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LOTUS EUROPA
Workshop Manual
LOTUS CARS LIMITED
Norwich Norfolk, Nor. 92W England
Telephone: Wymohdham 3411. Cables: Lotus. NORWICH Telex: 97401
Part No A046T0327Z August 1972 ©
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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.
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CONTENTS
Technical Data Page 9
Chassis A
Body B
Front Suspension C
Rear Suspension D
Engine E
Transmission F
Hubs, Wheels and Tyres G
Steering H
Brakes J
Cooling System K
Fuel System L
Electrical Equipment M
Lubrication and Maintenance O
Heating and Ventilation P
Clutch Q
Exhaust System S
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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 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 body, i.e.
working on the engine, or removing the windscreen, it is recommended that body protection covers be used.
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SECTION CHECK LIST
The number of pages in each Section is correct at: November 1971.
Section Description Number of Pages
TECHNICAL DATA 20
A CHASSIS 9
B BODY 40
C FRONT SUSPENSION 18
D REAR SUSPENS ION 13
E ENGINE 63
F TRANSMISSION 45
G WHEELS, HUBS AND TYRES 9
H STEERING 13
J BRAKI NG SYSTEM 22
K COOLING SYSTEM 10
L FUEL SYSTEM 34
M ELECTRICAL EQUIPMENT 56
O LUBRICATIONS AND MAINTENANCE 13
P HEATING AND VENTILATION 5
Q CLUTCH 10
S EXHAUST SYSTEM 4
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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.
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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
As there are at present 16 different model types, the following codes will be used for model
identification.
VEHICLE IDENTIFICATION (Chassis Numbering)
7001 Denotes year and month of manufacture (1970, January)
01 Denotes the production batch
0001 Denotes the chassis number
P Denotes the model
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' G. Britain & N. Ireland L
Elan +2'S' Export M
Elan +2'S' Federal Export N
Europa G. Britain & N. Ireland P
Europa Export Q
Europa Federal Export R
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TECHNICAL DATA
I NDEX
Description Page
Dimensions 9
Capacities 9
Engine:
General 9
Performance 9
Cylinder Head 10
Camshaft 10
Crankshaft 11
Connecting Rod 11
Gudgeon (Piston) Pin 11
Piston 11
Lubrication 12
Fuel System:
Pump 12
Air Cleaner 12
Carburetters 12
Ignition System:
Ignition Timing 13
Sparking Plugs 13
Distributor 13
Cooling System 13
Clutch 14
Transmission:
Bearings 14
Adjustment 14
Ratios 14
Speedometer Gears 14
Overall Ratios 14
Front Suspension 15
Steering 15
Rear Suspension 15
Brakes 15
Wheels & Tyres 16
Electrical Equipment:
Battery 16
Fuses 16
Alternator 16
Starter 16
Lamp Bulbs 17
Additional Information:
Ignition Distributor (Exhaust Emission) 17
Torque Loading Figures 18
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TECHNICAL DATA
Above image from Motor Magazine 6 Sep 1969. [2]
DIMENSIONS
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 ¼in. (399.4 cm.)
-Width 64½ in. (163.8 cm.)
- Height 42½ in. (107.9 cm.)
Ground clearance (design) 6 ½ in. (16.5 cm.)
Turning circle 44 ft. (13.4 m.)
Kerb weight (unladen) - Series I 1350 lbs. (612 kg.)
- Series II 1566 lbs. (710 kg.)
CAPACITIES
Engine sump (including filter) 7½ 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
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 Exhaust Emission 82 @ 6,000
- Exhaust Emission 80 @ 6,000
Max. Torque @ r.p.m. (all) 79 lbs.ft. (10.92 kg.m.) @ 4,000
Road speed per 1,000 r .p .m. in top gear 17.7 m.p.h. (28.5 k.p.h.)
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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.
Angle of valve seats and faces 45°
Valves - 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.)
- Stem clearance in guide - Inlet .0010/.0018 in. (.025/.045 mm.)
- Exhaust .0016/.0024 in. (.040/.060 mm.)
- 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.)
- Fitted height above head .472 in. (12 mm.)
Camshaft
Number and type of bearings 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.)
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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.)
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Lubrication System
Pump - Type Eccentric rotor
- Drive Skewgear from camshaft
- Inner to outer rotor clearance See Section 'E' (Engine)
Normal pressure (hot) @ 2,000 r.p.m. 30 lbs.in.sq. (2. kg.cm.sq.)
Filter Full - flow ('throw away' canister)
FUEL SYSTEM
Pump operation Mechanical
Air cleaner type Paper element (dry)
Choke control Manual
Carburetter - 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
Carburetter - 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
Type Coil and distributor
Firing order 1,3,4,2
No. 1 cylinder Nearest to clutch
Ignition advance control Centrifugal
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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.)
*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 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
COOLI NG SYSTEM
Type Centrifugal pump and fan
Radiator cap relief valve 7 lbs .in .sq. (.49 kg.cm .sq .)
Thermostat nominal opening temperature 68° C.
Water pump belt tension (at longest run) 09375/.15625 in. (2.3812./3.9687 mm.)
Alternator belt tension (at longest run) .28125/.375 in. (7.1437/9.525 mm.)
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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 withdrawal 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
- 1st. 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
- 1st. 12.851:1
- Reverse 10.964:1
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FRONT SUSPENSION
Type Independent
Spring - 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
Type Rack and pinion
Steering angles - Camber 0° to +- 30'
- Castor 3° +- 30'
- Swivel pin (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
Type Independent
Spring - Number of coils 19½
- 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 3/16 in. (4.76 mm.) to Zero
BRAKES
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 1.5 in. (3.8 cm.)
- Lining material Don. 242
Handbrake type Mechanical, on rear only
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WHEELS AND TYRES
Wheel - Type Pressed steel bolt on
- Size 4½ J
Tyres* - Type Firestone F.100 tubeless or,
Dunlop SP Sport with tubes.
Tyres* - Size 155 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
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.
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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
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
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TORQUE LOADING FIGURES
ENGINE lbs .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
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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,
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. [JJ]
[2] Not in original manual. Added for clarification [JJ]
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