By Don Zeunert
1991 Elan and 1988-2002 Esprits
If your headlights fail to rise and the motors keep spinning, the following rebuild kit will solve your problem. Fail to rise could mean they don't lift at all, lift partially, or fall back down. Then you probably only need a simple rebuild. I say simple as it takes more tune to get the units out of the vehicle than it takes to rebuild them. If the motor(s) don't run, you may have a wiring or controller problem. The headlight control module is the same one in the 92/93 Pontiac Firebird/Trans Am.
The part number for the headlight lift motor used on 1991 Elans or 1988-2002 Esprits is the same, though they are mounted differently. They all have GM second generation redesigned headlight motors. According to Lotus Cars USA, these were unavailable as of a few years ago. They are very similar to 1987-1988 Fieros, 1987-1992 Firebirds. and 88-96 Corvettes of similar vintage. But the mechanical linkages are different and the Lotus ones would need to be reused.
Removal - the Esprit owners are lucky in this matter as the unit is accessible from under the hood and the screws go into the lift motor housing. The Elan uses smaller diameter bolts that pass through the threaded holes of the motor housing and into nuts welded to the body. Unfortunately the head of the bolts are only accessible from the fender wells. On the passenger side this is simply a matter of removing all the fender wall shroud screws. On the drivers side you also have to remove the Intercooler piping. This is not hard... just time consuming.
Rebuilding - A Headlight Actuabor Rebuild Kit is available that contains 3 Delrin bushings and excellent rebuilding instructions. In addition it would be wise to acquire new gaskets to keep the water out. The actuator and gasket kits for both sides is approximately $18.00 including S&H, and can be ordered from
http://www.rodneydickman.com. My headlight motors were lifting the lights about half way then they wouldn't even hold them up at all. The motor sounded like a blender chopping ice cubes. Upon opening up the unit I found the bushings had dried out and turned into a substance resembling rock salt for the driveway. These bushings are what stops the motors motion and increases the electrical draw which is detected by the controller and shuts off the electricity. So they take the beating instead of the other parts. These bushings are available from other sources, but for more money. And Rodney worked w/ me to determine they were compatible w/ Elans and now multiple sites are also listing this fact. I don't use my car much at night, but mine failed. I think it's more of a temperature and time factor than a usage factor. So it seems that droops headlights are just another sign of age that can he cured with new implants.
