e n e g a t i v e b a t t e r y c a b l e , and t a p e back t o e n s u r e t h a t
@
b)
it cannot c o n t a c t t h e battery terminal.
c) From beneath t h e passenger s i d e f a s c i a , l o c a t e and disconnect t h e
s i x way S I R f a s c i a h a r n e s s connector block.
d) Unplug t h e orange 3-way connectoe t o t h e . i n f l a t o r .
1. Remove the upper steering column assembly (see sub-section HB.3).
2. From beneath the vehicle, remove the pinch bolt securing the lower
intermediate shaft to the lower u/j. From inside the vehicle, withdraw the
intermediate shaft assembly from the steady bearing and body grommet.
3. If necessary, remove the pinch bolt securing the lower intermediate shaft u/j
to the upper intermediate shaft, and withdraw the upper shaft.
4. If necessary, remove the pinch bolt securing the lower u/j to the steering
rack pinion shaft, and withdraw the u/j. -
Upper i n t e r m e d i a t e L o w e r intermediate
column column
TO upper
column u/j
. . . .
. .
Support bearing To s t e e r i n g
rack pinion
shaft
a.
The lower i n t e r m e d i a t e s h a f t s t e a d y b e a r i n g , i s a n o i l i m p r e g n a t e d s y n t h e t i c
( R a i l k o ) bush p r e s s e d i n t o a b r a c k e t b o l t e d t o t h e c h a s s i s f r o n t crossmember.
The p o s i t i o n o f t h e b r a c k e r i s s e t by j i g d u r i n g v e h i c l e m a n u f a c t u r e , and s h o u l d
n o t b e d i s t u r b e d u n l e s s t h e bush i s t o b e r e p l a c e d .
To r e p l a c e t h e b u s h , remove t h e two s c r e w s s e c u r i n g t h e b r a c k e t , and p r e s s
o u t t h e bush. P r e s s t h e new bush i n t o p o s i t i o n , where it i s r e t a i n e d by a r i b
around t h e o u t s i d e o f t h e bush l o c a t i n g ' i n a groove i n t h e housing. The o i l
impregnated b u s h i s s e l f - l u b r i c a t i n g . F i t t h e bracket t o t h e c h a s s i s with t h e
two b o l t s , b u t d o n o t t i g h t e n a t t h i s s t a g e .
To R e f i t I n t e r m e d i a t e ' S t e e r i n g Column Assembly: With S . I . R .

' I n o r d e r t o e n s u r e t h a t t h e lower u / j is n o t s l i d t o o f a r o n t o t h e p i n i o n
s h a f t , w i t h t h e c o n s e q u e n t d a n g e r o f t h e s h a f t end f o u l i n g t h e u / j s p i d e r , o r
of t h e u / j f o u l i n g t h e c h a s s i s , a c i r c l i p i s f i t t e d o n t o t h e pinion s h a f t
f o l l o w e d by a r u b b e r s p a c e r t u b e .
A l i g n t h e p i n c h . b o l t h o l e i n t h e lower u / j w i t h t h e f l a t on t h e p i n i o n s h a f t
and f i t t h e u / j o n t o t h e s h a f t t o a b u t t h e spacer t u b e , o r u n t i l t h e s h a f t
e n d i s f l u s h w i t h t h e i n s i d e o f t h e u / j yoke. F i t t h e p i n c h b o l t and t i g h t e n
t o 22 - 27 Nm ( 1 6 - 20 1 b f . f t ) .
F i t t h e s h o r t e r end o f t h e u p p e r i n t e r m e d i a t e s h a f t i n t o t h e lower
intermediate s h a f t u / j with t h e f l a t aligned with t h e pinch b o l t hole.
R e t a i n w i t h t h e p i n c h b o l t and a new Nyloc n u t and t i g h t e n t o 2 4 Nm (18
lbf .ft).
F i t t h e i n t e r m e d i a t e s h a f t assembly t h r o u g h t h e bulkhead s e a l . , t h r o u g h t h e
s t e a d y b e a r i n g , and i n t o t h e lower u / j w i t h t h e f l a t on t h e s p l i n e s a l i g n e d
w i t h t h e p i n c h b o l t h o l e . F i t t h e p i n c h b o l t and r e t a i n w i t h a new M 8 Nyloc
h a l f n u t . T i g h t e n t o 24 Nm ( 1 8 l b f - f t ) .
R e f i t t h e u p p e r s t e e r i n g column assembly ( s e e s u b - s e c t i o n H B . 3 ) .
T e m p o r a r i l y f i t t h e s t e e r i n g wheel and t u r n a s n e c e s s a r y t o f i n d t h e p o i n t of
minimum c l e a r a n c e between t h e i n t e r m e d i a t e s h a f t assembly and t h e f u l l y
depressed clutch pedal:
- I f t h e lower s h a f t s t e a d y b e a r i n g was n o t d i s t u r b e d , c h e c k t h a t t h e r e i s a
minimum c l e a r a n c e o f 5 mm a t t h i s p o i n t .
- I f t h e lower s h a f t s t e a d y b e a r i n g h a s b e e n renewed o r d i s t u r b e d , a d j u s t
t h e p o s i t i o n o f t h e b r a c k e t on t h e c h a s s i s t o a c h i e v e a c l e a r a n c e o f 5 -7 m
b e f o r e t i g h t e n i n g t h e s t e a d y b e a r i n g f i x i n g b o l t s t o 11 Nm ( 8 1 b f . f t ) .
HB.5 - TRACK ROD ENDS L TOE-IN ADJUSTMENT
The t r a c k r o d e n d s ( o u t e r b a l l j o i n t s ) are t h r e a d e d o n t o t h e e n d s of t h e
t r a c k r o d s , a n d are s e c u r e d t o t h e hub c a r r i e r s t e e r i n g arms by t a p e r e d b a l l p i n
s h a n k s and Nyloc n u t s . By s c r e w i n g t h e t r a c k r o d s i n o r o u t o f t h e r o d e n d s , t h e
e f f e c t i v e l e n g t h o f t h e t r a c k r o d s i s a l t e r e d , t h e r e b y p r o v i d i n g a means of
t o e - i n a d j u s t m e n t f o r t h e f r o n t wheels.
I n o r d e r t o m a i n t a i n t h e r e q u i r e d bump steer c h a r a c t e r i s t i c , it i s i m p o r t a n t
t o e n s u r e t h a t t h e s t e e r i n g r a c k i s c e n t r a l i s e d i n t h e s t r a i g h t ahead p o s i t i o n ,
i . e . b o t h t r a c k r o d s are t h e same l e n g t h , w i t h i n t h e l i m i t a t i o n s o f s t e e r i n g
wheel a l i g n m e n t ( s e e s u b - s e c t i o n HB.2).
Toe-in a d j u s t m e n t : B e f o r e measuring t h e f r o n t wheel a l i g n m e n t , s e t t h e car t o a

, r i d e h e i g h t o f 170 mm below t h e c h a s s i s f r o n t crossmember.
Page 19
specification: Prior VIN 82 D 3582, From VIN 82 D 3582, 85 D 3587
85 D 3887, 8 2 / ~2728 82/F 2728, 8 2 / ~5000
Toe-in : 1.6mm e a c h s i d e ; to, -1mm 0 . 1 t o 1.9mm o v e r a l l
To a d j u s t t h e t o e - i n ( f r o n t wheel a l i g n m e n t ) , h o l d t h e t r a c k r o d e n d s b y t h e
f l a t s provided w h i l s t releasing t h e i r locknuts. Turn e a c h t r a c k r o d , a n EQUAL
amount, e i t h e r t o i n c r e a s e t h e e f f e c t i v e l e n g t h o f e a c h t r a c k r o d ( i n c r e a s e
t o e - i n ) , o r t o s h o r t e n each t r a c k rod (reduce t o e - i n ) . Take c a r e n o t t o t w i s t
t h e s t e e r i n g rack g a i t e r s during t h i s operation; loosen t h e g a i t e r o u t e r c l i p s i f
n e c e s s a r y . When a d j u s t m e n t i s correct, .hold t h e t r a c k r o d e n d s and t i g h t e n t h e i r
l o c k n u t s ' t o 60 Nm ( 4 4 1 b f . f t ) . Recheck t o e - i n and t i g h t e n t h e g a i t e r c l i p s .
For f u l l s t e e r i n g geometry specification and adjustment of castor, see

s u b - s e c t i o n CD.2/3.
T r a c k r o d e n d r e p l a c e m e n t : I f t h e b a l l j o i n t b o o t i s damaged, o r i f any p l a y i n
t h e j o i n t is d i s c e r n i b l e , t h e j o i n t should be replaced. B e f o r e removing t h e
j o i n t , measure t h e l e n g t h of v i s i b l e t r a c k rod t h r e a d i n o r d e r t h a t t h e i n i t i a l
s e t t i n g o f t h e new j o i n t may be a p p r o x i m a t e l y correct. Remove t h e n u t s e c u r i n g
t h e b a l l p i n i n t o t h e s t e e r i n g arm, and u s e a b a l l j o i n t s p l i t t e r t o o l t o
s e p a r a t e t h e j o i n t from t h e s t e e r i n g arm. R e l e a s e t h e l o c k n u t , and unscrew t h e
j o i n t from t h e t r a c k r o d .
Thread t h e new j o i n t o n t o t h e t r a c k r o d and screw up t o t h e p o s i t i o n n o t e d
b e f o r e removal. F i t t h e b a l l p i n i n t o t h e s t e e r i n g arm from t h e t o p , s e c u r e w i t h
a new Nyloc n u t ( w i t h o u t w a s h e r ) and t o r q u e t i g h t e n t o 4 1 - 47 Nm (30 - 35
1 b f . f t ) . Check a n d a d j u s t t o e - i n and t i g h t e n t h e r o d end l o c k n u t s as above.
HB.6 - STEERING RACK GAITERS
The g a i t e r s f i t t e d a t e a c h end o f t h e r a c k assembly a r e a v a i l a b l e as a k i t

which i n c l u d e s t h e t w o g a i t e r s and f o u r c l i p s . The i n t e g r i t y o f t h e g a i t e r s a n d
t h e i r s e a l i n g t o t h e r a c k h o u s i n g and t r a c k r o d s i s v i t a l t o t h e l o n g e v i t y o f t h e
s t e e r i n g a s s e m b l y , as any w a t e r or d i r t i n g r e s s w i l l c a u s e r a p i d wear a n d
d e t e r i o r a t i o n o f t h e moving p a r t s . The g a i t e r s s h o u l d b e c a r e f u l l y i n s p e c t e d a t
e v e r y s e r v i c e , and r e p l a c e d i f showing any s i g n s o f damage, w e a r , a g e h a r d e n i n g
or p e r i s h i n g . A q u i c k c h e c k method i s t o s q u e e z e e a c h g a i t e r i n t u r n a n d l i s t e n
f o r any e s c a p e o f a i r from a g a i t e r h o l e , j o i n t , o r f a u l t y r a c k h o u s i n g .
Only 'Neoprene' t y p e g a i t e r s s h o u l d be u s e d , r e c o g n i s i b l e by t h e i r f l e x i b l e
rubbery t e x t u r e and m a t t appearance. D o n o t u s e t h e more r i g i d p l a s t i c
( ' S a n t o p k e n e ' ) g a i t e r s which a r e less l i k e l y t o form a s a t i s f a c t o r y seal w i t h t h e
r a c k housing and t r a c k rods.
To F i t Gaiter K i t
1. Remove t h e n u t s e c u r i n g e a c h t r a c k r o d end t o t h e h u b carrier s t e e r i n g arm
and u s e a b a l l j o i n t s e p a r a t o r t o disconnect t h e j o i n t .
2. At e a c h s i d e , mark t h e p o s i t i o n o f t h e t r a c k r o d end a g a i n s t i t s t r a c k r o d ,
a n d c o u n t t h e number of v i s i b l e t h r e a d s b e f o r e s l a c k e n i n g t h e t r a c k r o d e n d
l o c k n u t , a n d u n s c r e w i n g t h e rod end a n d l o c k n u t from t h e t r a c k r o d .
3. S l a c k e n t h e t w o c l i p s s e c u r i n g e a c h g a i t e r , and s l i d e t h e g a i t e r o f f t h e
t r a c k rod.
4. I n s p e c t t h e c o n d i t i o n o f t h e r a c k assembly a n d i n n e r b a l l j o i n t s and r e p l a c e
a
Page 20
t h e s t e e r i n g u n i t i f n e c e s s a r y . I f t h e assembly i s s e r v i c e a b l e , c l e a n o f f
a n y d i r t i f n e c e s s a r y b e f o r e l u b r i c a t i n g t h e r a c k w i t h e i t h e r EP90 o i l ( e a r l y
c a r s ) o r , on later cars, Texaco CUP 2 g r e a s e o r e q u i v a l e n t ( l i m e b a s e d , water
resistant).
5. At e a c h s i d e , f i t t h e new g a i t e r and c l i p s o v e r t h e t r a c k r o d , l o c a t e t h e
l a r g e end i n t h e groove on t h e r a c k h o u s i n g ( p i n i o n e n d ) o r j u s t i n b o a r d of
t h e end bush l o c a t i n g h o l e s , and s e c u r e w i t h t h e c l i p . To a i d t r a c k r o d
a d j u s t m e n t , a p p l y a s m a l l amount o f r e d r u b b e r g r e a s e t o t h e t r a c k r o d g r o o v e
b e f o r e l o c a t i n g t h e o u t b o a r d end of t h e g a i t e r . Do n o t t i g h t e n t h e c l i p a t
t h i s stage.
6. A t e a c h s i d e , f i t t h e l o c k n u t a n d t r a c k r o d end o n t o t h e t r a c k r o d , and screw

on t o t h e same p o s i t i o n as n o t e d p r i o r t o removal. T i g h t e n t h e l o c k n u t t o 70
- 80 Nm ( 5 0 - 60 1 b f . f t ) .
7. F i t e a c h t r a c k rod end i n t o i t s hub c a r r i e r s t e e r i n g arm, and s e c u r e w i t h a

new Nyloc n u t , t i g h t e n i n g t o 4 1 -
47 Nm ( 3 0 - 35 1 b f . f t ) . T i g h t e n t h e g a i t e r
outer clips.
8. Check f r o n t wheel a l i g n m e n t .
HB.7 - RACK & PINION ASSEMBLY
The manual s t e e r i n g r a c k and p i n i o n assembly f i t t e d t o t h e E s p r i t , i s

m a i n t e n a n c e f r e e , and w i t h t h e e x c e p t i o n of t h e t r a c k r o d g a i t e r s , i s a non-
s e r v i c e a b l e u n i t which must be renewed i f e x c e s s i v e p l a y d e v e l o p s , e x e m p l i f i e d by
'clanking' n o i s e s , wheel shimmy, o r any more t h a n t h e s m a l l e s t amount of f r e e
p l a y a t t h e s t e e r i n g wheel. Any a t t e m p t t o compensate f o r wear i n t h e s t r a i g h t
a h e a d p o s i t i o n by re-shimming t h e r a c k t h r u s t p a d , may r e s u l t i n t i g h t n e s s o r
jamming a t some o t h e r p o i n t o f r a c k t r a v e l .
The r a t i o o f t h e r a c k and p i n i o n g e a r i s 4 5 : l ( 4 5 nun r a c k t r a v e l p e r p i n i o n
r e v o l u t i o n ) , and t h e r a t i o o f t h e c o m p l e t e s t e e r i n g s y s t e m is 1 5 . 4 : l ( a n g u l a r
movement o f s t e e r i n g wheel : a n g u l a r movement o f r o a d w h e e l ) .
The r a c k and p i n i o n assembly i s s e c u r e d t o two p l i n t h s on t h e f r o n t o f t h e
c h a s s i s f r o n t crossmember v i a a p a i r of two b o l t clamp b r a c k e t s and r u b b e r
i s o l a t o r b u s h e s . L a t e r a l l o c a t i o n o f t h e u n i t i s a s s u r e d by a p a i r o f l u g s on
t h e non-pinion end of t h e r a c k h o u s i n g , which s t r a d d l e t h e c h a s s i s p l i n t h .
To Remove Rack & P i n i o n Assembl

1. Remove t h e f r o n t r o a d wheel: and d i s c o n n e c t t h e t r a c k r o d e n d s from t h e hub
carrier s t e e r i n g arms.
2. Remove t h e p i n c h b o l t s e c u r i n g t h e u / j t o t h e s t e e r i n g r a c k p i n i o n s h a f t .
3. R e l e a s e t h e two b o l t s s e c u r i n g e a c h of t h e t w o s t e e r i n g u n i t clamp b r a c k e t s ,
a n d remove t h e clamp b r a c k e t s , r u b b e r mountings, and l o o s e t a p p i n g p l a t e s .
4. Withdraw t h e p i n i o n s h a f t from t h e u / j , and manoeuvre t h e u n i t o u t from t h e

c h a s s i s towards t h e d r i v e r ' s s i d e .
To R e f i t Rack & P i n i o n Assembly

1. B e f o r e f i t t i n g t h e s t e e r i n g u n i t , check t h e f o l l o w i n g p o i n t s :
- b o t h g a i t e r s a r e undamaged and c o r r e c t l y l o c a t e d a n d s e a l e d ; s q u e e z e e a c h
-,
.
g a i t e r t o check f o r a i r l e a k s from g a i t e r s , j o i n t s o r h o u s i n g .
Page 21
- t h e c i r c l i p and s p a c e r t u b e a r e f i t t e d o n t o t h e p i n i o n s h a f t .
2. Feed t h e u n i t i n t o p o s t i o n i n t h e c h a s s i s from t h e d r i v e r ' s s i d e and s l i d e

t h e pinion s h a f t i n t o t h e u / j with t h e pinch b o l t h o l e aligned with t h e f l a t
on t h e s h a f t . .
3. F i t t h e mounting r u b b e r s around t h e r a c k housing, and s e c u r e t h e u n i t w i t h

t h e two clamp b r a c k e t s , i n s e r t i n g t h e t a p p i n g p l a t e s i n t o t h e c h a s s i s
p l i n t h s . T i g h t e n t h e f i x i n g s t o 16 -19 Nm (12 - 14 1 b f . f t ) .
4. F i t t h e p i n c h b o l t and new Nyloc n u t t o s e c u r e t h e lower u / j t o t h e p i n i o n

s h a f t , and t i g h t e n t o 22 - 27 Nm ( 1 6 - 20 l b f - f t ) .
5. F i t each t r a c k rod end i n t o i t s hub c a r r i e r s t e e r i n g arm, and s e c u r e w i t h a

new Nyloc n u t , t i g h t e n i n g t o 4 1 - 4'7 Nm ( 3 0 - 35 l b f - f t ) .
6. Check f r o n t wheel a l i g n m e n t .
--
Page 22
SECTION JB Page 1
BRAKES
SECTION JB - ESPRIT S3 & TURBO: PRIOR TO '85 MODEL YEAR
This section i s applicable to c a n up to and including 1984 Model

Year which use solid brake discs and G i r l i n g calipers front and
rear.
Section Page
-
General Description
Front Brake Pad Replacement
Rear Brake Pad Replacement
Handbrake
Front Brake Caliper Overhaul
Rear Caliper Overhaul
Brake Discs
Master Cylinder
Servo Unit
Page 2 SECTION JB
GENERAL DESCRlPTl ON
The braking system comists of a G i r t i n g Type 28 Supervac servo unit attached to

a tandem master cylinder with a bore of 19.05mm (0.75 i n ,) operating type GA2,
calipers w i t h 250mm (9.7 in.) diameter discs a t the front, and type 9CH sliding
caliper w i t h 275mm (1 0.82 i n .) diameter discs a t the rear. The rear brakes are
m ounted inboard .
The separate front/rear hydraulic. circuits share a brake fluid reservoir fitted with
a low f l u i d level warning switch. This circuit, which operates a fascia t e l l tale
lamp, may be checked by depressing the test button on the reservoir cap.
The handbrake lever connects via individual cables to each rear brake caliper,
and mechanically operates their hydraulic pistons. Each piston incorporates a
self adjusting mechanism which operates on footbrake application to compensate
for brake pad wear.
JB. 1 - FRONT BRAKE PAD REPLACEMENT
Minimum pad thickness = 3mm

Always change brake pads i n axle sets.
1 . After raising the front of the vehicle, remove the front wheels:
WARNING: When both front w'heels are raised, do NOT move the road wheels
quickly from lock to lock, as this w i l l cause hydraulic pressure to
build up within the steering gear, which may cause the rubber
bellows to bunt or blow off.
2. Remove any accumulated road f i l t h from the area of the brake pad.
3. Pull out the pad retaining pin clips (A), withdraw the retaining pins
(B) and remove the brake pads with the shims (C). Note the position
of the dust shield (D) fitted over the brake pads .
SECTION J B Page 3
4. Toenablethenewpdstobefitted,pushthepistonsinthecalip4n
back into the bores. This action w i l l cause hydraulic fluid to be
returned to the master cylinder, which i f i t has recently been topped-
up, m y overflow. To avoid this, examine the fluid level a n d i f
necessary, remove a quantity o f fluid BEFORE pushing the pistons back
into the bores. D O NOT USE REMOVED FLUID FOR TOPPING-UP
PURPOSES.
5. F i t the new brake pads with the shim taking care that both are fitted
correctly. The shim are marked with an arrow which MUST point i n
the direction of forward rotation of the wheel. Replace the dust shield,
refit the retaining pins and the locking clips.
6. Operate the brake pedal several times to bring the pads into correct
operating position. Check that the pads are free to move and that the
retaining pins are not fouling the pads.
7. Replace the road wheels, lower the vehicle to the ground, check the
brake, fluid and top up if necessary. Tighten the wheel nuts to the
specified torque loading .
CAUTION: The brakes w i l l not work a t f u l l efficiency until the new brake pads
have bedded-in. If, initially, the brakes are used too heavily, the surface of
the pads w i l l burn and irregular braking result. Use the brakes gently for the first
few miles and gradually build up brake effort.
JB. 2 - R E A R BRAKE PAD REPLACEMENT
Minimum pad thickness = 3mm
1. Remove the two self locking screws securing the caliper body to the two
guide pins, whilst holding the guide pins stationary with a spanner to
prevent damage to their dust covers.
2. Remove the caliper body a d support to avoid straining the flexible hose.
Remove the pads and clean the pad abutment areas taking care not to
damage the guide pin or pis ton dust coven.
. 3. Before fitting new pads, the piston must be pushed back into the
caliper and the handbrake auto-adjust mechanism reset. Fit a
0
screwdriver against the piston and turn the piston 45 to disengage
the ad jvster ratchet. Press back the piston (take care that the fluid
reservoir does not overflow), and then turn the piston back 450 to
re-engage the ratchet.
Page 4 SECTION JB
4. Fit new pads and damper spring into the caliper bracket, and r e f i t
the caliper body, alighing the stot i n the piston with the lug on the
brake pad backplate.
5. F i t new self locking bolts to secure the caliper body to the guide
pins. F i t the top bolt .first, then compress the p d damper spring
and f i t the lower bolt. Torque tighten both bolts to 3.2 - 3.6
kgf.m. (23-26 Ibf.ft.).
6. Operate the footbrake several times to bring the pads to their correct
working position and to take up the handbrake adjustment.
CAUTION: The brakes w i l l not work at f u l l efficiency u n t i l the new brake

pads have bedded-in. If, initially, the brakes are used too heavily, the
surface of the pads w i l l burn and irregular braking result. Use the brakes
gently for the first few miles and gradually build up brake effort.
JB. 3 - HANDBRAKE
The handbrake lever connects to an actuating link which uses a compensator

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

when the handbmke i s applied.
The cylindkr end covers on the brake caliper asselnblies, contain a handbrake
automatic adjustiment mechanirm to accommodate brake pad wear. Movement
of the caliper lever causes a cam to rotate and exert a force via a pushrod and
adjuster mechanism, on the caliper piston and brak
The 'relaxed' position of the piston i s

controlled by the piston seal i n the cylinder
wall, which pulls the piston back a specified
amount after each brake application. As the
brake pad wears, and the piston moves out-
wards accordingly, the ratchet teeth '0' are
pulled past the pawl 'A', so keeping the
handbrake mechanism i n constant ad justment.
A
SECTION JB Page 5
A small amount of lost motion i s permitted which prevents over-adjustment,

and permits proper relaxation of the pads after each brake application.
I n 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 disengaged. To do this, rotate the pis ton 45O i n either direction.
Turn back to re-engage the ratchet, and align piston slot with the lug on the brake
pad backpla te .
JB. 4 - FRONT BRAKE CALIPER OVERHAUL
Note: N o attempt should be made to remove the bolts and separate the two halves
of the caliper body.
1. Disconnect the flexible hose from the caliper and remove caliper from
the vertical link. Drain brake fluid from the caliper.
2. Remove the brake pads as i n JB . I and pull o f f the piston dust covers.
3. Using rag to protect from brake fluid spray, and keeping fingers well
clear, use compressed air to eject the pistons from their cylinden.
4. Remove the sealing rings from the cylinders taking care not to damage
the bores or grooves.
5. Clean a l l park thoroughly with G i r l i n g Cleaning Fluid or unused brake

fluid. Examine cylinder bores and piston for any signs of scoring, scuffing
or corrosion. Replace the pistons or complete caliper i f there i s any daub .
6. Lubricate the cylinden and new sealing r i n g with clean brake fluid and
f i t the seals into their grooves.
7. Fit the pistons and dust coven .

8. Refit the calipers (see TDD for torque loading) and brake pads (see JB. 1).
9. Reconnect the flexible hose and bleed the hydraulic system.
JB. 5 - REAR CALIPER OVERHAUL

1. Disconnect the flexible hose and handbrake cable and remove the
.
bmkepads (JB 2).
..
2. Pull the guide pin dust covers from the caliper bracket, and withdraw
the guide pins. Inspect guide pins for any signs of corrosion or seizing,
and replace with new parts ifi n any doubt, Note thdt the guide p i n
with the bushing, i s fitted to the bottom (trailing) end of the caliper and
the plain steel p i n to the top (leading) end. Grease the guide pins and
check that they slide easily i n the caliper bracket. Locate the guide pin
dust covers.
Page 6 SECTION JB
3. 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.
4 The handbrake mechanism can be separated from the cylinder body

after releasing the three bolts on i i s cover plate.
IMPORTANT N o attenpt should be made to dismantle the auto-ad just
mechanism. If i t i s faulty, a complete new unit must be fitted.
5. Remove the sealing ring from the cylinder, and clear a l l parts with
fresh brake fluid. . Examine cylinder bores and pis tons for any signs of
scoring, scuffing or corrosion and replace pistons or caliper i f i n any
doubt.
6. Lubricate a new piston seal with clean brake f l u i d and fit into its
groove i n the cylinder wall .
7. Lubricate t h e piston, and f i t the dust cover onto the piston as shown.
Offer the piston and dust cover assembly to the cylinder with the
piston orientuted to clear the handbrake auto adjustment (see JB. 2).
Locate the l i p of the dust cover into the cylinder groove and carefully
push the piston fully home through the dust cover. Emure the dust
cover i s not trapped between the piston and the bore and that the inner
l i p of the dust cover i s located i n the pis tori groove.
PISTON PISTON
PISTON SEAL DUST COVER
DUST COVER \ /
PISTON
0
PISTON
\
1
Turn the piston 45O to engage the handbrake adjustment ratchet and
refit the brake pads and caliper to the car.
Wconnect handbrake cable and flexible hose and bleed brake system.
OPERATE THE BWKE PEDAL SEVERAL TIMES TO BRING THE PADS
TO THEIR CORRECT OPERATING POSITION.
SECTION JB Page 7
JB. 6 - BRAKE DISCS
Check the braking surface on both sides of the brake discs for scoring or corrosion.
Replace i f i n 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.) 0.09 mm (0.0035 in.)
:
I f the run-out i s excessive, replace the disc.
a NOTE: Ensure the front wheel bearings are correctly adjusted before measuring
front disc run-out .
JB. 7 - MASTER CYLINDER
To Overhaul
1. Drain brake fluid from the reservoir, dis connect the brake pipes a nd
remove master cylinder assembly to a clean work area .
2. Remove the reservoir retaining pins, and carefully pull the reservoir
from the master cylinder. Lever out the two seals.
3. Push the plunger down the cyli~iderand withdraw the secondary plunger
stop pin. (9)
9 22
O J O O O
D O O O O O O O O
4. Remove the retaining circlip and wi thdmw the primary .plunger assembly.
Use low pressure compressed air to eeject the secondary plunger assembly.
'a 5.
Remove the secondary plunger spring, .(22) seal retainer '(1 7) recuperating
s e a l (1 8) and washer (1 9). Taking care not to damage the plunger, remove
the seal (20). Keep the plunger and i t s spring together a t a l l times.
Page 8 SECTION JB
6. Remove the primary plunger spring (16), seal refainer (17) recuperating
0
seal (1 8) and washer (19). Slide off the vacuum seals (34) and spacers
(24) and (25). Keep the plunger and i t s spring together a t a l l times.
7. Check that the breather hole at the rear underside of the cylinder i s
clear and wash with Girling Cleansing Fluid i f necessary..
8. The new parts supplied i n the overhaul k i t indicate which old partsare to
be discarded. Clean a l l remaining parts with Girting Cleaning Fluid,
or new brake fluid and examine the cylinder bore meticulously. Unless
unmarked, a complete new unit should be fitted.
TO HELP PREVENT DAMAGE, I T I S ESSENTIAL THAT GENEROUS,
AMOUNTS OF UNUSED GIRLING BRAKE FLUID ARE USED AT ALL
STAGES OF SEAL ASSEMBLY.
9. p it secondary plunger seal (20) by squeezing between finger and thumb

to stretch over plunger l i p . Fit washer (1 9) recupemting seal (1 8) seal
retainer (17) and spring (22). Ensure seals are correctly fitted as shown.
O J O O O
D O O O O O O O
10. Fit the primary piston washer, recuperating seal, seal retainer and spring
i n a similar manner.
11. Use the special BMS grease provided to lubricate the inside diama ter of the
vacuum seals and spacers, and the corresponding outer surface of the primary
plunger.
I T IS VITAL THAT THE FOLLOWING INSTRUCTIONS ARE CARRIED OUT
PRECISELY OTHERWISE DAMAGE WILL ENSUE TO THE NEW SEALS WHEN
1NSERTl NG THE PLUNGERS IWTO THE CYLI NDER BORE.
12. Clamp c y l i ndet im vice, and copiously l u b r i ~ te

a cyli nder bore and
secondary plunger assembly with unused Girling Brake Fluid. Offer
the plunger assembly to the cylinder until the recuperation seal i s
SECTION JB Page 9
resting centrally i n the mouth of the bore. Ensuring the seal i s 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 i n one continuous movement.
13. Repeat this lubricating and f i t t i n g procedure exactly for the primary
plunger assembly.
14. Press the plunger down the bore to enable the secondary plunger stop
pin to be fitted as shown.
15. Whilst holding the plunger pressed in, f i t the thin vaccum seal spacer
into the end of the cylinder, followed by one vacuum seal ( l i p side
first), a thick spacer, the other seal and thick spacer, and retain with
the c i r c l i p .
16. Lubricate new reservoir seals with brake fluid, and f i t into the cylinder.
Press the reservoir into position and f i t the reservoir retaining pins.
17. Use a new master cylinder/servo '0' ring, and refit the master cylinder
assembly to the servo, torque tightening the two nuts to 2 . I - 2.6 kgf. m
-
(15 19 Ibf. ft.).
18. Reconnect the brake pipes, r e f i l l the reservoir, and bleed the entire
system.
Page 70
JB. 8 - BRAKE SERVO UNIT
The 'Supervac' brake servo is, with the exception of the a i r f i l t e r and non return
valve, a non-servicable sealed unit which must be replaced i f found to be faulty.
The a i r f i l t e r (surrounds input push rod) should be replaced whenever the brake
system i s overhauled, and cleaned or replaced more frequently if the vehicle i s
operated i n d u s v conditiom. The f i l t e r is supplied together w i t h the input dust
cover and servo/master cylinder '0' ring i n the servo 'service k i t ' A075J6033F.
The vacuum non-return valve i s incorporated into the vacuum hose elbow connector
i n the front case of the servo unit. The valve i s a push f i t into a grommet, and i s
supplied complete with new grommet. Use the grease supplied to lubricate the ribs
of the NRV before assembly.
As a quick check of servo operation proceed as follows:
W i t h engine stopped, press the bmke pedal several times to exhaust the servo unit
of vacuum. Keeping the pedal pressed (which should be 'hard' and 'high') start
the engine; the pedal should drop slightly as the servo vacuum builds up.
SECTION JC Page I
BRAKES
SECTION JC - ESPRIT S3 & TURBO: 1985 MODEL YEAR ONWARDS
This section i s 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 A C G rear disc brake assemblies.
Section
General Description
Front Brake Pad Replacement
Rear Brake Pad Replacement
Handbrake Adjustment
Front Caliper Overhaul
Rear Caliper Overhaul
Brake Discs
Servo Unit
Master Cylinder
.,..
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 'Nivocode' low fluid level warning switch.
This circuit, which operates a fascia tell-tale lamp, may be checked by
depressing the test button on the reservoir cap.
The handbrake lever connects via individual cables to each rear brake caliper,
and mechanically operates their hydraulic pistons via a self adjusting mechanism.
JC. 1 - FRONT BRAKE PAD REPLACEMENT
Pad thickness may be checked using the inspection hole i n the caliper.
Standard pad thickness - 1OSmm (0.41 in.)

Minimum pad thickness - 2 mm (0.08 in.)
To remove pads
Remove the bolt from the lower of the two caliper sliding pins, and swing
.
up the caliper to allow access to the pads The caliper may be supported
i n the raised position by inserting a bolt into the torque plate hole.
Slide out both brake pads. Referring to the illustration remove each anti-
rattle ~ ~ r i n g / ~ u iplate/support
de plate ONE AT A TIME, and replace with
the new item supplied with the new pad set.
NOTE: Pay special attention to the correct assembly of anti-rattle springs

and pad guide plates to the caliper. Most of these are handed.
Note that the inner pad guide plate forms a solid abutment and i s fitted to
the top (or thrust) end of the caliper, whilst the inner pad anti-rattle spring
is fitted to the lower end.
Fit the anti-squeal shim to the outer pad and insert into the caliper, ensuring
that the anti-rattle spring tongues are tucked into the brake pad backplate
slots.
Insert the inner pad into the caliper.
Lower the caliper cylinder, and secure with the lower sliding pin bolt,
torque tightening to 1 .6- . -
2.4 kgf m. (12 17 lbf ft) . .
NOTE: If new pads are fitted i t w i l l be necessary to push the piston
back Into the caliper bore. This action w i l l return fluid to the master
cylinder, which may, i f i t has been topped up, overflow. Remove fluid
from the master cylinder reservoir beforehand i f necessary.
Press the brake pedal several times to bring the pads to their correct running
position.
Page 3
-% \
~ A t i - s ~ u e oshim
Outer pad anti-rattle spring

C A U T I O N The brakes w i l l not work at f u l l efficiency u n t i l the new brake pads
l
have bedded-in . if i n i t i a l l y , the brakes are used too heavily, the surface o f the
pads w i l l burn and irregular braking result. Use the brakes gently for the first few
miles and gradually b u i l d up brake effort.
JC. 2 - REAR BRAKE PAD REPLACEMENT

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, i t i s necessary to retract the caliper pis ton i n i t s
bore. To do this, use a a" drive ratchet i n the slot of the piston to screw
the piston clockwise down i t s handbrake adjuster mechanism. Take care
that the fluid reservoir does not overflow during this opera tion. When fully
retracted, screw out again until the slot i s parallel with the two support wings,
and thegroove i s toward the bleed nipple side of the cylinder as shown.
6. F i t the brake pads, with their anti-rattle springs into the caliper bracket
7. Refit the caliper over the pads ensuring that the caliper wire springs are
located correctly, and slide i n both retaining plates. F i t the locking c l i p .
Correct
Anti-Rattle Spring
Ca Iiper
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 i s a feature o f the Bendix handbrake mechanism that a large amount o f handbrake
lever travel i s required i n order for the handbrake to work efficiently and for the
automatic adjustment to function. For this reason, a 'fold down' type handbrake
lever i s used to ease driver entry/exit.
The handbrake i s applied by pulling the lever upwards i n the usual manner. After
application, the lever may be pushed down again (WITHOUT pressing release button
i n end o f handgrip) whits t the fascia t e l l tale lamp warns of handbmke application.
To release the handbrake, pull lever up, press release button and HOLDING BUTTON
PRESSED IN, lower lever fully.
The handbrake lever i s connected via a short link to a multiplier lever to increase
leverage and reduce operator effort. The multiplier lever connects to an actuating
link which uses a compensator lever to balance the force applied to each handbmke
cable.
The Bendix calipers incorporate a screw thread self adjusting mechanism within their
hydraulic cylinders, which keeps the mechanical handbrake linkage adjusted with each
.
application o f the footbmke For this sys tern to function correctly, i t i s essential that
each caliper handbmke lever i s allowed to return fully, and i s not prevented from
doing so by maladjustment of the handbrake cable.
To check that this condition i s achieved, with the handbmke 'off', measure the distance
between the cable abutment and caliper lever as shown.
Page 6 SECTION JC
After verifying this dimension, any slack i n the cables may be adjusted out a t
their forward abutment inside the driver's s i l l trim panel. For access, slide the
driver's seat fully forward and lift the rear end of the s i l l carpet to expose the
trim p n e l aperture. After adjustment, re-check the caliper lever 'off' dimension
as above.
JC.4 - FRONT CALIPER OVERHAUL

1. Disconnect the brake hose from the caliper brake pipe and
bracket. Remove the caliper swing release bolt, raise the
caliper and draw off from the top slide pin.
2. Remove the sliding bush and its rubber boots.
3. Remove the top pin boot from the caliper using a small chisel
as shown.
4. Remove the spring ring and boot from the piston bore and use
compressed air to eject the piston from the cylinder.
WARNING: Keep fingers well clear during this operation,

and use rags to guard against brake fluid spray.
5. Remove piston seal from cylinder.
6. Reassembly. Apply rubber grease to parts as indicated.
7. Instal piston seal into cylinder bore, and insert piston .

Fit cylinder dust boot, and retain with spring ring.
8. Fit the top slide pin boot by using a 21mm socket as shown.
9. Fit the sliding bush with i t s two boots.

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 from the caliper.
2. Remove the locking clips, slide out the caliper retaining plates, and
remove caliper to bench.
3. Clean the caliper thoroughly. Remove piston boot. Using a a"

drive
ratc het, unscrew the piston from the handbrake adjustment mechanism.
4. Using a rag to protect against brake fluid spray, and keeping fingers
well clear, use compressed air to eject the piston from the cylinder.
Remove seal from groove i n cylinder.
5. Clean the groove, cylinder bore and piston with methylated spirit and
dry with compressed air. lmpect the groove, bore and piston surface
for any signs ofscratching or pitting. I f any such signs are apparent,
a replacement cylinder assembly should be fitted.
6. Fit a new seal into the cylinder groove. Lubricate the piston and bore
with brake fluid and press the piston into the cylinder.
-7. Smear the exposed part of the piston with the special Lockheed grease
supplied i n the seal kit, and f i t a new dust boot.
8. Screw the piston fully i n along the handbrake adjuster mechanism, and
then position with the piston slot parallel with the two support-wings
and the groove toward the bleed nipple side. (See brake pad replacement
. .
procedure JC 1)
Cylihder Removal If i t i s necessary to replace a cylinder assembly, special spreader

tool TOOOT0556 must be used to avoid damaging the special protective coating on the
cylinder and wings of the carrier bracket:
Position the tool as shown and turn the screws

(A) to adjust the alignment of i t s two a r m
against the two wings of the carrier bracket.
Gradually tighten the two nuts (B) until the

cylinder i s no longer gripped by the carrier
bracket. I t may be necessary to re-position
the tool to enabl e the cylinder to move
easily.
Using a 3mm allen key or similar, depress

the spring loaded pawl and slide the cylinder
ov t of the carrier.
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 i s 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 on both sides of the brake discs for scoring or corrosion.
Replace i f i n doubt.
Measure the disc thickness and run-out:
Front Rea r
Thickness, nominal 20.0 mm (0.79 i n .) 12.0 mm (0.47 in.)

Thickness, minimum 19.0 mm (0.75 in.) 1 1 .Omm (0.43 in.)
Run-out, maximum 0.15 mm (0.006 in.) 0.20 mm (0 .008 i n .)
I f the run-out i s excessive, replace the disc.
NOTE Ensure the front wheel bearings are correctly adjusted before measuring
front disc run-out .
JC. 7 - BRAKE SERV.0 UNIT
The 'Master-Vac' brake servo i s , with the exception of the air filter and non return
valve, a non- serviceable sealed unit which must be replaced i f found to be faulty.
The air filter (surrounds input push rod) should be replaced whenever the brake
system i s overhauled, and cleaned or replaced more frequently i f the vehicle i s
operated i n dusty conditions .
The vacuum non-return valve i s incorporated into the vacuum hase elbow connector
tn the front case of the servo unit. The valve i s a push f i t into a grommet, and i s
supplied complete with new grommet.
As a quick check of servo operation proceed as follows:
With engine stopped, press the brake pedal several times to exhaust the servo unit
'
of vacuum. Keeping the pedal pressed (which should be 'hard and 'high') start
the engine; the pedal should drop slightly as the servo vacuum builds up.
When replacing a servo unit, ensure that the input pushrod i s located i n the
brake pedal lower hole marked 'B' (Brake) and not i n the upper hole 'C' (Clutch)
SECTION JC Page 9
a 3C. 8 - MASTER CYLINDER OVERHAUL
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 pull out from its two master cylinder grommets.
Push on the primary piston and remove the stop screw from the undenide
of the cylinder, and circlip from the cylinder end.
Withdraw the primary piston assembly

and eject the secondary piston assembly
and spring using compressed air (max
3 bar). Never tap or strike the master
cylinder to remove the piston.
Clean a l l parts with methylated spirit or brake system cleaning fluid and inspect.
If the master cylinder bore shows any signs whatever of scoring, wear, or corrosion,
the complete unit should be replaced.
Note: The screw securing the return spring to the primary piston i s factory set
and must not be disturbed.
Coat both new pistorl assemblies from a master cylinder repair k i t with clean
brake fluid and insert the secondary piston assembly with i t s spring into the
cylinder. Use a screwdriver with rounded blade to ease sealing washer entry
into the bore, and a rounded end 3mm diameter brass rod to ease the seals past
the reservoir ports and stop screw h d e .
F i t the primary piston assembly and

spring i n a similar manner, and retain
i n the cylinder by inserting the brass
rod through the rearmost reservoir
port, whilst pushing on the piston.
Page 70 SECTION JC
Coat the exterior of the projecting primary piston tube, vacuum sealing
washers, and guide bush with the silicone grease provided i n the repuir
kit.
F i t 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 washer
(lip side fint)and second stop washer i n a
similar manner, and retain with the new circlip.
Using a new sealing washer, f i t the secondary piston stop screw into the
cylinder body. Tighten to 1 kgf.m. (7.5 Ibf. ft.). Press on the primary
piston, and remove the brass rod from the r,eservoir port.
Refit the reservoir assembly to the master cylinder using new grommets .
Refit the master cylinder to the servo, using a new '0' ring and tightening
the two nuts to 1 .4 kgf. m ( 10 Ibf. ft.).
Refit the brake pipes into the master cylinder ports, refit 1 the reservoir with
the specified brake fluid, and bleed the complete system. Connect the low
fluid level switch leads .
SECTION KB Page 7
C O O L I N G SYSTEM
SECTION KB - ESPRIT S 3 & TURBO
Operation Page
General Description KB. 1 1 to 7
Drain/Refill Procedure KB.2 7/8
Cooling Fans - Replacement o f

E a r l y T y p e Motors
Cooling Fans Thermal T r i p
Cooling Fans Thermal Switch
Replacement o f E a r l y Type Rad.

Duct S t a y s .
Esprit 53 Cooling System
DodRoW Turbo Cooli na System
I tor
-
codant Circulation ~ i a ~ r n r n& w i t 53 8 U .S .A. Turbo
Heater Take-Off
SECTION Kt3 Page 7
KB.l - GENERAL DESCRIPTION
--
A c e n t r i f u g a l w a t e r pump i s mounted on t h e f r o n t f a c e of t h e c y l i n d e r
b l o c k and i s d r i v e n by a s i n g l e 'V' b e l t from t h e c r a n k s h a f t . C o o l a n t
is pumped by t h e i m p e l l o r i n t o t h e f r o n t o f t h e b l o c k , a r o u n d t h e ' w e t '
c y l i n d e r l i n e r s and i n t o t h e c y l i n d e r h e a d .
E s p r i t S3 and U.S.A. T u r b o : Water l e a v e s t h e c y l i n d e r head v i a a p i p e

c a s t i n t e g r a l l y w i t h t h e i n l e t m a n i f o l d , w i t h , o n U.S.A. Turbo models, a n
a d d i t i o n a l o f f t a k e from t h e f r o n t f a c e o f t h e h e a d , and f l o w s i n t o t h e
t h e r m o s t a t h o u s i n g which i s above and i n t e g r a l w i t h t h e w a t e r pump
housing. When t h e t h e r m o s t a t i s c l o s e d , w a t e r f l o w s downwards back i n t o
t h e w a t e r pump t o commence a n o t h e r c y c l e . When t h e t h e r m o s t a t o p e n s ,
t h i s r o u t e i s c l o s e d o f f and w a t e r i s d i r e c t e d upwards p a s t t h e t h e r m o s t a t
and i n t o pipework l e a d i n g t o t h e f r o n t mounted r a d i a t o r . Coolant r e t u r n i n g
from t h e r a d i a t o r f l o w s back i n t o t h e w a t e r pump i m p e l l o r h o u s i n g t o
commence a n o t h e r c y c l e .
DOM/ROW Turbo: On t h e s e c a r s , w a t e r l e a v e s t h e c y l i n d e r h e a d from a p i p e

i n i t s f r o n t f a c e and v i a o u t l e t s between t h e i n l e t p o r t s l i n k e d by an
e x t e r n a l c o l l e c t o r p i p e . T h e s e two s t r e a m s c o n v e r g e and f l o w t o a r e m o t e l y
mounted t h e r m o s t a t a t t h e r i g h t hand f r o n t o f t h e e n g i n e bay. When t h e
t h e r m o s t a t i s c l o s e d , w a t e r i s d i r e c t e d v i a a ' b y - p a s s ' pipework r o u t e
back t o t h e w a t e r pump, b u t when t h e t h e r m o s t a t o p e n s , c o o l a n t f l o w s f o r w a r d
t o t h e f r o n t mounted r a d i a t o r b e f o r e r e t u r n i n g t o t h e w a t e r pump.
A h e a d e r t a n k i s f i t t e d a t t h e r i g h t hand r e a r of t h e e n g i n e bay and i s

c o n n e c t e d w i t h t h e w a t e r punp i n l e t pipework (S3 & U S A ) o r t h e by-pass
pipework (DOM/ROW T u r b o ) .
The r a d i a t o r i s l o c a t e d i n t h e n o s e o f t h e c a r and i s mounted i n t o a

G.R.P. r a d . d u c t f i x e d t o t h e u n d e r s i d e o f t h e s p o i l e r and f r o n t l u g g a g e
compartment. Turbo models u s e a f u l l w i d t h r a d i a t o r p r o v i d e d w i t h 3 c o o l i n g
f a n s w h i l s t S e r i e s 3 v e h i c l e s u s e a s m a l l e r 2/3 w i d t h r a d i a t o r w i t h 2
cooling fans. S e r i e s 3 c a r s w i t h a i r c o n d i t i o n i n g have a s i m i l a r l y s i z e d
c o n d e n s o r mounted ahead o f t h e r a d i a t o r and o f f s e t t o t h e o p p o s i t e s i d e of
t h e r a d . d u c t w i t h t h e non o v e r l a p p i n g p o r t i o n p r o v i d e d w i t h i t s own c o n d e n s o r
cooling fan.
KB.2 - --
DRAIN/REFILL PROCEDURE
It i s most i m p o r t a n t t h a t t h e c o o l a n t c o n t a i n s a c o r r o s i o n i n h i b i t o r t o
p r o t e c t t h e aluminium a l l o y o f t h e L o t u s e n g i n e . A minimum o f 25%
i n h i b i t o r / a n t i f r e e z e s h o u l d b e u s e d a l l y e a r round w i t h up t o 60% i n t h e
coldest climates. A l l c a r s a r e f i l l e d w i t h a 40%mix a t t h e f a c t o r y .
To d r a i n t h e s y s t e m , set t h e h e a t e r t e m p e r a t u r e c o n t r o l t o h o t , r e l e a s e
t h e h e a d e r t a n k c a p and remove t h e r a d i a t o r d r a i n p l u g . Also r e l e a s e
h o s e c o n n e c t i o n s i n t h e e n g i n e bay as n e c e s s a r y t o f u l l y d r a i n pipework
To r e f i l l t h e s y s t e m , r e f i t h o s e c o n n e c t i o n s s e c u r e l y , r e p l a c e d r a i n p l u g
a n d , on Turbo m o d e l s , open t h e r a d i a t o r b l e e d p l u g from i n s i d e t h e
f r o n t l u g g a g e compartment.
Page 8
F i l l w i t h c o o l a n t u n t i l a s t e a d y s t r e a m f l o w s from t h e b l e e d .
b l e e d and add c o o l a n t u n t i l t h e system i s f u l l y f i l l e d .
Close t h e
Run t h e e n g i n e
a
t o o p e r a t i n g t e m p e r a t u r e and open t h e b l e e d u n t i l a c o n t i n u o u s s t r e a m a f
water f l o w s o u t . C l o s e t h e b l e e d , a l l o w t h e e n g i n e t o c o o l , and f i l l t o
w i t h i n 50mm (2 i n . ) o f t h e bottom o f t h e h e a d e r t a n k n e c k .
KB.3 - COOLING FANS - REPLACEMENT OF EARLY TYPE MOTORS.
E a r l y S e r i e s 3 and Turbo models ( p r i o r t o mid '83) u s e d c o o l i n g f a n

motors A074M6027Z w i t h r i v e t t e d m e t a l f a n b l a d e s , w h i l s t l a t e r c a r s u s e
a f a n motor assembly w i t h an o r a n g e p l a s t i c b l a d e . I f i t is necessary t o
r e p l a c e an e a r l i e r t y p e f a n motor, i t i s recommended t o f i t t h e l a t e r t y p e
f a n motor assembly i n t h e f o l l o w i n g manner.
Qty. p e r Motor I
P a r t s Required
I
Fan Motor
.
Fan, r a d c o o l i n g (plastic)
C i r c l i p , f a n t o motor
Washer, f a n t o motor
S p a c e r , motor t o mtg.
Washer, shakeproof
Nut, p l a i n , M6
Permabond, A136
Extension l e a d (53)
Reverse P o l a r i t y Lead (Turbo)
1. Remove t h e o l d f a n and motor from i t s mounting s h r o u d .
. .
a
2. E n l a r g e t h e f a n motor f i x i n g h o l e s i n t h e s h r o u d i e g s
t o 6mm c l e a r a n c e . , . . .
. __.
. .- ~ -
_ . . . - - -
SECTION KB Page 9
a' 3. F i t t h e new f a n and motor a s s e m b l y , u s i n g s p a c e r s A079K4175

between t h e motor and s h r o u d l e g s a s shown, and Permabond A136
on t h e f a n motor mounting s t u d s .
A075W3020
S hakeproof Washer
A O75W4046
4. On S e r i e s
---- 3 models, d i s c a r d t h e e x i s t i n g r e v e r s e p o l a r i t y connection
and c o n n e c t t o loom u s i n g e x t e n s i o n l e a d A 0 8 2 M 4 1 9 4 .
On Turbo models c o n n e c t motor t o loom u s i n g r e v e r s e p o l a r i t y

lead A082M4193.
Switch on f a n s ( b r i d g e ' O t t e r ' s w i t c h ) and check c o r r e c t d i r e c t i o n

o f r o t a t i o n of each i n d i v i d u a l f a n , i e : draws a i r t h r o u g h r a d i a t o r
and blows backwards, r o t a t i n g a n t i - c l o c k w i s e when viewed from
behind.
The f a n f a i l t e l l - t a l e w i l l f u n c t i o n a s p r e v i o u s l y .
KB.4 - COOLING FANS THERMAL TRIP
E a r l y Turbo models, S 3 c a r s with a i r c o n d i t i o n i n g , and S e r i e s 3 c a r s w i t h

h e a t e r p r i o r t o commonisation w i t h Turbo f a s c i a (mid ' 8 5 ) u s e d a f u s e d
r e l a y i n t h e c o o l i n g f a n c i r c u i t l o c a t e d a t t h e l e f t hand f r o n t o f t h e f r o n t
l u g g a g e compartment. L a t e r c a r s were f i t t e d w i t h a r e v i s e d c i r c u i t t o
i n c o r p o r a t e a d o u b l e p o l e r e l a y and a modular t h r e e p o l e t h e r m a l c i r c u i t
b r e a k e r w i t h manual r e s e t . On t h e s e c a r s , an e x c e s s c u r r e n t i n any o n e o r
a- more motors w i l l c a u s e i t s own t h e r m a l c i r c u i t b r e a k e r t o o p e r a t e . I f any

Page 10 SECTION KB
t h e r m a l t r i p i s o p e n , o r any motor f a i l s t o r o t a t e a t a n e f f e c t i v e s p e e d . a n
a
e a r t h p a t h o r v o l t a g e d i f f e r e n c e i s c r e a t e d and t h e f a n f a i l u r e t e l l t a l e
w i l l l i g h t . P r e s s i n g down t h e r e d reset b u t t o n on t h e t r i p h o u s i n g ( a d j a c e n t
t o w i n d s c r e e n w a s h e r r e s e r v o i r ) w i l l r e s t o r e any t r i p p e d c i r c u i t .
. --
--\_
Cooling Fans Thermal Trip

. --
KB.5 - COOLING F A N S THERMAL SWITCH
The c o o l i n g . f a n s t h e r m a l s w i t c h ( s o m e t i m e s r e f e r r e d t o by i t s m a n u f a c t u r e r s
name, ' O t t e r ' ) i s f i t t e d i n t o a w a t e r p i p e between t h e t h e r m o s t a t o u t l e t
and r a d i a t o r i n l e t , u s i n g a s p e c i a l grommet and s p r i n g c l i p . Never r e - u s e
a grommet, b u t renew e a c h t i m e t h e s w i t c h i s removed.
Cars used i n h o t c l i m a t e s a r e f i t t e d w i t h a b l u e c o l o u r coded s w i t c h

which m a k e s / b r e a k s a t t e m p e r a t u r e s o f 82/72OC. The s w i t c h i n g p o i n t f o r
c a r s i n t e m p e r a t e c l i m a t e s was r a i s e d from 86/76 t o t h e 92/82 o f t h e
c u r r e n t g r e e n c o l o u r coded s w i t c h .
On DOM/ROW Turbo models t h e s w i t c h i s f i t t e d i n t h e r a d i a t o r i n l e t elbow

pipe. U n t i l Dec. ' 8 4 , t h e p i p e was f i t t e d w i t h t h e s w i t c h p o i n t i n g upwards
b u t t h e p o s s i b i l i t y o f an a i r p o c k e t b e i n g t r a p p e d a r o u n d t h e s w i t c h and
t h e consequent e r r o n e u s t e m p e r a t u r e s e n s i n g , l e d t o t h e p i p e and s w i t c h
being inverted.
Page 1 1
On an e a r l i e r c a r , i f i n c o n s i s t e n t f a n o p e r a t i o n i s e x p e r i e n c e d , o r i f
t h e t h e r m a l s w i t c h o r w a t e r - p i p e i s d i s t u r b e d f o r any r e a s o n , t h e
elbow p i p e s h o u l d be r e - f i t t e d i n t h e ' i n v e r t e d ' p o s i t i o n a s shown.
E s p r i t 5 3 c a r s p r i o r t o mid ' 8 5 and U.S.A. Turbo models h a v e t h e s w i t c h

f i t t e d h o r i z o n t a l l y i n t o t h e w a t e r pump o u t l e t p i p e . L a t e r S3 c a r s
a d o p t e d t h e r a d i a t o r i n l e t p i p e l o c a t i o n o f t h e Dom. T u r b o .
KB.6 - REPLACEMENT OF EARLY TYPE RAD. DUCT STAYS
E a r l y S e r i e s 3 and DOM/ROW Turbo c a r s u s e d r a d i a t o r d u c t stays f a b r i c a t e d

from 'U' s e c t i o n c h a n n e l and u s i n g a n ' L ' b r a c k e t t o f i x t h e s t a y
t o t h e c h a s s i s . L a t e r c a r s u s e d a more d u r a b l e t u b u l a r s t a y which may
be f i t t e d t o e a r l i e r c a r s i n t h e f o l l o w i n g manner.
P a r t s Required
Rad. Duct S u p p o r t T u b e , RH A082K4188K

Rad. Duct S u p p o r t Tube, LH A082K4189K
S e t s c r e w , M 6 x 2 0 , Tube/Chassis A075W10302
Washer, f l a t , T u b e / C h a s s i s A075W4013Z
N u t , N y l o c , M6, T u b e / C h a s s i s A075W30092
Remove and d i s c a r d e x i s t i n g s t a y s and 'L' b r a c k e t s
D r i l l a 7mm d i a m e t e r h o l e e a c h s i d e of t h e c h a s s i s f r o n t f r a m e a s
shown, and p a i n t w i t h a z i n c r i c h p r i m e r .
F i t t h e r e a r end o f e a c h t u b e t o t h e c h a s s i s a t t h i s p o i n t u s i n g t h e
f i x i n g s l i s t e d , a n d s e c u r e t h e f r o n t end t o t h e r a d . d u c t w i t h t h e e x i s t i n g
f i x i n g s , r e - d r i l l i n g i f necessary.
SECTION LA Page 7
FUEL SYSTEM
SECTION L A - EXCEL & ESPRIT S3
Operat ion Page
General Description LA. 1

Installation of Revised Fuel
Filteration System LA. 1 A
Carburettor Theory of Operation LA.2
Float Level Checking LA.3
Carburettor Balancing Procedure LA. 4
Carburettor Mounting LA.5
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 o f the right hand tank.
Fuel is fed from the left hand tank to an electric fuel pump fitted beneath the left
hand front corner of the engine bay. From here fuel i s pumped through a line
filter at the left hand front of the engine bay, to a 'Flowlock' valve at the right
hand side of the engine bay. The 'Flowlock' valve i s a solenoid operated fuel line
valve designed to shut off the fuel supply to the engine except when the solenoid
0
i s energised by switching on the ignition. A plastic fuel pipe then carries fuel to the
carburetton .
EXCEL
A s i n g l e f u e l t a n k i s f i t t e d between t h e r e a r wheel a r c h e s a t t h e f r o n t o f
t h e b o o t a n d i s p r o v i d e d w i t h a f i l l e r neck and l o c k a b l e c a p o n t h e l e f t
hand s i d e . T h e f u e l gauge s e n d e r u n i t i s f i t t e d i n t o t h e t o p o f t h e t a n k .
On c a r s p r i o r t o mid ' 8 5 , f u e l i s drawn t h r o u g h a g a u z e f i l t e r i n c o r p o r a t e d
i n t o t h e b a n j o b o l t f u e l t a k e o f f , and t h r o u g h a ' F l o w l o c k ' v a l v e b e f o r e
r e a c h i n g t h e e l e c t r i c pump. Both pump and ' F l o w l o c k ' v a l v e a r e c o n t a i n e d
w i t h i n t h e s p a r e wheel w e l l a t t h e f r o n t o f t h e b o o t . F u e l i s t h e n pumped
t h r o u g h a p l a s t i c p i p e r u n n i n g t h r o u g h t h e c h a s s i s backbone and i n t o t h e
carburett o r s .
E a r l y c a r s w e r e f it t e d w i t h a f i l t e r i n t h e f u e l p i p e t o c a r b u r e t t o r
a d a p t o r . T h i s was l a t e r r e p l a c e d by a f l o a t n e e d l e v a l v e f i l t e r w i t h i n
the carburettor.
From mid '85 o n w a r d s , a r e v i s e d f u e l f i l t e r a t i o n s y s t e m was f i t t e d
i n c o r p o r a t i n g a r e p l a c e a b l e p a p e r element f u e l f i l t e r . With t h i s s y s t e m
a c o a r s e r mesh f i l t e r (450 m i c r o n s ) i s u s e d o n t h e t a n k b a n j o b o l t ,
from w h i c h f u e l f l o w s t o t h e f u e l pump. F u e l i s t h e n pumped t h r o u g h
a f i l t e r a t i o n u n i t mounted t o t h e r i g h t o f t h e f u e l t a n k , t h e n t h r o u g h t h e
f l o w l o c k v a l v e and t o t h e c a r b u r e t t o r s .
On e a r l i e r E x c e l m o d e l s , w h e r e a h i s t o r y o f p e r s i s t e n t f u e l s t a r v a t i o n
problems have been experienced, t h e r e v i s e d f u e l f i l t e r a t i o n system can
be i n s t a l l e d .
LA.1A. - INSTALLATION OF REVISED FUEL FILTERATION SYSTEM
-
PARTS
REQUIRED:
Banjo Bolt/Filter Assy.
Crush Washer (BanjoIFil t e r Assy .)
1 off
2 off
Fuel P i p e - Tank t o Pump 1 off
-
Fhel P i p e Pump t o Filter 1 off
h e 1 Filter Assy. 1 off
Fuel P i p e -
Filter t o Flowlock 1 off
Set Screw M6 x 20 2 off
Washer 6 x 20 x 2.5 2 off
Nyloc Nut M6 2 off
Page 2 B SEC T/ON
5 Remove e x i s t i n g f u e l p i p e from tank t o flow lock and flowlock
t o pump and d i s c a r d .
Disconnect f u e l p i p e from pump o u t l e t .
Fit new banjo b o l t / f i l t e r a s s y . ( ~ 0 8 4 ~ 0 1 F)
8 1 u s i n g new c r u s h
washers and new f u e l p i p e (AO89L0211F) from tank t o pump i n l e t
Torque t i g h t e n banjo b o l t l f i l t e r a s s y . t o 2.8 k g f m (20 l b f . f t . ) .
New Fuel Filter

Tank Filter
\
\ \ -
Spare Wheel Well / 7 c l i p & Tie Wrap
Tank S.U. Pump Fud Filter Flowlock

Fuel System Schematic Layout
F i t new f u e l p i p e (A089M212F) from pump o u t l e t t o f i l t e r i n l e t

( r e a n n o s t connection ) .
Reverse t h e flowlock on its e x i s t i n g mounting ( d i r e c t i o n o f
flow arrow towards e n g i n e ) and f i t new f u e l p i p e (A089M213F)
from f i l t e r t o flowlock. C l i p l t i e wrap p i p e a s shown.
Connect t h e e x i s t i n g ( f r o n t t o r e a r ) f u e l p i p e t o t h e flowlock.
Route p i p e i n a l o o p i n s i d e boot - d o n o t push p i p e forward through
g r m e t i n body.
When r e f i l l i n g t h e t a n k , s t r a i n t h e d r a i n e d p e t r o l through a
f i n e mesh f i l t e r (e.g. l a d i e s s t o c k i n g or t i g h t s ) t o avoid any
contaminated f u e l e n t e r i n g t h e t a n k .
ENSURE THAT ALL FUEL PIPE CONNECTIONS ARE SECURE AND THAT THERE
ARE NO 'FUEL LEAKS
Refit tank board, s p a r e wheel, boot f l o o r , RH r e a r wheel and

reconnect b a t t e r y .
SECTION LA Page 3
LA.2. - CARBURETTOR THEORY OF OPERATION
C a r b u r e t t o r Type - Standard Engines - D e l l o r t o DHLA 45E

- 'H.C.' E n g i n e s
- D e l l o r t o 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 into the float chamber, thereby maintaining a constant level.
The float chamber i s vented to atmosphere (via the airbox) through the hole (4)
i n the chamber (3).
Starting
With the choke valve (8) opened fuel

metered through jet (14) passes into the
emulsion tube (13), where i t mixes with
air from the channel (16), communicating
with the float chamber top through hole
(6). The mixture formed flows, through
holes (7), into the valve chamber (9),
further mixing with air from the two
channels (5).
Page 4 SECTION LA
With the choke valve (8) partially closed, when a leaner mixture i s 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, i n this condition,
are partially closed.
With the choke valve (8) closed, communication between the main barrels and the
starting circuit is cut off as i s also communication between the two barrels by
meats of the dividing bushing (19).
Idling
Fuel coming from the float chamber, metered by the idle jets (21), mixes with the
air from the well (23) through channels (22); the mixture thus formed, through
channels (24) arrives to the adjustment screw (27) and then, metered, flows into
the main barrels (11) downstream the throttle valve (12).
Replacing the plug (26) with an adaptor connected to a suitable manometer i t
is possible to check, through channel (28) the pressure existing i n the barrels
(11) with the throttle valve (12) i n idling position and equalize the air flow
adjusting the bypass screw (25) which controls the hole (29).
SECTION LA Page 5
Ptogression
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 lever (43) which
acts directly on the diaphragm (44) held out by the spring (45).
Moving pf the diaphragm (44) causes delivery of fuel to the main barrels (1 1)
through the respective valves (36) and jets (37).

On closing of throttle valves (1 2), diaphmgm (44) returns to the original
pas ition pushed by the spring (45) and draws fresh fuel from the fuel well
(33) through the valve (35).
Page 6 SECTION LA
0
Full Throttle
With the throttle valves (12) opened, fuel from the float chamber (461metered
by the jets (47),enters the well (48) and mixes with air metered by the air
corrector (49).
The mixture thus formed, passes through the inner venturi (50) where i t furthr
mixes with air drawn through the main barrel of the carburettor, flows into the
venturis (51) and then, through the main barrels (I 1) reaches the engine.
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 drawn from the float chamber top (53).
Page 8 SECTION LA
lA.3. - FLOAT LEVEL CHECKING
Remove the carburettor top complete with float assembly. Ersure the correct
weight of 8.5g i s indicated on the float, and that the float assembly pivots
freely on its pin. Hold the cover vertical with the float hanging downwards
and i n light contact with the needle.
Measure the dimension 'A' between float and gasket as shown i n the diagram,
for each float of the assembly, and if necessary carefully bend the float arm
at 'B' to correct.
LA A . - CARBUREnOR BALA NCI NG PROCEDURE

Ensure ignition timing is correct and the air filter and a l l trunking etc .
fitted.
Remove anti-tamper caps from idle C O adjustment screws and balancing
screws.
Replace vacuum tapping screws with manometer adaptors TOOOT04915 and
connect to manometer TOOOT0499.
Fully close a l l balancing screws (do not 'graunch').
Set idle C O adjustment screws 6 x 3 turns open, and start engine.
Wlth engine at normal running temperature with ACU off and cooling
fans on, adjust throttle stop screw to give specified idle speed of
850 to 950 rpm.
SECTION LA Page 9
Adjust throttle coupling screw to balance lower o f 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 i t is
balanced with the lower column to within 3 mrn.
Carry out the same procedure for the rear car5urettor, and if necessary re-
adjust the throttle coupling screw to balance all columns to within 3 mm,
Ensure correct idle speed is maintained.
Correct exhaust gas analper to the exhaust tailpipe and check C O reading.
Move a l l idle C O adjustment screws the same amount i n or out of a turn a t
a time t o bring C O level within the range 0.7 - 1 .5%.

Disconnect manometer and adapton, and replace blanking screws. F i t new
anti tamper caps where necessary. Ensure a l l fuel pipe connections are
secure.
IA .5. - CARBURETTOR M O UNTING

The spacer plates and '0' rings used at this joint cct as insulators to absorb vibration
and prevent frothing of fuel i n the float chambers. It i s essential that the carburettor
mountings are not overtightened, as the ' 0 ' rings may be displaced with a resultant
a i r leak.
A uniform 1 mrn gap must be maintained between carburettor and spacer plate, and
between spacer plate and manifold as shown.
= 1.0 mm
carb/spcer plated
= 1.0 mm
Page 2 A
1 > Disconnect the battery
2) Remove fuel tank board, boot floor and spare wheel

Take necessary precautions t o avoid fuel spillage, remove
banjo b o l t / f i l t e r assembly and drain tank COMPLETELY. Discard
removed banjo bolt /ft l t e r assy .
4) Use the i l l u s t r a t i o n a s a guide and f i t the new fuel f i l t e r
assy. ( A089L6012F) t o the body panel on the right hand side
of the fuel tank.
Remove the RH rear wheel for easier access.
2 x 7mm 0 hdes
25mm between centres
Riel Filter F i x i n g
Hole Detail
\
h e 1 Filter bunting.
Fuel Filter
Key to Fuel System Diagram
LH Fuel Tank Breather Hose 3.2 m Insulator Strip

RH Fuel Tank 'PI Clip Fuel Filter Clamp
LH Tank Top Board Hose, Tank Crossover Clamping Bolt
RH Tank Top Board Hose Clip Plain Was her
Bmcket, Board to Bulkhead Crossover Pipe Nyloc Nut
Studplate, Bracket to Bulkhead Grommet, c/o Pipe Studplate, Filter Clamp
Was her Plate Grommet, c/o Pipe Fuel Pipe, Filter to Bundy
Bracket, Board to Wheelarch Ring, Grommet Fixing Clip, Fuel Pipe
Washer Plate Fuel Feed Banjo Fuel Bundy Pipe
Washer Plate Fuel Return Banjo Fuel Pipe, Bundy to P .R .V.
Foam, Tank Clamping Copper Was her, Banjo Fuel Pipe, Return
Sender Unit, Fuel Gauge Crush Was her, Ba njo 'PI Clip
Gasket, Sender Unit Banjo Bolt Grommet, Return Pipe
LH Filler Neck Fuel Pipe, Tank to Pump Fuel Pressure Regulating Valve
RH Filler Neck Clip, Fuel Pipe Screw, P .R.V. Fixing
Filler Cap Grommet, Fuel Pipe Spring Washer
Clamp Ring, Filler Neck Fuel Pump Fuel Pipe, P.R.V. to Rear Carb
Gasket, Clamp Ring Imulator Strip Fuel Pipe, P.R.V. to Front Carb
Hose, Filler to Tank Fuel Pump Clamp Adaptor, Fuel Pipe to Carb
Hose Clip Clamping Bolt Filter, Carb Inlet
Vent-!--e, Tank to-Neck Plain Was her Sealing Was her
Hose Clip Nyloc Nut Pressure Hose, P.R.V. to Banio
Breather Hose, 260 mm Bolt, Clamp to Chassis Banjot Rear Carb
Anti-Svrge Valve Was her Was her, Large
Breather Hose 200 mm Fuel Pipe, Pump to Filter Was her, Small 3
Breather Hose 2 m Bolt, Banjo
'T' Piece
Clip, Fuel Pipe
Fuel Filter Hose, Banjo to Diffuser 8m
C*>
SECTION LB Page I
FUEL SYSTEM
SECTION LB - ESPRIT TURBO, DOWROW
Operation -
Page
General Description
Carburettor Theory o f 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 i s provided for each tank, and the two tanks are
interconnected by a large bore balance pipe. A single sender unit f o r the

fuel gauge i s fitted into the top of the right hand tank.
Fuel i s fed from the left hand tank to a high pressure turbine type fuel pump
capable of delivering 100 litres/hour. Fuel i s then fed through a canister filter,
also fitted beneath the left hand front corner of the engine bay, and. then to the
f u e l pressure regulating valve mounted on the rear of the carburettor plenum
chamber.
A spring and diaphragm system i n the regulating valve, i s adiusted to set fuel
2
pressure to 3.5 Ib/in during idle and light load conditions, but as inlet
boost pressure is developed, a sersing pipe from the diffuser (via the rear carb.
cold start banjo) adds a boost pressure signal to the spring pressure to ersure that
2
fuel pressure is maintained at 3.5 Ib/in above boost pressure.
Excess fuel supplied to the regulating valve is returned via a port i n the bottom
of the valve to the right hand tank, whilst two seperate pipes from the valve carry
fuel to the front and rear carburettors.
LB .2. - CARBURETTOR THEORY OF OPERATI ON

-
.
-
Carburettor Type - Dellorto DHlA 40H (2 off)

Fuel Supply
Fuel from the union (1) passes through the filter (2) and reaches the needle valve
seat (18), where the needle valve (17), attached to the float (15), controls the
fuel flow into the float chamber, thereby maintaining a constant level.
The float chamber i s vented to the plenum chamber through the hole (4) i n the
chamber (3).
SECTION LB Page 5
Starting
W i t h the choke valve (8) opened, fuel metered through jet (1 4), passes into the
emulsion tube (13), where i t mixes with a i r from the channel (16), communicating
w i t h the float chamber top through hole (6).
The mixture formed flows, through holes (7), into the valve chamber (9), further
-mixing with a i r from the two channels (5).
From the valve chamber (9),

mixture is divided into the two
channels (1 0) which lead into

the main barrels (11) downstream
of the throttle valves (12).

Page 6 SECTIONLB
mixtvre flows into the valve chamber (9) through one o f the two outlet POIS (7),
further mixing with air from the two channels (5), which, i n this condition,
are partially closed.
starting circuit is cut off as is also communication between the two barrels by
means of the dividing bushing (19). .
Id1ing
a i r from the well (23) through channels (22); the mixture thus formed, through
channels (24) arrives to the adjustment screw (27) and then, metered, flows into
Replacing the plug (26) with an adaptor connected to a suitable manometer, i t
(11) with throttle valve (12) i n idling p i t i o n and equalize the air flow adjvsting
the bypass screw (25) which controls the hole (29).
SECTION 1B Page 7
Progress
- - ion
On f i r s t opening the throttle valves (12),

that i s when passing from idle to f u l l
throttle, mixture arrives to barrels (11)
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 lever (43) which
acts directly on the diaphmgm (44) held out by the spring (45).
Moving of the diaphragm (44) causes delivery of fuel to the main barrels (1 1)
O n closing of throttle valves (12), diaphmgm (44) returrs to the original
position pushed by the spring (45) and draws fresh fuel from the fuel well
(33) through the valve (35).
The ball valve (34) emures that the pump circuit i s cut off when the turbo-
charger starts operating.
The p
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 a i r corrector (49).
The mixture thus formed, passes through the inner venturi (50) where it further
mixes with a i r drawn through the main barrel of the carburettor, flows into the
v e n b r i s (51 ) and then, through the main barrels (I 1) reaches the engine.
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 i s indicated on the float, and that the float assembly pivots
freely on i t s pin. Hold the cover vertical with the float han3ing downwards
and i n light contact with the needle.
Measure the dimension 'A' between float and gasket as shown i n the diagmm,
for each float of the assembly, and if necessary carefully bend the float arm
at 'B' to correct.
LB A . - CARBURETTOR BALANCI NG PROCEDURE

Ensure ignition timing i s correct and the air filter and a l l trunking etc.
fitted .
Remove anti-tamper c a p from idle C O adjustment screws and balancing
screws.
Replace vacuum tapping screws with manometer adaptors TOOOT0496 and correct
to ma nometer TOOOT0499.
Fully close a l l balancing screws (do not graunch).
Set idle C O adjustment screws 6 x 4 turra open, and start engine.
With engine a t normal running temperature with ACU off and cooling
fans on, adjust h r o t t l e stop screw to give specified idle speed of 850 rpm.
Adjust throttle coupling screw to balance lower of mercury columra 1 and 2
w i t h lower of mercury columns 3 & 4, to within 3 mrn.
SECTION LB
Considering the front carburettor, gradually unscrew the air bleed
balancing screw of ONLY the carburettor barrel with the highest
mercury column, until i t i s 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 a l l columns to within 3 mm.
Ensure correct idle speed i s maintained.

Connect exhaust gas analyser to the inboard (Turbine) exhaust tailpipe
and note 'CO' and 'HC' readings. Screw down each idle C O adjustment
screw i n turn until 'HC' reading starts to increase, then return (unscrew)
again by a & turn. 'HC', as hexane, should normally be not more than 400 ppm.
C O maximum i s 1.0%. Maintain idle speed and manometer balance throughout.
Disconnect manometer and adapton and replace blanking screws. F i t new anti-
tamper caps where necessary. Ensure a l l fuel pipe connections are secure.
LB .5. - CARBURETTOR MOUNT1NG

The spacer plates and '0' rings used at this joint act as insulators to absorb
vibration and prevent frothing of fuel i n the float chambers. It is essential that
the carburettor mountings are not overtightened, as the '0' rings may be displaced
with a resultant air leak.
A uniform 1 .5 - 2.0 mm gap must be maintained between carburettor and
spacer plate, and between spacer plate and manifold as shown.
= 1.5 -2.0 mm
SECTION LC Page 7
FUEL SYSTEM
SECTION LC - U .S .A. ESPRIT TURBO - CARBURETOR
Operation
- -- Page
General Description
Carburettor Theory of Operation
Fuel Control Pressure
Float Level Checking
Carburettor Balancing Procedure
Carburettor Mounting
-Key-to
--- Fuel System
-. Diagram
LH Fuel Tank Breather I-lose 3.2 m It-sulator Strip

RH Fuel Tank 'PI C l i p Fuel Filter Clamp
LH Tank Top Board Hose, Ta nlc Crossover Clamping Bolt
RH Tank Top Board Hose C l i p Plain Washer
GI-acket, Board to Bulkhead Crossover Pipe Nyloc N u t
Studplate, Bracket to Bulkhead Grommet, c / o Pipe Studplate, Filter Clamp
Washer Plate Grcmrnet, c/o Pipe Fuel Pipe, Filter to Bundy
Bracket, Bourd to Wheelurch Ring, Cro:nrne t Fixing Clip, Fuel Pipe
Washer Plute Fuel Fcecl Balijo Fuel Bundy Pipe
Washer Plute Fuel 2eturn Banjo .
Fuel Pipe, Uundy t o P .R .V
Foam, Tank Clamping Copper Was her, Bunjo Fuel Pipe, Return
Sender Unit, Fuel Gauge Crush Vdus her, Bo t i jo 'P' C l i p
Gasket, Sender Unit Banjo Bolt Gr~mrnet, Return Pipe
LH Filler Neck Fuel Pipe, Tank to Pump Fuel Pressure Regulating Valve
RH Fit lei- Neck Clip, Fuel Pipe Screw, P.R.V. Fixing
F i l l e r Cap Grommet, Fuel Pipe Spring Washer
Clamp Ring, Filler Neck Fuel Pump Fuel Pipe, P.R.V. l o Rear Carb
Gasket, Clamp Ring lmu!ator S h i p Fuel Pipe, P.R.V. t o Front Carb
Hose, Filler to Tank Fuel Pump Clamp
Hose C l i p Clanpi ng 601 t
Vent Hose, Tank to Neck Plain Washer
Hose C l i p I\!yloc N u t
Breather Hose, 260 mm Bolt, Clamp f.0 Chassis
Anti-Surge Valve Was her
Breather Hose 200 mrn Fuel Pipe, Pump to Filter
Breafher Hose 2 m Cllp, Fuel Pipe
'TI Piece Fuel Filter
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 i s fed from the leff hand tank to a high pressure furbine type fuel pump capable
of delivering 100 litres/hour. Fuel i s then fed through a canister filter also fitted
beneath the left hand front corner of the engine bay, and then to the fuel pressure
regulating valve mounted on the rear of the carburettor plenum chamber.
A spring and diaphragm system i n the regulating valve i s adjusted to set fuel
2
pressure to 4.0 - 4.5 Ib/in under light load conditions, but as inlet boost
pressure i s developed, a sensing pipe from the plenum chamber adds a boost
pressure signal to the spring pressure to ensure that fuel pressure i s maintained
2
at 4.0 - 4.5 Ib/in above boost pressure. However, a micro-switch mounted
on the front of the front carburettor and operated by the throttle lever in its
fully closed position energises the fuel pressure solenoid, fitted beneath the
rear of the plenum chamber. The signal to the fuel pressure regulator is then
switched to number one cylinder inlet manifold depression, thus reducing fuel
pressure to the carburettors and mixture strength under closed throttle 'overun'
conditiorrs.
Excess fuel supplied to the regulating valve i s returned via-a port i n the bottom
of the valve to the right hand tank, whilst two sepemte pipes from the valve,
carry fuel to the front and rear carburettors.
LC .2 - THEORY OF OPERATION
- CARBURETTOR
Carburettor Type - Dellorto DHIA 45M (2 off)

Fuel Supply
Fuel from the union (1) passes through the filter (2) and reaches the needle valve
seat (18), where fhe needle valve (li'),
attached to the float (15), controls the
fuel flow into the float chamber, thereby maintaining a constunt level .
The float chamber is vented to the plenum chamber through the hole (4) i n the
chamber (3).
SECTION LC Page 5
Starting
With the choke valve (8) opened, fuel metered through jet (1 4), passes into the
emulsion tube (13), where i t mixes with air from the channel (16), communicating
with the float chamber top through hole (6).
The mixture formed flows, through holes (7), into the valve chamber (9), further
mixing with air from the two channels (5).
Fr6m the valve chamber (9),

mixture is divided into the two
cliani.lels (10) which lead into

the main barrels (11) downstream
of the throttle valves (12).
Page 6 S E C ~ / O NLC
mixture flows into the valve chamber (9) through one o f the two outlets poris (7);
further mixing with air from the two channels (5), which, i n this condition,
are p r t i a l l y closed.
starting circuit is cut off as i s also communication between the two barrels by
meam of the dividing bushing (1 9).
Idling
air from the well (23) through channels (22) ;the mixture thus formed through
channels (24) arrives to the adiustment screw (27) and then, metred, flows into

Replacing the plug (26) with an adaptor connected to a suitable manometer, i t
(1 1) with throttle valve (12) i n idling position and equalize the air flow adjust-
ing the bypass screw (25) which controls the hole (29).
The vacuum advance i s connected through the calibmted hole (31) by the union (30).
Screw (20) adjusts opening of the throttle valves at idle.
SECT/ON LC Page 7
Progression
On first opening the throttle valves (12),

that i s when passing from idle to f u l l
throttle, mixture arrives to barrels (1 1 )

also through progression holes (32).
Acceleration
O n opening of throttle valves (1 2), lever (39) attached to spindle (38), by means
o f the rod (30) and the spring (41) pushes the pump lever (43) which acts directly
on the diaphragm (44) held out by the spring (45).
Moving of the diaphragm (44) causes delivery of fuel to the main barrels (1 1)
O n closing ofthrottle valves (12), diaphragm (44)returns to the original position

pushed by the spring (45) and draws fresh fuel from the fuel well (33) through the
valve (35).
The ball valve (34) eraures that the pump circuit i s cut off when the turbocharger
starts operating.
The clearance between pump diaphragm and lever can be adjusted by nut (42) .
m
Page 8
Whereas o n 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 4 5 M carburettors, the volume delivered is fixed, but the point
o f delivery commencement is adjustable. The correct setting is such that

+
w i t h the throttle closed, there is a clearance of 0.6 - O.lmm between the
end of the pump lever and the diaphragm plunger.
Full Throttle
With the throttle valves 412) opened, fuel from the float chamber (46) metered b y
the jets (47), enters the well (48) and mixes with air metered by the air corrector (49).
The mixture thus formed, passes through the inner venturi (50) where i t further mixes
with air drawn through the main barrel of the carburettor, flows into the venturis (51)
and then, through the main barrels (1 1) reaches the engine.
- -
-
SECTION LC Page 9
Power Jet Operation

A t 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 float chamber top (53).
Page 70 SECTION LC
LC.3 - FUEL CONTROL PRESSURE
1 . Connect fuel pressure test gauge as shown below.
n FUEL SUPPLY TO CARBURETTORS
SCREW
FUEL PRESSURE
REGULATOR
F R E S ~ J R ETEST GAUGE KIT

LOTUS PART NO. TOOT0500
Switch on ignition and check fuel pressure = 4.0 -

4.5 p .s .i. I f outside specification,
remove anti-tamper plug from Fuel pressure regulator adjustment screw, and adjust as
necessary.
If the pressure reading is too high, and cannot readily be adjusted to specification, a
0
restriction i n the return line is indicated, Rectify as necessary.
If the pressure reading i s too low, and cannot readily be adjusted to specification, a
restriction i n the supply line, or Faulty fuel pump is indicated.
Check for an unrestricted supply to the fuel pump, and for fuel filter restriction.
Test fuel pump
2. Start engine and allow to reach normal running tempemture,
Check fuel pressure at the regulator. This should be lower than 3.5 p .si, at idle
(950 -+ .
50 rpm) I f above specification, check that the micro-switch o n the front
o f the front carburettor i s activated. If not, rotate theswitch down towmds the
lever until switch contact i s made.
SECTION LC Page 1 1
View from front
If switch adiustrnent i s carried out, open throttle to 2500 rpm and then return
throttle to idle position. Check that when engine speed i s above 1800 rpm, the
micro-switch i s 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 just switch
position i f necessary but always ensure that idle pressure requirements are met.
If switch contact is made at idle, but fuel pressure remains a b v e 3.5 p.s .i, check
fuel pressure regulator solenoid pipework and wiring for leakage or disconnection.
I f no fault i s found, replace fuel pressure regulator solenoid valve.
LC .4 - FLOA,T LEVEL CHECK! NG

Remove the carburettor top complete with float assembly. Ensure the correct weight
of 8.5 g is indicated on the float, and that the float assembly pivots freely on i t s pin.
8
Hdd the cover vertical with the float hanging downwards and in l i g h t cbntact with t h e
needle.
Measure the dimension 'A' between float

and gasket as shown in the diagram, for
each float of the assembly, and if
necessary carefully bend float arm a t
I
B' t o correct.
Page 72
LC .5 - CARBURETTOR BALANCING PROCEDURE
1 . Ensure ignition timing i s correct and the air filter and a l l trunking etc, fitted.
2. Remove anti-tamper caps from idle C O adjustment screws, air bleed balancing
screws, and throttle coupling screws.
VACUUM TAPPING SCREW
I
BALANCIN
SCREW
FRONT
OF
VEHICLE
REAR
CARBURETTOR h
ENGINE IDLE
SPEED SCREW
FRONT
- CARBURETTOR
IDLE STOP BRACKET THROTTLE COUPLING

SCREWS
Replace vacuum tapping screws with manometer adaptors TOOOT0496 and connect
to manometer TOOOT0499. Fit exhaust probe to exhaust outlet pipe of
turbocharger and connect to CO/HC analyser (e .g. Sun EPA 75 or equivalent).

Fully close a l l balancing screws (do not 'graunch').
Set idle C - 0 adjustment screws 6 x $ tur'ns open, and start engine.
With engine at normal running temperature with ACU off and cooling fans
+
a
on, ad just throttle stop screw to give specified idle speed.of 950 - 50 rpm .
Adjust throttle coupling to balance lower of mercury columns 1 and 2 with
lower o f mercury columns 3 and 4 to within 3 mm, ensuri'ng that the two
coupling screws securely clamplagainst the throttle lever.
Considering the front carburettor, .gradually unscrew the air bleed balancing
screw of ONLY the carburettor barrel with the highest mercury column,
u n t i l . i t is balanced with the- lower column to within 3 mm.
Carry out the same procedure for the rear carburettor, and ifnecessary
-re-adjust the t h r o ~ l ecoupling to balance a l l columns to within 3 mm.

Ensure correct idle speed i s maintained.
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%. I f higher or lower levels are found,
move each mixture screw o f a turn i n or out as the reading dictates. Check the
CO reading and repeat procedure until correct specification is achieved. A
balance between CO and HC i s required, and the Hexane level should be
below 550 ppm for a 'new' engine and below 350 ppm for a 'run-in' engine.
11 . Disconnect manometer and adaptors, and replace blanking screws. F i t new

anti-tamper caps where necessary. Ersure a l l fuel pipe connections are
secure. Disconnect exhaust sample probe, and refit blanking plug securely.
LC.6 - CARBURETTOR MOUNT1 NG

.-.--. -
The spacer plates and '0' rings used at this joint act as insulaton to absorb vibration
and prevent frothing of fuel i n the float chambers. It i s essential that the carburettor
mountings are not overtightened, 3 s the '0' rings may be displaced with a resultant
air leak.
A uniform gap must be maintained between carburettor and spacer plate, and between
spacer plate and manifold as shown.
= 2.2 mm (0.090")
SECTION LD Page I
FUEL SYSTEM
SECTION LD - USA ESPRIT TURBO H.C.1 .

Operation Page
General Description LD.1 2 to 5

Fuel Injection System Description LD .2 5
Fuel Feed (pump, accumulator, filter) LD .3 5 to 7
Mixture Control Unit LD .4 7 to 11
Fuel Injecton LD .5 12
Mixture Adaptation LD .6 13
Cold Start lnjector LD.7 13
Thermal Time Switch LD. 8 14
Auxiliary Air Valve LD .9 14/15
Warm Up Regulator LD.10 15
i High Altitude Compensation
Exhaust Emission Control
LD.11
LD.12
16
16
Lambda Sensor LD.13 17
Frequency Valve LD.14 17/18
Electronic Control Unit LD.15 18/19
Fuel By-Pass Valve LD.16 19
Vacuum Operated Engine Management Devices LD.18 20 to 23

Air Cond. Idle Up Solenoid LD.19 20
Evapomtive Loss System LD .20 24/25
Engine Warm Up Summary LD .21 26
Fuel System Precautiom LD .22 26
Engine Management System Check/Set Up Procedure LD .Z3 27 to 30
Fault Diagnosis LD.24 31
Torque Settings, Fuel Injection
' LD .25 51
Ignition Box Component Location LD .26 52
Wiring Diagram Schematics, Fuel lnjection LD .27 53 to 65
Electrical Component, Function & Fault Diagnosis LD .28 66 to 72
Mixture Control Unit Comprises of the Air Flow Sensor and 13A. Fuel Enrichment Module Supplies signal to E:C.U.
Fuel Distributor. (LD .4)
(enrichment) at engine speeds over 3250 rpm (LD.15)
A i r Flow Sersor Measures air flow into the engine and moves
14. A .C.U. Idle Up Solenoid Maintains idle speed when air
fuel distributor control valve accordingly.
conditioning i s operating. (LD.19)
Fuel Distributor Comprises:
i) Rirnary Ressure Regulator to control pressure of fuel
15. Engine Overspeed/Fuel Pump Failure Module Limits normal max .
rpm to 7,000 reducing to 2,800 i f one fuel pump fails (LD .3)
delivered by pump.
ii) Control valve to regulate fuel delivered to injectors 16. Fuel By-Pass Valve Allows air to by-pass Airflow Semor, thus
dependent on air flow. shutting off fuel supply, on closed throttle engine overun
iii) Four Distributor Differential Valves to maintain constant conditions (LD. 16)
pressure drop across each control valve s l i t . 18. lgnition Solenoid Operates Throttle Jacking Capsule a t water
temperatures below 60°C (increased idle speed). (LD -18)
Electronic Control Unit (E .C .U .) Controls Frequency Valve
cycle rate. (LD.15) 19. Overboost Switch Cuts out fuel pumps i f overboost i s detected (LD .3)
Warm Up Regulator Enrichens air/fuel ratio during engine 20. Throttle Position Switch Switches a signal to the electronic controi
warm up. Compensates for high altitude conditions. (LD .I0) unit and engine management system at idle, off idle to 30' throttle,
and over 30' throttle opening. (LD .15,16)
High Temperature Switch Switches lgnition Solenoid at water
c
temperatures below 700 (increased ignition advance) (LD .18) 21 . Low Tempemture Switch makes on fall below 2 5 O ~ .
o i l temg and
switches E.C .U. for cold enrichment. Breaks on rise @ 35 C (LD. 15)
Auxiliary Air Valve Supplies extra air ( and fuel) to cold
engine to improve driveability and idling (LD .9) 22. Thermal Time Switch Regulates cold start injection time dependent
on water temperature. (LD .8)
23. Lambda Sensor Senses oxygen content i n exhaust for Frequency
Valve. (LD.13)
-
Frequency Valve Amends mixture strength dependent on exhaust
.
oxygen cbntent to reduce harmful emissions '(LD .14) 24. Fuel lniector One i n each manifold port; continuously inject fuel
supplied by distributor. Surrounded by air stream. (LD .5)
10,' Fuel Pumps Feed fuel from the tanks to the fuel distributor
111 25. Thermal Ignition Valve l ncreases ignition advance at water
.temperature below 53O C (cold driveability). (LD .18)
1.2. Fuel Filter Protects system from impurities. (LD ,3)
26. Throttle Jacking Capsule Increases cold engine idle speed (LD.18)
13. Fuel Accumulator Maintains fuel system pressure after engine
switch off to aid re-starting .
(LD .3) 27. Cold Start Injector Supplies cold engine with extra fuel for short
period whilst cranking to aid starting. (LD ,7)
Q:
FUEL ACCUMULATOR FUEL
TANK
"
I
fp-"
&
FUEL PUMPS
FUEL SYSTEM - SCHEMATIC DIAGRAM

"' FUEL FILTER
JJ LE 395
SECTION L D Page 5
a
LD . 1-.- GENERAL DESCRIPTION
Two fuel tanks are fitted, one ahead of each rear wheelarch. A separate f i l l e r
neck with lockable cap i s provided for each tank, and the two tanks are inter-
connected by a large bore balance pipe. A single sender u n i t for the fuel gauge
i s fitted into the top o f the RH tank.
Fuel i s fed from the RH tank through a n integral strainer to the fuel pumps and
injection system, w i t h excess fuel being returned into the top of the RH tank.
F i l l i n g of the fuel tanksis best achieved by twisting the pump nozzle 45O to allow
.
i t to be iraerted f u l l y around the bend i n the f i l l e r ne&
LD. 2. - FUEL INJECTION SYSTEM DESCRIPTION

0
Lotus fuel injection engines use a Bosch K-Jetronic system to provide an optimum
air-fuel mixture under a l l operating conditions. The sptem i s based on the principle
of continuous injection of fuel into the intake port of each cylinder, and derives i t s
designation 'K' from the German word for 'continuous'. The fuel injection m y be .
said to opemte mechanically, w i t h the quantity o f fuel delivered being regulated by
the amount of a i r drawn i n b y the engine.
The basic system i s regulated to provide the correct air/fuel ratio for normal running
conditiom, and f u l l power running. Various supplementary devices are used to modify
this ratio to achieve efficient overall performance when cold, decelerating, starting,
idling, operation a t high altitude etc.
A n oxygen sensor i n the exhaust system i s used to determine the mixture strength
being supplied to the engine, andan electronic control unit makes corrections
accordingly .
LD. 3. - FUEL FEED
T h e fuel feed system comprises the fuel pumps, fuel accumulator, and fuel filter. All
fhese components are fitted a t the RH front underside o f the engine bay.
Fuel Pumps Two fuel pumps, corrnected i n series, draw fuel from the RH petrol
tank and supply i t via the fuel accumulator and filter to the fuel distributor.
Both pumps are fitted withmon-return valves i n their outlet connections,
5 Electric Fuel Pump
1. Fuel Intake
2. Excess Pressure Valve
3. Roller-Cell Pump
4. Electric Motor Armature
5. Non-Return Valve
6. Fuel Outlet
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 i n this chamber, uses rollers contained i n slots around its circumference and
thrown out by centrifugal force against the wall of the eccentric chamber, to transfer
fuel from the motor side of the chamber into the fuel feed pipeline.
1 . Fuel Intake 4. Pump Housing

2. Rotor Disc 5. Fuel Outlet
The lack of an ignitable air/fuel mixture i n the pump prevents any explosion. The pump
operate whilst the engine i s cranking or running, but do not opemte i n the stalled engine
condition. The combined output bf both pumps i s more than the maximum requirement 6f
the engine, excess fuel being returned to the ta& via the prlmary piessure regulator. I n
order to protect the engine from damage if one pump fails, the engine overspeed/fuel
pump failure module senses the failure and limits maximum engine speed to approx. 2,800
rpm by cutting out the remaining pump when this speed i s reached.
The fuel pumps are also cut out i f the Overboost Switch senses too great a boost
pressure a t the inlet manifold cold start air m i l (i.e. exhaust wastegote failure).
Fuel Accumulator The fuel accumulator i s fitted between the fuel pump and fuel
filter and is designed to maintain fuel pressure i n the system after the engine has
been switched off i n order to aid re-&ting and .
vapour locks f o k f ng
The accum"lator also serves to deaden
any noise arising from pulsations i n the
fuel line. The accumulator'consists' of
a fuel storage chamber and spring
loaded diaphragm.
Diagram A shows the storage chamber
empty and the diaphragm pushed by its
spring against the divider plate.
1
2.
. Spring Chamber
Spring
5. Storage
Chamber
3. Stop (full) 6. Baffle
4. Diaphragm 7.. Fuel Entry
8. Fuel Exit
Page 7
When the fuel pump are running, the pressure of fuel pshes the diaphragm back against
its spring u n t i l the storage chamber i s filled as i n diagram B.
When the pumps are switched off, the non-return valve fitted i n the outlet of the second
pump, prevents fuel returning to the tank, through the pump, and the fuel distributor
primary pressure regulator shuts off the fuel return pipeline.
The accurnulator spring then maintains a rest pressure i n the system for sufficient time
to aid hot re-siurt .
Fuel F i l t e r The fuel filter i s fitted between the fuel accumulator and fuel distributor.
Due to the extremely close tolerances of the injection equipment, a special fine filter
i s fitted to protect the system from impurities i n the fuel.
The filter consists of a sealed cannister containing a paper f i l t e r element backed up by
a l i n t o r fluff filter, and a restraining strainer.
Fuel Filter
1 . Paper Element
2. Lint or Fluff Filter
3. Stminer
i t i s most important that the filter i s fitted with the arrow stamped on the body pointing
i n the direction of fuel flow. The connections are armnged to permit only the correct
fitment .
LD. 4. - MIXTURE CONTROL UNIT
The Mixture control unit is the heart of the fuel injection system, and comprises an
a i r ffow sensor and fuel distributor.
The a i r flow sensor is fitted between the air filter and turbocharger, and senses the
amount of a i r b e l q drawn into the engine. This measurement i s used to move a control
vafve i n the fuel distributor which regulates fuel delivery to the injectors.
Page 8 SECTION L D
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 i s positioned i n an air funnel and operates on the suspended body
principle such that the greater the quantity of air dmwn i n by the engine, the greater
the sensor plate movement. The funnel i s specially shaped to provide the necessary
sensor plate movement and fuel delivery characteristics.
Buffer Fuel Control Valve
Sensor Plate
Funnel
//
To Engine 4-. Setting Screw
I n order to prevent damage to the sensor i n case of pressure shocks i n the intake system
(backfiring) etc .) provision i s made for the sensor to swing upward and open a relief
cross-section i n the funnel before being restrained by a buffer. The rest position of
the sensor i s controlled by a preset spring pin.
The screw setting the fuel control valve operating arm i s preset and requires no adjustment
under normal operating conditions.
Fuel Distributor The fuel distributor comprises:
i) Primary Pressure Regulator (System Pressure)
ii) Fuel Control Valve
iii) Four Distributor Differential Valves
i) Primary Pressure Regulator

The primary pressure regulator i s incorporated into the body of the fuel
distributor bid takes the form of a spring loaded plunger. -
Fuel i s delivered by the pump into the fuel distributor a d exerts a force on
the pressure regulator valve which i s calibrated to maintain a primary fuel
pressure of 6 .O Bar with excess fuel being returned to the tank.
A - Engine Stopped B - Engine Running

'1 .
Primary Pressure .Input 4. Plunger
2.Seal 5. Regulator Spring
3. Return to Tank
. ...
Page 9
When the engine i s 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 i n the primary system.
ii) Fuel Control Valve

The fuel control valve i s located centrally i n the fuel distributor, and controls
the fuel delivery to the injecton relative to the air flow sensor position.
/To 1njec tors
Fuel Intake
The control valve slides inside a barrel into which i s fed fuel at primary
pressure. The fuel then flows through 4 metering slits to the distributor
differential valves and then to the fuel injecton. As the air flow sensor i s
deflected further by an increasing airflow, so the control valve i s raised i n
its barrel, progressively
. opening
. a larger proportion of the metering slits, and-
increasing fuel flow to the injectors,
Engine Stopped ' Part Load Full Load
1 Control pressure
2 Control plunger
3 Metering slit in the
barrel
4 Control edge
5 Fuel Intake
6 Barrel with metering
slits
The Lotus fuel distributdr has metering slits with two different widths, the smaller,
stclndard section for light and part load running and the larger width for mid to f u l l
power runnlng . . . , . .
Page 7 0 SECTION LD
Control Pressure In order to damp any tendency o f the control valve and air flow
sensor to osillate, and to provide a means whereby the movement o f 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 o f the control valve and oppose the force applied
to i t b y the airflow sensor.
1. Control Pressure Force

2. Damping Restriction
3. To Warm Up Regulator
4. Control Pressure Take
Off Orifice
4 5.
6.
Fuel a t Primary Pressure
Force from Airflow Sensor
a
A small bore take off from the primary pressure supply directs fuel a t a reduced pressure
into the top of the fuel control valve cylinder. This 'control pressure' i s regulated by
the warm up regulator (see later) which reduces the control pressure when the engine
i s cold. This reduced force above the control valve, at lows the airflow sensor and control
valve to move a greater distance for a given airflow, and exposea greater proportion o f
the metering slits. More fuel then flows to the injectors to achieve a richer cold running
mixture.
The warm up regulator achieves this control pressure regulation by allowing a proportion
o f the fuel to return to the tank, but i n order to maintain control pressure after engine
switch off, and to aid re-start, the return line from the warm up regulator i s fitted with
a shut off valve which closes when the engine is stopped.
L Primary Pressure Regulator With

Control Pressure Shut Off Valve
r
A - Engine Stopped
B - Engine Running
Primary Pressure
Return to Tank
Plunger
Shut Off Valve
Control Pressure
This shut off valve i s incorporated into the primary pressure regulator such that i t i s
held open a g a h t spring pressure oniy whilst the primary pressure regulator i s operating
.
(I.e engine runnf ng) .
SECT/ON LD Page I 7
Distributor Differential Valves One distributor differential valve for each engine
cylinder i s incorporated i n the fuel distributor to maintain a constant pressure drop
across the metering slits regardless of their opening. This i s necessary i n order to
ensure that the fuel flow to the injecton i s dependant only on the length of metering
slit exposed, and also i s not affected by any variation i n primary pressure.
The valves are mounted i n 4 cavities inside the fuel distributor. Each cavity i s divided
into upper and lower chambers by a steel diaphragm. A l l the lower chambers are
interconnected by a ring main and are supplied with fuel at primary pressure from the
pumps. The upper chamben are isolated from each other and each i s connected individually
to one of the metering slits. Each diaphragm i s spring loaded downwards away from a flat
seat valve leading to one of the fuel iniecton .
Fuel Intake a t
Primary Pressure
Upper Chamber
To Fuel Injector
Control Valve
Metering Slit
Helical Spring
Steel Diaphragm
Lower Chamber
LOW HIGH
FUEL FUEL
D ELIVERY DELIVERY
As the metering slit i s opened, and the upper chamber pressure tends to increase, the
diaphragm is pushed downwards increasing the flat seat valve opening to the injector
line such that the upper chamber pressure remains a t 0.1 bar below that o f the lower
chamber, This pressure differential i s set by the helical spring. Hence, during
operation, the diaphragm is held i n equilibrium by the force of the primary fuel pressure
on the underside, and by the upper chamber press&e plus the spring-pressu.re on the
topride
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 i s 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 with a valve needle which vibrates at high frequency
as the fuel flow pressure lifts the valve on and off i t s seat, producing a finely atomised
spray
Fuel atomisa tion i s further aided, especially at low engine speeds, by an air stream
flowing around the injector This air stream i s supplied via a passageway running across
the top of the inlet manifold, and a hose connecting with the intake plenum.
When the engine inlet valves are closed, the air/fuel vapour cloud formed, i s stored i n
the intake port,
. . to be drawn into the cylinder when the inlet valves open again.
When the engine is stopped, the fuel pressure drops below that required to open the
f njector valves, so shutting the valves and preventing fuel dripping into the ports.
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 i n order to adapt the mixture strength
.
for differing climatic, transient and emissions related conditiom These components
include those providing enriched mixture strength for cold starting and running,
fuel cut-off on overun, and adjustment of mixture to achieve minimal harmful
emissions.
LD. 7 - COLD START INJECTOR
When starting a cold engine, the cranking speed induces very low air flow with
resulting low fuel delivery to the injectors. The additional fuel necessary for
cold starting i s supplied by the cold start injector only at cranking, and for a
maximum duration of between 0.1 and 8.0 seconds dependant on coolant temperature.
Auxiliary
Cold Start Injector Air Valve
I / Fuel l njector
Cold Start
The single cold start injector i s fitted into an air rail running alongside the fuel
injector air stream rail on the inlet manifold. Connecting passages join this air
r a i l with each intake tract. A hose from the auxiliary air valve allows a flow of
air to be drawn around the cold start injector on engine cranking to finely atomise
the fuel sprayed from its nozzle.
'
The cold start iniector i s a solemid valve supplied with fuel at primary pressure
from the fuel distributor, and i s opened by a current supplied via, and for a time
period governed by the thermal time switch.
Page 14 SECTION LD
LD. 8. - THERMALTIME SWITCH
The thermal time switch i s 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 i s mounted an electrical contact
controlled by a bimetallic strip wound with a heating coil.
The current, supplied to the thermal time switch only whilst the engine i s cranked,
i s passed through the heating coil, and switch contacts to the cold s b r t inlector.
As the bimetal strip heats up, i t bends and opens the contacts, shu'tfing off the injector.
-
Maximum injection time, at 20° C i s approx. 8 secs. The warmer the engine is,
the more heat i s absorbed by the bimetal strip, so that a shorter electrical heating
time is needed to break the contact. When the engine i s a t normal running temperature
the switch absorbs sufficient heat to keep the contacts open rendering the cold start
injector inoperative.
LD. 9 - AUXILIARY AIR VALVE
I n order to overcome the increased friction present i n a cold engine, and enable the
engine to idle satisfactorily after cold start-up, an auxiliary air valve i s fitted between
the plenum chamber and cold start air mil to by-p& the throttle butterflies and provide
an additional air flow to the engine. Since this air i s drawn through the airflow sensor,
additional fuel i s injected accordingly.
Valve Plate
Bi-metallic Strip
Opening Spring
The auxll iary air valve comists of a ptvoted plate provided with a specially shaped aperture
such that by moving the plate the by-pass air supply line m y be regulated between fully
open and fully closed. Movement of the disc i s controlled by an opening spring and a
closingheating coil wound, bimetal strip.
SECTION LD Page 15
0- AsI n the cold engine condition the plate adopts a position fully opening the by-pass line.
soon as the ignition switched on, current flows through the heating coil and
is
gradually causes the bimetal strip to bend and rotate the plate,reducing the by-pass
aperture. As the engine warns, and its heat i s absorbed by the valve body, the heating
effect of the coil i s augmented and the plate i s rotated further to fully close the by-pass.
Engine heat alone is sufficient to ensure that the by-pass remains closed when the engine
IS warm.
LD.10 - WARM UP REGULATOR
I n order to compensate for the condensation of fuel on the inlet tract and cylinder walls
whilst the engine i s running cold, and to maintain driveability until normal running
temperature i s reached, i t i s necessary to enrich the fuel/air mixture during this period.
The warm up regulator fulfils this function by reducing the control pressure by an amount
dependent on engine temperature. When the control pressure i s reduced, the fuel control
valve i n the distributor is allowed to move further for a given airflow and open a greater
proportion of the metering slits, increasing fuel flow to the iniectorr.
A ENGINE COLD B NORMAL RUNNING

9 8
TEMPERATURE I I 1: _I
1. Valve Diaphragm 4. Valve Spring 7. Spring

2. Return to Tank 5. Bimetal Spring 8. Aneroic Capsule
3. Control Pressure 6 , Heating Coil
The warm up regulator comists of a flat seat valve controlling the return of fuel from the
control pressure line to the tank. The valve i s held closed by a coil spring, but this i s
opposed by a bimetallic spring wound with a heating element which i s fed with current
whilst the ignition i s switched on.
When cold, the bimetal spring overcomes the coil spring and opens the valve, such that
the control pressure is low, a.nd the mixture rich o n engine start up. . As the engine runs,
the bimetal spring i s heated, both by' i t s heating coil, andby &in& heat absorbed by
the regulator, and gradually reduces i t s opening force on the valve. Finally, when the
.engine reaches normal running temperature, the bimetal spring i s sufficiently heated to
l i f t clear of the valve rod so that the control pressure i s controlled only by the coil
.
spring
Page 16 SECTION LD
LD. 11 .- HIGH ALTITUDE COMPENSATION
Operating the engine at high altitude where the air density i s 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 valve rod i s extended to abut against the capsule, which i s
held i n a 'flattened' condition by atmospheric pressure and a leaf spring as shown i n
the warm up regulator diagram. A t high altitude, the reduced atmospheric pressure
results i n the aneroic capsule 'expanding' and exerting an additional closing force on
the control pressure valve, raising the control pressure and compensating the mixture
strength for altitude.
LD. 12 - EXHAUST EMISSION CONTROL

The minimum production of harmful exhaust gas emissions i s achieved primarily through
the use of starter and main 'three way' catalysts combined with very accurate fuel metering.
a
The optimum air/fuel ratio for minimum emission of a l l three noxious components -
carbon monoxide CO, unburnt hydrocarborn HC, and nitrogen oxide NOx, and also
for minimum f u e l consumption w i t h maximum driveabilitpis about 14 to 1 by weight.
This i s sometimes referred to as the 'stoichiometric ratio'.
The air/fuel ratio may also be represented by expressing the amount of air present i n
the mixture as a proportion of that amount required for a stoichiometric ratio. This
proportion, the excess air factor, when used i n connection with Bosch fuel injection, i s
. ,
referred to by the Greek letter Lambda (L) Thus, when Lambda (L) = 1 the correct
amount of ai; i s present, and the air/fvel ratio = 14 to 1 .
Excess-air factor L
When L I s greater than 1, too much air i s present and the mixture i s lean. When' L i s
less than one, too l i t t l e air i s present, and the mixture rich.
Page 17-.
LD. 13 - U M B D A SENSOR
It i s 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 i s achieved by fitting a Lambda sensor into the exhaust system between the
turbocharger and =ato1yst .
The Lambda sensor i s calibrated such that deviations from L = 1 (the desired air/fucl ratio)
result i n a sudden change to its output voltage signal. This signal i s used by an electronic
control unit to determine the fuel delivery correction necessary. This correction i s made
via a 'Frequency Valve' fitted between the fuel distributor and tank. The sensor is
fitted with its own heating coil which i s used to heat the semor to operating temperature
after engine start up. Signals from the sensor are only processed a t engine o i l temperatures
above 3 5 O ~ .
- FREQUENCY VALVE
a LD. 14 (Timing Vafve)
Corrections to the fuel delivery as determined by the Lambda sensor and electronic
control unit (E.C.U.), are made by altering the fuel pressure beneath the diaphragm
of the differential valves i n the fuel distributor.
1. Fuellnlet
2. Small Orifice
(Fixed Throttle)
3. Lower Chamber
4. Frequency Valve
H 5. Return to Tank
6. Metering Slit
I n order that the pressure i n these lower chambers may be varied, the connection between
their ring main and the regulated primary pressure i s fitted with a small orifice (ftxed
throttle), and a return line from the lower chambers to the tank i s provided with a variable
throttle. In this way, ifthe variable throttle i s closed, regulated primary pressure w i l l be
present i n the lower chambers, whilst opening the variable throttle allows fuel i n the
lower chambers to bleed off back to the tank, hence lowering the pressure.
Page 18
Lowering the pressure beneath the diaphragms w i l l 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 control unit .
LD. 15 - ELECTRONIC CONTROL UNIT (E .C .U .)
The function of the electronic control unit i s to process information fed to i t by

various sensors including the exhaust gas Lambda sensor, and set an operl/close
ratio for the frequency valve.
This method of regulating the air/fuel ratio to Lambda = 1 .O by continuously

monitoring exhaust gas oxygen content, i s called Lambda closed loop control,
and may be represented by the following flow chart.
Rich mixture
Injected fuel N o Oxygen i n
quantity increases ex haust g ases
Regulated fuel
pressure decreases
Open/close ratio ~ ~ e n / c l o sratio

e
of Frequency Valve of Frequency Valve
i s increasing i s decreasi ng
Low sensor
voltage
Regulated fuel
pressure increases a
Oxygen i n Injected fuel
ex haust gases quantity decreases
Lean mixture
Certain operating conditions require different air/fuel ratios, and i t i s necessary

to switch to an open loop control system with a preset frequency valve open/close
ratio.
The opeq/close ratio of the solenoid opemted frequency valve is conholled by an

electrical pulse sent to open the valve many times a second. Under normal
runntng conditions, the valve i s openedfor about 50% of the time, and the pulse
rate supplied to it i s referred to as 50% duty cycle. 100% duty cycle would mean 0
the valve I s held permanently open.
The E.C.U. sets fixed duty cycles under the following conditiors:
i) 75% duty cycle a t engine o i l temperatures below 3 5 ' ~as sensed by the
the low temperature switch.
ii) 65% duty cycle on engine overun, when fuel by-pass valve (LD.16) i s
.
opera t i ng
iii)65% duty cycle a t throttle butterfly openings of more than 30°, as
sensed by the throttle position switch.
i v ) 65% duty cycle at engine speeds higher than 3250 rpm as sensed by
'fuel enrichment module' mounted on RH fuel tank board.
v) 50% duty cycle i f a defect i n the Lambda sensor i s detected (unless
conditions i,ii,iii or i v above apply).
a A t idle speed, the E.C.U. updates the closed loop duty cycle rate more quickly i n
order t o stabilize idle rpm.
LD. 16 - FUEL BY-PASS VALVE
The fuel shut off valve has been incorporated into the fuel system to improve economy
during engine overun by returning the air sensor plate to its rest position, shutting off
the fuel supply. This i s achieved by collapsing the depression below the sensor plate
b y allowing air from the a i r cleaner homing to be fed directly into the a i r ducting
below the plate.
The valve i s controlled by a n electric power supply and manifold vacuum but governed
by the engine coolant temperature, engine speed and the position of the throttle. The
valve has an a i r inlet and outlet w i t h the inlet spigot pressed into a grommet i n the a i r
cleaner main body while the outlet i s connected by hose to the a i r flow sensor lower
housing. When the valve i s triggered to its open position air w i l l be drawn through the
valve into the lower housing collapsing the vacuum below the plate. The sensor plate
movement w i l l be restored as soon as the valve closes.
The following conditions must occur for the valve to be acti\cqted:
The coolant temperature, sensed by the high temperature switch must

be above 70° C This i s to ensure that the driveability i s not affected
during engine warm up.
The throttle must be 'closed'. A throttle position switch controls this

operation ensuring that the by-pass valve only operates i n the i d l e
position.
The engine must be decelemting from a speed greater than 16d0 rprn .
Two critical speeds control the valve operation. It w i l l not be
activated unless the engine is deceierating from above 1600 rpm and
. i t w i l l cut out once the speed dropsdown to !400cpm. The engine
speeds are monitored by a speed sensing relay, mounted i n the ignition
box at the rear of the engine bay.
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 " l e .
Thermal Ignition Valve (T. I.V .)

The T.l .V. i s fitted into the inlet manifold water rail and controls the vacuum feed to
the distributor advance capsule (D .A.C.) . At water temperatures below 530 C, the T. I.V.
directs a vacuum pump feed to the distributor advance capsule to improve cold driveability,
but changes the feed above this temperature to a throttle edge drilling on no. 3 intake
tract.
lgnition Solenoid & Throttle Jacking Capsule (T. J.C.)

The ignition solenoid controls the vacuum supply to the throttle iacking capsule, and i s
switched by an electrical feed from the high temperature switch, fitted into the inlet
manifold water jacket between tracts 1 & 2.
A t water temperatures below 7

0' Cthe high temperature switch supplies current to the
ignition solenoid, which then directs a vacuum pump fed to the T. J.C. to increase cold
engine idle speed. Above 70' Cthe solenoid i s de-energised and the T. J.C. connected
with the upstream throttle port.
LD. 19 - AIR CONDITIONING IDLE UP SOLENOID

-
The purpose of the A/C idle up solenoid i s to maintain engine id1 e speed when the air
conditioning compressor i s operating.
' The solenoid i s fitted on the RH fv'el tank board, and connected by hose between the
inlet manifold cold start air r a i l and the underside of the airflow sensor. The valve i s
of the 'normally open' type, and i s closed when the solenoid i s energised.
A t water temperatures below 70' C the valve i s open a t a l l times, to aid cold
.
running and,-id1lng A t water' temperatures above 70' c the solenoid is energised
and the valve sh.uts , If however, the air conditioning compressor is opemting,
the solenoid valve de-energf es .and
. .opens whenever engine speed i s below 1400
rpm.. (Controlled by the fuel by-pass relay).
r
. .
Vacuum Pump,
VACUUM SWITCHING DIAGRAM - BELOW 5

3
' C WATER TEMP.
Vacuum Pump
I .
I TO
DISTRIBUTOR CAPSULE IC
-
I-
.-..."".". .."."-.-.'
Vacuum Pump Feed
Upstream Throttle Port - Ignition
Solenoid
Edge Drilling
VACUUM SWITCHING DIAGRAM - BETWEEN 53' - 70° C WATER TEMP.

u
THROTTLE
EDGE PORT
DISTRIBUTOR CAPSULE
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 h e .
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 i s inverted) to p o r t ' ~ ~ ' othe
n charcoal canister,
where the fumes are absorbed i n charcoal before being purged into the engine.
Similarly, when the engine i s stopped, fumes from the intake system are vented to
the canister via a hose linking the airflow sensor lower body to canister port 'C' .
I n order to cleanse the charcoal of fuel absorbed i n this manner, arrangements
are made for fresh a i r to be drawn through the canister and consumed by the engine.
Two different connections are used to purge the canister under different engine
operating conditions.
Port 'PI on the canister i s connected via a one way valve to the inlet manifold cold
start a i r rail, such that when the engine i s running a t small throttle opening, or on
.
overun, (i.e with high manifold vacuum) air i s drawn through the canister and one
way valve into the inlet manifold, and i s then consumed by the engine.
SECTION LD Page 25
I n 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 i n developed, inlet manifold pressure becomes positive,
and the manifold air r a i l hose is sealed by the one way valve, and A/C idle up
solenoid (will not open above 1400 rpm). Purging now takes place through
canister port 'C' to the depression (greater now with increased airflow) below
the airflow sensor.
Cra nkcase Breather Va Ive .

Crankcase fumes are ventilated via the crankcase breather valve into the a i r cleaner
housing. Positive crankcase pressure developed during normal running, i s able to vent
through the one way breather valve into the a i r cleaner housing.
I n order to prevent these fumes, under low airflow engine idle conditions, escaping
through the i n l e t trunking to atmosphere, the valve i s also connected via a smaller bore
hose, to the mild depression below the airflow sensor. This enables crankcase fumes a t
idle to pass directly into the intake tract and supresses opening of the breather valve.
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 i s 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. I n addition, fuel i s supplied by the cold start
r
injector for a period controlled by the thermal time switch. Air b -passes the throttle
butterflies via the auxiliary air valve and a/c idle up solenoid va ve.
-
Cold Run Below 35' C Oil Temp.
When the engine starts, the cold start injector closes, if i t has not already done so,
but air continues to flow via the auxiliary air valve, which closes as the engine warms.
The ignitionsolenoid directs a vacuum pump supply to the throttle iacking capsule, and
to the thermal ignition valve which itself directs the supply to the distributor advance
capsule.
he control pressure set by the warm up regulator, i s low, but increasing as the engine
a
warm.
The frequency valve i s set to run open loop @ 75% duty cycle rate.
-
Cold Run Above 3 5 ' ~ Oil Temp., Below 5 3 ' ~Water Temperature
. .
As 35'C o i l temperature is reached, the E.C U switches the frequency valve to run
'closed loop' (i.e. controlled by Lambda sensor @ around 50% duty cycle for L = 1).
-
Cold Run Between 53O and 70° C Water Temp,
When 53O C water temp. is reached, the thermal ignition valve cuts off the vacuum
.
pump supply to the D .A .C and connects i t with the throttle edge drilling.
-
Normal Running Above 70° C Water Temp.
When 700 C water temp. i s reached, the ignition solenoid cuts off the vacuum pump
supply to the throttle jacking capsule.
The a/c idle up solenoid valve opens only at idle with the compressor operaying.
LD 22 - FUEL SYSTEM PRECAUTIONS

Always ensure absolute cleanliness when working on any part of the fuel system.
Thoroughly clean around any joint before disconnecting a component.
Pressure i s maintained i n the fuel system after the ignition i s switched off by the
action of the fuel accumulator, primary pressure regulator and control pressure
shut-off valve. Therefore whenever disconnecting a fuel system joint, take care
to use an absorbent cloth to protect from spray, and soak up the small amount of fuel
released.
Take a l l necessary precautions to prevent sparks occuring whilst a fuel joint i s
disconnected.
Ensure that new sealing washers and gaskets are used on re-assembly, and that a l l
joints are torque tightened i n accordance with Section LD 25.
When fuel system tests are being performed involving the collection of fuel from
.,
,
fuel pumps, fuel injectors etc the very strictest precautions must be tbken to prevent
sparks occuring i n the vicinity of the working area. Any electrical switching necessary
i n the course of these tests should be performed by the ignition switch, or fuel pump
inertia switches .'
Ersure the working area is well ventilated
SECTION LD Page 27
a LD 23 ENGINE MANAGEMENT SYSTEM CHECK/SET UP PROCEDURE
Tools Required
i> Duty Cycle Meter . TOOOT0567

ii) Continuity Meter TOOOT0568
iii) khaust Sample Probe TOOOT0501
iv) Stroboscopic Timing Light (proprietory)
1. Connect the duty cycle meter to the frequency valve:

The frequency valve is located ahead of the fuel distributor. Disconnect the
electrical plug from the valve and plug i n the meter to both the valve, and
the harness connector block as shown. Connect the crocodile c l i p to a good
u Block
Connect the exhaust sample probe into the

turbocharger adaptor and connect t o a
CO/HC analyser (e.g. Sun EPA 75 or
equivalent).
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 i s reached (water
temp. above 80O~).
2. Check idle speed. 950 !

: 50 rpm.
D O NOT ADJUST IDLE SPEED WITHOUT FIRST SLACKENING THROllLE
POSIT1ON SWITCH MOUNT1NG SCREWS ON REAR OF No. 3/4 THROTTLE
BODY.
0
Switch
I f adjustment i s required, f i n t slacken the throttle p i t i o n switch scram, and

then adjust idle speed at the stop screw between throttle bodies 2 and 3.
Idle Speed Stop Screw
Ad jvst throttle cable to suit i f necessary.

After adjustment, connect continuity meter TOOOT0568 to the throttle position
switch, and rotate switch until continuity i s JUST made. Tighten screws and
recheck setting.
SECTION LD Page 29
3. Check ignition timing a t idle: 15O BTDC using the strobe and flywheel
timing mark.
V i e w o f Clutch Housing
Timing Aperture
A d just, i f necessary, a t the distributor clamp. (special Socket TOOOT0503)
Check throttle jacking capsule adjustment:

Bridge connections to i n l e t manifold high tempemture switch (use a s p r e fuse)
.
to activate the capsule. Engine speed should hold a t 1300 to 1500 rpm Adjust
i f necessary a t the clamp behveen capsule rod and throttle lever.
Remove electrical bridge and re-check i d l e speed.
-
Check duty cycle i s between 45 55% w i t h a 5 to 6% c y c l i c variation. The
cyclic variation (flicking back and forth over a 5 to 6% range) indicates that
the 'closed loop' feedback system i s operating w i t h the mixture strength
constantly being amended by the frequency valve i n conjunction w i t h the Lambda
sensor and E.C.U.
A steady reading indicates that a n open loop circuit i s operating (see Electronic
Control Unit and wiring diagrams).
Check the CO level is 0.8% 1 : 0.5% and the HC level, as Hexane, i s less
than 500 ppm,
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 i s Lambda heating coil).
If the mixture setting is correct disconnecting the Lambda sensor should have no
effecfon idle rpm.
Refer to the following table:
C O Readings
Closed Loop Closed Open Remark See

Duty Cycle Loop Loop Section
I O.K. I O.K. I SyrtemSatisfactory I

ii) l njec tor Distribution LD 24E 3
iii) Throttle Imbalance LD 24P
i) M.C.U. Setting too Lean L b 24H

O.K. Low
ii) Inlet System Air Leak LD 2 4 0
Over 55%
-
Hiah 1 O.K.
I i) Exhaust System Leaking I ~ ~ 2 1 4 0
ii) Sensor Faulty
O.K. High M.C.U. Setting too Rich LD 24H

Under 45%
Low I 0.K . 1 Sensor Faulty I I
SECTION LD Page 37'
-
LD 24 - FUEL INJECTION FAULT DIAGNOSIS
Note: When using this chart i t i s assumed that the general engine condition i s sat&factory
and ignition system is adjusted correctly. It i s also assumed that the electrical
system, including the safety cut-out circuit for the petrol iniection system, has
been checked and is i n good working condition.
Electric fuel pump faulty

'Cold'control pressure outside specification
'Warm' control pressure too high
'Warm' control pressure too low
Auxiliary air valve does not c l a e
Auxiliary air valve does not open
Cold start injector does not operate
Cold start injector leaking
Primary fuel pressure outside specification
Sensor plate rest position incorrect
Sersor plate and/or control plunger sticking
Vacuum system leaking
Overall fuel system leaking
Fuel iniector(s) leaking or opening pressure low
Basic mixture ad justment too r i c h
Basic mixture adjustment too lean
Throttle does not open/close completely
Thermo time switch does not close
Fuel by-pass valve
Throttle jacking capsule
Throttle position switch
A i r leaks i n exhausr/inlet
Throttle imbalance
E.C.U. faulty. See electrical LD 26/27/28
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 f i t electrical test bridges TOOOT0569.
The fuel pump should be heard running. If no sound i s heard, refer to
LD 26/27/28 for electrical diagnosis.
3. With pumps running, check voltage drop at terminals of both pump.
Minimum = Engine Running: 11.5 V, Engine Stopped: 10.0 V.
Remove test bridges from pump control relay bases.
To check that sufficient fuel i s supplied to the injection system:
Tools required: Test Hose TOOOT0579

Graduated Flask TOOOT0582
Electrical Test Bridges TOOOT0569
4. Check Fuel Return Quantity from Distributor

Fit the test hose TOOOT0579 to the fuel distributor return connection (see
Fuel System Precautions LD 22) and place into draduated flask
Fit test hose here i n place
Trip inertia switch and f i t electrical test bridges TOOOT0569 to fuel

pump control relay bases.
hess down inertia switch for a short time to prime the system. Empty
flask.
hess down inertia switch for exactly 30 seconds and measure quantity -
of fuel delivered.
Specification: 1ZSO f 100cc
Page ..33 >
,
. .
.. .. . .
If the quantity i s insufficient: .
.
. .,. .. .. . ...
5. Check Fuel Delivery Quantity at Secondary h m p 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 f i t electrical test bridges to fuel pump control relay bases.
Ress down inerfia switch for exactly 30 seconds, and measure fuel quantity
del ivered.
Specification: 1850 f 100cc
If delivery i s OK, replace the fuel filter.
If below specification:
Check Fuel Delivery Quantity at primary Pump Outlet
Fit the test hose to the primary pump outlet connection, and place end i n graduated
flask.
Primary Pump
Outlet Connection Ik
I r
FUEL PUMPS
; 96* FUEL ACCUMULATOR
FUEL FILTER
FUEL
TANK
With electrical test bridges fitted, press down inertia switch for exactly 30 seconds
and measure fuel quantity delivered.
Specification: 1800 f 1OOcc
Ifd e l i v e v is below specification, .disconnect supply pipe from pump and provide
with alternative known supply. Repeat test.
If delivery i s now OK, clecrn, repair or replace t a d . If delivery insufficient .
replace primary fuel pump.
Page 34. SECTION LD
0 - FUEL PRESSURES
Tools requIred: Test Gauge TOOOT0575

Electrical Test Bridges TOOOT0569
1 . Check Prtmary Pressure

Trtp inertia switch, remove fuel pump control relays and f i t electrical test
bridges into relay bases.
Fit test gauge to fuel distributor inlet connection with gauge valve toward
.
dtstributor (see Fuel System Precautions LD -22)
Ensure gauge valve i s OPEN
Supply pip;?
from Pump
Reu down inertta switch and record primary fuel pressure from gauge.
Trtp inertta switch.
Specification: 6.0 - 6.8 Bar O 20°c
If pksure is ,below specification:
Check Supply Pressure to Fuel Distributor

1) Check gauge valve i s fully open.
11) Press down tnertta switch and gradually close gauge valve very slowl
unttl pressure rkes to 10.0 Bar. DO NOT c l a e gauge valve further as press~res
I n excess of 10 Bar are liable to cause damage to the system and/or gauge.
ttt) Trtp t nertta switch
Spsclftcatton: A t least 10.0 Bar

If pressure k below speclficat~on, check quantity of fuel deltvered a t secondary f&l
pump outlet (see LD 24 A5).
If supply pressure to dtstrtbutor is OK, but primary pressure too low:
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).
M I S ITEM SHOULD NEVER

REQUIRE ATTENTION UNDER
Adjust the shim pack as necessary to correct primary pressure - adding O.lmm
shim thickness increases pressure by about 0.15 bar.
Renew '0' ring and replace regulator into distributor.
Re- test primary pressure.
Check-Cold Control Pressure

Carry out this test ONLY at an ambient temperature of 30°C or lower.
F i t the test gauge to the warm up regulator as shown.
(See Fuel System Precautions LD .22).
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
860
4,o 880
900
920
3,s 940
a,
L
1
n
d
3'0
E
3
V)
w
aJ
L
f
U
0
a
-
.4
L
2,5
I5
10" 20" 30' 40"
Ambient Temperature
The basic curve applies for a n air pressure of 947 mbar and higher (corresponding
to see level up to an altitude of about 600 m above see level).
Permissible tolerance of the basic curve: +- 0.2 bar.
If the site where the measurements are made i s located at higher altitudes,
it i s essential that the exact air pressure i n known on the day when ths
measurements are made in order to determine the correct control pressure.
(Use an accurate barometer, or ask the weather bureau or an airport if one
or the other i s near and at the same altitude).
Tolerance of the control-pressure altitude curves: +- 0.25 bar.
If the "cold" control pressure differs from the nominal value, replace the
warm-up regulator.
Check Warm Control Pressure

With the test gauge fitted as i n (4), (gauge valve open) remove the electrical
test bridges, refit fuel pump control relays, and press down inertia switch.
Start engine and observe gradual rise i n control pressure. When the warm up
regulator bimetal strip is fully heated the pressure w i l l stabilise. Record reading
and switch off.
SECTION LD Page 37
The nominal control pressure should be read from the curve i n accordance with the
air pressure.
The effect of the altitude compensation begins a t an air pressure of about 933 rnbai,
i.e. starting at about 600 m. A t higher altitudes i t i s essential that the exact air
pressure i s known o n the day when the measurements are made. (Use a n ac,curate
barometer, or ask the weather bureau or an airport i f one or the other i s near and
a t the same altitude).
Time taken to achieve Warm Control Pressure Effect of Altitude on Warm Control Pressure
(at 20°C and 944 mbar)
bar
kgf/cml
ffl
800 750 700 650 600 550 Torr

1067 1020 933 867 800 733 mbar
Time ( sec. )
Air pressure
If the control pressure does not rise from the cold setting, check the feed and earth
connections at the warm up regulator.
Ifwarm control pressure i s outside specification, replace warm-up regulator.
6. Check for Fuel System Leaks, Internal & External

With the fuel pumps running, carry out a thorough visual inspection of al.1 fuel
system connections.
With the test gauge fitted as in(4) and with the gauge valve open, start
engine and switch off when 'warm' control pressure i s reached. Observe and
record the drop i n pressure with time.
Specification: Minimum 3.0 Bar after 30 mins.
I f the pressure drops too quickly, repeat the test, closing the gauge valve as the
engine i s switched off, thus isolating the control pressure circuit.
If the same result i s found, the leak i s i n the, primary pressure circuit. If however,
the second result i s within specification, the..leek k,'tnthe control pressure circuit.
Possible causes of primary . pressure

. leak:
i) Non return valve i n secondary fuel pump. Replace pump. .
...
i i ) Leak from cold start valve or fuel injector. (see Section D & G).
111) '0' ring i n primary pressure regulator leaking. Replace '0' ring.
i v ) Fuel accurnulaior leaking past diaphragm. Replace.
Page 38
F i t the pressure gauge a t the fuel distributor inlet connection, and a t 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-making a fuel system connection, and refer to
fuel system torque settings Section LD 25.
C - AUXILIARY AIR VALVE

Cold Test
If the engine i s not cold, the valve may be removed and cooled by freezer.
Remove both b& from the unit, and with the aid of a mirror and lamp, observe the
position of the valve plate, which should be partially open, dependent on temperature.
I f the valve i s completely closed, replace the auxiliary air valve.
Quick Test: Clamping off an air valve hose on a cold engine should reduce idle rm.
A i r Valve
Hot Test
D'aconnect RPM relay and bridge connector block termiml; 30 and 87.
After a maxlmum of 5 minutes the auxiliary air w l v e must be completely closed aided If
necessary by tapping the valve assembly with a soft faced mallet t o compensate for lack
of engine vibratlon.
If the valve does not close completely, check the electrical feed to the valve and
reststance of the w l v e heati -Q coil for open circuit. Replace ifdefective.
Qvick Test: Clamping off an air valve hose on a warm engine should have no
effect on idle rpm.
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 i n a glass jar, or graduate, and f i t electrical test lead TOOOT0570.
Connect test leads to ignition coil terminals. switch on ignition and press test
lead button. Fuel should spray from the injector. I f no spray, check electrical
feed and, i f necessary, renew cold start injector .
If spray is OK, switch off ignition and wipe injector nozzle clean. Remove
electrical test lead and refit cold start iniector plug. Switch o n ignition and
observe valve for one minute, during which time no fuel should be seen to seep
from the valve. Refit injector to manifold.
E - SENSOR PLATE
1 . Remove the air cleaner body for access to the sensor plate. Check that the sensor
plate i s concentric with and can move freely through the narrowest part of the a i r
funnel.
Re-position i f necessary after loosening the plate fastening screw, and re-tighten
-
to 0.51 - 0.56 kgf.m (3.7 4.1 lbf. ft.).
2. Remove fuel pump control relays, and f i t electrical test bridges TOOOT0569
into relay bases for about 1 0 seconds to run the fuel pump and apply
control pressure to the fuel control valve i n the fuel distributor. Remove
test bridges.
Check the rest position of the sensor plate.
The upper edge of the sensor plate must be flush with the top edge of the funnel's
narrowest section, as shown. A position up to a maximum o f 0.5 mm higher i s
permissible, but the lower edge of the sensor plate must not project at any point
on its circumference above the funnel narrow section.
NOTE:
The lower edge of the seeor plate i s chamfered. Ensure the plate i s fitted the
correct way up, with the word 'TOP' uppermost and the chamfered edge on the
Chamfered edge on bottom

Page 40 SECTION L D . .
If the sensor plate rest position i s 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 w i l l
loosen
Rest position Pin
If adjustment has to be made, also check ignition system as the likely cause of
sensor plate mal-adjustment i s backfire down inlet system.
3. Check the free movement of the airflow sensor and fuel distributor control valve,
.
and comparative fuel delivery between injectors Remove each injector from
m n i f l o d (leave pipe attached) and lace i n graduated flask ~ 0 0 0 ~ 0 5 9 4 ~ .
Trip inertia switch. Remove fuel pump control relays and f i t electrical test
bridges TOOOT0569 into relay bases. Depress inertia switch.
a) Press down the airflow sensor. The same resistance must be felt over the entire
movement.
Move the sensor plate rapidly back to a position just i n front of the zero stop.
The control plunger follows this rapid movement pf the sensor plate only
sluggishly, and therefore initially loses contact with the sensor plate lever.
It must be possible, however, to feel the.plunger make contact with this
lever again. If this condition i s fulfilled, the control plunger can be
considered to move freely.
b) Check that the control lever moves freely; press the sensor plate to its
full deflection again, and then release i t . The semor plate should snap back
to the zero position and bounce up about twice from the spring-loaded stop.
c) Trip inertia switch and remove test bridges.

Compare quantity of fuel delivered from each injector.
Maximum permissible difference between any two injectors: 7.0 %
If this tolerance i s exceeded, interchange injectors and/or injector feed pipes,
and repeat test to establish whether fault lies with injecto~feedpipe, or fuel
distributor. Replace parts as necessary.
If the semor control lever i s found not to move freely, free pivot as necessary,
or replace airflow sensor.
If the control plunger does not move freely, remove fuel distributor for access
to plunger:
SECTION LD Page 4 1
See Fuel System Precautions LD 22.

i> Use a cloth to absorb the small amount of pressurised fuel released when
the warm up regulator feed pipe i s gradually slackened from the distributor.
Release a l l other fuel pipe connections to the fuel distributor taking a l l
precautions necessary to minimise fire hazard .
ii ) Release the three screws securing the distributor to the a i r flow sensor
body and remove distributor taking care that the control valve does not
drop out.
Dis trib
Fixing
Screws
it;) -
Remove the plunger under certain conditions, i n order to do this i t may
be necessary to blow compressed air against the plunger through the control -
pressure connection hole. Hold the plunger with your hand while doing this.
Clean the plunger thoroughly with petrol. If the plunger s t i l l does

not move freely, replace the fuel distributor.
Refit the 'fuel distributor using a new sealing ring between distributor
and alrflow sensor body. Tighten the three fixing screws to 0.32 -
-
0.38 kgf .m (2.3 2.7 lbf. ft .). Refit fuel pipes to distributor using
new sealing washers and tightening M8 bolts to 8.3 kgf. m (7 Ibf. ft .),
MlO bolts to 2.0 kgf .m (15 lbf. ft .).
Carry out the mixture setting up procedure described i n LD 23 - H.

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 i n the vacuum line switched
to the vacuum pump (with engine running).
If a lesser figure is obtained, check at the vacuum pump. If pump performance i s
.
below specification, check vac pump exhaust pipe for restriction, and 'V' belt drive
for fault.
Replace pump i f necessary.
With satisfactory vacuum pump performance, clamp off, or disconnect individual
components to isolate leaks and replace pipes or components as necessary. Check
secure f i t of a l l vacuum pipes.
- Upstream Throttle Port
Throttle Edge Drllllng
VACUUM SWITCHING DIAGRAM - BELOW 53' C WATER TEMP.

Page 43
- " ' " "
VACUUM SWITCHING D I A G W M
Vacuum Fhnp Feed
Upstream Throttle Port
Throttle Edge Drilling
- BETWEEN 53O -
i Ignition
Solenoid
70° C WATER TEMP.
-- . .'".'.. '" .""

Vacuum Pump Feed
Upstream Throttle Port
Throttle Edge Drilling
-Ignition
Solenoid
VACUUM SWITCHING DIAGRAM - ABOVE 70° C WATER TEMP.

Page 44 SECTION L D ''
G - FUEL INJECTORS
Remove the i n j e c t o ~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 tighten the union nut.
Check for dirt.
Move the hand lever slowly (about 2 seconds per stroke) back and forth with the
stopcock on the pressure gauge open. If the pressure does not b u i l d u p to 1 1 .5 -
bar, the injection valve has a leak, caused possibly b y dirt i n the valve.
Attempt to flush the injection valve clear by moving the lever back and forth
several times vigorously.
If this attempt is successful, continue the test. If i t is not possible to flush the
valve clear, replace it.
Test the opening pressure.
With the stopcock closed, flush the valve out and bleed i t with several rapid
movements o f the lever.
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 i s outside. tolerance, replace the injection valve.
l ndividual valves can be changed within a set.
5. Leakage test.
Open the stopcock, build the pressure up slowly to a value 0.5 Bar under
the opening pressure determined previosly and hold i t constant a t that
level. The injector must not drip for a t least 15 seconds.
6. Chatter test, evaluationof spmy.
Move the lever back and forth at about 1 stroke per second. As this i s done,
the valve must chatter. N o drops o f fuel must form at the mouth of the valve.
The valve must not produce a "cord spray". Formation of a single-sided atomized
spray within an overall spray angle of about 35' i s permissible (see example given
i n illustmtiow).
Good spray forma tion ,
single-sided but nevertheless good spmy formation.

Page46 SECTION LO
Poor spray formation; replace injection valves.
Drop formation
"Cord" spray
"Spray i n strands "

SECTION LD
Refitting fuel injectors:

Emure '0' r i n g are undamaged. Lubricate the manifold injector hole with a
silicone spray and carefully slide the injector down the hole pressing i t 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 i s applied directly to the '0' ring.
Fit and tighten the injector retaining clamp.
Torque tighten fuel pipe connection to 2.0 kgf .m (15 Ibf .ft .).
H - BASIC MIXTURE ADJUSTMENT

Refer to section LD 23 to establish whether the basic mixture setting requires
adjustment, or some other component i s the cause of an out of specification
duty cycle reading.
I f adjustment i s required:
Mixture Adjustment Screw
Remove the anti-tamper plug from the mixture control unit, and use a 3 mrn allen
key to turn the airflow sensor lever adjusting screw clockwise to reduce the duty
cycle rate, or counterclockwise to increase the duty cycle meter reading. Turn
only a small amount a t a time, and blank off the access hole (with finger) between
adjustments. 'Blip' the throttle and re-check duty cycle reading.
When adjustment i s completed, refit the anti tamper plug to the access hole. Repeat
LD 23 checking procedure.
If a newmixture control unit, or component thereof, is fitted to the engine, or if,

for whatever other reason the setting-of the basic mixture adiustment screw is unknown
or i n doubt, i t i s essential to carry out the following procedure to prevent the possibility
o f the engine hydraulic locking and causing extersive internal damage.
Disconnect one injector pipe and fit a slave injector, placing into a glass jar or
graduate. Trip inertia switch. Remove fuel pump control relays and f i t electrical
.
,
. .. test bridges TOOOT0569 into relay bases

~ernoveanti-tamper plug from mixture adjustment screw access hole.
Press down inertia switch and briefly press down airflow semor to prime fuel
inlector.
Page 48 SECTlON LD
Using a 3mn1 allen key, turn the mixture adjustment screw, without ptessing down
the airflow sensor, until fuel can i ~ s be
t 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
re-connect injector pipe.
Tempomrily blank off mixture screw access hole whilst following LD 23 procedure to
check duty cycle rate, and adjust if necessary as above.
-
I THROTTLE DOES NOT OPEN COMPLETELY
Check that with the accelerator pedal pressed to its fullest extent, the full throttle
stop bracket on the butterfly spindle i s i n contdct with the throttle body abutment.
Adjust throttle pedal downstop as necessary.
-
J THERMO-TIME SWITCH
To test the switch, remove from the manifold and plug the hole to prevent coolant low.
-
The switching temperature and time period at 20° C are stamped on one of the swttch
hexagon f lots .
I -
DeSfgn
-
1 At a temperature
- -
Resistance measurement i n ohm between
O c
Over I Them 'G' and
'Ground' (Housing)
Term 'W' and
'Ground'
Term 'G ' and
term 'W'
Measure the reststance between the connection listed i n the table after standtng the
swttch i n water at the appropriate tempemture for 10 minutes. Replace swttch tf
necessary.
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 down the pipe.
M - THROTTLE SACKING CAPSULE
With engine idling a t normal operating temperature, check f i n t that idle speed i s
correct @ 950 50 rpm. Do not adjust without f i n t referring to Section LD 23.
Capsule Rod Clamp Screw
Bridge connections to high temperature switch in inlet manifold (use a spare fuse)
to activate the capsule. Engine speed should hold at 1300 to 1500 rpm. Adjust
i f necessary at the clamp between capsule rod and throttle lever.
Remove electrical bridge and re-check idle speed.
N - THROTTLE POSITION SWITCH

Connect continuity meter TOOOT0568 to the throttle position switch. With the throttles
shut the meter should indicate continuity by buzzing, which should stop at the smallest
throttle opening. A t about 30° of throttle angle, continuity should again be made.
I T IS ESSENTIAL TO SLACKEN THE THROTTLE POSITION SWITCH MOUNTING

SCREWS BEFORE ADJUSTING ENGINE IDLE SPEED. IMBALANCE OF THE
THROTTLE BUTTERFLIES MAY OTHERWISE OCCUR.
\
Throttle Position Switch

Mounting Screws
Page 50 SECTION L D
If the throttle position switch requires adjustmen~t,check first that the warm i d l e speed
a
i s correct. Slacken the throttle position switch mounting screws before making any i d l e
.
speed adjustment When completed, rotate the position switch slowly u n t i l continuity
i s JUST made, and tighten screws. Recheck setting.
0 - AIR LEAKS IN EXHAUST/INLET
To check for a i r leaks i n the exhaust and inlet system:

Disconnect the turbo to diffuser hose, and apply a n airline w i t h a suitabl'e sealing
adaptor into the diffuser. Seal the exhaust tailpipe with a bung.
Paint a l l inlet/exhaust system joints and seals with a soap &water solution and
check for leaks whilst applying a n a i r pressure o f 5 Ib/in2 into the diffuser.
P - THROTTLE IMBALANCE
If throttle imbalance i s diagnosed i n procedure LD23, check the throttle
position switch switch adjustment (LD24N).
CAUTION The throttle bodies and inlet manifold assembly are balanced
as a car set by mass flow, and rhe throttle bleed channels permanently
sealed a t the factory. Although provision i s made for measuri hg the i n l e t
manifold depression on cylinders 2 & 3 and adjusting the throttle spindle
coupling, this setting should not be disturbed unless essential .
Throttle imbalance can only be caused by abuse o f the thrott1e:spindle assembly,
or replacement of a throttle lever or return spring.
Investigate a l l other potential causes of incorrect C O levels before proceeding.
Tools required: Special Diffuser TOOOT0583

Coupl ing Spanner ~000~0584
Manometer TOOOT0499
Balance Tubes TOOOT0496 (2)
Remove the blanking plugs from i n l e t tracts 2 and 3 and f i t the balance tubes
TOOOTOQ96. Connect to manometer. Remove diffuser, and f i t special diffuser
TOOOT0583 i n its place.
SECTION LD Page 5 1
With engine idling at normal running temperature examine the depression i n

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. I f throttle imbalance i s

s t i l l indicated as the cause of high CO reading, the throttle bodies and
manifold assembly must be replaced as a set, mass flowed at the factory.
LD 25 - TORQUE SETTINGS - FUEL SYSTEM
Fuel Distributor 8x1 9 Nm 0.9 kgf.m 7 Ibf .ft.

12x1.5 20 N m 2.0 kgf.m 15 1bf.ft.
Fuel Injectors 20 N m 2.0kgf.m 15 1bf.ft.
Cold Start Injector 9Nm 0.9kgf.m 7 1bf.ft.
Warm Up Regulator 8x 1 9Nm 0.9kgf.m 7 Ibf .ft.
lox1 14 N m 1.4kgf.m 10 1bf.ft.
Frequency Valve 12 N m 1 .2 kgf .m 9 Ibf.ft.
Fuel h m p 22 N m 2.2 kgf.m 16 Ibf .ft.
Fuel Accumulator 25 N m 2.6 kgf.m 18 lbf .ft.
Fuel Filter - i n 26 N m 2.7kgf.m 19 1bf.ft.
- out 35 Nm 3.6kgf.m 26 1bf.ft.
Fuel Tank (in & out) 22 N m 2.2 kgf.m 16 1 b f . f ~
REPLACE SEALING WASHERS EVERY TIME A JOINT I S BROKEN

'
Main Injection
Fuse 7.5 Amp.
Idle
Cha ngeover
Relay
I
Fuel Pump
Confro l Relays
A
\ Fuel Pump Inertia Switch
I I / Over host
Ignition
Amplifier -t--
I
- -k-
15 A Fuses Idle Up
Relay
Switch . RPM Relay Fuel Pump

C o n ~ a Relay
l
SECTION LO Page 53
LD 27 - WIRING DIAGRAM SCHEMATICS - FUEL INJECTION
Circuit Descriptions
Base Circuit. Ignition Off. Cold Engine (Below 3 5 ' ~ )
A positive feed i s provided to the RPM relay.
Cold Crank. Below 3 5 ' ~ Oil Temp.
When the ignition i s switched on, the Lambda sensor heating c o i l i s operated, and
the fuel by-pass control relay activated via the throttle position switch earth
circuit. A n ignition feed i s also provided to terminal 15 of the rpm relay.
When the engine i s cranked, a negative signal from the ignition c o i l activates
the electronic control i n the RPM relay allowing the ignition feed to operate
.
the relay coil, and earth via terminal 31 The relay contacts now connect
the positive feed from terminal 30 to the fuel pumps via terminal 876, and to
the injection control circuit via terminal 87.
The injection control circuit supplies a positive feed to terminal 8 of the E.C.U.,
the frequency valve and the heating coils o f the auxiliary a i r valve and warm up
regulator.
The closed high temp. switch supplies the fast warrr up relay. See circuit (3).
A feed from the cold start contact on the starter motor solenoid supplies the cold
start injector which i s controlled by the thermal ti.ne switch.
Earth signals are supplied to terminals 12 and 6 of the E.C .U. via the low temp.
switch and fuel by-pass control relay (via i d l e changeover relay).
Cold Run & Idle. Below 3 5 ' ~ Oil Temp.
Similar to circuit (2) except:

The cranking circuit feed to the thermal time switch and cold start injector i s
switched off.
The fast warm up relay, activated by the closed high temperature switch, provides
a n earth circuit for the ignition solenoid which receives a feed from the ignition
auxiliary circuit. The ignition solenoid operates the throttle jacking capsule which,
a t idle, prevents the throttle position switch 'closed' contact closing. N o earth
signal is supplied to E.C .U. terminal 6.
Cold Run & Idle. Above 3 5 ' ~ Oil T e m ~ . Below 70°C Water Temp.
Low temp. switch opers and cuts o f f earth signal to E.C.U. terminal 12. Lambda
sensor operational.
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 i s
energised and closes .
The ignition solenoid i s de-energised, which de-activates the throttle jacking
capsule (vacuum operated) allowing the throttle position switch to close. The
throttle position switch energises the fuel by-pass control relay, which provides
an earth signal (via idle changeover relay) to E.C.U. terminal 6.
6. Normal Run. Above 1600 rpm . Above 70°c Water Temp. Below 30' Throttle Angle

Throttle position switch i s open. N o earth signal to E.C .U. terminal 6.
Negative feed from ignition coil activates speed sensing module i n fuel
by-pass speed sensing relay and allows ignition feed from terminal 15 to
energise the relay and earth via terminal 31 and the fast warm up relay.
Terminal 8% o f the fuel by-pass speed sensing relay, supplies a 12 volt
positive to the idle up control relay, which prevents the a/c idle up
solenoid opening, and to the idle changeover relay.
7. Normal Run. Above 700 C Water Temp, Over JOo Throttle Angle.
Throttle position switch supplies earth signal to E.C.U. terminal 7.
8, Overun. Above 1400 RPM. Decelerating from over 1600 RPM
Throttle position switch i s closed energising the fuel by pass-control relay.

This provides an earth signal via the idle changeover relay to E.C.U.
terminal 7.
The energised fuel by-pass control relay also provides an earth circuit for the
'
fuel by-pass valve and ECON'lamp.
Below 1400 rpm, the fuel by-pass speed sensing relay drops out, and circuit
(5) applies.
. ', . .
SECTION LD Page 55
9. Air Conditioning Compressor Operating. A t Idle. Above 70° C Water Temp.
A feed from the compressor circuit i s 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 i s de-energised and opened.
This circuit only operates below 1400 rpm.
10. Light Throttle. Over 3250 RPM
The fuel enrichment module, supplied with a negative feed from the ignition
coil, senses when an engine speed of 3250 rpm i s reached, and allows an
ignition feed to operate the relay coil and close the relay contacts. This
provides an earth signal to E.C .U. terminal 7.
Stu KU
AC.U.
KO YK
YS IDLE
-
-
CHANGEOVER RELAY WARM UP
RELAY RELAY RELAY RELAY
-
A
KS
ELECTRONIC
CONTROL UNIT
- 4b 2
w %LE u p
SOLENOID G
BY
-'"
L
4) RPM RELAY
YO -
T
FUEL BY-PASS
YR SPEED SENSING R'ELAY
+f1gyaEi!i!31
12
8* - Y y
-- - -
31e
7 eYN
I
" 131b
5
6. YB IGNITION AUX.
KG YG
- 5
L-- 4L
YLG YU
-
IGNITION
SOLENOID
Y
- WS
COI L-ve
G
WY - IGNITION
G
ib
YN
( 0
YP YO
0 c
Y
4Q T 1 n
WY
COLD START
SWITCH
I ~ N S O R
- HEAT1NG
COIL
_
1,
THROTTLE
POSITION
FREQUENCY COLD
VALVE START.
THERMAL
TIME
L AUXILIARY
I
I WARM UP
AIR REGULATOR
SWITCH INJECTOR SWITCH VALVE
1 . BASE CIRCUIT. IGNITION OFF. COLD ENGINE (BELOW 3 5 ' ~ )

ELECTRONIC
CONTROL UNIT
n
il
COLD START
&Aso~
HEATING
L I
THROTTLE FREQUENCY COLD
L
THERMALAUX~LIARY WARM UP
COIL POSITION VALVE START TIME AIR REGULATOR
2. COLD CRANK. BELOW 3 5 ' ~OIL TEMP.

COIL THROTTLE
POSITION FREQUENCY
VALVE COLD
START THERMAL
TIME AUXILIAKY
AIR WREGULATOR
A R M UP
3. COLD RUN & IDLE. BELOW 3 5 ' ~ OIL TEMP.

IDLE
-
- FUEL BY-PASS
'
CHANGEOVER CONTROL
RELAY yp RELAY
L I -
A I
ELECTRONIC
CONTROL UNIT
n
I WY
COLD START
k- u
SENSOR
HEATING - THROTTLE FREQUENCY COLD
I
THERMALAUXILIARY WARM UP
COIL POSITION VALVE START TIME A 1.R REGULATOR
4. COLD RUN & IDLE. ABOVE 3 5 ' ~ OIL TEMP. BELOW 70°c WATER TEMP.
1 WY
COLD START
FREQUENCY COLD THERMAL AUX~LIARY WARM UP

VALVE START TIME AIR REGULATOR
5. NORMAL IDLE. ABOVE 70'~ WATER TEMP.

ELECTROh
CONTROL
*16
15-
12-
8
7-
- I
6-
YLG IGNITION AUX.

IGNITION'
SOLENOID
-=-
5
L-
2 - 41
r
WY A
T I
Y
IGNITION
WY
COLD START
SWITCH
- SENSOR -
- HEATING FREQUENCY COLD THERMAL AUXILIARY WARM UP
COIL THROTTLE
POSITION VALVE START TIME AIR REGULATOR
6. NORMAL RUN. ABOVE 700C WATER TEMP. ABOVE 1600 rpm. BELOW 30° THROTTLE ANGLE
VALVE
CONTROL
p - q L -
RELAY
1 I FUEL PUMP
ELECTRONIC
CONTROL UNIT
n
FUEL BY-PASS
KG L
YG
YLG YU tGN ITION AUX.
IGNITION
SOLENOID
7
Y
IGNITION
<b
POSITIVE
WY
CO-LD START'
COIL THROTTLE FREQUENC~

COLD THERMAL AUXILIAW WARM UP
POSITION VALVE-
- START TIMF AIR REGULATOR
SWITCH [NJECTOR W ~ ~ CVALVE
H
NORMAL RUN. ABOVE 70°C WATER TEMP. OVER 3
' THROTTLE ANGLE
0
a KU
a KU
'ELAY
IGN ITION AUX.
WY
COLD START
s
-
o
HEATING
I
- THROTTLE FREQUENCY COLD T H E ~ M A L AUXlLlART W A R M UP
8, OVERUN. ABOVE 1400 rpm DECELERATING FROM ABOVE 1600 rpm

WY
COLD START
LAMBDA,- -
SWITCH
ISENSOR
-
I
HEATING - THROTTLE FREQUENCY COLD THERMALAUXILIARY WARM UP
.
9. AIR CONDlTlONl NG COMPRESSOR OPERATING AT IDLE. ABOVE 70"~
WATER TEMP.
LOW
I TEMP
SENSOR SWITCH
SENSOR
POSITIVE =
B
-
cb
'3
HEATING
COIL THROTTLE FREQUENCY COLD THERMAL AUXILIARY WARM UP I COLD START &
POSITION VALVE START TIME AIR REGULATOR
LIGHT THROTTLE, OVER 3250 rpfi SWITCH, INJECTOR SWITCH VA LV E
CBHC
PRIMARY
FUEL PUMP
RHC
TO IDLE UP I FAST
WARM UP VALVE
SEE SHT. 3A
I
G
rGB ---I
L W G - !
L-,
RHC CBHC 1 1
W
FUSE BOX
SPLICE ' D
SEE SHT 27
'
TO TACH0
SEE SHT. 2
TO RPM. RELAY 2
SEE SHT. 3A
WS
ENGINE WERSPEED I FUEL PUMP

FAILURE MODULE
WG 70
N
I FUEL
RELAYS
PUMP
KR
KP
I
@
rrr
n
I-----
wp-+)-WP-.
RHC
1
' 1,
b"* OVERBOOST
WITCH
SECONDARY
FUEL PUMP
b
' 8
0,
TO BATTERY 01
INERTIA
SWITCH
FUEL PUMPS
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, when fuel by-pass control
relay i s energised, on deceleration until 1400 R.P.M. when i t changes over to
switch pin 6 of electronic control unit to ground
Normally open change over relay
a
Terminals 85 and 86 relay windings
Terminals 30/51, 87A and 87 switching

contacts
Lotus Part A079M6141F

(Silver)
Fuel By-Pass Control Relay

Location: Coil box
Mating connector colour: Blue
Double contact relay controlled by ignition ( h e 23 i n fusebox) and throttle
position switch. Energised when throttle is i n the closed position.
Switches idle change over relay and fuel by-pass valve to ground when ignition
is on and throttles are i n the closed position.
Terminals 85 and86 relby hindin@

Terminals 30, 87 and 87b switching contacts
Lotus Part AO82M6182

(Grey)
SECTION L O Page 67
3. ldle Up Relay
Location: Coil box
Change over relay (schimatic as shown item one). Controlled by idle up
control relay. De-energises idle up solenoid, when air condition compressor
i s operating, below 1400 R. P.M.
4. Fast Warm Up Relay

Location: Coil box
Changeover relay (schimatic as shown item one). Controlled by high temperature
switch energises ignition solenoid when the high temeprature switch i s closed
.
circuit Energises idle up solenoid and fuel by-pass speed sensing relay when the
high temperature switch i s open circuit.
5. ldle Up Control Relay
Location: Coil box
Changeover relay (schimatic as shown i n itemone). Controlled by fuel by-pass
speed sensing relay.
Energised when R. P.M. has exceeded 1600 and de-energised below 1400 R. P. M.
Switches out idle up relay above 1600 R. P.M.
6. Fuel By-Pass Speed Sensing Relay

Location: Coil box
Mating connector colour: Black. Additional information see LD 16.
88a 31
Controlled by low tersion ignition pulses to give
l5 engine speed serrring, also thermally inhibited
31e
operation by fast warm up relay.
Energises fuel by-pass valve and econ tell-tale on
deceleration from an engine R. P.M. of greater
1 than 1600 until 1400 R.P.M. when the throttles
are closed. This unit also supplies a 12 volt
31 b
posotive to the idle changeover relay and idle
up contiol relay supply when engine R.P.M. has
exceeded 1600 and maintains that supply until
engine R.P.M. has dropped to 1400.
7. Fuel By- Pass Valve

Location: Rear of induction air box
Electrically controlled vacuudair valve, controlled by the fuel by-pass speed
sensing relay i n conjunction with the fuel by-pass control relay.
8. "Econ" Tell-Tale Lamp

-
Location: Right hand bank o f tell tale lamps on instrument binnacle.
Tell-tale lamp to indicate to the driver when the fuel by-pass valve i s operating.
, Page 68 SECTION LD -
9. High Temperature Switch 0
Location: Water mil, inlet manifold. Additional information see LD 18. -
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. Additional information see LD 19.
Electrically operated atr valve. Air way open when valve i s electrically
de-energised. Controlled electrically by the idle up relay and fast warm
12 Volts 0 Volts
Airway
Closed
A irway
Open 1
1 1 . RP.M. Relay
Location: Coil box
Mating connector colour: Blue
87 Senses ignition pulses i n the low
\ 31 tension circuit and requiresa
minimum of 4 R.P.M. before
making contact and thereby
energising the fuel pump and
injection circuits. There i s a n
inbuilt delay i n the relay that
alIo\vs the contacts to remain
closed for approx. 5 seconds
after the low temion circuit has
ceased to function.
Blue Moulding
12. Ignition Solenoid

Location: Coll box
Matlng connector colour: Black. Additional information see LD 18.
Electrically controlled vacuum solenoid valve. Controls distributor advance '
by vacuum. See engine operating spec. Controlled by ignition auxiliary
(fuse 22 fusebox) being swltched also by the fast warm up relay. (Does not
,operate during starter motor cranking).
. <
SECTION LP Page 69
13. Low Temperature Switch

Location: Oil gallery cover. Additional information see LD 15.
Serrses o i l 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
a t ZOc.
15. Warm Up Regulator

Location: Bolted to alternator bracket
a Mating connector colour: Grey. Additional information see LD 10.

Electrical/thermal fuel pressure control valve, feed 12 volts positive
from the R.P.M. relay.
Positive Negative
Connection Connection
\ I Negative Positive
0 0
View on
top of
Warm Up
Regulator
b
-
-
-
16. Auxiliary Air Valve

a Location: Inlet manifold
-
Electrically operated air valve. Feed 12 volts positive from the R. P.M. relay.
17. Thermal Time Switch

Location: Screwed into water jacket inlet manifold
Mating connector colour: Brown. Additional information see LD 8.
Electrical/thermal switch which control the time period the cold start iniec tor
i s operating during engine cranking.
.- .
Page 70 .,.... SEC.T/ON. LD

.
J
r,.-.
At a temperature Raistance measurement in ohms between

Design
under over Therm 'G' and Term 'W' and Term 'G' and
a
OC OC 'Ground' (Housing) 'Ground' term 'W'
-
38Oc/% +30 .
25. .40 0 25.. .40
-140 50.. .80 100.. .I60 50.. .80
t
18. Cold Start Injector

Locotion: Cold start adaptor, inlet manifold
Mating connector colour:. ~ l l e 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 injection period.
19. Throttle Position Switch

Locotion: Rear 'of throttle body spindle
Mating connector colour: Black. Additional informa tion see LD 15 & LD 16.
A two contact rotary switch used to ground the fuel by-pass control relay windings
a
a t closed throttle and ground both pin 7, of the electronic control unit, and
contact 87, of the idle change over relay at a throttle opening of 29O and above.
Schematic shown i n closed throttle position
Black
I 0 2
Connector Cavity ~ u m b e n ' \ Switch Cavity Numbers
20, Frequency Valve

Location: Front of mixture control unit
Mating connector colour: White. Additional information see LD 14.
Electrically controlled fuel ,valve. Receives4 positive feed from the R. P. M.
relay and the .negative is controlled by the electronic control unit.
Although the frequency valve itself is not polarity comcious for correct
operation of the test equipment i.e. duty cycle meter, i t i s essential that
the cables into the connector are i n the correct orientation, shown below .
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
the frequency valve.
Connect as below. (Cavity numbers are moulded into connector)
Cavity 2 Cable to Lambda probe 1 co-axiel cable

Cavity 4 Screen for Lambda probe cable)
cavi6 5 Unit ground. lack cable to at engine via
wiring harnesses.
Cavity 6 Yellow/black cable grounded at idle via the idle change over
relay and fuel by-pass control relay to give a faster update
time and therefore stabilises idle speed.
Cavity 7 Yellow/brown cable. G i v e a fixed duty cycle of 65% when
grounded by the idle change over relay and fuel by-pass relay
under deceleration, and the throttle position switch on throttle
openings of 29O and above. Also at engine speeds aver 3250 rpm .
Cavity 8 Yellow cable. 12 volts positive supply to electronic control
unitfrom the R.P.M. relay.
Cavity 12 Yellow/red cable switched to ground, to give a 75% duty

cycle, by the low temperature switch .
Cavity 15 Yel low/orange cable controls the duty cycle (open/close ratio)
of the frequency valve.
Cavity 16 Unit ground. Black cable to ground at engine via wiring harnesses.
22. Fuel Pumps

a Location: Underside of body R. H. rear. Additional information see LD 3.
Twin fuel pump installation electrically connected i n parallel through individual
fuses, the engine overspeed/fuel pump failure module,and fuel pump control relays.
23. Inertia Switch

Location: Coil box
Mating connector colour: Grey
The safety inertia switch i s designed to operate on impact, such as would
occur i n anaccident, to disconnect the fuel pumps and minimise any fire
hazard.
To reset the switch, i n the event of its tripping, press down the reset
plunger on the top.
Page 7 2 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.
I n the event of excessive engine speed (7,000 2 50 R.P.M=) this feed i s removed
thereby stopping the injection system operating and limiting engine R. P. M.
Also i n the event of one of the two fuel pumps failing to operate the maximum
engine R.P.M. i s restricted to 2,800 + 50 R.P.M. This i s achieved by
monitoring the current drawn by e a ~ h - ~ uand m ~ removing the negative to
the fuel pump control relay windings at 2,800 + 50 R. P.M. i n the event of
one pump failing to draw any current. ~hereforeany part of the circuit between
the module and the pump, going open circuit, w i l l be detected and engine R. P.M.
restricted. (This unit w i l l therefore sense blown fuse, broken or disconnected
fuel pump wiring .)
Disconnection of the module w i l l not allow the fuel pumps to operate. Single
pump failure may cause the fuse i n the other pump circuit to blow due to the
increased load imposed on i t (dependent on position i n which failed pump fails).
This circuit is designed as a "get you home" aid i n the event of failed fuel pump
but the vehicle require attention to the fuel pump system as soon as possible.
25. Fuel Pump Control Relays (2)

Location: Coil box
Mating connector colour:Black
Double contact relay (schematic as shown i n item 1 ) .
Controlled by the engine ovenpeed/fuel pump failure module, overboost switch
and inertia switch. Switches positive feed, via 15 amp fuses to individual
fuel pump circuits .
26. Overboos t Switch
Location: Coil box
Mating connector colour: White. Additional information see LD 3.
Supplies, v i a terminal 8% of the R.P:M. relay, a positive feed to the winding of
the fuel pump control relay. This feed i s removed, thereby de-energising the fuel
pumps, i n the event of an engine fault condition of excessive turbo boost pressure.
Fuel Enrichment Module

Location: Top of right hand fuel tank board.
Mating connector colour: White. Additional information see LD 27 --
10
Senses engine speed of 3250 rpm via negative feed from ignition coil, and
switches ignition feed to operate relay coil and close relay contacts.. This
.
: provides earth signal to E .C .U terminal 7.
SECTION M B Page I
ELECTRICAL
SECTION MB - ESPRIT S 3 & TURBO ( ~ o m / ~ o w )
Section
C i r c u i t Diagrams: MB. 1
S3 - Lumenition & Fused Fan Relay

S3 - A/C, C o n s t a n t E n e r g y & T h e r m a l T r i p
S 3 - A/C, EEC ( S y m b o l ) S w i t c h e s
S 3 - From V I N 85D2153 ( J u l y ' 8 5 )
S 3 - ' 8 7 M.Y. o n w a r d s
Turbo - Commemorative, L u m e n i t i o n
T u r b o - C o n s t a n t E n e r g y , F u s e d Fan R e l a y
Turbo - C o n s t a n t Energy, Thermal T r i p
Turbo - ' 8 7 M.Y. onwards
Component L o c a t i o n D i a g r a m MB.2
Harness Routing Diagram MB. 3
Lumenition I g n i t i o n System MB.4
Lucas Constant Energy I g n i t i o n MB.5
'Maintenance Free' B a t t e r y Charging
Procedure MB.6
Dim-Dip H e a d l a m p S y s t e m ( U . K . m o d e l s ) MB. 7
DEC 1986
TURBO ESPRIT WIRING OIAGRAW ( DOMESTIC.RO.W>
!rnWIOELlEaR I 1% X I
.. ..-
1-4
S
U
W
Y
SLATE
BLUE
WH!TE
YELLOW "
T W ESPRIT WIRING MPGRAM IWMESTL R.O.W. t .
WIM WNWtil EIERir lGMTlXl8 WQTI W T C R Fffl RELAY LSL 2U
REDSTIT 2 m
CENTRE LO*HIE P A N 3
UWTL
nOul LIGHTER M U
53 ,ESPRIT WIRING DIAGRAM (DOMESTIC.R.0.W.) WITH K U
W T H ~ a a 4 n C N m a Y I R L ( 1 F I N ~ ~ P . I E L C l S R B C l l u~r tn
53 ESPRIT WIRING DIAGRAM (DOMESTIC.R.0.W.I
!mi UMMTIII UO FUYD FN4 W Y LSL 2L9
t I
S3 ESPRIT WIRING DIAGRAM (DOMEST1C.RO.W) WITH ACU.

bllI'mswCrwrrZrwmaC&llbDldmRFPN~W 1%2%
WINDSCQEEN WASH WMP MOTOR
RCITDRELAYS
m
RADIATOR COOLING
FANS
mo (briar 87MY) & S 3 1 R v b o 8 7 m m
b
H/L Cantrol H/L Flash
H/L Flash H/L Motor Iul PUMP
THERMAL SWITCH ( Water pumpoutletpipe)
H/L Motor RH
H/L Motor LH
I WL Motor LH I For component usage (53 - RAD. FANS I EARLY 53 )
(Grey) Rad Fans see circuit diagrams - PURGE PUMP ( '87 MY on TURBO )
(if thermal trip fitted)
(Fused) Rad Fans
( i f no thermal trip) MB.2. - COMPONENT LOCATION DIAGRAM
A.C. TEMPERATURE CONTROL UNlT
LOW COOLANT LEVEL ( TURBO & LATE S 3 1
MODULE ( TURBO 1 /
FAN FAIL RELAY INTERIOR LIGHT DELAY FUSEBOXES
AERIAL RELAY
11 INNER HEADLAMP
RELAYS \ CIGAR LIGHTER \
FUSES ( 17A)
WIPE! DELAY \
IT . \ 'b.
HAZARD/TURN
FLASHER UNITS
A.C.U. CO MPARATOR
UNIT (TURBO )
INTERIOR
FAN RELAY
A.C. COMPRESSOR Q.
RELAY m
MB.2. - COMPONENT LOCATION DIAGRAM - Fascia

MB.3. - HARNESS ROUTING DIAGRAM
SECTION M B Page 7 7
MB.4. - LUMENITION IGNITION SYSTEM
E a r l y S e r i e s 3 and Turbo models used Lumenition i n f r a r e d s o l i d s t a t e

c o n t a c t b r e a k e r l e s s i g n i t i o n . On e a r l y T u r b o m o d e l s , t h e L u m e n i t i o n
power m o d u l e was mounted on t h e e n g i n e bay s i d e o f t h e r i g h t h a n d f u e l
t a n k w e l l , b u t w a s moved o n i n t r o d u c t i o n o f t h e E s p r i t S3, t o t h e
i g n i t i o n box a t t h e r e a r o f t h e e n g i n e bay.
An o p t i c a l s w i t c h i s f i t t e d i n t h e o t h e r w i s e s t a n d a r d d i s t r i b u t o r a n d i s
o p e r a t e d by a 4 - b l a d e c h o p p e r f i t t e d o v e r t h e d i s t r i b u t o r cam. A
s p e c i a l f i b r e w a s h e r i s s o m e t i m e s u s e d below t h e c h o p p e r b l a d e t o
a c h i e v e t h e c o r r e c t b l a d e h e i g h t through the o p t i c a l switch.
Two t y p e s o f L u m e n i t i o n s y s t e m h a v e b e e n u s e d , t h e e a r l i e r Mk 16 t y p e
b e i n g s u p e r c e d e d by t h e Mk 17 t y p e , d u r i n g 1 9 8 0 a s a r u n n i n g c h a n g e o n
production. Components o f e i t h e r t y p e a r e n o t i n d i v i d u a l l y c o m p a t i b l e .
Identification - Power Module
I d e n t i f i c a t i o n o f power m o d u l e s i s o n l y p o s s i b l e by t h e c o l o u r o f t h e
r e s i n o r p l a s t i c b l o c k s e a l i n g t h e w i r e s i n t o t h e module u n i t .
Mk16 u n i t s a r e s e a l e d w i t h r e d o r b l a c k r e s i n . . Mk17 u n i t s a r e s e a l e d by
a w h i t e p l a s t i c clamp.
- O p t i c a l Switch
MK 1 6 o p t i c a l s w i t c h u n i t s a r e marked w i t h numbers s i m i l a r t o 8 2 4 0 , t h e
8 a n d 0 b e i n g t h e y e a r a n d 24 t h e week o f p r o d u c t i o n .
Mk 1 7 o p t i c a l s w i t c h u n i t s w e r e a l s o p r o d u c e d i n 1 9 8 0 b u t have a 17
p r e c e d i n g t h e number i . e . 17 8240.
A l l u n i t s p r o d u c e d i n 1981 a r e Mk 17 w i t h numbers s i m i l a r t o 8 1 2 4 , w i t h
8 1 b e i n g t h e y e a r a n d 24 t h e week o f p r o d u c t i o n . I n the event of a n
ambiguous d a t e code ( e . g . 8120) c o n t a c t t h e L o t u s S e r v i c e Department f o r
advice.
Replacement
I f a new power module f o r a Mk 16 s y s t e m i s r e q u i r e d , i t c a n o n l y be

r e p l a c e d w i t h a Mk 17 power module i n c o n j u n c t i o n w i t h a Mk 1 7 o p t i c a l
switch .
I f a Mk 1 6 o p t i c a l s w i t c h i s t o be r e p l a c e d , i t c a n o n l y be r e p l a c e d
w i t h a Mk 17 o p t i c a l s w i t c h , w h i c h , i f t h e Mk 1 6 power m o d u l e i s t o be
. r e t a i n e d , w i l l n e c e s s i t a t e t h e u s e o f c o n v e r t o r u n i t A083M6305F f i t t e d
b e t w e e n t h e Mk 1 6 power module a n d Mk 17 o p t i c a l s w i t c h .
AJLAAP
DEC 1986
Page 72 SECTION M B
Summary :
Power Part Connector Colour Length Compatible

Module Number Block of of Optical
Shape Sea 1 Lead * Switch
Mk 16 A075M0335F Rectangular Red o r 790 mm A907E6331F ( ~ 16)

k
(No Black o r B907E6331F (MK 1 7 )
longer + A083M6305F ( c o n v e r t o r )
available)
Mk 17 ~ 0 8 3 ~ 0 3 8 Oval
4 ~ or White 790 mrn B907E6331F (Mk 1 7 )
Rectangular
Mk 1 7 B083M0384F Oval o r White 470 nun B907E6331F (Mk 1 7 )

Rectangular
* With power module by RH f u e l tank - 790 mm

With power module i n i g n i t i o n box - 470 mm
Connector Blocks
Mk 16 s y s t e m s used a r e c t a n g u l a r c o n n e c t o r b l o c k between t h e o p t i c a l
s w i t c h and power module. Mk 17 s y s t e m s used a n o v a l c o n n e c t o r b l o c k
w i t h r e t a i n i n g p r o n g s , which was s u b s e q u e n t l y found t o be l e s s d u r a b l e
than the e a r l i e r r e c t a n g u l a r type.
A l l s e r v i c e r e p l a c e m e n t components a r e s u p p l i e d f i t t e d w i t h t h e
t e c t a n g u l a r t y p e c o n n e c t o r , and i n c l u d e t h e o p p o s i t e ' h a l f ' o f . t h e
a
c o n n e c t o r b l o c k which may be used i f n e c e s s a r y t o r e p l a c e t h e r e m a i n i n g
oval connector. viz: -
1. Use s p e c i a l t o o l TOOOT0473 t o c l o s e l o c k i n g t a g o n p i n a n d
remove from w i r e end of c o n n e c t o r b l o c k by p u l l i n g . MOST IMPORTANT
- open tag t o o r i g i n a l l o c k i n g a n g l e .
AJLAAP
SECTION M B Page 73
a/
2. H a v i n g made c e r t a i n t a g s a r e i n l o c k i n g p o s i t i o n , p u s h ,each p i n i n
t h e c o r r e c t t u n n e l o f t h e new c o n n e c t o r b l o c k u n t i l t h e t a g c l i c k s
into position.
The c o n n e c t o r i s numbered a s i l l u s t r a t i o n
w =IBlue
a NOTE: On no a c c o u n t m u s t Mk 17 power m o d u l e s be c o n n e c t e d w i t h Mk 16
o p t i c a l s w i t c h e s . A l s o , Mk 16 m o d u l e s m u s t n o t be c o n n e c t e d
t o Mk 17 o p t i c a l s w i t c h e s w i t h o u t u s e o f a d a p t o r A083M6305F.
TESTING INSTRUCTIONS FOR "LUMENITION"

MK 16 AND MK 17 IGNITION SYSTEMS
A l l t e s t s a r e c a r r i e d o u t w i t h i g n i t i o n s w i t c h e d on a n d c e n t r e HT l e a d
removed f r o m t h e d i s t r i b u t o r a n d h e l d a p p r o x i m a t e l y 6 . 5 mm ( 1 1 4 i n c h )
f r o m a n e a r t h p o i n t s u c h a s t h e e n g i n e , b u t away from t h e c a r b u r e t t o r s
region.
CAUTION: HT c a n be d a n g e r o u s a n d c a n jump 2 5 mm ( 1 i n c h ) . Leads s h o u l d

be h a n d l e d c a r e f u l l y .
1. To t e s t t h e c o m p l e t e s y s t e m -
W i t h t h e d i s t r i b u t o r c a p removed a n d o u t o f s t r o n g s u n l i g h t , p a s s
a p i e c e of opaque m a t e r i a l , such a s a p i e c e of b l a c k c a r d
between t h e l e n s e s o f t h e o p t i c a l s w i t c h - t h i s s h o u l d produce
a s p a r k from t h e HT l e a d t o e a r t h .
2. To test power m o d u l e ( a n d c o i l ) -
a). Unplug 3-way connector leading to the d i s t r i b u t o r .
b). C o n n e c t ( b y means of a s m a l l p i e c e o f w i r e ) -
On Mk 16 t h e b l u e t o t h e r e d
On Mk 17 t h e b l u e t o t h e b l a c k
I DEC 1986
Page 74 SECTION M B . ,
w i r e l e a d i n g t o t h e power module. A s t h i s connection is

made a s p a r k i s p r o d u c e d a t t h e HT l e a d . If no s p a r k i s
p r o d u c e d t h e power m o d u l e i s s u s p e c t . If a w e a k s p a r k i s
-
produced - t h e c o i l may be s u s p e c t .
3. To t e s t t h e o p t i c a l s w i t c h -
The o p t i c a l s w i t c h m u s t be c o n n e c t e d t o a good power m o d u l e .
With a s e n s i t i v e v o l t m e t e r measure t h e v o l t a g e between b l u e and
b l a c k l e a d s . W i t h i n f r a r e d beam - not interrupted, the voltage is
approximately -
Mk 1 7 (2.7V) Mk 16 (1.8V) - t h i s d r o p s t o
Mk 17 (1.OV) Mk 1 6 ( 0 . 3 ~ ) - w i t h beam i n t e r u p t e d .
N.B. The v o l t a g e on t h e r e d l e a d i s a p p r o x i m a t e l y 7.5V.
4. Do n o t l e a v e t h e i g n i t i o n o n f o r a l o n g t i m e (max 15 m i n s ) w i t h t h e
o p t i c a l switch assembly disconnected.
NOTE: Under no c i r c u m s t a n c e s s h o u l d :
a). A f u l l p o s i t i v e f e e d be a p p l i e d t o a n y c o n n e c t i o n o t h e r
t h a n t h e r e d p o s i t i v e w i r e o f t h e powex m o d u l e s u p p l i e d
w i t h a male Lucas t e r m i n a l .
b). The c o i l t e r m i n a l s be s h o r t c i r c u i t e d o r t h e brown w i r e

( c o i l - V E ) o f t h e power module be c o n n e c t e d t o f u l l
p o s i t i v e feed.
F a i l u r e t o o b s e r v e t h e n o t e s a b o v e w i l l r e s u l t i n c a t a s t r o p h i c damage t o
t h e power m o d u l e , i n v a l i d a t i n e t h e w a r r a n t y .
SECTION M B Page 7 5 '
, '
MB.5. - LUCAS C O NISTANT ENERGY IGNITION

a The Lucas constant energy ignition system i s an inductive system in which the energy
stored i n the coil i s maintained constant over a wide range of 'engine speeds, thereby
providing consistently high output voltages. The system comprises a distributor model
45 DM, and ignition coil model 32 C5, an ignition amplifier model AB 14 and an
electronic rev. limiter.
The distributor incorporptes a variable-reluctance position transducer (pick up) to

provide a basic timing waveform. The sintered reluctor has four projections which
correspond i n function with the cam lobes of a conventional distributor. The pick up
comprises a coil and magnet assembly, the pick up air gap (0.20 0.35 mm.) being set -
during manufacture and requiring no subsequent adjustment .
A conventional type-rotor arm i s fitted, moulded (as i s the distributor cap) from track
.
retardant material The two cables connecting the distributor to the ignition amplifier
terminate i n a non-reversible "shur plug".
a The high energy coil (model 32 C5) is specially designed to achieve the very fast
current rise times required for thir system. ~ h ; coil requires no ballast and &rsumes
no current i n the stalled engine condition.
The ignition amplifier (AB14) i s mounted in the ignition box whilst the electronic rev ..
limiter unit is fitted on the RH fuel tank board .-
The ignition must be switched on for the following checks.
TEST
1 CHECK HT SPARKING
RESULT
Should be:
-
-
Regular sparking
No sparking
TEST6
TEST 2
Measure voltages at 1-4 incl.
-
should be:
1-More than 11.5V
2-lvmax. below V at 1
3-1V max. below V at 1
4-ov-o.1~
All correct
TEST 3
Incorrect reading($)
F
SEE CHART
Battery discharged
Ignition switch and/or wiring
Coil or amplifier
Amplifier earth (ground)
DEC
Page 16 SECTION M B
3 CHECK AMPLIFIER SWITCHING
Voltage increases
while cranking
7
-
TEST 5
Voltage does not increase

while cranking
TEST 4
-
4 PICK-UP COIL RESISTANCE Ohmmeter should show
2-5 kO,
Correct
-
Change amplifie~
TESl 5
Incorrect
Change pick-up
TEST 5
5 C H E C K HT S P A R K I N G Should be good HT sparking
-
Repeat with original HTlead
Good sparking
If engine will not start -w
-
TEST 6
No sparking. replace HT lead
TEST 6
No sparking
Replace coil
If engine will eill s t a t
TEST 6
Should be:
No sparking 7
-
TEST 7
HT sparking
Replace rotor arm/rotor vane
If engine will no1 start
TEST 7
7 VISUAL AND HT CABLE C H E C K S

EXAMINE Should be :
1 Distributor Cover
1 Clean. dry, no tracking marks
2 C o i l Top 2 Clean, dry, no tracking marks
3 H.T. C a b l e Insulation 3 Musl not be cracked, chafed
or perished
4 H.T. C a b l e Continuity 4 Must not be open circuit
5 Spark Plugr 5 Clean, dry, and set to correct gap
Recommended Test Equipment
DC moving coil voltmeter, scale 0 20V -

DC moving coil ohmmeter
HT jumper cable
DEC 1986
Page 78 SECTION M B
MBJ. - DIM-DIP HEADLAMP SYSTEM (U. K . Models)

The Motor V e h i c l e s (Dim-Dip L i g h t i n g D e v i c e s ) R e g u l a t i o n s 1983
of t h e Road T r a f f i c A c t , d e c r e e s t h a t c a r s m a n u f a c t u r e d on o r
a f t e r 1 s t O c t o b e r 1986 f o r u s e i n t h e U . K . and f i r s t
r e g i s t e r e d on o r a f t e r 1 s t A p r i l 1987, s h a l l b e f i t t e d w i t h
Dim-Dip l i g h t i n g s y s t e m s .
The Dim-Dip s y s t e m must o p e r a t e a s f o l l o w s :
I f , with t h e v e h i c l e sidelamps lit, t h e i g n i t i o n i s

s w i t c h e d o n , t h e headlamp d i p beams ( h a l o g e n ) w i l l
o p e r a t e on a r e d u c e d c u r r e n t t o p r o v i d e 10% o f t h e i r
normal i n t e n s i t y .
A l l 1987 Model Year Domestic c a r s a r e f i t t e d w i t h

Dim-Dip s y s t e m s which o p e r a t e a s f o l l o w s :
The l i g h t i n g s w i t c h i s l o c a t e d a t t h e l e f t hand t o p of
t h e fa s c - i a b i n n a c l e .
With t h i s s w i t c h i s t h e ' u p ' p o s i t i o n , a l l l i g h t s a r e

off.
I n t h e c e n t r e p o s i t i o n , t h e s i d e , r e a r and p a n e l l i g h t s
a r e s w i t c h e d on. On U . K . market. c a r s f i t t e d w i t h
'Dim-Dip' h e a d l a m p s s w i t c h i n g on t h e i g n i t i o n w i l l r a i s e
t h e headlamp pods w i t h t h e d i p beams o p e r a t i n g i n 'dim'mode.
With t h e swi-tch i n t h e 'down' p o s i t i o n t h e headlamp p o d s

a r e r a i s e d w i t h t h e headlamps l i t .
Dip and f l a s h c o n t r o l i s unchanged and o p e r a t e s a s p r e v i o u s l y .
Component L o c a t i o n
The dim-dip module i s mounted i n b o a r d of t h e r i g h t
- -
hand headlamp pod w e l l , and. t h e f u s e and r e l a y a l o n g s i d e t h e

e x i s t i n g headlamp r e l a y s , b e h i n d t h e l e f t hand pod.
Dim-Dip Module
A085M6315F
- /
-
8
I
Dim- Dip \
D E C 1986
SECTION M B
To Headlamp Ignition
DIM-DIP Mo ton Feed
Feed from MCDIJLE B
Beams -
Ignition I I
Feed
With s i d e l a m p s s w i t c h e d o n , a f e e d i s s u p p l i e d t o
module t e r m i n a l 1 a n d t h e r e l a y i s e n e r g i s e d .
When t h e i g n i t i o n i s s w i t c h e d o n , a f e e d i s s u p p l i e d
t h r o u g h t h e e n e r g i s e d r e l a y t o t h e headlamp m o t o r s t o
r a i s e t h e pods. In addition, a feed is supplied t o
module t e r m i n a l 7. The module p r o c e s s e s t h e s i g n a l s
r e c e i v e d v i a t e r m i n a l s 1 and 7 t o o u t p u t a 10% v o l t a g e
f e e d t o t h e d i p beams v i a t e r m i n a l 5 ,
iii) With t h e headlamps s w i t c h e d o n , a f e e d from t h e headlamp

s w i t c h i s s u p p l i e d t o module t e r m i n a l 2 . When d i p beam
i s s e l e c t e d , a n a d d i t i o n a l f e e d i s s u p p l i e d t o module
t e r m i n a l 3. The module p r o c e s s e s t h e s i g n a l s r e c e i v e d
a n d e i t h e r s u p p l i e s n o o u t p u t t o t e r m i n a l 5 (when main
beam i s o p e r a t i n g ) o r f u l l v o l t a g e (when d i p beam s e l e c t e d ) .
ELECTRICAL
SECTION MC - ' E S P R I T TURBO U.S.A. (Prior to '86 M.Y.)
Circuit Diagrams:
Component lndex
Legend
Supplies
Start, Alternator, lgnition
Engine Management & Operation
Choke Switch & Fuel Level
Radiator Cooling Fans
A i r Conditioning
Internal Fans
Headlamp Beam, Dip, Flush
a Horns, Beam, Dip & Column Switch Supply

Headlamp Motor Operation
Direction Indicators & Hazard
Rear Lights, Instrument Illumination
Clock, Door Lamps, Interior Lamps, Cigar Lighter
Stop Lights Reverse Lights
Wipers, Was her & Powerwash
Brake Fail & Handbrake Warning
Seat Belt Logic, Water & Battery Gauges
Heated Rear Screen
Window L i f t
Mirron
Radio & Radio Amp (if fitted)
Pulsafe Alarm (if fitted)
Alarm Components Location
Engine Bay Ventilation
Fuse Box, Circuits & Ratings
Relay Connections
Splice 'GI
$1 ice 'A1
Splice 'B'
Splice 'Dl
Component Location Diagram
Harness Routing Diagram
Instrument Binnacle Removal
Lucas 'Constant Energy' lgnition
Battery Re-charg ing Procedure
- -
COMPONENT INDEX
SECTION MC
Sheet/Page
. ..
A C U Compressor Radio Amp. (if fitted)
A .C .U. Tern. Control -
Relays ACU Control
.
A .C .U Thermistor - Brake Fail
A Iternator - Dip Beam
Battery - .
D .I & Hazard Unit
Cigar Lighteis - Engine Bay Vent
Clock - Engine Management
Distributor - Flash
Engine Speed Limiter - Headlamp Motors
Fuel Sender Unit - Heated Rear Screen
Fuse Box - Horn
Heated Rear Screen - Rnternal Fars
lgnition Amplifier - Lamp Delay Unit
lgnition Coil - Main Beam
Intermittent Wipe Unit - Power (aux.)
-
Instruments Battery Condition - Power (ign.)
- Fuel Gauge - Radiator Cooling Fam
- Tachometer Rheostats
- Temp Gauge -
Solenoids Carb. Evap.
Inverter, D. I. Warning Control - Cold Start Changeover
-
Lights Brake Fail Warning - Divertor Valve
-Door Warning - Fuel Pressure
- ..
D I & Hazard Lamps - Starter
-D. I. Warning - Throttle
- Fan Fail Warning Speaken
- Handbrake Warning Switches - Mirror Changeover
- Headlamps - Choke
- lgnition Warning - Door
-Instrument Illumination - Column, Dip/Beam
- Interior Lamp - Handbrake
-Low ~ u e l / ~ h o kWarning
e - Hazard
-Licence Plate Lamps - Heated Rear Screen
-Panel Lights 1 - lgnition
-Reverse Lamps - Inertia
-Seat Belt Warning - Internal Fans, speed
-Side Marker, Front - Isolator (engine-bay vent) 21
-Side Marker, Rear - Lights 8
-Stoplamps - Low Brake Fluid 15
-Tailamps - Low Pressure Cut-Out (ACU) 5
Mimrs - Low Vacuum (brakes) 15
Mirror Control Unit - Power W a s w i p e 14
-
Moton Antenna. - Reven Light 13
- Engine Bay Vent Fan -Seat Belt 16
- Headlamp -Stop Light 13
- Internal Fans -Thermal (engine
. - Radiator Cooling Fans management) 3
- Window Lift -Thermal (engine bay vent) 21
- Windscreen Wiper -Throttle Micro 3
Pumps - Fuel -Window Lift 18
-
Radio
-
Headlamp Wash
Screen Wash
-
-
-
Temp Transmitter
Timer (engine bay vent) l61
2 a
Voltage stabiliser 4,16
SECTION MC
LEGEND
BIN Binnacle Connector

D.H.C. Door Harness Connector
D.I. Direction Indicator
E.B.C. Engine Bulkhead Connector
E.H.C. Engine Harness Connector
F.H.C. Front Harness Connector
L.H.. Left Hand
P.H.C. Pumps harness Connector
R.H. Right Hand
R.H.C. Rear Harness Connector
SOL Solenoid
SD' Switch
W/LT . Warning Light
C.C.C. Centre Console Connector
M.H.C. Manifold Harness Connector
C.F.H.C. Cool ing Fans Harness Connector
Cable Colour Code
B Black 0 (3-aw e
G Green R Red
K Pink S Slate
P Purple U Blue
LTG Light Green W White
N Brown Y Yellow
SHEET 1
HEAD LAMP
M A I N I O I P 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 2 5
I
-NR-1-NR
IGN
TO I G N I T I O N
SIW. SEE SHT 2
w
SPLICE .
\ B'
i
SEE SHZ 26
SPLICE 4
'D'
SEE SHT. 27
4
-W+ W
SHEET 1
a
SHEET 2
TO L.H. DOOR SIW.
i/
I
BW+-LGW-
SEE SHT 12
IGNITION SIW
NR
30 50
SEE SHT 1 P SPLICE'G'+-G

o SEE SHT 2 4
3
Y
-i(-
TO ENGINE RELAY
A,CY CONTROL
RELAY SEE SHT 6
ENGINE SPEED
LIMITER
TO L A M P OELAY
UNIT SEE SHT '12 EHC
I
I
ALTERNATOR
I
I I SEE SHT 27
NY
ENGINE BAY o+
I VENT CIRCUITSEE StiT21 I INERTIA S I N .
RHC 91 I
BATTERY
12 v. FUEL 0
L N y a - G - SPLICE '6'
SEE SHT 24
FILTER
PHC
w P - ) L w P ~
RHE.
-. . :
.
>el
.
-. . .
IGNITION WILT
FUEL PUMP . ..
START, ALTERNATOR & IGNITION CUCcT ?
SHEET 3 A EHC7 MHC
SEE CHOKE SIN 6 FUEL- WU-, , ,;!G 4, wU
TO STARTER MOTOR (COLD START)
. .
ISEE SKI. 2 LEVEL CIRCUIT ON SHT 4
1
ENGINE RELAYS
4 COLD START
CHANGE OVER
SOL.
. . . VENT. CIRCUIT ON SHT21 1

I -I
(CLOSED CIRCUIT WITH THRUTTLE CLOSED 1
THROTTLE MICRO SIW.
RHC
10
KU KU
FUEL CARB. THERMAL DIVERTER THROTTLE

FUS
PRESS. EVA!? SIW. VALVE 2 SOL.
801
SOL. SOL. ( 7O9C. MAX. BREAK ON RISE
SOL.
I 6 6 ~MIN.
. MAKE ON FALL.) 1 SEE A.C.U. CIRCUIT
f
SPLICE 'O" SPLICE '8'
T
*
ON SHT. 6
SEE SHT. 27 SEE SHT. 2 6

ENGINE MANAGEMENT
0
SHEET@ . .
KU~T~"
'
ENGINE MANAGEMENT OPERATION

A.1 C.
. . . .
KU A A I C . COMPRESSOR.
. . . . . . , ..
' , . -., j au.i7.i .<i'$i,,..
- 8. STARTER MOTOR.
START SOL.
C CARB. EVAP SOLENOID:

CLOSED WHEN
IGN. AUX.
- Y v YG- YP YP IGNITION OFF, OPEN WHEN I G N I T I O N ON.
D T E M P CHANGE OVER RELAYS :
CONTROLLED BY THERMAL SWITCH 'F'
. .
E THROTTLE SOLENOID: TO OPERATE WHEN;
1 AlC. COMPRESSOR I S ENERGISED.
2 STARTER MOTOR CRANKING ON HOT START.
3.COLD STARTING EXCEPT DURING CRANKING
THERMAL SWITCH:
M A X . BREAK ON RISE 70' C
MIN. MAKE O N FALL 60°C.
DIVERTER VALVE :
ENERGISED WHEN COOLANT TEMP ABOVE 609:
COLD START CHANGE OVER SOLENOID:

ENERGISED WHEN' CHOKE I S USED BUT NOT
WHILST CRANKING. ' '
. ,. . . FUEL PRESSURE SOLENOID:

'8
ENERGISEO BY THROTTLE MICRO SWITCH ' J '

. . .. . . . .. . .
. : :. .
THROTTLE MICRO SWITCH.
CHOKE SWITCH.
..
told Start. Choke operated & crank~ng LOW. . FUEL '~W~TCH.
......... .... . . . . . .
I. ::.I.. . .
. ,.::. ...::;,a:* - ... ,'<. . .:. .. . . . .
la ENGINE MANAG.EMENT CIRCUIT - FEDERAL S H E E T 38 CROKEI LOW FUEL WARNING

the
.
A A l C . COMPRESSOR.
Is
START SOL. B STARTER MOTOR.
WR
CLOSED WHEN
IGN. AUX.
Y-YG IGNITION OFF, OPEN WHEN IGNITION ON.
10A.
0 TEMP CHANGE OVER RELAYS:
THROTTLE JKK E THROTTLE SOLENOID: TO OPERATE WHEN;

I. AIC. COMPRESSOR I S ENERGISED.
2. STARTER MOTOR CRANKING ON HOT START.
3.COLD STARTING EXCEPT DURING CRANKING.
THERMAL SWITCH:
MAX. BREAK ON RISE 70° C.
MIN. MAKE ON FALL 60° C.
DIVERTER VALVE :
ENERGISED WHEN COOLANT TEMP ABOVE 609

ENERGISED WHEN CHOKE I S USED BUT NOT
WHILST CRANKING.
FUEL PRESSURE SOLENOID:

ENERGISED BY THROTTLE MICRO SWITCH 'I'
CHOKE SWITCH.
Cold Run -choke operafed LOW FUEL SWITCH.
ENGINE MANAG.EMENT' CIRCUIT - FEDERAL SHEET 3 c CHOKE 1 LOW FUEL WARNING - LAMI?' ..
0
ENGINE MANAGEMENT 0 RATION
A.1C.
KU
A A I C . COMPRESSOR.
B STARTER MOTOR,
START SOL.
WR
C [ARB. EVAP SOLENOID:
CLOSED WHEN
IGN. AUX.
y-YG- IGNITION OFF, OPEN WHEN IGNITION ON.
D TEMP CHANGE OVER RELAYS:

THROTTLE J K K E THROTTLE SOLENOID: TO OPERATE WHEN;

1 AIC. COMPRESSOR I S ENERGISED.
3.COLD STARTING EXCEPT DURING CRANKING
THERMAL SWITCH :
MAX. BREAK ON RISE 70' C.
IGN.
MIN. MAKE O N FALL 60' C.
DIVERTER VALVE :
ENERGISED WHEN COOLANT TEMP ABOVE 600[:

WHILST CRANKING.

ENERGISED B Y THROTTLE MICRO SWITCH 'J'
c HOKE SWITCH.
Cold Run (below 70O C) LOW 'FUEL.'.SWITCH.
ENGINE MANAGEMENT C I R C U I T - FEDERAL SHEET 3~ CHOKE T'LOW FUEL WARNING LAMP

ENGINE .MANAGEMENT OPERATION
A A i C . COMPRESSOR.
B - STARTER MOTOR.
s10
CLOSED WHEN
IGN. AUX.
Y-Y -G IGNITION OFF, OPEN WHEN IGNITION ON.
10A.
D TEMP CHANGE OVER RELAYS
THROTTLE JACK THROTTLE SOLENOID: TO OPERATE WHEN;

1: AIC. COMPRESSOR I S ENERGISED.
THERMAL SWITCH:
MAX. BREAK ON RISE 70° C.
IGN
MIN. MAKE ON FALL 60° C.
DIVERTER VALVE :
ENERGISED WHEN COOLANT TEMP ABOVE 6m
COLD START, CHANGE OVER SOLENOID:

ENERGTSEO WHEN CHOKE IS USED BUT NOT
WHILST CRANKING.

ENERGISEO BY THROTTLE MICRO SWITCH 'I'
THROTTLE MICRO SWITCH
CHOKE SWITCH.
Hot,Run (above 70°C:)

ENGINE MANAGEMENT CIRCUIT - FEDERAL SHEET 3~ CHOKE I LOW FUEL WARNING . LA
. ..
e e
'
A A I C . COMPRESSOR.
B STARTER MOTOR.

CLOSED WHEN
IGN. AUX.
Y P Y G I G N I T I O N OFF, OPEN WHEN IGNITION ON.
10A.
1 D TEMP CHANGE OVER RELAYS:
E THROTTLE SOLENOID: TO OPERATE WHEN;

1 AIC. COMPRESSOR I S ENERGISED.
2 STARTER MOTOR CRANKING ON HOT START.
THERMAL SWITCH:
M A X . BREAK ON RISE 70' C
MIN. M A K E ON FALL 6 0 ° C .
DIVERTER VALVE :
ENERGISED WHEN COOLANT TEMP ABOVE 600C

WHILST CRANKING.

ENERGISED B Y THROTTLE MICRO SWITCH 'J'
Hof Start LOW F U E L SWITCH.
ENGINE MANAGEMENT CIRCUIT - FEDERAL SHEET 3F CHOKE 1 LOW FUEL WARNING LAMP
SHEET 4
CHOKE SIW. RHC EHC

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

POSI7Q c' POST
C F-HC FHC FUSE BOX

5
G
B
-G-
C FHC FHC
2+=Tl
BG
FUSE BOX
BN BN
RELAY
-RAD. FAN
3
BG ----<- BG1
- BN
BN
BN
TO A CU C O N T CIK
C F H-C FHC RELAY SEE SHT 6 G
K- - I) C C C
8
BG-(-BG-9-
A.C.U. THERMISTOR
CONTROL U N I T
I I
GK BO
A.C.U.
-
. . . .>.
.,.
. .. . -..
..... .
.
B I N 'B' FAN FAIL.WILT
THERMISTOR I
K
A.C.U. TEMP
I
K,U - L B O
u CONTROL
CUT- OUT
KU
1SPLICE
W
'O'
SEE SHT 27
FUSE BOX 21 TO INT. FAN RELAY
TO START MOTOR
RAO. COOLING -GK
FANS CIRCUIT
SEE SHT. 5 -YG WR
L-r: IGNITION
S/W. SEE SHT. 2
SEE SHT. 2
BIN '0'
WR 16 TO BRAKE FAIL RELAY
c'WR- SEE SHT. 15
A.C.U. CONTROL RELAY
LOGIC BOX SEE SHT 16
RAD. COOLING
FANS CIRCUIT
-nul
RHC EHC
SEE SHT. 5 -KU 9 K - - - - + ~ K u
YP-ENGINE MAN.
CIRCUIT
A.C.U.
COMPRESSOR
A I R CONDITIONING
SHEET b
FUSE BOX
SPLICE '6'-Y
SEE SHT 26
FUSE BOX
FAN SPEED SIW 21
a W d S P L I C E '0'
8 SEE SHT 27
A CU CIRCUIT
SEE SHT 6
I N T FAN
MOTOR 2
INTERNAL FANS
. I , . SHEET 7
SHEET 8 FHC
POSITIVE POST
NU
uwl
I I P I MAIN BEAM
C COLUMN S I N
SEE SHT. 9
I .
B FHC
R H HEAD LAMPS FUSE BOX
UG 2 BIN 'A'
NOT USED
-w SEE POWER
OUT-BOARD WASH CIRCUIT
ON SHT. 14
HEAD LAMP MAIN BEAM, D I P BEAM & FLASH SHEET 8
a
MOTOR L H RELAY L H
FUSE BOX
FHC 16 SPLICE 'A'
5 A 8
PA) P - N
SEE SHT 25
FLASH CIRCUIT
SEE SHT. 8
NLG UG
MOTOR. R H RELAY R H H E A D 'LAMP MOTOR
HORN RELAY
FHC FUSE BOX

9 I
TO ALARM
SEE SHT 27 AL
7
-
- Y HC AL4
HORNS
D I P 1 M A I N BEAM g
COLUMN SIW
HORNS, D I P I M A I N BEAM & COLUMN S/W SUPPLY SHEET 9~
POSITIVE HEAO LAMP MOTOR OPERATION
m
PODS DOWN
l+.sA LH MOTOR
RELAY
HEAD LAMP OR CIRCUIT

HEAD LAMP MOTOR -
, 10A
I
@-i./
MOTOR
.:-.
.. .. :...
..-.
PODS TRAVELLING UP
. . :.
:;::
. ..,:.
....
.....
:::: :.:.
-
$1 .:
.. :.
........
....
......
.:. :::
:iiI:;
:..:..:..:
-
..........
7.
......
...
........
......
:.:. $
: .:.>
: I=
........
.. . ..
UG
.. .. ..
.....
......
. :..
.. ..
.,.
NLG ::.. ::
::.:..: ::.:.
:::
...
........
.,..
......
....... ,.
,. ...
.,......
::: :.:
:,.
:.::. :.::
TO MA1 N BEAM
:;; ::;:
;::$i
:::. .:::: RELAY COIL 7
' \
2'
3 0
;;;:>
i:i
....:;:i
... .:.
,:. .:.:
z
>;:;
i NU LIGHT SIW :%
UR
.n
I
TO D I P B E A M
RELAY COIL
L H HEADLAMP L H MOTOR -4
MOTOR S RELAY
........ ......
. . . . . H E A D L.AMP MOTOR CIRCUIT ... ... . . . . . ..;". '.':.;-'..

. .....
I . , ; . .
. -
. - . _. - SHEE.T - 9 :. ~
_I
....
, .....
POSITIVE HEAD L A M P MOTOR OPERATION
N
I
HEAD LAMP MOTOR CIRCUIT SHEET 9 0

I(h
H E A D L A M P MOTOR. OP ATION
PODS TRAVELLING DOWN
NU L I G H T SIW
HEAD LAMP MOTOR CIRCUIT SHEET 9~

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

7
I, SEE SHT.25
BIN'B'
I
20 12
SPLXE '0'G W - 1-6
SEE SHT. 27 B A
TO CLOCK \
R B- FUSE
SEE SHT.12 3
R. H. SID
MARKER
B (RG-
jJ
FUSE
'1
R
F HC 9
BOX
\
R.H. FRONT rR+ R O ~ ~ R O -
TO RHC 8
LIGHT S / W
RHC
/
~!!GW*B+I'
R H REAR 0.1. . ....
..
..
. . .
.
D.I.& HAZARD SHEET 10. ..
INSTRUMENT 2 ILLUMINATION
7
B&
FIBRE
BAT TACHO. BOOST SPEEDC. TEMF! FUEL OPTIC
RN RN RN RN RN
TO ALARM BIN%&
27SHT
AL N
-7
Y FAL4
A t U HC 1 L.H. OttC
SHT. 1 2 .
CIRCUIT
1 ,-~LRO-0.1. 8 HAZ.
-RHC )( CIRCUIT
8T /RO- SEE SHT 10 -
RB
1 r I
RB RO RO
LH. SIDE LICENCE LICENCE R.H. SIDE
MARKER NO PLATE NO. PLATE MARKER
LT L H LT R H.
"
A B------t------B . -
A - -
a
, SHTo FUSE BOX
TO RADIO AMP.
CONNECTOR
STARTER CIRCUIT a,
LAMP
CIGAR
;f LIGHTER
3
B A
R- B 1 WR
R. H. DOOR SIW
0.1.1 HAZARD CIRCUIT I
SEE SHT.10
P RH.
SPLICE
'A' *N
4
SEE SHT. 25
FUSE BOX
FUSE BOX
PANEL
SPLICE'A-N
SEE SHT 25 LIGHTS
0 INTERIOR LAMP
_t
- L.H. DOOR SIW RW
TO R.H. RHEOSTAT
I rRwP SEE SHT. 11
STARTER C I R C U l l 'L.H. K H . oHc
-B W ~ - -
SEE SHT. 2
L G W - - ~ ]
PLG
DHC
I
I
LOGIC BOX
SEE CIRCUIT ON SHT. 1 6
DOOTL
AMP
3@-1CIGAR
LIGHTER
-
CLOCK, DOOR WARNING & INTERNAL LAMPS

SHEET 13 03
RADIO AMP ( I f fitted) RADIO - SEE CIRCUIT ON SHT 20 Rl
0
Y
SPLICE 'A'
SEE SHT 25
6
N- =!
STOP LIGHT S/W
RHC
s0
STOP LIGHTS
LOGIC BOX LH
SEE CIRCUIT ON SHT 16
STOP LIGHT
REVERSE LIGHT
14
-6 W S P L I C E '0'
SEE SHT. 27 HEAD LAMP WASH
NLG ULG
I
4" P t
-RLG - , ~ ~ L G u @ 31 4
WIPER MOTOR
3 5
-
RLG-
-NLG
POWER
WASH i
WIPE siw RHc 1.
LGU
LGU
PUMP
- ULG-
- POWER WASH
INTERMITTENT LG B TIMER RELAY
WIPE UNIT
FHC 18
- I
0 1 j - L G B L G B
FUSE BOX FUSE BOX

SCREEN WASH PUMP 2 11
NOT USED- U P N - S PLIC E 'A'
RU A T A I3 SEE SHT25
HEAD LAMP
\ - u p
CIRCUIT SEE SHT. 8
POWER WASH 8 WIPER
SHEET 14
BIN TO ACU CONTROL
SPLICE'G' RELAY SEE SHT 6
J
FUSE BOX SEE SHT 24
G
SPLICE '0' -W
SEE SHT. 27 VAC S/W BIN BIN'B.
BS W R - - ~ WR+-w R
14
( BINNACLE)
@
BRAKE FAIL -WR- h
I W/ LT 0
LOW BRAKE FLUID
LEVEL S/W
I
I BRAKE FAILURE WARNING
HAND BRAKE S/W B I N 'A' HAND BRAKE WILT

BW
-+B
- .
SEE SHT: 24
HAND BRAKE WARNING

-PLG TO L.H. DOOR SIW
SEE SHT 12
-
f
5
P TO STOP LIGHT S I N
SEE S H T 13
LOGICBOX 6 5 4 3 2 1
SEAT BELT S/W.

TO ACU CONT. RELAY
SEE SHT. 6
-WR p B--LF~-B-+~
I
SEAT BELT WILT.
BIN A
-B p--------4. 5
SEE SHT 24
S E A T B E L T I LOGIC
syErGg
+-B
~ E SHT.
E
24
VOLTAGE
sTABILIsE:G TEzE
GU1-
BIN 'A'
4
) -G u
RHC
3
G U-
EHC
L--GU--+T
TEMP TRANSMITTER
11
:(n
LG
TO FUEL GAUGE
SEE SHT.4
1 BATTERY GAUGE
WATER TEMPERATURE & BATTERY GAUGES SHEET. I 6

SHEET 17
FUSE
BOX WUQ
A
- B I N 'A'
SPLICE 'A' -N
SEE SHT. 25
A B \ HRS eJ1
K-------
HRS S/W
SPLICE 'G'
SEE SHT.24
TAILGATE HINGES
HEATED R E A R SCREEN ( H R S )
SHEET 17
L.H. MIRROR R.H. MIRROR
MIRROR
CONTROL
-BU
L.H. DHC 4 b
I I
A -YG-TO RADIO AMF!

FUSE BOX 7
SEE SHT. 20
B
(If f i t t e d )
SPLICE 'B' '

MIRRORS ( Movement by solenoids)
SEE SHT. 26
SHEET 19
SHEET 18
SPLICE 'B' SEE SHT. 26
----------------SU 8 7
-
L.H. WINDOW 5
-6 R.H. WINDOW
LIFT S I N A--Y-- 4 3 LIFTSIW
r-- sP
2 1
L.H. WINDOW LIFT MOTOR WINDOW LIFT

---4---su
R.H. DHC
-
R.H. WINDOW L I F T MOTOR
= 11
0 %
SHEET 1.
MIRROR CONTROL CIRCUIT
SPLICE 'B' -Y
SEE SHT. 26
II II
T O CLOCK
YG d d b d b
SEE SHT 12
SPLICE 'A' -N
SEE SHT 25
SEE SHT 1.3
RADIO & RADIO AMP ( I f fitted)

SHEET 20A
1111
1111
REED SW.
&U REED SW.
S *>
FACIA HC AL3
G -TO FACIA HC 4
SEE SHT 24AL
P FUSE BOX
P-+&P--o FACIA HC AL 4
SEE SHT 22AL
I
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
- AL 2
FACIA\HC AL2
.'I+,
LT G
R
WB R
I 1
R RB
I I ?7 I
%
O
Pl,
INUNE FUSE.
I (Next to stby
battery,
BEEPER
SIREN ULTRACWSTIC
DETECTORS
-I
Standby buttery. -
NOTE:- REED SWITCHES SHOWN
DOORS OPEN
PULSAFE ALARM
SHEET 20A
SHEET Z
OO
ULTRACOUSTIC DETECTOR TAILGATE REED SWITCH
(in front of right
hand headla-mp motor)
S I R E N (inside right hand \ BONNET REED
STANDBY BATTE
(below left hand (behind left hand seat) (bottom of 'B' post)
tunnel vent)
TO START MOTOR SEE SHT. 2
I'"
3
15 AMP
BATTERY 12 v.
[ -
THERMAL SWITCH
MAKE ON RISE 8 5 : ~ 2 : ~
BREAK ON FALL 6 8 C + 2 C
*
1 E.H.C.
5 ENGINE MANAGEMENT
CIRCUIT SEE SHT. 3
.GF
I N H I B I T SWITCH L . LGO
I
TIMER
ENGINE BAY VENTILATION

0 0
'. NO. FUSE RATING CIRCUIT
1 20A. INTERIOR FANS
11 11
3
SA. I L.H. STDE ITAIL IN O PLATE L A M P S
4 15A. 1 HAZARD LAMPS l INTERIOR LAMP ICLOCK 1
5 15A. CIGAR LIGHTERS 1 DOOR LAMPS
6 10A. RADIATOR FAN N O . l
7 1 0 A. DOOR MIRRORS I RADIO (AUX. 1 RADIO AMP I A U X [ I f fitted I
8 5A. INSTRUMENTS & WARNING LAMPS
9 SA. R.H. SIDE 1 TAIL 1 LICENCE NO. PLATE L A M P S
I 10 15A. STOP LAMPS1 SEAT BELT BUZ RADIO IMem) RADIO AMP ( If fitted1 ANTENNA
!
11 25A. HEAD L A M P WASH
12 10A. RADIATOR FAN NO. 3
13 5 A. HEATED REAR SCREEN
14 15A. WIPER MOTOR 1 SCREEN WASH
15 5A. H E A D LAMP MOTORS (DOWN CONTROL1
16 10A. HEAD LAMP MOTORS
17 10A. HORN I HEAD LAMP F L A S H
19 10A. REVERSE LAMPS

20 10A. INDICATORS
-- .-
21 10A. A.C.U. COMPRESSOR / A.C.U.- RADIATOR FANS CONTROL

22 10A. ENGJNE CONTROL (AUX.)
23 10A. ENGINE CONTROL ( IGN. )
24 10 A ALARM
FUSE BOX - CIRCUITS 8 RATINGS

CHANGEOVER DOUBLE CONTACT ELECTRONIC UNIT
I@
-l
c)
RELAY CONNECTIONS
SHEET 23
H.R.S. SIW. TACH0 IGN. WILT.
TO ALARM
SEE SHT17 SEE SHT2 SEE SHT.2
.SE[E-
I I I
G
SEE SHT. 1L
-"TG
SPLICE '0'
FUSE BOX
G
L H 0.1. WILT.
SEE SHT. 10
FACIA H C
G -
4
R H 0.1. W I L T G
SEE SHT. 10
SEAT BELT WILT
SEE SHT 16
BATTERY GAUGE
SEE SHT. 1 6
VOLTAGE STABILISER
SEE SHT. 1 6
BRAKE F A I L WARNING .
CIRCUIT SEE SHT. 15
G G G
HAND BRAKE WLIT. L O W FUELI BRAKE FAIL RELAY

SEE SHT 15 CHOKE WILT. SEE SHT 15
SEE SHT L
SPLICE ' G I
SHEET 24
@
'm
POSITTVE POST 0
HEAD LAMP WASH A 11 8 P

SEE SHT 1
A 13 B H.R.S. .
$ -
SEE SHT.14 -N-P . N W U SEE SHT.17
HEAD LAMP M O T O R S p A _N16 B \
/
SEE S H T 9
"-P SEE SHT. 12
I
I
. .
HORN 8 HEAD INT. LAMP 8 CLOCK
SEE SHT 12
LAMP FLASH
SEE SHT. 9 - HAZARD LAMPS
SEE SHT. 10
STOP LAMPS RADIO

SEE SHT. 13 SEE SHT. 20
SPLICE 'A' SHEET 25

. ' '\\
a". '
POWER RELAY ( A U X . )
' SEE SHT1
rYG-
DOOR MIRRORS
SEE S H T 1 9
RADIO
Y SEE SHT. 20
WINDOW LIFT
5
SEE SHT. 18
B 22 A ENGINE MANAGEMENT'
Y-G- SEE SHT. 3
I I
INTERNAL F A N S
SEE SHT 7
SPLICE '0' SHEET 26

_
SHEET .27
POWER RELAY (IGN.)
SEE SHT 1
ENGINE MANAGEMENT
SEE SHT 3
- -
A 23 B
? R HC
START, ALT & IGN.
SEE SHT 2
INTERNAL F A N S
SEE SHT. 7
INDICATORS A20 B
W- G
SEE SHT. 10
A I R CON0 g R A D
FANS- SEE SHT 6
REVERSE LAMPS
SEE SHT 19 WIPER MOTOR/
SCREEN WASH
NOT USED - SEE SHT 14
G G
1 I
SPLICE'G BRAKE FAIL W/LT
SEE SHT 2 4 SEE SHT. 1'5
SPLICE 'D' SHEET 27

,.
A- HEADLAMP POWERWASH TIMER ( IF FITTED )
C - HEATED REAR SCREEN RELAY
1 D -AIR CONDITIONING ' DROP OUT'RELAY

E -INTERIOR FANS RELAY
F -RADIATOR FANS RELAY
FUSEBOX
FRONT BRAKE FAIL
HARN~S
CONNECTORS / / I. ,WARNING LIGHT RELAY
REAR
HARNESS
Page 30
INSTRUMENT BINNACLE REMOVAL
The i n s t ~ m e n binnacle
t 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 s i b ' by removing the four screws
securing the centre panel ABS trim, followed by the single screw securing each side
panel at i t s outermost edge. Access to the fibre optic light source (switch illumination)
.
may be obtained after removal of the right hand side panel Voltmeter and fuel gauge
illumination bulbs may also be replaced after removal of the appropriate side panel.
The Brake fail warning lamp relay may also be reached after removal of the left hand
side panel .
For access to an instrument housed i n the centre panel, it i s necessary.fint to remove the
binnacle assembly from the fascia. After removal of the four M6 bolts securing the
binnacle assembly to the scuttle crossbeam (accessible from beneath) the binnacle may be
raised sufficiently to enable the three wiring loom block connectors to be unplugged, the 1
speedo cable to be released, and the boost and o i l pressure gauge pipes to be disconnected.
Also release the demist vent duct from the binnacle adaptor.
LUCAS CONSTANT ENERGY IGNITION
The Lucas constant energy ignition system is an inductive system i n which the energy
stored i n the coil i s maintained constant over a wide range of engine speeds, thereby
providing consistently high output voltages. The system comprises a distributor model
45 DM, and ignition coil model 32 C5, an ignition amplifier model AB 14 and an
electronic rev. limiter.
The distributor incorporates a variable-reluctance position transducer (pick up) to

provide a basic timing waveform. The s i ntered reluctor has four projections which
correspond i n function with the cam lobes of a conventional distributor. The pick up
comprises a coil and magnet assembly, the pick up air gap (0.20 -
0.35 mm.) being set
during manufacture and requiring no subsequent adjustment.
A conventional type rotor arm i s fitted, moulded (as is the distributor cap) from track
retardant material. The two cables connecting the distributor to the ignition amplifier
terminate i n a non-reversible "shur plug".
The high energy coil (model 32 C5) i s specially designed to achieve the very fast
current rise times required for this system. The coil requires no ballast and consumes
no current i n the stalled engine condition.
The ignition amplifier (AB 14) i s mounted i n t he ignition box whilst the electronic rev.
limiter unit i s fitted on the RH fuel tank board.
SECTION M C 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 RESULT
1 C H E C K HT S P A R K I N G
Should be:
Regular sparking *
-
TEST6
No sparking
+ -
TEST 2
Measure voltages at 1-4 incl.

should be:
1-More than 1 1 W
2 - l V max. below V a t 1
3-lV max. below V at 1
-
4-ov-0.lV
All correct -
I
TEST 3
Incorrect reading(s)
SEE CHART
SUSPECT
Low J Battery discharged
J 1 LOW Low J Ignitionswitch andlor wiring
Low J Coil or amplifier
Amplifier earth (ground)
3 CHECK A M P L I F I E R !S W I T C H I N G
Voltage increases
while cranking
-
TEST 5
Voltage does not increase

while cranking
TEST 4
Page 32 SECTION. MC
9
-
4 P I C K - U P COIL R E S I S T A N C E Ohmmeter should show
2-5 kQ
Correct
-
Change amplifier
Incorrect
Change pick-up
If engine.will not start
~--
TEST 5
5 C H E C K HT S P A R K I N G Should be good HT sparking

Repeat with original HT lead
II TEST HT LEAD CRANK 3
ENGINE
Good sparking
-
TEST 6
No sparking, replace HTlead
Lf engine will not start -
w
T E ~ 6T
No sparking
-
Replace coil
TEST 6
Should be:
No sparking
-
TEST 7
HT sparking
Replace rotor armlrotor vane
TEST 7
7 V I S U A L AND HT C A B L E C H E C K S
EXAMINE Should be:
1 Distributor Cover
1 Clean, dry. no tracking marks
2 CailTop
2 Clean. dv, no tracking marks
3 H.T. Cable Inrulafion 3 Must not be cracked. chaled
or perished
4 H.T.CobleContin"ity 4 Must not be open circuit
5 Spark Plugs 5 Clean. dry, and set to covect gap
Note: If a fault i s diagnosed with the distributor pick up assembly, the complete
distributor must be replaced as without the specialist equipment required
for correct adjustment, extenshe. engine damage c d d result from any
. .
attempt to replace internal components.
. .
SECTION MC Page 33
BATTERY RE-CHARGI N G PROCEDURE
Instructions for Tungstone Powermaster Maintenance Free Batteries.
To determine the state of charge o f the battery, apply a brief discharge o f no more
than ten seconds duration (e .g. turn on headlights) w i t h the engine off, and then
a l l o w to stand o n open c i r c u i t for two to three minutes.
Measure the terminal voltage o f the battery.
If steady voltage i s below 12.4 Volts, recharge battery as follows.
Note: The battery -

must
- not be boost charged.
If necessary, f i t a replacement battery to the vehicle, whilst original
battery i s charged as follows .
Remove battery from vehicle.
a). G n s t a n t Current: The battery must be charged a t a maximum o f 5 amps u n t i l

the battery terminal voltage (on charge) has stabilised over a one hour period,
a t which time the voltage w i l l be i n the range 16.0 - 16.5 V. A t this stage
the battery must be taken o f f charge IMMEDIATELY, to prevent excess gassing
w i t h resulting water loss which w i l l ultimately reduce the guaranteed service
life.
b). Constant Voltage: The battery may be charged a t avoltage up to a maximum

o f 15.8V providing the current i s carefully monitored and the charge terminated
when the current has tapered off and changes b y less than 0.1 amp over a period
of one hour. I f i t i s not possible to monitor the current during charging, then
the voltage must be restricted to 14.4 V maximum.
Battery access
ELECTRICAL
SECTION ME - USA ESPRIT TURBO, '86 M . Y . O N (H.C.I.)
C i r c u i t Diagrams :
Component Index
Legend
Supplies
S t a r t , Alternator, Ignition
Fuel I n j e c t i o n Management System
Fuel .Pumps
Fuel Level
R a d i a t o r Cooling Fans
Air C o n d i t i o n i n g
I n t e r n a 1 Fans
Headlamp Beam, Dip, F l a s h
Horns, Beam, Dip and Column Switch Supply
Head1 amp Motor Operat ion
D i r e c t ion I n d i c a t o r s & Hazard
Rear L i g h t s , I n s t r u m e n t I l l u m i n a t i o n
C l o c k , Door Lamps, I n t e r i o r Lamps, Cigar L i g h t e r
S t o p ' L i g h t s , Reverse L i g h t s
Wipers & Washer
Brake F a i l & Handbrake Warning
S e a t Belt Logic, Water & B a t t e r y Gauge
Heated Rear Screen
Window L i f t
Mirrors
Radio & Radio Amp ( i f f i t t e d )
Low o i l and c o o l a n t warning
Fuse box, C i r c u i t s and R a t i n g s
Relay c o n n e c t i o n s
Splice ' G I
Splice 'A'
Splice 'B'
Splice ID'
Eomponent Location Diagram
Harness Routing Diagram
I n s t r u m e n t B i n n a c l e Remova 1 50
Lucas ' C o n s t a n t Energy I I g n i t i o n See S e c t ion MC
COMPONENT INDEX
SECTION M E
Sheet / Page Sheet / p a 4
A.C.U. Compressor 6 Radio Amp. ( i f f i t t e d ) 20
A.C.U. Tem. Control 5 Relays - ACU Control 6
A.C.U. Thermistor 5 - Brake F a i l 15
Alternator 2 . - Dip Beam 8
A u x i l i a r y Air Valve 3B - D.I. & Hazard Unit 10
Battery 2 - Engine Management 3A
Cigar L i g h t e r s 12 - Flash 8
Clock 12 - Fuel Pump Control 3C
Cold S t a r t I n j e c t o r 3B - Headlamp Motors 9
Compressor, a i r horns 9 - Heated Rear Screen 17
Distributor 2 - Horn 9
E l e c t r o n i c Control Unit (ECU) 38 - I n t e r n a l Fans 7
Engine, OverspeedIFuel Pump f a i l u r e 3C - Lamp Delay Unit 12
~ r e q u e n c yVa 1ve - Main Beam 8
Fuel Enrichment module - Power (aux. ) 1
Fuel Sender Unit - Power ( i g n ) 1
Fuse Box - Radiator Cooling Fans
Heated Rear Screen Rheostats 11
I g n i t i o n Amp1 i f i e r Solenoids - S t a r t e r 2
I g n i t i o n Coil Speakers 20
I n t e r m i t t e n t Wipe Unit Switches - Door 12
Instruments - B a t t e r y Condition - Door Mirror c / o 19
- Fuel Gauge - Door Mirror Control 19
- Tachometer - Column, Dip/Beam 8
- Temp Gauge - Handbrake 15
Lambda Sensor - Hazard 10
Brake Fai 1 Warning - Heated Rear Screen 17
Door Warning - Ignition 2
D. I . & Hazard Lamps - Inertia 3C
Economy Warning - I n t e r n a l Fans, speed 7
Fan F a i l Warning - Lights 8
Handbrake Warning - Low Brake Fluid 15
Head 1amps - Low Pressure C u t Out
I g n i t i o n Warning (ACU) 5
Instrument Illumination - LowVacuum ( b r a k e s ) 15
I n t e r i or Lamp - Oil Temperature
Low Fuel Warning - Overboost 3B
3C
Low Coolant Warning - Reverse Light 13
Licence P l a t e Lamps - Seat Belt 16
Panel Lights 1 - Stop Light 13
Reverse Lamps - Thermal (engine
Seat B e l t Warning management ) 3B
Side Market, Front - Throttle position 3B
Side Marker, Rear - Window L i f t 18
Stop1amps - Temp Transmitter 16
Tai lamps - Voltage S t a b i l i s e r 4,16
- Water Temperature 3B
Antenna - Warm Up Regulator 38
I n t e r n a l Fans
Mirrors
Radiator Cooling Fans
Window L i f t
Windscreen Wiper
Fue 1
Screen Wash
SECTION M E
LEGEND
BIN Binnacle Connector

D.H.C. Door Harness Connector
D.I. Direction Indicator
E.B.C. Engine Bulkhead Connector
E.H.C. Engine Harness Connector
F.H.C. Front Harness Connector
L.H. Left Hand
P .H .C'. Pumps Harness Connector
R.H. Right Hand
R.H.C. Rear Harness Connector
SOL Solenoid
sm .
W/LT
Switch
Warning Light
C.C.C. Centre Console Connector
M.H.C. Manifold Harness Connector
C.F.H.C. Cool ing Fars Harness Connector
C.B.H .C. Coil Ejox Harness Connector
Cable Colwr Code
B Black 0 Orawe
G Green R Red
K Pink S Slate
P Purple U Blue
LTG Light Green W White
N Brown Y Yellow
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
SIW. SEE SHT. 2
-Y~)LY
-1 Y
SPLICE
' B'
SEE SHT 26
1
SPLICE
'0'
I
.
SEE SHT. 27
SUPPLIES
BW-)LGW-
TO L.H. DOOR W
SEE SHT. 12
SI. a
TACH0 TO ENGINE OVERSPEE01
FUEL PUMP FAILURE
SPLICE'G'+G
SEE SHT. 1 0 SEE SHT. 24 RHC
TO RPM. RELAY 1
ISEE SHT. 3A
TO LAMP DELAY
UNIT SEE SHT 12
Lw W-&/ -R.
WR /
RHC
-
POSITIVE POST
SEE SHT. 1
LNY*-I SPLICE 6'

SEE SHT 24
IGNITION WILT.
START, ALTERNATOR & IGNITION SHEET 2
I
-4
SHEET 3A CBHC RHC BIN 'A'

TO ENGINE OVERSPRD I
FUEL PUMP FAILURE MODULE
ECONOMY WlLt
CBHC fk
T
YN
T
YB
I I TO ENGINE OVLASPEED I FUEL PUMP FAILURE MODULE. SEE SHT. 3C -
TO E.C.U. R P M . RELAY 2
SEE SHT. 38
TO COLD START INJECTOR. SEE SHT 38 ----YG Y-L(G
-
5
CBHC ' TO THERMAL TIME SWITCH. SEE SHT. 3B
T O THROTTLE
TO THROTTLE POSITION SWITCH TO INERTIA SW
POSITION SWITCH -Y N
SEE SHT. 3 8 SEE SHT. 38 SEE SHT. 3C
TO SENSOR HEATING
TO FREQUENCY VALVE
PI-/)
RELAY No. COIL SEE SHT. 3 8 TO WATER TEMP SW.
SEE SHT. 38
1 - DECELL CONTROL
2 - IDLE CHANGEOVER TO E.C.U. Y \L y3 ~ q ~ ~ ~ ~ , 3 ~ RPM. RELAY 1
3 - FAST WARM UP SEE SHT. 3B CBHC
4 - A.C.U. IDLE UP TO IGNITION COIL
5 - A.C.U. IDLE CONTROL SEE SHT 2
FUSE BOX TO ENGINE OVERSPEED l

TO STARTER MOTOR
FUEL PUMP FAILURE MODULE
SEE SHT. 3C
fa @?L INJECTION MANAGEMENT SYSTEM
N
N+%
RHC
3~
FAST WARM UP RELAY
SEE SHT. 3A
ELECTRONIC CONTROL UNIT 3?8‘ HC
I:
I
I R.PM. RELAY 2
WATER SEE SI-IT. 3A
I
I I
I I DECELL CONTROL
TEMP
SWITCH I TO START MOTOR
(
SEE SW. 3A
I I
I YLG
SCREENED I I
CABLE I I
I
I I
I I CBHC
IDLE
SEECHANGEOVER
SHT. 3A
I DECELL CONTROL
SEE SHT 3A
CBHC
I
I
I YLG WY
I
k!
t:
F I
FREQUENCY
VALVE
COLD START
INJECTION
THERMAL
TIME SWITCH B
-
I
THROTTLE POSITION OIL TEMP AUXILIARY WARM UP

SWITCH SWITCH AIR VALVE REGULATOR
FUEL INJECTION MANAGEMENT SYSTEM SHEET 38

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

SEE SHT 24-SPLICE G
' -G
'
W ltT
SPtICE -G TO TEMP GAUGE
?: I '
SEE SHT.16
'G' B I N '0'
RHC FUEL SENDER UNIT
SEE SHT 24
GO - + G O Go
RHC B I N '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
I '0'
BN FAN FAIL WILT THERMISTOR OTTER SIW.
LOW PRESS.
KU
A.C.U. CIRCUIT-~~J
SEE SHT 6
0 RADIATOR COOLING FANS SHEET 5 0 .'.

SPLICE ' 0 '
I SEE SHT 27
W
TO INT. FAN RELAY

SEE SHT. 7
TO START MOTOR
RAD. COOLING
I
rWR
SEE SHT. 2
FANS CIRCUIT CCC
SEE SHT 5 -YG
RELAY
RAD. COOLING K U
1
FANS CIRCUIT
RHC EHC
SEE SHT.5 -KU K"le-, 9 TO A.C.U. IDLE CONTROL RELAY
K
Ku 7)' SEE SHT. 3A
COMPRESSOR
a
A I R CONDITIONING SHEET 6
SHEET 7
FUSE BOX
SPLICE '6'-Y I
SEE S H I 26
INT. FAN
MOTOR 1
r
FUSE BOX
FAN SPEED SIW.
----.SPLICE 'D'
SEE SHT: 27
INT. FANS
RELAY
LGS-1 @
CCC r?
BY)-
G
I
A CU CIRCUIT
SEE SHT. 6
C CC
INT. FAN
MOTOR 2
YG I
INTERNAL FANS
a
POSITIVE POST
OUT- BOARD
7 U B NU
uw
D I P I M A I N BEAM
&COLUMN SiW
FHC
(b,
-UR
h
SEE S HT. 9 <)
Y
BIN
'3 B
2
J
LIGHT
S/W
Lh
- 8 7 -RG-
SEE FRONT
6 5 SIDE TURN
IN-BOARD
,/ @)
R H HEAD LAMPS
4
U Y
OUT-BOARD
HEAD LAMP MAIN BEAM, DIP BEAM & FLASH SHEET 8

SHEET 9 A
MOTOR L H RELAY L H
FUSE BOX
FHC 16 SPLICE 'A'
) -P
5 -P
A 0
-N
SEE SHT. 25
FLASH CIRCUIT
SEE SHT 8
MOTOR RH RELAY R H H E A D LAMP MOTOR
I HORN RELAY, ! rm 20A

N-
ii
10
HORNS
u /I \ I A 17 B SPLICE 'A'
FUSE BOX SEE SHT. 2 5
- 1- D I P i M A I N BEAM 8
COLUMN SIW
HORNS, D I P I M A I N BEAM & COLUMN SIW SUPPLY SHEET 9 A
0 7 0 0
RELAY
UG
I
UR
I
NU LIGHT SiW
sh
--8 7
I -
TO DIP BEAM 6 5
RELAY COIL
- 4 3 7
2 11
I LH MOTOR
R r w
d
HEAD LAMP MOTOR CIRCUIT

HEAD L A M P MOTOR OPERATION
P O D S TRAVELLING U P
- ....
L H HEADLAMP LH MOTOR
MOTOR S RELAY
HEAD LAMP YOTOR CIRCUIT SHEET 9 C

Y
POSITIVE
HEAD LAMP MOTOR OPERATION
PODS UP
1 TO M A I N BEAM
RELAY COIL
f ~
UR
I
1
]
NU LIGHT SIW
TO DIP BEAM
RELAY COIL
-RS
9-
LH MOTOR
S RELAY
HEAD LAMP MOTOR CIRCUIT SHEET 9 0

POSITIVE HEAD LAMP MOTOR OPERATION
D S TRAVELLING D OWN
N L G A
TO M A I N B E A M
RELAY C O I L
TO DIP' BEAM
RELAY COIL
LH HEADLAMP
MOTOR
HEAD LAMP MOTOR CIRCUIT SHEET 9E
a
a
POSITIVE 11
HEADLAMP FLASH
POD TRAVELLING UP
I
NU L I G H T SIW
-
HEAD LAMP MOTOR
.. . CIRCUIT SHEET 9~
L H REAR 0.1.
DIP,MAIN BEAM g 0.1.

SEE SHT. 25
c
4
GW- 3 2 1 - rn
c)
FUSE BOX
SEE SHT. 27
D.I. WILT.
TO CLOCK
.I.lHAZARD UNIT
HAZARD WILT.
R H REAR 0.1.
..
0.1. & HAZARD SHEET 10-
0
SHEE @ INSTRUMENT 1 ILLUMINATION
@
-I-
B&B
OIL FIBRE
BAT. PRESS. TACHO. BOOST SPE EDC TEMP FUEL OPTIC
RN RN RN RN RN
0.1. & HAZ.-RB I

CIRCUIT 7 R0
I RO
RHC CIRCUIT
Ro- SEE SHT 10
R.H. SIDE
LICENCE LICENCE
MARKER
NO. PLATE NO. PLATE
03
LT. L.H. LT. R.H. r?
0
REAR LIGHTS 8 INSTRUMENT ILLUMINATION SHEET 11

SHEET12
I
R H DOOR SiW
I
SEE SHT.10
~
I
TO R H RHEOSTAT
I
STARTER C IRCUTT
SEE SHT. 2-
sw---.I- LG W
I
LOGIC BOX
I SEE CIRCUIT ON SHT 16
CLOCK, DOOR WARNING & INTERNAL LAMPS SHEET 12
' - - - 0
a
SHEET 13
a a
RADIO AMP. ( I f fitted) RADIO - SEE CIRCUIT ON SHT 20
SPUCE 'A'
SEE SHT 25
N-
STOP LIGHT SIW RH
RHC
GP
STOP LIGHTS
LOGIC BOX
SEE CIRCUIT ON SHT. 16
STOP LIGHT
HIGH MOUNTING STOP LIGHT
CI,
h
c,
FUSE BOX NOT USED =!
SPLICE' D ' 0
2
--.Q
SEE SHT 27
RHC
R E V LIGHT SIW.
( I N GEARBOX) RH
s
G
-c-6-
I REV. LIGHTS
REVERSE LIGHT
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
TO ACU CONTROL
G
G
SPLICE '0' -W LOW
SEE SHT. 27 B A VAC S/W
1 ob
1 BS
LL
TO D.I.IHAZARD
RELAY
B
SEE SHT. 10
BS
LOW BRAKE FLUID
LEVEL S I W L - B
BIN ' A
S /;.,-+I B 1.
-- BRAKE FAIL WILT
BRAKE FAILURE WARNING
HAND BRAKE SIW B I N 'A' HAND BRAKE WILT
11~ B - ~ W - C ~ S W
--@- G A SPLICE 'G'
SEE SHT 24
HAND BRAKE WARNING

SHEET 16
rpLG TO L.H. DOOR SIW.

SEE SHT 12
TO STOP LIGHT SIW
w
SEE SHT. 13
LOGIC BOX 6 5 4 3 2 1
SEAT BELT SIN.

TO ACU CONT. RELAY
-WR LpB----~F+B+~l l
SEE SHT. 6
SEAT BELT WILT.
BIN A
5 ' p B
SEE SHT. 24
SEAT BELT I LOGIC
STABILISER TEMP. GAUGE

BIN RHC EHC TEMP TRANSMITTER
4
SEE SHT.
24 ~u-$------~u-&---~~-----.+~~~~,
LG
I
TO FUEL GAUGE
SEE SHT. 4
1 BATTERY GAUGE
WATER TEMPERATURE 8 BATTERY GAUGES

--iB
FUSE
BIN 'A'
SPLICE 'A' -N
SEE SHT. 25
1 2
3 4 H R S 51W
-G SPLICE 'G'
= l1 SEE SHT.24
TAILGATE HINGES
HEATED REAR SCREEN ( H R S )
SHEET 17
SHEET 18
SPLICE 'B' SEE SHT. 26
A
~ L.H. WINDOW R.H. WINDOW

LIFT SIW. LIFT SIN.
I SN+-J U
L.H. OH(: R.H. DHC

s -(R A s u m
L.H. WINDOW LIFT MOTOR 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
R A D I O & RADIO AMP (If fitted)

BIN '8'
i- yG
R G LEVEL
LowMODULE
OIL
LOW OIL
LEVEL PROBE
LOW OIL WlLt
S P U E '0' +,-j
SEE SHT. 26
LOW COOLANT EHC

Wl L t
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 ITAIL INO. PLATE LAMPS
4 15A. HAZARD LAMPS IINTERIOR LAMP 1 CLOCK
5 15A. CIGAR LIGHTERS1 DOOR LAMPS
- -- -- - - - - - -

7 10A. DOOR MIRRORS 1 RADIO (AUX. RADIO AMP ( A U X . [ If fitted 1
-- - - -
8 5A. INSTRUMENTS & WARNING LAMPS

I
9 5A. R.H. SIDE 1T A I L 1 LICENCE NO. PLATE LAMPS

10 15A. STOP LAMPS/ SEAT BELT BUZ RADIO (Mem.1 RADIO AMP ( If f~ttedl ANTENNA

13 5 A. HEATED REAR SCREEN
14 ISA. WIPER MOTOR / SCREEN WASH
-
15 SA. HEAD LAMP MOTORS (DOWN CONTROL)
16 1OA. HEAD ,LAMP MOTORS
17 10A. HEAD . ~ @ MFLASH
P (early cars 2Q4 to include horn - no line fuse)
18
I
( 1 0 A.
I
I RADIATOR FAN N O 2 1
26 10A. INDICATORS
21 10A. A.C.U. COMPRESSOR IA.C.U.- CONTROL
22 10A. ENGINE CONTROL (AUX.1
- - - -
1 23 1 10A. 1 ENGINE CONTROL I IGN. J

1 24 1 5A I RADIATOR FANS CONTROL I
FUSE BOX - CIRCUITS 8 RATINGS

e
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
SPLICE D
' -M
FUSE BOX
L.H. 0.1. W I L T G
SEE SHT.10
FACIA H.C
\
--', G- SEAT BELT WILT.
SEE SHT 16
-BATTERY GAUGE
R.H. 0.1. W I L T G G -VOLTAGE STABILISER

I1 SEE SHT. 10 SEE SHT. 1 6
BRAKE F A I L WARNING
CIRCUIT SEE SHT. 15
HAND BRAKE WILT. LOW FUELI BRAKE FAIL RELAY

SEE SHT. 15 CHOKE WILT. SEE SHT 15
SEE SHT 4
SPLICE 'G'
POSITIVE POST
-N
?
SEE SHT. 1
W
N
-U
A 13 B H.R.S.
SEE SHT.17
HEAD LAMP M O T O R S p
SEE S H T 9
-
A 16 B
CIGAR LIGHTERS
& DOOR LAMPS
SEE SHT. 12
cn
h
c,
2
0
2
Lh
INT. L A M P & CLOCK
HEAD
A17 B SEE SHT. 12
LAMP FLASH -P- N
SEE SHT. 9 HAZARD LAMPS
SEE SHT. 10
STOP LAMPS RADIO

SPLICE 'A' SHEET' 2 5

SHEET 26
POWER RELAY (AUX. 1
SEE S H T l
DOOR MIRRORS
SEE SHT. 1 9
RADIO
SEE SHT. 20
WINDOW LIFT
SEE SHT. 18
FUEL INJECTION
MANAGEMENT SYSTEM
SEE SHT. 3A
YG YG
I I
INTERNAL F A N S
SEE SHT 7
SPLICE '5'
SHEET
POWER RELAY (IGN.)
SEE SHT. 1
FUEL W JECTION
MANAGEMENT SYSTEM
SEE SHT. 3 A
-wG-- A 23 B
7
P
W
R HC
START, A LT. & IGN.
SEE SHT. 2
INTERNAL FANS
rG- SEE SHT. 7
INDICATORS A 20 B
W- G
SEE SHT. 10
L G - A I R CONO. g RAD.
FANS- SEE SHT. 6
RAD. COOLING
w- FANS SEE SHT. 5
REVERSE LAMPS
SEE SHT. 19
SCREEN WASH
-_ h
SEE SHT 14-

NOTUSED -
CI,
G 'm
I c,
SPLICE'G BRAKE FAIL WILT. 3
SEE SHT. 24 SEE SHT. 1 5 0
2
3
'm
SPLICE D - SHEET 27
aQADIATOR COOLING COMPONENT LOCATION DIAGRAM (1)
FANS WINDSCREEN WIPER
MOTOR '-• .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 M E Page 30
INSTRUMENT BINNACLE REMOVAL
The i n s t ~ m e nbinnacle
t contains a centre panel housing ihe main instruments, and two
side panels housing the t e l l tale lamps, switches and v o l t 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 by the single screw securing each side
panel at its outermost edge. Access to the fibre optic light source (switch illumination)
may be obtained after removal o f the right hand side panel. Voltmeter and fuel gauge
illumination bulbs may also be replaced after removal of the appropriate side panel .
The Brake fail warning lamp relay may also be reached after removal of the left hand
side panel.
For access to an instrument housed i n the centre panel, it i s necessary first to remove the
binnacle assembly from the fascia. After removal of the four M6 bolts securing the
binnacle assembly to the scuttle crossbeam (accessible from beneath) the binnacle may be
raised sufficiently to enable the three wiring loom block connectors to be unplugged, the
speedo cable to be released, and the boost and o i l pressure gauge pipes to be disconnected.
Also release the demist vent duct from the binnacle adaptor.
SECTION OB Page I
MAINTENANCE & LUBRICATION
SECTION OB - ESPRIT 53 & TURBO (Dornertic/Export)
-
Page
Recommended Lubricants
Bodywork Defects Sample Sheet
Pre-Del ivery Inspection Sample Worksheet
F i n t After Sales Service Sample Worksheet
Maintenance Plan Sample Worksheet

Page 2 SECTION OB
RECOMMENDED LUBRICANTS
ENGINE: L o t u s C a r s L t d . s t r o n g l y recommend t h a t t h e
following engine l u b r i c a n t s a r e used a t
o i l c h a n g e s , a n d where p o s s i b l e / p r a c t i c a l
between s e r v i c e s .
Above O°C V a l v o l i n e HP Racing SAE 20W/50

Elf Competition SAE 20W/50
Mobil 1 R a l l y Formula SAE 5W/50
Below O°C V a l v o l i n e XLD SAE 15W/40

Elf S p o r t i SAE 15W/40
Mobil 1 R a l l y Formula SAE 5W/50
I n s e v e r e w i n t e r c o n d i t i o n s b e l o w -lS°C a
SAE 10W/40 O i l o r Mobil 1 R a l l y Formula
SAE 5W/50 i s recommended.
When reco'mrnended p r o d u c t s a r e u n o b t a i n a b l e ,
engine l u b r i c a n t s meeting t h e following
s p e c i f i c a t i o n s may be u s e d .
VISCOSITY PERFORMANCE
Above 0 "C SAE 20W/50 API S e r v i c e SF
Below O°C SAE 15W/40 API S e r v i c e SF
Below -15OC SAE 10W/40 API S e r v i c e SF
TRANSMISSION SAE 80 API GL5

FRONT HUBS Lithium base wheel
bearing grease N L G l No.2
STEER1N G SWIVELS (Prior '85 MY) SAE 90 API GL5
BRAKE 8, CLUTCH HYDRAULICS - DOT 3 or DOT^
APR 1987
SECTION OB Page 3
0 Bodywork Defects Sheet
/ DEFECT CODE
A SCRATCHES
B OVERSPRAY
C DIRTUNDERPAINT
D RUN
E SINKAGE
F THIN PAINT
G GEL CRAZING
H CHIPS
J PIN HOLES
K FLAKING
I UNIT No. I
1 COLOUR I
I. OWNER
APR 1987
Page 4 SECTION OB
P?
D T ~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
SECTION OB Page 5
PRE-DELIVERY INSPECTION - ALL MODELS

V I N:
I MODEL I ENGINE NO.
OPEfWTIONS - Tick box i f 0.K . OPERATOR

1
1
- X box i f additional work reqd . - submit defect report L
INITIALS
J
MECHANICAL
Check coolant level and check system for leaks.
Renew engine o i l and filter (Federal only)
Check engine, gearbox and rear axle o i l levels and check for leaks.
Check security of engine o i l filter .
Check brakelclutch fluid reservoir level.
' Check fuel system for leaks.
1 Completely fill fuel tanks and check for leaks. I I I
I Check clutch ad justrnent.
1
I Check tightness of wheel nuts/bdts . 1 1
Check tyre pressure including spare.
Check engine idling speed.
I Check power assisted steering fluid level and system for leaks (when fitted). 1 I
I Check automatic transmission fluid level (when fitted). I I.-
ELECTRICAL -
Check security of battery terminals.
Check operation of a l l lamps.

Check operation of horns and direction indicators.
0 Check opemtion and park position o f screen wipers.
Check operation of windscreen washers.
Check opera tion of a l l instruments.
Check operation o f headlomps and door windows .
Check operation of heater and fan.
- Check headlamp al ignment .

Check operation o f air conditioning equipment (when fitted).
BODY
Check opera tion of doors and locks .
Check bonnet and tailgate release mechanism.
Check interior trim for damage and cleanliness.
0PC
00.
@ Check opemtion of seat be1ts .
Check a l l bright work and paint for condition.
n
4 Check presence of tool k i t and literature pack.
n
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 i s subject to the following conditioru:
(a) I t is the responsibility of the supplying Distributor/importer/dealer to

ensure that the car i s delivered to the customer i n the best possible
condition.
(b) A l l costs incurred during the inspection are the responsibility of the
suppl ying distribu tor/importer/dealer .
(c) F ~ i l u r eto return a signed copy of this inspection to Lotus Can Limited
by the distributor/importer/dealer, may result i n warranty claims on
the particular car being rejected .
DATE: DEALERS STAMP A N D SIGNATURE:
APR 1987
SECTION OB Page 7
@ First After Sales Service (NOT)

U.A.
LSL 2468
excel esprit S3 esprit turbo

Owner's name . . . . . . . . . . . . . . . . . . . . . .. D a t e . . . . . . . . . . . . . . M a r k as follows:
To be carried out at:
Adjustments made €4
Registration No. ...................... J o b no. ........... 500-1000 miles
O.K. d (800-1600 km)
V.1.N . . . . . . . . . . . . . . . . . . . . . . . . Mileage
. ................... Repairs desirable
(See seDarate sheet)
M A I N T E N A N C E NOTES:
" l n s p e c t " m e a n s check f o r correct operation o r c o n d i t i o n - if wrong, advise before c a r r y i n g o u t repairs or a d j u s t m e n t s

ta. extra time.
"Check" m e a n s test a n d a d j u s t / f i l l or t i g h t e n a s necessary.
Install protective covers Check clutch operation and adjust if necessary

Renew engme oil and filter, ensurmg filter Check security of front and rear suspension, and
seals fully steering column and steering rack assembly
Renew manual gearbox/transaxle 011 Check front wheel alignment
Check auto. transmission fluid level lnspect rear wheel toe-in
Renew final drive oil Check security of propshaft bolts
Lubricate propellor shaft un~versaljolnts Check front hub bearing adjustment
Lubricate lower steering sw~vels(11 appl~cable) lnspect operation of all electrical equipmen:
Lubricate throttle linkage and controls
Lubricate door locks and bonnet catches
Lubricate headlamp pod pivots
Check camshaft toothed belt tension and inspect valve timing
Check ignition timing and advance operation
Check all V-belt tensions
Check security of all fixings, especially engine
.
. e n
0
Check battery electrolyte level, security of
terminals and main earth connections
Check headlamp alignment
lnspect all lyres for damage, and set tyre
pressures
Tighten all wheel nuts to specified torque
load~ng
mounting bolts, exhaust manifold and system. Check body c o n d ~ t ~ ogenerally,
n includ~ngdoor
and inlet manifold and carburettor mountings adjustments, bonnet and tailgate/boot
Check and adjust idle speed and CO level adjustment (opening and closing), operation of
Check security and cleanliness of ignition door locks and tailgate/boot lock
harness joints including alternator and starter lnspect seat adjustment mechanism and
motor connections operation of seat belts
Top up cooling system and check security of all lnspect operation of heater/air conditioning a ~ d
water hose connections controls
lnspect fuel system for leaks and check fuel pipe Check final drive, gearbox and drive Shaft
connections o n carburettors mounting bolts to specified torque loadings
Inspect foot brake system for leaks and correct Enslrre upholstery and driving controls are clean
operation Top LIP screen washer reservoir
Check handbrake adjustment and operation
lnspect all brake pipes and vacuum pipes and
connections for damage, chafing, or leaks
Check brake, clutch and P.A.S. fluid reservoir Work completed by. .................................
levels
lnspect operation of brake fail/handbrake
warning lamp
R o a d Test Performance
Engine performance Suspension noises 0 Turbo boost p r e s s u r e
Q 0
t c h operation Brake p e r f o r m a n c e Light o p e r a t i o n 0
r b o x operation/noise W h e e l balance 0
Drive l i n e noise/vibration 0 Steering performance
W o r k completed by ......................
SECTION OB Page 9
LSL 2458
Maintenance Plan (Not USA)

excel esprit S3 esprit turbo
P l e a s e t i c k Service: required:
Owner's name ................... Date .............. M a r k a s follows:
A-
. . 0
Adjustments made
Registration N o . ...................... J o b no. . . . . . . . . . O.K.
B-
@ C- 0
V.1.N . . . . . . . . . . . . . . . . . . . . . . . . .Mileage ................... Repairs desirable
(See separate sheet) For intervals see overleaf
MAINTENANCE N O T E S :
"lnspect" m e a n s c h e c k f o r c o r r e c t o p e r a t i o n or c o n d i t i o n - if w r o n g , a d v i s e b e f o r e c a r r y i n g o u t r e p a i r s o r a d j u s t m e n t s
at extra time.
"Check" m e a n s t e s t a n d a d j u s t / f i l l or t i g h t e n a s n e c e s s a r y
-
e
-
.-
L
C A B C
Install protective covers Inspect exhaust system condit~on.mountings
Renew englne oil and fllter and joints
Check manual gearbox 601, lnspect for leaks . . o n Check brake fluid level
Check auto. trans, fluid level, inspect for leaks 0 . 0 Renew brake fluid & check seals
Renew manual gearbox oil, inspect for leaks 0 0 48,000 mls.
Renew auto. trans, fluid and clean filter. intervals Renew all brake system rubber pans & hoses
~nspectfor leaks . . n o 0 lnspect brake system for leaks & damage
0 Check final drive 011,mspect for leaks . . 0 0 0 lnspect pads & llnings for wear
0 C Renew ftnal drive 011, inspect for leaks . . o n 0 Check adjustment of handbrake
..
U O T L.ubr~catepropshaft un~versaljolnls e . 0 0 0 lnspect brakes tell tale
D O C Lubricate speedo angle drtve . . o n 0 Check/adjust clutch
0 0 0 Oil front trunnions (11appl~cable) . . o n 0 lnspect for clutch fluid leaks
C l G O Check P.A.S. fluid level 0 0 Check steermg U / J clamp ttghtness
0 0 lnspect PAS for leaks & damage . . O D 0 Inspect condlt~onof steering joints and gaiters
G 0 Lubricate handbrake linkage 0 Renew trunnion bushes (if applicable)
O O G Lubricate locks, hinges & catches 0 . 0 0 lnspect condition of all suspension rubber bushes
0 I3 G Lubricate throttle linkage & other controls . . 0 0 0 Check security of front & rear suSpen~i0n
U Ci 0 Lubricate headlamp pivots 0 . 0 0 lnspect dampers for leaks & performance
G O Z Check coolant level and strength 0 . 0 Check/adjust front hubs
0 i Inspect cooling system for leaks/damage 0 . 0 Check condition front hub bearings & seals.
0 I
i lnspect engine mounting rubbers Repack grease
0 0 Check/adjust cam-belt. lnspect valve timing lnspect tyre condition, set pressures (incl. spare)
0 Renew cam-belt Inspect road wheel balance
0 0 lnspect cam-belt tensioner Check/tighten wheel nuts to spec. torque
0 0 Check/adjust V-belts cond~tion& tenslon lnspect front & rear wheel toe-in
0 Renew all V-belts Check security of propshalt bolts
0 0 0 Renew spark plugs Check banery (except 'maintenance free')
o C 3 0 Check/adjust ignition tuning & advance Remove battery leads, clean & inhibit
0 0 0 Check engine ancillar~esfor security Clean Electric aerial
0 0 lnspect valve clearances (extra time to adjust) Check engine bay eanh leads
0 0 Renew air cleaner element lnspect operation of all lights
0 0 Renew fuel filter (Nat. Asp~ratedmodels) Check/adjust headlamps
36,000mls. lnspect operation of all electrics
intewals Renew fuel filter (Turbocharged models) lnspect operation of A.C.U.
0 0 0 Check fuel connections to carburenors Top up screen wash reservoir
0 0 Check security of all fuel system connections Check/adjust door lock strikers
0 0 0 Check thronle/kickdown/cruise control cable. lnspect seat belts condition & operation
adjustment Clean all drain holes, check drains
Check/adjust idle speed & CO level . Check security of major unit mountings
lnspect operation/condition of cooling fans
Work completed b v ..
C
Y- ,Road Test Performance
a i n e performance 0 Suspension noises 0 Turbo boost pressure

YI Clutch operation Brake performance Light operation 0
L
Gearbox operation/noise 0 W h e e l balance 0
Drive l i n e n o i s e / v i b r a t i o n 0 Steering performance
Work completed by .............................
A SERVICE This service has been
completed in.accordance
with the Maintenance
A SERVICE
This service has been
completed in accordance
At 30,000 mls./50,000 km, Schedule.
At 6,000 mIs./10,000 km. Schedule.
or 6 months from Registration Dealer's Stamp:
or 6 months from last Service Dealer's Stamp:
(whichever sooner) (whichever sooner)
Signature: Signature:
Mileage: Date: Mileage: Date:
B SERVICE This service has been

B SERVICE This service has been
AT 12,000 mls./20,000 km. Schedule. AT 36,000 mls./60,000 km. Schedule.
or 6 months from last Service Dealer's st am^:
A SERVICE This service has been

A SERVICE
At 18,000 mls./30,000 km. Schedule. At 42,000 mls./70,000 km. Schedule.

Signature: Signature-
C SERVICE This service has been

C SERVICE
AT 24,000 mls./40,000 km. Schedule. AT 48,000 mls./80,000 km. Schedule.
or 6 months from last Service Dealer's Stampr or 6 months from last Service Dealer's Stamp:

SECTION OC Page 7
MAINTENANCE & LUBRICATION
SECTION O C - 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
Page 2 SECTION OC
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
Mobil 1 Rally Formula SAE 5W/50
a
In severe winter conditions below -15OC a
SAE 10W/40 Oil or Mobil 1 Rally Formula
SAE SW/St! is recommended.
When recommended products are unobtainable,
engine lubricants meeting the following
specifications may be used.
VISCOSITY PERFOFUIANCE
Above 0°C SAE 20W/50 API Service SF
Below O°C SAE 15W/40 API Service SF
Below -15°C SAE 10W/40 API Service SF
TRANSMISSION SAE 80 API GL5

FRONT HUBS Lithium base wheel
S T E ~ R I NSWIVELS
G (Prior '85 MY)
bearing grease
SAE 90
N L G l No.2
API GL5
a
BRAKE & CLUTCH HYDRAULICS - DOT 3 or DOT 4
APR 1987
SECTION O C Page 3
PRE-DELIVERY INSPECTION - ALL MODELS

VIN:
I MODEL I ENGINE NO.
OPERATIONS - Tick box if O.K. OPERATOR

- X box i f additional work reqd , - submit defect report INITIALS
L
MECHANICAL
I I I I
Check coolant leve1 and check system for leaks.
I
Renew engine o i l and filter (Federal only)
Check engine, gearbox and rear axle o i l levels and check for leaks.
I I I
Check security of engine o i l filter.
I Check brake/clutch fluid reservoir level
--
. I I I
I Check fuel svslern for leaks.
Completely f i l l fuel tanks and check for leaks.
Check clutch cdjvstmcnt.
Check tightness of wheel nuts/bol ts.
Check tyre pressure including spare.
Check engine idling speed.
1 I
- -
Check power assisted steering fluid level and system for leaks (when fitted).
I Check automatic transmission fluid level (when fitted). I I I
ELECTRICAL
Check security of battery terminals.
Check operation of a l l lamps.
Check operation of horns and direction indicators.
0 Check operation and park position of screen wipers.
Check operation of windscreen washers.
Check opera tion of a l l instruments.
1 I
Check operation of headlamps and door windows. 1
Check operation of heater and fan.
Check headlamp alignment ,
Check operation of a i r conditioning equipment (when fitted).
BODY
-
Check opera tion of doors and locks.

Check bonnet and tailgate release mechanbm.
- --
Check interior trim for damage and cleanliness.

Check operation of seat belts.
Check a l l bright work and paint for condition,
I
Check presence of tool k i t and literature pack,

d
Page 4 SECTION O C
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 i s subject to the following conditions:
(a) It i s the responsibil ity of the supplying Distributor/importer/dealer to

ensure that the car i s delivered to the customer i n the b;?st possible
condition.
(b) A1 1 costs incurred during the inspection are the responsibi l i t y of the
svppl ying distributor/importer/deal-er .
(c) Failure to return a signed copy of this inspection to Lotus Cars Limited
by the distributor/importer/dealer, may result i n warranty claims on
the particular car being rejected.
DATE: DEALERS STAMP A N D SIGNATURE:
APR 1987
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 Page 7
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 u p coolant.
lnspect cooling system hoses and connections.
Check valve clearances, adiust if necessary
Renew spark plugs.
Check operation of engine management Systems. x
Check toothed timing belt condition and tension, adjust if necessary. x
Renew toothed timing belt.
Check all "V" belt condition and tension, adjust if necessary. x
Renew air cleaner elements.
Renew fuel filter. (x* NOT HCI models)
Inspect fuel system cap, tank, lines and connections. x
Toraue exhaust svstem mountinn bolts. x
Renew exhaust catalyst.

LUBRICATION
Renew engine oil and filter.
Renew transmission oil.
Check and if necessary top u p transmission oil
Lubricate lower steering swivels. (ifapplicable) x
Lubricate locks. hinaes and catches.
Lubricate speedo a i g l e drive.
Repack front hubs.
B R A K I N G SYSTEM
Check brake fluid level.
Check entire system for leaks and damage to pipes.
Renew hvdraulic
, - fluid and seals.
Check brake paddlinings for wear.
Check o ~ e r a t i o nof brake fail warning lamp. x
Check torque of caliper mounting b o k ' x
Check handbrake adjustment. x
CLUTCH
Check and adjust if necessary. x
Check clutch fluid level. x
STEERING A N D SUSPENSION
Check security of all steering connections and mountings. x
Check anti roll bar connections and rubber mountings. x
Check torque of front and rear suspension and damper bolts. x
Check all moving parts for wear and bellows for oil leaks.
Check front wheel bearing adjustment.
Check torque loading of drive shaft bolts.
Check dampers for leaks and deterioration.
Check front and rear wheel alignment.
heck security of battery and earth connections and (if applicable)

heck operation of all lights. electrolyte level.
Check headlamp alignment.
Check operation of all electrical equipment and instruments.
APR 1987 Continued overleaf. ..

SECTION OC
MAINTENANCE SCHEDULE EXCEPT CALIFORNIA
-Continued
a
DESCRIPTION OF OPERATION
WHEELS A N D 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 seat adjustments.
Check air conditioning operation.
Top up screen washer reservoirs.
GENERAL
Inspect condition of all major unit mounting rubbers.
Check torque loading of major unit mounting bolts.
APR 1987
SECTION OC Page 9
MAINTENANCE SCHEDULE CALIFORNIA

0 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, emissionsperformance and
dependability of your vehicle. Take any problems to your dealer for service advice. Whenever repairs are
necessary, have them completed at once.
Required Engine Maintenance 0
These operations are the minimum required intervals necessary for compliance
w i t h California emissions regulations.
DESCRIPTION O F OPERATION
- --- - -
ENGINE
Check and i f necessary top u p coolant. x
Inspect cooling system hoses and connections. 0
Check valve clearances, adjust if necessary
Renew spark plugs.
Check operation of engine management Systems. 0
Check toothed timing belt condition and tension, adjust if necessary.
Renew toothed timing belt.
Check all "V" belt condition and tension, adjust if necessary. x
Renew air cleaner elements.
Renew fuel filter. (x* NOT HCI models)
lnspect fuel system cap, tank, lines and connections.
Torque exhaust system mounting bolts.
LUBRICATION
Renew engine oil and filter. 0
Renew transmission oil. x
Check and if necessary top up transmission oil.
Lubricate lower fleering swivels. (if applicable) x
Lubricate locks, hinges and catches.
Lubricate speedo angle drive.
Repack front h ~ l b s .
B R A K I N G SYSTEM
C h x k brake fluid level.
Check entire system for leaks and damage to pipes.
Renew hvdraulic
, -
fluid and seals.
Check brake p a d d l i n i n g s for wear.
Check o ~ e r a t i o nof brake fail warning l a m ~ .
' x
Check torque of caliper mounting b o k .
Check handbrake adjustment.
CLUTCH
Check and adjust if necessary.
Check clutch fluid level.
STEERING AND SUSPENSION
Check security of all steering connections and mountings. x
tc Check anti roll bar connections and rubber mountings. x
Check torque of front and rear suspension and damper bolts. x
Check all moving pans for wear and bellows for oil leaks.
heck front wheel bearing adjustment. x
er :heck torque loading of drive shaft bolts.
X
Check dampers for leaks and deterioration.
Check front and rear wheel alignment. x
Page 7 0 SECTION OC
MAINTENANCE SCHEDULE CALIFOR NlA -Continued

w w w
2 2
f f 5
0 0 0
0 0 0
99u!
U J F b
( Y m m
Q ) Q ) Q )
;. ;.
v , W $
.$
DESCRIPTION OF OPERATION am
ELECTRICAL
Check security of battery and earth connections and (if applicable) x x X X
Check operation of all lights. electrolyte level. x x x x X X X
Check headlamp alignment. x x X X
Check operation of all electrical equipment and instruments. x x x x X X X
WHEELS AND TYRES

Check tyre cond~tionand pressures, including spare x x x x X X X
Check torque of all wheel nuts. x x x x X X X
Check road wheel balance. x X X
BODY
Check all hinge and lock operations. x x X X
Check seat belts and seat adjustments. x x x x X X X
Check air conditioning operation x x X X
Top u p screen washer resetvoirs. x x x x X X X
GENERAL
Inspect condition of all major unit mounting rubbers. x X X
Check torque loading of major unit mounting bolts. x X X
APR 1987
SECTION PB Page 7
HEATEWAIR C O N D I T I O N I N G
SECTION PB - ESPRIT S3 & TURBO
'Operation
Air Conditioning Operating Principles

Aitflow Distribution
Refrigerant Ha ndl ing
Refigerant Pipework Precautions
Charging Unit with Refrigerant

Refrigerant Quick Check Procedure
Recommended Refrigera nt Oil
Refrigerant Oil Level Checking Procedure

Compressor PB9
Removal of Heater/Air Conditioning Assembly PBl 0
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 i s cooled i n the condenser changing into a liquid, from here i t flows into the
receiver-drier, where any foreign matter i s expelled.
A sight glass following the receiver-drier provides a means of checking the system is f u l l
of refrigemnt and operating correctly. High pressure liquid enters the expansion valve
where it expands rapidly changing from high to low pressure liquid. As the refrigemnt
expands i n the evaporator i t begins to boil, absorbing heat from the core and cooling the
air passing through to the passenger compartment. The compressor draws off the low
pressure vapourised refrigerant completing the closed circuit and recyclirtg the refrigerant
passenger compartment
Conderser
The condenser i s located i n front of engine radiator. Air passes over the condenser
cooling fins, cooling the 'hot' high pressure refrigemnt vapour and condensing it into @
SECTION PB Page 3
a high pressure liquid. The corstruction of the condenser i s similar to the engine radiator
but is designed to withstand higher pressures .
Receiver-Drier
Located i n the front compartment on the right hand side iis purpose is to ensure a supply
of liquid refrigemnt to the expansion valve i n an operational condition. A drier is
incorporated i n the base of Receiver-drier whichahsorbs any moisture that entered the
system during assembly. Any foreign matter i n the refrigerant w i l l also be trapped i n the
drier.
Some models are fitted with a low pressure cut out switch at the receiver-drier to prevent
damage to the compressor due to lack of lubrication from running with a discharged system.
Exmnsion Valve
The expansion valve i s located a t the side of the evaporator and thermostatically meters
the flow of high pressure liquid refrigerant into the evaporator. The refrigerant supply i s
controlled by a capillary tube strapped to the outlet pipe of the evaporator, as the
temperature changes at the outlet pipe so the refrigerant flow through the valve changes.
When liquid to the core of the evaporator exceeds requirement the outlet temperature
drops, this i s sersed via the capillary tube, closing down the expansion valve and reducing
the flow of liquid refrigerant. The expansion valve i s pre-set internally and has no
external adjustment .
Temmrature Control Switch
Turning the control clockwise to the required temperature position w i l l engage the
compressor clutch and drive the compressor. On some models when the compressor is
running a red light (a light emitfing diode above the temperature control switch) is
illuminated.
The output from t he temperature sensor i n the evapomtor is compared by a n electronic

comparator with the setting made on the temperature control switch . When the temperature
sersed i s greater than the setting, the compressoi i s engaged via the clutch a d the red
light is illuminated. The clutch w i l l disengage when the temperature is reached and the
red light w i l l extinguish.
Page 4 SECTION PB
The electronic comparator i s fifted to the rear of the temperature confrol.switch;
PB2 - AIRFLOW DlSTRlBUTlON

The heater/air conditioning unit i s 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 behind a cover i n the front luggage compartment on the
bulkhead. Fresh air is drawn into this cover from a chamber at the base of the
windscreen via a fresh air flap, and i s then blown into the heater/air conditioning
unit for heating/refrigeration and distribution to the various outlet vents. The
heater/air conditioning unit itself contains two flaps, a mode flap, controlling
airflow through the heater matrix, and a screen flap controlling airflow to the
windscreen vents. The fresh air flap and mode flap are opemted by vacuum
actuators supplied with vacuum on Domestic and ROW cars by the inlet manifold
via a non-return valve and reservoir mounted on the left hand fuel tank board,
whilst Federal Esprit Turbo's are supplied with vacuum from an engine driven pump.
The vacuum supply i s controlled by two valves mounted on a control plate and
operated by a cam connected by cable to the distribution control knob. The screen
flap i s mechanically opemted via the distribution control cable, and a bellcrank
lever and link.
Front Bonnet Fresh air Windscreen

intake '1
Footwell Vents
To Screen Vents
Hole (deleted mid '86)

Can Only)
SECTION PB Page 5
I
OFF
I
In the 'OFF' position, the fresh air vent i s closed and the re-circulation vent open.
A l l 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 fan from the interior of the car through the re-circulation vent, and is blown
through the evaporcitor to the centre and outer face level vents. Also through the
footwell bleed holes (deleted mid '86).
- -- -
SERIES 3 HEATER ONLY

TURBO
OFF VENT HEATER DEF
INTERIOR T
n
aCOLD HOT/DEF
SERIES 3 WITH A / C
OFF/AC DEF
n n
COLD HOT/DEF
fresh air/\recirc. flap valve

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.
A l l 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 'normal ' refrigeration setting, supplying
refrigerated fresh air to the centre and outer face-level vents either by 'ram' effect or
fan assisted . --

TURBO
OFF VENT HEATER DEF
0 0
INTERIOR
n n
COLD HOT/DEF
SERIES 3 WITH A / C
-
DEF
0
U U
1
COLD HOT/DEF
SECTION PB Page 7
The control cam operates the mode flap valve and s t a r t s 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 i n the red sector, heated fresh air is supplied by ram
effect or fan assisted, to both screen and footwell vents. Ambient air i s s t i l l
available from the outer face level vents.
The air conditioning may be used with this setting to produce de-humidified air. Close
off the outer face level vents for optimum performance .
.
TURBO
OFF VENT HEATER DEF
Dn
r l
COLD HOT/DEF
SERIES 3 WITH A/C
-
OFF/AC DEF
COLD HOT/DEF
Page 8 SECTION PB
DEFROST
The screen flap i s m v e d f u l l travel to shut off the footwell vent, and direct a l l
a i r to the windscreen vents.
This i s the defrost position. With the temperature control i n the red sector, heated
air i s suppl ied solely to the screen. (keep outer face level vents clcsed) .

TURBO
OFF VENT HEATER DEF
Er1
0
I
HOT/DEF
COLD
SERIES 3 WITH A/C
OFF/AC DEF
v0
L7
a
COLD HOT/DEF
SECTION PB Page 9
PB.3 - REFRIGERANT HANDLING

The refrigerant used i n the air conditioning system i s '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 i n the passenger compartment of a car.
3, Do NOT expose refrigerant drums to high temperature.

4. Do NOT weld or use a steam cleaner i n close proximity of the air
conditioning unit.
5. Do NOT discharge refrigerant vapour into an enclosed area where there
is a naked flame. Heavy concentrations of refrigerant when exposed to a
naked flame produces a toxic gas, which w i l l also attack metal.
6. Do NOT expose the eyes to vapourised or liquid refrigerant - ALWAYS
wear safety goggles when handling refrigerant.
PR .4 - REFRIGERANT PI PEWORK PRECAUTIONS
The following precautions should be read carefully before carrying out any work on the
refrigerant pipework.
1 . When disconnecting any pipe or flexible connection, the system MUST

FIRST BE DISCHARGED OF ALL PRESSURE.
Open either connection of receiver-drier SLOWLY, cover union with a
cloth, so that no injury w i l l occur i f liquid is present i n the pipe. If
pressure i s noticed, ALLOW TO BLEED SLOWLY - slacken the union nuts a
'flat' at a time; allow pressure to bleed, slacken the nut a further 'flat',
allow pressure to bleed, and so on until a l l pressure has been expelled
(approximately 2 to 3 minutes).
ALWAYS WEAR SAFEW GOGGLES WHEN OPENING REFRIGERANT
CONNECTIONS.
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, A N D
AT ROOM TEMPERATURE, to prevent condensation of any moisture which
may enter when the sealing is removed.
The receiver-drier should be the LAST component to be connected, this i s to
ENSURE optimum dehydration and maximum moisture protection of the
system.
Precautions MUST be taken to prevent damage to fittings and connections;
minute damage could cause a leak due to the high pressures used i n the
system. ALWAYS USE TWO SPANNERS OF THE CORRECT SIZE (one on
each union nut), when releasing or tightening pipes, or connections. This
is purticurlarly important with the pipes on the condenser as this unit i s con-
structed from aluminium.
A l l joints should be coated with refrigeration o i l BEFORE making any
connections, as this w i l l aid seating.
A l l pipes and haes MUST BE FREE from any kinking. The efficiency of the
system can be impaired by a single kink, or restriction, Flexible hoses
should not be bent to a radius which i s less than ten times the diameter of
the hose.
PB.5 - CHARGING UNIT WITH REFRIGERANT

The procedure for charging the air conditon system is supplied by the manufacturer of the
charging trolley used; follow this procedure carefully.
Before charging the system i t i s first necessary to evacuate the system for the following
reasons:
1 A l l air is removed from the system to ensure i t can be fully charged.
2. A l l moisture i s removed, which could b e harmful to the system.
3. It provides a means of checking for leaks, which m y occur i n a faulty

amnection.
Evacuate the system to a vacuum to 28 inches of mercury (28in Hg) for NOT LESS THAN
20 minutes. The hold period of 20 minutes w i l l allow any leaks to be seen easily and
purge the system of any moisture .

. - - - - .. - - -
SECTION PB Page 7 1
The system i s charged with 1.4kg (3 Ibs) of 'Refrigerant 12', which is made up from
'Freon 12' and 'Arcton 12'. After charging the system i t must be checked for gassing,
using the following procedure:
1 . Start the engine and ad just engine speed to 1200 r.p.m.

2. Turn the air conditioning switch fully clockwise, and the fan speed switch
to fast. Check that the engine cooling fans have automatically switched on.
3. View the refrigerant through the sight glass on the top of the receiver-drier,
after 5 minutes running there should be no bubbles visible (gassing); an
occasional bubble is however acceptable. If the ambient temperature i s
0
below 4 C, continuous gassing may occur, i t is therefore advised to carry
out the checks i n a covered garage.
4. .
Increase the engine speed to 2000 r .p .m and check that the refrigerant
passing the sight glass i s clear of bubbles. If a continuous stream of
bubbles s t i l l persists then, the refrigerant charge should be increased until
the bubbles are no longer present.
5. Before disconnecting the service valves from the compressor, check the
system for leaks using a leak detector capable of detecting a leak of 1 Ib
i n 32 years. This leak standard appl ies to a l l connections except the
following:
1 . Compressor front seal

2. Uncapped Schraeder valves
3. Sight glass
The leak stadard for the above i s 1 Ib ih 10 years. It w i l l therefore be necessary t o
have a leak detector capable o f covering both standards. I t is recommended that the
leak test be +rFormed i n a halogen-free atmosphere with m significant draughts of a i l .
..
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 i n the system, or by eliminating
this possibility from the overall diagnosis.
Start engine and 'run' a t 1200 r.p.m. -maximum cold, with fan at fast speed
Set controls for
Symptom Cause Remedy
Continous bubbles System low on Check with leak detector.

present i n sight glass charge. Correct leak, i f any, and f i l l
system to correct charge.
No bubbles. Sight System i s either Feel high and low pressure pipes
glass clear. fully charged or of compressor. High pressure
empty. pipe should be warm, low
pressure pipe should be cold.
N o appreciable System empty, or Switch 'off' engine. Re-charge

temperature nearly empty. system with refrigerant, and
differential noted check with leak detector.
Temperature Even though a Check by disconnecting the

differential noted differential i s compressor clutch connection
at compressor. noted, there exiis (at upper front) while observing
a possibility of the sight glass.
overcharge. A n
overcharge fil led
system w i l l result
i n poor cool ing .
Refrigerant i n sight System over- Verify with performance checks.
glass remains clear for charged.
more than 45 secs.,
before foaming and
settling away from
,glass.
Refrigerant foams and System correctly Continue checking out system
settles away from sight using checks as previously given.
glass in less than
45 secs.
SECTION PB Page 73
PB .7 - RECOMMENDED REFRIGERANT 01L
The refrigerant o i l recommended for use i n 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 i n any order of preference and a l l are
equally suitable.
(b) Keep the o i l container tightly capped at a l l times.

Add additional o i l i n the following amounts for any of the system components listed which
are being replaced:
Receiver-Driver 1 fluid oz.

Condenser 1 fluid oz.
Evaporator (air
conditioning unit) 3 fluid ozs.
PB .8 - REFRIGERANT OIL LEVEL CHECKING PROCEDURE
To check the refrigerant o i l level during servicing of the Compressor or the system, proceed
i n the following manner:
1 . Run the compressor a t the engine idle speed for 10 minutes.
2. Recover a l l the refrigerant 12 from the compressor, being careful not to lose any o i l .
3. Place the angle gauge (Sankyo Part No. 32448) across the top of the top two mounting
lugs. Centre the bubble i n the level indicator and read off the mounting angle of the
compressor to the nearest degree.
4. Remove the o i l filler plug and looking through the plug hole, centre the internal
parts as they move towards the rear of the compressor (discharge stroke). This w i l l
allow the dipstick to be inserted to i t s full length.
a
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 o i l f i l l e r hole, and insert the dipstick until it reaches the
'stop'
Remove the dipstick and count the number of increments covered with oil.
Compare the measurement taken i n 3 (compressor angle) and the oil level
increment with those shown i n following table.
Mounting Angle in Acceptable o i l level

Degrees I i n Increments
8. If the increments indicated on the dipstick do not f a l l between the figures given
i n the above table, add or subtract o i l until the mid-range figure i s achieved.
9. Refit o i l filler plug and tighten to 6 to 9 f t . lbs. (0.8 to 1 .2 kg-m). Ensure the
O-ring i s not twisted and that the O-ring seating is clean before fitting, Do not
overtighten if plug leaks, fit a new O-ring. Re-charge the system with
refrigerant as previously described.

Page 15
PB .9 - COMPRESSOR
The compressor i s factory charged with 6 -+ + 15cc) of refrigerant o i l
0.5 fluid ounces (175 -
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 to the receiver-drier. Take the necessary precautions described under the
heading 'Refrigerant Pipework'.
2. Remove the pipe connections to the compressor, taking the necessary precautions
described under the heading ' ~ e f r i ~ e r c l n
Pipework'.
t
3. Loosen and remove the compressor drive belt and disconnect the electrical
connections to the compressor clutch.
4. Remove the two nuts and bolts securing t h e compressor to the mounting bracket.
Drain the o i l from the compressor and measure the amount drained. Make a note
of the amount of o i l dmined as this information is required when replacing the
compressor.
To Replace
1 . Reverse the removal procedure. Refill the compressor with the same amount of
new o i l as that drained during removal, plus an additional one fluid ounce.
Before assembling the p i p w o r k lubricate the flared ends and union threads with
refrigerant o i l .
2, Recharge the system as previously described.
3. The compressor drive belt should be correctly tersioned to give a total movement
of 9 mm (0.35 its) on the longest run of belt.
Fitting a New Compressor
The following procedure is to be wed when replacing a compressor containing
uncontaminated o i l with a new compressor, when there i s no evidence o f o i l

having escaped from the system.
1 . Drain the o i l from the new compressor.
2. Drain and measure the o i l from the o l d compressor.

Page 76
3. Refill the new compressor with an amount of new o i l equal to that drained from
the old compressor, plus an additional one fluid ounce (30 cc) of new o i l .
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 o i l to the 6 fluid oz. (175 cc)
of o i l suppl ied i n the new compressor.
I
NOTE: Satisfactory operation of the compressor depends on there being sufficient
o i l i n the system. However too much oil decreases the cooling efficiency
of the installation.
PB .I 0 - REMOVAL OF HEATEWAIR CONDITIONING ASSEMBLY

To Remove:
1 . Disconnect battery. Drain cooling system. Depressurise refrigerant system.

2. From imide front luggage compartment:
Remove bulkhead ABS cover. Disconnect both fan motors, release the two
screws and remove the motor scroll casing from the unit.
3. Remove the re-circulation vent flap, and through the aperture exposed,
disconnect the inlet water hose from the water valve. Disconnect the
control cable to the valve, and release the valve from the pedal box.
4. Release the dividing panel fixings: Two pop rivets along inner edge of
aperture; flap bracket lower fixing; two additional screws.
5. From inside vehicle:

Remove the binnacle, fascia and tunnel trim assemblies together with the
radio, i f fitted.
6. Remove passenger side demist vent. Remove the front bonnet release bar.
Release the return water hose from the heater matrix.
7. Remove the centre face level vent nozzle from the unit, and through the
aperture exposed, release the two screws securing the unit to the tunnel top
bracket.
SECTION PB Page 7 7
Remove the two screws i n 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 two refrigerant pipes to the evaporator, taking precautions
detailed i n REFRIGERANT PIPEWORK.
Release the vacuum supply pipe and fresh air flap actuator vacuum pipe.
Release drain pipe from beneath unit.

Carefully withdraw unit towards passenger side of vehicle, taking care not to
damage the water valve capillary tube.
To Replace:
Reverse the removal procedure, positioning the unit such that the dimension from
the inboard edge of the large hole i n the bulkhead (passengers side) to the end of
.
the unit (where fan motor scroll fits) is approx 150 mm . Also ersure that there
i s celamnce between the vacuum control valve assembly and the bonnet release bar.
If a new evaporator i s fitted, see section P8.7. for additional o i l quantity.

SECTION QB Page 7
CLUTCH
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 Page 3
Key to Clutch S y s t e m Drawing
1. Cover/Pressure P l a t e Assembly. Adjuster S c r e w , R e l e a s e Fork.

2. C e n t r e Plate. L o c k n u t , Adjuster.
3. R e l e a s e BearingICarrier Assembly. Lug, R e t u r n spring.
( C a s t Type) R e t u r n Spring, R e l e a s e Fork.
4. Spring, Fork t o Carrier. M a s t e r Cylinder.
5. R e l e a s e BearingICarrier Assembly Slave Cylinder, S3.
(Fabricated Type) Slave Cylinder, T u r b o -
6. Spring, Fork t o Carrier. Bleed Nipple.
7. R e l e a s e Fork. Push rod, S3.
8. Pivot, Release F o r k , S3 Push rod, Turbo.
9 . S c r e w , Pivot Ball. Flexible Hydraulic Pipe .
10. Pivot, R e l e a s e F o r k , Turbo. Banjo.
11. s p l i t . p i n , Fork t o Pivot. Banjo Bolt.
12. G r o m m e t , R e l e a s e Fork. Washer, Large.
Washer, Small.
GENERAL DESCRIPTION
The c l u t c h assembly c o m p r i s e s a diaphragm s p r i n g p r e s s u r e p l a t e w i t h a s i n g l e

driven, dry friction plate. The f r i c t i o n p l a t e i s f r e e t o s l i d e a l o n g t h e s p l i n e s
o f t h e c l u t c h s h a f t whose r e a r end i s s p l i n e d i n t o t h e g e a r b o x p r i m a r y s h a f t
a n d w h o s e f r o n t e n d i s s u p p o r t e d by a n e e d l e r o l l e r b e a r i n g i n t h e r e a r o f t h e
crankshaft.
The c l u t c h r e l e a s e i s o p e r a t e d h y d r a u l i c a l l y v i a a m a s t e r c y l i n d e r a t t h e
p e d a l b o x and a s l a v e c y l i n d e r on t h e c l u t c h b e l l h o u s i n g . On S e r i e s 3 m o d e l s
u n t i l l a t e ' 8 4 , t h e s l a v e c y l i n d e r i s mounted o n t o p o f t h e c l u t c h h o u s i n g
t o g e t h e r w i t h a r e l e a s e f o r k ' p u l l o f f ' s p r i n g . S e r i e s 3 c a r s from l a t e ' 8 4
a n d a l l T u r b o m o d e l s u s e a s e l f a d j u s t i n g s l a v e c y l i n d e r mounted o n t h e r i g h t
hand s i d e o f t h e c l u t c h h o u s i n g .
QB 1 - ADJUSTMENT
Pedal
With t h e c l u t c h p e d a l f u l l y d e p r e s s e d and t h e m a s t e r c y l i n d e r b o t t o m i n g
o u t , check t h e c l e a r a n c e between t h e lower e d g e o f t h e c l u t c h p e d a l pad
( m e t a l ) and t h e GRP body. If necessary, adjust t h e clutch master cylinder
pushrod l e n g t h t o a c h i e v e a c l e a r a n c e of 2 -
5 mm, i . e . t h e pedal s h o u l d
j u s t touch t h e carpet.
2. With t h e c l u t c h p e d a l r e l e a s e d , a d j u s t t h e p e d a l u p s t o p ( i f f i t t e d ) , o r
d i s c a r d i f n e c e s s a r y t o a c h i e v e 2 - 5 mm upward f r e e p l a y o f t h e p e d a l , i.e.
t h e master c y l i n d e r is 'topping o u t t .
I f t h e m a s t e r c y l i n d e r p i s t o n i s r e s t r i c t e d from r e a c h i n g i t s f u l l t r a v e l
i n e i t h e r d i r e c t i o n c l u t c h drag and/or s l i p w i l l r e s u l t .
I f n e c e s s a r y , a d j u s t t h e brake pedal pushrod l e n g t h t o o b t a i n c o m p a t i b l e

pedal heights .
Thus set up t h e c l u t c h p e d a l s h o u l d r e q u i r e a d j u s t m e n t o n l y a f t e r
r e p l a c e m e n t o f a p e d a l box component.
Page 4 SECTION QB
-
Master C y l i n d e r
Pushcod Ad justrnent Pedal Upstop
Adjustment
Minimal C l e -- - . -
2 - 5mm Free Play
RELEASE FORK
The s i d e mounted c l u t c h s l a v e c y l i n d e r ( s e r i e s 3 a f t e r l a t e '84 and a l l Turbos)

i s s e l f a d j u s t i n g , with f l u i d being returned t o ihe master c y l i n d e r a s the f r i c t i o n
p l a t e wears i n s e r v i c e and the s l a v e c y l i n d e r p i s t o n i s pushed p r o g r e s s i v e l y
f u r t h e r back on i t s r e t u r n s t r o k e . The "adjuster" i n the r e l e a s e f o r k end should
b e s e t such t h a t 22m of a d j u s t e r p r o j e c t s beyond t h e locknut a s shown i n the diagram.
NmE A previous s p e c i f i c a t i o n c a l l e d f o r t h e "adjuster" t o b e screwed i n f u l l y .

However, t h e 2 2 m s e t t i n g allows a g r e a t e r degree of c l u t c h f r i c t i o n p l a t e wear
a
t o t a k e p l a c e b e f o r e the s l a v e c y l i n d e r p i s t o n ' tops o u t ' on i t s r e t u r n s t r o k e
causing c l u t c h s l i p and i n d i c a t i n g that c l u t c h replacement is necessary.
CAUTION: An a d j u s t e r s e t t i n g of less than 2 2 m may cause damage t o p r e s s u r e p l a t e

and flywheel , and/or incomplete disengagement .
Page 5
SEC
Series 3 c a r s up t o l a t e '84 with the top mounted slave cylinder, require checking
f o r r e l e a s e fork clearance a t service i n t e r v a l s i n the following manner:
i) A t t h e s l a v e c y l i n d e r e n d , unhook t h e r e l e a s e
f o r k s p r i n g , and measure t h e f r e e p l a y a t t h e end o f
the release fork.
ii) I f n e c e s s a r y , s l a c k e n t h e locknut and a d j u s t
t o o b t a i n 3 mm movement. Early Series 3 cars
were n o t f i t t e d w i t h a l o c k n u t , b u t t h e i r use
i s recommended t o improve adjustment r e t e n t i o n .
iii) A f t e r a d j u s t m e n t , t i g h t e n l o c k n u t and r e f i t s p r i n g .
A s t h e c e n t r e p l a t e wears i n s e r v i c e t h e c l e a r a n c e
w i l l reduce.
QB 2 - HYDRAULIC UNITS
S e r v i c e k i t s a r e a v a i l a b l e f o r b o t h t h e m a s t e r and s l a v e
oylinders.
Before commencing work on t h e h y d r a u l i c system, t a k e

p r e c a u t i o n s a s n e c e s s a r y t o p r o t e c t paintwork from b r a k e
fluid spillage.
NOTE: For c l e a n i n g purposes useONLY commercial a l c h o h o l ,

methylated s p i r i t o r brake f l u i d . On no account
should m i n e r a l based f l u i d s s u c h a s p e t r o l o r
p a r a f f i n be u s e d .
On reassembly, c o a t t h e p i s t o n s e a l s w i t h r u b b e r g r e a s e b e f o r e
i n s e r t i n g i n t o t h e c y l i n d e r , r e f i t t h e c y l i n d e r and b l e e d t h e
h y d r a u l i c system of a i r .
Page 6
QB 3 - CLUTCH ASSEMBLY
The gearbox o r engine/gearbox assembly must f i r s t be removed

from t h e v e h i c l e b e f o r e a c c e s s t o t h e c l u t c h c e n t r e p l a t e o r
s p r i n g / p r e s s u r e p l a t e may be o b t a i n e d . I f t h e gearbox assembly
i s t o be removed from a Turbo model, i t may be found e a s i e r i f
t h e t u r b o c h a r g e r i s f i r s t removed.
B e f o r e re-assembly, e n s u r e t h a t t h e s p i g o t b e a r i n g and
N y l a t r o n t h r u s t washers a r e c o r r e c t l y f i t t e d ( s e e QB 5 ) ,
and t h a t a s m a l l q u a n t i t y of molybdenum d i s u l p h i d e l i t h i u m
b a s e g r e a s e (NLG1 No. 2) i s a p p l i e d t o t h e c l u t c h s p l i n e s .
Torque t h e c l u t c h assembly t o flywheel b o l t s t o 2.3 - 2.6

kg f.m (17 - 19 lbf f t ) .
Note t h a t i f t h e c l u t c h housing i s t o be r e p l a c e d , t h e
gearbox c a s i n g must be r e t u r n e d t o t h e f a c t o r y f o r mating
and machining.
A revised c l u t c h cover (pressure p l a t e assembly) has been f i t t e d t o a l l E s p r i t
Turbo models from engine number 22728.
This new cover has a diaphragm spring with curved fingers, instead of s t r a i g h t as
used previously. This n e c e s s i t a t e s a corresponding change to the r e l e a s e bearing
assembly from a curved t h r u s t face to a f l a t face.
I t i s nos t important t h a t 'old' and 'new' specification components a r e not mixed

on the same vehicle although l a t e r type covers and r e l e a s e bearings may be used
a s a p a i r on any c a r .
QB.4 - RELEASE BEARING
S e v e r a l d i f f e r e n t t y p e s of r e l e a s e b e a r i n g have been u s e d , and g r e a t c a r e

must be t a k e n t o e n s u r e t h e c o r r e c t f i t m e n t .
Summary - S e r i e s 3: P r i o r t o t h e i n t r o d u c t i o n of t h e C35 t y p e gearbox ( l a t e 1983)

S e r i e s 3 c a r s w e r e f i t t e d w i t h a c a s t i r o n r e l e a s e b e a r i n g c a r r i e r , whereas C35
equipped c a r s u s e a f a b r i c a t e d c a r r i e r . Both t y p e s use a f l a t f a c e a d a p t o r p r o f i l e .
Turbo: A l l Turbo models u s e t h e f a b r i c a t e d t y p e r e l e a s e b e a r i n g c a r r i e r ,

b u t w i t h two t y p e s of a d a p t o r p r o f i l e . P r i o r t o Eng. No. 22728, a curved p r o f i l e
w a s used ( f o r s t r a i g h t diaphragm f i n g e r s ) w h i l s t l a t e r c a r s u s e a f l a t p r o f i l e
( f o r curved f i n g e r s ) . E a r l i e r c a r s may however be f i t t e d w i t h t h e l a t e r c l u t c h
c o v e r and r e l e a s e b e a r i n g a s a p a i r . See P a r t s L i s t f o r d e t a i l s .
On r e a s s e m b l y , l u b r i c a t e t h e o u t e r s u r f a c e of t h e r e l e a s e
. .
b e a r i n g ' c a r r i e r With molybdenum d i s u l p k i d e ' , l i t h i u m b a s e
g r e a s e ( N L G ~N o . 2 ) and a p p l y a l s o t o t h e c o n t a ~ tp o i n t s of
release arm a n d c a l ' r i e r , r e l e a s e arm p i v o t , r e l e a s e arm
a d j u s t e r t o pushrod, and s p a r i n g l y t o t h e f r o n t f a c e of t h e
: release bearing.
it t h e b e a r i n g c a r r i e r i n t o t h e guide t u b e and c l i p t o t h e
r e l e a s e arm.
SECTION QB Page 7
.
Turbo Prior t o Eng No. 22728
.
Turbo After Eng No. 22728
11
All Series 3
/I
F l a t Adaptor
Profile
S t r a i g h t Diaphragm
Spring Fingers
Release Bearing \\
and C a r r i e r
QB 5 - SPIGOT BEARING
The s p i g o t b e a r i n g (A907E 6319F) must b e f i t t e d i n t o t h e

c r a n k w i t h i t s i d e n t i f y i n g numbers f a c i n g outwards
( i - e . towards g e a r b o x ) , and p r e s s e d i n ONLY UNTIL FLUSH
w i t h t h e r e a r f a c e of t h e c r a n k . Ensure t h e bearing i s
l u b r i c a t e d w i t h e i t h e r Esso U n i r e x N 3 , o r S h e l l A l v a n i a
Spigot bearing MUST BE

FITTED flush with crank
\ Thrust washer
I t i s e s s e n t i a l t h a t t h e N y l a t r o n t h r u s t washer
(Ao79F 4029F) i s f i t t e d between c l u t c h s h a f t and spigot
b e a r i n g a s shown.
Page 8 SECTION Q B
QB 6 - CLUTCH SHAFT
The c l u t c h s h a f t i s s p l i n e d i n t o t h e g e a r b o x p r i m a r y s h a f t
and r e t a i n e d by a c i r c l i p and s p r i n g .
Old t y p e c l u t c h s h a f t A079F 6066F h a s b e e n r e p l a c e d by
m o d i f i e d s h a f t B085F 40685 which i n c o r p o r a t e s a h a r d e n e d
s t e e l s l e e v e (A089F 0 4 0 4 F ) , t o r u n i n s i d e t h e s p i g o t b e a r i n g .
T h i s s l e e v e i s f i t t e d t o t h e s h a f t u s i n g Permabond A148, and
i f t h e r e i s any doubt about t h e s e c u r i t y of t h e s l e e v e , i t
s h o u l d b e removed and r e f i t t e d a s f o l l o w s : -
i) . Roughen i n s i d e s u r f a c e o f s l e e v e w i t h 320 g r a d e
emery p a p e r . D e g r e a s e , c l e a n and d r y .
ii) Apply Permabond A148 (A089F 6060) t o s p i g o t s h a f t

and i n s i d e s u r f a c e of s l e e v e . F i t sleeve onto shaft
and r o t a t e two o r t h r e e t i m e s t o e n s u r e e v e n
d i s t r i b u t i o n of adhesive.
iii) Remove s l e e v e , r e - a p p l y a d h e s i v e and r e p e a t i i )
iv) To e n s u r e s l e e v e t o s h a f t c o n c e n t r i c i t y , t h e f i n a l
f i t t i n g s h o u l d be p e r f o r m e d w i t h t h e s p i g o t s h a f t
i n a v e r t i c a l p o s i t i o n and l e f t i n t h i s p o s i t i o n u n t i l
cured i . e . c a n n o t b e moved w i t h l i g h t f i n g e r p r e s s u r e
(approximately Q - 1 hour).
NOTE: E n s u r e t h a t a l l t r a c e s of a d h e s i v e a r e removed
from t h e c l u t c h s h a f t s p l i n e s b e f o r e r e - a s s e m b l y
of t h e c l u t c h .
NOTE: E a r l i e r m o d i f i e d s h a f t A085F 40685 u s e d a s h o r t e r

(15mm) s l e e v e A089F 0400F, which may b e r e p l a c e d
by t h e l o n g e r ( 1 8 . 5 ) s l e e v e A089F 0404F. '
SECTION VB Page I
INTERIOR TRIM
SECTION VB - ESPRIT 53 & TURBO
Ocerat i o n
Cent r e Consolc VB 1
Tunnel S i d e s
Instrument Binnacle
Fascia
Cant Rails
' A ' P o s t Covers
Windscreen Header R a i l
Rear Bulkhead T r i n
Door Trim Panel-

Page 2
SECTION VB
VB.l. - CENTRE CONSOLE
To remove:
1. P u l l o f f centre tunnel top armrest.

2. R e l e a s e t h r e e s c r e w s s e c u r i n g choke/window s w i t c h p a n e l and
lay aside.
3. Remove r a d i o , o r r a d i o b l a n k i n g p a n e l and r e l e a s e k n o b s f r o m
h e a t e r a / c c o n t r o l p a n e l . Remove g r a p h i c c o n t r o l p a n e l .
4. On c a r s p r i o r t o V I N 82/85 D2153, r e l e a s e t h e h e a t e r a / c c o n t r o l s
from t h e i r l i g h t b o x .
5. On c a r s a f t e r V I N 8 2 / 8 5 D2270, r e l e a s e t h e two wing n u t s , v i a
t h e r a d i o a p e r t u r e , s e c u r i n g t h e t o p of t h e c e n t r e c o n s o l e .
6. R e l e a s e t h e f i x i n g a t t h e r e a r o f t h e c o n s o l e and remove t h e g e a r
l e v e r k n o b . Withdraw t h e c o n s o l e , u n h o o k i n g t h e t o n g u e a t i t s
f r o n t e n d from t h e f a s c i a .
Choke/window
switch w n e l
VB.2. - TUNNEL S I D E S
A f t e r removing t h e c e n t r e c o n s o l e ( V B . 1 ) r e l e a s e t h e two s c r e w s e a c h
s i d e s e c u r i n g t h e t u n n e l s i d e t o t h e f a s c i a , and f o u r s c r e w s i n t o t h e
t u n n e l t o p . R e l e a s e t h e r e a r bulkhead t r i m f i x i n g s i f n e c e s s a r y t o
e n a b l e t h e r e a r end o f t h e t u n n e l s i d e t o b e w i t h d r a w n .
fascia
SECTION VB Page 3
VB.3. - INSTRUMENT BINNACLE

0
-
Domestic & R . O . W . c a r s . B e f o r e t h e b i n n a c l e may b e r e m o v e d , i t i s n e c e s s a r y
t o dismantle t h e instrument/switch panels i n order to disconnect t h e
w i r i n g h a r n e s s , s p e e d o c a b l e , o i l and b o o s t p i p e s , a n d s c r e e n v e n t
ducting.
P r i o r t o 1985, S e r i e s 3 c a r s used a b i n n a c l e layout s i m i l a r t o t h a t o f

S2 m o d e l s , w i t h s l i d e r t y p e h e a t e r c o n t r o l s i n t h e r i g h t h a n d s i d e , and
a f a c e l e v e l v e n t i n t h e l e f t . The c e n t r e i n s t r u m e n t p a n e l a n d s i d e s w i t c h
p a n e l s must b e r e l e a s e d a n d t h e wires m a r k e d and d i s c o n n e c t e d f r o m t h e
s w i t c h e s and g a u g e s . R e l e a s e t h e s p e e d o c a b l e , o i l p r e s s u r e gauge p i p e ,
h e a t e r c a b l e s and v e n t d u c t i n g .
D u r i n g 1 9 8 5 , t h e S e r i e s 3 f a s c i a a n d b i n n a c l e was c h a n g e d t o t h a t o f t h e
DOM/ROW T u r b o t y p e . On t h e s e c a r s , t h e r h e o s t a t k n o b s a r e p u l l e d o f f t o
r e v e a l t w o o f t h e f o u r i n s t r u m e n t mask s c r e w s . A f t e r r e m o v i n g t h e
i n s t r u m e n t mask and m o u n t i n g p a n e l t h e s w i t c h s i d e p a n e l s a n d masks a r e
r e l e a s e d by r e m o v i n g t h e screws o n t h e b i n n a c l e u n d e r s i d e .
Side
1 nstrument
The b i n n a c l e , c o m p l e t e w i t h m o u n t i n g b r a c k e t , i s removed by r e l e a s i n g
t h e f o u r b o l t s s e c u r i n g t h e m o u n t i n g b r a c k e t t o t h e s c u t t l e c r o s s beam,
a c c e s s i b l e from w i t h i n t h e b i n n a c l e .
Page 4
U.S.A ( F e d e r a l ) Models
On t h e s e c a r s i t i s n o t n e c e s s a r y t o d i s m a n t l e t h e i n s t r u m e n t p a n e l s
t o remove t h e b i n n a c l e . Release t h e f o u r b o l t s beneath t h e f a s c i a
s e c u r i n g t h e b i n n a c l e m o u n t i n g b r a c k e t t o t h e s c u t t l e c r o s s beam.
Raise t h e binnacle s u f f i c i e n t l y t o enable t h e wiring connector blocks
s p e e d o c a b l e , o i l p r e s s u r e and b o o s t gauge p i p e s and d e m i s t v e n t h o s e
t o b e d i s c o nn e c t e d .
L_L___>
I
Wiring connector
block plate I
VB.4 - FASCIA
To Remove:
1.
f Mounting bracket to
scuttle fixing bolt
Remove c e n t r e c o n s o l e ( V B . l ) , s t e e r i n g w h e e l , column s h r o u d s
column s w i t c h e s .
2. Remove i n s t r u m e n t b i n n a c l e ( U . S . A . ) o r dismantle instrument/
s w i t c h p l a t e s (DOM/ROW) t o d i s c o n n e c t h a r n e s s , p i p e s a n d
cables.
3. Release t h e t h r e e f i x i n g s s e c u r i n g t h e glovebox f l o o r t o t h e
f a s c i a and remove t h e ' A ' p c s t c o v e r s (VB. 6 )
4. Release t h e four M 6 nuts securing t h e f a s c i a t o t h e s c u t t l e
bqam, a n d t h e two screws s f z v r i n g t h e l o w e r e d g e o f t h e f a s c i a
t o the ' A ' post. Release t h e s i n g l e f i x i n g on t h e tunnel top.
5. Withdraw t h e f a s c i a w h i l s t d i s c o n n e c t i n g f a c e l e v e l v e n t
hoses, courtesy l i g h t switch leads, wiring harness c l i p s e t c .
L e a v e g l o v e b o x f i x e d t o s c u t t l e beam.
Fascia top to
scuttle
Fascia to
"A' post
SECTION VB Page 5
VB.5. - CANT RAILS
The c a n t r a i l s a r e s e c u r e d by a s i n g l e s c r e w a t t h e i r f r o n t e n d , by
two s c r e w s from o u t s i d e t h e d o o r a p e r t u r e a n d , o n s u n r o o f m o d e l s ,
by t h e t r i m m a t e r i a l wrapped i n t o t h e r o o f a p e r t u r e .
VB.6. - ' A f POST COVERS
Remove c a n t r a i l (VB.5) and p u l l o f f d o o r s e a l from a r o u n d f r o n t

o f d o o r a p e r t u r e . Peel o f f ' A ' p o s t t r i m from a p e r t u r e and p u l l t i f m
c o v e r o u t , sideways from i t s t h r e e push f i x i n g s .
VB.7. - WINDSCREEN HEADER RAIL
On c a r s w i t h a g l a s s , o r removeable r o o f p a n e l p u l l o f f t h e w e a t h e r s t r i p
from t h e f r o n t o f t h e a p e r t u r e and p e e l o f f t h e h e a d e r r a i l t r i m
material. Remove one c a n t r a i l CVB.5) and r e l e a s e t h e t o p o f t h a t s i d e s
' A ' p o s t c o v e r . R e l e a s e t h e f o u r s c r e w s s e c u r i n g t h e h e a d e r r a i l and
withdraw, w h i l s t disconnecting t h e clock l e a d s .
VB.8 - REAR BULKHEAD TRIM
P u l l o f f t h e w e a t h e r s t r i p from a r o u n d t h e r e a r o f b o t h d o o r
a p e r t u r e s , and o n g l a s s o r removeable r o o f c a r s , from t h e r e a r o f
t h e r o o f a p e r t u r e , and p e e l o f f t h e t r i m m a t e r i a l . R e l e a s e seat
b e l t f i x i n g from s i l l .
Page 6 SECTION VB
On U . S . A . c a r s , t h e t a i l g a t e r e l e a s e h a n d l e must b e r e l e a s e d from t h e
b u l k h e a d ( s e e BD.12). Remove t h e f o u r s c r e w s s e c u r i n g t h e t r i m p a n e l
t o t h e b u l k h e a d , and o n s u n r o o f m o d e l s , t h e s c r e w , a b o v e e a c h r o o f
c a t c h , c o n c e a l e d by t h e ABS t r i m . Withdraw t h e b u l k h e a d t r i m ,
u n c l i p p i n g t h e t o p e d g e on s o l i d r o o f cars from t h e f i x i n g d o w l i n g .
'Sun roof' c a n
Fixed roof c a n
U .S .A. type tailgate

release handle
VB. 9 - DOOR TRIM PANEL
The t r i m p a n e l i s s e c u r e d b y a s i n g l e s c r e w a t t h e f r o n t and
r e a r o f t h e p a n e l , a l i p a l o n g t h e t o p e d g e and t h e i n t e r i o r r e l e a s e
handle bezel. To remove t h e b e z e l , s l a c k e n t h e two s c r e w s s e c u r i n g t h e
h a n d l e t o t h e d o o r and s l i d e o u t t h e two h a l v e s o f t h e b e z e l .
Door
handle
bezel
I
Panel
screw
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 r p t e d 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 characters of the VIN are coded
in accordance with ED2 directives as follm:
1. Seperate serial nunber sequences are used for the following groups of
chassis nrarket (character 12);
D
AvEvG&S L= Dcmestic
2= 49 States ( W A )
2. Foa: &ange point identification in Service Notg , Parts Lists and Service 3= California
Bulletins, the follauing VlN charactets ONLY will be quoted; 4= Sweden/
Engine Type Australid
Danestic h Export - 5,6,12,14 to 17 907= 2 Litre Switzerland
Manufacturer 910= 2.2 Turbo Pht 5= Japan
Rxamle A typical change point d d Identifier 912= 2.2 N/A %Hethe1 6= 50 States ( W A )
be listed as follcars;
82 D 1100 ~~c Turbo ll00
- L /
82 mG/€J/S 0341(- Turbo 0341) S C C

Note that ttm Nmbers are needed to 1 2 3 4 7 8 9 1 0 l l 1 2
identify the single change point due
to the different serial nunber
- Vehicle Type
sequences outlined in note 1. 079= Esprit S2
If a dash is used in place a€ the 082= Turbo Esp
chassis m r k e t letter code 083= Elite S2
(e.g. 82 - 0341). this is the change 084= Eclat S2
point for all markets not otherwise listed. 085= Esprit S3 B= 49 States
0893 B r a d (WA) I+ Exprt (hot)
C= California LFP>
D= Danestic J= Japan
E= Eurcpe (cold)K=Canada b
F= 50 States Puerto Rim
(W A ) IF Saudi Arabia
S= Sveden
FUnction Contents Function Contents
r
-
-
10.00
10.01A
B
Bodv
- ~
C O Y v
R e ~ a l rSections. Front
34.00
34.0lA
WJmShTYRES
Wheels, Tyres, Spare Wheel Retention
10.02A . & i rsections; ear
~ o d j~ EK;
m
Timber ~ u l k h e a d , Speaker Bins Blcck, Main w i n g Rcusing, m t i n g s
10.05A S e a t Belt M m t i n g k a u , S c u t t l e m, Jacking srmp M Y ) Sunp
Plates, Seat Belt S i l l Plates Cylinder Head
10.07A Readlanp Pods, Pod P i v o t s Prior '87 K Y . C a m h a i t s , Cam H a i n g s
10.09A Front Bonnet & Release Mechanism '87 M.Y. On. Camshafts, Cam Hcusings
10.1lA T a i l g a t e & Release M h a n i s m P i s t o n s & Liners. Con. R d s
10. UA m i n e Carpartrent Q'ankshaft & Flywheel
10.19 Dwr S h e l l , Door Beam, Ringe P o s t Water Punp
10.17A Dwr Handles, Iack -ism, S t r i k e r Post Aux. Rsg. O i l Pimp, F i l t e r , Turbo Lubrication
10.23A. LWnp=rs, S i l l s , Valence, S p o i l e r (Dry Swq Only) Scavenge Manif o l d , O i l Purrp,
-
11.00
11.01A
c.;IAzm,DOCR i m m m s m P S , WINcW IXFT
Glass, F i n i s h e r s , Door Weatherstrips
O i l Tank
D i s t r i b u t o r , I g n i t i o n S y s t w , C o i l Box
ll.02A m r Window F-, L i f t t4azhanism Altermtor, S t a r t e r Wor
11.05A 'Glass R d ' bust Manifold, Turbocharger, W a s t e g a t e
-
12.00
12.0IA
E x I ' m U Q 7 ~ 6 ' I R P I S
cam. R a i l s , A i r Sass, 'B'Fost Fin. Wind Defl.
A/C C m r e s s o r
'87 M.Y'. On. Vacuum P u p , Brackets, P u l l e y
12.05A &&band Finisher, kl
s 40.28A w i n e Upper Gasket Set
12.09A Dwz tA-irrors 40.288 Enqine Loser Gasket S e t
-
13.00
l3.03A
S F P ~ & s E x r ~
Seat P r a m & Runners
41.00
41. O l A
BELTs&PumE!zs
P r i o r '87 M.Y. Canshaft B e l t , Pulleys, Tensioner
13.09A Seat F-, Suspension & Backboard 4l.OlB '87 M.Y. On. Canshaft B e l t , Pulleys, Tensioner
13.U Trhme.3 Seats, Trimred Backboard 41.03A A u x i l i a n Belts, Pulleys
.
U 27A Seat Eelts. R e d Cover 42.00 l-m?m&&
-
14.00 !?Fvm .fEaX 6 FASCIA 42.0lA Airbox. Diffuser. Plenum Chambes. Enaine Bav IXIctim -
14.01A -
RED Pedal Bcor, T h r o t t l e & Choke Cables 42.031 carbur&tor ASS&. ~ u e Regulatingl vkve
l4.Ol.B
14.05A
-
Lao Pedal Box, T h r o t t l e & Choke Cables
Fascia hint& Panels. Column ~ h r a d
42.04A
42.O7A
Carburettor I n t e r n a l Conwnents
P r i o r '87 M.Y. I n l e t !+!anifold, Water F a i l , Vacum F a i l
14.07A Binnacle I n s t r m m t Panels & Masks 42.07B '87 M.Y. On. Inlet Manifold
14.08A Centre Console, Light Box, G h e v e r G a i t e r 43.00 PITSSION
14.10A h M Instmmmt B i n ~ c l e 43.031 '87 M.Y. On. Engine t4mq-t System, Vacuum Pipes
14.12A Gl~ebox 44.00 Eum SYSTEM
-
15.00
15.0lA
lxlmJ.m llRM
Roof h i m , Mirror, Sun Visors
44.0lA
44.03A
Fuel Tanks, F i l l e r s , Sender Unit
Pmp, F i l t e r , p i p e s -
15.1lA Rear E d k h e d Trim 44.0511 F u e l Tank Breather System
15.13A Dmr h i m , (Ashtray i n D m r ) 45.00 EXAAUSP
l5.lgA Tunnel Trim, G/Lever Low G a i t e r 45.031 h T s y s t e m , mtings
15.24A Rear Luggage C o q m r t m n t Carpet 45. OSA Heat Shields
15.30A Passenaer Camwtrrent Camet. lih3rake G a i t e r 46.00.
-16.00
16.01A
xaa 6&m
Passenger tC
- Insulation
46.03
46.0lB
E W 8 7 : k . m i a t o r ~ a n s ,pipes, E e a e r ~a.., 4d. met
'87 M.Y. ON. Ra4iiietor Fens, Pipes, ??=&or Tz-k, M.
16.02A Duct M y underside Insulation 46.03A m-G1zT~oses, Therrrostat
17.00
17.0-
- -
ELFCrrmCAL
HKness h Leads
47.00
47. OlA
~ S S I O N
Clutch, Release Mechanism
l7.03A Relays, Delay Units, Horns 47.02A 'C35' Geartnx I d e n t i f i c a t i o n
17.05A Switches, F i b r e @tics 47.03A G/W Assy. Maurtings, Clutch Hmsing, Speedo Drive
l7.07A Ins'JU1112nts. T e l l T a l e Larrps 47.09 Gear Lever, External GBaechange Linkage
l7.OgA Epeedo Cable, Oil/Bmst Pipes 47.06A Tcp Wer, Selector Mschanisn ( I n t e r ~ l )
17.1U E x t e r i o r Larps, Except R e a d l . 47.07A Gears, Shafts, w i n g s
17. UA H8adlarrps & Slprr- 47.m o'ownwheel & Pinion, D i f f e r e n t i a l
17.15A iieadlarrp L i f t Mechanism 47.19 o u t p u t Shafts, Rausings, Bearings
17.17A I n t e r i o r Laup, C w r t e s y Switches 60.00 TCCaS
l7.lgA Fuse Boxes, T h e d h i p , Inertia Switch 60. OIA Tml~it,Jack ti s w a g e
17.2l.A Wmdscreen W l p e r & Washer 60.02A Special Tools
17.271 R d o / C a s s e t t e , Speakers, A e r i a l 60.04A Transhission Tools -
17.29A Suppressmn D w i c e s 80.00 B U L K m
17.3lA Pat-, B a t t e r y Cables 8O.2OA P a i n t Ccdes & T a c h - i n P a i n t
18.00 H F ITE R m C0W)ITIONIN;
18.0lA Heater WC Casirg
18.03A h r Cm&tiorung P l d i n g
18. OSA Heater P1uwbir-g
18.07A BLcwer M o r S
18.09A w h a n i c a l l y Cperated P a r t s & Controls
18.1lA Vacuum Operated P a r t s & Controls
18.UA Trunking, Vents, Plenum Chamber
30.00 (gASSIS
30.01A Chassis Fram
31.00 SUSPENSION
31. OlA Prior t o '85 M.Y. Front SuspMsion
31.0- '85 M.Y. ~ n Front
. suspension
3l.O3A Rear Suspension & Drive S h a f t s .
32.00 STgEIUN;
32. OlA Steerina Rack Assv. I n t e m d i a t e C o l m
32.O5A
33.00 BRAKES
33.01A P r i o r to '85 M.Y. Calipers & Discs
33.0- '85 M.Y. On. Calipers & Discs
33.03A Prior to '85 M.Y. RydFaulic System, Swo
33.038 '85 M.Y. On. Hydraulic System, Servo
33.05A
lU6ABI
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.,
E I N E PAEIT NUMBERS
All engine part nunhers m n c e with the engine type nun&er on which the part was first used:
907 - 2 Litre Naturally Aspirated 911 - 2.2 Litre Naturally Aspirated (Talbot)
910 - 2.2 Litre Turbocharged 912 - 2.2 Litre Naturally Aspirated (Mtus)
.......................
This publication has been designed primarily for W u s Dealers, and will be updated by issue of Service Bulletins
to Lotus Dealers when necessary. Lotus policy is one of continuous product irrprwenwt and the right is reserved
to alter specifications at any tim without prior notice.
Whilst wery care has been taken to ensure correctness of information, it is inpossible to guarantee conplete
freedan from anissions and errors, or to accept liability arising £ran such anissions and errors, but nothing
contained herein shall affect your statutory rights.
.......................
MID-NOSE SECTION, 2 8 INCHES FRONT
TO REAR.
SHUT LINE.
TURBO
1o.olA
ILLUS
NO. QUANTITY
DESCRIPTION PART NUMBER REMARKS
B o d y s h e l l ( i n c . sills) W 'Glass Roof'

I
I 11 I
I 11 n
' G l a s s Roof
I
I
I
I
I1
n
II
11
II
I
I
I
I
I
I
N X ' G l a s s Roof '
'Glass Roof1
B o d y Section, Mid Nose, F u l l W i d t h
I1 I1 I1 I1 I1 II II
B o d y Section, Mid Nose, RH H a l f

I
I I1 II I1 I1 I1 I1
B o d y S e c t i o n , M i d Nose, LH H a l f
I1 . I
I II I1 I
I I1 I1
B o d y Section, F u l l N o s e , F u l l W i d t h
I
I I
I II I1 I
I II II
B o d y Section, F u l l Nose, RH H a l f
I
I I
I 11 I
I I
I I
I n
Body Section, F u l l Nose, LH H a l f

I1 I
I I1 I1 11 I
I 11
B o d y Section, Roof (NOT ' G l a s s 1 R o o f )

Body Section, Roof ( ' G l a s s Roof' M o d e l s )
ILLUS
NO. QUANTITY
MAY P(9N
DESCRlPTlON PART NUMBER ALL REMARKS
Body Section, S h o r t Rear, F u l l Width 1

Body Section, Short Rear, RH Half 1
Body Section, S h o r t Rear, LH Half 1
Body Section, F u l l Rear, F u l l Width 1
Body Section, F u l l Rear, RH Half 1
Body Section, F u l l Rear, LH Half 1
Bulkhead, Upper, (Timber) 1 Not ' G l a s s Roof1
Bulkhead, Upper, (Timber) 1 'Glass Roof Models
Wllkhead, Centre, (Timber 1
Bulkhead, m r , (Timber) 1
Speaker Enclosure, Rear Wllkhead (ABS) 2
1 TURBO
I 10.05A
a
NO. QUANTITY
DESCRIPTION PART NUMBER ALL REMARKS

1
Cross Beam, S c u t t l e , RHD
Cross Beam, S c u t t l e , LHD
Setscrew, M8 x 25, Beam to Hinge P o s t
Setscrew, M8 x 20, Beam to ~ i n g ePost
Washer, Spring, Beam to Hinge P o s t
Washer, P l a i n , Beam to H i n g e P o s t
Crossbeam, R e a r Bulkhead, S e a t B e l t M t g .
Bolt, Thinhead, Beam End to Door Aperture
Washer, Large O/D
Nut, M8
Setscrew, M 6 x 25, Beam t o Bulkhead
Washer, Large O/D
Nut, Nyloc, M 6
P l a t e , S e a t B e l t Mamting t o S i l l , LH
P l a t e , S e a t B e l t Mounting t o S i l l , RH
B o l t , M8 x 25, Mounting P l a t e to S i l l
Washer, Large O/D S p e c i a l
Washer, F l a t
S t i f f e n e r Bracket, T a i l g a t e A p e r t u r e , RH Dry Surrp C a r s
S t i f f e n e r Bracket, T a i l g a t e Aperture, RH Wet Surrp C a r s P r i o r '87 M.Y.
S t i f f e n e r Bracket, T a i l g a t e A p e r t u r e , RH '87 M.Y. on, With Purge Punp Bracket
S t i f f e n e r Bracket, T a i l g a t e Aperture, IlI
Setscrew, Thinhead, M8, BrM/Aperture 2 Only i f G a s S t r u t s anchored i n a p e r t u r e
Washer, F l a t
Setscrew, M8 x 25, Brkt/Body Brkt/Oil Tank on Dry Sunp C a r s
Washer, Large O/D, Brkt/Body 6 On D r y Sunp Cars
Nut, Nyloc, M8, ~ r k t / B o d y 2 On D r y Sunp C a r s
Jacking P l a t e '85 M.Y. on
Jacking P l a t e With Stepped J o i n t Face P r i o r t o Body Mod.
P q Rivet, Jacking P l a t e to Body
T w Eye, F r o n t
Reinforcing P l a t e , Tad Eye
Setscrew, M 6 x 20, T w Eye
Washer, F l a t , T w Eye
Turbo 10.05A
I
1 TURBO
10.07A
i
NO. QUANTITY
DESCRIPTION PART NUMBER ALL
Headlanp Pod, RH ~ u c a s / H e l l a Headlanps

Headlanp Pod, RH C i b i e Headlanps
Headlanp Pod, LH ~ u c a s / ~ e l lHeadlanps
a
H e a d l a p Pod, LH C i b i e Headlanps
B a l l J o i n t , Pod Outer P i v o t
Pcp Rivet, B a l l J o i n t Fixing
Setscrew, M6 x 30, Pod Outer P i v o t
Washer, F l a t , Pod Outer P i v o t
Washer, Large O/D, Pod Outer P i v o t * Cars p r i o r V I N 82 D 2265
Nut, Nyloc, M6, Pod Outer P i v o t 82 - 0624
Bearing Housing, LH O u t e r / ~ HInner W i l l also r e q u i r e new Headlanp
Bearing Housing, RH Outer/LH Inner surround. 17.13A
Pcp Rivet, Bearing Housing F i x
Bearing Bush, Pod Inboard P i v o t
H i n g e Pin, Pd/Bonnet
S p l i t Pin, H i n g e P i n Retention
'R' Pin, Hinge P i n
Water S h i e l d
Pcp Rivet, S h i e l d to Body
Turbo 10.07A
1 TURBO
10.09A
a
NO. QUANTITY
MAY 199
REMARKS
Bonnet Panel )up t o VIN 82 D 1060

S e a l Bonnet 1 82 - 0337
H i n g e , Bonnet, IH 1
Hinge, Bonnet, RH 1 R/B Bonnet B085B4357J
1 w i t h S e a l and Hinges
Bonnet Panel, S i x S l o t >From VIN 82 D 1061
Bonnet Panel, !I'm S l o t
S e a l , Bonnet > 82 - 0338
Hinge, Bonnet, LH >
H i n g e , Bonnet, RH >
S t i f f e n e r , Bonnet, Front Edge Curvature R/B B082B4473F
S t i f f e n e r , Bonnet, F r o n t Edge Curvature Included i n Bonnet Panel
Shim P l a t e , H i n g e to Bonnet
Setscrew, M6 x 18, Hinge t o Bonnet 1
Setscrew, M6 x 16, Hinge to Bonnet )Alternatives
Washer, Shakeproof, Hinge t o Bonnet
Washer, F l a t , Hinge t o Bonnet
Tapping P l a t e , Bonnet Hinge
G r i l l e , Bonnet
Screw, G r i l l e to Bonnet
Insert Bush, G r i l l e t o Bonnet
S t r i k e r , Bonnet Catch
Shim P l a t e , S t r i k e r to Bonnet
Setscrew, M8 x 25, S t r i k e r t o Bonnet
Washer, Spring, S t r i k e r to Bonnet
Washer, F l a t , S t r i k e r to Bonnet
Tapping P l a t e , Bonnet S t r i k e r
Bracket, Bonnet Latch D i s c Mamting
Setscrew, 10 UNF x 3/4", Bracket/Body
Washer, F l a t , Bracket/Body
Turbo 10.09A
Page 1
1 TURBO
10.09A
NO. QUANTITY MAY ldl
Latch D i s c , Bonnet Lack

C l e v i s Pin, Latch D i s c to Bracket
'R' Pin, Latch D i s c C l e v i s
Washer, F l a t , D i s c to Bracket
C l e v i s Pin, Latch ~ o to d Disc
Rod, Bonnet Latch Cperating
Bush & Clip, Rod to Cross S h a f t
Cross-Shaft, Bonnet b k , RHD
Cross-Shaft, Bonnet Leek, LID
Bracket, Cross-Shaft Pivot
Setscrew, M6 x 12, Bracket t o Body
Washer, F l a t , Bracket to Body
Stay, Telescopic, Bonnet Support )Top Bracket Rivetted t o Stay
Stay, Telescopic, Bonnet Support )Tap Bracket Bolted t o Stay
Bracket, Bonnet Stay t o Bonnet ) U s e With B079U4277K
Gas S t r u t , Bonnet Support )Alternative
Bracket, G a s S t r u t to Bonnet & Wheelarch
Washer, F l a t , S t r u t to Brackets
Nut, Nyloc, S t r u t t o Brackets
Setscrew, Strut/Stay Bracket to Wheelarch
Nut, Nyloc, M5 " 11 11 It
Washer, F l a t 11 n II 11
Washer, Large O/D )I 19 !I
Setscrew, M5 x 12, Brkt. t o Bonnet

Washer, Shakeproof, Brkt. t o Bonnet
Jacknut, M5 In It
Turbo 10.09A
Page 2
a
NO. QUANTITY
GLASS
DESCRIPTION PART NUMBER WXlF
T a i l g a t e Panel
Foam Seal, T a i l g a t e to Engine Lid
S e a l , T a i l g a t e to Body On Body
Foam S t r i p , T a i l g a t e to Body On T a i l g a t e . If Fitted
Hinge Blade, T a i l g a t e , LH
Hinge Blade, T a i l g a t e , RH
B o l t , Hinge P i v o t
Nut, Nyloc, M10, Hinge P i v o t
Hinge Blade, T a i l g a t e , LH
Hinge Blade, T a i l g a t e , RH
Bracket, T a i l g a t e Hinge t o Body
Setscrew, T a i l g a t e Hinge P i v o t
Washer, Shakeproof, T/Gate Hinge P i v o t
Washer, F l a t , T/Gate Hinge P i v o t
Setscrew, M8 x 25, Bracket t o Body
Washer, F l a t , Bracket to Body
Washer, Large O/D, Bracket to Body
N u t , Nyloc, M8, Bracket to Bady
Gasket, Bracket t o Body
Setscrew, M8 x 25, ~ i n g eladen nail gate
,
Washer, Spring Hinge ~ladefiailgate
Washer, F l a t , Hinge ~ l a d e f i a i l g a t e
Tapping P l a t e , Hinge Blade, LH I n s i d e T a i l g a t e Panel
Tapping P l a t e , Hinge Blade, RH I n s i d e T a i l g a t e Panel
Lcxlvre, T a i l g a t e
Nut, Nyloc, M6
Washer, F l a t
G r m t , h v r e , F r o n t Edge F i x i n g s
Screw, Louvre, S i d e Fixing
G a s S t r u t , T a i l g a t e Support With Anchors on Body Aperture and
T a i l g a t e Edge
Gas S t r u t , T a i l g a t e Support With Anchors o n Cabin Bulkhead and
T a i l g a t e I n n e r Skin
Turbo 10.11A
Page 1
0
ILLUS
NO. QUANTITY
I
1991
FIXED
10.11A PART NUMBER ROOF
REMARKS I
Bracket, LH, Gas S t r u t t o T a i l g a t e

Bracket, RH, Gas S t r u t to T a i l g a t e
Setscrew, M6 x 30, Bracket t o T a i l g a t e
Washer, F l a t , Bracket to T a i l g a t e
Nut, Nyloc, M6, Bracket t o T a i l g a t e
Bracket, LH, . G a s S t r u t t o Cabin Bulkhead
Bracket, RH, G a s S t r u t t o Cabin Wllkhead )For U s e With S t r u t A
Studplate, Bracket to Bulkhead
Washer, F l a t , Bracket Fixing
N u t , Nyloc, M6, Bracket Fixing
Washer, F l a t , S t r u t to Bracket
'R1 Pin, S t r u t to Bracket
S t r i k e r , T a i l g a t e Latch
Tapping P l a t e , S t r i k e r I n s i d e T a i l g a t e Panel
Shim P l a t e , S t r i k e r Adjustrent
Setscrew, M8 x 20, S t r i k e r Fix
Washer F l a t , S t r i k e r Fix
Washer, Spring, S t r i k e r Fix
G r m t , Tapping P l a t e Access
Cross Shaft, T a i l g a t e Latch
Bearing Bracket, Cross S h a f t
Washer, F l a t , Bearing Bracket Fix
Nut, Nyloc, M8, Bearing Bracket Fix
Support Bracket, IH, Latch Cross-Shaft 1-r End Fixes t o Floor
Support Bracket, RH, Latch Cross-Shaft
Support Bracket, LH, Latch Cross-Shaft )Imer End Fixes t o
Support Bracket, RH, Latch Cross-Shaft P r i o r to '87 M.Y. )Rear Larrp Aperture
Support Bracket, RH, Latch Cross-Shaft '87 M.Y. on 1
Screw, Thinhead, M6, Support Brkt. T q
Studplate, M6 x 16, Support Brkt. Bottom
Washer, F l a t , Support B r k t . Fixing
Nut, Nyloc, M6
Spring, , T a i l g a t e Latch Opening Used W i t h Support Brkt. A079U4505K
Spring, T a i l g a t e Latch @ening Used With Support Brkt. A082U4989K
Setscrew, M6 x 20, Latch Upstq, Turbo 10.1lA
Page 2 I
TURBO
10.11A
a
ILLUS I
NO. QUANTITY
- MM 1991 I
FIXED
DESCRIPTION PART NUMBER REMARKS I
-
ROOF
Nut, Nyloc, M6, Latch Upstcp 1

Release Lever, Tailgate Latch 1 P r i o r '87 M.Y.
Release Lever, Tailgate Latch 1 '87 M.Y. o n
Screw, Release Lever Pivot 1
Washer, F l a t , Release Lever Pivat 1
Nut, Nyloc, M6, R e l e a s e Lever Pivot 1
Spring, Release Lever 1
Rod, I m k to Release Lever 1 >
Trunnion, Rod t o Release Lever 1 > P r i o r t o '87 M.Y.
h k Assembly & Keys, Tailgate 1 >
Lever Arm, Tailgate Lock 1 >
Lever, ail gate I n t e r n a l Release 1
S p i r o l Pin, 5 x 30, Lever Pivot 1
Washer, Lever to Bracket 2
Hinge Bracket, Release Lever 1 ) '87 M.Y. on
Recess, Release Lever, ABS 1 RID)
Recess, Release Lever, ABS 1 LHD)
Washer, F l a t , Brkt. & Recess to Bulkhead .1 1
Nut, Nyloc, M6, Brkt. & Recess t o Wllkhead 1 1
Cable, ailg gate Release 1 Rm)
Cable, Tailgate Release 1 LHD)
Adaptor, Tailgate Channel Drain, LH 1 I
Adaptor, Tailgate Channel Drain, RH 1 I R/B A085U4813K
Adaptor, Tailgate Channel Drain 2
Pop Rivet, Drain Adaptor Fix 6
Elbow, Tailgate Channel Drain 2
Hose, Tailgate Channel Drain 1.5m
Clip, Drain H o s e Securing 2
Turbo 10.1lA
Page 3
TURBO
10.13A
a
ILLUS
QUANTITY
NO.
-
DESCRIPTION PAFIT NUMBER ALL
Engine Bay Sidewall 1 For Twist Iack Engine Lid F a s t e n e r s

Engine Bay Sidewall 1 For Overcentre Engine Lid F a s t e n e r s
Engine Bay Sidewall 1 '87 M.Y. on
Screw, M6 x 25, Sidewall to Body 8
Washer, F l a t , s i d e w a l l t o Body 8
P u l s e r t , M6, Sidewall to Body 8
Setscrew, M6 x 25, Sidewall t o F r o n t Hinge
2
Washer, Large, O/D 2
Nut, Nyloc, M6 2
Edge F i n i s h e r 3M
R e a r Wall/Floor , Engine Bay 1 For Twist lnck Engine Lid F a s t e n e r s
Rear ~ a l l / F l o o r ,Engine Bay 1 E a r l y Canadian Cars Only. Twist Iack
Fasteners
Rear ~all/Floor,Engine Bay 1 For Overcentre ~ n g i n eL i d F a s t e n e r s
Foam S t r i p , R e a r Floor to Body 3m
Studplate, M6 x 20, Coilbox F i x 4
Pop Rivet, S t u d p l a t e F i x 8
Washer, Pop R i v e t 8
Gramrret, Gearbox F i l l e r Access 1
Setscrew, M6 x 25, Floor t o Body 11
Washer, F l a t , F l o o r to Body 11
P u l s e r t , M6, Floor t o Body 11
Lid, ~ n g i n eBay 1 For Twist IAck ~ n g i n eLid F a s t e n e r s
Lid, Engine Bay 1 F o r Overcentre Engine L i d F a s t e n e r s
Tongue, Engine Lid F r o n t Hinge 2 1
Eye, Engine Lid F r o n t Hinge 2 1
Setscrew, 10 UNF x *", T o n g u e m e 8 1
Washer' 8 )For U s e With Lid A082B4288K
Nut, Nyloc, 10 UNF 8 )
Twist Iack Catch, Male, Engine Lid 4 1
Rubber Washer, Male Catch 4 1 Turbo 10.13A
Twist Lock c a t c h , Ferrrale, Engine Lid 4 1 Pqe 1
Pop Rivet, Catch Fixing 8 1
a
NO. QUANTITY

REMARKS
Hinge, LH, Engine L i d

Hinge, RH, Engine Lid
Screw, 10 UNF x i", Hinge t o Lid
Washer, F l a t , Hinge to Lid
Nut, Nyloc, 10 UNF, Hinge to Lid 1
Catch, Overcentre, Engine Lid IChraw )For Use With Lid B082B4288K
S t r i k e r , Overcentre Catch 1 1
Catch, Overcentre, ~ n g i n eL i d >Zinc 1
S t r i k e r , Overcentre, Catch > 1
Screw, 4BA, Catch/Striker F i x 1
Washer, F l a t , Catch/Striker F i x 1
N u t , 4BA, C a t c W S t r i k e r F i x 1
Rivet, Zinc S t r i k e r F i x
Foam Seal, Engine Lid
Mesh, Engine Lid Aperture
S l a t Assembly, Engine Lid Aperture
Screw, Mesh and S l a t Fixing
S p i r e N u t , Mesh and S l a t Fixing
Water S h i e l d , Engine L i d Aperture
Screw, M6 x 12, Water S h i e l d F i x
Washer, Shakeproof, Water S h i e l d F i x
Jacknut, M6, Water S h i e l d F i x
Trim Panel, Rear 1/4, IH NX 'Glass Roof' >Including
Trim Panel, R e a r 1/4, LH 'Glass Roof8 >Carpet
Trim Panel, R e a r 1/4, RH Dry Sunp Only >
Trim Panel, R e a r 1/4, RH Wet S u p . WI' ' G l a s s Roof' >For Carpet
Trim Panel, R e a r l/4, RH 'Glass Roof I >See 15.24A
C l i p Bracket, Trim Panel t o g gate P g e r t u r e 1
Pop Rivet, Brkt. t o Panel 1
Screw, Brkt. to Body 1
S p i r e Nut, Brkt. t o Body ) F i x i n g s Replaced by mter S e t
Screw, Panel to Engine Bay 1
Washer, F l a t , Panel t o Engine Bay 1
S p i r e N u t , Panel t o Engine Bay 1
Turbo 10.13A
Page 2
--
ILLUS
a a
NO. QUANTITY
S p i r e C l i p 'U' Nut, Trim Panel t o Body

S p i r e Nut, F l a t , Trim Panel t o Body
S p i r e Nut, Trim Panel t o Engine Ray
Screw, Panel to Body & Engine Ray
Setscrew, M5 x 20, Panel Rear t o Engine Ray
Jacknut, M5, Panel Rear to Eng. Ray
Washer, F l a t , Panel t o Engine Ray
Undertray, Engine Ray R/B Shorter Undertray B082B4292K
Undertray, Engine Bay R/B A082B4559K
Undertray, Engine Bay
Retaining S t r i p , Undertray Front
Pop Rivet, Retainer to Body
Setscrew, M6 x 20, Undertray Fixing
Washer, F l a t , Undertray Fixing
P u l s e r t , M6, Undertray Fixing
Turbo 10.13A
Pqe 3
TURBO
10.1SA
a
a
ILLUS
a
NO. QUANTITY
ALL
Door S h e l l , Ill P r i o r Change P o i n t *

Door S h e l l , LH, RH) > From Change P o i n t *
Door S h e l l , LH, IHD >
Door S h e l l , RH P r i o r Change P o i n t *
Door S h e l l , RH, RHD > From Change P o i n t *
Door S h e l l , RH, LFD >
Door Beam, LH
Door Beam, RH * Change P o i n t VIN 82 D 2137
Setscrew, M8 x 20, Door Rear to Beam 82 - 0606
Washer, Large O/D, " It #I I!
Washer, Spacing, Door Rear to Beam If Fitted

Setscrew, M6 x 16, Door Front t o Beam
Washer, Large O/D, Door Front to Beam
Fixing P l a t e , M6, Door Front t o Beam
Washer, Spacing, S h u t l i n e Adjust If Fitted
Hinge Post, Door, Ill I n Body ' A * P o s t
Hinge Post, Door, RH I n Body 'At P o s t
Reinforcing Bracket, Hinge P o s t t o S i l l 1
Setscrew, M8 x 16, Bracket to P o s t 1
Washer, P l a i n , Bracket t o P o s t 1
Washer, Spring, Bracket to P o s t )If Fitted
Tapping P l a t e , Bracket t o S i l l 1
Setscrew, M8 x 20, Bracket to S i l l 1
Washer, P l a i n , Bracket t o S i l l 1
Washer, Spring, Bracket to S i l l 1
Hinge Bracket, Upper, Ill
Hinge Bracket, Upper, RH
Hinge Bracket, I a e r
CLanp P l a t e , Door Hinge
Shim, 18 s q , Hinge t o Body
Shim, 18 swg, Hinge to Body Slotted
Shim, 12 swg, Hinge to Body Slotted
Shim, Abrasive, Hinge to Body Turbo 10.15A
Nut, Nyloc, 3" UNF, Hinge t o Body Page 1
T i e Rod, Upper t o hner Hinge
TURBO
10.I S A
e
NO. QUANTITY

ALL
Washer, T i e R o d t o Hinge 4
Nut, Nyloc, M8, T i e Rod to Hinge 4
P i v o t Bush, Door Beam 4
P i v o t Pin, Door Beam 2
Nut, Nyloc, Ml2, P i v o t P i n 4
Check S t r a p , Id3 1 1
Check S t r a p , RH 1 1
Bolt, M8 x 45, S t r a p to Hinge Brkt. 2 1
Nut, Nyloc, M8, S t r a p t o Hinge
.
Guide Assy Check S t r a p S l i d e r , Id3
2
1
1
) E a r l i e r Type Check S t r a p With C o i l
Guide Assy. Check S t r a p S l i d e r , RH 1 )Spring Activated Catch
Setscrew, M6 x 12, Guide t o Bracket 4 1
Washer, Shakeproof, Guide to Bracket 4 1
N u t , M6, Guide to Bracket 4 1
Check S t r a p , inc. Spring, LH 1 >
Check S t r a p , i n c . Spring, RH 1 >
Spring, Door Check, IH 1 >
Spring, Door Check, RH 1 >
Guide, Check S t r a p 2 >Later Type Check S t r a p With Spring
Setscrew, M6 x 30, Guide to Brkt. 2 >Wire Catch
Washer, P l a i n 2 >
Nut, Nyloc, M6, Guide to Brkt. 2 >
B o l t , M8 x 45, S t r a p t o Hinge 2 >
Nut, Nyloc, M8, S t r a p to Hinge 2 >
Bracket, Check S t r a p Guide t o Beam, IH 1
Bracket, Check S t r a p Guide to Beam, RH 1
Bracket, Window Motor Mamting, Id3 1
Bracket, Window M o r Mmnting, RH 1
Studplate, M6, Bracket t o Door Beam 6
Nut, Nyloc, M6, Bracket to Door Beam 6
Turbo 10.15A
Page 2
TURBO
10.17A
0 0
ILLUS
e
NO. QUANTITY
E x t e r i o r Door Handle S e t (Black) coprises LH & RH Door Handles,

Federal Cubby Box & Keys
E x t e r i o r Door H a n d l e S e t ( S i l v e r & Black) Conprises LH & RH Door Handles & Keys
Door Handle, E x t e r i o r , RH, (Black)
Door Handle, E x t e r i o r , RH, ( S i l v e r & Black)
Door Handle, E x t e r i o r , LH, lack)
Door H a n d l e , E x t e r i o r , LH, ( S i l v e r & Black)
C l a p Bracket, Handle to Door
Nut, 10 UNF, Handle to Clanp
Washer, 3/16", Handle t o C l a p
Door H a n d l e , I n t e r i o r , RH
Door Handle, I n t e r i o r , LH
Tapping P l a t e , Door H a n d l e t o Door
Screw, 1 0 UNF x 3/4", Handle t o Door
Screw, 10 UNE' x l", H a n d l e t o Door
Washer, Handle to Door
Bezel, Door Handle
Latch Mechanism, Door b k , RH
Latch Mechanism, Door h x k , IH
P l a t e , Latch to Door Beam
B o l t , M6 x 45, Latch to Beam
Nut, Nyloc, M6, Latch to Beam
Trunnion, Rcds t o Latch
C i r c l i p , Latch Trunnions
C l i p , Rod End, Ext. Release t o Latch
C l i p , Rod End, E x t e r i o r Handle
Bracket, Rod Guide
Guide C l i p , I n t e r i o r Handle ~cds
Pop R i v e t , Guide Bracket t o Door
Washer, Pop Rivet
Turbo 10.17A
Page 1
@
ILLUS
NO. QUANTITY

-
ALL
P l a t e , I n t e r i o r Lock Rod Retaining 2

Screw, P l a t e to Door 2
S p i r e Nut, P l a t e to Door 2
Rod, Exterior Release to Latch, RH 1
Rod, E x t e r i o r Release to Latch, LH 1
Rod, E x t e r i o r LO& to Latch, RH 1
~ o d ,E x t e r i o r LO& t o ~ a t c h ,LH 1
Rod, I n t e r i o r Release to Latch 2
Rod, I n t e r i o r Lock t o Latch, LH 1 R/B B079U4626F
Rod, I n t e r i o r Lack t o Latch 2
G r a r m t , Blanking, Lock Rod Access 2
S t r i k e r Post, RH 1
S t r i k e r Post, LH 1
Washer, Large O/D, S t r i k e r P o s t Top 4
Nut, Nyloc, M8, S t r i k e r P o s t Top 4
Washer, 1% 2
Setscrew, M12 x 30, S t r i k e r P o s t -tan 2
S t r i k e r P l a t e , Door Latch 2
Spacer, 3mn, S t r i k e r to Body A/R
Spacer, 1.5mn, S t r i k e r t o Body A/R
Abrasive Washer, S t r i k e r t o Body 2 R/B F r i c t i o n P l a t e A082U5004F
F r i c t i o n P l a t e , S t r i k e r to Body 2
Shim, l . h , S t r i k e r P o s t t o Body A/R
Shim, ~MI, S t r i k e r Post to Body
Tapping P l a t e , Door Latch S t r i k e r 2
Screw, M6 x 35, S t r i k e r Fixing 4
Turbo 10.17A
Page 2
NO. QUANTITY
DESCRIPTION PART NUMBER
F r o n t Bunper, GRP, Inc. Brkts. With L i n e a r D i f f u s i o n P a t t e r n

Side/Turn Lanps
F r o n t Burrper, GRP, Inc. Brkts. With C i r c u l a r Diffusion P a t t e r n
Side/Turn Laps
F r o n t Bunper, RRIM Prior '85 M.Y. WB A082B460l.J (S/B 1986/0-

F r o n t Bumper, RRIM '86 M.Y. on, w i t h Lucas Side/Turn Lanps
F r o n t Burrper, R R I M '86 M.Y. on, w i t h Cobo S i d e n u r n Lanps
Bracket, GRP Bunper M t g . 1
Setscrew, Bracket to GFW Wlnper 1
Washer, Spring, Bracket to GRP Bunper ) U s e w i t h GRP Bunpers
Setscrew, M8 x 25, GFW Bunper t o Body )A082B4240/4533
Washer, Spring, GRP Bunper to Body
Washer, Large O/D, GRP Bunper t o Body
G r a m & , GRP Bunper B o l t Access ( I n Pod W e l l )
Setscrew, M8 x 25, Burrper Centre F i x i n g >

Nut, Nyloc, M8, Bunper Centre Fixing >
Washer, F l a t , Bunper Centre ~ i x i n g > U s e With R R I M Bunper
Stud, 'Bighead' M6 x 20, Outboard Fixing >A082B4428F
Washer, F l a t , Bunper Outboard Fixing >
Nut, Nyloc, M6, Burrper Outboard ~ i x i n g >
Setscrew, M8 x 25, Wlnper C e n t r e ~ i x i n g
Washer, F l a t , Bunper Centre ~ i x i n g
Nut, Nyloc, M8, Bunper Centre ~ i x i n g ) U s e w i t h RRIM Wlrrper
Shim P l a t e , Bunper Outboard ~ i x i n g )4/~082B46OLJ
Stud, M6 x 30, Emper Outboard Fixing 1
Washer, F l a t , Bunper Okbua.rd Fixing 1
Washer, s p r i n g , Bunper Outboard ~ i x i n g 1
Nut, P l a i n , M6, Burrper Outboard Fixing 1
Spoiler, Front P r i o r '87 M.Y.
Spoiler, Front '87 M.Y. on
Setscrew, M8 x 25, S p o i l e r To l3ody
P u l s e r t , M8, S p o i l e r t o Body Turbo 10.23A
Page 1
I TURBO
0 a
ILLUS
NO. QUANTITY
Washer, Flat, Spoiler to Body 6

Washer, Spring, Spoiler to Body 6
Spire Bolt, Spoiler to Rad. Duct 5
Spire Nut, Spoiler to Rad. Duct 5
Washer, 6 m , Spoiler to Rad. Duct 5
Grille, Radiator Air Intake 1 Prior '87 M.Y.
Grille, Radiator Air Intake 1 '87 M.Y, on
Nut, Nyloc, Intake Grille Fix 5
Washer, 5m, Grille Fix 5
Undershield, Front (Pair) 1 Used With 306m Rad. Duct Stays
Undershield, Front (Pair) 1 Used With 266 & 286rm Rad. Duct
Stays
Spire Bolt, Undershield Fixing 12
Washer, Spire Bolt 12
Spire Nut, 'J' Type 7 )Used With Undershield A082B4275K
Spire Nut, Flat 5
Screw, s/t, Undershield to Spoiler 14 >
Screw, s/t, Undershield to Rad. Duct 6 >Used With Undershield A082B4492K
Washer, Undershield Fix 20 >
Spire Nut, Undershield Fix 20 >
Sill, Iil 1
Sill, RH 1
Spoiler, Rear 1 Prior '87 M.Y.
Spoiler, Rear 1 '87 M.Y. on
Pulsert, M6, Spoiler ~ixing 10
Setscrew, M6 x 25, Spoiler Fixing 10
Washer, Large O/D, Spoiler Fixing 10
Washer, Shakeproof, Spoiler Fixing 10
Screw, s/t, Spoiler Fixing 8
Spire Nut, Spoiler Fixing 8
Foam Strip, Spoiler Seal 3m
Turbo 10.23A
Page 2
TURBO
I 10.23A
- - -
a a
ILLUS
NO. QUANTITY MAY pcjr
. i
Rear Wlnper (GRP) Inc. Brkts.

Bracket, GW Bunper Mamting
Setscrew, Bracket t o GRP Wlnper
Washer, Spring, Bracket to GRP Bunper
Setscrew, M8 x 25, Wlrtper t o Body
Washer, F l a t , Bunper t o Body
Washer, Spring, Bumper to Body
Seal, Neoprene, Bunper t o Body
R e a r Valance
P u l s e r t , M8, Valance to Body
Setscrew, M8 x 25, Valance t o Body
Washer, Spring, Valance t o Body
Washer, F l a t , Valance to Body
Setscrew, M8 x 20, Valance t o Emper
Washer, F l a t , Valance t o Wlnper
Nut, Nyloc, M8, Valance to Bunper
Turbo 10.23A
Page 3
NO. QUANTITY
"Betaseal"Screen F i t t i n g K i t s/R Used for W i d s c r e e n and Rear

-rises : Bulkhead G l a s s F i m n t
B e t a s e a l 71904 i n 300cc Cartridge 1
G l a s s Primer Applicator Bottle 1
G l a s s P r i m Applicator H e a d and F e l t Pad 1
G l a s s P r i m r , Black, 84132-11 1
Wipe Cleaner No. 4 1
Piano Wire 0.6mn x 120an 1
S p e c i a l Cleaning Paper 1
Spacing Blocks 10 x 14 x 20mm 4
, T h e m E l e c t r ic S e a l e r , 9. Smn
"Solbi tw Shi Replaces 8mm S o l b i t . U s e d on
Door l / 4 L i g h t , Rear 1/4 Light, Drop
G l a s s and T a i l g a t e G l a s s
"Solbit" P r i m 4/R
Windscreen, T i n t e d 1
Windscreen, C l e a r 1
Spacer, 4mn, Screen to Body 8
F i n i s h e r , Windscreen Top 1
F i n i s h e r , Windscreen, RH 1
F i n i s h e r , Windscreen, LH 1
F i n i s h e r C l i p , Windscreen Top Corner 2
Black S t r i p , 1 3/4" Screen B o t t a n 1.5m
G l a s s , Door l / 4 Light, RH, T i n t e d 1
Glass, Door l / 4 Light, RH, C l e a r 1
Glass, Door l / 4 Light, LH, T i n t e d 1
G l a s s , Door 1/4 Light, LH, C l e a r 1
Drop G l a s s , Door, RH, T i n t e d 1
Drop Glass, Door, RH, T i n t e d 1
Drop Glass, Door, RH, Clear 1
Drop Glass, Door, LH, T i n t e d 1
Drop G l a s s , Door, LH, T i n t e d 1
Drop G l a s s , Door, LH, C l e a r 1
F i n i s h e r , W r Top, External, RH 1 Turbo 11.01A
Page 1
TURBO
11.01A
NO. QUANTITY

ALL
Finisher, Door Top, External IlI 1

N u t , Plain, 4BA, Finisher Fixing 6
Washer, F l a t , Finisher Fixing 6
Weatherstrip, Door G l a s s , Fxternal 2
Backing S t r i p , Weatherstr i p / F i n i s h e r 2
Pop Rivet, Weatherstr i p / F i n i s h e r 26
Finisher/tJeatherstrip Assy. RH 1
F i n i s h e r r n e a t h e r s t r i p Assy. LH 1
Seal, Drop Glass, I n t e r n a l 2 )1 C l i p On, P r i o r VM*
Seal, Door V 4 Light, I n t e r n a l 2
Clip, Seal, t o Door Trim Channel 16 1
Seal, Drop G l a s s , ti 1/4 Light, I n t e r n a l 2m ]Stick On, From VIN*
Door Weatherstrip 2
Secondary Door Seal (Wedge) 2
G l a s s , R e a r 1/4 Light, RH, Tinted 1
G l a s s , R e a r V 4 Light, RH, Clear 1
Glass, R e a r 1/4 Light, LH, Tinted 1
G l a s s , R e a r V 4 Light, LH, Clear 1
Spacer, 4mn, Glass t o Body 8
Trim, ABS, R e a r 1/4 G l a s s , RH 1
Trim, ABS, R e a r 1/4 Glass, LH 1
S i l l Finisher, R e a r V 4 G l a s s , RH 1
S i l l Finisher, R e a r 1/4 Glass, IH 1
N u t , 10 UNF, Finisher Fixing 4
Washer, Finisher Fixing 4
G l a s s , R e a r Bulkhead 1
Spacer, G l a s s t o Surround 6
Surround, Bulkhead Glass Mamting 1 Without 'Glass Roof1
Surround, Bulkhead Glass Mounting 1 With 'Glass Roofv
Foam S t r i p , Surround t o Body 3In
Screw, i", Surround t o Body 9
Screw, 3/4", Surround to Body 5 Turbo 11.01A
Page 2
TURBO
11.01A
QUANTITY
HAY 199:

REMARKS
- -
Glass, Tailgate, Heated 1

Glass, Tailgate, Unheated 1
Spacer, 4mn, Glass t o Tailgate 4
Surround, Tailgate Glass 1
Turbo 11.Ol.A
Page 3
TURBO
11.02A
NO. QUANTITY
1431
Door Window Fran-e, LH 1

Door Window Frame, RH 1
F i x i n g S t r a p , Windcrw Frame Top Rear 2
Screw, 10 UNF, S t r a p to Door S h e l l 4
Washer, S t r a p to Door S h e l l 4
S t u d p l a t e , M6, Frame to Door Beam 10
Washer, M6 x 25 x 1.4 10
Washer, M6 x 20 x 2.5 20
Nut, Nyloc, M6 10
S i l e n t Channel, D r o p G l a s s Guide 2
Guide R a i l , Drop Glass, LH 1
Guide R a i l , D r o p G l a s s , RH 1
F i x i n g P l a t e , M6, Guide t o Beam 4
Screw, csk. M6 x 18, Guide to Beam 4
C a r r i a g e P l a t e , LH 1 Drop G l a s s Channel t o Guide R a i l
C a r r i a g e P l a t e , RH 1 Drop G l a s s Channel t o Guide R a i l
Wheel, C a r r i a g e P l a t e 8
Shoulder P i n , Wheel P i v o t 8
Washer, Wheel P i v o t 8
Carrier Channel, D r o p G l a s s , L&i 1
C a r r i e r Channel, D r o p Glass, RH 1
Nut, Nyloc, M6, Channel to Carrier 4
Pad, D r o p G l a s s Abutrrrent 2
Window Motor, LH 1
Window Motor, RH 1
Screw, 1/4" UNF x 3" Motor to Brkt. 8
F i n i s h e r , F r o n t , Door Shell/Mindcrw Fran-e, LH 1
F i n i s h e r , F r o n t , Door ShelIJWindow Frame, RH 1
F i n i s h e r , Rear, Door Shellhindcrw F r a m , IlI 1
F i n i s h e r , Rear, Door ~ h e l l / W i n d o wFrame, RH 1
Turbo 11.02%
FOR WIND DEFLECTOR. SEE 12.01A
TURBO
11.OSA
a
NO. QUANTITY
-
DESCRIPTION PART NUMBER ALL REMARKS I
G l a s s Roof
P l i n t h , Tongue t o Roof G l a s s
Tapping P l a t e , Tongue P l i n t h
Sealing Ring, Tapping P l a t e
Screw, P l i n t h to Tapping P l a t e
Washer, P l i n t h to Tapping P l a t e
Tongue, Roof G l a s s Front
Screw, 10 UNF, Tongue to P l i n t h
Washer, F l a t , Tongue t o P l i n t h
Washer, Shakeproof, Tongue to P l i n t h
S l o t Recess, LH, Roof Aperture Front
S l o t Recess, RH, Roof Aperture Front
Gasket, S l o t Recess t o Body
Bracket, Anti-rattle, G l a s s Roof If Fitted
Screw, S l o t Recess to Body
Washer, S l o t R e c e s s to Body
Washer, S l o t Recess to B d y
Catch Handle Assy. Roof G l a s s R e a r
S l i d i n g P i n Assy. Catch H a n d l e
Screw, M4 x 10, Sliding Pin Assy. t o Brkt.
Washer, S l i d i n g Pin Assy. t o B r k t .
Mmnting Bracket, Sliding Pin/Body R/B D082U4974E'
Mounting Bracket, S l i d i n g P i n / ~ o d y With Roof Abutrrwt Buffer
Buffer, Rubber, Roof Abutmnt Used With Bracket D082U4974F
Shim, Mounting Bracket t o Body
Screw, M6 x 16, Brkt. to Body
Washer, Bracket t o Body
R e c e s s M l d i n g , Catch Bracket, IA
Recess Mmlding, Catch Bracket, RH
Screw, lJbulding Fix
spire Nut, Moulding Fix
Seal, Roof G l a s s t o Body
Bag, Roof G l a s s Protection Turbo 11.05A
0
NO. QUANTITY lYAY lgg 1 !

REMARKS I
Capping R a i l , LH With ABS I a e r 'A1 P o s t Finisher

Capping R a i l , LH With I n t e g r a l Imer 'A' Post Finisher
Capping R a i l , RH With ABS Imer 'A' P o s t Finisher
Capping R a i l , RH With I n t e g r a l L n w r 'A' Post F i n i s h e r
Pop Rivet, Capping R a i l t o Body
F i n i s h e r , 'A' P o s t Laer, LH ABS Used With Capping R a i l A079B401l.K
F i n i s h e r , 'Ap P o s t Lower, RH ABS Used With Capping R a i l A079B4012K
Pop Rivet, F i n i s h e r Fixing
Drive F a s t e n e r , Black
F i n i s h e r S t r i p , Capping R a i l to Body
Pop Rivet, F i n i s h e r t o Body
Air Scoop, IlI, Engine Bay V e n t i l a t i o n
A i r Scoop, RH, Engine A i r I n t a k e
G r i l l e , LU, A i r Scoop 1 '87 M.Y. on
G r i l l e , RH, A i r Scoop 1
G r m t , A i r Scoop to Body
Rubber Washer, A i r Scoop F i x
Washer, F l a t
Nut, Nyloc, 10 W
F i n i s h e r , 'B1 P o s t , LH
F i n i s h e r , 'B' Post, RH
Pop Rivet, F i n i s h e r F i x
Foam Mesh, 'B' P o s t V e n t i l a t i o n
Wind D e f l e c t o r I n P r i m r . 'Glass Roof ' Models
R e t a i n e r Tongue, LH, Wind Deflector
Retainer Tongue, RH, Wind D e f l e c t o r
Screw, 10 UNF, Tongue t o D e f l e c t o r
Washer, Tongue to Deflector
S t r a p , D e f l e c t o r Retaining
Rivet, S t r a p t o D e f l e c t o r
Spring C l i p , S t r a p Rivet
Turbo 12.01A
4
PRIOR TO '85 M.Y.
v--.
?7
1905 M.Y.
.
22 21
TURBO
12.05A 8
a a
w
I
/'
16
"YE-
TURBO
12.OSA
NO. QUANTITY Mfiy 1991
S i n g l e S t r i p e , 30 mn Wide, Red >

11 11 I1
" Gold > Prior '85 M.Y.
11 I1 II
" Black >
11 In I# Silver >
P i n S t r i p e , 3 mn Wide, Red I
I1 II 11
" Gold I '85 & '86 M.Y.
I1 11 II
Black I
I$ II I# " Silver I
P i n S t r i p e , 3 mn Wide, Red 1
II II 11
" Gold ) '87 M.Y. on
I1 I1 II
" Ble 1
11 II I1
" Silver 1
Black Tape, 8 mn Wide, Spoiler/Wrnper Prior to '85 M . Y .
F i n i s h e r S t r i p , Waistband ('.Squarev P r o f i l e ) Prior to '86 M.Y.
F i n i s h e r S t r i p , Waistband ('Squarev P r o f i l e ) '86 M.Y. P r i o r t o VIN* * VlN 82 D 2360
F i n i s h e r S t r i p , Waistband (vRcmndedvP r o f i l e ) '86 M.Y. on F r a n VIN* 82 - 0691
C a r r i e r , Waistband F i n i s h e r t o Door
Screw, s/t, Carrier t o Door WB Pop R i v e t s
Pop R i v e t , C a r r i e r t o Door
Double Sided Tape, Carrier t o Door
Adhesive, P a r t A, Waistband ini is her
Adhesive, P a r t B, Waistband ini is her
Turbo 12.05A
Pqe 2
I
TURBO
I 12.09A
I
-
ILLUS
NO. QUANTITY

~
Door Mirror, RH, Convex 1

Door Mirror, RH, F l a t Optional 1
Door Mirror, LH, Convex 1
Door Mirror, LH, F l a t Optional 1
Washer, Large O D , Mirror t o Door 1 P r i o r t o VIN 82 D 2137
Nut, Nyloc, M6, Mirror to Door 1 82 - 0606
Mirror Glass, Convex 1
Mirror G l a s s , F l a t 1
Bezel, Mirror 1
Door Mirror, RH, Less Mirror G l a s s >
Door Mirror, RH, Less Mirror G l a s s >
Door Mirror, LH, Less Mirror G l a s s >
Door Mirror, LH, Less Mirror G l a s s > Fran VIN 82 D 2137
Glass/Pad Assembly, Convex > 82 - 0606
Gasket, Door Mirror >
Washer, Mirror to Door >
Nut, Nyloc, M6, Mirror to Door >
Turbo 12.09A
TURBO
l3-03A
0
ruus
NO. QUANTITY
PRIOR
DESCRIPTION PART NUMBER '87 M.l REMARKS
Seat Fram
S e a t F r m , Reclining, RH
S e a t F r a m , Reclining, LH
Spring, Anti-Rattle
S e a t R e c l i n i q Mechanism, RH
S e a t Reclining W h a n i s m , LH
Nut, Nyloc, M8
B o l t , M8 x 60, Button Head
Bolt, M8 x 30, Button H e a l
Stud, Pawl Pivot
Bolt, M8 x 20, Button H e a l
Spacer
Locking P l a t e , T i l t Pawl
Pop Rivet, Lacking P l a t e F i x
Washer, Drive P l a t e Clanp
Washer, Recline Mechanism S h a f t
H a n d w h e e l , Seat Recline
Trim, Handwheel Centre
Badge, Handwheel Trim Centre
Seat Runner, Locking
S e a t Runner, Non-Lockiq
Setscrew, Runner to S e a t F r m
Washer, Runner t o S e a t F r a m
Washer, F l a t , Large O/D, Floor Underside
Nut, Nyloc, M8, Runner t o Floor
Turbo 13.03A
ILLUS
a
NO. QUANTITY
Cushion F m n Q u a n t i t i e s Are Per Car

Backrest Foam
Armrest Foam, RH )Fixed Seat. P r i o r '87 M.Y.
Armrest Foam, LH 1
Armrest Foam, RH >Reclining Seat. '87 M.Y. on
Armrest Foam, LH >
I n s e r t , A r m r e s t Foam
Headrest Foam
Suspension Unit, Backrest
Suspension Unit, Cushion
Flexolator, Backrest, 5 2 h
Flexolator, Cushion, 490mn
Hogring, Flexolator t o Suspension Unit
Tube C l i p , Trim to F r a m
Rivet, Rokut, Cushion U n i t to F r a m
Backboard
Fmn, 3mn, Seat Backboard
Staple
Bracket, Seat Backboard Fix
Pop Rivet, Bracket to Backboard
Washer, Pop Rivet
Screw, Backboard to Seat F r a m
Screw, P r e s s Stud Fix
Press Stud, Headrest Collar Fix
S p i r e Nut, Press Stud F i x
Turbo 13.09A
a
NO. QUANTITY
DESCRIPTION PRIOR
PART NUMBER '87 M.'
rimmed S e a t Assembly, Complete Fixed Backrest.

Trimned Seat Assembly, C a r p l e t e , RH >Reclining.
TrimPTled S e a t Assembly, Complete, LH >
l Flank
Trim Cover, S e a t U 1
Trim Cover, Seat C e n t r e ) E a r l y C a r s With 3 - Piece S e a t Trim
Trim Cover, Seat, RH F l a n k 1
Trim Cover, S e a t , Complete
Trim Cover, Seat, C a r p l e t e , LH

Trim Cover, S e a t , Complete, RH
C o l l a r , S e a t Head R e s t r a i n t
Trim Cover, S e a t Head R e s t r a i n t
Trim Cover, Seat Head R e s t r a i n t , Removeable
Trim Cover, Head R e s t r a i n t Frame
Seat Backboard, T r i m e l
S e a t Backboard, T r i m
* P r e f i x Trim P a r t Numbers With:

A - A l l W t h e r ( S t a t e Smooth or Ruched)
B - A l l Cloth
F - L e a t h e r & C l o t h ( S t a t e Smooth or Ruched:
A l s o S p e c i f y or Supply Sartlple of Colour

and V e h i c l e I d e n t i f i c a t i o n Number ( V I N )
Turbo 13.11A
0
NO. QUANTITY
Seat B e l t Assembly 2
Seat Belt Assembly 2
Seat B e l t Assembly 2
Finisher, Seat Belt Bulkhead S l o t 2
Button, S l o t Finisher Fixing 4
Cover, Seat B e l t Reel, ABS 2
Screw, B e l t Reel Cwer 8
Turbo 13.27A
ILLUS
a
NO. QUANTITY
T h i s Page LHD Only. For RHD See 14.0111
Pedal Box (Uses Threaded S t o p Switch) R/B D079J40595 with s t o p switch A089%019F,
Bush A089M6020F & mtng b r k t A082J4169K
Pedal Box (Uses Push & Twist Stop Switch) With i n t e g r a l t o p mamted s t o p switch b r k t ,
R/B DO79540595 w i t h b r k t A082J4169K
Pedal Box (Uses Push & Twist Stop Switch) U s e s separate rear w t e d s t o p switch b r k t
Setscrew, M8 x 25, Pedal Box to Chassis
Washer, Spring, Pedal Box t o Chassis
Washer, F l a t , Pedal Bcx to Chassis
Bearing, T h r o t t l e Pedal P i v o t
Washer, T h r o t t l e Pedal P i v o t
Bracket, T h r o t t l e Pedal Upstop
Setscrew, M6 x 16, Upstop t o P/Bax
Washer, F l a t , Upstop F i x
Nut, Nyloc, M6, Upstop F i x With No P e d a l Box Weldnuts
Washer, Shakeproof With Pedal Box Weldnuts
T h r o t t l e Pedal
S p l i t P i n , T h r o t t l e Pedal Retention
B o l t , M8 x 60, Pedal Dawnstop
Locknut, M8, Downstcp
B u f f e r , Pedal Dawnstop
Spring, T h r o t t l e Pedal Return
Abutment Bracket, T h r o t t l e Dawnstop
Setscrew, M6 x 16, Bracket F i x
Washer, Large O/D, Bracket F i x
Nut, Nyloc, M6, Bracket F i x
T h r o t t l e Cable, Inc. Adjuster
Grartmret, T h r o t t l e Cable
C l e v i s P i n , Cable t o Pedal
Washer, Cable C l w i s t o Pedal
S p l i t P i n , C l w i s Retaining
Abutment, T h r o t t l e Cable
Pop Rivet, Abutmnt t o Body
Turbo LHD 14.018
Page 1
a
NO. QUANTITY

,
T h i s Page RHD Only. For LHD See 14.01B
Pedal Box (Uses Threaded Stop Switch) R/B D079J4059J with stop switch A089M6019F,
Wlsh A089M6020F & mtg b r k t A08W4169K
Pedal Box (Uses Push & Twist Stop Switch) With i n t e g r a l t o p mamted s t o p switch b r k t
R/B D079J4059J w i t h b r k t A082J4169K
Pedal Box (Uses Push & Twist S t o p Switch) Uses separate rear mcunted s t o p switch b r k t
Setscrew, M8 x 25, Pedal BcDc to Chassis
Washer, Spring, Pedal Box to C h a s s i s
Washer, F l a t , Pedal Bax to Chassis
Bearing, T h r o t t l e Pedal P i v o t
Washer, T h r o t t l e Pedal P i v o t
Bracket, T h r o t t l e Pedal Upstop
Setscrew, M6 x 16, Upstop t o Pedal Bax
Washer, F l a t , Upstop F i x
Nut, Nyloc, M6, Upstop F i x With No Pedal Box Weldnuts
Washer, Shakeproof With Pedal Box Weldnuts
T h r o t t l e Pedal R/B C079J4060F With D x n s t o p
T h r o t t l e Pedal, With Downstop
B o l t , M8 x 45, T h r o t t l e Pedal Downstop
Nut, M8, Downstop Iacknut
Spring, T h r o t t l e Pedal Return
Lever, T h r o t t l e
S p i r o l P i n , M5 x 30, Lever to Pedal S h a f t
T h r o t t l e Cable, Inc. Adjuster
Gromrret, T h r o t t l e Cable
Washer, Cable C l e v i s t o Lever
S p l i t P i n , Cable C l e v i s t o Lever
Abutment, T h r o t t l e Cable, F r o n t
Pop Rivet, Abutment to Body
Bracket, T h r o t t l e Cable Abutment On Plenum B/Plate)With Hairpin
Trunnion Barrel, Carb. T h r o t t l e Lever Less Clanp Screw )Type Carb.
Barrel, S o l d e r l e s s Nipple (Modify) )Lever Return
Screw, S o l d e r l e s s Nipple Spring
Turbo RHD 14.01A
Page 1
a
ILLUS
NO. QUANTITY
plpy w91 1
T h i s Page RHD Only. For LHD See 14.01B

Bracket, T h r o t t l e Cable Abutment ) U s e d With Extension Type Carb.
Trunnion B a r r e l , Carb. T h r o t t l e Lever )Lever Return Spring, With S/Less
Spacer, Trunnion t o Nipple )Nipple A t Pedal End. Replace P a r t s
B a r r e l , S o l d e r l e s s Niple Ibbrked * With P a r t s Marked + And F i t
Screw, S o l d e r l e s s Nipple )S/Less Nipple A t Carb. End. Refer To
)S/B 1985/08
Bracket, T h r o t t l e Cable Abutmnt >Used With Extension Type Carb.
Trunnion B a r r e l , Carb. T h r o t t l e Lever >Lever Return Spring, With S-s
Spacer Trunnion t o Nipple >Nipple A t Carb. End.
S o l d e r l e s s Nipple >
Setscrew, Abutment Bracket t o Plenum
Washer, Spring, Abutment Bracket to Plenum
Anchor Bracket, T h r o t t l e Cable t o Cam C w e r

Screw, Anchor Bracket to Cam Cover
S o l d e r l e s s Nipple, T h r o t t l e Cable
Cable Extension
Trunnion Barrel, Carb. T h r o t t l e Lever
Spring P l a t e , T h r o t t l e Return Spring
Pedal, Brake and Clutch P r i o r t o '85 Model Year

Pedal, Brake and Clutch '85 Model Year Omard
Pad, Brake & Clutch Pedals
P i v o t Bush, Brake & Clutch Pedals
Spacer, ~ r a k e / c l u t c h P e d a l s
S h a f t , Brake and Clutch Pedal P i v o t
S p l i t P i n , Pedal S h a f t Retaining
Setscrew, M8 x 50, Brake/Clutch Upstop
Locknut, M8, ~ r a k e / C l u t c hUpstop '85 Model Year Onward
Switch, Stop Light ) Thread & Nut Fixing
Locknut, Stop Switch 1
Turbo RHD 14.01A
Page 2
NO. QUANTITY
This Page RHD Only. For LHD See 14.OLB

Switch, Stop Light > ' ~ u i c l ; f i t ' , Push and mist
Bush, Stop Switch R e t e n t i o n a l >
Bracket, Stop Light Switch Mounting Used with Pedal Box D079J4059J
F o o t r e s t , Left FootBrake/Clutch Upstop
Jacknut, M5, F o o t r e s t Fixing
Setscrew, M5 x 12, F o o t r e s t Fixing
C w e r , Footrest
Jacknut, M6, C w e r Fixing
Setscrew, M6 x 12, Cover Fixing
Washer, Shakeproof Cwer Fixing
Choke IRver 1
Bracket, Choke Lever Mounting 1
Pop Rivet, 1/8", Bracket F i x 1
Pivot Pin, Choke Lever 1
Bush 'Start01 Ring', Choke Lever Pivot )With Tunnel Mrxlnted Choke Control
Bracket, Choke Cable Abutnent 1
Clip, Choke Cable Abutnmt 1
Choke Cable 1
Micro-Switch, Choke Warning 1
Choke Cable ( i n c . Micro Switch) >
Mounting P l a t e , Choke Cable t o Fascia >With Fascia Mounted Choke Control
Pop Rivet, Mcunting P l a t e to Fascia >Prior t o VIN 82 D 2402
Clip, Choke Cable to Engine Bay R e a r
Choke Cable ( i n c . Micro Switch)
> 82 0708 -
Mounting P l a t e , Choke Cable to Fascia )With F a s c i a Mrxlnted Choke Control
Pop Rivet, Mamting P l a t e t o Fascia I F r a n VIN 82 D 2402
Washer, Pop Rivet 1 82 - 0708
C l i p , Choke Cable t o P l a t e
Turbo RHD 14.01A

Page 3
TURBO LHD
lLOl B
a
ILLUS
NO. QUANTITY
T h i s Page LHD Only. For RHD See 14.01A

Bracket, T h r o t t l e Cable Abutmnt On Plenum B/Plate )With Hairpin Type
Trunnion B a r r e l , C a b . T h r o t t l e Lever Less Clanp Screw ) C a b . Lever Return
B a r r e l , S o l d e r l e s s Nipple (modify) ) Spring
Screw, S o l d e r l e s s Nipple 1
Bracket, T h r o t t l e Cable Abutnwt )Used With Extension Type Carb.Lever
Trunnion Barrel, Carb. T h r o t t l e Lever )Return Spring, With S/LRSS Nipple A t
Spacer, ~ r u n n i o nt o Nipple )Pedal End. Replace P a r t s Marked * With
B a r r e l , S o l d e r l e s s Nipple ) P a r t s Marked + And F i t S/Less Nipple A t
Screw, S o l d e r l e s s Nipple )Garb End. Refer To S/B 1985/08
Bracket, T h r o t t l e Cable A b u m n t >Used With Extension Type Carb. Lever
Trunnion B a r r e l , Carb. T h r o t t l e Lever >Return Spring, With S / k s s Nipple A t
Spacer Trunnion t o Nipple X a r b . End.
S o l d e r l e s s Nipple >
Setscrew, Ahtrnent Bracket to Plenum
Washer, Spring, Abut. Brkt. t o Plenum
Anchor Bracket, Throttle Cable to Cam Cover

Screw, Anchor Bracket t o Cam C w e r
S o l d e r l e s s Nipple, T h r o t t l e Cable
Cable Extension ) '87 M.Y. on
Trunnion B a r r e l , Carb. T h r o t t l e Lever
Spring P l a t e , T h r o t t l e Return Spring
Pedal, Clutch P r i o r to '85 We1 Y e a r
Pedal, Clutch 1985 Model Year Onwards
Pedal, Brake P r i o r to '85 Model Y e a r
Pedal, Brake 1985 Model Y e a r Onwards
Pad, Brake & Clutch Pedals
P i v o t Brush, Brake & C l u t c h Pedals
Spacer, ~ r a k e / C l u t c hPedals
S h a f t , Brake & Clutch Pedal P i v o t
S p l i t Pin, Pedal S h a f t Retaining Turbo LHD 14.01B
Page 2
0
NO. QUANTITY MAY 1991
T h i s Page IlZD Only. For RHD See 14.01A

Setscrew, M8 x 50, Brake/Clutch Upstop
lhcknut, M8, ~ r a k e / C l u t c h Upstop
Switch, Stop Light ) T h r e d & Nut F i t t i n g
Locknut, Stop Switch 1
Switch, Stop Light >Quickfit', Push & mist
Bush, Stop Switch Retention >
Bracket, Stop Light Switch Mamting U s e d with Pedal Box D079J4059J
Choke lever 1
Bracket, Choke Lever Mounting 1
Pop Rivet l/8" Bracket F i x 1
P i v o t Pin, Choke Lever 1
Bush, 'Start01 Ring' Choke Lever Pivot )With Tunnel Mounted Choke Control
Bracket, Choke Cable Abutmnt 1
C l i p , Choke Cable Abutmnt
Choke Cable
Micro-Switch, Choke Warning
Choke Cable (inc. Micro Switch) >
Mounting P l a t e , Choke Cable to Fascia >With F a s c i a Mounted Choke Control
Pop Rivet, Mounting P l a t e to Fascia >Prior to VIN 82 D 2402 Outer Cable
C l i p , Choke Cable to Engine Bay Rear > 82 - 0708 Length 3.0m
Choke Cable ( inc. Micro Switch)
Mamting P l a t e , Choke Cable t o Fascia )With F a s c i a Mounted Choke Control
Pap Rivet, Mounting P l a t e to Fascia )From VIN 82 D 2402 Outer Cable
Washer, Pop Rivet 8 2 - 0708 Length 2.7m
Clip, Choke Cable to P l a t e 1
Turbo LHD 1 4 . 0 1 ~
Pqe 3
TURBO
1
!
14.05A
!
IUUS
DESCRIPTION PART NUMBER RHD REMARKS
Fascia, Trimmed With Rectangular C e n t r e Vents

Fascia, T r i d With R a n d C e n t r e Vents. N o Choke Aperture
Fascia, T r i n m d , Square Choke Cable Aperture ) R m d Centre Vents. Choke Cable Aperture
F a s c i a , T r i d , ' D l Shape Cable Aperture 1
Fascia, Trirraned With Rectangular Centre Vents
Fascia, T r h m d With R a n d C e n t r e Vents. N o Choke Aperture
Fascia, T r i d , Square Choke Cable Aperture ) R m d Centre Vents. Choke Cable Aperture
F a s c i a , T r i d , ID' Shape Cable Aperture 1
Jacknut, M6, F a s c i a Fixing
Bracket, F a s c i a t o 'A' Post
Trim C w e r , Screen Landing With P e r f o r a t i o n s f o r Concealed Speakers
Trim C w e r , Screen Landing P l a i n . Cut Speaker Apertures i f Required
Column Shroud, Top, Trimned
Column Shroud, Bottom, T r i d
S p i r e Nut, Column S h r a d Fixing
* P r e f i x T r i m P a r t Numbers With:
A - Leather ( S t a t e 3~10th or Ruched)
B - C l o t h (Brushed V e l a r
Also S p e c i f y or Supply Sanple of
Colour and Vehicle I d e n t i f i c a t i o n
t Change Point: VIN 82 D 2402

82 -
0708
Turbo 14. O5A

TURBO
14.07A
e
ILLUS
a
NO. QUANTITY MAY IS.:^,
I n s t m n t Mounting Panel, S t e e l White Illumination

I n s t m n t Mamting Panel, S t e e l Green Illumination. R/B E082U473QJ
Inst-t Maunting Panel, S t e e l '87 M.Y. on
Bracket, I n s t m n t Panel to Binnacle P r i o r t o '87 M.Y.
Bracket, Instrument Panel t o Binnacle 1
C l i p , I n s t m n t Panel t o Bracket 1'87 M.Y. on
Screw, s/t, No. 6 x f " , Panel F i x 1
S p i r e Nut, Panel Fix 1
Mask, Instrument Panel, ABS P r i o r t o '87 M.Y.
Mask, I n s t m n t Panel, ABS '87 M.Y. on
S i d e Panel, Binnacle, RH, S t e e l
S i d e Panel, B i n n a c l e , IH, S t e e l
Bracket, Fuelfloltn&er Mounting
Mask, Side Panel, RH, ABS
Mask, S i d e Panel, IH, ABS
Turbo 14.07A
,1
1
I
I
1
I
1
I
I
I
I
!
TURBO
i
I
14.08A
~
I
1
ILLUS
a
NO. QUANTITY
C e n t r e Console, Trimred, i n c . L e v e r G a i t e r ) F e t t l e R a d i o A p e r t u r e as R e q u i r e d
~ l a n k i n gP a n e l , T r M , R a d i o A p e r t u r e ) P r i o r t o V I N 82 D 2153
L i g h t Box, Heater/A/C C o n t r o l s 82 - 0609
S p a c e r , Heater/A/C C o n t r o l s
C l o c k M u t i n g P a n e l , ( ABS ) )> E s s e x m r a t i v e Only
C a s s e t t e S t o r a g e Bin, (ABS) 1>
C e n t r e Console, Trimred, inc. G a i t e r & B r k t s . > VIN 82 D 2153 t o 2270

B l a n k i n g P a n e l , T r i d , Radio Aperture > 82 - 0609 t o 0622
B r a c k e t , C e n t r e Console, Rear >
S e t s c r e w , M6 x 20, C o n s o l e t o T u n n e l >
Washer, F l a t , C o n s o l e to T u n n e l >
Rawlnut, M6, C o n s o l e t o T u n n e l > ] A l t e r mtives
Rawlnut, M6, 'Neoprene' C o n s o l e t o T U M ~ >I
N m n t i n g B r a c k e t & L i g h t Bax, Heater/A/C
Controls
Screw, Heater/A/C B r a c k e t F i x
S p i r e Nut, Top F i x
Edge P r o t e c t o r , 'Neoprene'
C e n t r e Console, T r i m f e d , i n c . G a i t e r & B r k t s . ) F r a n VIN 8 2 D 2271

B l a n k i n g P a n e l , Trimrred R a d i o A p e r t u r e 1 82 - 0623
F a s t e n e r , Blanking P a n e l F i x
B r a c k e t , C e n t r e Console, R e a r
S e t s c r e w , M6 x 20, C o n s o l e to Tunnel
Washer, F l a t , C o n s o l e t o T u n n e l ) * P r e f i x T r i m P a r t Numbers With :
Rawlnut, M6, C o n s o l e to T u n n e l ) A - L e a t h e r ( S t a t e S o o t h or Ruched)
B - C l o t h (Brushed Velour)
A l s o S p e c i f y or S u p p l y Sample o f
C o l o u r and V e h i c l e I d e n t i f i c a t i o n
Number (VIN)
T u r b o 14.08A
Page 1
-..--
I
-._
TURBO 23
14.08A
NO. QUANTITY
Mounting Bracket Light Bax, Heater/s/C

&
Controls 1 Fran VIN 82 D 2271
Screw, Bracket to Tunnel Top 2 1 82 - 0623
Washer, Flat, Console/Brkt. to Fascia 2 1
Wing Nut, Console/Brkt. to Fascia 2 1
Washer, Shakeproof, Console/Brkt. to Fascia 2 1
Gaiter, Gear Lever 1
Retaining Ring, Gear Lever Gaiter 1
Choke/Window Switch Panel, T r i m 1 With Tunnel Mated Choke Control
Window Switch Panel, Trimred 1 With Fascia Mnted Choke Control
* Prefix Trim Part Numbers With :

A - mther (State Smooth or Ruched)
B - Cloth (Brushed Velour)
Also Specify or Supply Sanple of
Colour and Vehicle Identification
Turbo 14.08A
Pirge 2
TURBO
14.10A
ILLUS
NO. QUANTITY
Instrurrrent Binnacle, Trirnrrred

Foam Binnacle, I n t e r i o r , Anti-Rattle
Mounting Bracket, Binnacle t o F a s c i a
Setscrew, M6 x 18, Binnacle to Brkt.
Washer, Large O/D, Binnacle t o Brkt.
F a s c i a ~ l a n k i n gPanel, Trim&, RHD
F a s c i a ~ l a n k i n gPanel, T r i d , LHD
* P r e f i x Trim P a r t Number With:

A - Leather
-
B C l o t h (Brushed Velcur 1
Also Specify or Supply Sanple of
Colour. and Vehicle I d e n t i f i c a t i o n
Turbo 14.10A
TURBO
14.12A
NO. QUANTITY
Glwe Box Lid, Trimned

Glove Box Inner, RHD
Glwe Box Inner, LED
Screw, Glwe Box Inner Top Edge F i x
S p i r e Nut, Glwe Box Top Edge F i x
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 F a s c i a Beam
Latch, Glwebox Lid
Bracket, Latch to F a s c i a
Screw, Latch t o Bracket
Nut, 4BA, Latch t o Bracket
Nut, Nyloc, 6BA, S t r i k e r t o L i d
Washer, S t r i k e r t o Lid * r e f i x Trim P a r t Nunhers With:
A - Leather ( S t a t e 3 1 ~ 0 t hor Ruched)
B - C l o t h (Brushed V e l a r )
Also S p e c i f y or Supply Sanple of
Colour and Vehicle ~ d e n t i f i c a t i o n
Turbo 14.12A
j
I
I
~
TURBO
15.01A
- -
e
ILLUS
NO. QUANTITY
MAY 14'iir
FIXED GLASS
DESCRIPTION PART NUMBER ZEOOF ROaF
REMARKS
Header R a i l , Trim& N o Clock - 'Essex' Cars Only

Header Rail, T r i n m d For 'Rocking Bar' Type Clock
Header R a i l , T r i d For 'Pin Button' Type Clock
Header Rail, Trimtled For 'Pin Button' Type Clock
Header R a i l , Trimrred For 'Rocking Bar' Type Clock
Cant Rail, T r i m e d , RH
Cant Rail, T r i m , RH,
Cant Rail, Trimred, LH,
Cant R a i l , Trimred, LH,
Bracket, Cant R a i l , Fixing
Screw, Header & Cant R a i l Fixing
'A' Post Trirrm3d Panel, RH 'Essex' Cars Only
'A' Post Tr- Panel, RH
'A' Post Trimred Panel, LH 'Essex' Cars Only
'A' P o s t Trimred Panel, LH
C l i p 'A' Post Trim Fixing
Headlining,
Mirror, I n t e r i o r S t i c k On
Mirror, I n t e r i o r Screw On
Screw, 2BA, Mirror to Header R a i l
Nut, Nyloc, 2BA, Mirror Fixing
Washer, Mirror Fixing
Sun V i s o r , Drivers, RIO
Sun V i s o r , Drivers, RHO, with ' t b c w e n t Strap
Sun V i s o r , Drivers, LED
Sun V i s o r , Drivers, LHD, with 'Docummt Strap
Sun V i s o r , Passenger, RIO With Mirror
Sun V i s o r , Passenger, LHD With Mirror
Swivel, Sun V i s o r * P r e f i x Trim P a r t tUumbers With:
Washer, Sun V i s o r Swivel A - Leather
Washer, Sun V i s o r Swivel B - Cloth (Brushed V e l o u r )
Nut, Nyloc, M6, Sun V i s o r Swivel Also S t a t e or Sumly Sanple of C o l a
& Vehicle ~ d e n t i f i c a t i o nNu&x?r ( V I N )
t S t a t e or Supply Sanple of Colmr

Turbo 15.01A
! TURBO
15.11A
I
ILLUS
NO. QUANTITY
m u IYYl
--
FIXED GLASS
DESCRIPTION PART NUMBER ROOF Rm? REMARKS
Bulkhead Trimwd Panel For I n t e r i o r Lanp w i t h Rocking Lens Switch

Bulkhead Trirm.4 Panel For I n t e r i o r Lanp with Button Switch
Bulkhead Trirrmed Panel '87 M.Y. on
Bulkhead Trimned Panel 1 For I n t e r i o r Lanp w i t h Rocking Lens Switch
Bulkhead Trimred Panel 1 For I n t e r i o r L a q w i t h Button Switch
Bulkhead T r i m Panel 1 '87 MY. on
G r i l l e , Rear Bulkhead, A i r O u t l e t 4
Screw, Rear Bulkhead Trim Fixing 4
Screw, Rear Bulkhead Top Fixing 2
Map Pocket, T r h m d 1 P r i o r t o '87 M.Y.
Map Pocket, Trimned 1 '87 M.Y. on
Doweling, Bulkhead Trim Fixing
C l i p , Bulkhead Trim -ling
Screw, C l i p t o ~uLkheadTrim
Screw, C l i p t o Body
S l o t Finisher, Seat Belt 2
Button, S l o t F i n i s h e r Retaining 4 * P r e f i x Trim P a r t Numbers With:
A - Leather ( S t a t e Smooth or Ruched)
B - C l o t h (Brushed Velour)
hso-state or Supply Sanple of ~ o l o u r
& Vehicle I d e n t i f i c a t i o n Number (VIN)
Turbo 15.11A
TURBO
15.13A
a
a
NO. QUANTITY
15.131 DESCRIPTION B R T NUMBER REMARKS
Door Trim Panel, Trimned, IH N o Ashtray. N o Speaker 1

Door Trim Panel, Tr-, LH No Ashtray. Speaker P e r f o r a t i o n s )
Door Trim Panel, Trhmd, IH With Ashtray. N o Speaker 1
Door Trim Panel, Trirmd, LH N o Ashtray. No Speaker 1
Door Trim Panel, Trim&, LH N o Ashtray. Speaker P e r f o r a t i o n s )
Door Trim Panel, TrimTed, LH With Ashtray. No Speaker I t
Door Trim Panel, Trirrmed, RH N o Ashtray. N o Speaker 1
Door Trim Panel, Trirnred, RH No Ashtray. Speaker P e r f o r a t i o n s
Door Trim Panel, Trimwd, RH With Ashtray. No Speaker 1
Door Trim Panel, Trimd, RH No Ashtray. No Speaker 1
Door Trim Panel, T r i m , RH N o Ashtray. Speaker P e r f o r a t i o n s )
Door Trim Panel, Trhmd, RH With Ashtray. No Speaker 1
t P r i o r t o V I N 82 D 2137
82 - 0606
Door Trim Panel, Trinmd, L,H >
Door Trim Panel, Tr-, LH >
Door Trim Panel, Trimtled, RH >
Door Trim Panel, Trimred, RH > FranVIN 82 D 2137
Stud P l a t e , Mirror Switch Fixing > 82 - 0606
Bracket, Mirror Control Switch Mcunting > P r i o r t o '87 M.Y.
Nut, Nyloc, M5, ~ r a c k e t / ~ t uPdl a t e >
For S i l l Mounted Ashtray, See 15.30A
P r e f i x Trim P a r t Numbers With:

A - A l l Leather ( S t a t e S m o t h or Ruched)
B - A l l Cloth
-
F l e a t h e r & C l o t h (Brushed V e l m r 1
Also S t a t e or -1y Sanple of Colour
Vehicle Identification Number (WIN)
Turbo 15.13A
Page 1
TURBO
15.13A
0
NO. QUANTITY
Door Trim Panel, T r i m & , LH 1

Door Trim Panel, Trim&, LH 1
Door Trim Panel, Trim-&, RH 1
Door Trim Panel, Trirnred, RH 1'87 M.Y. on
Stud P l a t e , Mirror Switch Fixing 1
Bracket, Mirror Control Switch Mounting 1
Nut, Nyloc, M5, Bracket t o Stud P l a t e 1
Flange, Window Weatherstrip Mcunting For C l i p on W/Strip,Inc. i n T r i m d Door
Flange, Windaw Weatherstrip Mounting For S t i c k on W / S t r i p , ~ a n e l
Ashtray Assembly (Chrarre F r m ) -.All Door Trim Panels Inc. Flange
Ashtray Assanbly (Black F r m ) S u i t a b l e f o r ' S t i c k o n t Type m t h e r s t r i p
Clarrp Bracket, Ashtray A089V6166V (See 11.01 A )
Screw, Ashtray Fixing
Door P u l l Handle, T r W , LH ) P r i o r '87 M.Y.
Door P u l l Handle, T r i m ~ d ,RH 1
Door P u l l Handle, Trirtxwd, LH >I87 M.Y. on
Door P u l l Handle, Trimrred, RH >
Washer, Door P u l l Handle F i x
Nut, Nyloc, M6, Handle Top F i x
Setscrew, M6 x 16, Handle m r F i x For Female Threaded Handle
Spacer, Handle Iower to Door 1
Nut, Nyloc, M6, Handle Imer F i x )For Handle With Stud
Screw, Door Trim Panel Fixing
Tapping P l a t e , Door Panel Screws
Pop Rivet, Tapping P l a t e t o Door S h e l l For S i l l Mcunted Ashtray, See 15.30A
P r e f i x Trim P a r t Numbers With:

A - A l l Leather ( S t a t e Smsoth o r Ruched)
B - A l l Cloth
F - m t h e r & C l o t h (Brushed V e l m r )
Also S t a t e or Supply Sanple of Colour
Vehicle I d e n t i f i c a t i o n Number W I N )
Turbo 15.1%
Page 2
TURBO
I 15.19A
ILLUS
a
NO. QUANTITY
I
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 )Alternatives
Rawlnut, M6 x 15, Tunnel Side Fixing 1
Tunnel Top Armrest, Trimrred P r i o r to '87 M.Y.
Tunnel Top A r m r e s t , T r h m d '87 M.Y. on
Clip, Tunnel A r m r e s t Fixing
P l a t e , Gear Lever Aperture
Gasket, Aperture P l a t e to Body
Screw, Aperture P l a t e t o Body
G a i t e r , G e a r Lever, l h e r
Clanp Ring, Gear Lever Imer G a i t e r
Screw, G a i t e r Clanp Ring Fixing
P l a t e , Tunnel I a a n Retaining
Screw, P l a t e t o Body *Prefix Trim P a r t Numbers With:
A - Leather ( S t a t e Smoath or Ruched)
B - Cloth (Brushed Velour)
Also S t a t e or Supply Sanple of Colour

& Vehicle I d e n t i f i c a t i o n W r WIN)
Turbo 15.19A
i TURBO
15.24A
ILLUS
NO. QUANTITY
923
PRIOR
-
15 M.Y.
Luggage Bag Assen33ly 1

Fixing S t r i p , Ehg t o R e a r Panel 1
Screw, Fixing S t r i p 6
S p i r e Nut, Fixing S t r i p 6
Rear Luggage t- Grey Fleck Carpet
Side, LEI
Wheelarch, IH
Engine Bay R e a r W a l l
Floor
R e a r Transan
B a t t e r y Board, Carpeted
Button, 'Durable D o t ' , Carpet Fixing
Socket, 'Durable Dot', Carpet Fixing
Bracket, Battery Board Top Lccating
Pop Rivet, Battery Board Bracket
Washer, Pop Rivet
I n f i l l Panel, IH R e a r Corner 1
R e a r , Bulkhead 1
R e a r , Quarter Light Trim Panel, RH 1
R e a r , Quarter Light Trim Panel, III 1
Turbo 15.24A
TURBO
15.30A
a
NO. QUANTITY
DESCRIPTION P#RT NUMBER REMARKS
Carpet, Footwell Front Specify or Supply Sanple of Colour I
Carpet, Front Floor, With M a t , RH & Vehicle I d e n t i f i c a t i o n N u m b e r ( V I N )

Carpet, Front Floor, With Mat, RH
Carpet, Front Floor, With Mat, LH * S t a t e i f Ashtray i n S i l l I
Carpet, Front Floor, With Mat, LH

Carpet, Underseat For Door Mounted Ashtrays, See 15.13A
Carpet, Front Wheelarch, With Mat, RH
Carpet, Front Wheelarch, With Mat, LH
Carpet, S i l l , RH, (Inc. H/Brake Gaiter) Includes GRP
Carpet, S i l l , RH With Heater Only) S i l l Panel
Carpet, S i l l , RH With a/c and ( i f a p p l i c a b l e )
Carpet, S i l l , LH With Heater Only) a/c hose ABS
Carpet, S i l l , llI With a/c ccnrer
Carpet, S i l l , LH, (Inc. H/E3rake G a i t e r ) 1
Gaiter
Carpet, Tunnel Side, RH
Carpet, Tunnel Side, LH
Carpet, R e a r Bulkhead, RH
Carpet, Rear Bulkhead, LH
Ashtray, S i l l m t e d
Turbo 15.30A
1 TURBO
16-01A
ILLUS
e
NO. QUANTITY
Foam, Front Floor, RH

Foam, Tunnel Side, RH
Foam, Tunnel Tcp
Foam, Tunnel Side, IH
Foam, Front Floor, LH
Foam, Underseat
Foam, Rear Bulkhead Uwer, RH
Foam, Rear Bulkhead Upper
Foam, Rear Bulkhead Iaer, LH
Felt, Wheelarch, LH
Felt, Wheelarch, RH
Turbo 16.01A
ILLUS
NO. QUANTITY
Sound l3arrier Mat, Rear B u l k h a 1

Screw, s/t, No. 6 x f ",Mat Fixing 14
Cup Washer, Mat Fixing Screw 14
Faam, Tunnel Top Underside 1
Faam, T U M Side,
~ Underside 2
Faam, Pedal Bax Seal 2
Foam, Chassis Front Crossnrember 1
Pad, Anti-Squeak 1
Sound Proofing , Engine Bay Sidewall 1 '87 M.Y. on
Turbo 16.02A
-
a
NO. QUANTITY
Extension Harness, Mirror 1

Main Harness 1 P r i o r to '87 M.Y.
Main Harness 1 1
Gromrret, Main Harness, Bulkhead & Engine Bay 2 1'87 M.Y. on. H.C. Engines only
Bush, G r m t 2 1 I
Door Mirror Harness 1
Harness, Door Mirror Control 1 F r m VIN 82 D 2137
82 - 0606
Alternator Harness 1
Earth Led, Tailanps 2
Reverse Lanp Lead 1
Door Ajar Iap Harness 2
Rad. Fan Harness 1 Used Only w i t h Rad. Fan Thermal T r i p
Cigar Lighter E a r t h h s 3 2
Cigar Lighter Harness 1
A i r Conditioning Harness 1 With Orange 'Cartier' D.P. Fan Relay
A i r Conditioning Harness 1 With Dmble Contact Relay
H e a t e r Only Harness 1 With Orange 'Cartier' D.P. Fan Relay
H e a t e r Only Harness 1 With Dcuble Contact Relay
Door Harness 2
Front S i d e n u r n Lanp Extension Harness 2 For C i r c u l a r Diffusion P a t t e r n bnps
R e p e a t e r Iap Extension Harness 2 Used Only W i t h Later Type Repeater Imps
mt, S t a r t e r / A l t e r n a t o r Terminals 2
m d , Heated R e a r Screen 1
Lead, Heated R e a r Screen 1
I g n i t i o n Harness 1 With ' L m n i t i o n ' I g n i t i o n
I g n i t i o n Harness 1 With Lucas 'Constant Energy' I g n i t i o n
'P' C l i p , I g n i t i o n Harness t o Ign. Bax 1
Screw, 'P' C l i p F i x 1
S p i r e Nut, 'P' C l i p F i x 1
Screw, No. 6 x 3/4", Laan F i x 6
'P' C l i p , Loan F i x 2
'PI C l i p , Door Mirror Control Harness 4 1 Frcan VIN 82 D 2137
P q Rivet, C l i p F i x 4 1 82 - 0606
Turbo 17.01A
Page 1
026
010 008 019 018 017
TURBO
17.01A
NO. QUANTITY

REMARKS
Clip, Loan Fix

Clip, I m n Fix
Clip, Loan F i x
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' C l i p Fix
Harness, Radio Feed m r o l a , Sparkanatic, Blaupunkt
Harness, A e r i a l Switch
Speaker Lrxm, Front For Blaupunkt 'Quickfit' Fascia Speakers
Speaker Loan, R e a r Routed Along Tunnel
m d , I g n i t i o n Anplifier to D i s t r i b u t o r With Lucas Constant Energy I g n i t i o n
G r a m & , I g n i t i o n Box
Harness, Engine Managanent '87 M.Y. on
Diode, 1 AM? (Black)
Turbo 17.01A
Page 2
ILLUS
a
NO. QUANTITY
PRIOR
DESCRIPTION PART NUMBER '87 M.Y
F l a s h e r U n i t , Hazard
C l i p , Hazard F l a s h e r U n i t
F l a s h e r Unit, Turn I n d i c a t o r s
Screw, F l a s h e r Unit Fixing
S p i r e Nut, F l a s h e r Unit Fixing
Relay, Double Contact I n n e r H/L ( 2 1, Rad. Fans ( 1) (For C a r s
F i t t e d With T h e m l T r i p ) , I n t e r i o r Fans
(1) (For Cars NCTT F i t t e d With Orange
Relay, Changewer, S i l v e r 30 Anp
' C a r t i e r ' Relay 1 .
R/B B079M6141F
Relay, Changeover, Black 40 Anp Horn ( 1 1 , H/L Control (1) ( P r i o r t o
Fi-t of Diode 1, H/L Flasher ( 1 1 ,
H/L Motor RH ( 1 1 , H/L Motor LH ( 1 1 ,
Fan F a i l ( 1) ( P r i o r t o T h e m l T r i p ) ,
HRS (1).
Relay, Changeover, Black 40 Anp '87 M.Y. On. T h r o t t l e Jack, Purge Punp
I g n i t i o n Solenoid Valve, Overboost Switch
Dim-Dip. 9/C Conpressor (With Switch
A082M6221F 1
Fused Relay, 4RA, Radiator Fans P r i o r t o Thexmal T r i p
' C a r t i e r ' Relay, I n t e r i o r Fans (Orange) P r i o r t o Relay A082M6182F
Moulding ' C a r t i e r ' Relay
Diode, Headlanp Changeover C i r c u i t L a t e r Cars Not Using Relay B079M6141F
Relay Bridge, Rad. Fan C i r c u i t With Fan T h e m l T r i p
Delay Unit, Wipers
Spacer, Delay U n i t t o F a s c i a
Delay U n i t , I n t e r i o r Lanp, Progressive D k r >As F i t t e d
Delay Unit, I n t e r i o r Lamp, T i m 4 Switch >
Horn, Lclw Note 1
Horn, High Note ) E l e c t r i c Horns
Bracket, Horn Mamting 1
A i r Horn K i t With A i r Horns
Turbo 17.03A
Page 1
ILLUS
NO. QUANTITY
PRIOR '87 M.'

DESCRIPTION PART NUMBER '87 M.' ON REMARKS
Setscrew, M6 x 25, Horn Brkt. t o Body 2

Washer, F l a t , Brkt. Fixing 2
Washer, 25mnO/D, Brkt Fixing 2
Nut, Nyloc, M6, Brkt. Fixing 2
Voltage ~tabiliser 1
Diode, Brake Warning Lanp 1
Module, 'DiwDipl 1
Screw, M4 x 30, Unit Fix 1U.K. only
Bracket, Relay Mounting 1
Pop Rivet, Brkt. Fix 1
Module, I# Coolant
Screw, s/t, Module Fix
S p i r e Nut, Module Fix
'PI Clip, Module Fix
Relay Engine Speed Sensing T h r o t t l e Jack Control
Screw, Relay Fix
Nut, Nyloc, 10 LJNE', Relay F i x
Washer, Relay Fix
I g n i t i o n Solenoid Valve
Screw, s/t, No. 8 x 3/8", Solenoid Fix
Washer, Solenoid Fix
Overboost Switch
Screw, No. 8 x 3", Switch F i x
Purge w
R e s i l i e n t Mounts, Purge Purrp
Nut, M6, Purge Pump Fix
Washer, I n t e r n a l Spring, Purge Punp F i x
Thermal Switch, Purge hmp Control M3R 70, BOF 60. Includes G r o m m t
G r m t , Purge Punp Switch
C l i p , Switch Retention
Solenoid Valve, Purge ~ i n S e hut-~ff
Turbo 17.03A
Pqe 2
0
ILLUS
NO. QUANTITY
L i g h t Source, F i b r e O p t i c s 1
Bulb, 12V W , L i g h t Source 1
C l i p , F i b r e O p t i c C a r r i e r t o Switch 4
F i b r e O p t i c L i g h t C a r r i e r , 880mn 1
F i b r e O p t i c L i g h t C a r r i e r , 435mn 2
R h e o s t a t , 27W, Binnacle/Switch Illum. 1
R h e o s t a t , 19.8W, Heater/Cigar Illum. 1
Knob, Rheostat, P l a i n 2
Kncb, R h e o s t a t , w i t h G r a p h i c 2
Heatshield, Rheostat 2 If Fitted
Blanking Plug, L i g h t Source 4
C i g a r L i g h t e r , I n n e r & Outer 2
I l l u m i n a t i o n Ring, C i g a r L i g h t e r 2
Bracket, C i g a r L i g h t e r Mounting 2
Pop R i v e t , Brkt. F i x i n g 8
Switch, D i p / F l a s h / T u r n / ~ o r n 1 On RH S i d e of S t e e r i n g C o l m
Switch, ~ i p / F l a s h / l ? u r n / h o r n 1 On LH S i d e of S t e e r i n g Colurm
Switch, W a s h h i p 1 On LH S i d e of S t e e r i n g Column
Switch, Waswipe 1 On RH S i d e o f S t e e r i n g Colurm
Bracket, Switches t o Column 1
Screw, 10 W x 119, 2 Wash/Wipe Switch t o B r a c k e t
Screw, 10 W x 135 2 Dip/l?lash/Turn Switch t o Bracket
Spacer, Switches t o C o l m 1
Switch, L i g h t i n g 1
C l i p , Bulbholder 1
Switch, Hazard Warning Lanps 1
Switch, Rear Fog Lanps 1
Switch, Heated Rear S c r e e n 1
Switch, Window L i f t 2
C l i p , Window Switch R e t e n t i o n 2
Turbo 17.05A
Page 1
~p
0 0
ILLUS
Switch, Mirror Adjust P r i o r t o Change P o i n t *

Switch, Mirror Adjust 1
Nut, 3/4 UNF, Switch Retaining 1
Spacer, Mirror Adjust Switch )Fran Change P o i n t *
Bezel, Mirror Adjust Switch 1
Spring C l i p , Bezel Retaining 1
Switch, Mirror S e l e c t P r i o r to Change P o i n t *

Switch, Mirror Select Fran Change P o i n t *
Switch, ~ n t e r i o rFan Speed

Switch, I n t e r i o r Fan Speed
Switch, Radio Aerial
Knob, Fan Speed Switch R/B Kncb A089P6102F & Cap A089P6103F
Knob, Fan Speed Switch
Cap, Fan Speed Switch Knob
Control Switch Assy. F r i d g e T a p P r i o r t o VTN 82 D 2153
82 - 0602
Control Switch, F r i d g e Tenp 1

C w e r , Control Switch, (ABS) 1 Fran V I N 82 D 2153
Control Unit, F r i d g e Tenp 1 82 - 0602
Harness, Control Unit to Relay
Knob, F r i d g e Switch R/B Knob A089P6102F & Cap A089P6103F

K n o b , F r i d g e Switch
Cap, F r i d g e Switch Kncb * Change P o i n t V I N 82 D 2137
82 - 0606
Turbo 17.05A
Page 2
ILLUS 4 I
DESCRIPTION PART NUMBER PRIOR REMARKS
87 M.Y
Clock, Digita1,LED (Rocking B a r A d j u s t n w t ) 1 3arly Cars, F l a t Connector Block

Clock, Digita1,LED ( p i n Button Adjustment) 1
Clock, Digital,LED (Rocking B a r Adjustment 1 1 1986 M.Y. Round Connector Block. (R/B
Clock, Digita1,LCD A082M6341F & Jwp Harness A082M4689F)
Screw, M4 x 20, Clock Fixing 2
Washer, F l a t , Clock Fixing 2 ) U s e w i t h Clock A089M6034F
Nut, Nyloc, M4, Clock Fixing 2 1
S p e e d m t e r , 170 nph, RHD 1 hite Illumination
S p e d o n e t e r , 170 nph, RHD 1 ;reen I l l u m i n a t i o n
S p e e d m t e r , 265 kph, IlID 1 dhite Illumination
Speedmeter, 260 b h , LHD 1 ;reen I l l u m i n a t i o n
Bulb, Speedo I l l u m i n a t i o n 1 ?or Speedo ~082N6040/1F
F u e l Gauge 1 aite Illumination
Fuel Gauge 1 ;reen I l l u m i n a t i o n
Boost Gauge 1 t/B A082N6047F
Boost Gauge 1
Bracket, Boost Gauge I l l u m i n a t i o n 1
Lens, Green, I l l u m i n a t i o n Bracket 1
Check Screw, Gauge Danping 1
Water Terrperature Gauge 1 dhite Illumination
Water Tenperature Gauge 1 ;reen I l l u m i n a t i o n
O i l P r e s s u r e Gauge 1 hite Illumination
O i l P r e s s u r e Gauge 1 ;reen I l l u m i n a t i o n
Tachometer 1 dhite Illumination
Tachmter 1 ;reen I l l u m i n a t i o n
Bulb, Tacho I l l u m i n a t i o n 1 Zor Tacho A082N6042F
Voltmeter, B a t t e r y Condition Gauge 1 White I l l u m i n a t i o n
V o l m t e r , B a t t e r y Condition Gauge 1 Green I l l u m i n a t i o n
T e l l q a l e Light Assanbly, RH 1 With S e p a r a t e L m F l u i d & Park. Brake I a n p
Tell-Tale Light Assembly, RH 1 With Canbined Law F l u i d & Park. Brake Lanp
T e l l q a l e Light Assanbly, LH 1 With S e p a r a t e F u e l & Choke L i g h t s
Tell-Tale Light Assembly, LH With Canbined Fuel/Choke Light
T e l l q a l e L i g h t Assanbly, Centre
Lens, Lm O i l P r e s s u r e TellJI?ale
Lens, Law Coolant Level T e l l - T a l e
Turbo 17.07A
a
QUANTITY
WAY is91
Speed0 Cable
'P' C l i p , Cable to Chassis
Pipe, O i l Pressure Gauge , Nut F i t t i n g
p i p e , Boost Gauge, Nut F i t t i n g R/B Items 5 , 6 , 7 and Take-Off Elbow
A910E6772 (See 42.0l.A)
Pipe, Boost Gauge, P l a i n End
Connector Tube, Boost Pipe to Engine
Restrictor, Boost Gauge Pipe
Washer, Oil/Boost Pipe to Gauge
Turbo 17.09A
LUCAS UNEAR UFFUPON PATTERN
SIDEITMW INDICATOR LAMP ,
-
ILLUS
NO. QUANTITY
DESCRIPTION
I PART NUMBER ALL
Turn Repeater Lanp 3/B Lanp A082M6180F and ~ x t e n s i o n

Harness A082M4188F
Turn Repeater Lanp
Screw, Lanp Fixing
~ i d e h u r nLanp, IH 1
Side/l?wn Lanp, RH ]Linear Diffusion P a t t e r n , ' I u m s 9
Lens, S i d e h u r n Lanp 1
Screw, Lanp Fixing 1
S p i r e Nut, Lanp Fixing 1
S i d e m n Lanp, LH 1
Side/lhrn Lanp, RH ) C i r c u l a r Diffusion P a t t e r n , 'Lucas'
Lens, Side/l?wn Lanp 1
Washer, F l a t , Lanp Fixing 1
Nut, Nyloc, M6, Lanp Fixing 1
S i d e h u r n Lanp, IH >
Side/l?wn Lanp, RH >Circular Diffusion P a t t e r n , 'Cobol
Lens, ~ i d e h u r nLanp >
Setscrew, M6 x 25, Lanp F i x >
Washer, M6, Lanp F i x >
Washer, Lanp F i x >
Nut, Nyloc, M6, Lanp F i x >
Rear Lanp Assy. LH
Rear Lanp Assy. RH
Nut, Lanp F i x
Washer, Lanp F i x
Licence P l a t e Lanp
Screw, Lanp Fix
'Door Open' Warning Larrp ( i n c . Gasket 1
S h i e l d , Door Lanp, IH
S h i e l d , Door Lanp, RH
Screw, Lanp F i x
S p i r e Nut, Lanp F i x
Turbo 17.11A
STRATED
a
ILLUS
NO. QUANTITY Mirv &yj
Head- A s s a b l y , Lucas/Hella 4 Fram/unit/Bulb

Headlanp Unit, Lucas/Hella 4 Includes H4 Bulb
Headlanp A s s d l y , Lucas/~ella Frame/Unit/Bulb
Headlanp Unit , Lucas/Hella Includes H4 Bulb
Headlanp Assembly, Inboard, C i b i e 2 Main Beam Only, H I Wllb
Headlanp Assembly, Outboard, C i b i e 2 Unit/Carritqe ~late/Bezel/H4 Bulb
Headlanp Assembly, Outboard, Cibie U n i t/Carriage ~late/Bezel/H4 Bulb
Bulb, Halogen H4, -Dip 4/2
Bulb, Halogen H I , Beam Only 2 C i b i e Inboard
Bulb, Halogen, H4, Y e l l o w France Only. Lucas/Hella Lanps
Screw, Headlanp t o Pod 16 Lucas/Hella
S p i r e Nut, Headlanp t o Pod 16 Lucas/Hella
P l a t e , Headlanp M m t i n g t o Pod 2 >
I n s e r t Bush, Adjuster Screw t o P l a t e 12 >
Adjuster Screw, Headlanp Aim 12 > C i b i e Headlanps
Capsule, V 4 Turn, HeadLanp Mounting 12 >
P q Rivet, Mtg. P l a t e t o Pod 32 >
Washer, Pop R i v e t 32 >
Surround, Headlanps, LH 1 1
Surround, Headlanps, RH 1 )Lucas/Hella Headlanps
Screw, Surround t o Pod 8
Surround, Headlanps, LH 1 > P r i o r t o VIN 82 D 2265 >
Surround, Headlanps, RH 1 > 82 - 0625 > Cibie
Surround, Headlanps, IH 1 )From VIN 82 D 2265 > Hedlanps
Surround, Headlanps, RH 1 82 - 0625 >
Button C l i p , Surround t o Pod 12
Turbo 17.13A
--
a e
ILLUS
NO. QUANTITY
Motor Assanbly, H e a d l a n p Pod R/B A082M4584F

Motor Assembly, H e a d l a r r p Pod Inc. Rotary Link
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, F l a t , Rod End
Connecting Link, Pod Actuation 1
Rod End, 1/4" UNF, Connecting Link )R/B Assembly A082U5006F
Locknut, 1/4" LINE', Rod End 1
Linkage Assembly, Pod Actuation M6 RH/LH Threads
Setscrew, M6 x 30, Link t o Pcd
Nut, Nyloc, M6, Link Fixing
Bracket, Link t o Pod
Setscrew, M6 x 18, Bracket to Pod
Washer, Shakeproof, Bracket t o Pod
Washer, F l a t , Bracket to Pod
Tapping P l a t e , Bracket t o Pod
Turbo 17.15A
ILLUS
NO. QUANTITY
I n t e r i o r Lanp (with rocking l e n s switch) 1

Bracket, Interior Lanp Mamting 1
Bulb, Festoon, I n t e r i o r Lanp, 6W 1
Interior Lanp (with button switch) 1 Fran 1986
Bracket, Interior Lanp Mamting 1
Bulb, Festoon, Interior Lanp, 10W 1
Door Switch, Courtesy Lanp 2
Spacer Washer, Fibre, Switch Adjust rn
Turbo 17.17A
a
ILLUS
NO. QUANTITY
Thermal T r i p , 3-Way, Rad. Fans R e d Spot. R/B BO82M6196F

Therrml T r i p , 3-Way, Rad. Fans Green Spot
Mounting Bracket, Thermal T r i p
P q Rivet, rip Connector M l d g h r k t .
Screw, Mounting Bracket t o Body
Inertia Switch, F u e l Punp Cut Out
Bolt, M5 x 50, Switch F i x
Nut, F u l l , M5, Switch Fix
Washer, Shakeproof, Switch F i x
Fusebox
Screw, 2BA x 1", Fusebox Fixing
Nut, Nyloc, 2BA, Fusebox Fixing
Turbo l7.lgA
- .
a
ILLUS
NO. QUANTITY
Wiper Motor, 16W El/B A085M6163F

Wiper Motor, 29W, Inc. C l a p & Pad Bronze Coloured W o r Casing
Clanp & Pad, Motor Mounting
Setscrew, M6 x 30, C l a n p t o Body
Washer, 25mn O/D, Motor M t g .
N u t , Nyloc, M6, Motor M t g .
Bundy Tube, Motor t o Wheelbarc
Bundy Tube, Wheelbox Runlxlt
Wheelbox Assembly, Inc. Nuts For 'Push-On' Type W i p e r Arm
R/B B083M6227F With Associated
Parts
Bracket, Wheelbox S t a b i l i s i n g 1
Setscrew, Bracket to Body 1
Washer, Bracket t o Body 1
Nut, Torqloc, Bracket to Body 1
Spacer, Wheelbax t o Body 1 'Push-on' Wiper Arm
Spacer, Lacking P l a t e t o Body 1
Locking P l a t e , Pantograph Arm 1
Lacking P l a t e , Pantograph Ann 1
Screw, Locking P l a t e to Body 1
Wheelbox Assembly Inc. Nuts >
Bracket, Wheelbox S t a b i l i s i n g >
Setscrew, Bracket to Body >
Washer, Bracket to Body >'Bolt-on'
N u t , Torqloc, Bracket to Body > Wiper Arm
Spacer, Wheelbax t o Body, 13m 1Selected by >
Spacer, Wheelbox to Body, hrm )Body Thickness >
Spacer, Locking P l a t e to Body, Arm With p/g swivel j o i n t >
Spacer, I m k i n g P l a t e to Body, 6.5mn with p/g b a l l j o i n t >
T u r b l7.2lA
Page 1
QUANTITY
NO. MA
UM
Radio/Cassette Unit National Panasonic 973

Radio/Cassette Unit National Panasonic 583
Radio/Cassette Unit Motorola 'Lotus'
Radio/Cassette Unit S p a r k t i c SR309F
Radio/Cassette Unit Blaupunkt Cambridge
Radio/Cassette Unit Blaupunkt Boston
Radio/Cassette Unit Blaupunkt Toronto
Radio/Cassette Unit Clarion '950'
Radio/Cassette Unit Clarion '920'
F i t t i n g K i t , Blaupunkt U n i t s R/B A082M6309F
F i t t i n g K i t , Blaupunkt U n i t s
Diode, 1 Arrp, Radio Harness )National Panasonic Unit
Support Bracket, Radio t o Tunnel
Speaker, 4 ohm, Frontmeat- Audax. No G r i l l e s on F a s c i a
G r i l l e , Speaker, Rear Bulkhead With
)I Audax
In Speakers
I#
Spacer, Speaker
Screw, M4 x 20, F r o n t Speaker F i x 11 I1 11
Nut, M4, Front Speaker Fix II I1 II
Washer, Front Speaker F i x II II II
Screw, Rear Speaker F i x II I1 11
Speaker Cable, R e a r , S h o r t II II II
Speaker Cable, Rear, Lmg I1 II II
Speaker Cable, Front I1 II II
Speaker, Oval, Door Mamted

Harness, Door Speakers
Speaker, F a s c i a , O IW Inc. F a s c i a G r i l l e
Speaker Cable, F r o n t
Speaker, F a s c i a , 'Quickfit' 15W IBLaupunkt
Locm, F r o n t Speaker
Loan, Front Speaker Clarion
Turbo 17.27A
Page 1
LHD SHOWN
ILLUS
a
NO. QUANTITY
MAY
Locking P l a t e , Pantograph A ~ T I with p/g swivel j o i n t >

I1 I1 II I0
with p/g ball j o i n t >
II
I1
II
II
I1
II
II
II
with p/g swivel j o i n t >' Eblt-on '
with p/g b a l l joint > W i p e r Arm
Screw, Locking P l a t e t o Body with p/g swivel j o i n t >
Screw, Locking P l a t e t o Body with p/g ball j o i n t >
Bracket, Downstop
Screw, Downstop Fixing
W i p e r A r m Assgnbly
W i p e r Arm Assembly
Bezel
W i p e r Arm Assembly >
W i p e r Arm Assgnbly >'Eblt-Onl Wiper Arm with Pantograph
Washer, W i p e r Arm N u t > Arm Swivel J o i n t
Adaptor P l a t e , W i p e r Arm Converts Swivel J o i n t t o B a l l J o i n t
W i p e r Arm Assembly 1
W i p e r Arm Assgnbly )'Eblt-Onl W i p e r Arm with Pantograph
Washer, W i p e r Arm N u t ) Arm B a l l J o i n t
W i p e r Blade
Grarmet, Washer Tubing
Washer hurp & Reservoir Assembly
Mounting Bracket, Washer Reservoir
Screw, Washer B r k t . t o Body
Washer, Washer Brkt. t o Body
Washer Tubing, 4mn
Twin Jet, Windscreen Washer
Turbo l7.2lA
Page 2
TURBO
17.27A LHD SHOWN
a a
0
NO. QUANTITY

ALL
Speaker, R e a r , 25W I P ~ Blauplnkt

Cable, Short, Rear Speaker 1 1
Cable, Long, R e a r Speaker 1 )Routed Along S i l l
Loan, R e a r Speakers 1 R a k e d Along Tunnel
Speaker, Rear, Eurotech 2 1
G r i l l e , R e a r Speaker, w i t h Badge 2 )Clarion Radio
Badge, 'Lotus', Speaker G r i l l e 2 1
Cable Assembly, R e a r Speakers 1
A e r i a l , Electric, External F i t 1 N a t . Panasonic, Mtorola, S p a r k a m t i c
Relay, E l e c t r i c Aerial 1 For A082M6149F
A e r i a l , Electric, Internal F i t 1 (See S/B 1984/10)
Jup Harness, Aerial 1 ) W i t h N a t . ~ a n a s o n i cRadio
Junp Harness, I g n i t i o n Feed 1 1
J q . H a r n e s s , Aerial/Radio 1 1
Harness, Radio Feed 1 M t o r o l a , Sparkanatic, Blaupmkt
Turbo 17.27A
Page 2
ILLUS
NO. QUANTITY
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 Stabiliser
Earth m d , Timing Belt Tensioner
Earth Bond, Seat & Tanks to Chassis
Earth Bond, Electric Aerial
Turbo 17.29A
ILLUS
No. QUANTITY
Tray, B a t t e r y C a r r i e r
B a t t e r y , Chloride, Type 362
Battery, Chloride, Type 385
B a t t e r y , Tungstone, Type 065 Maintenance F r e e
Battery, Tungstone, Type 088 Low Maintenance '87 M.Y. on
Clanp P l a t e , B a t t e r y Retention 1
Bolt, M8 x 35, B a t t e r y Retention )For B o l t Fixing
Bolt, M8 x 100, B a t t e r y Retention 1
Washer, F l a t , B a t t e r y Retention 1
Clanp P l a t e , B a t t e r y Retention > P r i o r '87 M.Y.
Clanp P l a t e , B a t t e r y Retention >'87 M.Y. on
Stud, Short, B a t t e r y Retention >
Stud, Long, B a t t e r y Retention >
Nut, M6, Stud Retention > For Stud Fixing
Sleeving, B a t t e r y Stud >
Washer, F l a t , B a t t e r y Stud >
Washer, Spring, B a t t e r y Stud >
Wing N u t , M6, B a t t e r y Retention >
Pad, ~ a t t e r y
B a t t e r y Cable, P o s i t i v e With Exide/Chloride B a t t e r y
B a t t e r y Cable, P o s i t i v e With Tungstone B a t t e r y
B a t t e r y Cable, Negative With Exide/Chloride B a t t e r y
B a t t e r y Cable, N e g a t i v e With Tungstone B a t t e r y
B o l t , 5/16" BSW, B a t t e r y Terminal
Nut, 5/16" BSW, B a t t e r y Terminal
Gr-t , B a t t e r y Cable/Harness
Grcmuret, Pos. Cable With Exide/Chloride B a t t e r y
Gr-t, Pos. Cable With Tungstone B a t t e r y
'P' C l i p , B a t t e r y -ad Securing
Pop Rivet 'P' C l i p
Washer, Pop R i v e t
Turbo 17.3lA
ILLUS
a
NO. QUANTITY
DESCRIPTION PART NUMBER RHD

REMARKS
H e a t e r Assembly ) I ~ cH.e a t e r Matrix, E ~ p 0 r a t o r

H e a t e r Assembly ) ( 9 / C O n l y ) , Vac. V a l v e s ,
H e a t e r / ~ i rC o n d i t i o n i n g A s s m b l y )Control Cables, Rotary
H e a t e r / A i r C o n d i t i o n i n g Assembly )Controls
C a s e , WE= H e a t e r Only
Case, Upper Air C o n d i t i o n i n g
C a s e , Upper H e a t e r Only
C a s e , Upper Air C o n d i t i o n i n g
C a s e , Lower Heater Only
C a s e , Laer Air C o n d i t i o n i n g
Case, Lower H e a t e r Only
C a s e , Laer Air C o n d i t i o n i n g
setscrew, M6 x 1 2 , C a s e t o M t g . BI
Washer, F l a t , Case t o M t g . B r k t .
Mmnting Bracket, Case to Tunnel
Pop R i v e t , M t g . B r k t . to Tunnel
Bush, F l a p P i v o t , I n n e r
Bush, F l a p P i v o t , O u t e r
C l o s i n g Panel
Screw, C l o s i n g P a n e l to Case
D r a i n Adaptor, Main C a s e
D r a i n Tube, 5/8" I W
Screw, U p p e r r n r C a s e F i x
Hose C l i p , 16-25mn, D r a i n Tube
Turbo l8.OlA
0
NO. QUANTITY Mf!Y 1s91
DESCRIPTION ! PART NUMBER RHD REMARKS
Evaporator
Evaporator
Foam, Open Msh
Elbow Adaptor
Expansion Valve
F l a r e Gasket, 10.4m~1 Exp. ~alve/Elbow/Emporator
Receiver D r i e r
Bracket, Receiver Drier
Bracket, Receiver D r i e r
Bolt, M6 x 50, Bracket Clanping Use with Bracket A075P0089F
Bolt, M6 x 30, Bracket Clanping Use w i t h Bracket A089P0278F
Nut, Nyloc, M6, Brkt. Clanping
Setscrew, M6 x 20, Brkt. t o Body
Washer, F h t , B r k t . t o Body
Washer, 25mn OD, Brkt t o Body
.
Nut, Nyloc, M6, Brkt t o Body
Hose, Receiver/Drier t o Exp. Valve
H o s e , Receiver/Drier t o Exp. Valve
Hose, Evaporator to Compressor Dry Sump Engine
H o s e , EMporator t o Carpressor W e t Surrp Engine
Hose, Evaporator t o Conpressor Dry Sunp Engine
H o s e , Evaporator t o Carpressor W e t Sunp Engine
F l a r e Gasket, Hose t o Evaporator 15. 7tm1
Hose, Carpressor t o Condenser D r y Sunp Engine
Hose, Conpressor t o Condenser W e t Sunp Engine
H o s e , Carpressor t o Condenser Dry Sunp Engine
Hose, Conpressor t o Condenser W e t Sunp Engine
Heatshield Wrap, Discharge Hose Dry Sunp Engine
G r m t , Fridge ~ o s e h n g i n eBay (Black) )As Fitted
G r a r m t , Fridge Hose/Engine Bay (Grey) 1
Hose, Condenser t o Receiver/Drier
'Ow Ring, j", Condenser Inlet
'0' Ring, 3/811, Condenser O u t l e t
P l a t e , Grarmet Turbo 18.03A
G r m t , Fridge ~oses/EWlkhed Page 1
TURBO
18.0 3 A
a
NO. QUANTITY

I
Screw, Granrrret P l a t e F i x i n g
G r m t , F r i d g e Hoses
Condenser
Foam S t r i p , Condenser t o Radiator
Setscrew, M8 x 20, Condenser t o Duct
Washer, Shakeproof, Condenser to ~ u c t
Washer, 25mn O/D, Condenser t o Duct
Bracket, Condenser Support ) P r i o r t o '87 M.Y.
Bracket, Condenser Support '87 M.Y. On
Setscrew, M6 x 16, Brkt. t o Condenser
Washer, F l a t , Brkt. t o Condenser
Nut, Nyloc, M6, Brkt. to Condenser
Neoprene S t r i p , A n t i x h a f e mn
Tape, Non-Drip, Evaporator Connections
Thermistor Strapped t o Evaporator
Turbo 18.03A
Page 2
ILLUS
a
NO. QUANTITY
MAY 19%
H e a t e r Matrix
Foam, H e a t e r Matrix to Case
Water V a l v e
B r a c k e t , Water V a l v e Mounting, RHD
B r a c k e t , Water V a l v e M a m t i n g , LED
S e t s c r e w , B r a c k e t t o Water V a l v e
Nut, B r a c k e t to Water V a l v e
B r a c k e t , C a b l e Abutment 1
C l i p , C a b l e Abutmnt 1 P r i o r t o Spot Welded A b u t m n t B r a c k e t
S e t s c r e w , Abutment B r a c k e t to V a l v e 1
Nut, Abutment B r a c k e t t o V a l v e 1
C l a n p , C a b l e to Water V a l v e Used w i t h Spot Welded Abutment B r a c k e t
Hose, C a p i l l a r y L i n e P r o t e c t i o n
Clip, Capillary Line
Hose, Water V a l v e to Matrix
Hose Clip
Hose, V a l v e Inlet/Matrix O u t l e t
Hose Clip
G r a m & , Hoses Thrcugh Body
Connector P i p e , H e a t e r Hose
Elbow Hose, H e a t e r P i p e , F r o n t
Hose C l i p , Elbow Hose
P i p e , H e a t e r Water, Thrcugh C h a s s i s
Gram&, Pipes/Chassis
Hose, H e a t e r Feed & R e t u r n
H o s e C l i p , Feed & R e t u r n Hose
T r a n s f e r P i p e , H e a t e r P i p e to Plenum
'PI C l i p , T r a n s f e r P i p e to Plenum
E l b w Hose, Water R a i l to T r a n s f e r P i p e
Turbo 18.05A
Ii TURBO
1 18.07A
ILLUS
e
NO. QUANTITY
Blower Motor & Fan Assembly, T q 1 CCW R o t a t i o n Vie& Motor End

B l m e r Motor & Fan Assembly, B o t t a n 1 CW R o t a t i o n Viewed Motor End
Clanp, Motor t o Housing 6
S e t s c r e w , M 5 x 20, Motor Clarrp 6
Washer, Motor C l a n p Screw 6
J a c k n u t , M5, Motor Clarrp Screw 6
Turbo 18.07A
TURBO
10.0 9A
ILLUS
F l a p , Def r o s t / F o o t e l l
Flap, De£rost/Footell
Foam, D e f r o s t / F o o t e l l F l a p
C l i p , F l a p S h a f t Ends
Lever, D e f r o s t / F o o t e l l F l a p S h a f t
Grubscrew, Lever t o S h a f t
C l i p , Rod t o Lever
Rod, D e £ r o s t / F o o t e l l F l a p * r a t i n g
Control P l a t e
Control P l a t e
S t u d , 1 0 UNF, Cam/Lever P i v o t
Nut, P l a i n , 1 0 W, P i v o t S t u d
Nut, Nyloc, 1 0 UNF, P i v o t S t u d
Cam, Vacuum V a l v e * r a t i n g
Trunnion, C a b l e t o Cam
S p a c e r , Lever t o Cam
S p r i n g , Cam R e t u r n
S p r i n g , Cam R e t u r n
Lever, B e l l Crank, D e f r o s t F l a p
Bush, Lever P i v o t
C l i p , Lever P i v o t
C l i p , Lever to F l a p R o d
S e t s c r e w , 1 0 UNF x 3/8", Cam O p e r a t i n g
Washer, Cam S e t s c r e w
Nut, Nyloc, 1 0 UNF, Cam Setscra~
Rotary C o n t r o l , T e n p e r a t u r e
Rotary Control, A i r Distribution
Nippleflrunnion, R a t a r y C o n t r o l
Screw, C a b l e to C o n t r o l
C o n t r o l C a b l e , Water V a l v e
C o n t r o l Cable, A i r D i s t r i b u t i o n
Clanp, Cable to C o n t r o l P l a t e
TLlrbo 18.09A
Page 1
TURBO
10.0 9A
0
ILLUS
NO. QUANTITY
DESCRIPTION PART NUMBER RHO REMARKS
Graphic Control Panel, with A/C With Essex Turbo Cockpit Unit
Graphic Control Panel, with A/C, Long With Hole f o r Ccrrpressor I n d i c a t o r Light
For Face Mounted Radio, or N o Radio
Graphic Control Panel, with A/C, Long With N o Hole f o r Conpressor I n d i c a t o r L i g h t
For Face Mounted Radio, o r N o Radio
Graphic Control Panel, w i t h 9/C, S h o r t With Hole f o r Conpressor I n d i c a t o r L i g h t
For Bax Mounted Type Radio
Graphic Control Panel, w i t h A/C, Short With No Hole f o r Conpressor I n d i c a t o r L i g h t
For Bax Mounted Type Radio
Graphic Control Panel, Heater Only, Long For Face Mount& ~ a d i o r No ~ a d i o
Cut Short f o r Box Maunted Type Radio
Screw, No. 6 x f " s/t, Panel F i x
S p i r e Nut, Panel F i x
Kncb, R o t a r y C o n t r o l s
Knob, R o t a r y Controls
Turbo 18.09A
Page 2
ILLUS
NO. QUANTITY MAY ;?PI
DESCRIPTION PART NUMBER LHD

REMARKS
Flap, Mode
Flap, Mode 1
Foam, Mode F l a p 2
C l i p , Flap S h a f t Ends 2
Mounting P l a t e , Actuator Brkt. 1
Pop Rivet, M t g . P l a t e t o Case 5
Bracket, Vacuum Actuator Mtg. 1
Pop Rivet, Brkt t o P l a t e 4
Vacuum Actuator, Modebresh A i r F l a p 2
Rod, Actuator to Mode F l a p 1
Locking Tab, Actuator t o Rod 1
C l i p , Rod t o Mode Flap Lever 1
Lever, F l a p Operating 1
Vacuum Switch, Modebresh Air F l a p s 2
Bracket, Vac. Switch Securing 2
Screw, No. 6 x l/4", Brkt. t o P l a t e 4
Elbaw Connector 7
I T t Piece, Vacuum P i p e s 1
Vacuum P i p e 6m
Elbaw Connector, Unequal Bore 2
Bracket, Vac. Actuator t o Bulkhead 1
Screw, No. 6 x 3/4", Brkt. t o Bulkhead 4
S p i r e Nut, Brkt. t o Bulkhead 4
C l e v i s Pin, Actuator to F l a p s 1
Washer, C l e v i s 4
S p l i t Pin, C l e v i s Retention 1
Flap, F r e s h A i r I n t a k e 1
Flap, Air Re-Circulation With A i r Conditioning
Flap, A i r Re-Circulation 1 With A i r Conditioning
Lev&, Fresh Air/Re-Circ. F l a p 1/2 2 With WC
Grub Screw, Lever to F l a p S h a f t 3
Bracket, Fresh Air/Re-Circ. F l a p Support, RH 1
Bracket, It
II tI I1 II It
'I , LH 1 Turbo 18.11A
Page 1
ILL"^ a
NO. QUANTITY
- I:..

RHD LHD
Screw, No. 6 x 3/411, Brkt t o Bulkhead 4 4

S p i r e Nut, Brkt. t o Bulkhead 4 4
Foam Seal, Fresh A i r Flap Im Im
P i v o t Bush, Inner 2/4 2/4 4 With A/C 1
P i v o t Bush, Outer 2/4 2/4 4 With A/C 1
Vacuum Reservoir 1 1 1
Pad, Anti-Vibration, Reservoir Mounting 1 1 1
Bracket, Reservoir Fixing 3 3 1
Setscrew, M6 x 16, Brkt. Fixing 3 3 )R/B A075W5014E' 1
Nut, Nyloc, M6, Brkt. Fixing 3 3 1 1
Screw, s/t, Bracket, Fixing 3 3 1
S t r a i g h t Connector, Reservoir/'T' P i e c e 1 1 1
'T' P i e c e 1 1 1 *
Tubing, Vacuum, Nylon A/R WR 1
Connector Hose, PIC A/R A/R R/B A075L6043V 1
Vacuum Hose, Rubber A/R WR 1
Non-Return Valve, ' I n Line ' 1 1 R/B A089P0714J 1
Non-Return Valve, ' I n Line' 1 1 On p r e '85 Turbo, Replaces NRV I n 1
Manifold Balance R a i l . See SB 1982/14)
Hose C l i p 3 3 1
Gromnet, Engine Bay W a l l 1 1 1
* P r i o r t o '87 M.Y.
Turbo 18.11.A
Page 2
LHD ILLUSTRATED
037
ILLUS
0
NO. QUANTITY A 1991
O u t l e t Adaptor, Centre F.L.V. For Rectangular Centre Vents

O u t l e t Adaptor, Centre F.L.V. For Round Centre Vents
O u t l e t Adaptor, D e m i s t
O u t l e t Adaptor, Outer F.L.V.
Pop Rivet, Demist & Outer F.L.V. Adaptors
Washer, Pop Rivet
Screw, Centre F.L.V. Adaptor
O u t l e t Adaptor, F o o t e l l
C w e r , Footwell Duct Take Off
Screw, No. 8 x 3/8", C w e r to Case
S c r o l l Extension RHD Upper, LHD Lower
S c r o l l Extension RHD Laer, LHD Upper
Washer, S c r o l l Extension
Screw, S c r o l l Extension
S c r o l l , Blower Fan RHDmr, LHDUppr
Scroll, Blower Fan RHD Upper, LHD Lower
Pop Rivet, Fan S c r o l l
Screw, S c r o l l t o S c r o l l Extension
S p i r e Nut
Ducting, 1iW, Footell
Bulkhead S e a l i n g Panel, Inboard
Bulkhead S e a l i n g Panel, I n t x x r d
Bulkhead S e a l i n g Panel, Outbuard
Bulkhead S e a l i n g Panel, Outtxxrd
Pop Rivet 1/8" Sealing Panel J o i n t
Washer, S e a l i n g Panel J o i n t
Screw, M i n g Panel Fixing
Flap, Cabin P r e s s u r e Relief
Hinge, P r e s s u r e Relief FLap
P q Rivet, F l a p Fixing
Grarmet, Bulkhead S e a l i n g Panel Turbo 18.13A
Page 1
I
LHD ILLUSTRATED
NO. QUANTITY
DESCRIPTION PART NUMBER RHD LHD
Plenum Chamber
Plenum Chamber
Adaptor, Plenum t o D r a i n Tube
C w e r , Bulkhead
C w e r , Bulkhead
Foam S t r i p , C w e r to Body
Screw, No. 6 x t", Bulkhead C w e r
Ducting, 1 7/8", O u t e r F.L.V.
Ducting, 2 1/411, Demist
Ducting, 2", C e n t r e F.L.V. With R e c t a n g u l a r C e n t r e F.L.V.'s
Ducting, It", C e n t r e F.L.V. With Round C e n t r e F.L.V.'s
O u t l e t Vanes, Dernist Vent
Demist Vent, P a s s e n g e r Side
-st! Vent, Binnacle
Adaptor, Demist Vent to Hose
F a c e L e v e l Vent, O u t e r
C l i p , O u t e r F.L.V. R e t a i n i n g
P q R i v e t , C l i p t o F.L.V.
Adaptor, 90°, F.L.V. t o Ducting P a s s e n g e r Side Vent
Adaptor, 90°, F.L.V. t o D u c t i n g D r i v e r ' s S i d e Vent
Adaptor, 90°, F.L.V. t o D u c t i n g D r i v e r ' s S i d e Vent
F a c e L e v e l Vent, C e n t r e , R e c t a n g u l a r
C l i p , C e n t r e F.L.V. Retaining
Pop R i v e t , C l i p t o F.L.V.
Adaptor, S t r a i g h t , F.L.V. t o Ducting R e c t a n g u l a r C e n t r e F.L.V.'s
F a c e L e v e l Vent, C e n t r e , R a n d
R e t a i n i n g Ring, R m d Vent Inc. I n Trimmd Fascia
N u t , Nyloc, M3, Vent F i x i n g
T u r b o 18.13A
Page 2
1
TURBO
1 30.01 A
I
ILLUS
NO. QUANTITY MAY 19(11
DESCRIPTION 1 PA#T NUMBER RHD LHD

REMARKS
Chassis Prior t o '85 Model Year* t

Chassis 1985/'86 Model Year t
Chassis '87 M.Y. on R/B B082A42345 + ( ~ / ~ i p e
Chassis Clanps 1
Chassis Prior t o '85 Model Year* t
Chassis 1985/'86 Model Y e a r t
Chassis '87 M.Y. on WB B082A42345 + pipe
Chassis Clanps 1
Rear Crossmnber
Clanp, Hose #
Clanp, P i p e LJI # W e n replacing a p r e '85 c h a s s i s ,
Clanp, Pipe RH # t h e following p a r t s m y a l s o be
required t o f i t t h e latest p r e '85
s p e c i f i c a t i o n Chassis dependent on VIN:
Anti-Roll Bar & Fixings (see 31.01.A)
Rear Top Link Fixings (see 31.03A)
Engine Writings (see 40.01A)
tmte
-When replacing a Pre'87 M.Y.
Zhassis, t h e o i l c o o l e r hoses must be
run through t h e Chassis backbone with
190mn of edge p r o t e c t o r AX75L602W i n
t h e Chassis rear diaphragm, and 85rrm
of foam tube A082E6022V i n t h e f r o n t
crossmmber .
I f a o i l c o o l e r thermostat is f i t t e d ,
r e p l a c e LH hose from t h e m s t a t t o
cooler with hose A082E4111F.
Turbo 30.01A
ILLUS
NO. QUANTITY
This Page Prior to '85 Model Year

For '85 M.Y. Cars see 31.01B
Front Hub Assmbly (With Studs) 1
Stud, Wheel )Carpanotive Wheels
Front Hub BBS Wheels
Brake Disc Ground Finish. R/B C075J0297F in pairs
Brake Disc Non Directional Machined
Bolt, 3/8" x 7/8" UNF >
Washer, Spring 3/8" >Brake Disc to Hub
Wheel Bearing, Inner
Wheel Bearing, Outer
Oil Seal, Front Hub
Stub Axle
Nut, Nyloc, 9/16" 1
Washer, Plain )Stub Axle to Vertical Link
Nut, Castellated >
Washer, ID1 >Hub to Stub Axle
Split Pin
Hub Cap
Vertical Link
Vertical Link RH
Plug, Lubrication, Vertical Link
Steering Arm, RH
Steering Arm, LH
Caliper Mounting Plate RH
Caliper Mounting Plate LH
Sealing Ring Caliper Mounting Plate to Vertical Link
Dust Shield IH
Dust Shield RH
Turbo (Prior '85 M.Y. ) 31.01A
Page 1
ILLUS
NO. QUANTITY
T h i s Page P r i o r t o '85 Model Year

F o r '85 M.Y. C a r s See 31.01B
B o l t 5/16" x 3/4" UNF 1
Washer, S p r i n g , 8 mn ) C a l i p e r P l a t e to Vertical Link
B o l t 3/8" x l . l / 4 " UNF >
Washer, S p r i n g , 1 0 mn > C a l i p e r ~ l a t e f i e r t i c a lLink/Steering Arm
B o l t , 3/8" x 2.1/411 UNF >
Nut, Torqloc, 3/8" UNE' >
Upper B a l l J o i n t
Nut, Torqloc, 7/16" UNE' )Upper B a l l J o i n t t o Vertical Link
Washer, P l a i n 1
B o l t , 8 x 100 mn >
B o l t , 8 x 60 mn >Upper B a l l ~ o i n t o Wishbone
Nut, Nyloc, M8 >
Washer, P l a i n >
Wishbone ~ r m
P i v o t Bush, Wishbone
Stud, Wishbone P i v o t
Nut, Nyloc )" UNF 1
Locknut, ) I v UNF )Wishbone P i v o t S t u d
Washer, Wishbone P i v o t Each S i d e o f Each P i v o t Bush
C w e r , Wishbone Stud Access
Screw, C w e r F i x i n g
Loher Trunnion, RH
Lower Trunnion, LH
Bush K i t , Lower Trunnion One K i t per Trunnion
S e a l , Trunnion Top 1
B o l t 7/16" UNF )Trunnion to Lmer Link
Nut, 7/16" UNF
Washer
Lower Link, LH Turbo ( P r i o r '85 M.Y.) 31.01A
Loher Link, RH Page 2
a
NO. QUANTITY
DESCRIPTION F#RT NUMBER ALL
T h i s Page P r i o r t o '85 Model Year

For '85 M.Y. C a r s See 31.01B
Bush, Lawer Link P i v o t
B o l t f n x 6" UNF 1
Nut, Nyloc f " UNF )Lover Link t o C h a s s i s
Wash e r 1
Anti-Roll Bar Up t o VIN 82 D 1262
82 - 0410 exc. 0399 & 0400
Anti-Roll Bar Fran VIN 82 D 1263

82 - 0411 p l u s 0399 & 0400
Bush, Anti-Roll Bar t o Lower Link

D i s t a n c e Tube >
Washer, S p e c i a l >
Washer, Chanter Tuward F r o n t >Anti-Roll B a r t o Lower Link
Nut, Nyloc, M12 >
Mmnting Rubber, A.R.B. t o C h a s s i s 1
Clanp P l a t e )Up t o VIN 82 D 1262
Spacer Washer, C a s t o r Adjust 1 82 - 0410 exc. 0399 & 0400
Setscrew, M12 x 30, A.R.B. t o C h a s s i s 1
Washer, S p r i n g , A.R.B t o C h a s s i s 1
Mounting Rubber, A.R.B. t o C h a s s i s >
Clanp P l a t e >Fran VIN 82 D 1263
Shim P l a t e , C a s t o r Adjust > 82 - 0411 p l u s 0399 & 0400
Setscrew, M12 x 35, A.R.B. t o C h a s s i s >
Washer, Spring, A.R.B. t o C h a s s i s >
Turbo ( P r i o r '85 M.Y.) 31.01A

Page 3
a
NO. QUANTITY Fny roql
T h i s Page P r i o r t o I85 Model Year

For '85 M.Y. Cars See 31.OlB
D a n p e r Assy. ( i n c l u d e s A08X6033F) R/B C08X4014F I n P a i r s

Danper Assy. ( i n c l u d e s A082C6033F) Green Spot on Laer Body
I f f i t t i n g to e a r l y car (up to
approx. VIN 82D 1029, 82H 03341,
with 1 6 m d i e t e r darrper stem
h o l e i n c h a s s i s : F i t only i n p a i r s
w i t h 2 o f f Top Stem Bush K i t A08X6032F.
L a t e r cars have 19.5m double t h i c k n e s s
h o l e and u s e Bush K i t A082C6033F.
Bush K i t , D a r r p e r Top Stem With 16 mn Darrper Stem Hole i n Chassis
Bush K i t , D a n p e r Top Stem With 19.5m Darrper Stem Hole i n Chassis
Bush, Danper Lower Eye Included i n Danper assembly
Washer, Danper/kwer Link/Nut
Bolt, $I1 UNF x 23" 1
N u t , Nyloc, 3" UNF IDanper t o Icver Link
Road Spring, Red/Green Heater Cars Only
Road Spring, R e d h e d A i r Conditioned Cars Only
Spring S e a t , R u b b e r Spring to C h a s s i s
Turbo ( P r i o r '85 M.Y.) 31.01A

Page 4
ILLUS
a
NO. QUANTITY
blN i:., .
This Page '85 W e 1 Year On

For Cars Prior to '85 M.Y. See 31.01A
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
Brake Disc, Front Ventilated
Bolt, Brake Disc to Hub
Washer, Brake Disc to Hub
Grease Seal, Front Hub A089D8003F May be used as Alternative
Washer, Claw, Bearing Retaining
Nut, Bearing Retaining
Split Pin, Locking Cap
Locking Cap, Bearing Nut
Grease Cap, Hub Bearing
Arm, Upper Wishbone
Pivot Bush, Upper Wishbone
Stud, Upper Wishbone Pivot
Buffer Washer, Pivot Bush
Nut, Nyloc, 3" UNE'
Locknut, 3" UNF May be used in place of front nyloc
if castor shim are fitted
Turbo ('85 M.Y. on) 31.01B
Page 1
a
NO. QUANTITY MAY 19%
This Page185Model Year On

For Cars Prior to '85 M.Y. See 31.0-
Shim Washer, Castor Adjust, 1.- 1
Shim Washer, Castor Adjust, 3.0mn If Fitted
Shim Washer, Castor Adjust, 6 . m 1
Ball Joint, Upper
Nut, Torqloc, 7/16" UNF Upper Ball Joint to Vertical Link
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
May be used if Castor Shims Fitted
Nut, N ~ ~ o cM8,
, II 11
II
Washer, Plain, In #I )I
Shinplate, Castor Adjust, l.hrm If Fitted

Shinplate, Castor Adjust, 3. tknn If Fitted
Lower Wishbone, RH
Lowr Wishbone, ZH
Pivot Bush, Laer Wishbone, Rear
Pivot Bush, Lower Wishbone, Front
Bush, Anti-Roll Bar/Imer Wishbone
Ball Joint, Lower
Nut, Nyloc, M14 Imer Ball Joint to Vertical Link
Pivot mlt, 4" UNF x 6" Imer Link Rear to Chassis
Nut, Nyloc, 4" UNE'
Pivot mlt, 4" UNF x 2 3/4" >-r Link Front to Chassis
Nut, Nyloc, 4" UNE' >
Anti-Roll Bar
Bush, Anti-Roll Bar to Chassis
Clanp, Anti-Roll Bar to Chassis
Setscrew, M12 x 35, ARB to Chassis
Washer, Flat, II n II Turbo ( '85 M.Y. on) 31.01B
Page 2
ILLUS
a
NO. QUANTITY
This Paqe -'85 Model Y e a r On.

For C a r s P r i o r t o '85 M.Y. See 31.01A
Nut, Nyloc, M12, ARB t o Chassis
A h t m n t P l a t e , Spring/~anper Top
Washer, Abutment ~ l a t e / C h a s s i s
N u t , M8 11 II II I1 I1
I n s u l a t o r , Front Spring Top
Spring/Darrper Assy. ( P a r a l l e l Spring)

.
Spring/Danper Assy ( P a r a l l e l Spring
Road Spring , P a r a l l e l , (Purple/Red)
Heater Only
With A/C
1
)Replaced by
Heater Only )Conical Spring/Danper
Road spring, P a r a l l e l , ( Y e l l o w / Y e l l a w ) With A/C )Ass&ly
.
Spring/Darrper Assy (Conical Spring ) Heater Only. Includes Top Abutmnt P l a t e
.
Spring/Daqer A s s y (Conical Spring With A/C. Includes Top Abutmnt P l a t e
Raad Spring , Conical, (Purple/Blue ) H e a t e r Only
Road Spring, Conical, ( Y e l l o w / W h i t e ) With A/C. R/B B08X4097F
Raad Spring, Conical, (Yellaw/Purple) With A/C (Ijonger than 'A')
Danper, Front, Black with White Spot For P a r a l l e l Spring (R/B ) Inc. Top
A082C4095F t Conical Spring) ) Stan Bush
Danper, Front, Black with Red Spot For Conical S ~ r i n g ) Kit.
Bolt, 4" UNF x 34" >Danper t o &r Wishbone
Nut, Nyloc, 4" UNF
Bush Kit, Oanper Top Stem
Blanking Plug, P l a s t i c
Gromnet, Wishbone Stud Access
Screw, C w e r Fixing
Turbo Y. on)
Page 3
a
NO. QUANTITY
MFil Ngl
Rear H u b A s s d l y (with s t u d s ) C o n p m t i v e Wheels

Stud, Wheel C a q m r o t i v e Wheels
R e a r Hub BBS Wheels
Nut, H u b Retaining
S p l i t Pin, H u b Nut
Cone, H u b Retention
Bearing, R e a r Wheel
C i r c l i p , Bearing Retaining
Spacer, rive ~ h a f t / B e a r i n g
Drive S h a f t , Outboard
Drive S h a f t A s s d l y , Intermediate
Boot K i t , Drive S h a f t C.V. J o i n t
Bolt, Allen, M10 x 65 x 1.5 rnn D.Sha£t t o Adaptor and Outboard D.Shaft
Segment Washer
Adaptor, D r i v e s h a f t
Nut S p e c i a l
Washer, Spring, 12 mn
Stud, Output Sha£t/Adaptor
Shim, Output S h a f t t o D i s c
H u b Carrier, RH
H u b C a r r i e r , ul
Radius Am, RH Carpcmotive Wheels
Radius Arm, RH BBS Wheels.R/B C082D4078K With 13(krm B o l t s
Radius Am, RH BBS Wheels.R/B B082D4110J
Radius Arm, RH
Radius Am, ul Carpanotive Wheels
Radius Arm, ul BBS Wheels.R/~C082D4077K With 1 3 0 m Bolts
Radius Am, IH BBS Wheels.R/B B082D411LJ
Radius Arm, IH
Bolt, Ml0 x 120, Rad. Arm/Hub Carrier E m e p t Rad. Arm C082D4077/8
Bolt, Ml0 x 130, Rad. W H u b C a r r i e r For Rad. Arm C082D4077/8
Nut, Nyloc Mlo \
1
Washer, P l a i n )Radius Arm t o H u b C a r r i e r
Turbo 31.03A
Pqe 1
ILLUS
NO. QUANTITY
Mounting Rubber Radius Arm t o Chassis

P l a t e , Reinforcing >
Spacer, 0.9mn, Toe-In Adjust >
Spacer, 1.5mn, Toe-In Adjust >
Spacer, 6. Omn, Toe-in Ad just >Radius Arm Mmnting t o Chassis
Setscrew, M8 x 35 >
Nut, Nyloc M8 >
Washer, P l a i n >
B o l t , 7/16" x 4.1/2", UNF 1
Nut, Torqloc, 7/16" UNF 1
Washer, Large, 7/16" x I f " )Radius Arm t o Mounting
Washer, Toe-In Ad just 1
Upper Link (Less Bushes) >
Bush, Upper Link (Metalastick) >
Bolt, f " UNF x 5", Link/Chassis Xorrpornotive Wheels
Spacer, S p l i t >
Washer, 3" x 1. 1/4" >
Nut, Nyloc, 4" UNF >
Upper Link (Less Bushes) )BBS Wheels
Bush, Upper Link ( S i l e n t b l o c ) 1
Bolt, f " UNF x 5", Link/Chassis >
Spacer, S p l i t >BBS Wheels up t o V I N 82 D 1161
Washer, f x 1 3/4" > 82 - 0346
Nut, Nyloc, f " UNF >
Bolt, 4" UNF x 4 i n , Link/Chassis 1
Spacer 1BBS Wheels From VIN 82 D 1162
Washer, 3" x 1 3/4" 1 . 82 - 0347
Nut, Nyloc, 4" UNF 1
Turbo 31.0324
Page 2
NO. QUANTITY
Bolt, 3" UNF x 5. 1/211 Top L i n k k a r r i e r 1

Washer, Bolt/Carrier, N u t / ~ i n k 1 Capomotive Wheels
Washer, 31' Hardened, L i n k / C a r r i e r 1
Nut, N y l o c , 3" UNF 1
Bolt, 3" UNF x 5.1/211 Top L i n k k a r r i e r >
Washer, B o l t Head > BBS Wheels
Washer, x 1.3/4" >
Nut, Nyloc 3" UNF >
Lower Link, (Less Bushes) 1
Bush, Lower Link, Outer, Metalastik 1 Ccrrpanotive Wheels
Bush, Lower Link, Inner, M e t a l a s t i k 1
Lower Link (IRSs Bushes ) > BBS Wheels
Bush, Lower Link, S i l e n t b l o c >
Bolt, 3" UNF x 2.1/2", Link/Chassis
Nut, Nyloc, 3" UNF, Link/Chassis
Stud, LakRr Link/Hub Carrier
S p l i t Spacer
Washer, 3" x 1.1/4It, Link/Spacer 1
Washer, 31° Hardened, L i n k k a r r i e r 1Ct- i v e Whee 1s
Washer, 311 x 1.3/4" BBS Wheels
Locknut, 311 UNF
Nut, Nyloc, 3" UNF
Danper Assy. ( I n c l u d e s A082C6033F) P r i o r t o '85 M.Y. R/B C082D4058F
Danper Assy. ( I n c l u d e s A082C6033F) P r i o r t o '85 Model Year
Blue With Green Spot on Zlowzr Body
I f f i t t i n g t o e a r l y car (up t o a p p r m .
VIN 82D 1029, 82H 03341, with 16rm
d i a m t e r danper stem h o l e i n c h a s s i s :
F i t o n l y i n p a i r s with 2 o f f t o p stern
bush kit A08X6032F.
L a t e r cars have 19.5mn double t h i c k n e s s
h o l e and use bush kit A082C6033F.
Turbo 31.03A
Page 3
. -
ILLUS
a
NO. QUANTITY
Danper Assy. (Includes A082C6036F) 2 1985 Model Y e a r Onward

Black With White Spot on Umer Body
Bush K i t , Danper Top S t a n ( 3/8" UNF 1 2 16rm Chassis Hole 1 Prior t o
Bush K i t , Danper Top Stem (3/8" UNF 1 2 19.5rrm Chassis Hole 1 '85 M.Y.
Bush K i t , Danper Top S t a n (NO1 2 1985 Model Y e a r On.
Spacer Washer, Danper k m r Fix 4
Washer, F l a t 2
Nut, Nyloc, 4" UNF, Danper/Carrier 2
Road Spring , ~ r e e n / G r e e n 2 Heater only c a r s
Road Spring, Green/Green 2 A/C cars. R/B D079D4003F i n p a i r s
Road Spring, Green 2 A/C cars. 4" longer than E079D4003F
I n s u l a t o r , Rear Spring 2
G r m t , RH Wheelarch 1
Turbo 31.03A
Page 4
TURBO
32.01A LHD ILLUSTRATED
i
I
NO. QUANTITY MAY 1991 I
DESCRIPTION PART NUMBER REMARKS i
P r o t e c t i v e S l e w e , Column S p l i n e
I n t e r m d i a t e Steering C o l m Assy. Inc. Upper U/J I
Universal Joint, Lower
Bolt, M8 x 35, Universal J o i n t Clanping
Washer, F l a t , U / J C l a q B o l t
N u t , Nyloc, M8 U/J Clamp Bolt
P r o t e c t i v e Sleeve, Pinion S h a f t R/B A082H4030H p l u s A082H6025F I
Spacer, Column Lower U / J
C i r c l i p , Pinion Shaft/Spacer
Rack 6 Pinion Assembly R/B D082H4021F With Reduced Travel
Rack & Pinion Assembly
Rack & Pinion Assembly R/B D082H4020F with Reduced Travel
Rack 6 Pinion Assembly
B a l l J o i n t Track Rod End
Locknut, 4'' UNF, B a l l J o i n t
Tapping P l a t e , Steering Rack Mxnting
Shim, Rack Assy. t o Chassis
Clarrp Bracket, Rack Assy. to Chassis Non-Pinion End
Clarrp Bracket, Rack Assy. t o Chassis Pinion End
Rubber Mounting, Rack Assembly Non-Pinion End
Rubber M a t i n g , Rack Ass&ly Pinion End
Setscrew, M8 x 20, Clanp to Chassis
Washer, Spring, Clarrp t o Chassis
Gaiter Set, Steering Rack ( i n c . c l i p s )
Turbo 32.01A
0
NO. QUANTITY
-
Nut, S t e e r i n g Wheel t o Colurm

Washer, S t e e r i n g Wheel Nut
C o l l e t , S t e e r i n g Wheel T h r u s t
Band, C o l l e t Retaining
S t e e r i n g W h e e l Assenbly, Black With 'Old' Badge 1
S t e e r i n g Wheel Assembly, Black With 'New' Badge lint. * Itens
S t e e r i n g W h e e l , Black Leather
S t e e r i n g Wheel, Coloured m t h e r S p e c i a l Order. S t a t e VIN or Colour
Hub, S t e e r i n g Wheel
R o l l Pin, Turn I n d i c a t o r Cancelling
Fixing, Wheel t o Hub
Wheel Centre ('Old' Badge)
W h e e l Centre ('New' Badge)
Crash Pad, Black I s a t h e r
Crash Pad, Coloured Leather S p e c i a l Order. S t a t e VIN or Colour
S t e e r i n g Column Assembly
Setscrew, MI0 x 25, Colurm/Scuttle
Washer, F l a t , Column/Scuttle
Washer, Shakeproof, Colurm/Scuttle
Nut, S p e c i a l , Column/Scuttle
Clanp, Column t o Pedal Box
Clanp, C o l m t o Pedal Box
Nut, Nyloc M8, Clanp t o Pedal Bax
Washer, F l a t , Clanp t o Pedal Box
Lock, S t e e r i n g Column c/w I g n i t i o n Switch
Shear ~ o l t ,k k t o column
S e a l P l a t e , Column t o Bulkhead
S e a l P l a t e , Column t o Bulkhead
Gasket, S e a l P l a t e t o Bulkhead
Setscrew, M6 x 20, P l a t e t o h head
Washer, S e a l p l a t e F i x
Nut, Nyloc, M6
Turbo 32.05A
NO. QUANTITY
MAY 1991 I
DESCRIPTION PART NUMBER REMARKS 1

I
This Page prior t o '85 M.Y.

For '85 M.Y. See 33.01B
C a l i p e r Assembly, F r o n t , RH I n c l u d e s Brake Pads
C a l i p e r Assembly, Front, IH Includes Brake Pads
Brake Pad S e t , F r o n t Includes P i n s & C l i p s
Pin, Pad Retaining
C l i p , p i n Retaining
Bolt, C a l i p e r to Mounting Bracket
S e r v i c e K i t , Front C a l i p e r Includes 4 P i s t o n S e a l s , 4 Dust Boots,
4 Dust Boot C l i p s
D i s c , Front Brake
Bolt, D i s c to Hub
Washer, Spring, 3/8"
C a l i p e r Assembly, Rear, RH
C a l i p e r Assembly, Rear, IlI
Brake Pad S e t , Rear Includes Lacking B o l t s
Bolt, M10 x 100, C a l i p e r Mounting
Bolt, M10 x 60, C a l i p e r Mounting
Washer, P l a i n , 10 mn
Ring Dowel, C a l i p e r
Adaptor, C a l i p e r t o Brake Hose
Pad Danping Spring
R e t u r n Spring, RH Handbrake Lever Arm
Return Spring, IH Handbrake Lever Arm
S e a l K i t , Rear Caliper
Guide P i n K i t I n c l u d e s 4 Guide P i n s , 4 Locking B o l t s ,
4 B o l t s and Grease
P i s t o n K i t , Rear C a l i p e r , IlI inc. H/Brake Mechanism
P i s t o n it, Rear C a l i p e r , RH 1
Bleed Screw, Rear C a l i p e r Turbo ( P r i o r t o '85 M.Y.) 33.01A
Page 1
a
NO. QUANTITY MAY 1991 iI
I
DESCRIPTION PART NUMBER REMARKS !!
T h i s Page P r i o r t o '85 M.Y

For '85 M.Y. See 33.01B
D i s c , Rear Brake
Nut, M12, D i s c Fixing
Washer, Spring, D i s c Fixing
Turbo ( P r i o r t o '85 M.Y.) 33.01A

Page 2
1 33.018 TURBO (85 M.Y. ON1
e
NO. QUANTITY
MAY '15si
T h i s Page '85 M.Y. Onward

F o r C a r s P r i o r t o 1 8 5 M . Y . See33.OlA I
Brake C a l i p e r Assembly, RH F r o n t Less Brake Pads
Brake C a l i p e r Assembly, L,H Front Less Brake Pads
Pad S e t , Including A n t i - R a t t l e Springs
C a l i p e r Repair K i t , Front
Bolt, C a l i p e r Swing Release
Bush, m r , C a l i p e r S l i d i n g
Bleed Nipple, F r o n t C a l i p e r
Dust Cap, Bleed Nipple
Bolt, C a l i p e r Fixing
Washer, Shakeproof, C a l i p e r F i x
Brake D i s c , Front, V e n t i l a t e d
Bolt, Brake D i s c to Hub
Washer, Brake D i s c t o Bolt
Brake C a l i p e r Assembly, RH R e a r I n c l u d e s Brake Pads
Brake C a l i p e r Assembly, LH Rear I n c l u d e s Brake Pads
Pad S e t , R e a r Calipers Inc. Anti-Rattle Springs & b k i n g C l i p s
Accessory K i t , R e a r C a l i p e r s Inc. Anti-Rattle Springs, Locking C l i p s
Retaining P l a t e s , Springs, Bleed Caps
Cylinder Assembly, RH ) Inc. W k i n g P i n & Spring
Cylinder Assembly, LH )
Seal K i t , Rear Caliper Inc. P i s t o n Seal, P i s t o n Boot, -king
C l i p s & Grease
Abutrrent, Park Braking Cable, RH
A b u b n t , Parking Brake Cable, LH
Setscrew, M8 x 20, Abutmnt/Caliper
Spring Washer, Ahtment/Caliper
Bolt, M12 x 85, C a l i p e r Fix, Top
Bolt, M12 x 75, Caliper Fix, Bottan Turbo ( ' 8 5 M.Y. On) 33.01B
Washer, F l a t , C a l i p e r F i x Page 1
a MAY f%i
NO. QUANTITY
DESCRIPTION PART NUMBER ALL REMARKS j
This Page '85 M.Y. Onward

For Cars Prior to '85 M.Y. See 33.01A
Washer, Spring, Caliper Fix
Brake D i s c , Rear White Colour Code or Cast Part Nunher
Nut, M12, D i s c Fixing
Washer, Spring, D i s c Fixing
Turbo ( ' 8 5 M.Y. On) 33.01B

Page 2
a i
NO. QUANTITY MAY 1931 I
I
DESCRIPTION PART NUMBER LHD REMARKS
T h i s Page P r i o r t o '85 M.Y.

For Cars '85 M.Y. On See 33.038
Servo Assembly, G i r l i n g Type 50
Push Rod, Brake Pedal t o Servo
C l e v i s Pin, P u s h r d t o Pedal
C l e v i s Pin, Pushrod t o Pedal
Spring C l i p , C l e v i s Retaining
Service K i t , Brake Servo
Non-Return Valve K i t
Bracket, Servo t o Pedal Bax
Bracket, Servo t o Pedal Box
Spacer, Bracket t o Pedal Bax
Nut, Bracket t o Pedal Box
N u t , Servo t o Mcunting Bracket
Hose, Vacuum, Servo t o Bun*
Grarmet, Servo H o s e
Bundy Pipe, Servo Vacuum
H o s e , Vacuum, Bundy t o Manif old
C l i p , Vacuum Hose
Brake Master Cylinder Assy.
Nut, M10, M/Cylinder t o Servo
Washer, M/Cylinder t o Servo
Reservoir K i t , Master Cylinder
F l u i d Leuel Warning I n d i c a t o r
Service K i t , Master Cylinder
Banjo, Master Cylinder t o Front Pipe Where F i t t e d
Gasket, Banjo
Gasket, Banjo
Bolt, Banjo
G r a m & , Pipes Thro' Bulkhead
Pipe, Front Brake, M/C t o 3-Way
Pipe, Front Brake, M/C t o 3-Way Turbo ( P r i o r t o '85 M.Y.) 33.03A
Page 1
NO. QUANTITY
DESCRIPTION PART NUMBER RHD REMARKS I
T h i s Page P r i o r t o '85 M.Y.

For C a r s '85 M.Y. On See 33.038
Union 3-Way, F r o n t
pipe, Brake, 3-Way to H o s e
C l i p , Brake P i p e
Screw, Pipe C l i p to Chassis
Hose, Front Brake
Locknut, Front Brake H o s e
Washer Shakeproof, Front Brake Hose
Pipe, Brake, Hose t o Front Caliper
Bracket, C a l i p e r P i p e Support, RH
Bracket, ~ipe/HoseSupport IH
Pipe, Brake, Rear Feed Master Cylinder t o Double Ended Union
Pipe, Brake, Rear Feed Master Cylinder t o Double Ended Union
Union, Double Ended
Pipe, Double Ended Union t o Rear 3+ay
Union, 3-Way, R e a r
Pipe, Brake, 3-Way to RH Hose
Pipe, Brake, 3-Way to LH Hose
Pipe, Brake, 3-Way to LH Hose
C l i p , Brake P i p e
Screw, C l i p to Chassis
Hose, Rear Brake Replaced by C08W6060F
H o s e , Rear Brake Armoured
Locknut, Rear Brake Hose
Washer, Shakeproof, 10 mn
Bracket, Hose/Pipe t o C a l i p e r LH
Bracket, Hose/Pipe to C a l i p e r RH
Pipe, Brake, Hose t o Rear C a l i p e r
Page 2
a
NO. QUANTITY 1
t i 1991 I
I
Pushrcd, Brake Pedal t o Servo T h i s page f o r '85 M.Y. on
C l e v i s Pin, Pedal t o Pushrod For cars p r i o r 1985 see 33.03A
Spring C l i p , C l e v i s Retaining
Locknut, Servo Pushrcd
Bracket, Servo & Clutch W y l i n d e r Eltg.
Gasket, Servo Bracket t o Body
Spacer, Bracket t o Pedal Box
Nut, Nyloc, M8, Brkt. to Pedal Box
Washer, Spring, Brkt. to Pedal Box
Servo/Brake Master Cylinder Assy . Inc. Reservoir Ibw F l u i d Switch & Cap
Servo Assgnbly, (Bendix DBA) Inc. N.R.V.
Non Return Valve & Seal
Nut, Nyloc, M7, Servo t o Bracket
Washer, Spring, S e m o t o Bracket
Brake Master Cylinder Assy.
Reservoir, Brake Master Cylinder
F l u i d Level Warning Switch ( N i v o c d e )
Cap, F i l l e r , ~ l u i dReservoir
Repair K i t , Master Cylinder
G r m t P i p e s Through Body
Nut, Nyloc, M8, M/Cylinder to Servo
Washer, F l a t , W l i n d e r to Senro
Pipe, Brake, W y l i n d e r t o RHF Hose
Pipe, Brake, M/Cylinder t o RHF Hose
Pipe, Brake, W y l i n d e r t o LHF H o s e
Pipe, Brake, M/Cylinder to IHF Hose
C l i p , Brake P i p e t o Chassis
Screw, Pipe C l i p t o Chassis
Hose, F r o n t Brake
Locknut, F r o n t Brake Hose
Washer, Shakeproof, Brake Hose
Pipe, Brake Hose to Front C d l i p e r
Bracket, p i p e h o s e Support
Setscrew, M6 x 20, Brkt. to C a l i p e r R/B A082W7041F
Screw, Socket Head, M6 x 20 Turbo ( '85 M.Y. on) 33.038
Page 1
ILLU4 e
NO. QUANTITY
Washer, F l a t , Brkt. t o C a l i p e r T h i s page '85 M.Y. on I

I
Washer, Shakeproof, Brkt. t o C a l i p e r For cars p r i o r 1985 see 33.03A
Nut, M6, Brkt. t o C a l i p e r
pipe, Rear Brake bI/Cyl. t o D/E Union
i
Pipe, R e a r Brake, M/Cyl. t o D/E Union
Union, Double Ended
Pipe, Rear Brake, D/E Union t o 3-Way
Union, 3-Way, R e a r
Bolt, M6 x 40, 3-Way Union t o Chassis
Washer, Spacer, 3-Way Union
Washer, F l a t , Union F i x
Nut, Nyloc, M6, Union F i x
Pipe, Brake, 3-Way t o RHR Hose
Pipe, Brake, 3-Way to UIR Hose
C l i p , Brake P i p e t o Chassis
Screw, Pipe C l i p to Chassis
Hose, R e a r Brake
Lacknut, Rear Brake Hose
Washer, Shakeproof, Brake H o s e
Bracket, Rear Hose t o C a l i p e r
Pipe, Brake, R e a r hose t o C a l i p e r
H o s e , Vacuum, Servo t o Bundy >
Bundy Pipe, Servo Vacuum, Throw C h a s s i s > Prior
H o s e , Vacuum Bundy t o Manifold mn. See S/B 1984/17 > '87
Hose C l i p , Vac. Hose >
.
Grorrmet , Servo V a c Hose >
M.Y.
Hose, Vacuum, T-Piece t o Bundy

pipe, Bundy, Servo Vacuum 1
C l i p , Hose 1'87 M.Y. on
H o s e , Vacuum, Bundy t o T-Piece 1
Hose, Vacuum, T-Piece t o Servo 1
pipe, Vacuum, T-Piece t o Irow Vacuum Switch 1
Turbo ( ' 8 5 M.Y. On) 33.038

Page 2
NO. QUANTITY
Switch, Low Vacuum 1

Screw, s/t, No.6 x + I 1 , Switch Fixing 1'87 M.Y. on
Nut, Spire, No.6, Switch Fixing 1
ITt-Piece, I m Vacuum !%itch Take+££ 1
Turbo ('85 M.Y. On) 33.038

Page 3
e
NO. QUANTITY
PRIOR 1985
DESCRIPTION PART NUMBER '85 MY I.Y. ON REMARKS 1I
W t i p l i e r Lever Introduced a t VIN

82D 1695. 82 A/E/G/H/S 0531
Handbrake Lever Assembly Without Multiplier
Handbrake Lever Assembly With Multiplier
Handbrake Lever Assembly 1 'Fold Down' Type
Grip, Handbrake Lever 1
Nut, Nyloc, M10, Lever Pivwt 1 A s Fitted
N u t , Nyloc, M8, Wer Pivot 1 1
Washer, F l a t , lOmn, Lever Pivot >
Washer, F l a t , 8m, Lever Pivot 1 > As F i t t e d
Mounting P l a t e , Handbrake Lever RHD 1 Without Multiplier
Mcunting P l a t e , Handbrake Lever LHD 1
Mounting P l a t e , Handbrake Lever 1 RHD > With Multiplier
Mamting P l a t e , Handbrake Lever 1 LHD>
Setscrew, Mounting P l a t e t o S i l l Without Multiplier
Setscrew, Mcunting P l a t e to S i l l 4 With Multiplier
Washer, Mounting P l a t e t o S i l l Without Multiplier
Washer, Large O/D, N t g . P l a t e t o S i l l 4 With Multiplier
Setscrew, M6 x 30, Ratchet Fixing 1 Also -rates Handbrake Switch
N u t , M6, Ratchet Fixing 1
Washer, Spring, Ratchet Fixing 1
Mamting Bracket, Handbrake Microswitch 1
Setscrew, M6 x 30, Switch B r k t . Fix 1
Washer, F l a t Switch Brkt. Fix 2
Nut, Nyloc, M6, Switch Brkt. F i x 1
Microswitch, Handbrake T e l l - t a l e 1
Screw, s/t, Switch t o Brkt. 2
Screw, M3 x 16, Switch t o Brkt. 2
Nut, Nyloc, M3, Switch t o Brkt. 2
Clevis Pin, Handbrake t o ~ i n k / ~ c tRod . 1
Spring Clip, Clevis Retaining 1
Washer, Handbrake Clevis 3
Washer, Clevis Spring C l i p 1 Turbo 33.05A
Page 1
LHD '85 MY. SHOWN
TURBO
33.05A
0 0 a
a .
NO. QUANTITY . 1 ' '
PRIOR
DESCRIPTION PART NUMBER '85 MY REMARKS
Multiplier Lever Introduced at VIN

82D 1695, 82 A/E/G/H/S 0531
Link, Handbrake to Multiplier
Multiplier Lever 1
Multiplier Lwer
Washer, Multiplier Lever Pivot
Split Pin, Multiplier Lever Pivot )With Multiplier
Clevis Pin, Multiplier Lever
Washer, Multiplier Clevis 1
'R' Pin, Clevis Retaining 1
Spring, Lever Return
Anchor Bracket, Return Spring
Pop Rivet, Anchor Bracket to Body
Actuating Rod, Handbrake Lever/Ccrrpensator Without Multiplier
Actuating Rod, Multiplier/~onpensator With Multiplier
Canpensator, H/Brake Cables
Clevis Pin, Conpensator
Washer, Clevis Pin
Spring Clip, Clevis Retaining
Cable, Handbrake
Cable, Handbrake
Cable Tie, Handbrake Cable Used if no Chassis tags Fitted
Abutment, Handbrake Cable, Forward RHD
Abutment, Handbrake Cable, Forward LHD
Setscrew, M8 x 25, Abutment to Body
Washer, Spring, Abutment to Body
G r m t Plate, Handbrake Cables
Gramnet, Handbrake Cable
Screw, Grarmet Plate Fix
Turbo 33.05A
Page 2
025'
TURBO
34.01A
e
NO. QUANTITY
DESCRIPTION PRIOR
PART NUMBER '85 MY
Road Wheel & Tyre Assembly, F r o n t 2

Rcad Wheel, Front 2
Tyre, Front, 195/60 VR15 Goodyear 2
Valve, Tyre, F r o n t Rcad Wheel 2
Road W h e e l and Tyre Assembly, Rear 2
Road W h e e l , Rear 2
Tyre, Rear, 235/60 VR15 Goodyear 2
Valve, Tyre, Rear Rcad Wheel 2
Badge, W h e e l C e n t r e 4
Wheel Nut 16
Wheel and Tyre Assembly, Spare 1
W h e e l , Spare 1
Tyre, Spare, 175/70 SR14 Goodyear 1
Valve, Tyre, Spare Wheel 1
Road W h e e l & Tyre Assembly, F r o n t 2 >
Road W h e e l & Tyre Assembly, F r o n t >
Road W h e e l , F r o n t 2 >
Tyre, Front, 195/60 VR15 Goodyear NIP 2 >
Tyre, Front, 195/60 VR15 Goodyear NIP >
Valve, F r o n t Tyre 2 >
Road Wheel & T y r e Assembly, Rear 2 > BBS Wheels
Rcad W h e e l & Tyre Assembly, Rear >
Road Wheel 2 >
Tyre, Rear, 235/60 VR15 Goodyear NIP 2 >
Tyre, Rear, 235/60 VR15 Goodyear WJ? >
Valve, Rear Tyre 2 >
W h e e l & Tyre Assembly, Spare 1
Wheel & Tyre Assembly, Spare
W h e e l , Spare 1
W h e e l , Spare
Turbo 34.01A
Page 1
. -
a
NO. QUANTITY
PRIOR
DESCRIPTION PART NUMBER 85 M.Y. REMARKS
Tyre, Spare, 175/70 SR14, m e w

Valve, Spare Tyre
Wheel Bolt
F i n i s h e r , Wheel Centre (With 'Old' Badge)
F i n i s h e r , Wheel C e n t r e (With 'New' Badge)
Clanp B o l t , Spare Wheel Securing

Clanp P l a t e
'0' Ring, C l a n p B o l t
Tapping P l a t e , Clanp B o l t
Pcp ~ i v e t ,Tapping P l a t e to Body
Turbo 34.01A
Page 2
a
NO. QUANTITY &%'/ 1991
DRY
DESCRIPTION PART NUMBER SUM' REMARKS
Cylinder Block & Main Bearing Housing >Inc. Items Up t o 012

Cylinder Block & Main Bearing Housing >
Cylinder Block & Main Bearing Housing H.C.>
Stud, M12 x 183, Block t o MBH Heater Only
Stud, M12 x 183, Block t o MIM )With A/C
Stud, M12 x 192, Block t o MBH 1
Stud, Ml2, Block t o MBH
Washer, F l a t , Block t o MBH
Nut, M12, Block t o MIM
Ring D a d , Block t o MBH
Stud, M8 x 47 Block t o MBH
Stud, M8 x 41 Block t o MBH
Stud, M8, Block t o MBH
Washer, F l a t , Block t o MBH
Nut, M8, Block t o ME33
Stud, M12, Cylinder Head t o Block
Plug, 1" NETT, Cylinder Block
Plug, 1/4" BSP, O i l Gallery
S p i r o l Pin, Cylinder Head t o Block
Union, O i l Pressure Gauge Take+££
Housing, Rear Crank S e a l
Housing, Rear Crank S e a l
Seal, Crankshaft R e a r , ( R e d )
Seal, Crankshaft R e a r , (Black)
Gasket, R e a r S e a l Housing
Setscrew, M6 x 25, R e a r Housing/~lock
Washer, F l a t , R e a r Housing/~lock
Button Head Screw, Housing/Block & MBH
Washer, Thin, ~ o u s i n g / ~ l o c&k MIM
Sprayshield
C w e r , O i l Gallery Std.
C w e r , O i l Gallery 1
Switch, oil Pressure, 17.6 PSI 1H.C.
Sealing Washer, Switch 1 Turbo 40.01A
Page 1
NO. QUANTITY
Gasket, O i l G a l l e r y
Bolt, M8 x 35, O i l G a l l e r y Cover
Setscrew, M8 x 20, O i l Gallery C w e r
Washer, F l a t , O i l G a l l e r y C w e r
Spout, Crankcase Breather
Bush, Breather Spout
Pipe, O i l Feed
'0' Ring, O i l Feed Pipe/=
Pipe, O i l P i c k Up
Union, O i l P i c k w e e d Pipe
Olive, Conpression, O i l P i p e
'0' Ring, D i p s t i c k Tube
Dipstick
Tube, Dipstick, (c/w O l i v e ) Std.
Tube, Dipstick, (c/w O l i v e ) H.C.
Tube Nut, D i p s t i c k Tube
Bracket, D i p s t i c k Tube t o Plenum Std.
Bracket, D i p s t i c k Tube to Plenum H.C.
C l i p , P l a s t i c , D i p s t i c k Tube Bracket
F r o n t Cover
Gasket, F r o n t C w e r
Setscrew, M6 x 25, Front Cover
Washer, F l a t , F r o n t Cover
S e a l , Crankshaft Front
-1, Engine to Clutch Housing
Snapper C l i p , Breather Hose
Hose C l i p , Breather Hose
Hose, Breather, Crankcase/Oil Tank
Hose, Breather, Crankcase/hrbo I n t a k e R/B A910E1842F Std. Engine Only.
H o s e , Breather, C r a n k c a s e h b o I n t a k e
Hose, Breather, C r a n k c a s e / ~ i r F i l t e r
) F o r 'H.C.'See43.03A 1
1
h m t i n g Rubber, Engine R/B A085E6012F sets of 4 (inc.Trans.Mtg.1
Mounting Rubber, Engine, Blue F i x i n g Hole Cntr. 9lmn.U~t o VIN 82D 1008
Turbo 40.01A
Page 2
a MAY d
IQ. 1
NO. QUANTITY
Ld'
-
vim'
DESCRIPTION PART NUMBER SUMP REMARKS
Buffer Washer, Mtg. Brkt. to Rubber

Bolt, 7/16'' UNF x 33", Mtg. Brkt/Rubber
.
Washer, Flat, Mtg . ~ r k t/Rubber
Nut, Nyloc, 7/16" UNF, Mtg. Brkt./Rubber )Use With Mtg. Rubber A085E6012F
Setscrew, M8 x 20, Mtg. Rubber/Chassis 1
Washer, Flat, Mtg. ~ubber/Chassis 1
Nut, Nyloc, M8 1
Mounting Rubber, Engine, RH, Blue 1 >Fixing Hole Centres 82mm Fran
~ountingRubber, Engine, LH, Pink 1 >VIN 82D 1009
Buffer Washer, Lovier 2 1
Buffer Washer, Upper 2 1
Bolt, M12 x 100, Rubber to m. Brkt. 2 1
Nut, Nyloc, Ml.2, Rubber to Mtg. Brkt. 2 )Use With Mtg. Rubber AO85E6008/9F
Setscrew, M8 x 20, ~ubber/Chassis 4 1
Washer, Flat 6
Washer, Spring 2
Nut, Nyloc, M8 2
Mounting Bracket, Engine, LH 1
Mounting Bracket, Engine, RH, With Relay 1 For Use With 0.86:l Ratio Gear Change
Lever Pivot Relay Lever. If Replacing Earlier
Fabricated Mounting Bracket, Replace
Also Relay Lever (see 47.05A)
Mounting Bracket, Engine, RH, With Relay 1 For Use With 1:l Ratio Gear Change
Lever Pivot (inc. Bush) Relay Lever
Bush, Gear Change Relay Lever Pivot 1 For Use With Mtg. Brkt. A912E9022J
Mounting Bracket, Engine, RH, Without Relay 1
Lever Pivot
Edge Finisher, Engine Mamting Brkt 4 m For Use With Mtg. Brkt. BO82E4078K
Bolt, M8 x 40, Bracket to Engine 6 R/B A082W7053F
Setscrew, Cap Head, M8 x 35, Brkt . to Engine 6
Washer, Spring, Bracket to Engine 6 Turbo 40.01A
Page 3
TURBO
4003 A
e
NO. QUANTITY
Oil Sup
Plug, Surrp Drain
Washer, S u p Plug
Baffle, Smp
Screw, B a f f l e 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, F l a t , Sunp to MBH
B o l t , M8 x 30, Smp to MBH
B o l t , M8 x 80, Sunp to MBH
Turbo 4
1
I
1 TURBO
40.05 A
6
1LI-u e
NO. QUANTITY
- MAY 1991
H.C.
-
mINE
Cylinder Head Assembly >Inc. Items Up To & Inc. 024

Cylinder Head Assembly 1 >
Core Plug, -11 6
Core Plug, Large, Rear 1
Plug, 1/8" BSP, Socket 2
Pipe, Heater Take-Off 1
Guide, I n l e t Valve, O/D Std. 1
Guide, Inlet Valve, O/D + 0.001" 8
Guide, I n l e t Valve, O/D + 0.002" I
Guide, Inlet Valve, O/D + 0. 005°1 I
Guide, Exhaust Valve, O/D Std. >
Guide, Exhaust Valve, O/D + O.OO1ll * 8
Guide, Exhaust Valve, O/D + 0.002" >
Guide, Exhaust Valve, O/D + 0.005" >
C i r c l i p , Valve Guide 16
Seat Insert, Inlet Valve, O/D Std.
Seat I n s e r t , Inlet Valve, O/D + 0.001"
Seat I n s e r t , Inlet Valve, O/D + 0.002"
Seat I n s e r t , I n l e t Valve, O/D + 0.005"
Seat Insert, Inlet Valve, O/D Std. >
Seat Insert, Inlet Valve, O/D + 0.001" 8
Seat Insert, Inlet Valve, O/D + 0.002" >
Seat Insert, Inlet Valve, O/D + 0.005" >
Seat Insert, Exhaust Valve, O/D Std. I

Seat Insert, Exhaust Valve, O/D + 0.001" 8
Seat Insert, Exhaust Valve, O/D + 0.002" I
Seat Insert, Exhaust Valve, O/D + 0.005" I
Turbo 40.05A
Page 1
TURBO
40.05 A
ILLUS
NO. QUANTITY
H.C.
DESCRIPTION PART NUMBER m1m
Stub Pipe, Water Outlet

Adaptor, Water Outlet 1
Roll Pin, Cyl. Head t o Cam Hsg. 2
'0' Ring, Roll Pin 2
Setscrew, O i l Gallery Plug 1
'0' Ring, O i l Gallery Plug 1
Washer, Flat, O i l Gallery Plug 1
Stud, M8, Cam Hsg. t o Head 4
Seat, Valve Spring 16
Spring, Valve, Inner 16
Spring, Valve, Outer 16
R e t a i n e r , Valve Spring 16
Collet, I n l e t Valve 16
Collet, Exhaust Valve 16
Valve, I n l e t 8
V a l v e , Exhaust 8
Gasket, Cylinder Head 1
Washer, Cylinder Head t o Block 10
Nut, M12, Cylinder Head t o Block 10
Stud, EMmust Manifold t o Head 12
Stud, I n l e t Manifold t o H e d 9
Turbo 40.05A
Page 2
TURBO (Prior '87 MY. H.C.)
40.07A
ILLUS
NO. QUANTITY MAY 'r391
PRIOR FROM
DESCRIPTION PART NUMBER 22911 22911
REMARKS
Enq. No. 22911 B u i l t January 1986

T h i s Page P r i o r t o '87 M.Y. H.C.
Camshaft Housing, Exhaust

C a m M t Housing, Exhaust 1
Camshaft Housing, Inlet
Camhaf t Housing, Inlet 1
Camshaft 107 2
Woodruff Key, Pulley t o Canshaft 2
Plug, Camshaft Front 2
Thrust Washer, 0.173 - 0.175"
Thrust Washer, 0.175 - 0.177" 2 Cam Endfloat Control
Dowel, Thrust Washer/Carnshaft 2
Setscrew, M10, Thrust Washer t o Cam 2
Washer, Spring 2
Tappet 16
Shim, Tappet ( S e l e c t i v e ) 16 See 40.07A Page 3
Rear C w e r , Canshaft Housing 2
'0' Ring, Rear cover 2
Washer, Large O/D 8
Washer, Spring 4
' T o n ' Bolt, Hausing t o H e d 16
Washer, F l a t , Housing t o Head 4
Nut, M8, Hausing t o He& 4
Stud, Cam Cover to Housing 6
Screw, Chrcarred, Cam C w e r t o Hsg. 6
Rubber Washer, Cam C w e r Screw 6
S p i r o l Pin, Gasket Lacation 8
Gasket, Cam Carer t o H s g .
Gasket, Cam C w e r t o Hsg. 2
Turbo ( P r i o r t o '87 M.Y. H.C.) 40.07A

Page 1
TURBO (Prior '87 MY. H.C.)
40.07A
0
NO. QUANTITY MM ~q
--
PRIOR FROM
DESCRIPTION PART NUMBER 22911 22911 REMARKS
Eng. No. 22911 B u i l t January 1986

T h i s Page P r i o r t o '87 M.Y. H.C.
Cam Cover, I n l e t , Without F i l l e r Dry Sunp Only

Cam Cover, I n l e t , With F i l l e r R/B B910E0992K
Cam C w e r , I n l e t , With F i l l e r W e t Surrp. With P r o v i s i o n f o r T h r o t t l e
Return S p r i n g Bracket R/B C910E0992K
Cam Cover, I n l e t , With F i l l e r 1
Cam Cover, Exhaust
Cam C w e r , Exhaust 1
P l u g , M20, Torx B o l t A c c e s s With Under Cut Thread. R/B A9116343F
w i t h Dowty Washer A910E6553F
Washer, F i b r e , Used With A910E1690F R/B A910E6553F
Plug, M20, T o m B o l t A c c e s s 10
Washer, 'Dowty', P l u g S e a l i n g
'0' Ring, P l u g S e a l i n g 1
O i l S e a l , Camshaft F r o n t 2
Snubber, I n l e t Cam P u l l e y 1
E c c e n t r i c A d j u s t e r , Snubber 1
Stud, Snubber F i x i n g 2
Washer, F l a t , Snubber F i x i n g 2
Nut, M8, Snubber F i x i n g 2
Cap, O i l F i l l e r 1 W e t Sunp Only
Setscrew, M5 x 12, Cap R e t e n t i o n 1
Washer, F l a t , Cap R e t e n t i o n 1
Washer, Shakeproof, Cap R e t e n t i o n 1
Gasket, F i l l e r Cap 1
Turbo ( P r i o r t o '87 M.Y. H.C.) 40.07A

Page 2
TURBO (Prior '87MY. H.C.)
40.07A
4 0 .O7A
I t e m 015 TAPPET S H I M S
Shim Part No. Shim Part No. Shim Part N o . Shim Part N o .
Turbo 4 0 .O7A
Page 3
TURBO ('87MY M.)
40.078
ILLUS
NO. QUANTITY
MAY 1991
'87 M.Y
DESCRIPTION PART NUMBER H.C.
REMARKS
Camshaft Housing, Inlet

Carrshaft ~ m s i n g ,Exhaust
Nut, M8, Cam Hausing to Head
Washer, 8mn, Cam Housing t o Head
Torx Bolt, Cam Housing t o H e a d
Plug, M20, Torx Bolt Access
'0' ~ i n g ,Access Plug
Tappet
Shim, Tappet see 40.07A Page 3
Thrust Washer, 0.175 - 0.177" Camha£t Endf loat Control
T h r u s t Washer, 0.179 - 0.181"
Dowel, Thrust Washer/Camshaft
Setscrew, NO, Thrust Washer t o Camshaft
Spring Washer, Thrust Washer t o Carrshaft
R e a r C w e r , Canshaft Housing
'0' Ring, R e a r C w e r
Stud, Cam Housing R e a r
Bracket, D i f f u s e r Support
Washer, P l a i n , Bracket t o D i f f u s e r
Nut, Nyloc, M6, Bracket t o D i f f u s e r
Camshaft, (Type ' 107 1
Woodruff Key, Carrshaft P u l l e y
O i l Seal, Camshaft Front
Blanking Plug, Carrshaft Front
Cam C w e r , Inlet, Red
Cam C w e r , Ekhaust, R e d
Screw, Cam C w e r F i x
'0' Ring, Cam Cwer Fixing Screws
Gasket, Cam C w e r to Housing
S p i r o l Pin, Gasket I m a t i o n Turbo ( ' 8 7 M.Y. H.C.)
O i l F i l l e r Cap Inc. S e a l 40.07B
I
I
I TURBO
40.0 9A
ILLUS
a
NO. QUANTITY
'87 M.Y
DESCRIPTION PART NUMBER H.C.
P i s t o n & ~ i n e Assenbly,
r ( 5mn O i l C o n t r o l R i n g R/B B910E6919F
P i s t o n & L i n e r Assembly, ( hO i l C o n t r o l Ring I n c l u d e s I t e m s up t o A008 i n c .
P i s t o n & L i n e r Assenbly II I1 II II I1 I1
Gudgeon P i n
Gudgeon P i n
C i r c l i p , Gudgeon P i n
C i r c l i p , Gudgeon P i n
C a n p r e s s i o n Ring, Top I n t e r n a l Tap Bevel
C o n p r e s s i o n Ring, Top I n t e r n a l Tap & Bottom Bevel
C a n p r e s s i o n Ring, Second I n t e r n a l Top S t e p
C o n p r e s s i o n Ring, Second Plain
O i l C o n t r o l Ring (5mm Width) E%A912E6985F
O i l C o n t r o l R i n g ( 5mn Width)
O i l C o n t r o l R i n g (.$rm Width) Use With P i s t o n B910E6919F
O i l C o n t r o l Ring
C o n n e c t i n g Rod R/B BglOEO7 14F
C o n n e c t i n g Rod I n c l u d e s Item up t o A012 i n c .
-1, Cap t o Rod
B o l t , Cap t o Rod
Bush, Smll End
B e a r i n g S h e l l , 'Big End' SLD.
B e a r i n g Shell, 'Big End' - 0.010"
B e a r i n g S h e l l , 'Big End' - 0.020"
Turbo 40.09A
TURBO
40.11 A
ILLUS
NO. QUANTITY
4O.lD DESCRIPTION PART NUMBER REMARKS
Crankshaft (Including Dowels & Spigot Brg. 1

Crankshaft (Includinq Dowels)
-1, Crank t o ~ l ~ w f i e e l
Spigot Bearing
Flywheel ( I n t e g r a l r i n g gear 1
Dowel, Flywheel t o Clutch
Bolt, ~lywheelt o Crank
S h e l l., Main Bearing, Std. I/D, Std. O/D (Groove/Hole Upper, except Centre
II II I1 II II I1 II
(Plain/Hole) Wpper, Centre
( P l a i n ) kmer. Qty. 5 f ram Engine
No. 20875
(Plain/Notch) W a r bwr* up t o Engine
No. 20874
S h e l l , Main Bearing - 0.010" I/D, Std. O/D (Growe/Hole Upper, except Centre
II II #I II I1 I1 II
(Plain/Hole 1 Upper, C e n t r e
II 11 I1 II I1 I1 I1
( P l a i n ) bwr. Qty. 5 from Engine
No. 20875
(Plain/Notch) Rear b w r * up t o Engine
No. 20874
S h e l l , Main Bearing - 0.020" I/D, Std. O/D (Groove/Hole 1 Upper, except Centre
I1 I# II II I1 II II
( P l a i n ) Lower. Qty. 5 from Engine
No. 20875
(Plain/Notch) F&arbwr* up t o Engine
No. 20874
*See S e r v i c e Notes S e c t i o n FA. 28
Turbo 40.11A
Page 1
TURBO
40.11A
ILLUS
NO. QUANTITY
S h e l l , Main Bearing, Std. I/D,+ 0.015" O/D (Growe/Hole 1 Upper, except Centre
II II 11 I1 II I1
( P l a i n ) Imer. Qty. 5 from Engine
No. 20875
(Plain/Notch) Rear Uwer* up t o Engine
No. 20874
S h e l l , Main Bearing, - (Groove/Hole ) Upper, e x c e p t Centre

11 II II
(Plain/Hole ) Upper, C e n t r e
( P l a i n ) Lower. Qty. 5 from Engine
No. 20875
(Plain/Notch) Rear m r * up t o Engine
No. 20874
S h e l l , Main Bearing, - 0.020" I/D + 0.015" O/! (Growe/Hole 1 Upper, e x c e p t Centre

I1 II I1 I8 I1 I1 I1
(Plain/Hole) Upper, C e n t r e
( P l a i n ) lhwer. Qty. 5 from Engine
No. 20875
(Plain/Notch) Rear Uwer* up t o Engine
No. 20874
Thrust Washer, Crank, Std.

Thrust Washer, Crank, + 0.0025"
*See ~ e v i c eNotes S e c t i o n EA. 28
Turbo 40.11A
Page 2
\
13 \12 PRIOR 'b7 N.Y.
TURBO
40.13A
ILLUS
a
NO. QUANTITY
MAY 1991
PRIOR
DESCRIPTION PART NUMBER '87 M.1 REMARKS
- -
Water Punp Assembly, inc. P u l l e y 1 Dry Sunp(Pul1ey Pressed Direct o n t o S h a f t

Water Pwp Assembly, ( less p l l e y 1 1 Inc. Hub, Elbow & Plug ) W e t
Hub, Purrp P u l l e y 1 ) sw
Elbow, Heater Return 1
Plug, Blanking 1 I f Fitted
B o l t , M6 x 75, Pwp t o Block 1
Setscrew, M6 x 25, Punp t o Block 4
Washer, F l a t , Pwp Fixing 5
Gasket, Purrp t o Block 1
Water Pwp Assy. inc. p u l l e y hub & adaptor p i p e s
Hub, Water Punp P u l l e y
Elbow Pipe, Heater Return
Adaptor Pipe, T h e m s t a t Housing
Gasket, Water Pwp to Block
Bolt, M6 x 30, P u q t o Block
Bolt, M6 x 35, Purrp to Block
Bolt, M6 x 55, P u q t o Block
Washer, F l a t , Water Plmp Fixings
Hose, Inlet Manifold t o Punp
H o s e C l i p , 32/50
Elbow Hose, Cylinder Head to Punp
Hose C l i p
T h e m s t a t C w e r O u t l e t Elbow
Gasket, T h e m s t a t Cover
Setscrew, M8 x 25, T h e m s t a t C w e r
Washer, F l a t , T h e m s t a t C w e r
T h e m 1 Transmitter, Tenp Gauge
T h e m s t a t , 74OC Hot C l i m t e s
T h e m s t a t , 82OC Terrperate Climates
022
TURBO
4015 A
QUANTITY
DRY WET
DESCRIPTION PART NUMBER SUMP SUM?
Auxiliary Housing and "Oil Punp" Assgnbly )Includes I t m

~uxiliaryHausing and Oil Pump Assembly 1 Withaut A/C )up to & inc. 018
~uxiliaryHousing and Oil P q Assgnbly 1 With~/C 1
Auxiliary Hausing
Auxiliary Housing 1 Without 4/C
Auxiliary Hausing 1 With 9/C
Plug, 3/8" BSP, Aw. Hsg. Oilway Blanking
Plug, ftt BSP, Aw. Hsg. Oilway Blanking
"Oil Punp", Housing, R/B E907E0803H
Oil Pump Housing Assembly 1 inc. relief valve and dist. stud
Stud, Distributor Clanp 1
Spacer Tube 1
Blanking Plug )Replaces oil pressure relief valve
'0'Ring, Blanking Plug 1
-1, Purrp Body to Aux. Hsg. 2
Gasket, Punp Body to Aux. Hsg. 1
Bolt, M6 x 30, Punp to Aux. Hsg. 6
Washer, Spring, Punp to Am. Hsg. 6
Washer, Flat, Purrp to Aux. Hsg. 6
Shaft & Rotor Assembly 1 Inc. key & circlip
Auxiliary Shaft
Adliary Shaft 1
Rotor, Oil murp 1
Woodruff Key, Oil Pmp Rotor 1
Circlip, Rotor to Shaft 1
Annulus, Oil Pump 1
Circlip, Pulley Abutment 1
Spring, Dist. Drive/Aux. Shaft
Spring, Dist. Drive/-. Shaft 1
Oil Seal, Aux. Shaft Front 1
Oil Seal, Am. Shaft Rear
Adaptor Union, Oil Filter 1
Gasket, Am. Hsg. to Cylinder Block 1
Turbo 40.15A
Page 1
TURBO
40.15 A
e
NO. QUANTITY MM 7991
DRY
DESCRIPTION PART NUMBER SUM? REMARKS
Setscrew, M8 x 25, Housing t o Block )Wet

Bolt, M8 x 40, Housing t o Block U s e Torx Bolt A912E1692K )Smp
a t f r o n t lower l o c a t i o n i f )Without
i n s u f f i c i e n t hex. head )s/C
clearance
Bolt, M8 x 60, Housing t o Block
Bolt, M8 x 90, Housing to Block
Washer, F l a t , Aux. H s g . F i x i n g s
Setscrew, M8 x 25, Housing t o Block >

Bolt, M8 x 40, Housing t o Block >
Bolt, M8 x 60, Housing to Block >
Bolt, M8 x 90, A l t . ~rkt/Housing/Block U s e d with Alt/Brkt A910E1760K > With
Bolt, M8 x 100, A l t . ~ r M / ~ o u s i n g / ~ l o c k U s e d with Alt/Brkt B910E1760K > A/C
Bolt, M8 x 115, A l t . ~rkt/Housing/Block Used w i t h Alt/Brkt C910E1760K >
Bolt, M8 x 90, A l t . ~ r k t / ~ o u s i n g / ~ l o c k U s e d with Alt/Brkt A910E1760K >
Bolt, M8 x 100, A l t . ~rkt/Housing/Block U s e d with Alt/Brkt B910E1760K >
Bolt, S/H, M8 x 100, A l t . Brkt/Housing/Block U s e d with A l t / ~ r k tC910E1760K >
Bolt, M8 x 100, A l t . ~rkt/Housing/Block U s e with Alt/Brkt 4/B910E1760K>
Bolt, M8 x 105, A l t . ~rM/Housing/Block U s e d with Alt/Brkt C910E1760K >
Washer, F l a t , Aux. Hsg. F i x i n g s 7 w i t h s/C >
Mounting Bracket, Alternator R/B C910E1760K
Mounting Bracket, Alternator R/B C910E1760K
Mounting Bracket, A l t e r n a t o r With P l i n t h ) with
Spacer, Alt. BrM. t o Hsg. s/c
Bracket, A/C Ccnpressor R e a r
Spacer, Conp. Brkt. to Hsg.
Turbo 40.15A
Pqe 2
1 TURBO
4015 A
ILLUS
1 ' i ,'
NO. QUANTITY C,. I ) .
DRY
!3uI'P
Extension Union, O i l F i l t e r
Sealing Ring, Adaptor/Housing
Adaptor, O i l Cooler
Union, O i l Cooler P i p e s
Washer, Union t o Adaptor
O i l F i l t e r ( i n c . Sealing Ring) 1 P r i o r t o '86 M.Y.
O i l F i l t e r ( inc. S e a l i n g Ring) '86 M.Y. On. Use A907E6000W i n S e r v i c e
Pipe, O i l Drain, Turbo t o Sunp 1
Pipe, O i l Drain, Turbo t o Sunp
Pipe, O i l Drain, Turbo to Sunp
'0' Ring, Drain P i p e t o Sunp 1
Setscrew, M6 x 16, Pipe t o Sunp 2
Washer, Spring, P i p e t o Sunp 2
Gasket, Drain Pipe t o Turbo 1
Setscrew, M8 x 20, P i p e t o Turbo 2
Washer, Spring, P i p e t o Turbo 2
Hose Assembly, Turbo O i l Feed 1
Hose Assembly, Turbo O i l Feed 1
Flange Adaptor, Turbo t o O i l Feed Hose 1
Gasket, Flange Adaptor to Turbo 1
Setscrew, M8 x 20, Flange t o Turbo 2
Washer, Spring, Flange t o Turbo 2
Turbo 40.15A
Pqe 3
ILLUS
a
DRY REMARKS
DESCRIPTION PART NUMBER SUMP
Scavenge Manifold
Gasket, Scavenge Manifold to Sunp
Stud, M6 x 87, Scavenge Manifold to Sunp
Stud, M6 x 67, Scavenge Nanifold t o Sunp
Nut, M6, Manifold t o Sunp
Bolt, M6, Manifold t o Sunp
Washer, 6 m , Manifold t o Sunp
Stud, M6 x 116, Manifold t o Punp
Stud, M6 x 123, Manifold t o Purrp
L o c t i t e 501, Studs t o Manifold
Stud, M6, O i l I n l e t Pipe to Manifold
O i l mmp Assembly Canplete Pump Assenbly but less Scavenge
Manifold, Pulley and Fixings
Nut, M6, Punp t o Manifold
Washer, 6mn, Punp t o Manifold
Union, Scavenge Purrp O u t l e t
"Dawty" Washer, O u t l e t Union
Pulley, O i l Punp, - 0.010" Diameter N o Dots
Pulley, O i l mnrp, Standard One Dot on Pulley R i m
Pulley, O i l R m p , + 0.010" Diameter Two Dots on Pulley R i m
Key, Pulley to Shaft
Washer, P u l l e y Rear/shaft
Washer, Conical, Pulley R e t .
O i l Seal, Punp S h a f t Front
Bolt, Socket Head, Pulley R e t .
B e l t , O i l Punp Drive -9/-8
B e l t , O i l Punp Drive -7/-6/-5
B e l t , O i l Punp Drive -4/-3/-2
Belt, O i l Plmp Drive -l/std/+l
B e l t , O i l Punp Drive +2/+3
B e l t , O i l Plmp Drive +4/+5/+6
B e l t , O i l Punp Drive +7/+8/+9
B e l t , O i l Plmp Drive +10/+11/+12
Pipe, O i l Tank Hose t o Punp Turbo (Dry Sunp) 40.15B
Page 1
ILLUS
NO. QUANTITY 4 I991
DESCRIPTION DRY
WRT NUMBER SUM?
REMARKS
'0' R i n g , p i p e t o Punp
Nut, M6, Nyloc, Pipe to Punp
Washer, 6nm
Support Bracket, O i l Pipe
Setscrew, M6 x 18, O i l Pipe t o Bracket
Washer, Shakeproof
O i l Tank
Bracket, O i l Tank Upper
Setscrew, M8 x 25, Tank t o Bracket
Washer, F l a t , Tank t o Bracket
Nut, Nyloc, M8 Tank t o Bracket
Bracket, O i l Tank Lower Front
Bracket, O i l Tank Lower Rear
Setscrew, M8 x 25 1
Washer, 8mn, Large O/D 1 O i l Tank t o Brkts. and Brkts. t o Body
Washer, Spring, 8mn 1
O i l Pick W t r a i n e r Assanbly
Gasket, Pick Up t o Tank
Screw, Pick Up t o Tank
Adaptor, Pick Up Assembly t o Hose
O i l Hose Assanbly, Tank t o Punp
Drain Plug
Dipstick ( i n c l u d i n g '0' Ring)
'0' Ring, Dipstick
F i l l e r Cap, O i l Tank
Gasket, F i l l e r Cap
Hose, Breather, Crankcase t o Sleeve
Sleeve, Junction
Hose, Breather, Sleeve/Oil Tank
C l i p , Breather Hose
Gromrret, Breather Hose/Body
Haze, Breather, Airbox/Oil Tank
C l i p , Breather Hose Turbo (Dry Sunpl 4 0 . 1 5 ~
G r m t , Breather Hose/Body Page 2
TURBO
4OA7 A
ILLUS
0
NO. QUANTITY
DESCRlPTION PART NUMBER ALL REMARKS
Distributor Assembly, Lumenition R/B C907E090W. See Optical

(With MK 16 Switch) Switch Ranarks
Distributor Assembly, Lumenition
(With Mk 17 Switch)
Distributor Assembly, Lucas 'Constant Energyv Prior '87 MY.
Distributor Assembly, Lucas 'Constant Energy' '87 M.Y. on ( 'HC' 1
'0' Ring, Distributor Spigot
Distributor Cap
Rotor Ann/kw. Limiter Used With 'Lwnition'
Rotor A m Used With 'Constant Energy'
Nut, Nyloc, Dist. Clanp to Engine
Washer, Flat, Dist. Clanp to Engine
Spark Plug, N3K BPR6ES
Ignition Harness, H.T. Early Cars With H.T. Coil Near Battery
Ignition Harness, H.T. R/B A910E9197F
Ignition Harness, H.T.
Lmnition Optical Switch/Interrupter
Kit (MK 16)
Lmnition Optical Switch/Interrupter When Replacing Mk16 Switch With MK17
Kit (MK 17) Switch, Use With Adaptor A083M6305F
if Retaining Mk16 P a ~ r
Module.
See S/B 1981/20 & 1982/13
Lurenition Pak;ler Module (MK16) R/B q/B083M0384F
Lwnition P m r Module (MK17)* Early Cars With Module by R.H. Fuel Tank
Lumnition Power Module (MK17)* With Module in Ignition Box
When Replacing MK16 Poker Module (Red
or Black Resin Sealing Wires Into Unit)
With MK17 Unit (White Plastic Sealing
Clanp), Use Only in Conjunction With
MK17 Optical Switch
Setscrew, M5 x 20, e l e Fixing
Washer, Smn, Module Fixing
Turbo 40.17A
Page 1
ILLUS MAY iS'31
NO. QUANTITY
Nut, Nyloc, M5, Module F i x i n g

L e n i t i o n Adaptor, Mkl7 Switch/MK16 Module When Required
F i b r e Washer, Chopper Blade H e i g h t Adjust When Required
Lucas ' C o n s t a n t Energy' I g n i t i o n
A n p l i f i e r (AB 1 4 )
Setscrew, M8 x 50, -14 F i x i n g
Washer, F l a t , AB14 F i x i n g
Washer, Shakeproof, -14 F i x i n g
Nut, M8, AB14 F i x i n g
Engine Speed L i m i t e r 'Constant Energy'
Setscrew, M5 x 20, L i m i t e r F i x i n g 1With Speed L i m i t e r F i t t e d T o
Nut, Nyloc, M5, L i m i t e r F i x i n g ) R e a r o f Wheelarch
Washer, F l a t , L i m i t e r F i x i n g 1
Screw, No. 6 x 3/4", L i m i t e r F i x i n g With L i m i t e r F i t t e d t o Wheelarch
R e i n f o r c i n g Timber Web. P r i o r t o '87 M.Y.
S e t s c r e w , M5 x 30, L i m i t e r F i x i n g >
Washer, M5, L i m i t e r F i x i n g >'87 M.Y. o n
Nut, Nyloc, M5, L i m i t e r F i x i n g >
I g n i t i o n Boos
Setscrew, M6 x 20, Ign. Box F i x i n g
W a s h e r , 2- O/D, Ign. E?QX F i x i n g
Nut, Nyloc, M6, Ign. Box F i x i n g
Grormrst, Harness T h o ' Bax
G r m t , H.T. ~ a r n e s s / ~ g n Boor.
I g n i t i o n C o i l , H.T. With P i n k m i t e Ballast 1
Resistor Wire I n Main )With
Harness ) ' Lumeni t i o n '
I g n i t i o n C o i l H.T. With Separate B a l l a s t ) Ignition
Resistor 1
Ballast Resistor U s e d With C o i l A085M6198F)
Ignition Coil With Lucas ' C o n s t a n t Energy'
Setscrew, M6 x 16, C o i l F i x i n g
Washer, C o i l F i x i n g
Nut, Nyloc, M6, C o i l ~ i x i n g Turbo 40.17A
Page 2
NO. QUANTITY
MAY 1991
Alternator, 70A Discard P u l l e y Supplied

Alternator and P u l l e y Assy. 70A Without A i r Conditioning, P r i o r '87 M.Y.
A l t e r ~ t o rand P u l l e y Assy. 70A With A i r Conditioning, A l l '87 M.Y. On
Fan K i t , A l t e r n a t o r
Pulley, A l t e r n a t o r
Nut, S p e c i a l , P u l l e y to A l t e r n a t o r
S t r a p , A l t e r n a t o r Adjusting
Setscrew, M8 x 20, S t r a p t o A l t e r n a t o r
Washer, Spring, S t r a p t o Alternator
Spacer, Adjusting S t r a p t o B e l t Tensioner
S t r a p , A l t e r n a t o r Adjusting
Setscrew, M8 x 20, S t r a p t o A l t e r n a t o r 1
Washer, Spring, S t r a p t o A l t e r n a t o r 1
Washer, F l a t , S t r a p to Alternator ) W e t Sump P r i o r t o '87 M.Y.
Spacer, Adjusting S t r a p t o B e l t t o Tensioner 1 Without 9/C
B o l t , M8 x 127, A l t e r n a t o r t o Aux. Hsg. 1
Washer, F l a t , Alternator t o Aux. Hsg. 1
N u t , Nyloc, M8, A l t . to Aux. Hsg. 1
S t r a p , A l t e r n a t o r Adjusting >
Bolt, S t r a p to Alternator R/B A910E2226F >
Bolt, S t r a p to Alternator >
Spacer, S t r a p t o A l t e r n a t o r >
Washer, P l a i n , S t r a p to A l t e r n a t o r > P r i o r t o '87 M.Y.
N u t , Nyloc, M8, S t r a p to A l t e r n a t o r > With A/C
Bolt, Ml.0 x 45, S t r a p t o Engine >
Washer, Spring, S t r a p to Engine >
Washer, P l a i n , S t r a p to Engine >
Steady Bracket, A k e r ~ t o r >
S t r a p , A l t e r n a t o r Adjusting (Nylon) 1
B o l t , Ml0 x 45, Strap/Brkt ./Engine 1
Washer, Spring, S t r a p Fixing ) '87 M.Y. on
Bush, A l t e r n a t o r S t r a p 1
Clanp Bolt, A l t e r n a t o r t o S t r a p 1
Turbo 40.19A
Page 1
TURBO
40.1 9A
ILLUS
NO. QUANTITY
DRY
40.19A DESCRIPTION PART NUMBER sw
Clarrp P l a t e , A b ? r n a t o r to S t r a p 1
Washer, F l a t , A l t e r n a t o r Fixing 1'87 M.Y. on
Nut, Nyloc, M8, A l t e r n a t o r Fixing 1
Steady Bracket, A l t e r n a t o r 1
Bolt, Steady Brkt. to Water Punp >
Washer, Spring, Brkt. to Water Punp >Prior to '87 M.Y. w i t h q/C
Washer, F l a t , Brkt. t o Water Punp >I87 M.Y. on, with & without A/C
push, S p l i t , Steady Bracket >
Stud, Alternator t o Aux. Hsg. >
Washer, F l a t , Alt. to Aux. Hsg. >
Nut, Nyloc, M8, A l t . t o Aux. Hsg. >
S t a r t e r Motor, Lucas 3N00 1 R/B A912E6884F
S t a r t e r Motor, Lucas M80R 1
I n s u l a t i o n Sleeve, Unused Terminal 1
Bolt, Ml0 x 75, S t a r t e r to Engine 2 U s e w i t h hcas 3M100 S/lubtor
Bolt, Ml0 x 80, S t a r t e r to Engine 2 U s e w i t h Lucas M80R S/Motor
Washer, S t a r t e r to Engine 4
N u t , Nyloc, M l O , S t a r t e r t o Engine 2
Turbo 40.19A
Pqe 2
i
I
TURBO
tQZlA
I
I
I
I 0
NO. QUANTITY
-
DESCRIPTION H.C.
PART NUMBER tEINE
REMARKS
Gasket, Exhaust Manifold t o Head

Gasket, Exhaust Manifold t o Head 4
Manifold, Exhaust
Manifold, Exhaust 1
Washer, F l a t , Manifold t o Head
Locking P l a t e , Manifold t o Head, Upper 2
Locking P l a t e , Manifold t o Head, Imer 4
Nut, M8, 'Aerotight' Manifold t o Head 12
Nut, M8, S p e c i a l 4 A l t e r n a t i v e Top Fixings i f I n s u f f i c i e n t
Clearance f o r A075W3035Z
Gasket, Manifold t o Adaptor 1
Adaptor, Wastegate 4 x M6/2 x M8 Wastegate Fixing
R/B E910E1389F
Adaptor, Wastegate 4 x M6/2 x MlO Wastegate F i x WB E910E1389F
Adaptor, Wastegate 1 2 x Ml0 Wastegate Fixing
Bolt, Adaptor t o Manifold 4
-late, Adaptor/Manifold B o l t s 2
Bolt, Wastegate Pipe t o Adaptor 2
Gasket, Wastegate Pipe t o Adaptor 1
Setscrew, Wastegate t o Adaptor For 4-Stud Fixing Wastegate. Replaces
Studs and Nuts
Locktab, Wastegate t o Adaptor For 4-Stud F i x i n g Wastegate
Stud, M8, Wastegate t o Adaptor
Stud, M10, Wastegate t o Adaptor 2
Reducing Sleeve, lo/-, Wastegate to Adaptor U s e t o F i t Ml0 Wastegate with M8 Studs
Washer, em, Wastegate t o Adaptor
Locking P l a t e , Wastegate Adaptor 2
Nut, M8, Wastegate t o Adaptor
Nut, M10, 'Aerotight', Wastegate t o Adaptor 2
Wastegate A s s d l y , 4 x M6 S t u d Fixing R/B E910E6373F w i t h M8 s t u d s and reducing
sleeves
Turbo 40.21A
Pqe 1
I TURBO
1 4Q21A
ILLUS
a
NO. QUANTITY
-
DESCRIPTION PART NUMBER SID. H.C.
WINE SINE
Wastegate Assembly, 2 x !+If3 Stud f i x i n g 1 R/B E910E6373F with reducing slewes

Wastegate Assembly, 2 x MI0 Stud f i x i n g 1
Wastegate Assmbly, 2 x Ml0 Stud f i x i n g 1
Diaphragm, Wastegate 1 1
Gasket, Diaphragm 2 )For wastegate D/E 910E6373F
Nut, IAcking, Valve Stem 2 1
S e a l i n g Washer, ~ i a p h r a g mClanping 2 1
Gasket, Wastegate to Adaptor 1 4 x M6 stud f i x i n g
Gasket, Wastegate t o Adaptor 1 2 x M8 stud f i x i n g
Gasket, Wastegate t o Adaptor 1 1 2 x M10 s t u d f i x i n g
Elbow, Wastegate t o Boost C o n t r o l Pipe 1 1
Ccpper Washer, Elbaw t o Wastegate 1 1
b k n u t , Elbow t o Wastegate 1 1
Pipe, Boost C o n t r o l 1
Pipe, Boost C o n t r o l 1
El-, Turbo t o Boost C o n t r o l P i p e 1 1
Olive, Boost C o n t r o l P i p e 2 2
Sleeve N u t , Boost C o n t r o l P i p e 2 2
Turbocharger Assembly 1 1
Gasket, Turbo t o Wastegate Adaptor 1 1
Bolt, Turbo t o Wastegate Adaptor 4 4
Lackplate, Turbo to Wastegate Adaptor 2 2
Stud, Turbo t o Exhaust P i p e 4 4
Nut, Exhaust P i p e to Turbo 4 4
L m k p l a t e , Exhaust P i p e t o T u r k 2 2
Gasket, Exhaust p i p e to Turbo 1 1
TLlrbo 4O.2lA
Page 2
TURBO
4Q23A
a
0
ILLUS
NO. QUANTITY MhY 1991
DESCRIPTION PART NUMBER DRY REMARKS
SUW
Conpressor, A i r Conditioning
Bracket, Canpressor to Engine
Screw, Socket Head, Conpressor to Bracket
Nut, Ml0, Carpressor to Bracket
Washer, 10mn, Conpressor to Bracket
Bush, Carpressor R e a r Fix
Bolt, M6, Conpressor Mounting R e a r
Washer, Canpressor Mounting R e a r
Nut, M6, Conpressor Mounting R e a r
Idler Pulley/Adjuster Bracket
Setscrew, M8, B e l t Adjuster
Washer, 8mn, P l a i n
Washer, 8mn, Conical
Washer, 8mn, Spring
Conpressor, A i r conditioning
Spacer, Carpressor t o R e a r Bracket
Bolt, Ml0 x 40, Corrpressor R e a r Fixing
Washer, Carpressor R e a r Fixing
Nut, Ml0, Conpressor R e a r Fixing
Bracket, Carpressor Front t o Block P r i o r '87 M.Y.
Bracket, Conpressor Front t o Block '87 M.Y. On
Bolt, Carpressor t o Front Bracket
Nut, Ml0, Conpressor t o Front Bracket
Washer, Carpressor to Front Bracket
Idler Pulley/Adjuster Bracket 27mn o f f s e t * Up t o engine N o 20825
Idler Pulley/Adjuster Bracket lOmn o f f s e t * Engine No 20826 onwards
*Dimnsion is pulley a x i s o f f s e t from l i n e
joining a d j u s t e r bracket f i x i n g hole
centres
Stud , P u l l e y ~racket/ConpBracket/MBH
Washer, F l a t , P u l l e y Bracket Fixing
Nut, Nyloc, M8, P u l l e y Bracket Fixing
Bolt, M8, Idler P u l l e y Adjust Turbo 40.23A
Washer, Conical, Adjusting S l o t R/B A079W4019F Page 1
Washer, Thick, Adjusting S l o t
1URBO
6023 A
ILLUS
Washer, Flat, Idler Pulley Adjust

Nut, Nyloc, M8, Idler Pulley Adjust
n=r bo
4O.23A
Page 2
I
TURBO (737M.Y. H.C.)
I 4Q27A
ILLUS
NO. QUANTITY
HAY 1991
40.27A DESCRIPTION PART NUMBER REMARKS
001 Vacuum murp / Hub Assembly

002 C a r r i e r Plate, Vacuum Punp
00 3 Setscrew, M8 x 25, PLmp to Carrier
004 Washer, Spring, Purrp t o C a r r i e r
005 Bracket, Pump to Block
006 Setscrew, M10 x 30, C a r r i e r t o Brkt.
007 Washer, Spring, Carrier to Brkt.
008 Washer, F l a t , Adjusting S l o t
009 Setscrew, M8 x 25, Brkt. t o Water Punp
010 Washer, Spring, Brkt. t o Water Punp
012 Hub, 'V' Pulley
013 'V' Pulley, Vacuum Punp
015 Setscrew, M8 x 16, Pulley to Hub
016 Washer, Spring, Pulley t o Hub
017 Hose, A i r Exhaust
018 Clip, Hose t o Punp Outlet
Clip, Hose to Chassis
Screw, C l i p t o Chassis
Washer, C l i p to Chassis
Turbo ('87 M.Y. on)

40.2714
d3p44
i
I
C TURBO
60-28A
ILLUS
NO. QUANTITY
DESCRIPTION WRT NUMBER STD . H.C.
Engine Upper Gasket S e t

Conprising
Cylinder Head Gasket
I n l e t Manifold Gasket
D i f f u s e r / ~ l e n u mGasket
Exhaust Manifold Gasket
Camshaft Cover Gasket Replaces Earlier Cork Type
Camshaft C w e r Screw Washer
Camshaft Front O i l S e a l
Camshaft Rear Cover '0' Ring
Camshaft Housing O i l Feed '0' Ring
C a r b u r e t t o r Mounting '0' Ring
Engine Upper Gasket S e t

Canprising
Cylinder Head Gasket
I n l e t Manifold Gasket
Diffuserfilenun Gasket
Thermostat Housing Gasket
Camshaft Cover Gasket
Camshaft C w e r Screw '0' Ring
Camshaft Front O i l S e a l
Camshaft Rear Cover '0' Ring
Camshaft Housing Access Plug '0' Ring
Camshaft Housing O i l Feed '0' Ring
C a r b u r e t t o r Mounting '0' Ring
For Exhaust Manifold Gaskets, Order
4-Off A910E2235F S e p e r a t e l y i f ~ e q u i r e d
Turbo 40.28A
TURBO
40-28B
a
NO. QUANTITY
Engine Laer Gasket S e t

Canprising :-
Front Cover Gasket
Water Punp Gasket N o t used on '87 M.Y.
O i l G a l l e r y C w e r Gasket
A u x i l i a r y Housing Gasket
O i l Punp Gasket
Rear S e a l Housing Gasket
Scavenge Manifold Gasket Dry Sunp Engines Only
Crankshaft Front O i l S e a l
Crankshaft Rear O i l S e a l
O i l P i c k Up P i p e O l i v e
'0' Ring, O i l Tank Hose t o Punp Dry Sunp Engines Only
'0' Ring, Turbo D r a i n t o Sunp
Gasket, Turbo Drain to Turbo
Turbo 4O.28B
ILLUS
a
NO. QUANTITY
DESCRIPTION 1 PART NUMBER

Belt, Camhaft Timing rrapezoidal Tooth Profile
Toothed Pulley, Canshaft/Auxiliary Shaft 104O M.O.P. Green dots
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 3lotted adjuster
Tensioner Assanbly, Timing Belt 3ex. Head adjuster
Hasing, Belt Tensioner
Piston, 'Nylatron' Belt Tensioner
Spring, Outer, Belt Tensioner
Spring, Inner, Belt Tensioner
Seat, Tensioner Spring, Slotted
Seat, Tensioner Spring, Hex. Head
Locknut, Spring Seat
Yoke, Front, Belt Tensioner
Yoke, Rear, Belt Tensioner
Bush, Pivot, Belt Tensioner
Pin, Pivot, Belt Tensioner
Spirol Pin, Pivot Pin Retention
Rubber Washer, Ydce Pivot
Pulley/Bear ing, Belt Tensioner
Locking Pin, 4 mn, Tensioner Piston
Belt, M6 x 30, Yoke Clanping
Nut, Nyloc, M6, Yoke Clanping
Washer, flat, Yoke Clanping
Bolt, M8 x 35, Yoke Centre Clanping
Nut, M8, Yoke Centre Clanping
Washer, Flat, Yoke Centre Clanping
Washer, Spring to Piston
Snubber, Auxiliary Shaft Pulley
Spacer, Snubber to Tensioner
Turbo (Prior to '87 M . Y . ) 41.01A
Page 1
ILLUS
NO. QUANTITY
I4AY 1991
EATER
41.OLA DESCRIPTION I PART NUMBER 3NLY REMARKS
-
Spacer, Tensioner to Block 2 W t e r cars with no snubber
Stud, Belt Tensioner to Block 1
Washer, Flat, Tensioner Fixing 1
Nut, Nyloc, M10, Tensioner Fixing I
Bolt, MLO x 70, Tensioner to Block 1
Washer, Spring, Tensioner Fixing 1
Washer, Flat, Tensioner Fixing 1
Toothed Pulley, Crankshaft, Cam Belt Drive 1
Woodruff Key, Crankshaft to Pulley 1
Flange, Crank Pulley Rear 1
Oil Rmp, Drive Pulley 1 Dry Sunp Only
Flange, Tooth Belt ~eparation 1 1
Turbo (Prior to '87 M.Y. 1 41.OLA

Page 2
I TURBO ('87 MY, ON )
1 41.01B
I
ILLUS.
NO. QUANTITY
lroothed Belt, Camshaft Driving Ehmded Tooth P r o f i l e (H.T.D.)

Toothed Pulley, Camshaft/ Aux S h a f t Green Dots. 104O M.O.P.
-her, Camshaft P u l l e y Retention
Washer, S p r i n g , Cam P u l l e y Retentian
B o l t , MlOx35, Can P u l l e y Retention
Bracket, B e l t Tensioner t o Block )Heater Only C a r s
B o l t , MlOx45, Tens i o n e r brkt/Block 1 ( F o r q/C Cars see 40.23A)
Washer, F l a t , Tensioner brkt Fixing 1
Stud, NO, Tensioner F i x i n g
E c c e n t r i c Hub, B e l t Tensioner
Pulley/Bearing, Belt Tensioner
Nut, N Y ~ O C , MlO
Washer, P l a i n Tensioner F i x
Toothed P u l l e y , Crankshaft, Can B e l t Drive Rounded Tooth P r o f i l e (H.T.D.)
Flange, Toothed P u l l e y Rear
Woodruff Key, Toothed P u l l e y
Turbo ('87 M.Y. on)

4l.OlB
PRIoR '87MY WITH AIC PRIOR 87 MY WITHOUT A I C
TURBO
41.03A
ILLUS
a
NO. QUANTITY
DESCRIPTION I PART NUMBER
'V' Belt, Water Punp P r i o r t o '87 M.Y.

'V' B e l t , Water Punpfiacuum Pump '87 M.Y. on
'V' B e l t , Alternator
'V' B e l t , Alternator P r i o r t o '87 M.Y. with Heater Only
'V' B e l t , Alternator P r i o r t o '87 M.Y. with q/C & '87 M.Y. on
'V' B e l t , a/c Carpressor
'V' Belt, (Standard Type), a/c Corrp. U s e With Adj. Brkt. B907E0898) See
'V' Belt, (Mculded Cog 1, a/c Carp U s e With Adj. Brkt. A910E9049) 40.23A
'V' Pulley, Water Punp
'V' Pulley, Water Punp
Setscrew, M8 x 16, Pulley
Washer, F l a t , Pulley Fixing
Washer, Spring, Pulley Fixing
'V' Pulley, Alternator
Nut, Pulley t o Alternator
'V' Pulley, Crankshaft, T r i p l e Groove
'V' Pulley, Crankshaft, T r i p l e Groove Except Heater Cars p r i o r t o '87 M.Y.
'V' Pulley, Crankshaft, Double Groove Heater Only P r i o r t o '87 M.Y.
S p i r o l Pin, 'V' Pulley Locating
Washer, Conical, Pulley Retention
Washer, P l a i n , P u l l e y Retention
Washer, Spring, Pulley Retention
Bolt 'V' Pulley t o Crank
Setscrew, 4" UNF' x If" Pulley/Crank
Turbo 41.03A
TURBO
4201 A
a
NO. QUANTITY
PRIOR
DESCRIPTION PART NUMBER '87 M.Y REMARKS
Plenum, RH A i r Scocp
Screw, Plenum t o Body
S p i r e Nut, Plenum
Adaptor, Plenum to H o s e
Pop R i v e t , Adaptor to Plenum
Trunking, Plenum t o Airbox
Hose C l i p , Trunking
Airbox
Insulation, A i r b o x
Foam S t r i p , Airbox to Body
S p i r e B o l t , Airbox t o Body
S p i r e Nut, Airbox to Body
Cwer, Airbox
Adaptor P i p e , B r e a t h e r to Airbox Not Used on Earlier C a r s
Clanp, Airbox C w e r to Body, U p p e r
Clanp, Airbox C w e r to Body, Laer
Setscrew, M6 x 30, C w e r t o Body
Washer, S p r i n g , C w e r to Body
Washer, F l a t , C w e r t o Body
Nut, ' P u l s e r t l M6, C w e r to Body
Trunkins, Airbox to Turbo Used With T u r b o Inlet Adaptor S l e e v e
Trunking, Airbox to Turbo C a r s W i t h a u t Turbo Inlet Adaptor S l e w e
Hose C l i p , Trunking t o A i r b o x
Hose C l i p , Trunking to T u r b o / S l e w e
Adaptor S l e e v e , Turbo I n l e t )Where F i t t e d
Seal, Adaptor S l e e v e t o Turbo 1
Plenum Backplate, C a r b u r e t t o r
Plenum Backplate, Carburettor
Gasket, D i f f u s e r t o B a c k p l a t e
G a s k e t , Plenum C w e r to Backplate
Plenum Chamber C w e r , C a r b u r e t t o r
Plenum Chamber Cwer, C a r b u r e t t o r
Dunp Valve Assembly
Gasket, DLmp valve Plenum
B o l t , M6 x 55, hurp Valve t o Plenum Turbo 42.01A
Page 1
See 17.0%
O O L
TURBO
4201 A
- see GROUP 10b5

a
ILLUS
a
NO. QUANTITY
Washer, F l a t , Durrp Valve to Plenum

E l b Union, Boost Gauge, Screw-on p i p e F i t . P r i o r t o A910E2274
E l b Union, Boost Gauge, Screw-on P i p e F i t .
Grub Screw, E l b Union, Danping F i t s A910E2274
f R/B Elbow Union A910E6772. Cut o f f end
f i t t i n g £ r a n boost p i p e & f i t connecting
hose A082N4020 with r e s t r i c t o r A912E6452
Elbow Union, Boost Gauge, Push-on Pipe F i t .
Elbow Union, Engine b a g e r r r e n t Take-Off
Bolt, Plenum C w e r t o Backplate
Washer, F l a t , C w e r to Backplate
B o l t , Plenum C w e r / ~ a c k p l a t e / D if f user
Washer, F l a t , C w e r / B a c k p l a t e / ~ i f f u s e r
Dif f u s e r , Turbo t o Plenum
Stub Pipe, Cold S t a r t Take Off
D i f f u s e r , Turbo to Plenum ( i n c . Stub P i p e )
Stub Pipe, Cold S t a r t Take-Off
Helicoil Insert
H o s e , Turbo to D i f f u s e r
Hose, Turbo t o D i f f u s e r
C l i p , Turbo/di f fu s e r H o s e
Gasket, Plenum Backplate to Carb.
Gasket, Plenum Backplate t o Carb.
Gasket, Plenum Backplate to Carb.
Gasket, Plenum Backplate t o Carb.
A i r F i l t e r Element
Seal, F i l t e r Element
Plenum, LH A i r Scocp
Adaptor, Plenum to Hose
Pop Rivet, Adaptor to Plenum
Washer, Adaptor to Plenum
Trunking, Adaptor to Sidewall
H o s e C l i p , Trunking
Adaptor, Angled
Pop Rivet, Adaptor t o Sidewall Turbo 42.01A
Page 2
NO. QUANTITY
Washer, M6 x 12, Adaptor to Sidewall

A i r Deflector, Engine Sidewall
Pop Rivet, Deflector Fix
Washer, Deflector Fix
Elbow Adaptor, Plenum Purge
Pipe, Purge, Elbcrw/Solenoid Valve
Pipe, Purge, Solenoid ~ a l v e / P u r g ePurrp
Pipe, Purge, Purge Punp Exhaust
Clip, 'Norma', 12-20mn, Pipe Fix
Gromnet, Purge -/Sidewall
Turbo 42.01A
Page 3
a e
ILLUS
NO. QUANTITY
MAY I991
C a r b u r e t t o r , Rear, DHLA 40H

Carburettor, F r o n t , DHLA 40H
C a r b u r e t t o r , Rear, DHLA 45M
Carburettor, F r o n t , WILA 45M
T h r o t t l e Lever F o r H a i r p i n Type R e t u r n S p r i n g
T h r o t t l e Lever F o r C o i l Type R e t u r n S p r i n g
T h r o t t l e Lever
Spring, T h r o t t l e Return H a i r p i n Type
Spring, T h r o t t l e Return C o i l Type
S p l i t P i n , C o i l S p r i n g to Lever
Anchor B r a c k e t , C o i l S p r i n g t o Cam C w e r
Screw, Anchor Brkt. t o Cam C w e r
Spring, T h r o t t l e Return
B r a c k e t , S p r i n g t o Plenum
S e t s c r e w , S p r i n g Brkt. to Plenum
S p r i n g Washer, B r k t . to Plenum
L i n k a g e A s s d l y , C o l d Start I n t e r c o n n e c t
L i n k a g e Assembly, C o l d Start I n t e r c o n n e c t
Screw, D r i l l e d , C a b l e t o L e v e r >
Screw, L i n k to Lever >
P i v o t Bush, Choke L i n k a g e > i n c . i n L i n k a g e Assy.
P i v o t Bush, Choke L i n k a g e >
Washer, F l a t >
Washer, S p r i n g >
B e l l Mouth, Carb. I n t a k e
B e l l Mouth, Carb. I n t a k e
P i p e , S t e e l B r a i d e d , PEW to F r o n t Carb.
P i p e , Steel Braided, PRV to R e a r Carb. 1
Adaptor, F u e l P i p e t o Carb. 1 With S t e e l B r a i d e d F u e l P i p e s
F i l t e r , Carb. F u e l Inlet
Washer, S e a l i n g , Adaptor t o Carb.
Turbo 42.03A
Page 1
ILLUS
NO. QUANTITY
MAY 1991
PRIOR
42.O3A DESCRIPTION PART NUMBER '87 M.Y REMARKS
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 Nylon
Plug, Anti-Tanper, Air Bleed Metal
Earth Iead, Carburettor/~ngine
Turbo 42.03A
Page 3
ILLUS
NO. QUANTITY
1991
PRIOR
42.O3A DESCRIPTION PART NUMBER '87 M.Y REMARKS
Pipe, Dunlop, PRV t o F r o n t Carb. Cut F r m A910E6650V > With Dunlop

Pipe, Dunlop, PEW to Rear Carb. Cut From A910E6650V > Fuel Pipes
Hose C l i p , Dunlop Fuel Pipes >
Adaptor, Fuel Pipe to Carb. >
Washer, Sealing, Adaptor t o Carb. >
Fuel P r e s s u r e Regulating Valve(8.5mn S/Spigot R/B A910E6615F + 180mm of A910E6785V
Fuel P r e s s u r e Regulating Valve(5.Om S/Spigot
Cap, A n t i q a n p e r , PRV
Setscrew, PRV Fixing
Washer, Spring, PRV Fixing
Hose, P r e s s u r e Sensing U s e w i t h PRV A910E1607F>PRV t o Rear Carb.
H c s e , P r e s s u r e Sensing U s e with PRV A910E6615F)
C l i p , Oetiker, P r e s s u r e Sensing Hose
Banjo, Front Carb. )Cold Start Air Supply
Banjo, R e a r Carb. )
Bolt, Banjo
Washer, Banjo, Large
Washer, Banjo, S m l l
Hose, Cold S t a r t , Banjo t o D i f f u s e r
Pipe, C a r b u r e t t o r Bdlance
Pipe, Cold S t a r t A i r Supply, Diffuser/Carbs.
Bolt, Banjo, Bdlance/Pipe Cold S t a r t Air Pipe!
Washer, Banjo, Large
Washer, Banjo, Small
Hose, Cold S t a r t , Banjo t o D i f f u s e r
Solenoid, T h r o t t l e Jacking
Bracket, Solenoid t o Carb.
Setscrew, M4 x 6, Solenoid F i x
Washer, Solenoid F i x
Washer, Spring, Solenoid F i x
Setscrew, M6 x 30, Brkt. t o Carb.
Turbo 42.03A
Page 2
ILLUS
NO. QUANTITY
MAY !)91
Air Corrector Jet, Main, 200 Quantities are per car

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
P u q Jet, 48H Special
Purr@ Jet, 35
Filter, Punp Jet If Fitted
Starter Jet, 80
Wlsion Tube, Starter
Air Bleed Screw
'0' Ring, Air Bleed Screw
Plug, Vacuum Tapping Orifice
Accelerator Punp Diaphragm
Accelerator Purrp Diaphragm
Adaptor, eng. man. & Spring Anchor
Turbo 42.04A
Page 2
a
ILLUS
NO. QUANTITY
Abutment, Choke Cable &antities are per car

Screw, Cable t o Almtment
Jet C w e r , Cold S t a r t A i r I n t a k e
Jet Cwer, Cold S t a r t Air I n t a k e
Gasket, Jet Cover
Gasket, Jet C w e r
Gasket, Jet C w e r
Top C w e r
Gasket, Top C w e r , ( F l o a t Chamber) X e d 0.7m >R/B B910E68352
Gasket, Top C w e r , ( F l o a t Chamber) 3lack 0 . h >R/B B910E68352
Gasket, Top C w e r , ( F l o a t Chamber) X e d 0.6m
Screw, Idle CO Adjust
'0' Ring, I d l e CO Screw
Gasket, Punp Body
'0' Ring, Small, Pwrp Jet
'0' Ring, Large, Punp Jet
'0' Ring, I d l e Ermlsion Tube
Needle Valve. F l o a t , 200
Gasket, Needle V a l v e
F i l t e r , Needle V a l v e If F i t t e d
Gasket K i t ( A l l Gaskets & S e a l s f o r 2 Carbs.) 2/B B910E6599F
Gasket K i t ( A l l Gaskets & Seals f o r 2 Carbs.) Inc. i n a d d i t i o n Naturally Aspirated
Fype Jet C w e r Gaskets (Brown)
Choke, 36mn
Choke, 35mn
Auxiliary Venturi
Auxiliary v e n t u r i
Screw, Auxiliary Venturi Retaining
F l o a t Assembly, 8.59
Accelerator Punp Body, 27
Main Jet, 185
Main Jet, 160
Turbo 42.04A
Page 1
TURBO
4 2.04A
ILLUS
a
NO. QUANTITY
PRIOR
DESCRIPTION PART NUMBER '87 M.Y
I n l e t Manif o l d
Gasket, Inlet Manifold t o Head
S t u d , Manifold t o C a r b u r e t t o r s
Water R a i l
Water R a i l
Hose, Manifold t o Water R a i l
Hose C l i p , M a n i f o l d h a t e r R a i l Hose
Elbow Hose, C y l i n d e r Head to Water R a i l
S t u b P i p e , Manifold Water O u t l e t
Nut, Manifold t o Head
Washer, Manifold t o Head
Spacer, Manifold t o C a r b u r e t t o r s
'0' Ring, Manifold/Spacer/Carb
Nut, Carb. t o Manifold
.
Cup Washer, Carb. t o Manifold
Rubber Washer, Carb. t o Manifold
Connector Union, Manifold Vacuum 1
Hose, Manifold t o Vacuum R a i l )Up t o VIN 82 D 1954
H o s e , C l i p , Connector Hose 1 82 - 0576
Vacuum R a i l , B a l a n c e P i p e 1
Connector Union, Vac. R a i l 1
Connector Union, Manifold Vaclnrm >From VIN 8 2 D 1955
Blanking P l u g , Manifold T r a c t 3 & 4 > 8 2 - 0577
Turbo ( P r i o r '87 M.Y. 1

42.O7A
see
TURBO ('87 MY ON )
4207 B
0
ILLUS
NO. QUANTITY

- -
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, Manifold/Spacer/~arb .
Nut, Carb. to Manifold
Cup Washer, Carb. to Manifold
Rubber Washer, Carb. to Manifold
Turbo ( ' 8 7 M.Y. ON) 42.078

041
k
S e e 33,038
060
TO HEATER
S e e 18.OSA
TURBO('87M.Y HC.) TO BRAKE SERVO
43.03A
a
ILLUS
NO. QUANTITY
DESCRlPTION PART NUMBER
Thermal I g n i t i o n V a l v e (T.I.V.) L i g h t Green, R/B A910E6893F

T h e I g n i t i o n Valve (T.I.V.) Green
Hose, Vacuum,(T.I.V.) to 1gn.Solenoid V a l v e Black/Red. ( 9OOm o f A910E6783F
Gr<xrmet, Engine Bay S i d e w a l l
Hose, Vacuum,(T.I.V.) t o T h r o t t l e Edge P o r t lackm mite. (350mn of A910E6784F)
H o s e , Vacuum,(T.I.V.) to D i s t r i b u t o r Black. (2601nm o f A910E6786F)
R e s t r i c t o r , P u l s a t i o n Danping
C r a n k c a s e B r e a t h e r V a l v e (C.B.V.)
Adaptor, C r a n k c a s e B r e a t h e r V a l v e
C o l d Enrichment T h e m 1 Valve (C.E.T.V.) R/B B910E6792F
C o l d Enrichment The& V a l v e (C.E.T.V.) Brown
Cap, Rubber, ~ l a n k i n g(C.E.T .V.
Hose, Vacuum,(C.B.V.) to (C.E.T.V.) Black. (200mn o f A910E6786F)
H o s e , Vacuum,(C.E.T.V.) t o Non R e t u r n V a l v e lacm mite. (45mn o f A910E6784F)
Non R e t u r n V a l v e
H o s e , Vacuum, Non R e t u r n Valve t o T-Piece
T-Piece
H o s e , Vacuum, T-Piece to Overboost S w i t c h
Overboost Switch
H o s e , Vacuum, ~unct i o n Connecting Black. ( 9 h of A910E6786F)
T-Piece, Rear C a r b u r e t t o r C o n n e c t i o n
H o s e , Vacuum, Rear Carb. t o T-Piece
P i p e , C o n n e c t i n g , 1/4" 0, Carburettor
Elbow, C o n n e c t i n g p i p e to Carburettor
Clip, E l b Pipe
Connector, 4-Way
Hose, Vacuum, 4-Way to D i s t r i b u t o r
H o s e , Vacuum, 4-Way to P r e s s u r e Reg. V a l v e
Hose, Vacuum, 4-Way to Plenum Adaptor
Hose, Vacuum, 4-Way to T-Piece
T-Piece
H o s e , Vacuum, pie to I g n . S o l e n o i d V a l v e
I g n i t i o n S o l e n o i d V a l v e (I.S.V.)
Turbo ( ' 8 7 M.Y. On) 43.03A

Page 1
ILLUS
NO. QUANTITY
MAY 1991
Hose, Vacuum,(I.S.V.) t o B o o s t G a u g e Pipe ~ l a c k / B l u e . (40(krm of A910E6785F)

Hose, Vacuum,(I.S.V.) to T - P i e c e B l a c k . ( 1 0 h of A910E6786F)
T-P iece
Elbow, H e a t e r / = Take-Off
C o n n e c t o r Sleeve, T - P i e c e n a c u u m Supply Pipes
Pipe, Vacuum Supply
Gr<rranet, E n g i n e B a y Sidewall, Boostflac .Pipes
Connector, Hose
T-P iece, H o s e C o n n e c t o r
H o s e Vacuum, T - P i e c e to Vacuum Pun@ 34Onn-n l e n g t h
P i p e , (C.B.V.) to Airbax
H o s e , (C.B.V.) t o C r a n k c a s e
C l i p , H o s e , (C.B.V.) Hoses
Turbo ( ' 8 7 M.Y. On1 43.03A

Page 2
TURBO
64.01A
ILLUS
a
F i l l e r Cap Assanbly, Luckable

F i l l e r Cap Cover
F i l l e r Cap S h u t t e r
F i l l e r Cap Base, (Inc. Lock & Keys)
Clanp Ring, F i l l e r Neck
Gasket, Clanp Ring to Body
Screw, No. 6 x 3'' Clanp Ring
Fuel F i l l e r Neck, Id-l 16.5m1-1Breather Hose Spigot
F u e l F i l l e r Neck, RH 1
Fuel F i l l e r Neck, LH >8.0mn Breather Hose Spigot
F u e l F i l l e r Neck, RH >
Hose, F i l l e r Neck to Tank
Hose C l i p , F i l l e r Hose
Pipe, F i l l e r Vent
Hose C l i p , F i l l e r Vent H o s e
F u e l Tank, LH (Requires Banjo OEftake)
F u e l Tank, LH ( I n t e g r a l Fuel P i p e S p i g o t )
Fuel Tank, RH (Requires Banjo O f f t a k e )
F u e l Tank, RH ( I n t e g r a l F u e l P i p e S p i g o t )
Grarmet, Crossover Hose/Body
Ring, G r a m & Fixing
Screw, Ring Fixing
S p i r e Nut, Ring Fixing
SCrW, Ring Fixing
Washer, Ring Fixing
F m , Tank Clanping
F m , Tank S e a t i n g
Pad, S e l f Adhesive, Noise Danping Tank S i d e & LH Top)
Pad, S e l f Adhesive, Noise Darrping Tank Tap )If
Pad, S e l f Adhesive, Noise Darrping RH Tank Top )Fitted
Pad, S e l f Adhesive, N o i s e Danping Tank B o t t o m 1
Setscrew, M8 x 20, Tank to Bcdy
Washer, Flat,M8 x 25, Tank t o Body
Washer, Spring, Tank t o Body
Turbo 44.01A
Page 1
002
.b
TURBO
4601A
ILLUS
NO. QUANTITY MAY m y
Pipe, C r o s s w e r
Hose, C l i p , C r o s s w e r P i p e Hoses
H o s e , Mculded, Tank to C r o s s w e r P i p e
G r m t , C r o s s w e r Pipe/Chassis
Sender Unit, F u e l Gauge R/B A082L6032F
Sender Unit, F u e l Gauge Inc. Gasket
Gasket, Sender Unit
Screw, 10 UNF x +'I, Sender F i x i n g 1
Washer, Spring, Sender F i x i n g )R/B A082W7044F
Washer, F l a t , Sender Fixing 1
Capscrew, 1 0 UNF x f", Sender F i x
Washer, F i b r e , Sender F i x i n g
Board, F u e l Tank Top, LH
Board, F u e l Tank Top, RH
Bracket, Tank Board t o Bulkhead
Bracket, Tank Board to Wheelarch
S t u d p l a t e , Bracket t o Bulkhead
Washer P l a t e , Bulkhead Brkt ./Board
Washer P l a t e , Wheelarch Brkt./Board
Washer P l a t e , Wheelarch Brkt/Budy
Setscrew, M8 x 20, Wheelarch Brkt.
Nut, Nyloc, M8, Bulkhead Brkt.
Turbo 44.01A
Page 2
TURBO
44.03A
ILLUS
a
NO. QUANTITY
Banjo, lOmn, LH Tank Fuel Feed 1

Banjo, l h n , LH Tank Fuel Feed 1
Copper Washer, Banjo )If Fitted
Crush Washer, i", Banjo 1
Bolt, Banjo 1
Pipe, S t e e l Braided, LFl Tank to mmp Cut Fran A082L6017V (40Qnm)
Pipe, Dunlop, U l Tank t o Punp Cut From A082L6038V ( 4OQrm)*
Pipe, Dunlop, LH Tank to Plmp Cut Fran A082L6038V (52Qnm)t
C l i p , Fuel Pipe t o Tank and Punp For S t e e l Braided Pipe
Clip, Fuel Pipe to Tank and Pump For Dunlop P i p e
Graranet, Pipe Thro' Bcdy
-1 Punp
Clanp, Fuel Punp M t g .
I n s u l a t o r S t r i p , Clanp t o Plmp
Bolt, M5 x 40, Pmp Clanping
Washer, P l a i n , Pump Clanping
Nut, Nyloc, M5, Punp Clanping
Setscrew, M6 x 20, Clanp to Chassis *
Washer, F l a t , Clanp t o Chassis 1
Rubber Bobbin, Plmp Brkt. to Body >
Nut, 5/16" UNF, Bobbin t o Punp Brkt. >
N u t , Nyloc, 5/16" UNF, Bobbin t o Body WB A082L4121F >
Tapping P l a t e , Pump Bracket t o Body >t
Pop Rivet, Tapping P l a t e t o Body >
Washer, F l a t , Bobbin F i x >
Washer, Spring, Bobbin t o Pump Brkt. >
Pipe, Punp to F i l t e r Cut From A075L6043V (30Qrm)*
Pipe, mmp t o F i l t e r Cut Fran A075L6043V (41Qnm)t
C l i p , Oetiker, 9/16"
'P' C l i p , Open, mmp t o F i l t e r Hose >t
Screw, 'PI C l i p Fixing > * with p u p mmnted on c h a s s i s
F i l t e r , Fuel t with pump m n t e d on body
Clanp, Fuel F i l t e r
I n s u l a t o r S t r i p , Clanp t o F i l t e r
Turbo 44.03A
Pqe 1
TURBO
b4.03A
a
ILLUS
NO. QUANTITY
Banjo, 10m-1, LH Tank F u e l Feed 1

Banjo, l h , IH Tank F u e l Feed 1
Copper Washer, Banjo )If Fitted
Crush Washer, +", Banjo 1
B o l t , Banjo 1
P i p e , S t e e l Braided, LH Tank t o Pwp Cut F r a n A082L6017V (40Qnm)
P i p e , Dunlop, LH Tank t o Punp Cut F r m A082L6038V (40(hm)*
P i p e , Dunlop, LH Tank t o Purrp Cut F r a n A082L6038V (52Qnm)t
C l i p , F u e l P i p e t o Tank and Punp For S t e e l Braided P i p e
C l i p , F u e l P i p e t o Tank and Purrp For Dunlop P i p e
G r m t , P i p e Thro' Body
F u e l Purrp
Clanp, F u e l E U p Mtg.
I n s u l a t o r S t r i p , Clarrp t o J?mp
B o l t , M5 x 40, Punp Clanping
Washer, P l a i n , Punp Clarrping
Nut, Nyloc, M5, Purrp Clanping
Setscrew, M6 x 20, C l q to C h a s s i s 1*
Washer, F l a t , C l a n p t o C h a s s i s 1
Kubber Bobbin, mmp Brkt. t o M y >
Nut, 5/16" UNF, ~ o b b i nt o Pump Brkt. >
N u t , Nyloc, 5/16" UNF, Bobbin t o Body R/B A082L4121F >
Tapping P l a t e , murp Bracket t o Body >t
Pop R i v e t , Tapping P l a t e t o Body >
Washer, F l a t , Bobbin F i x >
Washer, S p r i n g , Bobbin t o Purrp B r k t . >
P i p e , Punp t o F i l t e r C u t From A075L6043V (3O(hm)*
P i p e , Punp t o F i l t e r Cut F r a n A075L6043V (41Qmn)t
C l i p , O e t i k e r , 9/16"
'P' C l i p , Open, mmp t o F i l t e r Hose >t
Screw, 'PI C l i p F i x i n g > * w i t h plnp m a n t e d on c h a s s i s
F i l t e r , Fuel t w i t h punp mcunted on body
Clanp, F u e l F i l t e r
I n s u l a t o r S t r i p , Ckmp t o F i l t e r
Turbo 44.03A
Page 1
1 TURBO
I
I 4 LO3A
ILLUS
NO. QUANTITY
44.03A DESCRIPTION PART NUMBER ALL
Bolt, M6 x 60, F i l t e r Clanping

Washer, F l a t , F i l t e r Clarrp
Nut, Nyloc, M6, F i l t e r Clarrp
S t u d p l a t e , F i l t e r Clarrp t o Body
Pipe, F i l t e r t o Bundy Cut From A075L6043V ( 35(krm)*
Pipe, F i l t e r to Bundy Zut F r a n A075L6043V (20(hrm)t
C l i p , Oetiker, 9/16"
Bundy Pipe, F'uel Feed
'PI C l i p , Bundy F i x i n g
Screw, s/t, P C l i p F i x
S p i r e Nut, P C l i p F i x
Pipe, S t e e l ~ r a i d e d ,Bundy to P.R.V.
Pipe, Dunlop, Bundy t o P.R.V. Cut From A082L6036V (50Ch~rn)
C l i p , P i p e to Bundy & P.R.V. For Dunlap P i p e
Pipe, S t e e l Braided, P.R.V. to RH Tank
Pipe, Dunlop P.R.V. t o RH Tank Cut F r a n A910E6650V (145Qnm)
C l i p , P i p e t o P.R.V. and Tank For Dunlop P i p e
T i e Wrap, Return H o s e t o C h a s s i s
'PI C l i p , Return Hose to Bcdy
Screw, s/t, 'PI C l i p Fixing
G r a m & , Return Hose/Body
Banjo, RH Tank
Ccpper Washer, Banjo
Crush Washer, #", Banjo
B o l t , Banjo
* With ~olrrpmounted on c h a s s i s
t With ~olnpmamted on body
Turbo 44.03A
Page 2
TURBO
4L.05A
a
NO. QUANTITY

ALL
Breather Hose, F i l l e r Neck t o Anti Surge Valw 2 5 . M I/D. U s e with 6. !3m F i l l e r Neck Spigot
Breather Hose, F i l l e r Neck to Anti Surge Valvc 2 7.lmn I/D. Use w i t h 8mn F i l l e r Neck Spigot
C l i p , Breather Hose t o F i l l e r Neck 2
C l i p , Breather Hose to Valve 2
Valve, Anti Surge 2
'PI C l i p , Valve Fixing 2
'PI C l i p , Valve Fixing 2
Pop R i v e t 2
Washer 2
Breather Hose, 200 mn, Anti Surge t o IT1 Piecc 1
Breather Hose, 2 m, Anti Surge t o IT' P i e c e 1
'T' Piece, Breather Hose 1
Breather Hose, 3.2 m 1
C l i p , Hose to 'TI & Valves 5
'P' C l i p , Breather Hose Fixing 4
Pop Rivet Breather Hose Fixing 4
Washer, Breather Hose Fixing 4
Turbo 44.05A
~
I
TURBO
45.03A
i
a
ILLUS
NO. QUANTITY
Exhaust Pipe, Main

Ekhaust Pipe, Wastegate
Bolt, P i p e s t o S i l e n c e r
Nut, Pipes t o S i l e n c e r
S i l e n c e r & T a i l Pipes R/B B082S4105F
S i l e n c e r & T a i l Pipes '84 M.Y. On
C l a n p , S i l e n c e r t o Channel
Setscrew, M8, S i l e n c e r Clanp
Nut, M8, S i l e n c e r Clanp
Channel, S i l e n c e r Writing
Nut, M10, Channel t o Bracket
Washer, Channel to Bracket
Bracket, S i l e n c e r Mounting P r i o r t o C35 G/Box
Bracket, Silencer Writing With C35 G/Box R/B D082S4126F & Fixings
Bracket, S i l e n c e r Mounting
Stud, Bracket to Gearbox R/B B079F4030F
Stud, M7 x 128, Bracket t o Gearbax Used with bracket D082S4126F
Nut, Nyloc, MI, Bracket to Gearbox
Washer, F l a t , Bracket t o Gearbox
Bolt, Bracket to Gearbox >R/B B079F403lF
Bolt, Bracket t o Gearbax With C35 G/BOX >
Bolt, M7 x SO, Bracket to Gearbox Used with Bracket D082S4126F
Turbo 45.03A
TURBO
4505A
ILLUS
NO. QUANTITY
45.05A DESCRIPTION PART NUMBER
Heatshield, Body & Tyre, (Aluminium) 2 P i e c e s , Inc. Jacknuts

Jacknut, M6, Heatshield
Screw, S/T, Alum. S h i e l d J o i n i n g
Pop Rivet, 3/16", S h i e l d to Body
Washer, Pop Rivet
Heatshield Assy. Body & Tyre ( F e r r o b e s t o s ) C a r p r i s e s Itms 6 and 10
Heatshield, Body, (Ferrobestos 1
Setscrew, M6 x 12, (Ferro.) S h i e l d F i x
Washer, Shakeproof, (Ferro.) S h i e l d F i x
Washer, Large O/D, (Ferro.) S h i e l d F i x
Heatshield, Tyre, (Ferrobestos 1
Setscrew, M6 x 16, (Ferro.) S h i e l d F i x
Washer, F l a t , (Ferro.) S h i e l d F i x
Washer, Large O/D, (Ferro.) S h i e l d F i x
Washer, S/Proof, (Ferro.) S h i e l d F i x
Nut, Nyloc, M6, ( F e r r o . ) S h i e l d F i x
Heatshield, Engine Bay R e a r
Screw, M4 x 10, Heatshield F i x
Washer, Shakeproof " I@
Spacer, I n s u l a t i n g " In
Washer, F l a t 11 II
Nut, Nyloc w II
Heatshield, LH Engine Mounting

Setscrew, M6 x 20, S h i e l d to Chassis
Washer, Large O/D, " In nu
Washer, F l a t , (I )I I#
Nut, ~ y l o c ,M6 II
II II
Heatshield, LH Radius Arm M t g .

C l i p , S h i e l d to C h a s s i s
Setscrew, M6 x 20, S h i e l d t o Chassis
Washer, F l a t , S h i e l d t o C h a s s i s
Heatshield, Carpressor/9/C P i p e s
Jacknut, Heatshield F i x
Setscrew, M6 x 20, Heatshield F i x
Washer, Large O/D, Heatshield F i x Turbo 45.05A
Page 1
TURBO
4505A
0
a a
ILLUS
NO. QUANTITY
Heatshield, Radius Arm Mounting

Setscrew, M6 x 20, Heatshield Fix
Heatshield
Washer, Flat, M6 x 15, Heatshield Fix
Washer, Spring, M6, Heatshield Fix
Nut, M6, Heatshield Fix
Heatshield, Vacuum Punp
Washer, Flat, M6 x 15, Heatshield Fix
Heatshield, Engine Mounting Cwer
Heatshield, Engine mnting
Washer, Flat, Heatshield Fix
Washer, M6 x 12, Heatshield Fix
Nut, Nyloc, M6, Heatshield Fix
Heatshield, Turbo
Heatshield, Turbo
Reflector, Turbo Heatshield
Washer, Flat, M6 x 15, 'Shield/Diffuser Brkt.
Washer, Flat, M6 x 15, 11 I# It
Washer, Spring
Nut, M6
Washer, Jbad Spreader
Spacer, Heatshield
Bolt, M6 x 30, Heatshield/Cwer/Housing
Washer, Spring
Heatshield, LH Danper Top
Clip, Heatshield to Chassis
Screw, Shield Fixing
Washer, Flat, Shield Fixing
Turbo 45.05A
Page 2
ILLUS
NO. QUANTITY MAY i991
DESCRIPTION I PART NUMBER ALL REMARKS
Radiator Duct Used With 306mm Support Stays

Radiator IXIct With 266 / 286m Stays.252mm Oil Cooler
Radiator Duct 325m Oil Cooler Union Centres
Radiator Duct Fettle to Fit Rad: A082K4237F
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 )R/B A082K4188/9
'L' Bracket, Stay to Chassis )Ref. S. Bulletin 1983/11
Support Stay, Rad. Duct, RH >306m Between Hole Centres
Support Stay, Rad. Duct, LH >
.
Support Stay, Rad Duct, RH
Support Stay, Rad. Duct, La-l
1266mn Between Hole Centres
1
Support Stay, Rad. Duct. RH >286m Between Hole Centres
Support Stay, Rad. Duct. La-l >1985 Model Year On.
Setscrew, M6 x 20, Stay to Chassis
Washer, Flat, Stay to Chassis
Nut, Nyloc, M6, Stay to Chassis
Spacer Washer, Stay to Chassis
Setscrew, M6 x 20, Stay to Duct 1
Washer, Large O/D, Stay to Duct )Use With 266 & 286m Stays
Washer, Flat, Stay to Duct
Nut, Nyloc, M6, Stay to Duct
Radiator
Radiator
Foam, Radiator top to Body Thick
Foam, Radiator bottan to Duct Thin
Drain Plug, Radiator
Setscrew, M6 x 25, Radiator to Duct
Washer, S/Proof, Rad. to Duct
Washer, Large O/D, Rad. to Duct
Turbo (Prior '87 M.Y.) 46.OlA
Page 1
ILLUS
NO. QUANTITY
Washer Bush, Rad. t o Duct 8 )If Fitted

Jacknut, M6, Rad. t o Duct 2 1
C w l , Radiator Fans, ABS 1 >
C w l , Radiator Fans 1 > F e t t l e t o f i t A082K4237F
Edge C l i p , C w l t o Radiator 18
Fan Shroud & Motor t4mnting 3 Use With M t a l Fans
Fan Shroud & Motor M m t i n g 3 Use With P l a s t i c Fans
Fan Motor, Rad. Cooling ( f o r m e t a l f a n ) 3 )R/B A082K6025F
Fan, Radiator Cooling, Metal 3 )See S. B u l l e t i n 1983/21
Fan M o r and Blade Assy. ( p l a s t i c f a n ) 3 R/B next f o u r i t a m
Fan Motor, Rad. Cooling ( f o r p l a s t i c fan) 3
Fan, Radiator, Cooling, P l a s t i c 3
C i r c l i p , P l a s t i c Fan t o Motor 3
Washer, P l a s t i c Fan to M o r 3
Setscrew, M5 x 12. Motor Mtg. 9 1
Nut, Nyloc, M5, Motor M t g . 9 )For Fan Eibtor A074M6027Z
Washer, 5 m , Motor M t g . 9 1
Washer, F l a t , Motor M t g . 9 >For Fan bbtor A082K6026H
Nut, Nyloc, M6, Motor Mtg. 9 >
Pcp Rivet, Fan Shroud to Caw1 30
Washer, Pop Rivet 30
H o s e , Cylinder Head to Water P i p e 1
H o s e C l i p , 32-50 2
H o s e , Water R a i l to Water Pipe 1
Pipe, Cylinder Head t o T h e m s t a t 1
H o s e , Air Bleed 1 Water P i p e t o Header Tank
H o s e C l i p , A i r Bleed Hose 2
C l i p , Bleed H o s e to Engine Bay 3
Hose, T h e m t a t Inlet 1 Except Wet S q A/C
H o s e , ThenuDstat Inlet 1 wet sunp A/C
Hose C l i p , 32-50m 2
Themstat 1
Hose, T h e m s t a t O u t l e t 1
H o s e C l i p , 32-50mn 2
Connector P i p 1 Turbo ( P r i o r ' 8 7 M.Y.) 46.01A
Page 2
0
QUANTITY FEB i987-
H o s e , Rad. Main Feed Pipe, Rear

Hose C l i p , 32-50mn
Pipe, Rad. Main Feed, Thro' c h a s s i s
H o s e , Reducer, Feed P i p e F r o n t
Hose C l i p , 32-50
Elbow Pipe, Radiator Inlet
Rad; -Fan T h e m s w i t c h ( ' O t t e r ' 1 Hot Climates. Includes G r m t
(82/72 1 Blue Coded
Rad. Fan T h e m . Switch ( 'Otter ' 1 ( 86/76 1 R/B A079M6200F
Rad. Fan T h e m . Switch ( ' O t t e r ' 1
( 92/82 1 Green Coded Tenperate Climates. Includes Grannet
Gram&, Fan Switch
C l i p , Fan Switch Retaining
Hose, Radiator I n l e t
H o s e , Radiator Inlet
H o s e C l i p , 32-50
J u n c t i o n Pipe, 'Stat/H. Tank/By+ass E3Cc-t Wet Sump A/C
J u n c t i o n Pipe, 'Stat/H. Tank/By-pass wet sunp A/C
H o s e , T h e m s t a t By-Pass
H o s e C l i p , 32-50
H o s e , J u n c t i o n P i p e to H. Tank P i p e
Pipe, Header Tank Except Wet Surrp A/C
Pipe, Header Tank wet Sunp A/C
H o s e , Header Tank to Water P i p e R/B A079K4034F
Hose, Header Tank t o Water P i p e
H o s e C l i p , 32-50
Hose, J u n c t i o n P i p e t o By-Pass P i p e 1
H o s e C l i p , 32-50 )Wet Sunp A/C
Pipe, R a d i a t o r By-Pass 1
H o s e , Radiator By-Pass
H o s e C l i p , 32-50
Turbo ( P r i o r '87 M.Y. 1 46.01A
Page 3
0
ILLUS
NO. QUANTITY
DESCRIPTION PART NUMBER ALL, REMARKS
J u n c t i o n Pipe, Return Rad . ~eturn/By-~ass/~urrp

H o s e , J u n c t i o n Pipe t o Reducer
Pipe, Reducing, Punp Inlet
Hose, Water Purtp Inlet
Hose, Rad. Main Return P i p e R e a r
Pipe, Rad. Main Return, Thro' Chassis
Sheathing, Chassis S t r u t Pipe P r o t e c t i o n
Snapper C l i p , Sheathing t o C h a s s i s
H o s e , stepped, Return Pipe Front
Pipe, E l b , Radiator O u t l e t
H o s e , Rad. O u t l e t to Elbow
Hose, Rad. O u t l e t t o Return P i p e
H o s e C l i p , 32-50
G r m t , Water ~ i p e s / C h a s s i s
Terp. Transmitter, Water Gauge
Header Tank
Setscrew, M8 x 20, Header Tank F i x
Washer, F l a t , Header Tank F i x
Nut, Nyloc, M8, Header Tank F i x
P r e s s u r e Cap, Header Tank, 10 p s i
P r e s s u r e Cap, Header Tank, 1 5 p s i
El-, Header Tank Overf lw
Turbo ( P r i o r '87 M.Y.) 46.0114

Page 4
ILLUS
a
Cooling System Modification K i t See S/Bulletin 1987/26

C a r p r i s i n g :-
Header Tank
Blanking Cap, Header Tank
Sensor Sensor used only a s a b l a n k
Grarmet, Sensor Mamting
Hose, Header Tank to Expansion Tank
Clip, Hose
Expansion Tank
P r e s s u r e Cap, Expansion Tank
Setscrew, M6 x 25, Expansion Tank F i x
Setscrew, M6 x 18, n II el
Washer, F l a t , M6 x 16, " @I !I
Washer, F l a t , M6 x 12, " @I IS
Nut, N ~ ~ o c M ,6 'I 11 I1
'Y' Piece, Heater Return Hose t o Header Tank

Hose, Header Tank t o 'Y' P i e c e
J u n c t i o n Pipe, Return
Pipe, Bypass
H o s e , T h e m s t a t to Bypass P i p e
Hose, Bypass P i p e t o J u n c t i o n P i p e
Themstat
C l i p , Hose, 8-16mn
T i e Wrap, Hose Securing
Grarmet , Rear Quarter Trim Panel
Turbo ( P r i o r '87 M.Y.) 46.01A

Page 5
ILLUS
NO. QUANTITY
R a d i a t o r Duct I'his page f o r '87 M.Y. 'H.C.' Turbo Cars.

Spacer, Radiator Duct F r o n t t o Body For cars p r i o r '87 M.Y. see 46.01,
B o l t , M8 x 127, R a d i a t o r Duct F r o n t Mounting
Nut, Nyloc, M8, R a d i a t o r Duct F r o n t Mounting
Washer, F l a t , R a d i a t o r Duct F r o n t Mounting
Setscrew, M6 x 25, Duct t o Body
Washer, 25 O/D, Duct t o Body
Nut, Nylcc, M6, Duct t o Body
Screw, s/t, Duct to Body
S p i r e Nut, Duct to Ekdy
Support Stay, Rad. Duct I33
Support Stay, Rad. Duct RH
Setscrew, M6 x 20, S t a y to Chassis
Washer, S t a y to C h a s s i s
Nut, Nyloc, M6, S t a y t o C h a s s i s
Spacer Washer, S t a y t o C h a s s i s
Setscrew, M6 x 20, S t a y t o Duct
Washer, 25 O/D, S t a y to Duct
Washer, F l a t , S t a y t o Duct
Nut, Nyloc, M6, S t a y t o Duct
Radiator
Radiator
Drain Plug, R a d i a t o r
Setscrew, M6 x 18, Rad. t o Duct
Washer, 25 O/D, Rad. t o Duct
Washer, S p r i n g ,Rail. t o Duct Thick
Foam, Rad. tq t o Body Thin
Foam, Rad. B o t t a n to Duct
C w l , Rad. Fans
C w l , Rad. Fans F e t t l e t o f i t Rad: A082K4237F
we C l i p , Cowl to R a d i a t o r
Screw, s/t, C w l to R a d i a t o r
S p i r e Nut, Cowl to R a d i a t o r Turbo H.C. ('87 M.Y. On)
Fan Shroud & Motor Mounting 46.OlB
Page 1
ILLUS
Pop Rivet, Shroud to Cowl T h i s page f o r '87 M.Y. 'H.C.' Turbo Cars.
Washer, Pop R i v e t For cars p r i o r '87 M.Y. see 46.01A
Fan Motor, Radiator Cooling
Fan, Radiator Cooling
Washer, Fan to M o r S h a f t
Spring C l i p , Fan t o Motor S h a f t
Washer, F l a t , Motor Mcunting
Nut, Nyloc, M6, Motor Mounting
H o s e , Radiator O u t l e t
Hose C l i p , O u t l e t Hose
Pipe, Water F e e d h e t u r n , thraugh Chassis
Sheathing, C h a s s i s S t r u t , P i p e P r o t e c t i o n
Snapper C l i p , Sheathing t o Chassis
G r m t , Water P ipe/Chassis
Elbow H o s e , Return p i p e t o J u n c t i o n Pipe
Hose C l i p
J u n c t i o n Pipe, Header Take+££
G r a m & , J u n c t i o n Pipe/Chassis
H o s e , Purtp Inlet
H u s e Clip
Rubber Pad, Hose/Chassis
Hose, Header Tank Feed
Connector Pipe, Header H o s e
Hose, Connector t o Header Tank
H o s e C l i p , Header H o s e
'P' C l i p , Header Hose t o Chassis
T i e Wrap, 290mn, H o s e Securing
Hose Clip
H o s e , T h e n m s t a t Housing to P i p e
Pipe, Engine O u t l e t
Bracket, Water P i p e Fixing
The& Switch, Radiator Fans 92/82 Green Coded I n c l u d e s Granrnet
Grcsrmet, Radiator Fans The& Switch
Turbo H.C. ( ' 8 7 M.Y. On)
46.OlB
Page 2
a
ILLUS
NO. QUANTITY
C l i p , Thermal Switch R e t e n t i o n T h i s page for ' 8 7 M.Y. 'H.C.' Turbo Cars.

Hose, O u t l e t P i p e t o C h a s s i s P i p e F o r cars prior ' 8 7 M.Y. see 46.01A
Hose C l i p , Elbow Hose & Water P i p e t o B r k t .
Hose, R e d u c i n g
Hose C l i p
Elbaw P i p e , R a d i a t o r I n l e t & T h e r m a l S w i t c h
Hose, R a d i a t o r Inlet
Hose C l i p , R a d i a t o r I n l e t Hose
B r a c k e t , Water P i p e to Chassis
Screw, B r a c k e t , t o C h a s s i s
Hose C l i p , P i p e to B r a c k e t
Edge C l i p , Header T a n k Hose
Edge C l i p , Header Tank Hose
Header Tank
S e t s c r e w , M6 x 20, H e a d e r Tank F i x
Washer, I n t e r m 1 S p r i n g , H e a d e r Tank Fix
Washer, M6 x 1 2 , Header T a n k F i x
P r e s s u r e Cap, H e a d e r Tank, 1 5 psi
Hose, Air B l e e d
Hose C l i ~ ,A i r B l e e d Hose
C l i p , A i r B l e e d Hose t o Airbox
P a p R i v e t , Sealed, C l i p to A i r h
Hose, H e a d e r Tank O v e r f l w
Elbaw, H e a d e r Tank O v e r f l o w Hose
C l i p , Hose t o Header T a n k
C l i p , O v e r f l w Hose t o Body
P o p Rivet, C l i p F i x
Washer, C l i p F i x
C l i p , O v e r f l o w Hose t o C h a s s i s
Probe, C o o l a n t Level T e l l q a l e
G r a r m e t , C o o l a n t Level P r o b e
Turbo H.C. ( ' 8 7 M.Y. On)

A6.01B
Page 3
e
ILLUS
NO. QUANTITY HAY 1991
-
DRY m
DESCRIPTION I PART NUMBER SUMP SUMP REMARKS
O i l Hose A s s d l y , Scavenge P u p to 1 dhen N o O i l Cooler T h e m s t a t F i t t e d

Cooler
O i l Hose Assembly, Scavenge Punp to
Themstat 1 1
T h e m s t a t , O i l Cooler 1 1
Bracket, T h e n m s t a t W n t i n g 1 1
Setscrew, M6 x 16, Bracket t o Body 2 1
Washer, 6 rrm, Bracket to Body 2 )With O i l Cooler Thermostat
Nut, Nyloc, M6, Bracket t o Body 2 1
O i l H o s e Assembly, Thermostat to 1 1
Cooler 1
O i l H o s e A s d l y , Cooler to 1 1
Themstat 1
O i l H o s e Assembly, T h e n m s t a t to 1 1
Tank
O i l H o s e Assembly, Cooler to Tank 1 When No O i l Cooler Thermostat F i t t e d
G r a m & , Tank Return Pipe/- 1
Ring, G r a m r s t Retaining 1
Screw, G r a m r s t Ring 4
O i l Hose Assembly, S t a t t o Engine 1
O i l Hose A s s d l y , Engine t o S t a t (5/8"@ S t a t 1 With O i l Cooler Thermostat A910E6550F
O i l H o s e Assembly, Engine t o S t a t (3/411@S t a t ) 1 With O i l Cooler Thermostat A082E6016F
T h e m s t a t , O i l Cooler 1 4 x 5/8" BSP > I f Thermostat
T h e m s t a t , O i l Cooler 1 3 x 5/8" 1 x 3/4" BSP > F i t t e d
Bracket, T h e m t a t Mounting 1 For A910E6550F > (Prior to
Bracket, Thermstat M n t i n g 1 For A082E6016F > Nwember '85)
Nut, Nyloc, M6 2 >
Washer, F l a t 2 >
Turbo 46.03A
Page 1
TURBO
46.03 A
a
ILLUS
NO. QUANTITY
DRY
46.O3A DESCRIPTION PART NUMBER SUM' REMARKS
Connector Union, O i l Hose, Eng. t o C o o l e r 3/4" -

5/8" BSP)
Connector Union, O i l Hose, C o o l e r t o Eng. 5/8" BSP x 2 ) I n t e r i m Spec.
Mcunting B r k t . C o n n e c t o r Unions )Without T h e m s t a t
CLanp P l a t e , Unions to Brkt. )(Nov.' 8 5 t o VIN 82 D 2321
Spacer, Union Locking 1 8 2 - 0672
Nut, Nyloc, M8, CLanping & F i x i n g 1
Washer, 25 O/D, B r k t . t o C h a s s i s 1
O i l Hose Assembly, C o o l e r / S t a t Ul >
O i l H o s e Assanbly, C o o l e r / S t a t RH R/B A082E4111F >With T h e m t a t
O i l Hose Assembly, C o o l e r / S t a t RH I n c . 45' T h e r m o s t a t Union>
.
O i l Hose Assembly, Eng/Cooler, C o o l e r / E n g Without T h e m s t a t
'P' C l i p , Hose t o C h a s s i s
Screw 'P' C l i p s
Nut, Spire
C l i p , O i l Hose t o F r o n t F r a n e
Screw, C l i p F i x i n g
Spire Nut, C l i p F i x i n g
G r a m e t , O i l Hose/Chassis With Hoses o n outside of C h a s s i s Backbone
Edge P r o t e c t o r , O i l Hose/Chassis Rr-Diaphram With H o s e s r u n t h r o u g h C h a s s i s Backbone
Foam Tube, O i l Hose/Chassis F r o n t X-rtlember
T i e Wrap, O i l Hose
Cooler, O i l ( S i l v e r ) 1 252rrun P i p e C e n t r e s . P r i o r Nov. '85
Cooler, O i l (Black) 325nm P i p e C e n t r e s . N w . '85 o n
P l a t e , Spreader 2
S e t s c r e w , M6 x 20 4
Washer, 6 m , F l a t 4
Nut, Nyloc, M6 4
Turbo 46.03A
Page 2
TURBO
47.01A
a
ILLUS
NO. QUANTITY
-- --
47.01A DESCRIPTION PART NUMBER ALL REMARKS
Master cylinder, Clutch

Clevis Pin, Clutch Pedal t o Clevis
'R' Pin, Clutch Pedal t o C l e v i s
Pressure Washer, Clutch Pedal t o Clevis
Washer, M a s t e r Cylinder F i x
Nut, Nyloc, M8, Master Cyl. Fix
Service K i t , Master Cylinder
F i l l e r Cap
Pipe, F l e x i b l e , Master to Slave Cylinder
Pipe, Flexible, Master to Slave Cylinder
Slave Cylinder
Setscrew, M8 x 25, Slave Cylinder Fix
Washer, Spring, Slave Cylinder F i x
Service K i t , Slave Cylinder
Bleed Screw, Slave Cylinder
Pushrod, Clutch Operating
Pressure P l a t e Assy. ( S t r a i g h t Fingers) R/B A082Q4018F With Rel/Brg. A085Q4016~
Pressure P l a t e Assy. (Curved Fingers)* U s e With R e l / Brg. A085Q4016~
Friction Plate R/B A082Q4019F
Friction Plate
Setscrew, C w e r t o Flywheel
Washer, Spring, C w e r t o Flywheel
Release Bearing Assembly (Curved Face) U s e With P.P. Assy. A082Q4006F
Release Bearing Assembly ( F l a t Face) U s e With P.P. Assy. AO82Q4018F
Spring Clip, Release Brg. t o Fork
Fork, Clutch Release
B a l l Pin, Fork Pivot
S p l i t Pin, Fork to Pivot
Grarmet, Fork to Housing
Adjuster Screw, Release Fork
Locknut, Adjuster Screw
* Fran Eng. No. 22728
Turbo 47.01A
PREVIOUS TYPE 'C35' TYPE
+..'
--I
-. . ... 1
- Gearbox Number Locati
(DO not remove) I - 4

O i l Level Plug
Revised Rear Cover Shape
I TURBO
I
47.02A
INTRODUCTION OF TYPE C35 GEARBOX ASSEMBLY
From e a r l y 1 9 8 4 , a l l E s p r i t m o d e l s were Level Plug

f i t t e d w i t h t h e t y p e 'C35' g e a r b o x .
A l l E s p r i t g e a r b o x e s are s t a m p e d w i t h a T h e o i l l e v e l p l u g ( p a i n t e d y e l l o w ) is
L o t u s s e r i a l number, r e p e a t e d on i t s f i t t e d i n t h e l e f t h a n d s i d e o f t h e case,
matched c l u t c h housing. A l l gearboxes as b e f o r e , a n d s h o u l d n o t b e c o n f u s e d w i t h
s t a m p e d w i t h a 'C' p r e f i x t o t h e s e r i a l a similar p l u g ( b l a n k i n g ) p o s i t i o n e d
number are t y p e C35. h i g h e r u p o n t h e t h e same s i d e o f t h e g e a r b o x .
Gearboxes w i t h t h e f o l l o w i n g serial E x h a u s t S i l e n c e r Mounting B r a c k e t

numbers ( w i t h o u t 'C' p r e f i x ) are a l s o
t y p e C35 The C35 t y p e g e a r b o x rear c o v e r i n c o r p o r a t e s
a l a r g e cast boss, n e c e s s i s t a t i n g a r e v i s e d
2914 t o 2920 s i l e n c e r mounting b r a c k e t and f i x i n g s .
2954 t o 2974
3 0 2 3 t o 3024
3028 t o 3039
3044 t o 3152
A l l numbers are i n c l u s i v e , and are t o b e
found on t h e t o p f r o n t o f t h e g e a r b o x and
a d j a c e n t s u r f a c e of t h e c l u t c h housing
Drain P l u g
C35 t y p e g e a r b o x e s h a v e o n l y o n e o i l d r a i n
p l u g which is s i t u a t e d b e n e a t h t h e main
case. T h e y are n o t f i t t e d w i t h t h e a d d i t i o n a l
rear case d r a i n p l u g as u s e d on p r e v i o u s
type gearboxes.
TU3AAK/2 Turbo 47.02A
FEZ 387
a
ILLUS
NO. QUANTITY
PRIOR
-C35
?or Identification of C35, See 47.02.A

Gearbox & Clutch Housing Assy. 1 V B A/B 082F407U
Gearbox b Clutch Housing Assy. irior to 85 M.Y.
Gearbox 6 Clutch Housing Assy. '85 M.Y. on
Clutch Housing 1 1 Must be machined to
Clutch Housing 1 Match Gearbox Casing
Rubber Mounting, Engine/G.Box Fear 2
Bolt 7/16", Mtg. to G/.Box Brkt. 2
Washer, Snubber, Mtg. to G./Box Brkt. 2
Washer, Flat, Mtg. Bolt 2
Nut, Nyloc, 7/16" Mtq. Bolt 2
Setscrew, M8 x 20, Mtg. to Chassis 4
Washer, Flat, mg. to Chassis 8
Nut, Nyloc, M8, Mtg. to Chassis 4
Bracket, Gearbox/Cdliper Mtg. LH 1
Bracket, Gearbox/~aliperMtg. LH
Bracket, Gearbox/Cdliper Mtg. RH 1
Bracket, Gearbax/Caliper Mtg. RH
Bolt, M14 x 75, Bracket/Gearbox 2
Bolt, M14 x 90, ~racket/Gearbox 2
Washer, Spring, Bracket to Gearbox 4
Washer, Flat, Bracket to Gearbox 4
Clutch Shaft 1 Includes Spigot Sleeve A089F0404F
Sleeve, Clutch Shaft Spigot (18.5mn Long) 1 Replaces Earlier 1% Sleeve
Thrust Washer, Nylon, Shaft/Spigot Brg. 1
Plug, Gearbox Joint Face
Stud, Silencer Mamting Bracket 1
Nut, MI, Nyloc 1
Pointer, Engine Timing 1
Gasket, Output Shaft Housing 1
Bolt, Ml0 x 35, Clutch Hausing/Engine 2 Not Dry Surrp
Bolt, Ml0 x 50, Clutch Housing/~ngine 5
Bolt, Ml0 x 60, Clutch Hausing/Engine 2 Turbo 47.03A
Pqe 1
ILLUS
NO. QUANTITY
PRIOR
DESCRIPTION PART NUMBER C35 REMARKS
Bolt, M10 x 75, Clutch Housing/Engine D r y sunp Only

Nut, Nyloc, M10, Clutch Housing/Engine 8 Used on Dry Sunp
Washer, F l a t , Clutch Hatsing/Engine 12 Used on Dry Surrp
Shim, Clutch Housing t o Sunp
C w e r , Timing Aperture
Switch, R w e r s e Light
Washer, R w e r s e L i g h t Switch
Drain Plug
Drain Plug
Washer, Drain Plug
Level Plug
Blanking Plug
Washer, I m e l / B l a n k i n g Plug
A i r Vent, Breather If F i t t e d
End Housing
End H a s i n g
End C w e r
End Cover
Core Plug, End C w e r Blanking
Screw, M7 x 100, Rear C w e r F i x
Screw, M7 x 28, R e a r C w e r F i x
Screw, M7 x 95, R e a r C w e r F i x
B o l t , M7 x 45, S i l e n c e r B r k t h r C w e r
Screw, M7 x 100, S i l e n c e r Brkt/Rear C w e r
Screw, M7 x 45, S i l e n c e r ~ r k t / R e a rC w e r
Screw, M9 x 65, Rear C w e r F i x Turbo 47.03A
Page 2
a
ILLUS
NO. QUANTITY
DESCRIPTION PART NUMBER PRIOR REMARKS

-C35
stop, Speedo P i n i o n 1
Nut, Speedo Pinion Stop 1
Nut, Speedo P i n i o n S t q
Screw, M9 x 30, Rear Cover/Main Case 5
Screw, M9 x 25, Rear Cover/Main Case 3
Outflow P l a t e 1 1
Outflow Tube 1 1 I n s i d e End C w e r
O i l Deflector 1 1
O i l Deflector 1
Stud, M12 x 73, ~ / B a x to Clutch H s g . 2
Stud, M12 x 58, G / B ~t o Clutch H s g . 2
Washer, 12mn, G/Box to Clutch H s g . 4
NU^, m 2 , G / B ~to c l u t c h ~ s g . 4
Speedo Driven Gear, (17 T e e t h ) 1
Nylon Bush, Speedo Driven Gear 1 Replaces E a r l i e r Bush With S t e e l Cap
Nylon Bush, Speedo Driven Gear
Right Angle Drive, SpeedD 1 R/B B079F6292F With ' 0 ' Ring
Right Angle Drive, Speedo 1 Use With '0'Ring A082F6315F
'0'Ring, Speedo Angle Drive 1
Turbo 47.03A
Page 3
ILLUS
NO. QUANTITY
tlAY I991
DESCRIPTION ' PART NUMBER REMARKS
Gear Lever Assembly M7 Knob Thread R/B A082F6313F

R o l l P i n , G e a r Lever, M5 x 40 For Gear Lever Ass. A079F6002F
G e a r Uver Assembly M8 Knob Thread R/B A082F4075F
G e a r Lever Assembly M8 Kn& Thread
Gear Lever MI3 Knob Thread
Knob, G e a r Lever, M7
Knob, G e a r Lever, MI3
Spacer, M7 G e a r Knob
Lock Ring, M8 Gear Kn&
Rwerse Gate For Gear Lever Assy. A079F6002F
Rwerse Gate For Gear Lever Assy. AO82F6313F/AO82F4075~
S p i r o l P i n , 5 x 14, Bellcrank t o Cable Yoke R/B A079W6245
S p i r o l P i n , 3/16" x 14
.
Yoke, Lever Assy t o Crossgate Cable
S p i r o l P i n , 5 x 18, Cable t o Yoke
k k w i r e , S/Steel P i n Retention
Crossgate Cable U s e With 240nan Extension Rod
Crossgate Cable U s e With 442/422 Extension Rod
Washer, Shakeproof, 14mn, C a b l e / ~ h a s s i s
Bracket, Cable A b u b n t Rear If F i t t e d
Dust C w e r , Cable Rear
Rod, Crossgate Cable Extension, 240mn
Rod, C r o s s g a t e Cable Extension, 442mn
Rod, Crossgate Cable Extension, 42211m-1
Locknut/Cable S t i f f e n e r U s e With 24(kran Extension Rod
Lmknut, C r o s s g a t e Cable t o Ext. Rod U s e With 442/422 Extension Rod
C l e v i s Pin, Rod t o Bellcrank
Spring C l i p , C l e v i s Pin
Washer, C l e v i s P i n
Bellcrank Lever, Crossgate
Bellcrank Lever, Crossgate
Bush, Bellcrank Lever
P i v o t P i n , Bellcrank Lever Turbo 47.05A
Page 1
e e
ILLUS
NO. QUANTITY
DESCRIPTION I PART NUMBER REMARKS

-
ALL
Washer, Bellcrank P i v o t 2
N u t , Nyloc, M10, Bellcrank P i v o t Bolt 1
p i v o t Pin, Gearchange Tubes 4 U Thread
P i v o t Pin, Gearchange Tubes 4 @ Thread
Rubber Bush, Tube End 4
Bearing, Nylon, Tube End 8
Nut, p i v o t P i n 4 U Thread
Nut, P i v o t P i n 4 @ Thread
Washer, 8mn, Gear Lever t o F r o n t Tube 1 Cf F i t t e d
Tube, Gearchange, F r o n t 1
Tube, Gearchange, R e a r 1 ? r i o r t o '85 M.Y.
Tube, Gearchange, Rear 1 '85 Model Y e a r
Adjustable End, R e a r G/Change Tube 1
Lx>cknut, Adjustable End 1
Relay Lever, Gearchange, 0.86 :1 R a t i o 1
Relay Lever, Gearchange, 1:l R a t i o 1 i/B B082F4059F With M8 P i v o t P i n s
Relay Lever, Gearchange, 1:l R a t i o 1 J s e s M8 P i v o t P i n s
Washer, 10mn, Relay Lever P i v o t 1 )Use With Relay Lever A082F4050K
S p l i t P i n , Relay Lever P i v o t 1 1
Thrust Washer, Relay Lever P i v o t 2 >
Washer, F l a t , Relay Lever P i v o t 1 > U s e With Relay Lever A / ~ 0 8 2 ~ 4 0 5 9 ~
'El C l i p , Relay Lever P i v o t 1 >
p i v o t Bracket, Relay Lever ( I n c . Bush) 1 Zhassis Mamted. E a r l i e r Cars
Jsed P i v o t on Engine Mounting LRg
Bush, Relay Lever P i v o t 1 ?or Bracket AO82F4lOW
Setscrew, M6 x 18, P i v o t Brkt./Chassis 3
Nut, Nyloc, M6, p i v o t Brkt/Chassis 3
Washer, F l a t , P i v o t Brkt ./Chassis 3
Edge P r o t e c t o r , p i v o t ~ r k t / A / C P i p e s * 205m A/c C a r s Only
Turbo 47.05A
Page 2
TURBO ///
0
ILLUS
NO. QUANTITY
PRIOR
DESCRIPTION I PART NUMBER C35 REMARKS
For I d e n t i f i c a t i o n of C35 See 47.02A

Top C w e r & Cross S h a f t Bearing Cap 1
Top Cover & Cross S h a f t Bearing Cap
Dowel, Top C w e r Locating 4
Setscrew, M7 x 35, Top Cover 3
Setscrew, M7 x 25, Top C w e r 5
Setscrew, M7 x 28, Top Cover 4
Setscrew, M7 x 50, Top C w e r 2
Shouldered Screw 2
Shouldered Screw
Washer, Top Cover Screw 4
F i l l e r Plug 1
Gasket, F i l l e r Plug 1
Cross S h a f t Assembly 1
Cross S h a f t Assembly R/B B082F4060F
Cross S h a f t Assembly Use With M8 Linkinge P i v o t Bolt
Prior t o '85 M.Y.
Cross S h a f t A s s e d l y 1985 Model Year on
'0' Ring, Cross S h a f t 2
'0' Ring, Cross S h a f t
Selector Shaft, Reverse 1
S e l e c t o r Shaft, 5th 1
Selector Shaft, 5 t h
Plunger, I n t e r l o c k Relay (Thro' Rod)
Selector !%aft, 3rd & 4th 1
S e l e c t o r Shaft, 3rd & 4th
Plunger, I n t e r l o c k Relay (Thro' ~ o d )
S e l e c t o r Shaft, 1st & 2113 1
Relay Dog, R e v e r s e Selector S h a f t 1
S e l e c t o r Fork, Rwerse 1
Relay Dog, 5 t h S e l e c t o r S h a f t 1
Turbo 47.06A
Page 1
ILLUS .::;;. , .j '
, 85;
NO. QUANTITY
DESCRIPTION I PART NUMBER ALL

REMARKS
Adjusting W a s h e r , 3.00
Adjusting Washer, 3.05
Crown Wheel and Pinion
Roller Bearing
Turbo 4 7 . 1 1 .
Page 2
TURBO
47.1 5A
0
ILLUS
NO. QUANTITY
Housing
Planet Wheel
Satellite Wheel
Satellite Spindle, Long
Satellite Spindle, Short
Lacking Screw, Satellite Wheel VB A082F6318F
Locking Screw, Satellite Wheel
Locking Screw, Crown Wheel
Planet Wheel Washer 1.52
Planet Wheel Washer 1.64 5elective
Satellite Gear Washer 1.54
Satellite Gear Washer 1.70 Selective
Crosshead Bush
Spacer
Spacer, 2.9
Spacer, 3.3
Spacer, 3.7
Spacer, 4.1 Selective
Spacerf 4.5
Spacer, 4.9
Spacer, 5.3
Spacer, 5.7
Turbo 47.1124
Pqe 1
TURBO
67.11A
a
ILLUS
NO. QUANTITY
- -
PRIOR
DESCRlPTION PART NUMBER C35
Spacer Washer, 2.61

Spacer Washer, 2.65
Spacer Washer, 2.69
Spacer Washer, 2.73 Selective
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 B a l l Bearing, Secondary Shaft Rear
Double B a l l Bearing, Secondary S h a f t Rear
Driven Pinion, 5th: Secondary S h a f t
Nut/Speedo Drive Gear
Idler Gear, Reverse, Inc. Bush
Spindle, Reverse I d l e r Gear
Screw, Reverse Gear Spindle
Nut, Reverse Spindle Screw
Turbo 47.07A
Pqe 3
1 TURBO
47.11A
ILLUS
NO. QUANTITY
- - - HAY 1997
PRIOR
Driven Pinion, lst, Secondary Shaft

Driven Pinion, 2nd, Secondary Shaft R/B A082F6316F
Driven Pinion, 2nd, Secondary Shaft Supplied With Matched Synchro. Ring
Needle R o l l e r 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 W a s h e r , 1.73
Spacer Washer, 1.77
Spacer Washer, 1.81
Spacer Washer, 1.85
Spacer Washer, 1.89
Spacer W a s h e r , 1.93 Selective
Spacer Washer, 1.97
Spacer Washer, 2.01
Spacer Washer, 2.05
Spacer Washer, 2.09
Spacer Washer, 2.13
Spacer Washer, 2.17
Spacer Washer, 2.21
Spacer Washer, 2.25
Spacer Washer, 2.29
Spacer Washer, 2.33
Spacer Washer, 2.37
Spacer Washer, 2.41
Spacer Washer, 2.45
Spacer Washer, 2.49
Space1 dasher, 2.53
Spacer Washer, 2.57 Turbo 47.07A
Page 2
TURBO
47-07A
ILLUS
0
No. QUANTITY lMAY as?
PRIOR
Spring, Clutch S h a f t Endthrust

C i r c l i p , Clutch Shaft Retention
Support Tube, Clutch Release Bearing
'0' ~ i n g ,Support Tube Sealing
S c r o l l and Housing
B a l l Bearing, P r i m r y Shaft Front
Primary S h a f t
Drive Pinion, 3rd, Primary Shaft R/B A082F6317F
D r i v e Pinion, 3rd, Primary S h a f t Supplied With Matched Synchro. Ring
Needle Roller Bearing, 3rd Pinion WB A082F6348F
Needle R o l l e r Bearing, 3rd Pinion
Synchroniser Assembly, 3rd & 4th
Synchroniser Assembly, 3rd & 4th
Synchro Ring, 3rd, 4th & 5 t h
Stop Ring, 3rd & 4th Synchro 2.20
Stop Ring, 3rd & 4th Synchro 2.25
Stop ~ i n g ,3rd & 4th Synchro 2.30 Selective
Stop ~ i n g ,3rd & 4th Synchro 2.35
D r i v e Pinion, 4th, Primary S h a f t
Drive Pinion, 5th, Prirmry Shaft
Needle R o l l e r Bearing, 4th & 5 t h Pinion
Needle R o l l e r Bearing, 4th & 5 t h Pinion
D o u b l e B a l l Bearing, P r i m S h a f t Rear
Double B a l l Bearing, Prirmry S h a f t Rear
Synchroniser Assembly 5 t h
Synchroniser Assembly, 5th
C i r c l i p , 5 t h Synchroniser
Screw, 5 t h Hub to P r i v S h a f t
Screw, 5 t h Hub t o Primary S h a f t
O i l Tube, 5th Hub Screw
R o l l e r Bearing, Secondary S h a f t Front
R o l l e r Bearing, Secondary S h a f t Front
Turbo 47.07A
Page 1
ILLUS
a
NO. QUANTITY
PRIOR
Relay Dog, 5th S e l e c t o r S h a f t

S e l e c t o r Fork, 5th
S e l e c t o r Fork, 5th
Selector Fork, 3rd & 4 t h
S e l e c t o r Fork, 1st & 2nd
Locking Screw, F o r k h e l a y to S h a f t
Locking Wire, F o r k h e l a y Screw
Screw, 5th Fork t o S h a f t
Spring Washer, 5 t h Fork Screw
Setscrew, M9 x 25, Fork Clanping
I n t e r l o c k Plunger, Short
I n t e r l o c k Plunger, Long
Blanking Plug, l2m Diameter
Blanking Plug, 17mn D i a m t e r
Detent B a l l , S e l e c t o r S h a f t
Spring, Detent Bdll
Spring, Detent B a l l
Turbo 47.06A
Page 2
ILLUS
a
NO. QUANTITY
Housing, D i f f . Output S h a f t , RH
.
Housing, Dif f Output S h a f t , RH
Housing, D i f f . Output S h a f t , Ill
.
Housing, Dif f Output S h a f t , IH
Gasket, Output S h a f t Housing
Drain Hose, Output S h a f t Hausing
B o l t , M7 x 20, Output Hsg.hrans.
B o l t , MI x 25, Output Hsg.hrans.
Bolt, M7 x 70, Output Hsg./Trans,
B o l t , M9 x 30, Output Hsg.firans.
Bolt, M9 x 75, Output Hsg.hrans.
Shaft, D i f f . Output, RH
S h a f t , Diff. Output, Ill
Wisher, O i l Retaining
O i l S e a l , Output S h a f t
T h r u s t Ring
Double Bdll Bearing
Ring Nut, Bearing to Housing
Ring Nut, Bearing to Housing
I m k i n g Screw, Ring N u t t o Housing
Nut, E3earing t o Output S h a f t
I m k i n g Screw, Output S h a f t Nut
TURBO
60.01 A
ILLUS
a
NO. QUANTITY BrFl

REMARKS
Toolkit & Roll With Conpomotive Wheels 1

Toolkit & Roll With BBS Wheels 1
Roll, Toolkit 1
Spanner, OD, 8 x 10 1
Spanner, O/E, 10 x 1 3 1
Spanner, OD, 13 x 1 7 ) ' R o l l 1 type
Screwdriver, P o s i d r i v e no. 2 1 Toolkit
Pliers 1
'TI Bar, S l i d i n g 1
Extension, 5 in., 3/8 i n . Drive 1
Spark Plug Socket, 13/16 in. 1
Socket 1% I n T o o l k i t B075T0728J 1
Socket, 17mn I n T o o l k i t A082T4003J 1
T o o l k i t & P l a s t i c Case >

S t r a p , Tool Case Retention > P l a s t i c Case t y p e T o o l k i t
Hook, Tool Case S t r a p >
R i v e t , S t r a p & Hook F i x >
Washer, R i v e t >
Jack, ( S c i s s o r Type
Jack, (With I n t e g r a l Baseplate)
Handle, 145mn Crank

Handle, 265mn Crank
S t r a p , J a c k Retention, (Front
S t r a p , Jack Retention, (Rear)
Anchor Hook, J a c k S t r a p
P q Rivet, S t r a p and Anchor Fixing
C l i p , J a c k H a n d l e Stowage ( 2 Hole F i x ) 1
C l i p , Jack Handle Stawage (1Hole F i x ) 1 As Fitted
Turbo 60. OLA

TURBO
60.02A
d
ILLUS
NO. QUANTITY
Engine S p e c i a l Tool K i t Assanbly Cortprises * Items

Cylinder Liner Clanps*
Cylinder L i n e r Extractor*
Cylinder Liner N i p Gauge*
D r i f t , I n l e t Valve Seat*
D r i f t , Exhaust Valve Seat*
I n s e r t e r , S p i g o t Bearing*
D r i f t , Valve Guide*
I n s e r t e r , Camshaft O i l Seal*
Spanner, O i l Pick-Up Pipe Union*
E x t r a c t o r , Camshaft O i l Seal*
Sleeve, Camshaft O i l Seal*
P i l o t , Rear O i l S e a l , Crankshaft*
P u l l e r , Crankshaft Pulley*
P i l o t , F r o n t Cover*
C l i p s , Tool Retention, set c/w Fixings
Shadow Sheet, S e l f Adhesive
Tool Board
Burroughs Gauge, Toothed B e l t R/B TOOOG0025J
Burroughs Gauge, Toothed B e l t Cantilevered Type
Tom. Socket, Cam Housing B o l t
C a r b u r e t t o r Balance Pdaptors
Carburettor F l o a t Setting Bar
C a r b u r e t t o r Manarreter M-With k r c u r y , F-Without Mercury
Rear Brake C a l i p e r Spreader 1985 Model Year
Screen R ~ n o v a lTool
Turbo 60.02A
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. QUANTITY
Transmission Tool Kit, 1

Carprises
Spanner, Bearing to Shaft Nut 1

Spanner, Bearing to Housing Lock Ring 1
Dial Gauge Support 1
Dial Gauge 1
Pinion Setting Fixture 1
Spanner, Speedo Drive Nut 1
Syncro Gauges (set of 6 ) 1 lst/2nd gear
Reverse Selector Gauge 1
Circlip Pliers, 3rd/4th Syncro Hub 1
Turbo
6O.O4A

Lotus Manual

Uploaded by

Copyright:

Available Formats

Lotus Manual

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Lotus Manual

Uploaded by

Copyright:

Available Formats

Publication Part No.

@ Lotus Cars Ltd June 1986

This publication has been designed primarily for Lotus Dealers,

Lotus policy i s one of continuous product improvement an

Whllst every care has been taken to ensure correctness o f

TURBO ESPRIT h ESPRIT S3 ( P r i o r '88 M.Y.)

T e c h n i c a l Data -. Engine - E s p r i t S3 TDA

F r o n t Suspension - P r i o r t o ' 8 5 M.Y.

Engine Management - USA Turbo, c a r b u r e t t o r ( P r i o r t o ' 8 6 M.Y.) EMA

Brakes - P r i o r t o ' 8 5 M.Y.

Electrical - E s p r i t S3 & Turbo, Dom/~xport

Maintenance & L u b r i c a t i o n - E s p r i t S3 & Turbo, Dom/Export

Heater & A i r Conditioning

501 = Basic E l i t e 521 = Basic E c l a t 701 = Basic Esprit

2. S e x r a t e serial number sequences a r e used f o r t h e f o l l m i n g groups of

3. For change p o i n t i d e n t i f i c a t i o n i n S e r v i c e Notes, P a r t s L i s t s and Service

Example A t y p i c a l change p o i n t could be listed as folluws;

Model Year Market ( C h a s s i s

SECTION TD A - ENGINE TYPE 9071912

For the purpose of clarification i n the TECHNICAL DATA SECTION ONLY,

(907 Single Prefix

FIRST PREFIX SECOND PREFIX TECHNICAL

(907 Single Prefix

(907) Single Prefix

Max. rpm of engine

( - Alternator 'V' belt 12 mm (0.5 in.) (& in.)

on longest i - Power steering pump 12 mm ( 0 5 in) (jin.)

Material Aluminium alloy

CAMSHAFTS AND VALVE TIMING

cam Type I$II;-I

1 groove 1270" 10.350" (110' (red 110" red

plain 100" blue 110" red

2 groove 1023" yellw 1023" yellow

plain 1023" yellw 110" red

777.. .. 104" green

* All cams are symnetrical opening closing

Angle of valve seats and faces 45O

Valve clearance (cold)

Valve Seat lrserts

c 0.025 mm (0.001 in) ' - lnlet 37.260/37.285 mm. (1.467/1 . a 8 in.)

- Exhaust 34.315/34.340 mm. (1,351/1 .352 i n .)

F 0.050 mm (0.002 in) - Inlet 37.285/37.315 mm. (1 .468/1 . a 9 in.)

Outside diameter of seat

S ta ndard - Inlet 37.325/37.350 mm. (1.4695/1 .4705 in .) -:

t- 0.025 mm (0.001 in) - lnlet .

Free Length Rate

912 engines 18105 on 42.2mn 48.5mn ll.Okg/an 22.5kg/an

Length - lnlet 53.34 mm. (2.100 in.)

Bore in camshaft housings 34.925 - 34.940 mm. (1.3750 - 1 .3756 in .)

* Bearing clearance i s measured with Plastigage.

MAIN E W K l N G SHELL CONFIGURATICN

ENGINE MAIN BEARING NUMBER

107 ~ l i t e / E c l a t UPPER G r o o v e / H o l e Groove/Hole G r o o v e / ~ o l e Grocwe/~ole Groare/Hole

I07 Esprit w i t h UPPER

m Plain Plain Plain Plain

112 E l i t e / E d l a t UPPER Groove/Hole Groave/Hole ~lain/Hole Groove/Hole

112 Excel w i t h UPPER G r o o v e / H o l e Groove/Hole Plain/Hole Groove/Hole

TYpe 'I' section

'a Gudgeoc (Piston) Pin

TYpe Fully floating