Lotus Europa A046T0327Z User's Manual
Contents
1. 1 69 kg cm sq 34 Ibs in sq 2 39 kg cm sq Exide 6 VTA 29 L 39 amp hr 12 volt negative earth 2 35 amp Sev Motorola A 1230 12 13 2 30 amps 3 000 r p m Sev Motorola E 144 5 2 2 ohms 25 C measured across slip rings Paris Rhone D 8 E 49 Pre engaged 8 lbs ft 1 1 kg m 355 amps Section Updated 1 10 2008 6 49 AM at http www lotus europa com Lamp Bulbs all 12 volt RHD LHD Headlamp France North America 410 45 40W with 989 6W pilot 411 45 40W with 989 6W pilot Sealed beam unit Front and rear indicators 382 21W Indicator repeater 501 SW capless Stop and tall lamps 380 21 6W Rear number plate lamp 254 6W festoon Reverse lamp Up to 46 0541 382 21W From 46 0542 273 21W festoon Interior lamp 254 6W festoon Panel instrument lamps 987 2 4W Warning lamps 987 2 4W ADDITIONAL INFORMATION Distributor Centrifugal Advance Exhaust Emission Distributor Distributor r p m degrees B T D C Below 550 No advance 800 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 degrees B T D C 1 3 3 3 4 5 5 6 6 5 7 0 Vacuum Hg milllmetres 100 150 200 250 300 350 Maximum advance 17 Section Updated 1 10 2008 6 49 AM at http www lotus europa com TORQUE LOADING FIGURES ENGINE Ib2. 0007 0015 in 020 041 mm Solid skirt Aluminium 2 1 Matched piston and liner sets 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 157 in 4 mm Section Updated 1 10 2008 6 49 AM at http www lotus europa com Lubrication System Pump Type Drive Inner to outer rotor clearance Normal pressure hot 2 000 r p m Filter FUEL SYSTEM Pump operation Air cleaner type Choke control Carburetter Non Exhaust Emission Type Slow running speed Choke Main jet Air correction jet Accelerator pump jet Power jet Inner venturi Carburetter Exhaust Emission Type Slow running speed Choke Main jet Air correction jet Slow running jet IGNITION SYSTEM Type Firing order No 1 cylinder Ignition advance control 12 Eccentric rotor Skewgear from camshaft See Section E Engine 30 Ibs in sq 2 kg cm sq Full flow throw away canister Mechanical Paper element dry Manual Solex 35 DIDSA 2 twin choke 900 1 000 r p m Primary Secondary 26 26 145 140 135 150 40 Nil Nil 80 270 28 32 Solex 26 32 DIDSA 5 twin choke 1 000 50 r p m Primary Secondary 23 5 27 120 142 5 125 125 60 95 Coil and distributor 1 3 4 2 Nearest to clutch Centrifugal Section Updated 1 10 2008 6 49 AM at http www lotus europa com Ignition timing static
3. 0016 0024 in 040 060 mm 008 in 20 mm 010 in 25 mm Helical double 1 492 in 37 89 mm 1 929 in 49 mm 1 968 in 50 mm 1 968 in 50 mm 472 in 12 mm 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 72 375 in 9 525 mm 225 in 5 72 mm Crankshaft Diameter Main journals Crankpin End float Dimension Controlled by Bearings Number Type Running clearance Maximum undersize for regrind Connecting Rod Type Material Distance between centres Bearings Type Running clearance Side clearance Gudgeon Piston Pin Location Diameter Class of fit In piston In connecting rod Piston Type Material No of rings Compression Oil control Piston clearance in cylinder liner Piston rings Gap in liner fitted Compression Oil control Groove clearance Compression Oil control Width Compression Oil control 11 2 158 in 54 8 mm 1 890 in 48 mm 002 009 in 05 23 mm Thrust washers on centre main bearing 5 Aluminium lead thin wall 0015 0031 in 038 079 mm 02 in 50 mm H section Steel forging 5 363 in 13 62 cm Aluminium Lead thin wall 0007 0028 in 017 058 mm 1 012 022 in 310 572 mm Force fit in connecting rod 787 in 20 ram 0001 0003 in 003 009 mm
4. LOTUS EUROPA Workshop M anual LOTUS CARSLIMITED 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 NOTE Lotus policy is one of continuous product improvement and the right is reserved to alter specifications at any time without prior notice Whilst reasonable efforts have been made to ensure that at the time of publishing this manual is correct the descriptions and illustrations appearing are not binding 1 Section Updated 1 10 2008 6 49 AM at http www lotus europa com Section Updated 1 10 2008 6 49 AM at http www lotus europa com CONTENTS Technical Data Chassis Body az D ya O O 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 a O VO ZrA TT Ta TtTmM UAB gt Exhaust System 3 Section Updated 1 10 2008 6 49 AM at http www lotus europa com 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
5. Non Exhaust Emission Exhaust Emission Coil Sparking plugs Type Gap 4 B T D C T D C Ducellier 2765 A Marchal 34 HS 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 Drive Direction of rotation from above Contact breaker gap Cam dwell angle Firing angles Centrifugal advance Non Exhaust Emission Distributor r p m Below 550 920 1 000 2 000 3 000 Vacuum advance Non Exhaust Emission Distributor degrees B T D C 1 5 4 6 6 5 7 0 COOLI NG SYSTEM Type Radiator cap relief valve Thermostat nominal opening temperature Water pump belt tension at longest run Alternator belt tension at longest run Ducellier 4 cylinder Skew gear from camshaft Anti clockwise 016 019 in 40 50 mm 61 3 0 90 180 270 1 Distributor degrees B T D C 13 No advance 7 8 8 0 13 0 18 0 Vacuum Hg inches 3 937 7 874 11 811 15 748 Centrifugal pump and fan 7 lbs in sq 49 kg cm sq 68 C 09375 15625 in 2 3812 3 9687 mm 28125 375 in 7 1437 9 525 mm Section Updated 1 10 2008 6 49 AM at http www lotus europa com CLUTCH Make and type Ferodo 200 D diaphragm spring Operation Cable Driven plate diameter 7 875 in 20 cm Clutch assembly adjustment See Section Q Clutch Free movement at wi
6. cm 6 in 16 5 cm 44 ft 13 4 m 1350 Ibs 612 kg 1566 Ibs 710 kg T2 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 4 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 82 6 000 80 6 000 79 Ibs ft 10 92 kg m 4 000 17 7 m p h 28 5 k p h Section Updated 1 10 2008 6 49 AM at http www lotus europa com Cylinder Head Material Valve timing Inlet opens Inlet closes Exhaust opens Exhaust closes Angle of valve seats and faces Exhaust Exhaust Exhaust Valves Head diameter Inlet Stem diameter Inlet Stem clearance in guide Inlet Clearance cold Inlet Exhaust Valve springs Type Free length Inner Outer Valve guides Length Inlet Exhaust Fitted height above head Camshaft Number and type of bearings Journal diameter Bearing running clearance End float Tappets Standard Oversize Drive Type Number of pitches Length of pitch Width of pitch Section Updated 1 10 2008 6 49 AM at http www lotus europa com H _________ 10 Aluminium 35 B T D C 65 A B D C 65 B B D C 35 A T D C 45 1 476 in 37 5 mm 1 220 in 31 mm 315 in 8 mm 315 in 8 mm 0010 0018 in 025 045 mm
7. 48 in 8 83 mm 12 75 in 32 38 cm 7 75 in 19 68 cm 100 Ibs in 1 15 kg m 002 004 in 05 10 mm Rack and pinion 0 to 30 3 30 9 30 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 Independent 19 329 in 8 35 mm 16 2 in 41 15 cm 10 4 in 26 42 cm 72 Ibs in 83 kg m 0 to 2 Negative 3 16 in 4 76 mm to Zero Girling hydraulic servo optional 9 75 in 24 76 cm Ferodo DS 31 004 in 10 mm 8 in 20 3 cm x 1 5 in 3 8 cm Don 242 Mechanical on rear only Section Updated 1 10 2008 6 49 AM at http www lotus europa com WHEELS AND TYRES Pressed steel bolt on 42 J 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 At speeds BELOW At sustained speeds 100 mph 160 kph Wheel Type Size Tyres Type Tyres Size Tyres Pressure cold Front Rear ELECTRICAL EQUIPMENT Battery Type Capacity 20 hr rating Voltage and polarity Fuses Quantity and rating Alternator Type Nominal system voltage Charging voltage Maximum output hot Control box type Field coil resistance Starter Type Drive Lock torque 18 Ibs in sq 1 27 kg cm sq 28 lbs in sq 1 97 kg cm sq 16 ABOVE 100 mph 160 kph 24 Ibs in sq
8. JJ 2 Not in original manual Added for clarification JJ 19 Section Updated 1 10 2008 6 49 AM at http www lotus europa com
9. 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 bo
10. dy i e working on the engine or removing the windscreen it is recommended that body protection covers be used 4 Section Updated 1 10 2008 6 49 AM at http www lotus europa com Section a O VO ZrA TT Tata mods gt SECTION CHECK LIST Description 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 5 Section Updated 1 10 2008 6 49 AM at http www lotus europa com The number of pages in each Section is correct at November 1971 Number of Pages 20 9 40 18 13 63 45 9 13 22 10 34 56 13 5 10 4 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 Bulletin Number Date Section Page No Subject il ELT i 6 Section Updated 1 10 2008 6 49 AM at http www lotus europa com VEHICLE IDENTIFICATION Chassis Numbering Commencing at the Ist of January 1970 a new f
11. hub 22 27 3 04 3 73 Front hub spindle nut 5 6 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 8 10 1 10 1 38 3 8 in UNF male bundy to master cylinder multi ways etc 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 14 21 1 93 2 90 Stop lamp switch 12 15 1 65 2 07 Brake hose to banjo 12 15 1 65 2 07 7 16in UNF female bundy to reservoir 12 14 1 65 1 93 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 7 69 96 5 16 in UNF and UNC 12 15 1 65 2 07 3 8 in UNC 17 22 2 35 3 04 3 8 in UNF 22 27 3 04 3 73 7 16 in UNC 30 35 4 14 4 85 7 16 in UNF 40 45 5 53 6 22 1 2 in UNC 45 50 6 22 6 91 1 2 in UNF 50 60 6 91 8 29 9 16 in UNC 60 70 8 29 9 68 9 16 in UNF 65 75 8 98 10 36 5 8 in UNC 75 85 10 36 11 75 5 8 in UNF 100 110 13 82 15 20 Editors Notes 1 Page 11 Corrected 0228 to 0028
12. ll Ratios Front Suspension Steering Rear Suspension Brakes Wheels amp Tyres Electrical Equipment Battery Fuses Alternator Starter Lamp Bulbs Additional Information Ignition Distributor Exhaust Emission Torque Loading Figures 8 Section Updated 1 10 2008 6 49 AM at http www lotus europa com oro wovok oO 10 10 11 11 11 11 12 12 12 12 13 13 13 13 14 14 14 14 14 14 15 15 15 15 16 16 16 16 16 17 17 18 TECHNICAL DATA Ground clearances Lowest point under front suspension 4i Under engine 6Y Under exhaust 9 Overall width 5 5 Height of male figures amp 10 approx Above image from Motor Magazine 6 Sep 1969 2 DIMENSIONS Wheelbase Track at wheel hub Front Rear Length Width Height Ground clearance design Turning circle Overall Kerb weight unladen Series I Series II CAPACITIES Engine sump including filter Transmission Coolant with heater Fuel ENGINE General Number of cylinders Capacity Non Exhaust Emission Exhaust Emission Stroke Non Exhaust Emission Exhaust Emission Bore 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 91in 231 1 cm 53 in 134 6 cm 53 in 134 6 cm 157 Yin 399 4 cm 64 2 in 163 8 cm 42 in 107 9
13. ormat 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 Ol Denotes the production batch 0001 Denotes the chassis number P 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 amp N Ireland A Elan STD Coupe Export B Elan STD Convertible G Britain amp N Ireland C Elan STD Convertible Export D Elan S E Coupe G Britain amp N Ireland E Elan S E Coupe Export F Elan S E Convertible G Britain amp N Ireland G Elan S E Convertible Export H Elan Federal Coupe Export J Elan Federal Convertible Export K Elan 2 S G Britain amp N Ireland L Elan 2 S Export M Elan 2 S Federal Export N Europa G Britain amp N Ireland P Europa Export Q Europa Federal Export R Section Updated 1 10 2008 6 49 AM at http www lotus europa com 7 TECHNICAL DATA I NDEX Description Dimensions Capacities Engine 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 Overa
14. s ft kg m Cylinder head tighten cold See also Section E 54 60 7 46 8 29 Rocker arm pillar 15 20 2 07 2 76 Crankshaft Main bearing caps 45 6 22 Cone 30 4 14 Sprocket 45 6 22 Flywheel 40 5 53 Oil pump To cylinder block 9 12 1 25 1 65 Strainer flange 16 20 2 25 2 75 Manifold to cylinder head 10 20 1 38 2 76 CLUTCH Clutch assembly to flywheel 25 3 45 TRANSMI SSION Gearbox casing halves 7 mm bolts 15 2 07 8 mm bolts 20 2 75 Differential case to crown wheel 10 mm bolts 45 6 22 11mm bolts 65 80 8 98 11 06 Differential bearing adjusting nuts 15 2 07 Pinion bearing nut 85 11 75 Speedometer drive worm 75 85 10 36 11 75 Reverse selector pivot 20 2 75 Side cover plates 15 2 07 FRONT SUSPENSION AND STEERING Stub axle retaining nut 65 75 8 98 10 36 Ball joint To vertical link 38 42 5 25 5 80 To upper wishbone 12 15 1 65 2 07 Lower wishbone To trunnion 35 4 83 To damper 50 60 6 91 8 29 Inner wishbone retaining nut 50 60 6 91 8 29 Caliper mounting plate to hub 22 27 3 04 3 73 Steering arm to vertical link 22 27 3 04 3 73 Steering tie rod ball joint 26 28 3 59 3 87 Steering tie rod adaptor 50 6 91 Steering column impact clamp 26 32 3 59 4 42 Tighten with suspension in static condition 18 Section Updated 1 10 2008 6 49 AM at http www lotus europa com REAR SUSPENSION Ibs ft kg m Lower link pivot bracket 18 23 2 48 3 18 HUBS Brake disc to
15. thdrawal lever 078 125 in 2 3 mm TRANSMISSION Type 4 forward speeds all synchromesh and reverse Bearings Mainshaft Taper rollers Secondary gear cluster Taper rollers Bearings adjustment See Section F Transmission Gear ratios Top 1 03 1 3rd 1 48 1 2nd 2 25 1 Ist 3 61 1 Reverse 3 08 1 Final drive Type Hypoid gear J Bearings Pinion Taper rollers Diff crown wheel assy Taper rollers Bearings adjustment Pinion bearing pre load See Section F Transmission Crown wheel pinion backlash 005 010 in 127 254 mm Number of teeth Crown wheel 32 Pinion 9 Final drive ratio 3 56 1 Speedometer gears Driving Gear Driven Gear 46 F 6049 6 teeth 46 F 6108 12 teeth Pink Blue Overall ratios Top 3 666 1 3rd 5 268 1 2nd 8 010 1 Ist 12 851 1 Reverse 10 964 1 14 Section Updated 1 10 2008 6 49 AM at http www lotus europa com FRONT SUSPENSION Type Spring Number of coils Wire diameter Length Free Fitted Rate Front hub end float STEERING Type Steering angles Camber Castor Swivel pin kpi Toe in Condition for checking toe in REAR SUSPENSION Type Spring Number of coils Wire diameter Length Free Fitted Rate Wheel camber Toe in BRAKES Make and type Front brakes Disc diameter Pads material Total disc run out Rear brakes Drum dia and width Lining material Handbrake type 15 Independent 17 3
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