Lotus Esprit Series Instruction manual

~@#US L iUP9 i%@d Norwich, Norfolk, N~f4 8EZ. England.
Jelegrants; Lotus Norwich. relex, Si"4E)i Telephone; Wymondha'm [phone] .
@ lotus Cars Lid 1982

INTROBIJGTIOM
Page 1
This Workshop Manual is produced primarily for Lotus Dealers to give repair and
maintenance information on the Lotus Esprit car. It
is divided into sections giving
comprehensive information insome sections on the main
sub-assemblies and in others
cover.only the features which will require maintenance.
If special tools are
required these will be shown at the end of the relevant section. Service Bulletins
andParts Bulletins will be ussued when necessary to update the manual.
MANUAL
FORMAT
.",.. ~ 2.:
.-.
.. ... :+,
;-S.,
The manual is divided into sections which are identified by letters. These letters are
,-
i
-9.- : :.. ... r?... 'CA~;:.-C . . P,,+, ! t;t' .TZ;! +C:= l! S-_hedv!e'. %here the 1
numbers (e.g. A907E or ~079~)carry the identifying letters for the ENGINE, lktter .:,:
'E' andTRANSMISSION, letter 'F'. The sections in this monual are as follows:
INTRODUCTION
TECHNICAL DATA
CHASSl S
BODY
FRONT SUSPENSION
REAR
SUSPENSION
ENGINE
. . - . . . ,
,. '> .,
', :
TRANSMISSION . .:'
HUBS, WHEELS, TYRES
STEERING
BRAKING SYSTEM
COOLING
SYSTEM
FUEL SYSTEM
ELECT RI CAL E Q U I P M E N T
HEATING/VENTlLATION
CL WCH
EXHAUST SYSTEM
ESPRIT
Issup M178

l\
C
.
INTRODUCTION -
Page 2
VEHICLE IDENTIFICATION
All cars are identifiedby a Chassis (Cor) Number, and this number will be found on
the Identification Plate which
is located in the front compartment on the rear bulk -
head. The engine nvmber is duplicated on the right - hand rear of the cylinder block,
above the starter motor. Inall communication with the Factory, the Chassis Number
MUST
BE QUOTED IN FULL.
An example of the Chassis (Car) Number
is given below, to
g
ether with the full
identification breakdown.
76 05 100 G
Chassis (Car) Number
76 05 Denotes year and month of manufacture (1976, May)
' (2
100 Denotes the number
G Denotes the Territory the car is destined for
G = Deomestic and Eurpean
H = North America
J = Rest of World
ESPRIT
Issue W178

TECHNICAL DATA
Page 1
CONTEN'TS
Description
DIMENSIONS
CAPACITIES
ENGINE
- Generol
- Engine Belt Tensions
- C
y
linder Heod
- Valves
- Valve Seat inserts ,:.:i:$
.?>V
~;.::!a,j;d:,
- valve springs .-..! .< .c!.- .... : ,.
;:+~,cf..-
.: ;:>.;
Poge
2
2
3
3
- Valve Guides
- Camshafts 8
- Cam Followers
- Auxiliary Shaft
- Crankshaft
- Flywheel
- Connecting Rod
- Gudgeon Pin
-' Piston and Liner
- Lubrication System
FUEL SYSTEM
IGNITION SYSTEM
DISTRIBUTOR
COOLING SYSTEM
CLUTCH
TRANSMISSION
FRONT SUSPENSION
STEERING
REAR SUSPENSION
BRAKES
W H E E L S A N D T Y R E S
ELECTRICAL EQUIPMENT
TORQUE LOADING FIGURES
MODEL
S2 CHARACTERISTICS

PECHWIBCAL DATA
'age 2
DIMENSIONS
Wheelbase
Track
- Front
- Rear
Overall Length (European Spec.)
Overall Length (North American Spec.)
Overall Width
Overall Height
Ground Clearance
Turning Circle (Between Kerbs)
Kerb Weight (European Spec.)
W -A \AI-:-LL lR1-JL A-.-.:rlr K-.-.+ I
..-.- ..-. -... \.
- "
(96 ins)
(59.50 ins)
(59.50 ins)
(165 ins)
(167.71 ins)
(73.25 ins)
(43.75 ins)
(6 ins)
(38 ft)
(2012.82 lbs)
l ><>Cl 1heI
..,A>
a'.;,.
I.Ai. CAPACITIES
';'
Engine (Inc. Filter) - Dty
5.95 litres (10.5 imp pts., 12.6 US pts)
,..... .
";
- Refill 4.83litres (8.5imppts., 10.2USpts)
ntcr .-..--. L-.. L?-L --.a I -... J:-..:-I. -- -I...
vltrr;lrv,Ls uw1nrr;w88 su~ts U*~U IVW US~BS~R IIIUU~..
$
0.85 litres (1.5 imp pts., 1.8 US pk)
. . ,W:%
Transmission 2.25 litres (4 imp pts., 4.8 US pts)
. .
Cooling System 10.8 litres (19 imp pts., 22.8 US pts)
C.-
Fuel Tank 67 litres (14.75 imp gal, 17.7 US gal)
ESPRIT
Issue 04/78

TECHNICAL DATA
Page 3
P
ENGINE
GENERAL
Engine Type
907, Twin overhead camshafts
Number of cylinders 4
Firing order 1 - 3 - 4 - 2
Capacity
1973 cc. (120.4 cu ins)
Stroke
69.2 mm (2.72 ins)
Bore (nominal)
95.2 mm (3.75 ins)
i '
Compression-rqio - European Spec. 9.5:l
<!,
c
- North American Spec. 8.4:l
Corppression - Pressure (At sea level)
.., ,..
. .
...,,;
C
, .
- European Spec. 11.65/12.65 kg cm sq (160/180 ibs insq.)
- North Americon Spec. 10.55/11.95 kg cm sq (150/170 lbs insq.)
'r-
Engine number location on top rear of cylinder block adjacent to
starter mounting
BELT TENSIONS
Toothed timing belt
(133 teeth) ' ..$-C h .;
):c;
With both iypes of belt tensioners set the belt tension to an average reading of
'. .
90 - 95 unitscold (120 - 125 units hot). Check to6thed belt tension between
1,'
auxiliary and inlet camshaft pulley, with Burroughs Gauge Type BT-33-86b 5 - 20.
IMPORTANT: Check the belt tension with number 1 or 4 cylinder at TDC after
>.
C -
C . ,
rotating engine at least one full turn clockwise (norrml running direction). Repeat
.. .,,
,.,..
, . :,$A;:&
, ."'.Lii:'
thls operation twice to obtoin specified average reading.
..:,
.l:< ,
G*;'"..
,..,..i.
.,.:.,. .,, .?
V - beltcompre~sor - 9 mm (0.35 ins) Deflection
Other V
- belts - 12 mm (0.50 ins) Deflection
ESPRIT
Issue 04/78

TECHNICAL DATA
'age 4
CYLINDER HEAD
Material Aluminium alloy
Gasket Steel asbestos DV
Head depth 82.04+ .254
mm (3.23 + .O1 ins)
- -
Combustion chamber depth 12.192/12.573
mm (0.480/0.495 ins)
Max. permissiblemetal
removal Nil
(To correct warping)
Valve Timing
Inlet opens
Inlet closes
Exhaust opens
Exhaust closes
European Spec. NorthAmerican Spec.
30°B.T.D.C. 26OB.T.D.C.
Valve M .O .P. (Maximum openinn noin?!
, European Spec. Inlet ~O~.~~A.T.D.C.
Exhaust 102.5' B . T . D . C .
NorthAmerican Spec.
. ..
.,: Inlet ~OO~A.T.D.C.
Exhaust lloOB.T.D.C.
Angle of valve seats 45O
..,-
-. -.
. .
VALVES ,j_ . ..
.<; .Z2..$
... :,.
.,. . . ...
.<<$::+., ..:
. .
.S::
Head diameter -,;,inlet 35.56
mm (1.40 ins)
- exhaust
. ,.
30.86 mm (1.215 ins)
Stem diameter
- inlet/exhaust 7.137 mm (0.281 ins)
Stem clearance inguide
- inlet 0.0076/0.0457
mm (0.0003/0.00 18 ins)
- exhaust 0.0076/0.0584
mm (0.0003/0.0023 ins)
Valve clearance (cold)
- inlet 0.127/0.178 mm, 0.005-0.007 ins
-yxhaust . . 0.254/0.305 mm, 0.010 - 0.012 ins
,. .
ESPRIT
Issue 04\78

TECHNICAL DATA
Page 5
C) Valve Seat Inserts
Bore in head:
Standard
- Inlet
- Exhaust
+0.0254 mm (0.001 in) - lnlet
- Exhaust
+0.0508 mm (0.002 in) - lnlet
- Exhaust
+O. 127 mm (0.005 in) - lnlet
- Exhaust
37.2364/37.2618 mm (1.466/1.467 ins)
34.29/34.3154 mm (1.350/1.351 ins)
37.2618/37.2872 mm ( 1 .467/1.468 ins)
34.3154/34.3408 mm (1.351/1.352 ins)
37.2872/37.3126 mm (1.468/1.469 ins)
34.3408/34.3662 mm (1.352/1.353 ins)
37.3634/37.3888 mm ( 1 .471/1.472 ins)
34.417/34.4424 mm (1.355/1.356 ins)
Outside diameter
of seats
Standard
- Inlet
37.2813/37.3507 mm ( 1 .4695/1.4705 ins)
- Exhaust
34.3789/34.4043 mm (1 .3535/1.3545 ins)
+0.0254 mm (0.001 ins) - Inlet
37.3507/37.3761 mm (l .4705/1.4715 ins)
- Exhaust 34.4043/34.4297 mm (l . 1345/1.3555 ins)
+0.0508 mm (0.002 in) - Inlet 37.3761/37.4015 mm (1 .4715/1.4725 ins)
- Exhaust 34.4297/34.4551 mm (1 .3555/1.3565 ins)
+O. 127 mm (0.005 in) - Inlet
37.4523/37.4777 mm (1 .4745/1.4755 i
- Exhaust 34.5059/34.5313 mm (1.3585/1.3595 in
'' v<
Valve Springs
Dual
Free length
- Inner
37.465 mm (1.475 in)
46.863 mm (1.845 in)
.::*;,>*,'<,i:<~ -
- Outer .z-?,.:...$2 .....- L.,::.
i. -
....
Rate - Inner (Compressed by 12 mm; 5 in = 13.6 kg; 30 ibs)
. .
.:; .
-
Outer (Compressed by 12 mm; 5 in = 28.57 kg; 63 lbs)
Valve Guides
,,:;;v:
Length - Inlet 53.34 mm (2.100 in) .
'<. . ::.;::.:,
..,;#c;,
,'l7.
- Exhaust 53.34 mm (2.100 in)
Internal diameter (to ream after fitting)
7.1450fl.1704 mm (0.2813/0.2823 in)
ESPRIT
Issue 04/78

PECHIMIICAL. DAn
'age 6
Valve Guides (cont.)
Bore in head
Standard
+.0254 mm (.001 in)
+. 0508 mm ( .002 in)
+. 127 mm (.005 in)
lrilet & Exhaust
11.9126/11.9253 mm (.4690/.4695 in)
1 1 .938/11.9507 mm (. 4700/.4705 in)
11.9634/11.9761 mm (.4710/.4715 in)
12.0396/12.0523 mm ( .4740/.4745 in)
Outside diameter of guide
Standard
1 1.938/11.9507 mm (. 4700/.4705 in)
+.0254 mm (.001 in)
11.9634/11.9761 mm (.4710/.4715 in)
+. 0508 mm (. 002 in)
1 1.9888/12.0015 mm (.4720/.4725 in)
+. 127 mm (.005 in) 12.065/12.0777 mm ( .4750/.4755 in)
CAMSHAFTS
End float
- Dimension .0254/.2032 mm (.001/.008 in)
- Controlled by Selective thrust washers
Running clearance
.0254/.0635 mm (.001/.0025 in)
. i :
.;E
..>.
:; .: CAM FOLLOWERS
. ..
..,#$,
...
Bore in camshaft housings 34.925/34.9402 mm (1.3750/1.3756 in)
Outside diameter
34.904/34.912 mm (1.3742/1.3745 in)
AUXILIARY
SHAFT
Running Clearance
End float
.025/.065 mm
(.000P/.0025 in)
.0127/.0381 mm (.0005/.0015 in)
Balance (inc. flywheel
8 clutsh) ,- ,.,, -.
Within 14.42 gr. cm. (.2 oz in)
Diameter
- Main journal (No. l to 4
inc.) 63.487/63.513 mm (2.4995/2.5005 in)
- Mainjournal(No,5only) 63.500/63.513mm (2.500/2.5005in)
- Crankpin 50.73q50.762 mm (1.995/1.9985 in)
End float
- Dimension .076/.203 mm (.003/.008 in)
ESPRIT
Issue 04/78

TECHNICAL DATA
Page 7
CRANKSHAFT (cont.)
End flwt
- Controlled by Selective thrust washers on rear main bearing
Bearings (main)
- Number 5
- TYP~ Steel backed, leaded bronze
- Static clearance* .025/.075 mm (0.0010/0.0030 ins)
Max. undersize for regrind .508 mm (.02 in)
* Bearing clearance is measured with Plastigage.
FLYWHEEL
Max. run
- out (lateral) .l01 mm (. 004 in)
T
Starter ring gear - Run - out - Lateral .406 mm (.016 in)
- Radial .l52 mm (.006 in)
CONNECTING
ROD
Type
I I
I section
. ~
..&.
>,. Material
Steel forging
., ..
. ,. -
'.,'I:'~~Distance : . . .:.,. between centres (139.7 mm (5.5 in)
+ .0254 mm (.001 in)
.,*.,fi.- . ,.
-
, ..
:..,.,?5<.
,,..
. ~
%rings (big end) - Type Steel backed, leaded bronze
- Static clearance* .0254/.0813 mm (.001/.0032 in)
- End float on crankpin .1016/.254 mm (.004/.010 in)
Small end bore (bushed) 25.405/25.410 mm (1.0002/1 .Q004 in)
'1
Permissible weight variation between rods 2 grammes inany set
* Bearing clearance is measured with Plastigage.
GUDGEON (PISTON) PIN
Type
Location
Diameter
Class of fit
PISTON AND LINER
Piston
- Type
- Material
Fully floating
Circlips
25.40 mm (1
.OO in)
Finger push
at 20'~ (68'~)
Solid skirt
Aluminium alloy
ESPRIT
Issue 04/78

TECHNICAL DAVA
Page 8
PISTON AND LINER (cont.)
Piston - Identification
.- Length
- Compression height
- Rings - Cornpression
- Oil Control
- Diometer - Grade 'A'
- Grade 'B'
- Gudgeon pin bore offset
Piston clearance in cylinder liner
Piston ring gap - Top
- Second
- Scraper (rails)
Flat top
- 9.5: 1 European
Dished top - 8.4: 1 Federol
75.260 mm (2.963 in)
40.919/41.021 mm (1.611/1~615in)
2
1
95.1662/95.1789 mm (3.7357/3.7472 in)
95.1789/95.1916 mm (3.7472/3.7477 in)
1.524
mm (.Or5 in) towards thrust face
.0965/. 1219 mm (.0038/.0048 in)
.381/.508 mm (.015/.020 in)
.483/.609 mm (.019/.024 in)
.381/1.143 mm 1.015/.065 in!
rermlssible welght variation between pistons 3 grammes.
Piston ring
to groove clearance
... . ...~?...
- Compression .0381/. 0889 mm (.0015/.0035 in)
- L? -
- Oil Control .0381/.0635
mm (.0015/.0025 in)
* Measured at grade diameter
?is:cn g:~de dloiiietei iri
15.6876 mm i.594 in) up from sikirt edge
Cylinder liner
- Type Slip
- fit, wet
- Material Cast iron
- Internal diameter:
- Grade 'A'
95.2754/95.2881 mm (3.7510/3.7515 in)
- Grade 'B1
95.2881/95.3008 mm (3.751 5/3.7520 in)
-Fittedheightabove .0762/.127mm(.003-0.005in)
Block (liner nip)
- Permissible variation between
adjacent liners .0254 mm (.001 in)
LUBRICATION SYSTEM
Oilpressure under normal operating condition (Hot)
a) Not below
5 lbs/sq in (0.35 kg cm sq) at idle speed
b) Notbelow351bs/sqin(2.46kgcmsq)at3.500R.P.M.
ESPRIT
issue.aa178

TECHNICAL DATA
Page 9
c LUBRICATION SYSTEM (cont.)
c) Notbelow
45 lbs/sq in (3.16 kgcm sq) at 6.500 R.P.M. ond above
Filter - fl~llflow disposoble conister type
Pvmp - Type Eccentric rotor
- Drive Toothed belt
- Inner/outer rotor clearonce .l5 . mm . .. (0.006 in) Mox.
*..
- Inner/outer rotor floot
.L@'/. 028 1 mm ( .0005/. 001 5 in)
Type of system Wet Sump
FUEL SYSTEM
Fuel Filter
c. Fuel Pump - Type AC
- Delco (Paper Element)
S. U. Type "AUF 301" (Electric)
- Pressure .27+
- .01 kg cm sq (3.8 - + .2 lbs in sq)
Carburettor - European Specification
Type and number Dellorto Dhlo 45E (two)
Slow running speed 950
- 1000 r.p.m.
Idle CO level (hot) 1.5-3.m
Identification Green Paint spot on "Dellorto' cast
label and no vacuum take off on rear
, -
carburettor.
SETTINGS
& "
Choke 36 Starter Jet 70
Main Jet 160 MainEmulsion Tube 7772-8
Main Air Corrector 230 Starter Emulsion Tube 7482 - 1
IdleJet 50L Flwt Setting Height 16.5/17.0 mm
IdleJet Holder 7850.7 Needle Volve 170
Pump Jet 40H/38V Float Assembly 7298 - 02
Carburettor NorthAmericon Specification
Type and number Zenith 175
CD 2SE (two)
Slow running speed 950
- 1000 r.p.m.
IdleCO level (hot)
3.E4.5%
U
Identificotion Red point on oir volve housing, and
internol/externo\ float vent valves.
ESPRIT
Issue 04/78

TECPIINIICAL DATA
Page 10
Needle
Spring colour
Damper
Oil
Fast Idle Setting
B.I.D.K.
Blue
Engine Oil
2.16/2.41 mm (.085/.095 in)
Between starter cam and screw head in
" off " position
IGNITION SYSTEM
Type Coil and distributor
Number 1 cylinder nearest to water pump
Ignition advance control fully automatic
Ignition timing:
With engine number prefix letters CC, CD
Eurooean soec. with DellortoCarburettors
- Nominal static 7O BTDC
Noadvance up to 1000r.p.m. Full
advance
is at a nominal 2500 engine r.p.m.
Set distributor to give 25' BTDC ignition
timing at between 3.500 and 4.000 r.p.m.
This will givean idle r.p.m. figure
-0 . -0 m-*,- ,
berween I - I I D I UL oecaure ofdisrriburor
tolerances.
NorthAmerican Spec. with Zenith
- CD Carburettors
. .
G -
Static ign. timing 8' BTUC at idle (950-1000 r.p.m.) 0' (TDC)
Coil (type) Lucas 45232E
Spark plug - Type European Spec. NGK - BP6ES
NorthAmerican NGK - BPSES
- Gap .584 mm (.023 in)
DISTRIBUTOR
European specification with engine number prefix letters CC, CD.
, :: :
, -,
..' ..
, ,.
Type Lucas 4304 or Lucas 25D4
Despatch No'
41 623 or 41584 (MC capsule not used)
Advance characteristic: No
odvance up to 1OOO erigirie r.p.m.
Full advance of 16' (Crankshaft) at Cont'd
a
ESPRIT
Issue M178

TECHNICAL DATA
Page 11
allow - +2 for distributor tolerances
North American Specification
Type Lucos 25D4 or Lucas 45D4
Advance characteristic:
Crankshaft r.p.m. Crankshoft degrees
Below l000
No advance
at 2000 so )
at 4000 180) o
1 22
at 5000 22O )
L.
at 6000 26' i
i : ..
:.,
Direction of rotation from drive end (all) Clockwise
."
. .
~. :
Drive (all) ; offset dog
Contact breaker gap (all) .35/.40 (.014/.016 in)'
0 , . 0
Firing angles
oO, 90°, 180 +g70 + - lQ
Cam dwell angle 60'
- + 3'(25~4), 52' +4' (43 8 45D4)
. .
1-3-4-2
Firing order
Condenser capacity .18/.23 m.f.d.
COOLING SYSTEM
3
..
..., ,; ' :..-.
:.?. "i ,"t%, %.,... .
:+.:+XL >:.;;
, ..,.
C>! :
. r:; ,:..:
Centrifu
g
al pump and electric fan
. L, . ;... .+h., ,.?. .i.:,..:, ; ;~.;c~+$>>
..;. .
. ., ;,?;.?,
operated by thermal switch.
,....~2..I~ :..: f:;:
Radiator cap relieve valve pressure 'L
.70 kg cm sq (10 ibs in sq)
Thermostat nominal opening
temperature 82'~
- winter, 74OC - summer
Impeller vanes to water pump
hwsing clearance .508/. 762
mm ( .020/. 030 in)
Coolin
g
system anti-freeze/inhibitor Shell safe or union carbide
"LIT 184 "
. .,
Minimum of 25% all the year round
.v:.? ..
More in cold climate (up to 66% maximum)
, .,.
Crossflow aluminium
. , ,:?.- . ..
. .. .
Radiator Type
ESPRIT
Issue 04/78

TECHNICAL DATA
Page 12
CLUTCH
Make and type
Operation
Master C
y
linder bore diameter
Slave Cylinder bore diameter
Drive plate
- diamet ;r
- number of springs
Free playat release lever
TRANSMISSION
I~. n ...~ k 1 n 1.1
.,,,u,as-. *.".S". ..a.. .S,.
v -
.. .
- ...
.*. . Fifth .76: 1 21.85
Fourth .97: 1 17.15
Third 1.32: 1 12.58
Second 1.941 8.56
First 2.92:l 5.69
Reverse 3.46: 1 -
Final drive 4.375:l -
Speedometer Gears - Driving Gear
Driven Gear
FRONT SUSPENSION
p-
Front Hub End Float
Borg
B Beck, diaphra
g
m spring
Single dry plate
Hydraulic
15.87 mm (.625 in)
22.22 mm (.875 in)
21.59 cm (8.5 in)
6
3 mm (. 12 in)
Manual
5 forward gears
(All synchromesh) and reverse
(? a, .. 0, . ,.,...
.. 4.. 8. 'vuv I .,,.l,,.
35.16
27.59
20.24
13.77
9.15
-
5 Starts
17 Teeth
Independent by twin upper wishbones with
single lower link and anti
- roll bar providing
lower location. Coil springs and telescopic
shock absorber units.
.08/. 13 mm (.003/.005 in)
ESPRIT
Issue 04/78

TECHNICAL DATA
Page 13
0
FRONT SUSPENSION (cont.) Dom/Eur Fedeml
Front Spring
- Colour Code None Green
- Number of Effective Coils 9 10.5
- Length, Free 35.30 cm 34.6 cm
- Coil Diameter 10.00 cm 10.00 cm
- Rate 55.14 kd2.5 cm 63.63 kg/2. 5 cm
STEERING
Type Manual rack and pinion, with energy absorbing saginaw steering column
0
Steering angles - camber* 0 to
-iO
c- - caster 3O to 3$O
- swivel pin(kpi) 9O
- toe in* 3 to 5 mm (1/8 - 3/16 in)
* At ride height (2 people in car)
Lock angles Front 32' Rear 33O
Turns (Lock to lock) 2 - 7/8
REAR SUSPENSION
-
Independent, by diagonal trailing orrn ond
c+c. .
. .... -,:.?L -S\
.. .. ..
. >,
later01 link with fixed length drive shafts.
Coil springs ond telescopic shock absorbers.
4 Dom/Eur Federal . .. .: :>:..
.;:,.. 7:'
. , L..: ::-'.:
Reor Spring - Colour Code None Green/Yellow
... , .
1 .,?
...
- Number ofEffective Coils l0 10.5
- Length, Free 34.80 cm 34.29 cm
- Coil Diameter 8.92 cm 9.04 cm
- Rote 67.14 kd2.5 cm 85.91 kg/2.5 cm
0
Camber angle* 0 to -h0
+Omm +Oin
Toe - in* 4 mm (5/32 in) rmx
1 .5mm - 1/16 in
* At ride height (2 people in car) at each wheel
ESPRIT :
Issue 04/78

TECHNICAL MTA
Page 14
BRAKES
Type Girling hydraulic with type 28 supervac
servo. split front to rear systems, discs all
round.
Eront brakes
- Disc diameter 250 mm (9.7 in)
- Disc thickness 12.7 mm (.50 in)
- Minimum thickness 11.7 mm (.46 in)
- Total disc run out 0.09 mm (.0035 in) TIR
- Lining area per brake 75 sq cm (l l .63 sq in)
- Brakin
g
area per brake 630 sq cm (97.01
sq in)
Rear brakes
- Disc diameter 275 mm (10.82 in)
- Disc thickness
10 mm (0.393 in)
- Minimum thickness
9 mm (0.354 in)
- Total disc run out 0.09 mm (0.0035 in)
TIR
- Lining area per brake 64 sq cm (9.92 sq in)
- Braking area per brake 68 sq cm (105.2 sq in)
Handbrake
- Mechanical rear wheel only.
WHEELS AND TYRES
Wheel Type
- Size - front
- Size - rear
Tyres
- Type
- Size - front
- Size - rear
Tyre Pressures European Spec
- Front
- Rear
Series
I
Bolt an Allov
6 JK X 14
7 JK X 14
Dunlop " SP Sport Super "
205/60 VR X 14 (Radial)
205/70 VR X 14 (Radial)
1.3 kg sq
cm (18 lb sq in)
1.9 kg sq cm (27 lbsq in)
ESPRIT
Issue wns

TECHNICAL DATA
Page 15
ELECTRICAL EQUIPMENT
Battery Type
- Capacity
- Voltage/Polarity
Headlamps
44 amp hr @ 20 hr Rating
12V Negative
4 - 3" diameter units two in each
hwdlamp pod.
Headlamp
- RHD inner 50 (Main Sealed beam
outer
60W (Dip) 37.5 (Main) Sealed beam
- LHD inner Halogen
H1 and H4
outer
Sealed Beam
SealedBeam
- North American inner No l
outer No2
Sidelamp 5W
Front and Rear Indicators 21W
Stop Lamps 21W
Tail Lamps 5W
Number plate lamps 6W
Panel Lamps 3W
S-'
Interior Lamps 6W
WarningLamps 2W Capless
Reverse Lamps 21W Festoon
AIternator: Lucas 18 ACR (45 amp)
Starter Motor: Type Lucas 3M100
Drive Pre - engaged
Fuses Located inside the glove box. Seven
circuits ore protected by foses; headlomps
motor, offside side lights, nearside side
-
lights, ignition controlled circuits, auxiliary
controlled circuits and two permanent live
circuits.
ESPRIT
ISSUC 04/78

TECHNICAL, DATA
Page 16
TORQUE LOADING FIGURES
ENGINE -- Kg m
Cylinder head (tighten cold)
. *
both pairs (front and rear) nuts
9.7
3 pairs (in middle) nuts 10.4
Sparking plugs 3.31 - 3.87
Camshaft covers .42-.55
Camshaft housings 1.93 - 2.21
Camshaft sprockets 3.46
Main bearing IFsing - 12 mm 7.60
.j
,,,.dT''
- 8 mm 1.93 - 2.21
. .-
.,.
CranksKaft pulley 8.02 - 8.29
Connecting rod (big end) caps 11.61 - 11.89
Flvwheel 6.50-6.77
Clutch Assembly 2.21-2.48 .%,.
Oil sump to main bearing housing (all) .981.10
Auxiliary housing to cylinder block
1 .SO-2.07
i~
AuxiIioryshaft sprocket
...
3.46
.
.. .
-. ,..
Oil pick - up pipe union
. , >. 4
7.6
\
Reioining nui (orli iensior~ri, 3.464.lS
A:
~ll%ther 6 mm nuts or setscrews
.96-1.10
Stud - Cylinder head to c 'nder block - 12 mm
Q'
5.53
- Main bearing housing - 8 mm 1.66
- Main bearing housing - 12 mm 5.53
- Camshaft housing to cylinder head - 8mm
l .66
- Sump to main bearing housin
g
- 6 mm
-
.69
- All other non-spe'cified 8 mm studs 1.66
Exhaust manifold to cylinder head 1.93 - 2 21
:*r
Inletmanifold to cylinder head
1.93-2.2-1
Baniobolt (fuel line to carburettors)
2.2
ESPRIT
Issue 04/78