LOTUS EUROPA S1/S2 WORKSHOP MANUAL

Technical Specifications Section

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Description
Introduction
Dimensions
Fluid Capacities
Engine
Fuel System
Ignition System
Cooling System
Clutch
Transmission
Steering
Front Suspension
Rear Suspension
Brakes
Wheels and Tyres
Electrical Equipment
Additional Information (Emissions)
Torque Loading Figures
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INTRODUCTION - Section Menu

    This Workshop Manual 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 above are distinguished by a reference letter, this letter being the same as is used in other service publications (i.e., Section A is the chassis in both the Workshop Manual and the Parts Lists). Each section thus referred to opens with a contents page so that any particular operation can be easily located. Selecting the link above will open the proper section in your browser.

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.

    This electronic copy is not guaranteed to be up to date.

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

    Your attention is invited to Section 'O' of this manual for the Factory approved recommended lubricants and intervals of Periodical Maintenance.

    Frost Precautions

    Your attention is directed 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 body, i.e. working on the engine, or removing the windscreen, it is recommended that body protection covers be used.

Section Check List

    ***Section deleted due to non-applicability to electronic version***

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.

    ***Table deleted due to non-applicability to electronic version***

VEHICLE IDENTIFICATION (Chassis Numbering)

    Commencing at the 1st of January 1970, a new format 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)
         01           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.
      Model                 Style           Market                       Suffix
      -----                 -----           ------                       ------
     Elan STD		Coupe           G. Britain & N. Ireland		A
     Elan STD		Coupe           Export				B
     Elan STD		Convertible	G. Britain & N. Ireland		C
     Elan STD		Convertible	Export				D
     Elan S/E		Coupe		G. Britain & N. Ireland		E
     Elan S/E		Coupe		Export				F
     Elan S/E		Convertible	G. Britain & N. Ireland		G
     Elan S/E		Convertible	Export				H
     Elan Federal		Coupe		Export				J
     Elan Federal		Convertible	Export				K
     Elan +2'S'		Coupe		G. Britain & N. Ireland         L
     Elan +2'S'		Coupe		Export				M
     Elan +2'S' Federal	Coupe		Export 				N
     Europa			Coupe		G. Britain & N. Ireland		P
     Europa			Coupe		Export				Q
     Europa Federal		Coupe		Export				R
    

    TECHNICAL DATA

    Click For Full Size Image
    Above image from Motor Magazine 6 Sep 1969. [2]

    DIMENSIONS - Section Menu

        
      Wheelbase				91 in.    (231 1 cm.)
      Track (at wheel hub)  - Front		53 in.    (134.6 cm.)
      		      - Rear		53 in.    (134.6 cm.)
      Overall 	      - Length		157 in.  (399.4 cm.) 
                            - Width		64 in.   (163.8 cm.)
      		      - Height		42 in.   (107.9 cm.)
      Ground clearance   			6  in.   (16.5 cm.)
      Turning circle				44 ft.    (13.4 m.)
      Unladen weight        - Series I 	1350 lbs. (612 kg.)
      		      - Series II	1566 lbs. (710 kg.)
      

    CAPACITIES

      Engine sump (including filter)		7 pints (4 litres; 9 U.S. pints)
      Transmission				3 pints (1.75 litres; 3.6 U.S. pints)
      Coolant (with heater)			18 pints (10.3 litres: 21.6 U.S. pints)
      Fuel					6 gallons (27 litres; 7.2 U.S. gallons)
      

    ENGINE - Section Menu

      General

        Number of cylinders			4
        Capacity - Non Exhaust Emission		89.7 cu. in. (1470 cc.)
        	 - Exhaust Emission             95.5 cu. in. (1565 cc.)
        Stroke 	 - Non Exhaust Emission		3.189 in. (81 mm.) 
        	 - Exhaust Emission		3.307 in. (84 mm.)
        Bore	 - Non Exhaust Emission		2.992 in. (76 mm.)
        	 - Exhaust Emission		3.032 in. (77 mm.)
        Compression ratio (all) 		10.25:1
        

      Performance

        Max. BHP @ r.p.m. - Non Emission     	82 @ 6,000 
        		  - Emission		80 @ 6,000
        Max. Torque 				79 lbs.ft. (10.92 kg.m.) @ 4,000
        Road speed/1K RPM in top		17.7 m.p.h. (28.5 k.p.h.)
        

      Cylinder Head

        Material 				Aluminium
        Valve timing 	- Inlet opens 		35 B.T.D.C.
        		- Inlet closes 		65 A.B.D.C.
        		- Exhaust opens		65 B.B.D.C.
        		- Exhaust closes	35 A.T.D.C.
        Valve seats/face angle			45
        Head diameter	- Inlet			1.476 in. (37.5 mm.)
                       	- Exhaust		1.220 in. (31 mm.)
        
        Stem diameter 	- Inlet			.315 in. (8 mm.)
        		- Exhaust		.315 in. (8 mm.) 
        Guide Clearance	- Inlet			.0010/.0018 in. (.025/.045 mm.)
                        - Exhaust		.0016/.0024 in. (.040/.060 mm.)
        Rocker Clearance (cold) 		
        		- Inlet 		.008 in. (.20 mm.)
        		- Exhaust		.010 in. (.25 mm.)
        Valve springs 	- Type			Helical, double
        -Free length	- Inner			1.492 in. (37.89 mm.)
        		- Outer			1.929 in. (49 mm.)
        Valve guides 	
        -Length		- Inlet			1.968 in. (50 mm.)
        		- Exhaust		1.968 in. (50 mm.)
        		- Height above head	.472 in. (12 mm.)
        

      Camshaft

        Bearing #/Type				4/white metal
        Journal diameter			1.653 in. (42 mm.)
        Bearing running clearance		.001/.0029 in. (.025/.075 mm.)
        End float				.002/.0047 in. (.05/. 12 mm.)
        Tappets		- Standard		.473 in. (12 mm.)
        	 	- Oversize		.480 in. (12.2 mm.)
        Drive		- Type			Chain
        		- Number of pitches	72
        		- Length (of pitch)	.375 in. (9.525 mm.)
        		- Width (of pitch)	.225 in. (5.72 mm.)
        

        Crankshaft

        Diameter	- Main journals		2.158 in. (54.8 mm.)
        		- Crankpin		1.890 in. (48 mm.)
        End float	- Dimension		.002/.009 in. (.05/.23 mm.)
        		- Controlled by		Thrust washers on centre main bearing
        Bearings	- Number		5
        		- Type			Aluminium lead, thin wall 
        		- Running clearance	.0015/.0031 in. (.038/.079 mm.)
        Maximum undersize for regrind		.02 in, (.50 mm.)
        

      Connecting Rod

        Type					'H' section
        Material				Steel forging
        Distance between centres		5.363 in. (13.62 cm.)
        Bearings 	
        		- Type			Aluminium Lead, thin wall
        		- Running clearance	.0007/.0028 in. (.017/.058 mm.) [1]
        		- Side clearance	.012/.022 in. (.310/.572 mm.)	
        

      Gudgeon (Piston) Pin

        Location				Force fit in connecting rod
        Diameter				.787 in. (20 ram.)
        Class of fit	
        		- In piston		.0001/.0003 in. (.003/.009 mm.) 
        		- In connecting rod	.0007/.0015 in. (.020/.041 mm.)
        

      Piston

        Type		 			Solid skirt
        Material				Aluminium
        No. of rings 	- Compression		2
        		- Oil control 		1
        Piston clearance in cylinder liner	Matched piston and liner sets
        

      Piston rings

        Gap in liner (fitted)
        		- Compression		.009/.015 in. (.25/.40mm.)
        		- Oil control		.009/.015 in. (.25/.40 mm.)
        
        Groove clearance
        		- Compression		.0019/.0029 in. (.05/.075 mm.)
                        - Oil control		.0005/.0023 in. (.015/.06 mm.)
        
        Width 			
        		- Compression		.078 in. (2 mm.)
        		- Oil control		.157 in. (4 mm.)
        

      Lubrication System

        Pump	
        		- Type			Eccentric rotor
        		- Drive 		Skewgear from camshaft
        
        Normal pressure (hot) 
        		-2,000 r.p.m.		30 lbs.in.sq. (2. kg.cm.sq.)
        
        Filter					Full - flow ('throw away' canister)
        
        For inner/outer rotor clearance, See Workshop Section 'E' (Engine)
        
      FUEL SYSTEM - Section Menu
        Pump operation				Mechanical
        Air cleaner type			Paper element (dry)
        Choke control				Manual
        
        Carburetor - Non Exhaust Emission:
        	
        Type					Solex 35 DIDSA 2 (twin choke)
        Slow running speed			900-1,000 r.p.m.
        
        					Primary	  Secondary 
        Choke					26	  26
        Main jet				145	  140
        Air correction jet			135	  150
        Accelerator pump jet			40	  Nil 
        Power jet				Nil	  80/270
        Inner venturi				28	  32
        
        Carburetor - Exhaust Emission:
        
        Type					Solex 26 - 32 DIDSA 5 (twin choke)
        Slow running speed			1,000 +/- 50 r.p.m.
        
        					Primary   Secondary
        Choke					23.5      27
        Main jet				120       142.5
        Air correction jet			125 	  125
        Slow running jet			60	  95
        
      IGNITION SYSTEM - Section Menu
        Type					Coil and distributor
        Firing order				1,3,4,2
        No. 1 cylinder		                Nearest to clutch
        Ignition advance control		Centrifugal
        
        Ignition timing (static)
        	Non Exhaust Emission		4 B.T.D.C.
        	Exhaust Emission		T.D.C.
        
        Coil					Ducellier 2765 A
        Sparking plugs	- Type*			Marchal 34 HS
        		- Gap			.023 in. (.584 mm.)
        (Alternates: Champion N4, Champion N7Y or Autolite AG22 may be used w/same gap)
        

        Distributor

          Type					Ducellier 4 cylinder
          Drive					Skew gear from camshaft
          Direction of rotation (from above)	Anti-clockwise
          Contact breaker gap 			.016/.019 in. (.40/.50 mm.)
          Cam dwell angle				61 +- 3
          Firing angles				0, 90, 180, 270 +- 1
          

        Centrifugal advance

          (Non Exhaust Emission):               	Distributor		Distributor
          			   		r.p.m.			degrees B.T.D.C.
                                        	Below	550			No advance
          					920			7.8
          					1,000			8.0
          					2,000			13.0
          					3,000			18.0
          

        Vacuum advance

          (Non Exhaust Emission):
          
          					Distributor		Vacuum
          		      		     	degrees B.T.D.C.        Hg. inches
          					1.5			3.937
          					4.6                     7.874
          					6.5			11.811
          					7.0			15.748
          
      COOLING SYSTEM - Section Menu
        Type					Centrifugal pump and fan
        Radiator cap relief valve		7 lbs .in .sq. (.49 kg.cm .sq .)
        Thermostat nominal temperature		68 C.
        Water pump belt tension 		09375/.15625 in. (2.3812./3.9687 mm.)
        Alternator belt tenslon 		.28125/.375 in. (7.1437/9.525 mm.)
        (both at longest run)
        
      CLUTCH - Section Menu
        Make and type				Ferodo 200 D, diaphragm spring
        Operation				Cable
        Driven plate diameter			7.875 in. (20 cm.)
        Clutch assembly adjustment		See Workshop Manual Section 'Q' (Clutch)
        Free movement at withdrawal lever	.078/.125 in. (2/3 mm.)
        
      TRANSMISSION - Section Menu
        Type					4 forward speeds, all synchromesh and reverse
        
        Bearings	
        	- Mainshaft			Taper rollers
        	- Secondary gear cluster	Taper rollers
        
        Bearings adiustment			See Workshop Manual Section 'F' (Transmission) [Dial-up]
        
        Gear ratios - Top			1.03:1
        	    - 3rd.			1.48:1
        	    - 2nd.			2.25:1
        	    - 1st.			3.61:1
        	    - Reverse			3.08:1
        
        Final drive:
        
        Type					Hypold gear
        	
        Bearings 	
        	    - Pinion 			Taper rollers
        	    - Diff./crown wheel:	Taper rollers
        
        Bearings adjustment
        	Pinion bearing pre-load		See Workshop Manual Section 'F' (Transmission) [Dial-up]
        	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
        		- 1st.			12.851:1
        		- Reverse		10.964:1
        
      FRONT SUSPENSION - Section Menu
        Type					Independent
        
        Springs
        		- Number of coils	17
        		- Wire diameter		.348 in. (8.83 mm.)
        	        - Length	
        			- Free		12.75 in. (32.38 cm.)
        			- Fitted	7.75 in. (19.68 cm.)
        
        		- Rate			100 lbs.in. (1.15 kg.m.)
        
        Front hub end float			.002/.004 in. (.05/.10 mm.)
        
      STEERING - Section Menu
        Type					Rack and pinion
        
        Steering angles	
        		- Camber 		0 to +- 30'
        		- Castor		3 +- 30'
        		- Swivel(kpi)		9 +- 30'
        
        Toe - in				3/16 in. (4.76 mm.) to 1/16 in. (1.6 mm.)
        Condition for checking toe - in		6t in. (16.5 cm.) ground clearance
        					at bottom of chassis closing plate.
        
      REAR SUSPENSION - Section Menu
        Type					Independent
        Spring 		- Number of coils 	19 
        		- Wire diameter      	.329 in. (8.35 mm.)
        		- Length 	
        			- Free		16.2 in. (41.15 cm.)
        			- Fitted	10.4 in. (26.42 cm.)
        		- Rate			72 lbs.in. (.83 kg.m.)
        
        Wheel camber				0 to 2 Negative
        Toe - in				Zero to 3/16 in. (4.76 mmm.) 
        
      BRAKES - Section Menu
        Make and type				Girling hydraulic (servo optional)
        Front brakes	
          		- Disc diameter		9.75 in. (24.76 cm.)
        		- Pads material		Ferodo DS.31
        
        Total disc run out			.004 in. (.10 mm.)
        
        Rear brakes 	
        		- Drum dia. and width	8 in. (20.3 cm.) x 1.25 in. (3.175 cm.) [3]
        		- Lining material	Don. 242
        
        Handbrake type				Mechanical, on rear only
        
      WHEELS AND TYRES - Section Menu
        Wheel		
        		- Type			Pressed steel bolt on
        		- Size			4J
        
        Tyres*		
        		- Type			Firestone F.100 tubeless or,
        					Dunlop SP Sport with tubes.
        
        Tyres* 	
        		- Size			155-80 x 13
                    	*If inner tubes are fitted, it is essential that these are of the
        		correct type for radial ply tyres.
        
        
        Tyres		
        		- Pressure (cold):	At speeds BELOW		At sustained speeds
        					100 mph (160 kph)	ABOVE 100 mph (160 kph)
        		- Front			18 lbs.in.sq.		24 lbs.in.sq.
        					(1.27 kg.cm.sq .)	(1.69 kg.cm.sq.)
        		- Rear			28 lbs.in.sq.		34 lbs.in.sq    
               					(1.97 kg.cm.sq.)        (2.39 kg,cm.sq.)
        
      ELECTRICAL EQUIPMENT - Section Menu
        Battery
        
        	Type				Exide 6 VTA 29 L
        	Capacity @ 20 hr. rating		39 amp.hr.
        	Voltage and polarity			12 volt negative earth
        
        Fuses
        		Quantity and rating	2, 35 amp.
        
        Alternator
        		Type			SEV/Motorola A. 1230
        
        	Nominal system voltage			12
        	Charging voltage			13.2
        	Maximum output (hot)			30 amps. @ 3,000 r.p.m.
        	Control box type			SEV/Motorola E.144
        	Field coil resistance			5.2 +- .2 ohms. @ 25 C. measured
        						across slip rings
        Starter
        		Type			Paris-Rhone D.8 E 49
        		Drive			Pre - engaged
        		Lock torque		8 lbs.ft. (1.1 kg.m.) @ 355 amps.
        
        
        Lamp Bulbs (all 12 volt)
        	Headlamp	- RHD, LHD		410 (45/40W) with 989 (6W) pilot
        			- France		411 (45/40W) with 989 (6W) pilot 
        			- North America		Sealed beam unit
        
        	Front and rear indicators		382 (21W)
        	Indicator repeater			501 (5W 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 - Section Menu
        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			Vacuum
        	degrees B .T.D.C.		Hg. milllmetres
        	1.3				100
        	3.3				150
        	4.5				200
        	5.6				250 
        	6.5				300
        	7.0				350 Maximum advance
        
        
      TORQUE LOADING FIGURES - Section Menu

        ENGINE

          					lbs .ft.	kg.m.
          Cylinder head 
          	- tighten cold 			54 - 60		7.46 - 8.29
          (See also Section ' E')
          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
          

        TRANSMISSION

          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
          

        REAR SUSPENSION

          					lbs.ft.		kg.m.
          Lower link pivot bracket		18 -23		2.48 - 3.18
          

        HUBS

          Brake disc to 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,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] Corrected .0228 to .0028. [JJ]
    [2] Not in original manual. Added for clarification. [JJ]
    [3] Changed from "1.5 in. (3.8 cm.)" to correct original manual error. ( [JJ]

    Other Notes: [edit]
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    Please be courteous with what you post, and do not erase someone else's work.

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