Lotus Pet Fence A046T0327Z User Manual

LOTUS EUROPA

Workshop Manual

LOTUS CARS LIMITED

Norwich Norfolk, Nor. 92W England

Telephone: Wymohdham 3411. Cables: Lotus. NORWICH Telex: 97401

Part No A046T0327Z

August 1972 ©

----------------------------------------------------------------------------------------Section Updated: 1/10/2008 6:49 AM at http://www.lotus-europa.com ----------------------------------------------------------------------------------------

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CONTENTS

Technical Data

Chassis

Page 9

Body

Front Suspension

Rear Suspension

Engine

Transmission

Hubs, Wheels and Tyres

Steering

Brakes

Cooling System

Fuel System

Electrical Equipment

Lubrication and Maintenance

Heating and Ventilation

Clutch

Exhaust System

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INTRODUCTION

This Workshop Manual, which is in loose-leaf form for easy amendment, has been compiled to assist Lotus

Dealers throughout the world in the efficient repair and maintenance of the Lotus Europa models.

The various units and systems of the vehicle are dealt with in sections which are listed on page 5, each

being distinguished by a reference letter, this letter being the same as is used in other service publications (i.e.,

A -- chassis in Parts Lists and in the Labour Schedule). Each section thus referred to opens with a contents page

so that any particular operation can be easily located.

Service Information

Design changes, product improvements or changes in procedure subsequent to the publishing of this

manual are given in Service/Parts Bulletins, which are issued regularly to all authorised Lotus Dealers. Should

existing instructions be affected or additional information be needed, new pages to this manual will be issued to

Lotus Dealers when convenient.

To ensure the manual is kept up-to-date, write the Bulletin number, the section and page number it

affects and the subject matter in the space provided on page 8.

Technical Data

Comprehensive information regarding dimensions, tolerances, weights and torque loading figures of all

nuts and bolts are given on page commencing 9.

Recommended Lubrication and Maintenance

Attention is drawn to Section 'O' of this manual for the Factory approved recommended lubricants and

intervals of Periodical Maintenance.

Frost Precautions

Attention is drawn to the recommendations given in Section 'K' (Cooling System) of this manual on the

importance of taking proper precautions against damage by frost.

Paint and Body Protection

When work is carried out on any part of the car where damage could be caused to the paint and body, i.e.

working on the engine, or removing the windscreen, it is recommended that body protection covers be used.

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SECTION CHECK LIST

The number of pages in each Section is correct at: November 1971.

Section

Description

Number of Pages

TECHNICAL DATA

CHASSIS

BODY

FRONT SUSPENSION

REAR SUSPENS ION

ENGINE

TRANSMISSION

WHEELS, HUBS AND TYRES

STEERING

BRAKI NG SYSTEM

COOLING SYSTEM

FUEL SYSTEM

ELECTRICAL EQUIPMENT

LUBRICATIONS AND MAINTENANCE

HEATING AND VENTILATION

CLUTCH

EXHAUST SYSTEM

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SERVICE BULLETIN RECORD

To ensure that the information contained in the manual is up-to-date, Lotus Dealers are asked, when they

receive them, to record in the columns below, the bulletin numbers with their subjects and the section and page

number affected.

If reference is then made to these columns before turning to the appropriate section, it will be seen

immediately if any amendment subsequent to the publishing of the manual is applicable.

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VEHICLE IDENTIFICATION (Chassis Numbering)

Commencing at the 1st of January 1970, a new format has been used for Vehicle Identification.

An example of a new chassis number is given below, together with the full identification breakdown.

7001.010001P Both chassis and body numbers being the same

7001

Denotes year and month of manufacture (1970, January)

Denotes the production batch

0001

Denotes the chassis number

Denotes the model

As there are at present 16 different model types, the following codes will be used for model

identification.

Elan STD

Coupe

G. Britain & N. Ireland

Export

Elan STD

Elan S/E

Convertible G. Britain & N. Ireland

Convertible Export

Coupe

G. Britain & N. Ireland

Export

Elan S/E

Convertible G. Britain & N. Ireland

Convertible Export

Elan S/E

Elan Federal

Elan +2'S'

Elan +2'S' Federal

Europa

Coupe

Convertible Export

G. Britain & N. Ireland

Export

G. Britain & N. Ireland

Export

Europa

Europa Federal

Export

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TECHNICAL DATA

I NDEX

Description

Dimensions

Capacities

Engine:

Page

General

Performance

Cylinder Head

Camshaft

Crankshaft

Connecting Rod

Gudgeon (Piston) Pin

Piston

Lubrication

Fuel System:

Pump

Air Cleaner

Carburetters

Ignition System:

Ignition Timing

Sparking Plugs

Distributor

Cooling System

Clutch

Transmission:

Bearings

Adjustment

Ratios

Speedometer Gears

Overall Ratios

Front Suspension

Steering

Rear Suspension

Brakes

Wheels & Tyres

Electrical Equipment:

Battery

Fuses

Alternator

Starter

Lamp Bulbs

Additional Information:

Ignition Distributor (Exhaust Emission)

Torque Loading Figures

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TECHNICAL DATA

Above image from Motor Magazine 6 Sep 1969. [2]

DIMENSIONS

Wheelbase

Track (at wheel hub) - Front

- Rear

91 in. (231 1 cm.)

53 in. (134.6 cm.)

157 ¼in. (399.4 cm.)

64½ in. (163.8 cm.)

42½ in. (107.9 cm.)

6 ½ in. (16.5 cm.)

44 ft. (13.4 m.)

Overall

- Length

-Width

- Height

Ground clearance (design)

Turning circle

Kerb weight (unladen)

- Series I

- Series II

1350 lbs. (612 kg.)

1566 lbs. (710 kg.)

CAPACITIES

Engine sump (including filter)

Transmission

Coolant (with heater)

Fuel

7½ pints (4 litres; 9 U.S. pints)

3 pints (1.75 litres; 3.6 U.S. pints)

18 pints (10.3 litres: 21.6 U.S. pints)

6 gallons (27 litres; 7.2 U.S. gallons)

ENGINE

General

Number of cylinders

Capacity

Stroke

Bore

- Non Exhaust Emission

89.7 cu. in. (1470 cc.)

95.5 cu. in. (1565 cc.)

3.189 in. (81 mm.)

3.307 in. (84 mm.)

2.992 in. (76 mm.)

3.032 in. (77 mm.)

10.25:1

- Exhaust Emission

-Non Exhaust Emission

- Exhaust Emission

- Non Exhaust Emission

- Exhaust Emission

Compression ratio (all)

PERFORMANCE

Max. BHP @ r.p.m. - Non Exhaust Emission

- Exhaust Emission

Max. Torque @ r.p.m. (all)

Road speed per 1,000 r .p .m. in top gear

82 @ 6,000

80 @ 6,000

79 lbs.ft. (10.92 kg.m.) @ 4,000

17.7 m.p.h. (28.5 k.p.h.)

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Cylinder Head

Material

Aluminium

Valve timing - Inlet opens

- Inlet closes

35° B.T.D.C.

65° A.B.D.C.

- Exhaust opens

65° B.B.D.C.

- Exhaust closes

35° A.T.D.C.

Angle of valve seats and faces

Valves - Head diameter

45°

- Inlet

1.476 in. (37.5 mm.)

1.220 in. (31 mm.)

.315 in. (8 mm.)

.0010/.0018 in. (.025/.045 mm.)

.0016/.0024 in. (.040/.060 mm.)

.008 in. (.20 mm.)

.010 in. (.25 mm.)

Helical, double

- Exhaust

- Inlet

- Stem diameter

- Exhaust

- Inlet

- Stem clearance in guide

- Clearance (cold)

- Exhaust

- Inlet

- Exhaust

Valve springs - Type

- Free length

- Inner

- Outer

- Inlet

1.492 in. (37.89 mm.)

1.929 in. (49 mm.)

1.968 in. (50 mm.)

.472 in. (12 mm.)

Valve guides - Length

- Exhaust

- Fitted height above head

Camshaft

Number and type of bearings

Journal diameter

Bearing running clearance

End float

4, white metal

1.653 in. (42 mm.)

.001/.0029 in. (.025/.075 mm.)

.002/.0047 in. (.05/. 12 mm.)

.473 in. (12 mm.)

.480 in. (12.2 mm.)

Chain

Tappets

- Standard

- Oversize

Drive

- Type

- Number of pitches

- Length (of pitch)

- Width (of pitch)

.375 in. (9.525 mm.)

.225 in. (5.72 mm.)

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Crankshaft

Diameter

- Main journals

- Crankpin

2.158 in. (54.8 mm.)

1.890 in. (48 mm.)

End float

Bearings

- Dimension

- Controlled by

- Number

.002/.009 in. (.05/.23 mm.)

Thrust washers on centre main bearing

- Type

Aluminium lead, thin wall

.0015/.0031 in. (.038/.079 mm.)

.02 in, (.50 mm.)

- Running clearance

Maximum undersize for regrind

Connecting Rod

Type

'H' section

Material

Steel forging

Distance between centres

5.363 in. (13.62 cm.)

Aluminium Lead, thin wall

.0007/.0028 in. (.017/.058 mm.) [1]

.012/.022 in. (.310/.572 mm.)

Bearings

- Type

- Running clearance

- Side clearance

Gudgeon (Piston) Pin

Location

Force fit in connecting rod

.787 in. (20 ram.)

Diameter

Class of fit

- In piston

- In connecting rod

.0001/.0003 in. (.003/.009 mm.)

.0007/.0015 in. (.020/.041 mm.)

Piston

Type

Solid skirt

Material

Aluminium

No. of rings - Compression

- Oil control

Piston clearance in cylinder liner

Piston rings:

Matched piston and liner sets

Gap in liner (fitted) -Compression

- Oil control

.009/.015 in. (.25/.40mm.)

.009/.015 in. (.25/.40 mm.)

.0019/.0029 in. (.05/.075 mm.)

.0005/.0023 in. (.015/.06 mm.)

.078 in. (2 mm.)

Groove clearance

- Compression

- Oil control

- Compression

- Oil control

Width

.157 in. (4 mm.)

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Lubrication System

Pump - Type

- Drive

Eccentric rotor

Skewgear from camshaft

See Section 'E' (Engine)

30 lbs.in.sq. (2. kg.cm.sq.)

Full - flow ('throw away' canister)

- Inner to outer rotor clearance

Normal pressure (hot) @ 2,000 r.p.m.

Filter

FUEL SYSTEM

Pump operation

Mechanical

Air cleaner type

Paper element (dry)

Manual

Choke control

Carburetter - Non Exhaust Emission:

Type

Solex 35 DIDSA 2 (twin choke)

900/1,000 r.p.m.

Slow running speed

Primary

Secondary

Choke

Main jet

145

135

140

Air correction jet

Accelerator pump jet

Power jet

150

Nil

80/270

Inner venturi

Carburetter - Exhaust Emission:

Type

Solex 26 - 32 DIDSA 5 (twin choke)

1,000 +- 50 r.p.m.

Slow running speed

Primary

23.5

120

Secondary

Choke

Main jet

142.5

125

Air correction jet

Slow running jet

IGNITION SYSTEM

Type

125

Coil and distributor

1,3,4,2

Firing order

No. 1 cylinder

Ignition advance control

Nearest to clutch

Centrifugal

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Ignition timing (static)

Non Exhaust Emission

Exhaust Emission

4° B.T.D.C.

T.D.C.

Coil

Sparking plugs

Ducellier 2765 A

Marchal 34 HS

- Type*

- Gap

.023 in. (.584 mm.)

*Alternatively, Champion N4, Champion NTY or Autolite AG22 may be used in all engines with a points gap

of .023 in. (.584 mm.).

Distributor

Type

Ducellier 4 cylinder

Skew gear from camshaft

Anti-clockwise

Drive

Direction of rotation (from above)

Contact breaker gap

Cam dwell angle

.016/.019 in. (.40/.50 mm.)

61° +- 3°

Firing angles

0°, 90°, 180°, 270° +- 1°

Centrifugal advance (Non Exhaust Emission):

Distributor

r.p.m.

degrees B.T.D.C.

Below 550

No advance

7.8

920

1,000

8.0

2,000

3,000

13.0

18.0

Vacuum advance (Non Exhaust Emission):

Distributor

Vacuum

degrees B.T.D.C.

Hg. inches

1.5

3.937

4.6

7.874

6.5

7.0

11.811

15.748

COOLI NG SYSTEM

Type

Centrifugal pump and fan

7 lbs .in .sq. (.49 kg.cm .sq .)

68° C.

Radiator cap relief valve

Thermostat nominal opening temperature

Water pump belt tension (at longest run)

Alternator belt tension (at longest run)

09375/.15625 in. (2.3812./3.9687 mm.)

.28125/.375 in. (7.1437/9.525 mm.)

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CLUTCH

Make and type

Ferodo 200 D, diaphragm spring

Cable

Operation

Driven plate diameter

Clutch assembly adjustment

Free movement at withdrawal lever

7.875 in. (20 cm.)

See Section 'Q' (Clutch)

.078/.125 in. (2/3 mm.)

TRANSMISSION

Type

4 forward speeds, all synchromesh and reverse

Taper rollers

Bearings

- Mainshaft

- Secondary gear cluster

Taper rollers

Bearings adjustment

See Section 'F' (Transmission)

Gear ratios

- Top

-3rd.

1.03:1

1.48:1

2.25:1

3.61:1

3.08:1

-2nd.

- 1st.

-Reverse

Final drive:

Type

Hypoid gear J

Taper rollers

Bearings

- Pinion

- Diff./crown wheel assy.

Bearings adjustment:

Pinion bearing pre-load

Crown wheel/pinion backlash

See Section 'F' (Transmission)

.005/.010 in. (.127/.254 mm.)

Number of teeth

- Crown wheel

- Pinion

Final drive ratio

3.56:1

Speedometer gears:

Driving Gear

Driven Gear

46 F 6108, 12 teeth

Blue

46 F 6049, 6 teeth

Pink

Overall ratios - Top

3.666:1

5.268:1

8.010:1

12.851:1

10.964:1

- 3rd.

- 2nd.

- 1st.

- Reverse

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FRONT SUSPENSION

Type

Independent

Spring - Number of coils

-Wire diameter

.348 in. (8.83 mm.)

12.75 in. (32.38 cm.)

7.75 in. (19.68 cm.)

- Length

- Free

- Fitted

- Rate

Front hub end float

STEERING

Type

100 lbs.in. (1.15 kg.m.)

.002/.004 in. (.05/.10 mm.)

Rack and pinion

Steering angles

- Camber

0° to +- 30'

- Castor

3° +- 30'

- Swivel pin (kpi)

9° +- 30'

Toe - in

3/16 in. (4.76 mm.) to 1/16 in. (1.6 mm.)

6t in. (16.5 cm.) ground clearance

at bottom of chassis closing plate.

Condition for checking toe - in

REAR SUSPENSION

Type

Independent

Spring

- Number of coils

- Wire diameter

19½

.329 in. (8.35 mm.)

16.2 in. (41.15 cm.)

10.4 in. (26.42 cm.)

72 lbs. in. (.83 kg. m.)

0° to 2° Negative

3/16 in. (4.76 mm.) to Zero

- Length

- Free

- Fitted

- Rate

Wheel camber

Toe - in

BRAKES

Make and type

Front brakes - Disc diameter

Girling hydraulic (servo optional)

9.75 in. (24.76 cm.)

- Pads material

Ferodo DS.31

Total disc run out

.004 in. (.10 mm.)

Rear brakes - Drum dia. and width

- Lining material

8 in. (20.3 cm.) x 1.5 in. (3.8 cm.)

Don. 242

Handbrake type

Mechanical, on rear only

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WHEELS AND TYRES

Wheel

- Type

- Size

Pressed steel bolt on

4½ J

Tyres*

- Type

- Size

Firestone F.100 tubeless or,

Dunlop SP Sport with tubes.

155 x 13

*If inner tubes are fitted, it is essential that these are of the

correct type for radial ply tyres.

Tyres

- Pressure (cold):

At speeds BELOW At sustained speeds

100 mph (160 kph) ABOVE 100 mph (160 kph)

- Front

18 lbs.in.sq.

24 lbs.in.sq.

(1.27 kg.cm.sq .)

28 lbs.in.sq.

(1.69 kg.cm.sq.)

34 lbs.in.sq

- Rear

(1.97 kg.cm.sq.)

(2.39 kg,cm.sq.)

ELECTRICAL EQUIPMENT

Battery

Type

Exide 6 VTA 29 L

39 amp.hr.

Capacity @ 20 hr. rating

Voltage and polarity

Fuses

12 volt negative earth

Quantity and rating

Alternator

2, 35 amp.

Type

Sev - Motorola A. 1230

Nominal system voltage

Charging voltage

Maximum output (hot)

Control box type

Field coil resistance

13.2

30 amps. @ 3,000 r.p.m.

Sev - Motorola E.144

5.2 +- .2 ohms. @ 25 C. measured

across slip rings

Starter

Type

Drive

Paris - Rhone D.8 E 49

Pre - engaged

Lock torque

8 lbs.ft. (1.1 kg.m.) @ 355 amps.

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Lamp Bulbs (all 12 volt)

Headlamp - RHD, LHD

410 (45/40W) with 989 (6W) pilot

411 (45/40W) with 989 (6W) pilot

Sealed beam unit

382 (21W)

- France

- North America

Front and rear indicators

Indicator repeater

501 (5W capless)

380 (21/6W)

Stop and tall lamps

Rear number plate lamp

Reverse lamp - Up to 46/0541

- From 46/0542

254 (6W festoon)

382 (21W)

273 (21W festoon)

254 (6W festoon)

987 (2.4W)

Interior lamp

Panel (instrument) lamps

Warning lamps

987 (2.4W)

ADDITIONAL INFORMATION

Distributor Centrifugal Advance (Exhaust Emission):

Distributor

r.p.m,

Below 550

800

Distributor

degrees B.T.D.C.

No advance

2.5

1,000

10.5

1,250

11.5

1,500

13.0

1,750

14.5

2,000

15.5

2,250

16.5

2,400

17.0 Maximum advance

Distributor Vacuum Advance (Exhaust Emission):

Distributor

Vacuum

degrees B .T.D.C.

Hg. milllmetres

1.3

3.3

4.5

5.6

6.5

7.0

100

150

200

250

300

350 Maximum advance

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TORQUE LOADING FIGURES

lbs .ft.

ENGINE

kg.m.

Cylinder head - tighten cold (See also Section ' E')

Rocker arm pillar

54 - 60

15 - 20

7.46 - 8.29

2.07 - 2.76

6.22

Crankshaft

- Main bearing caps

- Cone

4.14

- Sprocket

6.22

Flywheel

Oil pump

5.53

- To cylinder block

- Strainer flange

9 - 12

16 - 20

10 - 20

1.25 - 1.65

2.25 - 2.75

1.38 - 2.76

Manifold to cylinder head

CLUTCH

Clutch assembly to flywheel

TRANSMI SSION

3.45

Gearbox casing (halves)

- 7 mm. bolts

- 8 mm. bolts

- 10 mm. bolts

- 11mm. bolts

2.07

2.75

Differential case to crown wheel

6.22

65-80

8.98-11.06

2.07

Differential bearing adjusting nuts

Pinion bearing nut

11.75

Speedometer drive worm

Reverse selector pivot

Side cover plates

75 - 85

10.36 - 11.75

2.75

2.07

FRONT SUSPENSION AND STEERING

Stub axle retaining nut

65 - 75

38 - 42

12 - 15

8.98 - 10.36

5.25 - 5.80

1.65 - 2.07

4.83

Ball joint

- To vertical link

- To upper wishbone

- To trunnion*

Lower wishbone

- To damper*

50 - 60

22 - 27

26 - 28

6.91 - 8.29

3.04 - 3.73

3.59 - 3.87

6.91

Inner wishbone retaining nut*

Caliper mounting plate to hub

Steering arm to vertical link

Steering tie-rod ball joint

Steering tie-rod adaptor

Steering column impact clamp

26 - 32

3.59 - 4.42

* Tighten with suspension in static condition

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REAR SUSPENSION

lbs.ft.

kg.m.

Lower link pivot bracket

18 -23

2.48 - 3.18

HUBS

Brake disc to hub

Front hub spindle nut *

22 - 27

5 - 6

3.04 - 3.73

.69 - .83

Rear hub retaining nut **

150

20.7

*Tighten nuts to this torque loading while rotating hub to ensure

bedding of taper rollers. Slacken nut one 'flat', then insert split pin.

** Assemble with Loctite 'AV'. A rotational free play NOT EXCEEDING

.005 in. (.127 mm.) between hub and shaft measured at the wheel stud

should be used for LEFT - HAND hubs.

BRAKE HYDRAULIC SYSTEM CONNECTIONS

3/8 in. UNF female (bundy and hose connections)

3/8 in. UNF male (bundy to master cylinder,

multi-ways, etc.)

8 - 10

1.10 - 1.38

5 - 7

.69 -.96

7/16 in. UNF male

7 - 10.5

.96 - 1.45

3/8 in. bore servo bundy (5/8 in.UNF male)

Stop lamp switch

14 - 21

12 - 15

12 - 14

1.93 - 2.90

1.65 - 2.07

1.65 - 1.93

Brake hose to banjo

7/16in. UNF female (bundy to reservoir)

Torque Wrenches

Torque wrenches in daily use should be checked at intervals, not exceeding 3 months, to ensure that accuracy is

maintained.

GENERAL - NUTS AND BOLTS

1/4 in. UNF and UNC

5/16 in. UNF and UNC

5 - 7

12 - 15

.69 - .96

1.65 - 2.07

3/8 in. UNC

3/8 in. UNF

7/16 in. UNC

7/16 in. UNF

1/2 in. UNC

1/2 in. UNF

9/16 in. UNC

9/16 in, UNF

5/8 in. UNC

5/8 in. UNF

17 - 22

22 - 27

30 - 35

40 - 45

45 - 50

50 - 60

60 - 70

65 - 75

75 - 85

100 - 110

2.35 - 3.04

3.04 - 3.73

4.14 - 4.85

5.53 - 6.22

6.22 - 6.91

6.91 - 8.29

8.29 - 9.68

8.98 - 10.36

10.36 -11.75

13.82 - 15.20

Editors Notes:

[1] Page 11: Corrected .0228 to .0028. [JJ]

[2] Not in original manual. Added for clarification [JJ]

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