WORKSHOP MANUAL ELAN

CHASSIS - AD BRAKES - JE
PAINT PROCEDURE - BH COOLING SYSTEM - KD
BODY REPAIR - BJ FUEL SYSTEM - LG
BODY FITTINGS - BK MAINTENANCE & LUBRICATION - OE
FRONT SUSPENSION - CE HEATING VENTILATION & AIR CONDITIONING - PE
REAR SUSPENSION - DD CLUTCH - QD
ENGINE - EC EXHAUST SYSTEM - SD
TRANSMISSION - FF TECHNICAL DATA - ENGINE - TDG
WHEELS & TYRES - GD TECHNICAL DATA - VEHICLE - TDH
STEERING - HC INTERIOR TRIM - VD
SERVICE BULLETINS

How to use these pages:
1- This page is the main index page.
2- You find a link to each chapter above.
3- In each chapter you will find an index of the chapter and a link to a Overview page and a Print page.
4- The Overview page is the whole chapter with small (5-9 K) images of each page of the chapter. You can click on each image to get the original, 300 dpi image of the page.
5- The Print page is also the whole chapter, but with original, 300 dpi images (50 - 150 K per page) of each page. Be aware that some chapter are big (chapter BJ is 7,9 MB big) and loading and printing is SLOW.
6- As soon as available I will include a link to ZIP-Files with all the images and HTML pages for easier downloading and offline printing.

CHASSIS - SECTION AD

Overview - Print (1.55 MB) - top Sub-Section Page
General Description AD.1 4
Change of Anti-Lift Angle AD.2 5
Dimensional Check AD.3 6
Longerons & Front Frame AD.4 9
Crash Structure AD.5 12
Body/Chassis Mounting Points AD.6 16
Chassis External Paint Repairs AD.7 17


PAINT PROCEDURE - SECTION BH

Overview - Print (1.33 MB) - top Sub-Section Page
Paint Codes BH.1 2
Safety Considerations BH.2 3
Essential Working Practice BH.3 4
Preperation for Primer BH.4 4
Primer Application BH.5 5
Preparation for Colour Coating BH.6 6
Colour and Clear Coat Application BH.7 7
Final Polishing BH.8 8
Paint Procedure for RRIM Components BH.9 9
Paint Removal BH.10 10
Paint Rectification Procedures BH.11 10
x x x x x x x * x x x x x x x x x x x x x x x

Some of the procedures detailed in this section are based on those used in the manufacture of Lotus cars, and start with the bare composite bodyshell. These sections are included only for general guidance in repair work, and do not constitute a complete service repair procedure. Note that different oven temperatures and thinners may be necessary dependent on the level of trim of the body, type of oven etc.

BODY REPAIR - SECTION BJ

Overview - Print (7.87 MB) - top Sub-Section Page
Lotus Composite Body Features
BJ.1 2
Body Care BJ.2 3
Body Structure BJ.3 4
Accident Damage Assessment BJ.4 5
Resin and Gel Mix BJ.5 6
Basic Bonds and Joints BJ.6 8
Superficial Defect Repairs BJ.7 8
Replacement Undertray Sections and Panels BJ.8 9
Bobbin Inserts BJ.9 10
Undertray Assembly Damage Assessment BJ.10 15
Repair of Minor Cracks and Gel Cracks BJ.11 16
Repair of Minor Surface Non Structural Damage BJ.12 19
Introduction and Sequence of Bonded Panel Removal BJ.13 20
Removal and Replacement of Sill Section BJ.14 22
Removal and Replacement of Sill Without Removing 'A' and 'B' Post Covers BJ.15 25
Remove Rear Top Shell BJ.16 28
Remove Transom BJ.17 28
Remove Lower Quarter Panels BJ.18 29
Remove 'B' Post Cover BJ.19 30
Remove 'A' Post Cover BJ.20 30
Remove Sill BJ.21 31
Remove 'B' Post Diaphragm BJ.22 31
Remove Rear Bulkhead BJ.23 32
Introduction and Sequence of Bonded Panel Fitment BJ.24 33
Fit Front Bulkhead BJ.25 36
Fit Demist Duct Assembly to Front Bulkhead BJ.26 38
Fit HVAC Duct Plenum to Front Bulkhead BJ.27 39
Fit Steering Column Infill to Front Bulkhead BJ.28 40
Fit Rear Bulkhead BJ.29 42
Fit 'B' Post Diaphragm BJ.30 43
Fit Sill Infill and Sill BJ.31 45
Fit. 'A' Post Cover BJ.32 47
Fit 'B' Post Cover BJ.33 48
Fit Rear Quarter Lower Panel BJ.34 49
Fit Rear Transom BJ.35 51
Fit Rear Top Shell BJ.36 52
Fit Fuel Filler Rebate BJ.37 54
Fit Battery Tray to Undertray BJ.38 55
Fit Fuel Strap Mounting Strengthening Bracket BJ.39 56
Fit 3 Centre Console Mounting Bracket BJ.40 58
Introduction to Undertray Repairs BJ.41 59
Repair Front Quarter Section of Undertray BJ.42 60
Repair Front Half Section of Undertray BJ.43 69
Repair Centre Section of Undertray BJ.44 76
Repair Mid Section of Undertray BJ.45 81
Repair Rear of Undertray BJ.46 90
Fit Outrigger to Undertray BJ.47 93
Fit Scuttle Beam BJ.48 95
Repair Fibre Glass Damage Around Bobbin BJ.49 96
Fit Bobbins to Undertray BJ.50 97
Fit 'B' Post Tie Brace BJ.51 99
Jigs Ect. BJ.52 100
Legislation BJ.53 103

BODY FITTINGS - SECTION BK

Overview - Print (9.2 MB) - top Sub-Section Page
Door Assemblies BK.1 2
Door Latch Mechanism BK.2 4
Door Window Glass BK.3 8
Door Window Lift Mechanism BK.4 14
Door Mirrors BK.5 14
'A' Post Panels BK.6 15
Front Topshell BK.7 15
Front Bumper/Spoiler BK.8 19
Rear Bumper BK.9 20
Bonnet Panel BK.10 22
Boot Lid BK.11 22
Roof Stowage Lid BK.12 24
Soft Top Roof BK.13 27
Headlamp Mechanism BK.14 30
Windscreen & Mirror Plinth BK.15 40
Windscreen Pillar Weatherstrips BK.16 45
Windscreen Frame BK.17 47
Body Removal BK.18 51
Addendum 1 - Water Ingress; areas of attention ADDENDUM 1 55
Addendum 2 - Replacement of Fold Back Headlamps by Single Pivot Type ADDENDUM 2 74
Addendum 3 - 'B' Post Tie Bar Setting Procedure ADDENDUM 3 82
Addendum 4 - Identification of Weatherstrips ADDENDUM 4 84


FRONT SUSPENSION - SECTION CE

Overview - Print (1.16 MB) - top Sub-Section Page
General Description CE.1 3
Geometry CE.2 3
Adjustments CE.3 4
Suspension Disassembly CE.4 6
Suspension Re-assembly CE.5 9
Hub Bearing Replacement CE.6 10

REAR SUSPENSION - SECTION DD

Overview - Print (1.09 MB) - top Sub-Section Page
General Description DD.1 3
Geometry DD.2 3
Adjustments DD.3 4
Suspension Disassembly DD.4 5
Suspension Re-assembly DD.5 8
Hub Bearings DD.6 10

ENGINE - SECTION EC

Overview - Print (7.96 MB) - top Sub-Section Page
General Description & Torque Charts EC.1 3
Lubrication System EC.2 11
Engine Maintenance Operations EC.3 14
Camshaft Drive Belt EC.4 16
Water Pump EC.5 20
Common Chamber, Fuel Injectors & Lower Manifold EC.6 20
Hydraulic Valve Lifters EC.7 23
Cylinder Head Assembly EC.8  
Oil sump EC.9 28
Oil Pump Assembly EC.10 37
Engine Removal/Replacement EC.11 38
Cylinder Block, Pistons & Connecting Rods EC.12 41
Crankshaft & Main Bearings EC.13 44
Turbocharger EC.14 52
Engine Mountings EC.15 59
Special Tools EC.16 62

TRANSMISSION - SECTION FF

Overview - Print (4.44 MB) - top Sub-Section Page
Main Data FF.1 3
General Description FF.2 3
Lubrication FF.3 4
Gearchange Cable Adjustment FF.4 5
Gearchange Cable & Gearlever Mechanism Replacement FF.5 6
Transmission Assembly Removal FF.6 9
Transmission Assembly Replacement FF.7 10
Major Component Disassembly FF.8 11
Major Component Assembly FF.9 16
Input & Output Shaft Disassembly/Assembly FF.10 25
Final Drive Disassembly/Assembly FF.11 31
Selector Housing Disassembly/Assembly FF.12 34
Driveshafts FF.13 35
Fault Diagnosis FF.14 39
Special Tools FF.15 40


WHEELS & TYRES - SECTION GD

Overview - Print (0.6 MB) - top Sub-Section Page
Alloy Wheels GD.1 2
Tyres GD.2 2
Spare Wheel & Tyre GD.3 2
Winter Tyres GD.4 5
Wheel/Tyre Assembly Balancing GD.5 6


STEERING - SECTION HC

Overview - Print (2.19 MB) - top Sub-Section Page
General Description HC.1 2
PAS Fluid Check & Oil Change HC.2 4
Steering Wheel & Column Assembly HC.3 5
Outer & Inner Ball Joints & Gaiters HC.4 10
PAS Pump & Testing Procedure HC.5 11
Steering Rack Assembly Removal/Replacement HC.6 13
PAS Rack Assembly Seal & Bush Replacement HC.7 14
Manual Rack Assembly Adjustment & Bush Replacement HC.8 16

BRAKES - SECTION JE

Overview - Print (2.4 MB) - top Sub-Section Page
General Description JE.1 3
Front Brake Pad Replacement JE.2 4
Rear Brake Pad Replacement JE.3 5
Parking Brake Mechanism JE.4 7
Front Caliper Overhaul JE.5 9
Rear Caliper Overhaul JE.6 11
Brake Discs JE.7 15
Brake Servo Unit JE.8 15
Master Cylinder JE.9 17
Proportioning Valves JE.10 17

COOLING SYSTEM - SECTION KD

Overview - Print (1.53 MB) - top Sub-Section Page
General Description KD.1 3
Maintenance KD.2 4
Drain/Refill Procedure KD.3 6
Radiator Fans & Control KD.4 7
Engine Cooling Radiator KD.5 8
Chargecooler Radiator KD.6 10
Oil Cooler Radiator KD.7 12

FUEL SYSTEM - SECTION LG

Overview - Print (2.18 MB) - top Sub-Section Page
General Description lg.1 4
Precautions lg.2 5
Fuel Pump/Sender Unit lg.3 5
Fuel Tank lg.4 8
Fuel Filter lg.5 14
Fuel Filler Flap lg.6 14
Fuel Filler Neck lg.7 16

Evaporative Emission Control System (EECS)
(Catalyst cars only)

lg.8 18

MAINTENANCE & LUBRICATION


Recommended Lubricants
   
Maintenance Schedule    
Pre-delivery Inspection    


HEATING VENTILATION & AIR CONDITIONING - SECTION PE

Overview - Print (3.48 MB) - top Sub-Section pe.Page

General Description
pe.1 2
Climate Controls & Airflow Distribution pe.2 6
Vacuum Pipework & Switching Logic pe.3 14b
Refrigerant Handling pe.4 16
Refrigerant Pipework Precautions pe.5 16
Evacuation & Charging Procedure pe.6 17
Refrigerant Oil pe.7 18
Compressor pe.8 20
Climate Control Switches pe.9 20
Air Intake/Blower Assembly pe.10 22
Evaporator Assembly pe.11 23
Heater/Distribution Unit pe.12 25

CLUTCH -SECTION QD

Overview - Print (0.6 MB) - top Sub-Section Page
General Description qd.1 2
Clutch Cable qd.2 2
Release Bearing & Fork qd.3 4
Clutch Assembly qd.4 5

EXHAUST SYSTEM - SECTION SD

Overview - Print (1 MB) - top Sub-Section Page
General Description sd.1 5
Exhaust System Mountings sd.2 7
Clamps and Joints sd.3 8
Heat Shields sd.4 9

TECHNICAL DATA - ENGINE - SECTION TDG

Overview - Print (0.5 MB) - top Page
General Specification  
Cylinder Head 2
Valves 3
Valve Guides 3
Valve Seats 3
Valve Springs 3
Valve Lifters 3
Camshafts 3
Cylinder Block  
Pistons & Rings 4
Connecting Rods 5
Crankshaft 5
Flywheel & Ring Gear  
Oil Pump 6
Water Pump 6

TECHNICAL DATA - VEHICLE - SECTION tTDH

Overview - Print (0.7 MB) - top Page
Dimensions  
Capacities 2
Front Suspension 2
Rear Suspension  
Steering 3
Wheels  
Tyres  
Brakes  
Transmission 4
Clutch 4
Engine Cooling 5
Electrical Equipment  
Fuel Consumption  
Torque Settings  


INTERIOR TRIM - SECTION VD

Overview - Print (1.82 MB) - top Sub-Section Page
Door Trim Panels 1 2
Centre Tunnel Console 2 3
Instrument/Switch Panel (Fascia Mask) 3 4
Main Fascia 4 7
Sill Tread Plates 5 7
Speaker Boxes 6 9
'B' Post Trim Panels 7 11
Capping Rail 8 12
Roof Stowage Shelf & Side Panels 9 13
Screen Surround Trim Panels 10 14
Seats 11 15
Seat Belts 12 16

SERVICE BULLETINS


Overview (400 KB) - Print (8.39 MB)
1990 / 11: Replacement of headlamp flap "J" links (1990 - 04 - 06)
1990 / 12: Replacement of steering rack spring plunger (1990 - 04 - 06)
1990 / 15: Relocation of safety inertia switch (1990 - 04 - 27)
1990 / 16: Replacement of fuel tank (1990 - 04 - 27)

1990 / 18: Additional clippin of headlamp harness (1990 - 05 - 09)

1990 / 19: Identification and replacement of early CDL module (1990 - 05 - 09)
1990 / 23: Introduction of sigle pivot headlamp mechanism. Revised fettling of right hand pod lower edge (1990 - 06 - 29)
1990 / 25: Wiper /washer precautionary checks (1990 - 08 - 24)
1990 / 26: Door windows glass sliders (1990 - 08 - 24)
1990 / 27: Alternative engine oil specification (1990 - 08 - 24)
1990 / 30: Introduction of revised VIN serial number sequence (1990 - 10 - 17)
1990 / 31: Fitment of single piece horn mounting bracket (1990- 10 -17)
1990 / 33: Introduction of new TECH1 connector lead, ABS TECH1 cartridge (1990 - 10 - 147)
1990 / 34: Identification of gearchange cable abutment clips (1990 - 11 - 06)
SEE ALSO 1991 / 16:
1991 / 15: Introduction of new body paint process (1991 - 07 - 01)
1991 / 16: Identification of gearchange cable abutment clips (1991 - 07 - 01)
1991 / 17: Introduction of exhaust downpipe support strap on non-catalyst ELAN S.E. (Turbo) (1991 - 07 - 01)
1991 / 19: Introduction of revised rear license plate plinth (1991 - 07 - 05)
1991 / 21: Precautionary replacement of chassis longeron positioning belt (1991 - 10 - 04)
1991 / 24: Modification of clutch pedal upstop buffer (1991 - 12 - 09)
1991 / 25: Change to switching logic of panel light (1991 - 12 - 09)
1991 / 26: Elimination of steering rack mounting shim washers used onsome Elans (1991 - 12 -16)
1992 / 02: Prohibition of Chip Tuning (1992 - 06 -12)
1992 / 03: Introduction of revised sun visor mounting spigots (1992 - 06 -12)
1992 / 04: Chassis anti-corrosion guarantee retreatment (1992 - 06 - 12)
1992 / 05: Radio serial resistance check (1992 - 06 -12)
1992 / 06: Introduction of anti-squeak pads for roof stowage lid (1992 - 06 -12)
1992 / 07: Check of oil hose elbow pipe clearance (1992 - 12 - 07)
1992 / 08: Fitment of chassis load spreading plate to rear engine mounting (1992 - 12 - 07)
1993 / 01: Replacement of alarm microwave sensor ( 1993 - 01 - 11)
1993 / 14: Service supply of parking brake lever and mounting bracket (1993 - 06 -23)
1994 / 03: Adjustment of Elan rear wheel bearings (1194 - 05 - 20)
1994 / 05: Introduction of Elan S2 (1994 - 07 - 25)
1994 / 07: Elan S2 Alarm System intrusion sensing (1994 - 09 - 23)
1994 /08: Elan S2: Revised instruction for alarm sensing of LHD dealer fit audio equipment (1994 - 09 - 23)
1994 / 09: Revised windscreen obscuration band (1994 - 11 -07)
1995 / 03: Misdiagnosis of leaking brake proportioning valves (1995 - 02 - 10)
1995 / 04: Relocaztion of windscreen washer diaphragm valve (1995 - 02 - 10)
1995 / 08: Body damage caused by manhandling (1995 - 04 - 10)
1996 / 01: Replacement tyres for M100 Elan (1996 - 05 - 01)
1996 / 14: Approval of Mobil 1 0W-40 engine oil (1996 - 09 - 30)