Lotus Esprit S4 - Repair, Service and Maintenance Manual

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LOTUS ESPRIT 1993 - SERVICE MANUAL

Service Manual in PDF format to vehicles Lotus Esprit 1993.


CONTENTS:


WORKSHOP MANUAL 1993 (1139 pages)

TECHNICAL DATA

- Engine

Engine Number
Engine
Cylinder Head
Camshafts & Valve Timing
Valves
Valve Seat Inserts
Valve Springs
Valve Guides
Camshafts
Cam Followers
Auxiliary Shafts
Crankshaft
Flywheel
Connecting Rod
Gudgeon Pin
Piston & Liner
Lubrication System
Ignition System
Cooling System
Torque Figures
Fuel Consumption

- Vehicle

Dimensions
Capacities
Suspension
Steering
Clutch
Transmission
Cooling System
Brakes
Wheels & Tires
Electrical Equipment
Torque Settings
Fuel Consumption

FRONT SUSPENSION

General Description  
Geometry & Adjustments  
Suspension Disassembly/Assembly
Front Wheel Bearings

REAR SUSPENSION

General Description  
Geometry & Adjustments  
Suspension Disassembly/Assembly  
Rear Hub Bearings  

ENGINE

General Description EF.1 4
Lubrication System EF.2 4
Engine Removal/Replacement EF.3 9
Compression Check EF.4 11
Valve Clearances, Camshafts & Cam Housings EF.5 11
Camshaft Driving Belt & Tensioner EF.6 17
Cylinder Head EF.7 21
Valves. Guides & Seats EF.8 25
Water Pump EF.9 28
Inlet Manifold/Throttle Bodies/Plenum EF.10 30
Auxiliary Housing & Oil Pump EF.11 31
Exhaust Manifold Turbocharger & Wastegate EF.12 34
Oil Sump EF.13 36
Connecting Rod ( “Big End” ) Bearing EF.14 38
Crankshaft & Main Bearings EF.41 41
Pistons. Connecting Rods & Cylinder Liners EF.18 46
Special Tools EF.19 50
Sealants, Adhesives EF.20

ENGINE MANAGEMENT
 
Electronic Control Module (ECM)
- Engine Coolant Temperature Sensor
- Mass Air Temperature (MAT) Sensor
- Manifold Absolute Pressure (MAP) Sensor
- Barometric Pressure Sensor
- Exhaust Oxygen (02) Sensor
- Throttle Position Sensor (TPS)
- Air Conditioning & Radiator Fan Control
- Vehicle Speed Sensor
Fuel Control System
- Fuel Pump
- Fuel Rail & Pressure Regulator
- Fuel Injectors
- Throttle Bodies/Inlet Manifold Assembly
- Idle Air Control (IAC) Valve
Direct Ignition (DI)
- Flywheel Sensor
- Ignition Module & HT Coils
- Electronic Spark Timing (EST)
- Electronic Spark Control (ESC) & Boost Control
Evaporative Emission Control System (EECS)
Crankcase Breather Valve
Exhaust Back Pressure Valve & Throttle Jack

TRANSMISSION

General Description
Lubrication
Gearchange Mechanism Adjustment
Gear Knob/Lever Replacement
Gearchange Lever Mechanism & Control Cables
Output Shaft Oil Seal Replacement
Rear Housing Gasket Replacement
Selector Cross Shaft Seal Replacement
Speedo Driven Gear Replacement
Transmission Removal/Replacement
Driveshaft Joint Gaiter Replacement
Transmission Disassembly
Primary Shaft
Secondary Shaft
Bevel Gear Differential ( S4 )
Lotus Compact Torque Biasing Differential ( Sport 300 )
Reverse Idler Gear
Gear Selector Forks & Shafts
Transmission Re-assembly
Primary Shaft Input Oil seal Replacement

WHEELS & TYRES

Wheels
Tires
Spare Wheel & Tire
Wheel/Tire Assembly Balancing

STEERING

General Description
Power Steering Rack Operation
PAS Fluid Check & Refill Procedure
Steering Wheel & Lock Stops ( Non S.I.R type )
Upper Steering Column Assembly
Intermediate Steering Column Assembly
Track Rod Ends & Front Wheel Alignment
Steering Rack Gaiters
PAS Pump & Testing Procedure
Rack & Pinion Assembly Removal/Replacement
Rack & Pinion Assembly Overhaul


BRAKES
 
- 4 Cylinder With Delco Moraine ABS IIIA

General Description
Tell Tale Lamps
ABS Brake Characteristics
Brake Fluid Level Check
Front Brake Pad Replacement
Sub-Section
Rear Brake Pad Replacement
Parking Brake Adjustment
Brake Bleeding Procedure
Front Caliper Overhaul
Rear Caliper Overhaul
Brake Discs l
Retro-Fitment of Brembo Brakes to Esprit S4
ABS Theory of Operation
Hydraulic Diagnosis
Brake Fluid Reservoir
Solenoid Valves
Booster/Master Cylinder
Pump/Accumulator Assembly
Wheel Speed Sensors
Proportioning Valve
ABS Controller, Relays, Fuses & ALDL Connector
Special Tools
ABS Trouble Code Diagnosis

-    V8 With Kelsey Hayes ABS 415

General Description
Tell Tale Lamps
Front Brake Pad Replacement
Rear Brake Pad Replacement
Parking Brake Adjustment
Brake Calipers
‘Brake Discs
Brake Master Cylinder
Vacuum Servo
ABS Theory of Operation
ABS Electra-Hydraulic Unit
Wheel Speed Sensors
Data Link Connector (DLC)
Special Tools

COOLING

General Description
Maintenance
Drain/Refill Procedure
Coolant Re-circulation Pump & Diverter Valve ( V8 Only )
Oil Cooling System
Charge Air Cooling System ( 4 - Cylinder models )
Radiator Cooling Fans
Radiator Ducts

ELECTRICS

Safety Precautions For S.I.R. Models
Introduction of Revised Wiring Harness
Switch & Tell Tale Lamp Operation
Central Door Locking
Vehicle Alarm System
Electronic Module Operation
Radio Wiring & Suppression
Battery, Battery Cables & Earthing Points
Heated Rear Screen & High Mounted Stop Lamp Wiring
Component Location & Fuse Ratings
Harness Routing Diagram
Circuit Diagrams - Early Cars (white pages)
Circuit Diagrams - 'Revised Harness' Cars (cream pages)
Esprit V8 (prior '98 M.Y.) Supplement & Circuit Diagrams
'98 M.Y. Supplement & Circuit Diagrams (gray pages)


MAINTENANCE & LUBRICATION

Recommended Lubricants
Paint Inspection Sheet
Pre-Delivery Inspection - 4 cylinder
- V8 7
Maintenance Schedule - 4 cylinder - Except California
- '93/94' M.Y. California
- '95 M.Y. California
- V8 - Non-USA
- USA

CLUTCH

General Description QE.1 2
Maintenance QE.2 5
Master Cylinder QE.3 8
Slave Cylinder QE.4 11
Clutch Assembly QE.5 11
Release Bearing & Fork QE.6 16
Spigot Bearing QE.7 19
Retrofitting of Twin Plate Clutch V8


SUPPLEMENTARY INFLATABLE RESTRAINT - DRIVER ONLY