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Lotus Service Notes
Introduction
CONTENTS
ESPRIT RANGE ’93 M.Y. ONWARDS
Section Technical Data
- Engine
- 4 cylinder - V8
TDI TDK TDJ
- Vehicle Body Fittings
BL
Front Suspension
CF
Rear Suspension
DF
Engine
EF ED
- 4 cylinder - V8
Engine Management * see separate publication D082T0327J
- 4 cylinder
EMH*
- V8
EMM~
~ see separate publication L082T0327J Transmission
FG
Wheels & Tyres
GE
Steering
HD
Brakes - 4 cylinder with Delco Moraine ABS IIIA † see separate publication G082T0327J - V8 with Kelsey Hayes ABS 415 ^ see separate publication M082T0327J
JF†
Cooling
KE
Fuel System
LK
Electrics
ML
Maintenance & Lubrication
OF
Air Conditioning, Heating & Ventilation
PJ
Clutch
QE
Supplementary Inflatable Restraint
WA# WC#
- driver only - dual # see combined publication (WA & WC) J082T0327J
JG^
Page 1
Lotus Service Notes
Introduction
VEHICLE IDENTIFICATION NUMBER & ENGINE NUMBER The Vehicle Identification Number (VIN) is stamped onto the chassis frame on the vertical surface of a flange between the inboard pivots of the right hand front suspension lower wishbone, viewable via the right hand front wheelarch. The engine number on 4 cylinder cars is stamped onto a horizontal surface at the right hand rear of the cylinder block, and on V8 models on a vertical flange at the left hand rear of the cylinder block. Both VIN and engine numbers are duplicated on bar code labels fixed to the front bulkhead in the front luggage compartment, and on some vehicles the VIN is repeated for convenience on a label viewable through the windscreen. Both numbers should always be quoted with any vehicle enquiries, as Factory records are filed against VIN, and specification change points are identified by VIN or engine number. The vehicle licence number may not accurately reflect vehicle age, and may be changed during the car’s life, and are an unreliable method of identification.
V.I.N. ON CHASSIS
4 CYL. ENGINE NUMBER
oh26
V8 ENGINE NUMBER (viewed from beneath)
intro_03
RHD V.I.N. USA V.I.N. Non-USA V.I.N. LHD V.I.N.
RHD V.I.N. e93
Page 2
Engine number intro5c
Lotus Service Notes
Introduction
There are three variations of the VIN; prior to '98 M.Y. there is one for domestic and non-USA export markets, which complies with European Economic Community (EEC) directives; and one for the USA which complies with requirements laid down by the National Highway Traffic Safety Association (NHTSA). From '98 M.Y. a common coding is used. The seventeen characters of the VIN are coded as follows: NOTES 1. Prior to '98 M.Y., different S4 prior to '95 M.Y.: S4 '95 M.Y. & GT3: S4S USA: S4S non-USA: Sport 300: Esprit V8: 2.
serial number sequences are used for the the following variants: 0001 to 0010, then 1011 onwards 2000 onwards 3000 onwards 4000 onwards 8001 onwards 5009 onwards
For change point identification in this manual, only VIN characters 10 (model year) and 14 to 17, (serial number) will be listed. e.g.: R 1242 (’94 model year S4, serial 1242) R 8030 (’94 model year Sport 300, serial 8030)
Non-USA Prior '98 M.Y.
Manufacturer Identifier Code
Engine Type 910 = 2.2 Turbo 920 = 2.0 Turbo 918 = 3.5 V8
Plant H=Hethel
123456789012345678901 123456789012345678901 123456789012345678901 123456789012345678901123456789012345678901 123456789012345678901 123456789012345678901 123456789012345678901 123456789012345678901 123456789012345678901 123456789012345678901 123456789012345678901 S C C 123456789012345678901 123456789012345678901 123456789012345678901123456789012345678901123456789012345678901 123456789012345678901 123456789012345678901 123456789012345678901 123456789012345678901 1 2 3 4 5 6 7 8 9 123456789012345678901 123456789012345678901 123456789012345678901 123456789012345678901 123456789012345678901123456789012345678901 123456789012345678901123456789012345678901 123456789012345678901
Vehicle Type 082 = Esprit Turbo
12345 12345 12345 12345 12345 12345 12345 10 12345 12345 12345
Model Year P = 1993 R = 1994 S = 1995 T = 1996 V = 1997 W = 1998 X = 1999 Y = 2000
123456 123456 123456 123456 123456 123456 123456 11 123456 123456 123456
Engine Emission Spec. 1 = Europe 6 = USA 50 State
123456 123456 123456 123456 123456 123456 123456 123456 123456 123456123456 123456 123456 123456 12 13 123456 123456 123456 123456123456 123456
123456 123456 123456 123456 123456 123456 123456 14 123456 123456 123456
Chassis/Body A = RHD B = LHD F = LHD
Model 1 = S4 2 = 95MY & GT3 3 = 95½MY 4 = S4S 5 = V8 8 = S300
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Serial Number
Page 3
Lotus Service Notes
Introduction
USA Prior '98 M.Y. Option 3 = A.C. + PAS 5 = PAS
Manufacturer Identifier Code
Engine 0 = 2.2 Turbo 3 = 3.5 Turbo 4 = 2.0 Turbo
Assembly Plant H = Hethel B = Shah Alam
Check Digit
Engine Emission Spec. 6 = USA 50 State Serial Number
123456789012345678901 123456 123456789012345678901 123456 123456789012345678901 123456 123456789012345678901 123456 S C C 123456789012345678901 123456789012345678901123456 123456 123456789012345678901 123456789012345678901 123456 1 2 3 123456 4 123456789012345678901 123456789012345678901123456 123456
Vehicle Type F = Esprit Turbo
123456 123456 123456 123456 123456 123456 123456 123456 5 123456 123456
Series D=4 E = V8
123456 123456 123456 123456 123456 123456 123456 123456 6 123456 123456
123456 123456 123456 123456 123456 123456 123456 123456 7 123456 123456
123456 123456 123456 123456 123456 123456 123456 123456 8 123456 123456
1234567 1234567 1234567 1234567 1234567 1234567 1234567 1234567 9 1234567 1234567
Restraint A = Active belts B = Driver SIR + Active belts C = Dual SIR + Active belts
123456 123456 123456 123456 123456 123456 123456 123456 10 123456 123456
123456 123456 123456 123456 123456 123456 123456 123456 123456 123456123456 123456 123456 123456 123456 11 123456 12 123456 123456123456 123456
Model Year P = 1993 R = 1994 S = 1995 T = 1996 V = 1997
123456 123456 123456 123456 123456 123456 123456 123456 13 123456 123456
123456 12345678901234567890 123456 12345678901234567890 123456 12345678901234567890 123456 12345678901234567890 123456 12345678901234567890 123456 12345678901234567890 123456 123456 12345678901234567890 14 12345678901234567890 15 16 17 123456 123456 12345678901234567890 12345678901234567890
Chassis/Body A = RHD catalyst B = LHD catalyst F = LHD catalyst D = RHD non cat H = LHD non cat
Model 1 = S4 2 = 95MY>3 3 = 95½MY 4 = S4S 5 = V8 8 = S300
'98 M.Y. onwards
Manufacturer Identifier Code
123456789012345678901 123456 123456789012345678901 123456 123456789012345678901 123456 123456789012345678901 123456789012345678901 123456 S C C 123456 123456789012345678901 123456 123456789012345678901 123456 123456789012345678901 123456 1 2 3 4 123456789012345678901 123456 123456789012345678901 123456789012345678901123456 123456
Engine Type B = 910; 2.2 4 cyl Turbo D = 918; 3.5 V8 Turbo E = 920; 2.0 4 cyl Turbo
Vehicle Type 082 = Esprit Turbo
123456 123456 123456 123456 123456 123456 123456 123456 5 123456 123456 123456
Check Digit
12345678901234567890 12345678901234567890 12345678901234567890 12345678901234567890 12345678901234567890 12345678901234567890 12345678901234567890 12345678901234567890 6 7 8 12345678901234567890 12345678901234567890 12345678901234567890
123456 123456 123456 123456 123456 123456 123456 123456 9 123456 123456 123456
Assembly Plant H = Hethel B = Shah Alam
12345 12345 12345 12345 12345 12345 12345 10 12345 12345
123456 123456 123456 123456 123456 123456 123456 123456 11 123456 123456 123456
Model 1 = Esprit V8 2 = Esprit S4, GT3 5 = Esprit S4S
123456 123456 123456 123456 123456 123456 123456 123456123456 123456 123456 123456 123456 123456 123456 123456 12 13 123456 123456 123456 123456123456 123456
Restraint A = Active belts B = Driver SIR + Active belts C = Dual SIR + Active belts
Model Year W = 1998 X = 1999 Y = 2000
Engine Equipment B = PAS N = PAS & A.C.
Engine Type No. 910 = 2.2 Turbo 920 = 2.0 Turbo 918 = 3.5 V8
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Chassis/Body A = LHD USA B = LHD Canada C = RHD D = LHD Other
Serial Number
Engine Number Coding
Market C = Domestic F = Sweden/Aus/Swit H = Canada/USA 49 J = California L = USA 50/ 91.441 EEC/Japan
Page 4
Year & Month of Manufacture Serial Number
Variant (4 cyl) C = C/cooler S = Sport 300 T = S4S (285)
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123456 123456 123456 123456 123456 123456 C 123456 123456
Lotus Service Notes
Introduction
JACKING POINTS 1.
Four body jacking points are provided on the car; one just ahead of each rear wheelarch, and one just behind each front wheelarch. Each of these jacking points is provided with a vertical locating tongue designed to engage with a trough in the vehicle wheel changing jack. Do not jack under any other part of the body, or attached panels.
2.
Jacking beneath the chassis may be carried out; Front - beneath either side of the chassis main front crossmember, adjacent to the lower wishbone rear pivot points. Rear - beneath the lower link inboard pivot points.
Jacking points
ESPRIT MODEL HISTORY - ’93 M.Y. ONWARDS (Excluding ’93 M.Y. USA) ’93 Model Year Introduction: March ‘93 Esprit S4 (U.K. & Export, not USA); VIN: P 0001 to 0010, 1011 onwards As ’92 M.Y. Chargecooler specification with following changes: Restyled front bumper and spoiler, bonnet, sills, rear aerofoil, transom spoiler, rear valance. Power steering. Front suspension geometry altered with provision for camber adjustment. Rear suspension camber changed, with provision for adjustment. 17 inch Lotus styled 5-spoke alloy wheels, with 215/40 ZR17 (front) and 245/45 ZR17 (rear) Goodyear Eagle GS-A tyres. New door window lift mechanism, incorporating ‘one touch’ and obstruction sensing. New door lock mechanism and CDL, with single key operation of vehicle locks. Megamoss vehicle alarm includes ‘deadlocking’ and engine crank immobilisation. Restyled interior including; fascia, crash pad and glovebox lid, seat upholstery, instrument layout and carbon fibre look-alike masks, centre console and tunnel trim, door panels, steering wheel. Elan type front side/turn lamps, new front fog lamps and interior lamp, electric vacuum pump, tailgate mounted radio aerial. Revised ‘High Torque’ RH shift transmission. New wheel changing scissor jack.
Page 5
Lotus Service Notes
Introduction
Sport 300: June ‘93 U.K. & Export (not USA) VIN: P 8001 As Esprit S4 specification with following changes: Lightweight body, bonded-in roof, scuttle brace, enlarged wheel housings with wheelarch extensions, ’92 style front bumper/spoiler, fog lamp recesses now brake cooling ducts, ’92 style rear bumper, valance and sills. New rear aerofoil. Reinforced chassis, bolt-in engine bay brace, roll cage mountings. 300 bhp engine with T3/T4 turbocharger, increased boost pressure, recalibrated ECM, larger inlet valves and ports, raised fuel pressure, combined chargecooler rad./condenser on non a.c. cars. Lotus limited slip differential, uprated clutch cover and flywheel. Revised front and rear suspension springs and dampers. Larger front and rear brakes, with AP Racing 4-piston calipers and ventilated discs at all four wheels. Separate parking brake calipers. 3-piece O.Z. wheels with 245/45 ZR16 (front) and P315/35 ZR17 (rear) Goodyear Eagle GSC tyres. Alcantara interior trim, Senotex instrument masks, larger tachometer and electronic speedometer moulded bucket seats, anti-slip pedal pads, individually numbered header rail plaque. ’94 Model Year Introduction: July ‘93 Esprit S4 (U.K. & Export inc. USA); VIN: R 1090 Sport 300 (U.K. & Export, not USA); VIN: R 8012 U.K. and Export S4 and Sport 300 unchanged. USA S4 introduced with following changes from U.K./Export spec.: Different window lift motors with no ‘one touch’ or obstruction sensing. Dual S.I.R. for USA and LHD Export: September ‘93 Esprit S4 (USA & LHD Export); VIN: R 1163 Introduced as legal requirement for USA cars, and as option in some LHD markets. S.I.R. equipment as driver only S.I.R. with following changes: Passenger side inflator module mounted in place of glovebox. Passenger side knee bolster. New DERM and dual pole arming sensor. Revised Wiring Harness: December ‘93 Esprit S4 LHD; VIN: R 1242 Esprit S4 RHD; VIN: R 1250 Sport 300; VIN: R 8030 As previous with following changes: Wiring harnesses rationalised. Electrical components resited inc. engine bay components to RHR wheelarch. Addition of sensing switches to front bonnet and tailgate for alarm and illumination. Addition of front luggage compartment lamp, and ‘lights on’ buzzer (non-USA). New type inertia switch RHF engine bay, and Elan type electric aerial for some markets, LHR quarter. New engine coolant header tank, with incorporation of chargecooling system. Brembo Brakes: June '94 Esprit S4 Non-USA; VIN: R 1443 (+ R 1377) July '94 Esprit S4 USA; VIN: S 1391 June '94 (Not applicable to Sport 300) Introduction on USA cars coincides with intro. of otherwise unchanged '95 M.Y. USA S4. Changes include the following: Front brakes; four piston calipers and larger discs. Rear brakes; new calipers and larger venti lated discs. Rear circuit pressure limiting/proportioning valve deleted. Revised front hubs and rear hub carriers. 16" spare wheel supplied to clear new brakes. Page 6
Lotus Service Notes
Introduction
'95 M.Y. S4 & S4S: January '95 S4 (non-USA); VIN: S 2000 (+ 1496) S4S (USA); VIN: S 3000 S4S (non-USA) VIN: S 4000 As previous with following principal changes: Caerbont instruments with 100 mm speedo & tacho, analogue clock. Oil temp. gauge and ice detection deleted. Footwell lamps added. Revised trim stitching. Walnut veneer replaces 'carbon fibre' instrument panel and door finishers. Sport 300 style seats on non-USA S4S. S4S: 285 bhp engine with revised turbo, inlet valves & ECM. Uprated clutch cover. Non-USA S4S: Enlarged body wheelhousings, wheelarch spats, Sport 300 rear aerofoil. Non-USA S4S: Wider O.Z. Futura 3-piece wheels with Michelin 235/40 ZR17 front & 285/35 ZR18 rear tyres. Revised springs & dampers. USA S4S: O.Z. Futura 3-piece wheels in unchanged size with unchanged Goodyear tyres. Non-USA S4S: Uprated chassis with reinforced backbone & revised rear spring platforms. Introduction of 'CFC Free' R134a Air Conditioning System: March 1995 S4; VIN: S 2031 (RHD) S 2017 (LHD) S4S (non-USA); VIN: S 4035 (RHD) S 4006 (LHD) S4S (USA); VIN: S 3012 Sport 300; VIN: S 8059 Changes include the following: New compressor with high pressure relief valve incorporated on rear cover; service Shraeder valves replaced by snap connectors in the suction and disharge hoses. Square shaped parallel flow condensers (2 off) mounted side by side and plumbed in parallel. New separate chargecooler radiator. Receiver-drier with changed molecular sieve material. New hoses and pipework for increased permeability gas. Commonised Undertray: May '95 S4; VIN: S 2034 USA S4S; VIN: S 3095 Body lower moulding commonised with non-USA S4S (enlarged wheelhousings) '96 M.Y. S4 & non USA S4S: September '95 S4; VIN: T 2044 non-USA S4S; VIN: T 4126 (+ 4096) Sport 300; VIN: T 8064 Specification unchanged. Note that no '96 M.Y. USA cars were built. Esprit V8: May '96 Esprit V8; VIN: T 5009 As S4S with following principal changes: New Lotus type 918 3.5 litre twin turbo V8 engine. No chargecooling. Lotus/Vertronix engine management. Kelsey-Hayes ABS-415 antilock brake system. Chassis modifications to accommodate engine and exhaust system. Cooling system includes recirculation pump and diverter valve. Larger capacity 'pull-type' clutch. Type UN1 027 transmission with higher 5th ratio and reverse gear brake. New one piece road wheels and restyled front spoiler. New variable displacement a.c. compressor. Esprit GT3: October '96 Esprit GT3; VIN: T 2100 (not USA) Based on S4 model with following changes: 2 litre (type 920) 250 bhp engine. Page 7
Lotus Service Notes
-
Introduction
No back pressure valve or throttle jack. No tailgate mounted aerofoil. Swiss type rear transom spoiler lip. Single fuel filler on LH side. GT3 decals along door bottoms. Sport 300 type seats with backs painted body colour. Cloth/vinyl interior trim. Senotex instrument masks. Body colour composite gear lever shroud. Aluminium gear lever knob. Optional panel lamps rheostat; alarm; door edge, bonnet and footwell lamps; lights on buzzer; one touch windows.
'97 M.Y. Esprit V8 & GT3: May '96 USA V8; VIN: V 5075 (May '96) Non USA V8; VIN: V 5215 (Oct. '96) GT3; VIN: V 2111 (Oct. '96) Specification unchanged. Introduction of V8 Twin Plate Clutch: February '97 Esprit V8; VIN: V 5280 Many cars also retro-fitted. New lightweight flywheel, low inertia twin plate clutch assembly, cast iron clutch housing, pedal downstop, re-calibrated ECM. '98 M.Y. Esprit V8 & GT3: October '97 Esprit V8; VIN: W 5408 plus 5374, 5382, 5385 GT3; VIN: W 2200 plus 2192 As previous with following principal changes: Restyled interior with compact instrument binnacle, new centre console and tunnel top. Four instrument set, new tell tale clusters, Elise style push switches. Deletion of boost and oil temperature gauges and time clock. Cobra 6422 security system with remote operation. Revised interior climate control system, with rotary selector switches and electro-pneumatic flap operation. Stepper motor water valve. New face level vents. Separate re-circulation switch. New windscreen wiper arm, washer bottle and pump. V8: Restyled rear aerofoil mounted on tailgate. Locking gas strut for tailgate. V8: New low effort clutch release system with new hydraulic cylinders and rigid pipe. Revised clutch fork and stiffer alloy clutch housing. V8: Revised twin cable gearchange mechanism dispenses with translator. Modified transmission selector cross shaft. Adopted on GT3 together with lower final drive and lower 3rd gear in June '98 at VIN W 2272. New Kelsey-Hayes EBC 430 anti-lock brakes electro-hydraulic control unit. Single fuel filler. Esprit V8-GT: January '98 Esprit V8-GT; VIN: W 5442 As Esprit V8 with following principal changes: No rear aerofoil. Long type rear body spoiler. Matt vinyl interior trim. No a.c. (compressor retained for belt routing). V8-GT decal in rear quarter windows. Esprit Sport 350: October '98 Sport 350; VIN: W 5603 Limited edition of 50. As Esprit V8-GT with following principal changes: (Esprit V8 adopts V8 S.E. moniker to aid identification) Lightweight handlay lower body half (except S.I.R. cars). Carbon fibre 'GT1' style rear aerofoil with alloy end plates. Sculpted alloy mounting plinths. Page 8
Lotus Service Notes
-
Introduction
Increased wall thickness chassis tubes around engine bay. Re-calibrated ECM with re-profiled boost curves. Blue painted plenum and cam covers. Front spoiler extension skirt and rubber lip. New Aluminium body colour with 'Sport 350' graphics on doors and sill treadplates. Blue decal tape in sill ducts and radiator air intake. Grilles in front valance coloured titanium. Magnesium 'Crono' O.Z. wheels in charcoal, with Pirelli P Zero tyres, marginally wider on rear. Larger A.P. Racing discs with curved vanes and cross drilling on both front and rear. A.P. Racing 4-pot alloy front calipers, finished in blue with 'Lotus' lettering. Seats with increased lateral support on cushion and backrest. Seat facings in blue Alcantara. Centre console, instrument binnacle, gear lever tray & lower switch panel in satin finish carbon fibre. HRS switch moved to upper switch row. Blue Alcantara door insert panels with body colour feature strips. Anodised aluminium instrument mask, gear lever knob & gear lever gaiter ring. Aluminium plaque on windscreen landing with limited edition no. Drilled alloy pads on brake & clutch pedals. Monroe N65 dampers and stiffer springs front & rear. Uprated anti-roll bar.
'99 M.Y. Esprit V8 S.E., V8-GT, Sport 350 & GT3: November '98 V8 models; VIN: X 5657 GT3; VIN: X 2287 Non-USA models unchanged. USA only: Revised evaporative emission system. Anodised aluminium instrument mask, gear lever knob & gear lever gaiter ring. Drilled alloy pads on brake & clutch pedals. '00 M.Y. Non-USA Esprit V8 S.E., V8-GT, Sport 350: October '99 Non-USA; VIN: Y 0001 Non-USA models unchanged. '00 M.Y. USA Esprit: February '00 VIN character 10 = Y Changes from '99 M.Y. include: A.P. Racing discs, 4-pot alloy front callipers. Lotus badge on O.Z. roadwheels. 'Lotus' lettering highlighted no intake plenum. Onboard refuelling vapour recovery system. '02 M.Y. Esprit: January '02 VIN: 2 0319. USA model known as '25th Anniversary Edition' commemorating 25 years of Esprit sales in the USA. Changes from '00 M.Y. include: Circular rear lamps on revised transom panel. Front spoiler extension and rubber lip (as Sport 350). Rectangular reflectors below each end of rear bumper. New 'Esprit' (all markets) and '25th Anniversary Edition' (USA only) decals on rear transom. Stainless steel sill plates etched with Lotus roundel and 'Esprit' (non-USA) or '25th Anniversary Edition' (USA). O.Z. Nova roadwheels with Lotus badge. USA only: Twin central tailpipes, perforated stainless steel rear valance Fixed rake passenger seat. Non-USA taller head restraints. USA only: Fascia mounted '25th Anniversary Edition' serial number plaque. U.K. only: Optional satellite navigation.
Continued.......................
Page 9
Lotus Service Notes
Final Edition: May '03 USA only; VIN: 3 0543 (continues into '04 M.Y. at 0581) Changes from '02 model include: Stiffened Bilstein/Eibach spring/damper units with adjustable platforms. 'SmarTire' tyre pressure monitoring. Grilles in front spoiler and engine cover are unpainted stainless mesh. Stainless rear valance has restyled hole pattern with satin finish. Signature plaque on engine intake plenum. New seat stitch pattern. Passenger seat recline re-introduced. New climate control and gear lever knobs. Last Esprit produced with VIN; 4 0621. Total Esprit production since 1976 = 10,675
LOTUS ESPRIT V8
Page 10
Introduction
LOTUS ESPRIT V8 (Specification may differ in detail for some markets)
Lotus Service Notes Introduction
Page 11
