S11pplemet11 to "Motnr Trader," 4 October /967 Mo1:or Trader SERVICE DATA No. 464 Manufacturers: Ltd., Norwich, Norfolk

All rights reserved. This Service Data Sheet is compiled by the technical staff of Motor Trader, from information made available by the vehicle manufacturers and from our own experience. It Is the copyright of this journal, and may not be reproduced, in whole or in part, without per• mission. While care is taken to ensure accuracy we do not accept responsibility for errors or omissions.

ITH this article in the Service Data sheet series, we depart W from our usual style of presentation. In order to give the DISTINGUISHING FEATURES: The Elan model is readily identifiable from its distinctive styling and maximum information possible with­ from the front by the concealed headlamps which are featured on this model in the available space, opportunity has been taken to devote the accom­ panying four-page Service Supple­ dealt with in this article, while the Lotus car, as certain similar­ contained within the axle casing. ment exclusively to the Lotus routine operations involved in ser­ ities exist. of the drive Drive to the rear road wheels is engine. Other mechanical compo­ vicing the unit, i.e. decarbonisation is taken through a single dry plate transmitted through short universally nents, together with routine service and description of processes involved diaphragm clutch to a four­ jointed drive shafts bolted up at their operations are detailed with this are dealt with in the Service Sup­ speed all-sym.:hrumesh gearbox. In inner ends to splined truncated eight-page article. To preserve correct plement. In this way it is hoped that design, this gearbox is near identical drive shafts located each side of the repair sequence, and where service confusion of reference may be with that fitted to the Ford Cortina axle casing. attention involving the engine unit is avoided and that the engine supple­ Lotus and blocker type ring synchro­ Suspension is independent front concerned, reference is made in the ment will serve the dual purpose of mesh is used. From the output shaft and rear and effected through coil appropriate place in this main article, companion article to this data sheet of the gearbox, the drive is taken to springs and wishbone links at the thus engine removal from the car is and be applicable to the Ford Cortina the hypoid bevel reduction gear front and by similar but McPherson type units at the rear. Wide based lower wishbones provide loca­ tion. In the case of the front sus­ pension, telescopic hydraulic shock absorbers are co-axially mounted within the suspension springs and those of the rear suspension are integral parts of each unit. Braking is by Girling hydraulic disc units on front and rear wheels. Those at the front of the vehicle are mounted in conventional manner to the wheel hubs and the rear units are fitted to the Inner sides of each rear wheelhub. is by . Vehicles are identified by serial numbers and engine numbers. The vehicle serials carry the prefix 36, Coupe fixed head, 45, Coupe drop­ head and commence at 0001. This serial, together with other relevant informationis to be found on a plate fixed to the passenger side of the bulkhead. The engine number is INSTRUMENTS, CONTROLS, GEAR POSITIONS, AND BONNET LOCK stamped on side of block below the inlet manifold. It is essential that 1. Headlamps flasher 9. Variable speed wipers 17. Lights master switch 25. Handbrake warning all these numbers and letters from 2. Horn and washers 18. Gearlever light the vehicle identification plate are 3. Indicators 10. Ignition/starter switch 19. Fuel gauge 26. Indicators warning light 27. Ignition warning light quoted when referring to the vehicle 4. Cold air vent 11. Heater fan motor switch 20. Engine rpm indicator 12. Panel lights switch 28. Main beam warning manufacturers, or distributors, or 5. Bonnet release 13. Interior lights switch 21. Speedometer light when ordering spare part's, 6. Cigar lighter 14. Choke control 22. Combined water temp. 29. Headlamps dipswitch Service,:iPolic)( of the manufac­ 7. Heater regulator 15. R/h electric window and oil pressure gauges 30. Clutch pedal 8. L/h electric window switch 23. Cold air vent 31. Brake pedal turers is that all\matters, relating to switch 16. Headlights switch 24. Handbrake 32. Accelerator service work, Warranty claims and so forth are handled through the Lotus Inset top left shows position of steering column mounted controls and lower: operative positions of Distributor network to whom all the centrP. mounted gearlever. such queries should be addressed. .. nr Trader," 4 October 1967 ii LOTUS El.AN Supp/eme,,, tn Mnt

, . Parts oft he e gine showing the fixedand moving components ,n� re Ia f ,v e order ofassembly Suppli'mcnt to .. Motor Trader,'' 4 October 1967 LOTUS ELAN 111

The manufacturers place special clear brackets and lift unit up and remove clutch operating mechanism. Extract locating ball and remove emphasis upon the fact that every out of car. Remove release bearing and arm spacer. Remove 3rd gear and 3rd/ Lotus service department is, in their assembly, secured by retaining top gear synchronized assembly. own words, "better equipped with Replacement of Engine spring, place assembly to one side. Remove small diameter circlip at every facility to carry out service In general terms, replacement of Take off bellhousing by removing forward end of mainshaft. Locate and repairs than the owner driver". engine is a reversal of removal four bolts and lockwashers securing adaptors on rear face of 3rd gear and sequence detailed above. Note fol­ it to gearcase. Drive out clutch in base of plate on bed of press. lowing points: Alignment of tail­ release arm fulcrum pin if necessary. Press mainshaft out of 3rd/top shaft and propeller shaft splines is Take offgear lever housing by re­ synchronizer and 3rd gear while ENGINE effected through access hole on moving four bolts and lockwashers supporting mainshaft from beneath. In a similar manner remove main­ Descriptive detail of the engine right-hand side of propellor shaft securing it to extension housing. appears in the accompanying four­ tunnel. This access hole is revealed If reverse relay lever is to be re­ shaft bearing, sandwich plate, I st after taking out right-hand seat and moved, invert housing, tap firmly gear, 1st/2nd gear synchronizer and page Service Supplement No. 452/ 2nd gear from mainshaft. Note: Cl 13. trim. This part of engine/gearbox on hard wood to remove retaining replacement is a two-man job, the dowel and withdraw lever. Remove synchronizer hubs and sleeves are assistant guiding tailshaft into its gearbox top cover plate-four bolts mated together and also to main­ Removal alignment position in propellor shaft and lockwashers, taking care to pre­ shaft. Mating marks are etched on Take off bonnet after removal of tunnel while unit is manipulated on serve selector shaft locating springs corresponding splines of hub and two retaining springs. Disconnect slings. which are located in cover plate end sleeve, and near hub and mainshaft battery leads, drain oil from engine flange. Take out selector shaft splines. Synchronizer and hub as­ and gearbox and coolant fromsystem. springs and balls and with gearbox sembly are serviced as a unit. Remove top and bottom hoses and TRANSMISSION in neutral, remove locking wire Note also that 1 st gear rotates on radiator core mounting nuts on from selector bolt heads, unscrew hardened steel bush that is lubri­ underside of bodyshell above steering Clutch square-head taper bolts securing cated via three holes in I st gear rack. Remove top pipe and hose and Borg and Beck single dry plate selector forks to shafts. Draw out adjacent to dog teeth. Assembly is thermostat housing, pull off coolant diaphragm spring unit. Hydraulic 3rd/4th selector shaft to rear, sup­ reversal of dismantling process, see temperature gauge connection. Undo actuation of release mechanism, porting sleeve for 3rd/4th shaft, following notes. jubilee clip and remove hose from master cylinder bore dia. jin, and then take out sleeve. heater take-off point. Undo heater slave cylinder bore dia. ¾in. Partially withdraw 1st/2nd gear control valve cable at valve. Sintered bronze bush self-lubrica­ selector shaft, remove floating pin from cross drilling at forward end, To Assemble Gearbox Part exhaust manifold/downpipe ting release bearing, fitwith flatface ° clamp and remove, undo and remove towards crankshaft and shouldered rotate shaft through 90 and with­ Reverse process of dismantling pipe clip and front section of face towards clutch. draw it from casing. Withdraw re­ noting following points: Mainshaft: verse selector shaft to rear, rotating downpipe from rear sections. Undo No provision for external adjust­ ° assemble 2nd gear, dog teeth to all other pipes, wires and controls to ment of clutch unit provided. Access through 90 clockwise to prevent it rear. Locate a blocker ring on cone and from engine and ancillary com­ to clutch unit forservice replacement fouling extension housing. Lift off face of 2nd gear. Assemble 1st/2nd ponents. Undo air box clamping after removal of engine/gearbox unit selector forks. Preserve interlock gear synchronizer. Ensure that mat­ bolt and remove air box and gasket. and parting them at bellhousing plungers. Remove extension hous­ ing marks are aligned. Locate Undo eight Nyloc mounting nuts revealing clutch which is retained on ing by undoing five securing bolts 1st/2nd gear synchronizer, selector and remove double spring washers flywheel face by six hexagon-headed and lock-washers, remove speedo­ fork groove to rear, make sure from carburettor manifold. Take off set bolts and located by two dowels. meter driven gear and gear bearing mating marks are aligned. Fit carburettors complete with air box Under no circumstances should any tfrom extension housing and draw blocker ring in 1st/2nd gear synchro­ from manifoldstuds and remove four attempt be made to repair clutch off extension housing. Mark sand­ nizer so that cut-outs in blocker ring "O" -ring gaskets. pressure plate assembly. In cases wich plate and gearcase to facilitate fitover blocker bars. Locate hardened Jack up car and support on stands. where transmission faults are traced alignment of dowel and locating steel bush in 1 st gear, shoulder in Remove 2BA bolts holding exhaust to a faulty clutch, a replacement unit hole in sandwich plate. With brass bush away from 1st gear dog teeth. pipe to gearbox. Remove four bolts should be used. drift, free layshaft at bellhousing Fit to shaft so that dog teeth are securing gearbox mounting cross­ end and drive out layshaft with located next to blocker ring and member to chassis, two nuts holding Gearbox dummy shaft, allow laygear cluster 1st/2nd gear synchronizer. Note crossmember to gearbox and take to rest on casing bottom. With­ possibility that slight interference Four-speed, synchromesh on all draw complete mainshaft assembly out crossmember. Undo speedo forward ratios, centre change speed fit may exist between this bush and drive cable at gearbox end. Remove to rear, note that top gear blocker mainshaft. Position sandwich plate lever operates selector rods direct. ring will be loose on main drive clutch slave cylinder after undoing Propellor shaft yoke end slides on on mainshaft, dowel hole to rear, securing circlip and withdrawing gear, and should be removed. Also and fit bearing. Locate adaptor splined end of extended mainshaft 13 needle rollers from drive gear in­ cylinder through its mounting lug. and in bush in rear extension housing .. over bearing, insert assembly and Unclip clutch hydraulic pipe from its ternal bore. Remove primary shaft fitslave ring. Ensure that cut-outs in location on bellhousing, after re­ bearing retainer, three bolts and 2nd gear blocker ring line up with leasing "P" -clip held by a bolt at To Remove Gearbox lockwashers, detach bearing circlip blocker bars in 1st/2nd gear syn­ top right-hand side of housing. Gearbox must be removed with and press out gear and bearing into chronizer, also that mating marks Arrange suitable slings around front engine as detailed in previous section, box. Take out laygear and two line up and press mainshaft down and rear of engine unit, passing since access forseparate removal with thrust washers. Note needle rollers to assemble 1st/2nd gear synchro­ slings around sump. Take weight of engine unit in situ is very limited and (20 each end). Draw out reverse nizer. Slide 3rd gear on to shaft, dog engine unit on slings and remove complete engine/gearbox removal is idler shaft. teeth away from thrust collar on four engine mounting bolts (two per recommended for all service work shaft and locate blocker ring on side). Note: that lower left-hand bolt where access to clutch, gearbox, etc. tape face of gear. Locate 3rd/top is involved. secures earth strap. Raise engine To Dismantle Mainshaft synchronizer hub on shaft, long boss slightly and ease unit forwards until to front. Assemble 3rd/top gear bellhousing contacts engine mount­ To Dismantle Gearbox Prise up tab on washer and re­ synchronizer hub, also synchronizer ing brackets on chassis members. Tilt With gearbox on bench or moun­ move retaining nut and extract sleeve, then spacer, locating ball, engine to right-hand side of car to ted upright on suitable stand, first speedo drive gear from mainshaft. speedometer drive gear, tab washer

CRANKSHAFT AND CON. RODS

Main Bearings Crankpins

Diameter 2.1255-2.1260in 2.0825-2.0830in GENERAL DATA Inter. 7ft Oin Front I Centre I Rear Track: front 3ft 11in in. 4ft O,',in Length (in) 1.219-1.239 J 1.247-1.249 J 1.273-1.283 1.308-1.328 1.062-1.066 Turningrear circle 29ft 6in Ground clearance (design) 6½ in Running clearance: main bearings .0015-.003i n Tyre size: front 165-13 big ends .005-.0022in } End float: crankshaft• .005°.00Bin rear big ends .004-.010in Overall length 12ft 1 in Undersizes not quoted Overall width 4ft Bin Con. rod centres not quoted Overall height (hood up) 3ft 10in Crankshaft balance to within .2 oz. in

• oversize thrust washers .0025, .005, .0075 .010in iv LOTUS ELAN Supplement to "Motor Trader," 4 October 1967

and retaining nut. Tighten nut to hydraulic dampers. Wide based outboard drive shaft spider. Undo to chassis. Ease unit out from left­ torque of 25-25lb.ft. lower wishbones provide lateral and ¾in Nyloc nut on outboard drive hand side. Assemble main drive gear (later longitudinal location. shaft and take offtwo spacer washers. Axle units should not be serviced models). Position main drive gear With suitable puller take hub off without range of special tools and bearing on gear, external circlip taper and keyed end of outboard fixtures to facilitate setting of clear­ groove away from gear and press on To Remove Rear drive shaft, which may now be pulled ances exactly to datum figures neces­ bearing. Fit smaller diameter circlip Suspension inwards through strut housing. Inner sary and to within the relatively in groove provided in main drive Jack up rear of car, and remove bearing will come away with shaft fine limits required for work in­ gear shaft. Reassemble layshaft and road wheel. Position second jack and may be parted after removal of volved in dismantling and reassemb­ retaining washers, and locate 20 under strut housing with jack crutch securing circlip and tapping off ling the crown wheel and pinion. needle rollers in each recess at under housing and take weight of shaft. Remove outer bearing retainer Bevel pinion shaft runs in taper layshaft ends. Place layshaft in car on this jack. Secure suspension circlip and with suitable drift, tap roller bearings, outer races pressed bottom of box. Locate thrust coil spring with suitable straps or out outer bearing from inner side of into final drive housing. Collapsible washers each end of laygear, tongues clamps and undo three ¾in Nyloc strut housing. spacer between inner races, which are locate in recesses provided. Fit main nuts securing Rotoflex coupling to Reassembly of components is a nipped up by driving flange and drive gear to box, followed by rear axle differential shaft and with­ reversal of procedure detailed above. nut. Flange hub passes through circlip and drive gear bearing re­ draw the 3in bolts. Undo ¾in Nyloc To remove differential assembly: lipped oil seal in housing. tainer. Install reverse idler gear and nuts and take out bolts securing lower jack up vehicle and support it on Bearings adjusted to give 9-11 lb shaft. Fit 13 needle rollers to counter­ wishbone to strut housing. Slacken stands. Take off rear road wheels. in pre-load with oil seal excluded, by bore of main drive gear, do not use inner wishbone/chassis mounting Remove rubber cap on left-hand collapsible spacer. grease. Position a blocker ring over bolts and allow wishbone to lower side of body decking to gain access Pinion mesh adjustment by shim taper face of top gear and gasket itself about these points. Remove to top of suspension strut mounting. between pinion and inner race of over rear face of gearbox. Offer up rubber cap on top deck of boot Undo three bolts on each spider to rear bearing. Shims available in 13 and assemble mainshaft assembly, fit behind rear seat, take out split pin release Rotoflex coupling each side thicknesses in .0!0in steps from.1304 layshaft. Fit extension housing. and take off castellated nut of rear of differential unit. Release clevis to .1428in. Further assembly is reversal of dis­ suspension strut. Lower suspension pin of handbrake push/pull rod on Crown wheel spigoted on one­ mantling process already described. unit (without complete lower wish­ left-hand caliper. Undo two bolts piece differential cage and retained bone) to floor. Lower wishbone may which pass through outer ends of by six self-locking setscrews. Dif­ be removed after taking out two lower wishbone and strut housing ferential side bevel gears have Final Drive & Rear ¾in attachment bolts. and slacken offinner bolts at attach­ spherical thrust washers behind, Suspension To remove drive shafts, take off ment points of lower wishbone to planet bevel pinions have flat thrust Chassis-mounted casing containing caliper after removing two wire­ chassis. Undo four ¾in propellor washers. hypoid bevel reduction gear. Fixed locked mounting bolts; remove shaft pinion flange securing bolts Differential assembly carried in length final drive shafts fitted with Rotoflex coupling adjacent to brake and nuts. Raise boot carpet and taper roller bearings in split hous­ special rubber constant velocity disc by taking off three bolts fitted undo two ¾in Nyloc nuts and take off ings, with ring-nuts for bearing and universal joints providing shock through disc and spider and take out washers from differential mounting mesh adjustment. Bearing caps have cushioning on drive take-up. Alterna­ drive shaft complete with inner and bolts. N.B.: earth wire is attached to hollow dowels. Tighten ring-nuts to tive ratio units available. outer Rotoflex couplings, which may right-hand mounting bolt. Release spread bearing housing .005-.007in Independent rear suspension em­ be dismantled by removing six bolts differential torque stabilising rods overall (special fixture advisable for ploys system incor­ retaining them to each end of shaft. each side of unit by removing nut at checking spread), then turnboth ring­ porating modifiedform of McPherson To dismantle hubs, remove bear­ rear of each Metalastik bush and nuts equally to adjust mesh for strut units with coil springs and ing retainer circlip located behind ¼in nut locating rod to stud welded .005-.007in backlash. Final tightening

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Parts of the gearbox showing the gear casing and extension housing together with the gear trains and the selector mechanism Supplement to ''Motor Trader," 4 October 1967 LOTUS ELAN V

CARBURETTORS BRAKES TYPE 40DCOE 18 40DCOE 18 40DCOE 31 40DCOE 31 40DCOE 31 Type Girling hydraulic disc 26S 710 A26S 710 B26S 710 C26S 710 D26S 710 Part No. 26S 711 A26S 711 B26S 711 C26S 711 D26S 711 Front Rear *Used on Elan S/E Elan Cortina Std. Elan S/E Elan (Pre. '68) (Pre. '68) ('67) ('68) ('68) Disc diameter 9½in I 101n Std. S/E Pads: type DA4 DSSS Cortina Cortina colour coding 2 blue 3 blue (Pre. '67) (Pre. '67) spots spots '68 2yelw. Choke 30mm 32mm 30mm 30mm 32mm spots Main jet 115 115 110 115 115 min. thickness ¼In ,',In Air correction 200 150 155 200 150 replace when worn to ¾in ¾in Slow running jet 45F9 45F9 45F9 50F8 50F8 Handbrake pad/disc Pump jet 40 40 35 40 40 clearance .003in Pump stroke 10mm 10mm 16mm 10mm 10mm Trumpet length 1¾in 1¾in t½in Hin 1½in N.B.: Pad Colours: Reference to Cortina is Cortina Lotus DS31-blue/white/dark violet DA3-3 yellow, 2 blue, 1 dark violet spots

PROPELLER SHAFT GEARBOX

Type tubular-needle Type Synchromesh roller brg. No. of forward speeds 4 SHOCK ABSORBERS Gear ratios: 1st 2.97:1 FINAL DRIVE 2nd 2.01 :1 Type -, Telescopic hyd. 3rd 1.04:1 Service Replacement Type hypoid 4th 1 :1 j Crownwheel/bevel pinion Rev 3.32:1 teeth ratio 3 77·1

FRONT-END SERVICE DATA

° STEERING BOX CHASSIS DATA Castor 3 ±30" Front 0' to +1' Camber { Make Alford & Alder Clutch: make Borg & Beck Rear 1' to 0' Type rack and pinion type Bin sdp. diaphragm Swivel pin inclination Front¼' to¼' Adjustments: rack end float shims Toe-in { mesh screw/locknut spring Rear ¼' to Zero

must be made fromcrownwheel side. with additional handbrake-operated Provision for adjustment at hand­ bly. Take offwashers and remove top Assembly sequence of dowel type mechanism. This incorporates ad­ brake adjustment nuts on inner side wishbone halves. Unscrew two Nyloc differential unit, involving dowel ditional pads and levers connected of each rear caliper and in event of nuts and remove bolts clamping method of differential assembly was via push/pull rods to chassis mounted excessive movement in handbrake lower wish bone halves to trunnion introduced on car No. 492 (approx). fulcrum, which is cable operated lever, slack can be taken up at cable assembly and lower end of spring When replacing differential carrier from handbrake lever. adjuster, located on left-hand side of damper unit. Take off nuts holding in casing, Lotus Part No. A26004, Pedal operated brakes are self­ chassis-gearbox mounting on the front and rear lower wishbone mem­ replacement follows a reversal of adj us ting, .in that they are set f­ earlier models, and on the right-hand bers to chassis mounted pivots. dismantling process. Later assem­ compensating for wear, but regular side engine mounting on later models. Remove washers and take out two blies require great care on reassembly, inspection is necessary to ensure that Locknut and screw provided for lower wishbone halves from pivot and a trial assembly should be made friction pads are not worn beyond adjustment in each case. points. With suitable press remove using a standard gasket .009-.0llin the minimum thickness (¼in). Re­ Clatonrite bushes from inner ends of thick. Insert outboard drive shafts placement of pads is recommended at upper and lower wishbone halves. with bearings and check shaft a wear limit of ¾in, and handbrake Front Suspension Undo locknuts at top of spring concentricity in differential casing cable adjusters should be set to pro­ Coil springs and wishbone links. damper unit mounting and remove by examining shaft entry into casing. vide a clearance of .003in between Co-axially mounted telescopic hy­ cup washers and rubbers, noting Fore and aft adjustments are ob­ each pad and brake disc with lever in draulic shock absorbers. assembly sequence, take out spring tained by fitting gasket of correct "off"position. To dismantle front suspension, damper. thickness. Vertical adjustments are To renew front wheel pads, jack jack up vehicle and place it on To dismantle vertical link assembly: obtained by rotation of nosepiece up front of car and chock rear road suitable stands, with rear wheels remove dust cover, after in casing. When shafts are truly wheels. Remove wire clips from pad chocked. removing two Nyloc nuts securing concentric in casing and may be retaining pins, and take out pins Remove road wheels and undo steering arm to vertical link. Take turned manually with least effort, and remove worn pads. Prior to brake hose at caliper end. Remove out two bolts from dust cover side differentialunit should operate at its insertion of new pads, all road dirt Nyloc nuts from steering arm ends and remove steering arm through its quietest in normal running con­ etc. should be cleaned from pad and part track rods and steering arms slot in vertical link. Undo two upper ditions. slots and pistons should be forced with suitable tool. Lower end of taper bolts securing dust cover to link Note: when using replacement back slightly to allow for new, ball pin will be found to have an assembly and part caliper mounting components: New nosepieces must thicker pads to be inserted. Depress engagement centre for this purpose. bolt which is sandwiched between be drilled and reamed using jig pedal several times to ensure correct Take off lock nut, nut cap, washers dust cover and vertical link. Screw No. 26T094 (Lotus) and two securing operation. Replacement of rear and rubber bush from end of anti out vertical link from bronze trun­ bolt holes enlarged to .340-.345in. wheel pads is carried out in similar roll bar on each front suspension nion and withdraw seal. N.B. Vertical Two dowels, part No. 26R013 must manner to that already described. It unit and lower anti roll bar about its link and trunnion are left-hand be driven into nosepiece using a new should be noted that to avoid con­ axis on chassis mountings clear of threaded on left-hand side of car gasket, part No. 26R014 and red fusion over pad replacement, re­ vehicle. Unscrew and remove brake and right-hand threaded on right­ Hermatite sealing compound. Check taining pins do not pass through pad caliper/caliper mounting plate bolts hand side of car. A r.h. trunnion is nosepiece for free movement. Clean plates on rear calipers. and take off spring washers. Part further identified by its being turned joint faces and smear them with red Handbrake pads are renewed as caliper from disc. Remove dust cap, down at its lower end. Take offsteel Hermatite. Locate gasket and casing follows: jack up rear of vehicle after which is push fit in hub. Take out sleeve, two rubber rings and two in position and secure with eight chocking front wheels. Remove rear split pin and unscrew slotted nut nylon bushes from trunnion. wheels. Unscrew adjustment nut on from stub axle. Remove thrust ¼in U.N.C. hexagonal bolts. Fit Remove Nyloc nut and washer drive shafts and rotate them to check handbrake lever clamping bolt, washer and withdraw brake and hub preserving spring locking clip which assemblies complete. end, with suitable press, part vertica1 for free movement and then tighten link from tapered pin of its ball bolts. will be removed. Unscrew nut and To dismantle hub assembly, undo remove spring washer from bolt four bolts retaining brake disc to joint. Undo Nyloc nut and plain fitted through handbrake pad re­ hub and part hub from disc. Bearings washer and, with suitable press part taining fingers. Take out bolt and and rings may then be extracted as stub axle from vertical link CHASSIS two retaining fingers. Swing lever required or necessary. In the main, replacement of parts outwards as far as possible away To dismantle wishbones, Unscrew is a reversal of the dismantling pro­ Brakes from brake disc, unhook worn pads two Nyloc nuts holding top wishbone cedure. Note that hub end-float Hydraulic, Girling disc brakes on by pulling horizontally from lever members to chassis mounted pivots should be .002-.008in and slotted nut front and rear wheels. Rear brake pivot pins in caliper body. On and reverse the washers. Unscrew may be adjusted one flat to achieve units mounted on inner side of each inboard pads, it may be necessary to nuts of two bolts clamping top this condition, after having tightened suspension wheel bearing are fitted pull on actuation rods. wishbone to upper ball joint assem- it to torque of Sib.ft. vi LOTUS ELAN Supplement to "Motor Trader," 4 October 1967

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Parts of the front suspension, and steer�ng gear, together with detail of the rear suspension and the rear axle Supplement to "Motor Trader," 4 October 1967 LOTUS ELAN vii

Lamps Model Part No. Voltage Wattage Cap LUCAS EQUIPMENT

Head R.H.D. dip, left F700 59768B 12 60/45 Sealed Beam GENERATOR Model C40-1 Part No. 22700K Export Europe (except F700 597698 12 45/40 Unified CONTROL BOX Model RB106-2 Part No. 3729OF countries stated) European STARTING MOTOR Export France F700 59770B 12 45/40 Unified Model M35G-1 Part No. 25083F Drive "SB" inboard European DISTRIBUTOR Export Sweden F700 58688E 12 45/40 Unified Model 23D4 Part No. 40953A Max. centrifugal advance (crank degrees) European 22°-26° Export NADA F700 59TT3B 12 50/40 Sealed Beam No advance below 400 r.p.m. (crank) Centrifugal advance springs Side/flasher (Switzerland) 691 52548B 12 6/21 S.B.C. Part No. 544 158 59 544 167 50 Max. vacuum advance (crank degrees) Front flasher 691 53956B 12 21 s.c.c. No Vac Stop tail flasher & reflex (L.H.D.) IGNITION COIL Model HA12 Part No. 45132D R.H. 684 54151B 12 21/6/21 SBC/SCC Primary resistance 3-3.4 ohms Running current at 1,000 r.p.m. 1.2 amp L.H. 684 541528 12 21/6/21 SBC/SCC WINDSCREEN WIPER Model DR3A Part No. 75501A (Motor) Side 658 52539 12 6 MCC Wiper arm 54710008 Wiper blade 54711283 FUSE UNIT Model 4FJ Part No. 54038033 Fuse ratings 35A

DASH DISTRIBUTOR SWI CH 8

I SWITCHES Model Part No.

1 TANK Ignition/starter RH t���E UNIT 47SA 31912K DOOR Starter solenoid 2ST 76445H WITCH ea GB R.H.D. Lighting { 71SA 34403E W PW L.H.D. 57SA 31788D Direction indicator 125SA AH. STOP LAMP 348288 1 I• Dip (L.H.D.) 1035A 345368 Stop light 25H 54033360 Panel 4R 78438A LH. STOP LAMP Wiper 89SA 34325K NY HORN PUSH BUTTON w Interior: RW FUEL GUAGE Heater/interior light &SSA 31828D (coupe) 575A 31788D G w Bati;,y Ma;ier , REV.C OUNTER I• SPEEDO I FUSE ,. ;IN l1NE ·• ITEM Part No. NG I 01 L TEMP GU AGE I ► *Rack 743221 Outer casing: R LH. SIDE LAMP I Motor to wheelbox 54717021 ,----+, Wheelbox to wheelbox 745043 L'j>- - _QJ 1 AA0IO Short, wheelbox 740746 &1 WHEN AH. SIDE LAMP Wheelbox 72776A J...!ITTEO

STARTER MOT OR LH. REAR LAMP NU 8

WR N NUM EA PLATE L MP 8 TUNE-UP DATA

YU RH. REAR LAMP Firing order 1-3-4-2 8 Tappet clearance (cold): inlet .OOS-.007in HEADLAMP AH. FRONTFLASHEA LAMP exhaust .006-.00Sin 8 I• Valve timing: s':.!ll�9. exhaust camshaft on full - ° 0 LH. FRONTFLASHEA LAMP lift at 110 BTDC 0 J, inlet camshaft on full 8 ° 0 lift at 100 BTDC Standard ignition timing: 0 AH, REAR FLASHER LAMP ° 0 ► (distributor A26M009) 7 BTDC 8 (distributor B26M009) 14° BTDC ♦ 0 (distributor C26M009) 10° BTDC tllV BATTERY 8 8 LH. REAR FLASHER LAMP I• Distributor contact points . .... 8 gap .014-.016in LH.HEADLAMP RH. HEADLAMP Plugs: make Autolite type AG.22 size 14mm 8 BLACK p PURPLE gap .023-.028in SNAP CONNECTIONS ----0- u BlU E G GREEN Carburettor: make Weber N BROWN A RED Lotus Cars Ltd. B I• EARTH CONNECTIONS W WHITE y YELLOW See table p. v MADE VIA CABLES OR Air cleaner: make AC -l G LIGHTGAEEN ------l• VIA FIXING BOLTS type paper element Fuel pump: make AC type mechanical pressure 1½-2½ psi Wirin[!diagram by permission of Lotus Cars Ltd. viii LOTUS ELAN Supplement ro 1 'Motor Trader/' 4 Octoher 196;

-:!.7 2 14 28 34 30 32 5 36 11 l 24 34 14 -1/---/---1------1------i-L---=::::::----

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14 16 4 7

KEY TO MAINTENANCE DIAGRAM

(ROUTINE SERVICES) EVERY 6,000 MILES (as for 3,000 Miles plus following) EVERY 1,500 MILES 26. ·cearbox-drain and refill FILL-UP DATA ---- •1. Chassis lubrication points-grease or oil gun 27. Differential unit-check and top up 2. Engine sump 28. Front hubs-repack with grease Pints Litres 3. Gearbox 29. Water pump--lubricate ------4. Rear axle 30. Engine oil filter element-renew Engine sump (incl. filter) 4 5. Clutch master cylinder reservoir } c h ec k and top u P *3 l. Cylinder head holding down bolts, manifolds, exhaust Gearbox 7½ .99 6. Brakes master cy]inder reservoir system engine, mountings and distributor fitting­ Rear axle 21¾ 1.13 7. Battery electrolyte level check Cooling system (incl. htr.) 14 7.95 •s. Throttle linkages, hinges, catches, door Jocks etc.- 32. Fuel pump filter-clean oil can • 3 3. Brake discs, pads, caliper mountings-check Fuel tank 10galls 45 Tyre pressure*: front 18 psi 1.266 *9. Vertical movement of carburettor on manifolds 34. Wishbone and damper connections, front and rear- 2 •10. Carburettor slow running adjustment check kglcm 11. Steerin11assembly security and condition rear 22psi 1.547 '"12. Electrical system operation EVERY 12,000 MILES (as for 6,000 Miles plus kglcm2 •13. Headlamps alignment } check following) 14. Correct tyre pressures *35. All engine ancillaries-check condition *15. Water hose connections security 36. Master cylinders and actuating mechanisms-check *Fast touring: front-22psi (1.547 kglm2) *37. Vacuum connections on headlamps system-check 2 38. Dynamu rear bearing--lubricate rear-26psi (1.828 kglm ) * Not shown on diagram N.B. Renew air cleaner element EVERY 3,000 MILES (as for 1,500 Miles plus at 12,000 miles following) I 6. Engine sum()-drain and refill *17. Valve clearances • 18. Fan belt tension } check DRAINING • t9. Timing chain tension *20. Sparking plugs-clean, check and reset gaps *21. Heater system and operation of valve-check POINTS 22, Distributor-oil shaft bearing, auto advance mechanism and contact breaker pivot, smear cam Left: shows the location of the radiator with grease, clean and reset points matrix drain tap and right: the cylinder *23. Front wheel alignment-check and reset, if necessary block drain tap 24. Propellor shaft and drive shafts-check tightness of nuts and bolts etc. *25. Road wheels-change round, incorporate spare

RECOMMENDED LUBRICANTS

Component Castro I Esso Mobil Shell B.P.

Engine: Castrol XL Extra 20Wl50 Mobiloil Super X-100 20Wl50 Super Viscostatic 20 W/50

Gearbox Hypoy Light Gear Oil GP80 Mobilube GX80 Spirax BOEP Gear oil SAE8DEP Rear axle AL1763 S&909 X511& Chassis greasing points Castrolease LM Multipurpose Mobilgrease MP Retinax A Energrease L2 Grease

Brakes and Clutch CastrollGirling "Crimson" Hydraulic Fluid or fluid which complies with SAE 70 R3 specification.

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