User manual LOTUS ESPRIT SERVICE MANUAL

[. . . ] Turbo 93-96 10. 00 11. 00 12. 00 13. 00 14. 00 15. 00 16. 00 17. 00 18. 00 19. 00 30. 00 31. 00 Body Structure Glazing, Door Weatherstrips, Window Lift Exterior Hardware & Trim Seat & Seat Belts Pedal Box & Fascia Interior Trim Sound Insulation Electrical Heater/Air Conditioning Labels & Literature Chassis Suspension 32. 00 33. 00 34. 00 40. 00 41. 00 42. 00 43. 00 44. 00 45. 00 46. 00 47. 00 60. 00 80. 00 Steering Brakes Wheels & Tires Engine Belts & Pulleys Induction System Emission Equipment Fuel System Exhaust System Cooling System Transmission Tools Bulk Items Body Structure 10. 01A 10. 02A 10. 03A 10. 04A 10. 05A 10. 07A 10. 09A 10. 11A 10. 13A 10. 15A 10. 17A 10. 23A 10. 23B 10. 31A Bodyshell & Front Body Repair Sections Rear Body Repair Sections Body to Chassis Fixings Body Attachment 'Bobbins' Body Crossbeams, Jacking Plates Headlamp Pods & Pivots Front Bonnet & Release Mechanism Tailgate & Release Mechanism Engine Compartment, Undertray Door Shell, Beam, Hinges, Hinge Post Door Handles, Lock Mechanism, Striker Posts S4: Bumpers, Sills, Valances, Spoilers Sport 300: Bumpers, Sills, Valances, Spoilers Towing Eye & Fixings Glazing, Door Weatherstrips, Window Lift 11. 01A 11. 02A 11. 05A 11. 05B Glass, Finishers, Door Weatherstrips Door Window Frames, Window Lift Mechanism Glass Roof Composite, Fixed Composite Roof Exterior Hardware & Trim 12. 01A 12. 02A 12. 05A 12. 07A 12. 09A Capping Rails, Air Scoops, Wind Deflector Fuel Filler Flaps & Release Mechanism Decals & Badges License Plate Plinths Door Mirrors Seats & Seat Belts 13. 03A 13. 09A 13. 11A 13. 27A Seat Frames, Runners, Recline Mechanism Seat Foams, Suspension, Lumbar Support Trimmed Seats, Covers Seat Belts & Reel Covers Pedal Box & Fascia 14. 01A 14. 05A 14. 05B 14. 07A 14. 08A 14. 10A 14. 12A Pedal Box & Pedals, Throttle Cable Except Dual S. I. R. : Fascia Trim, Knee Bolster Dual S. I. R. : Fascia Trim, Knee Bolster Binnacle Instrument Panel & Masks Centre Console, Climate Controls Mtg. Trimmed Instrument Binnacle Glovebox Interior Trim 15. 01A 15. 11A 15. 13A 15. 19A 15. 24A 15. 30A Roof Trim, Interior Mirror, Sun Visors Rear Bulkhead Trim, Bulkhead Pocket Door Trim Tunnel Trim, Gear Level Gaiters Luggage Compartment Carpet Passenger Compartment Carpet, Handbrake Gaiter Sound Insulation 16. 01A 16. 02A S4: Passenger Compartment Sound Insulation Body Underside Sound Insulation Electrical 17. 01A 17. 03A 17. 03B 17. 03C 17. 03D 17. 05A 17. 06A 17. 06B 17. 06C 17. 07A 17. 09A 17. 11A 17. 13A 17. 15A 17. 21A 17. 27A 17. 29A 17. 31A 17. 33A Harnesses, Leads & Fuses Prior VIN*: Relays, Modules & Horns From VIN*: Relays, Modules & Horns Prior VIN*: Engine Bay Relay Box & Inertia Switch From VIN*: Engine Control Relays & Inertia Switch Driver Operated Switches & Cigar Lighter Engine Management ECM & Sensors S. I. R. : Inflator Modules, D. E. R. M. & Sensors ABS: ECM & Sensors Instruments, Senders, Tell Tales, Clock S4: Speedo Cable Lamps (except headlamps), Door Switches Headlamps, Carriers & Masks Headlamp Pod Motors & Lift Mechanism Windscreen Wiper Mechanism & Washers Audio Equipment, Speakers, Aerial Earth Braids & Suppression Devices Battery & Battery Cable Alarm System Controller & Sensors Heater/Air Conditioning 18. 01A 18. 03A 18. 05A 18. 07A 18. 09A 18. 11A 18. 13A Heater/Air Conditioning Assembly, Casings Condenser, Evaporator, Rec. Drier, Hoses Heater Matrix, Water Valve & Plumbing Interior Blower Motor Rotary Controls, Graphic Panel, Screen Flap Mech. [. . . ] Use a shop towel to absorb any escaping fluid, and cap the pipe ends and valve ports immediately after disconnection. Release the valve fixing screw and remove the valve. JF. 21 - ABS CONTROLLER, RELAYS & FUSES The ABS controller, or electronic control unit (ECM), is mounted on the passenger side front bulkhead in the front luggage compartment. The mounting bracket uses a clamping channel to secure the ECM to the bracket, and also carries a row of relays and fuses, and on pre `revised harness' cars, the wheel speed sensor harness connector socket. The relays are: - radio isolator (only on pre `revised harness' cars); - front solenoid enable; - rear solenoid enable. ABS relay control (3A) ABS controller fuse (10A) ABS pump fuse (30A) front solenoid fuse (30A) rear solenoid fuse (15A) The fuses are: To remove the ABS controller, slacken the two clamping bolts, and slide the controller out of the bracket sufficiently to disconnect the electrical plug. Earlv Cars: Passenaer side front bulkhead A BS con troller Radio isolator relay A BS relay con fro/: 3A A BS con troller fuse: 1 OA ASS pump fuse: 30A Front solenoid fuse: 30A Front solenoid enable relay Rear solenoid fuse: 15A Rear solenoid enable relay Wheel speed sensor harness connector Page 68 I Revised Harness' Cars: Passenger side front bulkhead , . . I ABS rear solenoid relay ABS rear solenoid fuse: 75A lenoid fuse: 30A pump motor fuse: 30A ABS controller fuse: 1OA ABS relay control fuse: 3A Cover protecting wheel speed harness connectors The ABS pump motor enable relay is fitted on the driver's side of the front bulkhead, adjacent to the main vehicle fusebox. ABS pump motor enable relay Page 69 Note that the lamp driver module (operates the ABS tell tale lamp) is taped to the fascia harness near to the wiper motor. ALDL Connector The Assembly Line Diagnostic Link (ALDL) connector is a ten way electrical connector plug which provides a means of communication between the ABS controller and electronic test/diagnostic equipment such as a `Tech 1' scanner tool. The connector plug is attached to the fascia harness and is secured when not in use in a stowage socket on the inboard side of the back of the glovebox, or on S4 models to the alarm controller mounting bracket in the same area. This connector is also used for engine management diagnosis, and on cars so equipped, for S. I. R. (Supplementary Inflatable Restraint) diagnosis. ALDL stowage socket Alarm con troller ALDL connector for S. & engine management for alarm ALDL Note that on Esprit S4 models, a similar connector is located at the outboard end of the glovebox, and is used solely for diagnosis of the vehicle alarm system. JF. 22 - SPECIAL TOOLS `Tech 1' Diaqnostic Scanner Kit TOOOT0896 Plugs into ALDL connector and displays stored trouble codes and sensor readings. Kit includes scanner, connector lead, self-test adaptor, operator's manual and carrying case. Cartridge must be ordered separately. Page 70 ARS Cartridae. `Tech 1' scanner TOOOT1115/1 Plugs into Tech 1 scanner and contains data. Identified by `LOTUS 1991 BRAKE' and `Part ' Number TK02380' printed on the label. Connector I ead. `T e c h 1' scan ner TOOOTO897/2 Included in `Tech 1' kit TOOOT0898. The 12 lead, which is also compatible with Elan models, is identified by `TA00053' embossed in gold lettering on the ALDL end connector. Pear Caljw Spreader TOam% Used to spread wings of carrier bracket when replacing rear caliper cylinder. Pressure Gauoe TOOOTl 112 Used in hydraulic diagnosis to test pump and accumulator and check for internal leakage in master cylinder/booster assembly. , /' - --. \ , / ( \\ I Id \ Section JF. 25 DM- ABS IIIA ANTILOCK BRAKE SYSTEM Some operations in this section require that the hydraulic lines, hoses and Fittings be disconnected for inspection of testing purposes. This brake System uses a hydraulic accumulator which, when fully charged, contains Brake fluid at high pressure. Before disconnecting any hydraulic lines, hose or fittings, be sure that the accumulator is fully depressurized. Failure to depressurize the hydraulic accumulator may result in personal injury. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [. . . ] Washer, flat, M8 x 16, gearbox mounting to chassis. Nyloc Nut, M8, gearbox mounting to chassis. Bolt, 7/16" UNF x 4%", mounting to bracket, LH. Bolt, 7/16" UNF x 4" , mounting to bracket , RH. Washer, flat, 7/16 UNF, gearbox mounting bolt. [. . . ]