|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Notes & Checklist from Esprit S2 907 Engine Rebuild |
|
|
|
|
|
|
|
|
Align-Bore the
Block & Main Bearing Panel (M.B.P., aka bearing girdle) |
|
|
|
|
|
|
Bore ID Specification |
|
(from
Vandervell bearing catalog - this info is not given in the Lotus Manual) |
|
|
|
|
|
Standard Bore
ID |
|
Esprit |
|
2.6652 to 2.6660 inch |
|
|
|
|
|
|
Standard Bore
ID |
|
All Others |
|
2.6655 to 2.6660 inch |
|
|
|
|
|
|
Oversize Bore
ID |
|
+0.0150
inch |
|
2.6805 to 2.6810 inch |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Re-Manufacture
Connecting Rod |
|
|
|
|
|
|
|
|
|
Distance Between Centers |
|
5.500
+/- 0.001 inch |
|
|
|
|
|
|
Std. Bore Diameters |
|
Crank Journal OD |
|
1.9976 to 1.9982 inch |
|
|
|
|
|
|
|
Rod Big End ID |
|
2.1460 to 2.1466 inch |
|
|
|
|
|
|
|
Static Clearance |
|
0.0010 to 0.0032 inch |
|
|
|
|
|
|
|
End Float on Crank Journal |
|
0.0040 to 0.0100 inch |
|
|
|
|
|
|
|
Small End Bushing ID |
|
1.0002 to 1.0004 inch |
Ream to size
AFTER installation |
|
|
|
|
|
|
|
Permissible Weight Variation between Rods |
|
2 grams |
|
|
|
|
|
|
|
|
|
|
Wrist Pin |
|
|
|
|
|
|
|
|
|
|
|
Standard |
|
OD |
|
1.000 inch |
|
|
|
|
|
|
|
|
Class of Fit |
|
Finger Push Fit at 68 degrees F |
|
|
|
|
|
|
|
|
|
|
|
|
Permissible weight
variation between pistons is 3 grams. |
|
|
|
|
|
Gudgeon Pin (wrist pin)
Bore Offset: 1.52mm (0.060 in) toward thrust face. |
Piston grade diameter at: |
|
|
|
|
|
907 Diameter, Grade A |
|
95.1662
/ 95.1789mm (3.7367 /
3.7472 in) |
15.0876mm (.594") up
from skirt edge |
|
|
|
|
|
907 Diameter, Grade B |
|
95.1789 / 95.1916mm (3.7472 / 3.7477 in) |
15.0876mm (.594") up from skirt edge |
|
|
|
|
|
912 Diameter, Grade A |
|
95.148 / 95.161mm (3.7460 / 3.7465 inch) |
15mm (0.6")
up from skirt edge |
|
|
|
|
|
912 Diameter, Grade B |
|
95.161 / 95.174mm (3.7465 / 3.7470 inch) |
15mm (0.6")
up from skirt edge |
|
|
|
Piston Ring Installation |
|
|
|
|
|
|
|
|
|
|
|
Oil Control Ring,
3-piece |
|
|
Piston Ring Gap -- 907 |
|
|
|
|
|
907 & 912 |
|
Gap in expander to the
rear. |
|
|
|
|
|
|
907 & 912 |
|
Gap in side rails 1"
either side of gap in expander. |
0.381/ 1.143mm (0.015/ 0.045") |
|
|
|
|
|
Lower Compression Ring |
|
|
|
|
|
|
|
|
907 |
|
Step on outer edge is
down. |
0.483/ 0.609mm (0.019/ 0.024") |
|
|
|
|
|
912 |
|
Step on inner edge is up. |
|
|
|
|
|
|
|
Top Compression Ring |
|
|
|
|
|
|
|
|
907 |
|
|
|
0.381/ 0.508mm (0.015/ 0.020") |
|
|
|
|
|
912 |
|
Step on inner edge is up. |
|
|
|
|
|
|
|
All compression Rings |
|
|
|
|
|
|
|
|
All
9XX |
|
Gaps
in compression rings are 120 degrees (1/3 circumference) |
|
|
|
|
|
All
9XX |
|
either side of the gap in
the expander in the oil control ring. |
|
|
|
|
|
|
|
|
|
|
|
|
Grind & Balance Crankshaft |
|
|
|
|
|
|
|
|
Main Journal Diameter |
|
1, 2, 3, 4 |
|
2.4995 to 2.5005 inch |
|
|
|
|
|
|
Main Journal Diameter |
|
(rear) No. 5 only |
|
2.5000 to 2.5005 inch |
|
|
|
|
|
|
Rod
Journal Diameter |
|
All |
|
1.9975 to 1.9985 inch |
|
|
|
|
|
|
Alternate Bearing Shell
Availability |
|
|
|
|
|
|
|
|
|
Mains,
ID |
|
-0.010 & 0.020 undersize |
|
|
|
|
|
|
|
Mains, OD |
|
+0.150 oversize,
only |
|
|
|
|
|
|
|
Static Clearance |
|
0.0005 to 0.0032 inch |
|
|
|
|
|
|
|
Rods,
ID |
|
-0.010 & 0.020 undersize |
|
|
|
|
|
|
|
Static Clearance |
|
0.0010 to 0.0032 inch |
|
|
|
|
|
|
|
|
Thrust Washers |
|
0.08
/ 0.20mm (0.003 / 0.008
inch) End Float |
|
|
|
|
|
Balance crank, flywheel
and clutch together within 15 gr-cm (0.2 oz-in) |
|
|
|
|
|
|
|
|
|
|
Lotus Part Number |
|
Part
Description |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
A 907 E 0401 YA |
|
|
Compression Ring, Top |
|
|
|
|
|
|
A 907 E 0402 YF |
|
|
Compression Ring, 2nd |
|
|
|
|
|
|
A 907 E 0404 ZB |
|
|
Oil Control Ring,
3-piece |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
B 907 E 0714 W |
|
|
Connecting Rod Ass'y |
|
|
|
|
|
|
|
A 907 E 0339 ZA |
|
Dowel |
|
|
|
|
|
|
|
A 907 E 0344 D |
|
Bolt |
|
|
|
|
|
|
|
A 907 E 0357 ZC |
|
Bush |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
A 907 E 0336 ZH |
|
|
Main Bearing Shell |
|
Std ID / Std OD |
|
|
|
|
A 907 E 0538 ZK |
|
|
Main Bearing Shell |
|
-0.010 us ID / Std OD |
us = Under
Size |
|
|
|
A 907 E 0539 ZD |
|
|
Main Bearing Shell |
|
-0.020 us / Std OD |
|
|
|
|
A 907 E 0675 ZD |
|
|
Main Bearing Shell |
|
Std ID / +0.015 os OD |
os = Over Size |
|
|
|
B 907 E 0675 ZH |
|
|
Main Bearing Shell |
|
-0.010 us ID / +0.015 os OD |
|
|
|
|
C 907 E 0675 ZA |
|
|
Main Bearing Shell |
|
-0.020 us ID / +0.015 os OD |
|
|
|
|
A 907 E 0336 ZH |
|
|
Main Bearing Shell |
|
Std ID / Std OD |
Groove / Hole,
Esprit Upper |
|
|
|
A 907 E 1170 F |
|
|
Main Bearing Shell |
|
Std ID / Std OD |
Plain, Eclat
Center Lower |
|
|
|
A 907 E 1315 F |
|
|
Main Bearing Shell |
|
Std ID / Std OD |
Plain / Hole,
Eclat Cntr Upper |
|
|
|
A 907 E 0538 ZK |
|
|
Main Bearing Shell |
|
-0.010 us ID / Std OD |
Groove / Hole,
Esprit Upper |
|
|
|
A 907 E 1172 F |
|
|
Main Bearing Shell |
|
-0.010 us ID / Std OD |
Plain, Eclat
Center Lower |
|
|
|
A 907 E 1317 F |
|
|
Main Bearing Shell |
|
-0.010 us ID / Std OD |
Plain / Hole,
Eclat Cntr Upper |
|
|
|
A 907 E 0539 Z |
|
|
Main Bearing Shell |
|
-0.020 us ID / Std OD |
Groove / Hole,
Esprit Upper |
|
|
|
A 907 E 1173 F |
|
|
Main Bearing Shell |
|
-0.020 us ID / Std OD |
Plain, Eclat
Center Lower |
|
|
|
A 907 E 1318 F |
|
|
Main Bearing Shell |
|
-0.020 us ID / Std OD |
Plain / Hole,
Eclat Cntr Upper |
|
|
|
A 907 E 0675 Z |
|
|
Main Bearing Shell |
|
Std ID / +0.015 os OD |
Groove / Hole,
Esprit Upper |
|
|
|
A 907 E 1171 F |
|
|
Main Bearing Shell |
|
Std ID / +0.015 os OD |
Plain, Eclat
Center Lower |
|
|
|
A 907 E 1316 F |
|
|
Main Bearing Shell |
|
Std ID / +0.015 os OD |
Plain / Hole,
Eclat Cntr Upper |
|
|
|
B 907 E 0675 Z |
|
|
Main Bearing Shell |
|
-0.010 us ID / +0.015 os OD |
Groove / Hole,
Esprit Upper |
|
|
|
B 907 E 1171 F |
|
|
Main Bearing Shell |
|
-0.010 us ID / +0.015 os OD |
Plain, Eclat
Center Lower |
|
|
|
B 907 E 1316 F |
|
|
Main Bearing Shell |
|
-0.010 us ID / +0.015 os OD |
Plain / Hole,
Eclat Cntr Upper |
|
|
|
C 907 E 0675 Z |
|
|
Main Bearing Shell |
|
-0.020 us ID / +0.015 os OD |
Groove / Hole,
Esprit Upper |
|
|
|
C 907 E 1171 F |
|
|
Main Bearing Shell |
|
-0.020 us ID / +0.015 os OD |
Plain, Eclat
Center Lower |
|
|
|
C 907 E 1316 F |
|
|
Main Bearing Shell |
|
-0.020 us ID / +0.015 os OD |
Plain / Hole,
Eclat Cntr Upper |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
A 907 E 1000 ZB |
|
|
Thrust Washer |
|
Standard |
|
|
|
|
A 907 E 1001 ZG |
|
|
Thrust Washer |
|
+0.0025 |
|
|
|
|
A 907 E 1002 ZA |
|
|
Thrust Washer |
|
+0.0050 |
|
|
|
|
A 907 E 1003 ZF |
|
|
Thrust Washer |
|
+0.0075 |
|
|
|
|
A 907 E 1004 ZL |
|
|
Thrust Washer |
|
+0.0100 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
B 907 E 0342 Z |
|
|
Rod Bearing Shell |
|
Standard |
|
|
|
|
B 907 E 0540 ZJ |
|
|
Rod Bearing Shell |
|
-0.010 us ID |
|
|
|
|
B 907 E 0541 ZC |
|
|
Rod Bearing Shell |
|
-0.020 us ID |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
B 907 E 6010 FE |
|
|
Oil Seal, Front
Main |
|
|
|
|
|
|
A 907 E 0624 ZB |
|
|
Pipe, Oil Pick-up |
|
|
|
|
|
|
A 907 E 0836 W |
|
|
Hose, Induction |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|