S11pplemet11 to "Motnr Trader," 4 October /967 Mo1:or Trader SERVICE DATA No. 464 LOTUS ELAN Manufacturers: Lotus Cars 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 engine similar­ contained within the axle casing. ment exclusively to the Lotus routine operations involved in ser­ ities exist. Transmission 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 spring 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 strut 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. Steering is by rack and pinion. 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.