service notes - Designed79.co.uk

service notes - Designed79.co.uk
SERVICE
NOTES
2004 Model Year Onwards
with 1ZZ/2ZZ/1ZR Engine
Lotus Cars Ltd. Hethel, Norwich, Norfolk, NR14 8EZ, England.
Tel: +44 (0)1953 608000 Fax: +44 (0)1953 608300 www.GroupLotus.co.uk
Lotus Service Notes
Introduction
CONTENTS
ELISE & EXIGE; 2004 M.Y. ONWARDS; WITH 1ZZ/2ZZ/1ZR ENGINE
Section
Technical Data - Engine TDP
- Vehicle
TDQ
Chassis
AH
Bodycare & Repair
BQ
Body Fittings
BR
Front Suspension
CI
Rear Suspension
DH
Engine & Engine Management - Lotus supplement
- Toyota 1ZZ/2ZZ repair manual * see separate manual E120T0327J
- Toyota 1ZR repair manual ** see separate CD T000T1523F
Engine Management
EH
*
Transmission
- Lotus supplement
- Toyota C64/C56 repair manual
# see separate manual E120T0327J
- Toyota EC60 repair manual
## see separate CD T000T1523F
**
EMP
FJ
#
##
Wheels & Tyres
GH
Steering
HG
Brakes
JJ
Engine Cooling
KH
Fuel System - Except North America
- North America
Electrics
LJ
LK
MP
Maintenance & Lubrication
OI
Air Conditioning, Heating & Ventilation
PL
Clutch
QH
Supplementary Restraint System - SRS (Airbags)
WD
Supplement - Exige Supercharged (S/C)
Exige S/C
Supplement - 2-Eleven
2-Eleven
Page 1
Lotus Service Notes
Introduction
VEHICLE IDENTIFICATION NUMBER & ENGINE NUMBER
The Vehicle Identification Number (V.I.N.) is stamped on the chassis in the right hand front wheelarch area,
viewable with the front wheels turned to right full lock, and is also printed on a label stuck to the inside of the
chassis sideframe alongside the driver's seat. 1ZZ and 2ZZ engine numbers are marked on a vertical patch at
the right hand side of the rear face of the cylinder block, adjacent to the clutch housing.
ohs119a
V.I.N. LABEL
On the 1ZR engine, the number is stamped on
the left hand front of the cylinder block, alongside the
alternator, and is prefaced by ‘1ZR’.
V.I.N. ON
CHASSIS
ohs104
1ZZ/2ZZ ENGINE NUMBER
1ZR
ENGINE
NUMBER
ohs133
5
:2
ohs176
Both V.I.N. and engine numbers should always be quoted with any vehicle enquiries, as Factory records
are filed against V.I.N., and specification change points are identified by V.I.N. or engine number. The vehicle
licence plate should be disregarded in this context as it may not accurately reflect vehicle age, and may also
be changed during the car’s life.
The V.I.N. comprises 17 characters, coded in accordance with European Economic Community (EEC)
and National Highway Traffic Safety Association (NHTSA) directives. For change point identification in Service
Notes, Service Bulletins and Service Parts Lists, typically, only characters 10 (model year), and 14 to 17 (serial
number) will be quoted.
Page 2
Lotus Service Notes
2004 M.Y. - 2010 M.Y. serial no. 0359
Vehicle Type
Manufacturer 111 = Elise/Exige Check Identifier Code 123 = 2-Eleven Digit
S C C
1 2 3 4
5
6 7 8
9
10
Assembly Plant Model
H = Hethel 2 = 2-Eleven
B = Shah 3 = Elise
Alam 8 = Exige
11
Engine Type Restraint Model Year
A = 2ZZ s/c 260 c/c A = Active belts 4 = 2004
C = 2ZZ 190 no evap C = Dual S.I.R. 5 = 2005
L = Motorsport + active belts 6 = 2006
N = 2ZZ s/c 255 7 = 2007
P = 2ZZ 190 evap 8 = 2008
V = 2ZZ s/c 220 c/c 9 = 2009
W = 2ZZ s/c 240 c/c A = 2010
Y = 1ZZ 140
Z = 2ZZ s/c 220 2010 M.Y. serial no. 0360 onwards
Manufacturer
Code
Model
HC = Elise
HH = Exige
NB = 2-Eleven
Restraint
A = 3pt no SIR
C = Dual SIR
L = 4pt no SIR
S = 5pt no SIR
Introduction
12
13
14151617
Chassis/Body
A = LHD Fed. C = RHD
D = LHD
F = U.K. SVA RHD
G = U.K. SVA LHD
H = M/sport LHD*
J = M/sport RHD*
L = LHD Fed. a.c.
M = LHD Can. a.c.
N = RHD a.c.
P = LHD a.c.
Model Year
A = 2010
B = 2011
C = 2012
D = 2013
E = 2014
F = 2015
Serial
Number
* Track only. Not
approved for road use
Market Spec.
A = LHD USAG = LHD SVA
B = LHD CanadaH = LHD Track
C = RHD OtherJ = RHD Track
D = LHD OtherL = South Korea
E = Gulf States
F = RHD SVA
S C C L H 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Brand
L = Lotus
Engine
A = 2ZZ s/c 260 c/c
B = 2ZZ s/c 260 c/c
no evap
C = 2ZZ 190 no evap
L = Motorsport
P = 2ZZ 190 evap
V = 2ZZ s/c 220 c/c
W = 2ZZ s/c 240 c/c
X = 1ZR 135
Y = 1ZZ 140
Z = 2ZZ s/c 220
Check
Digit
Plant
H = Hethel
Build Type
1 = Std.
2 = Proto.
Serial Number
Page 3
Lotus Service Notes
Introduction
MODEL HISTORY MILESTONES (does not include all special editions)
Elise 111R Introduction: January 2004
VIN character 4 = P; Character 13 = 3; Serial number from 0970
Note that the serial number sequence is shared with other Elise variants.
Changes from previous model include: Toyota powertrain with 1.8 litre VVTL-i engine and 6-speed transmission. Twin exhaust tailpipes exiting through centre of diffuser. Larger fuel tank with new pump. Revised
chassis rail rear ends, new rear subframe, revised seat belt mounting frame backstays. Revised rear suspension wishbones, springs and dampers. ABS brake control with vacuum servo. Revised front bonnet grilles
and access covers.
2004 Exige Introduction: March 2004
VIN character 4 = P; Character 13 = 8; Serial number from 1092
Note that the serial number sequence is shared with other Elise variants.
Differences compared with Elise 111R include: Restyled front and rear clamshells with roof scoop, new
tailgate panel and strut mounted rear aerofoil. Front body splitter panel. Re-styled road wheels, wider on the
front, and Yokohama A048 tyres.
2005 M.Y. Elise for North America: May 2004
VIN character 10 = 5; Character 12 = L; Serial number from 0001
Note that the serial number sequence is shared with other Elise variants when '05 M.Y. is adopted for
those models later in the year.
Differences compared with Elise 111R include: Driver and passenger airbags, pyrotechnic seat belt pretensioners; Re-styled fascia and dashboard structure; Front speakers moved onto top surface of fascia, stowage pockets incorporated into dashboard end panels, fixed windscreen demist vents. Engine start button in
driver's side switch panel. Revised springs and dampers, Yokohama AD07 tyres. Side marker lamps on front
and rear wheelarch lips. Revised fuel system with fuel filler flap.
Lotus Sport Exige 240R: March 2005
Limited edition of 50 units produced as post registration official factory conversions of '05 Exige by the
Lotus Sport workshops at Hethel, for U.K. and certain overseas territories. The car is not identifiable from the
VIN coding.
Differences compared to standard Exige include: 243 bhp engine upgrade using Eaton M62 supercharger
with integral by-pass valve, air/air chargecooler and 5th fuel injector. Re-programmed ECU. Accusump.
Stiffened springs & Ohlins adjustable dampers. Adjustable front anti-roll bar. Chassis rear brace kit. Forged
5-spoke widened roadwheels & Yokohama A048 tyres. Motorsport brake pads, braided hoses, yellow callipers,
Castrol SRF brake fluid. Sport Yellow body colour with black wheels, or Sport Black body with silver wheels.
Black interior with yellow inserts. 4-point harnesses, T45 roof hoop and backstays.
2006 M.Y. Introduction: September 2005
VIN character 10 = 6; Serial number restarts at 0001, common to all variants.
Introduction of USA Exige and Canadian Elise.
5-speed Elise remains unchanged.
Differences between 6-speed '06 Elise and '05 include; Electronic throttle control (using no mechanical
cable). Optional Lotus Traction Control (LTC) or Limited Slip Differential (LSD) with LTC. Standard fit Yokohama
AD07 tyres on non-USA cars. Optional forged wheels with new 6.0 in front size. LED rear lamp clusters incorporating reflectors (formerly separate), and commonised USA type CHMSL. ProBax seat foams. New body
colours. USA & Canadian Elise; revised fuel tank and evap. loss system. Canadian Elise uses daytime running
lights and clutch down start allow switch. USA Exige similar to non-USA, but with USA airbag interior.
Sports Racer: October 2005
Special paint versions of '06 M.Y. 111R in either Ardent Red with triple Monaco White stripes, or Nightfall
Blue with twin Monaco White stripes. Combined total of 199 units with unique build plate on sill. Forged wheels
(6J on front), AD07 tyres, sport suspension, twin front oil coolers, LTC. Black leather interior with red or blue
stitching, and red or blue 'Elise' embroidered into head restraints. Sports Racer decals.
Page 4
Lotus Service Notes
Introduction
Exige Cup 190 & 240: January 2006
Limited number of competition oriented naturally aspirated (190) or supercharged (240) models produced
as post registration official factory conversions of '06 Exige by the Lotus Sport workshops at Hethel for U.K.
and certain overseas territories. Not identifiable from VIN coding.
Differences compared to 240R (see above) include: Electronic throttle, high flow port injectors (no 5th).
Cup 240 fitted with torque sensing LSD with LTC. Cup 190 uses friction plate LSD. Standard Exige wheels in
'Hi-power' silver. Race cars fitted with FIA 6-point roll cage, remote kill switch, extinguisher system. Standard
body colours.
Exige S: February 2006
VIN character 4 = V
Factory built type approved supercharged Exige. Not USA.
Differences to standard Exige include: 221 PS supercharged engine similar to 240R but using electronic
throttle, smooth flow inlet adaptor, standard injectors without 5th injector, modified downpipe, optimised muffler
with single oval tailpipe. Enlarged roof duct inlet for chargecooler. Body colour splitter, scoops and aerofoil.
'Exige S' decal on rear transom, 'S' on front quarter panels.
USA Lotus Sport Elise: March 2006
Limited edition of 50. Saffron Yellow with twin Storm Titanium stripes. Saffron Yellow centre console. Yellow highlighted sports seats, 'carbon' door trim inserts. Harness bar, T45 seat belt mounting frame. Motorsport
mats, stalks, winders and parking brake sleeve. Traction control, supersport suspension, black forged wheels,
Yokohama A048s, braided brake hoses, silicone fluid, motorsport clutch. Lotus Sport decals and Union flags.
Lotus Sport chassis plate.
2007 M.Y. & Elise S Introduction: June 2006
VIN character 10 = 7; Serial number restarts at 0001, common to all variants.
VIN character 4 identifies engine type. Elise S = Y
Differences between '07 Elise/Exige and '06 include: Elise 111R renamed Elise R; New sealed headlamp
units; raised LOTUS lettering on rear transom; additional screen pillar seal; Alpine audio; improved HVAC ducting. New model Elise S uses 1ZZ-FE engine producing 100 kW, with variable inlet timing but fixed valve lift,
plastic inlet manifold, revised intake snorkel, revised exhaust manifold and downpipe, smaller tailpipes within
standard trims. Elise S also uses new C56 5-speed transmission and 6-spoke roadwheels sharing styling of
standard '01 model wheels.
USA Exige S: October 2006
The specification of the USA Exige S is that of the standard USA Exige and option packs, apart from the
engine, which is as non-USA Exige S with the following exceptions: High flow port injectors, specific engine
programming, 223 PS, 223 Nm. Carry-over features from the non-USA Exige S include exhaust downpipe and
optimised muffler with single oval tailpipe, roof air intake funnel mouth.
Exige S British GT Special Edition: November 2006
Celebrating Lotus Sport Cadena’s 2006 British GT3 Team Championship victory.
Differences to standard Exige S include: Torsen LSD & Lotus Traction Control. Chassis rear brace kit.
T45 roof hoop & stays. Braided brake hoses. Level 1 sports exhaust. Forged 7-bifurcated spoke silver wheels.
Lotus Sport black metallic body colour with Sport yellow & Arctic silver quad stripes, supplier decals on sills,
Lotus Sport visor strip, Cadena decals on front wings, GT3 decal on rear clam, GT3 winners decal with unique
build number on rear quarter panel, Lotus Sport build plate with build number. 4-point harnesses, black/yellow
door trims and unique black/yellow trimmed seats. Optional a.c. Optional GT pack available as post registration
official factory conversion by Lotus Sport workshops at Hethel for U.K. and certain overseas territories, includes:
High flow injectors, different ECU & unique calibration for 243 bhp, Accusump, 2-way adjustable Ohlins dampers
with uprated springs, 308mm front discs & 4-piston A.P. callipers, Pagid pads, Castrol SRF brake fluid.
Page 5
Lotus Service Notes
Introduction
USA Low Speed Damage Mitigation: January 2007
From ‘07 USA VIN serial no. 1579.
To meet USA safety legislation, modifications made to Elise/Exige: Front; armatures and foam inserts
added between crash structure and clamshell. Rear; bumper panel housing foam pads either side of licence
plate, narrower rear grilles, reinforced boot floor and diffuser support panel, stiffened diffuser. Some elements
commonised for all markets.
Lotus Sport Exige Cup 255: January 2007
Produced as post registration official factory conversions of '07 Exige S by the Lotus Sport workshops at
Hethel for certain territories, excluding U.K. and USA. Not identifiable from VIN coding.
Based on Exige Cup 240 (see above) with following differences: Power increase to 255 PS by; unique
ECU calibration, enlarged chargecooler, extended roof duct, larger air cleaner and intake spout, uprated fuel
pump. A.P. Racing 4 piston alloy front callipers, 308mm front discs.
2-Eleven Introduction: May 2007
VIN character 6/7/8 = 123; Character 13 = 2
Extreme, minimalist, track focussed Elise variant based on Exige Cup 255 powertrain componentry, but
using new chargecooler arrangement. Produced in small numbers for U.K. and certain overseas territories. In
U.K. only, SVA road going version available. All other territories only for track use, in LHD or RHD.
New body with no doors or roof. Aeroscreen. Rear aerofoil in two versions. FIA compliant roll over bar.
Chassis rear brace, unique front top wishbones and steering arms, optional Ohlins suspension. Accusump,
twin front oil coolers. Standard LTC, optional variable LTC & Launch Control. Uprated clutch. Odyssey battery.
Limited warranty for SVA cars. Extensive options list.
USA Elise Limited Edition 'Type 72D'
Limited edition of 50 cars to commemorate the 35th anniversary of Lotus' F1 1972 World Championship
victory with the type 72D.
Phantom black body colour with hand painted gold pinstriping. Rear body spoiler, black diffuser. Gold
laurel leaf decal on front quarters, gold 'Elise' and 'Type 72D' decals, gold raised LOTUS lettering, gold/black
nosebadge, gold fuel filler cap. Gold Exige 8 split-spoke wheels with Yokohama A048 tyres and sports suspension. Black & gold seats and interior trim details with Limited Edition plaque. Scale model crash helmet.
Club Racer: September 2007
Limited edition of 25 for U.K. Unlimited for Europe.
For U.K., spec. based on '07 Exige S with Sport, Touring & Super Touring packs and a.c.. Sports exhaust
supplied for dealer fitment.
For Europe, spec. based on '08 Exige S (see below) with Sport and Performance packs. Forged
wheels.
All cars: Hethel track decal on rear transom, Le Mans blue body with Phantom black triple stripe. Black
leather and carbon effect trim with colour coded stitching.
Introduction of 2008 Model Year Elise/Exige: October 2007
VIN character 10 = 8. VIN serial number restarts at 0001. Exige N.A. built only to special order.
All cars now with dual airbags and start button in matt charcoal finish fascia. PFK 457 security system
with Lotus design transmitter key. Tyre pressure monitoring for USA only. High rpm sequential tell tales. CAN
bus diagnostics using laptop Lotus Techcentre. New paint colours. Performance Pack option (VIN character
4 = W) with 240 hp calibration, high flow injectors, big roof scoop, uprated clutch, 4-piston front brake callipers
and enlarged front discs, variable traction and launch control (excludes warranty).
Elise S Hethel 40th Limited Edition: October 2007
Commemorating 40 years of production at Hethel. All LHD.
'08 M.Y. Elise S in Burnt Orange with hardtop. Orange body grilles and centre console. Black diffuser
and wheels. Black leather seats and door trim with orange stitching. Build plaque. Country decals below side
repeater lamps. 7 Union Flag, 6 Swiss, 2 Belgium, 4 French, 10 German, 6 Italian.
Page 6
Lotus Service Notes
Introduction
Elise 'California' Limited Edition: October 2007
USA only. 25 off Ardent Red with cream/red leather and champagne trim; 25 off Saffron Yellow with black
leather and champagne trim.
Based on USA Elise with touring pack. Rear body spoiler. Silver front intake grilles, other grilles in body
colour. 16-spoke cast wheels in Hi-power silver, AD07 tyres. Lotus roundel and California decals on front
wings. Sports seats in cream & red or black leather. Other trim in cream & red or black leather. Hardtop lining
in Beige cloth. RHD footwell divider.
Exige Sprint: November 2007
Limited edition of 40 cars for U.K. market, one for each year from 1967 to 2006. +20 E.U. +2 Japan.
'08 M.Y. Exige S with Sport, Touring and Performance Pack, a.c., black forged wheels, 2-tone paint in
Aspen White and either Persian Blue or Saffron Yellow, with gold decal strip and 'Exige Sprint' logo. Union flag
on rear body, laurel decal on LHR quarter, colour coded leather seats and trim, embroidered footwell carpet
mats. Build plaque on chassis sill.
Introduction of Elise SC: February 2008 (final '07 M.Y. serial no. 3579)
Supercharged Elise without chargecooler.
VIN character 4 = Z
Based on Elise R, but using new Eaton M45 supercharger rotor pack integrated into inlet manifold, high
flow fuel injectors and unique calibration to produce 220 PS. Rear body spoiler, Lotus styled 12-spoke road
wheels in 6.0 and 8.0 front/rear widths, standard AD07 tyres. Wheelarch lips on non-USA cars. 'Elise Supercharged' decals on rear transom and front wings.
Lotus Sport Exige Cup 260: February 2008
Fully Type Approved version of Exige Cup 255 (see above).
VIN character 4 = A
Based on Exige S with: Big roof scoop, high output fuel pump, unique calibration to produce 260 PS.
Accusump, lightweight flywheel, uprated clutch, Torsen LSD, Variable Traction and Launch control (excludes
warranty). 4-piston front brake callipers and enlarged front discs, braided hoses, Bilstein or Ohlins adjustable
spring/dampers, stiff adjustable ARB in hard mounts, hi-power silver 16-spoke cast wheels, A048 tyres. FIA
compliant battery isolator and plumbed-in fire extinguisher. T45 seat belt anchorage frame. FIA compliant
cage and 4-point harnesses supplied separately. NO airbags and none pre-tensioner 3-point belts. No CDL.
Black Alcantara/carbon effect seats and door trim. Build plaque on dash, 'Lotus Sport' decal on front quarter
panels, 'Cup 260' decal on rear transom, black diffuser. Restricted warranty.
USA Elise SC '60th Anniversary': May 2008
Limited edition of 60 USA cars to commemorate 60th anniversary of Lotus Cars.
Based on Elise SC with hard and soft tops, Touring and Sport Packs, supersport suspension, forged
wheels, A048 tyres, T45 seat belt frame & harness bar. Body and double stripe paint in BRG/Saffron, Saffron/
Black, Black/Arctic, Storm Titanium/Canyon Red. Complimentary trim inserts and 60th Anniversary embroidery.
Anniversary decal on rear transom.
Clark Type 25 Elise SC: June 2008
Limited edition of 25 U.K./25 E.U./25 USA cars to commemorate 40th anniversary of Jim Clark's death.
Donation to the Jim Clark memorial fund.
Based on Elise SC with hard top and Sport Pack. BRG (B04) with Saffron single centre stripe, Lotus Sport
wheels with black spokes and silver rims, A048 tyres. Black & red leather themed interior, with sports seats,
wood gearknob and build plaque. Type 25 decal on rear transom, Jim Clark signature on LH buttress and inner
door panels, race roundels on doors with Type 25 decals. USA cars used 7-splitspoke black forged wheels,
alloy gear knob, black diffuser.
2009 M.Y. Introduction: September 2008 (final '08 cars: Elise 2308; Exige 2304; 2-Eleven 2292)
VIN character 10 = 9. VIN serial number restarts at 0001.
No changes apart from Cup 260.
Page 7
Lotus Service Notes
Introduction
2009 M.Y. Lotus Sport Exige Cup 260: October 2008
Lightweight body panels using carbon fibre, rear window deleted from rear bulkhead. Lightweight components incl. battery, c/c U-bends, billet flywheel, new forged 12-spoke roadwheels in 7 & 8 inch widths, rear
subframe with DeltaProtekt coating, deletion of footwell pads, interior mirror, sunvisors, tailgate strut. HANS
approved seats. Body coloured SBAF 'A' frame. Chassis drilled for front cage. New body graphics.
2010 M.Y. Introduction: May 2009 (final '09 cars: Elise TBA; Exige; TBA; 2-Eleven TBA; USA TBA)
VIN character 10 = A. VIN serial number restarts at 0001.
Elise range unchanged. Exige S (on USA & Gulf only from 0360): Front clamshell with restyled lower section including larger air intake ducts with a horizontal vane in each oil cooler duct. New full width body colour
front splitter. Wider, body mounted rear aerofoil, supported by end plates. All models: reduced emissions and
improved economy figures.
2010 M.Y. Lotus Sport Exige Cup 260: August 2009
Adoption of Exige S front clam and rear aerofoil (see above) using some carbon elements. Strengthened
engine bay undertray with new fixings to provide 'shear panel' stiffening of subframe suspension mounts. Ohlins
2-way adjustable dampers. Lightened Lotus Sport 5-spoke wheels. Carbon centre console.
Exige S Type 72: December 2009
Celebrates Type 72 F1 twenty GP victories. Limited edition of 20 for U.K., 20 for Europe, plus selected
RoW territories. Phantom Black with gold pin-striping, gold Exige S on rear, Type 72 on passenger 'B' panel.
Sport and Touring Packs. Machined forged 5-spoke wheels in black and gold. Black microfibre trim with gold
stitching. Build plaque with GP win.
Exige Scura/Stealth: January 2010
Limited edition of 35 cars for Europe and some RoW territories. Badged as 'Stealth' for Japan. Based
on Exige S with Cup 260 features including powertrain, suspension and body. Soft feel matt black paint finish
with gloss Phantom Black triple stripes. Forged 10-splitspoke wheels in matt black. Laquered carbon fibre
seat shells and centre tunnel. Anthracite gear knob and parking brake sleeve.
2011 M.Y. Introduction: March 2010
VIN character 10 = B. VIN serial number restarts at 0001.
Exige range unchanged. Changes to Elise range include: Revised front body with enlarged oil cooler intake
ducts and chin spoilers, restyled radiator outlet ducts, one-piece lift out access cover, aluminium mesh grilles.
Revised rear body with restyled bumper incorporating licence plate plinth, new engine/boot lid, aluminium mesh
grilles, separate rear transom panel without faux end grilles, new diffuser. New headlamp units incorporating
LED turn lamps and LED daytime running lamps. New 12-spoke cast roadwheels, or new 5-'Y'spoke forged
wheels. Elise S model replaced by base Elise with 1.6 ltr. IZR FAE engine, featuring inlet and exhaust cam
VVT-i, and VALVEMATIC inlet valve lift control, Lotus T6 controller; new 6-speed type EC60 transmission;
revised rear subframe; optional cruise control.
Page 8
Lotus Service Notes
Introduction
ENGINE BAY UNDERTRAY/DIFFUSER
For certain service operations, it may by necessary to remove the engine bay undertray and/or diffuser
panel. The panels contribute to the aerodynamic performance of the car, and also help to keep the engine bay
clean. Do not run the car without the panels fitted.
Typical model shown - others similar
3 screws to licence
plate plinth
1 screw each side
to grille panel
b275b
Diffuser panel
3 screws
each side
Single screw each to tank bay
side to clamshell panel
Undertray
front edge
M8 button head slots into
(2) to subframe 5 screws M8 button head chassis
undertray (2) to lower
to diffuser link brackets
Page 9
Lotus Service Notes
Introduction
JACKING POINTS
Care must be taken when using a lifting jack or hoist to position the device only in one of the the areas
shown in the illustration, with a suitable rubber or timber pad protecting the chassis from surface damage. If a
4-point lift is to be used, the engine bay undertray/diffuser panel (if fitted) must first be removed. When using
a 4-point lift, it is strongly recommended that for optimum stability and safety, positions B and D are used.
A; Identified by a blue sticker. Beneath crossmember ahead of fuel tank bay. To be used one side at a time
for wheel changing - lifts both wheels on one side. Do not use with a four point garage lift.
B; Beneath the front end of the right or left hand main chassis rail, behind the front wheelarch. Garage use
with 4-point lift in conjunction with (C).
C; The engine undertray/diffuser panel must first be removed. Beneath the outboard end of the chassis
crossmember ahead of the rear wheelarches. Take care to position the jack between the fixing screws
for the fuel tank bay perforated undershield. Garage use with 4-point lift in conjuction with (B).
D; The engine undertray/diffuser panel must first be removed. Beneath the rear subframe, close to the lower
wishbone rearmost mountings.
Jacking at any other point may damage the chassis or body structure and/or jeopardise safety.
Page 10
ohs49sn
Publication Part Number A120T0327J © Lotus Cars Ltd. May 2010
This publication has been designed for use by Lotus Dealers familiar with general workshop safety procedures and practices. Take all appropriate action to guard against injury to persons or damage to property.
Lotus policy is one of continuous product improvement, and the right is reserved to alter specifications at
any time without notice.
Whilst every care has been taken to ensure correctness of information, it is impossible to guarantee complete freedom from errors or omissions, or to accept liability arising from such errors or omissions, but nothing
herein contained shall affect your statutory rights.
Lotus Service Notes
Introduction
CONTENTS
ELISE & EXIGE; 2004 M.Y. ONWARDS; WITH 1ZZ/2ZZ/1ZR ENGINE
Section
Technical Data - Engine TDP
- Vehicle
TDQ
Chassis
AH
Bodycare & Repair
BQ
Body Fittings
BR
Front Suspension
CI
Rear Suspension
DH
Engine & Engine Management - Lotus supplement
- Toyota 1ZZ/2ZZ repair manual EH
* see separate manual E120T0327J
- Toyota 1ZR repair manual ** see separate CD T000T1523F
Transmission
- Lotus supplement
Engine Management
- Toyota C64/C56 repair manual
# see separate manual E120T0327J
- Toyota EC60 repair manual
## see separate CD T000T1523F
*
**
EMP
FJ
#
##
Wheels & Tyres
GH
Steering
HG
Brakes
JJ
Engine Cooling
KH
Fuel System - Except North America
- North America
Electrics
LJ
LK
Circuit Diagrams: non - USA prior '06
Circuit Diagrams: USA - prior '06
Circuit Diagrams: '06 Onwards
Circuit Diagrams: '08 Onwards
Circuit Diagrams: '11 Onwards 1ZR Powertrain
MP
MP14a
MP14b
MP14c
MP14d
MP14e
Maintenance & Lubrication
OI
Air Conditioning, Heating & Ventilation
PL
Clutch
QH
Supplementary Restraint System - SRS (Airbags)
WD
Supplement - Exige Supercharged (S/C)
Exige S/C
Supplement - 2-Eleven
2-Eleven
Page 1
Updated 18th May 2010
Lotus Service Notes
Introduction
VEHICLE IDENTIFICATION NUMBER & ENGINE NUMBER
The Vehicle Identification Number (V.I.N.) is stamped on the chassis in the right hand front wheelarch area,
viewable with the front wheels turned to right full lock, and is also printed on a label stuck to the inside of the
chassis sideframe alongside the driver's seat. 1ZZ and 2ZZ engine numbers are marked on a vertical patch at
the right hand side of the rear face of the cylinder block, adjacent to the clutch housing.
ohs119a
V.I.N. LABEL
On the 1ZR engine, the number is stamped on
the left hand front of the cylinder block, alongside the
alternator, and is prefaced by ‘1ZR’.
V.I.N. ON
CHASSIS
ohs104
1ZZ/2ZZ ENGINE NUMBER
1ZR
ENGINE
NUMBER
ohs133
5
:2
ohs176
Both V.I.N. and engine numbers should always be quoted with any vehicle enquiries, as Factory records
are filed against V.I.N., and specification change points are identified by V.I.N. or engine number. The vehicle
licence plate should be disregarded in this context as it may not accurately reflect vehicle age, and may also
be changed during the car’s life.
The V.I.N. comprises 17 characters, coded in accordance with European Economic Community (EEC)
and National Highway Traffic Safety Association (NHTSA) directives. For change point identification in Service
Notes, Service Bulletins and Service Parts Lists, typically, only characters 10 (model year), and 14 to 17 (serial
number) will be quoted.
Page 2
Lotus Service Notes
2004 M.Y. - 2010 M.Y. serial no. 0359
Vehicle Type
Manufacturer 111 = Elise/Exige Check Identifier Code 123 = 2-Eleven Digit
S C C
1 2 3 4
5
6 7 8
9
10
Assembly Plant Model
H = Hethel 2 = 2-Eleven
B = Shah 3 = Elise
Alam 8 = Exige
11
Engine Type Restraint Model Year
A = 2ZZ s/c 260 c/c A = Active belts 4 = 2004
C = 2ZZ 190 no evap C = Dual S.I.R. 5 = 2005
L = Motorsport + active belts 6 = 2006
N = 2ZZ s/c 255 7 = 2007
P = 2ZZ 190 evap 8 = 2008
V = 2ZZ s/c 220 c/c 9 = 2009
W = 2ZZ s/c 240 c/c A = 2010
Y = 1ZZ 140
Z = 2ZZ s/c 220 2010 M.Y. serial no. 0360 onwards
Manufacturer
Code
Model
HC = Elise
HH = Exige
NB = 2-Eleven
Restraint
A = 3pt no SIR
C = Dual SIR
L = 4pt no SIR
S = 5pt no SIR
Introduction
12
13
14151617
Chassis/Body
A = LHD Fed. C = RHD
D = LHD
F = U.K. SVA RHD
G = U.K. SVA LHD
H = M/sport LHD*
J = M/sport RHD*
L = LHD Fed. a.c.
M = LHD Can. a.c.
N = RHD a.c.
P = LHD a.c.
Model Year
A = 2010
B = 2011
C = 2012
D = 2013
E = 2014
F = 2015
Serial
Number
* Track only. Not
approved for road use
Market Spec.
A = LHD USAG = LHD SVA
B = LHD CanadaH = LHD Track
C = RHD OtherJ = RHD Track
D = LHD OtherL = South Korea
E = Gulf States
F = RHD SVA
S C C L H 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Brand
L = Lotus
Engine
A = 2ZZ s/c 260 c/c
B = 2ZZ s/c 260 c/c
no evap
C = 2ZZ 190 no evap
L = Motorsport
P = 2ZZ 190 evap
V = 2ZZ s/c 220 c/c
W = 2ZZ s/c 240 c/c
X = 1ZR 135
Y = 1ZZ 140
Z = 2ZZ s/c 220
Check
Digit
Plant
H = Hethel
Build Type
1 = Std.
2 = Proto.
Serial Number
Page 3
Lotus Service Notes
Introduction
MODEL HISTORY MILESTONES (does not include all special editions)
Elise 111R Introduction: January 2004
VIN character 4 = P; Character 13 = 3; Serial number from 0970
Note that the serial number sequence is shared with other Elise variants.
Changes from previous model include: Toyota powertrain with 1.8 litre VVTL-i engine and 6-speed transmission. Twin exhaust tailpipes exiting through centre of diffuser. Larger fuel tank with new pump. Revised
chassis rail rear ends, new rear subframe, revised seat belt mounting frame backstays. Revised rear suspension wishbones, springs and dampers. ABS brake control with vacuum servo. Revised front bonnet grilles
and access covers.
2004 Exige Introduction: March 2004
VIN character 4 = P; Character 13 = 8; Serial number from 1092
Note that the serial number sequence is shared with other Elise variants.
Differences compared with Elise 111R include: Restyled front and rear clamshells with roof scoop, new
tailgate panel and strut mounted rear aerofoil. Front body splitter panel. Re-styled road wheels, wider on the
front, and Yokohama A048 tyres.
2005 M.Y. Elise for North America: May 2004
VIN character 10 = 5; Character 12 = L; Serial number from 0001
Note that the serial number sequence is shared with other Elise variants when '05 M.Y. is adopted for
those models later in the year.
Differences compared with Elise 111R include: Driver and passenger airbags, pyrotechnic seat belt pretensioners; Re-styled fascia and dashboard structure; Front speakers moved onto top surface of fascia, stowage pockets incorporated into dashboard end panels, fixed windscreen demist vents. Engine start button in
driver's side switch panel. Revised springs and dampers, Yokohama AD07 tyres. Side marker lamps on front
and rear wheelarch lips. Revised fuel system with fuel filler flap.
Lotus Sport Exige 240R: March 2005
Limited edition of 50 units produced as post registration official factory conversions of '05 Exige by the
Lotus Sport workshops at Hethel, for U.K. and certain overseas territories. The car is not identifiable from the
VIN coding.
Differences compared to standard Exige include: 243 bhp engine upgrade using Eaton M62 supercharger
with integral by-pass valve, air/air chargecooler and 5th fuel injector. Re-programmed ECU. Accusump.
Stiffened springs & Ohlins adjustable dampers. Adjustable front anti-roll bar. Chassis rear brace kit. Forged
5-spoke widened roadwheels & Yokohama A048 tyres. Motorsport brake pads, braided hoses, yellow callipers,
Castrol SRF brake fluid. Sport Yellow body colour with black wheels, or Sport Black body with silver wheels.
Black interior with yellow inserts. 4-point harnesses, T45 roof hoop and backstays.
2006 M.Y. Introduction: September 2005
VIN character 10 = 6; Serial number restarts at 0001, common to all variants.
Introduction of USA Exige and Canadian Elise.
5-speed Elise remains unchanged.
Differences between 6-speed '06 Elise and '05 include; Electronic throttle control (using no mechanical
cable). Optional Lotus Traction Control (LTC) or Limited Slip Differential (LSD) with LTC. Standard fit Yokohama
AD07 tyres on non-USA cars. Optional forged wheels with new 6.0 in front size. LED rear lamp clusters incorporating reflectors (formerly separate), and commonised USA type CHMSL. ProBax seat foams. New body
colours. USA & Canadian Elise; revised fuel tank and evap. loss system. Canadian Elise uses daytime running
lights and clutch down start allow switch. USA Exige similar to non-USA, but with USA airbag interior.
Sports Racer: October 2005
Special paint versions of '06 M.Y. 111R in either Ardent Red with triple Monaco White stripes, or Nightfall
Blue with twin Monaco White stripes. Combined total of 199 units with unique build plate on sill. Forged wheels
(6J on front), AD07 tyres, sport suspension, twin front oil coolers, LTC. Black leather interior with red or blue
stitching, and red or blue 'Elise' embroidered into head restraints. Sports Racer decals.
Page 4
Lotus Service Notes
Introduction
Exige Cup 190 & 240: January 2006
Limited number of competition oriented naturally aspirated (190) or supercharged (240) models produced
as post registration official factory conversions of '06 Exige by the Lotus Sport workshops at Hethel for U.K.
and certain overseas territories. Not identifiable from VIN coding.
Differences compared to 240R (see above) include: Electronic throttle, high flow port injectors (no 5th).
Cup 240 fitted with torque sensing LSD with LTC. Cup 190 uses friction plate LSD. Standard Exige wheels in
'Hi-power' silver. Race cars fitted with FIA 6-point roll cage, remote kill switch, extinguisher system. Standard
body colours.
Exige S: February 2006
VIN character 4 = V
Factory built type approved supercharged Exige. Not USA.
Differences to standard Exige include: 221 PS supercharged engine similar to 240R but using electronic
throttle, smooth flow inlet adaptor, standard injectors without 5th injector, modified downpipe, optimised muffler
with single oval tailpipe. Enlarged roof duct inlet for chargecooler. Body colour splitter, scoops and aerofoil.
'Exige S' decal on rear transom, 'S' on front quarter panels.
USA Lotus Sport Elise: March 2006
Limited edition of 50. Saffron Yellow with twin Storm Titanium stripes. Saffron Yellow centre console. Yellow highlighted sports seats, 'carbon' door trim inserts. Harness bar, T45 seat belt mounting frame. Motorsport
mats, stalks, winders and parking brake sleeve. Traction control, supersport suspension, black forged wheels,
Yokohama A048s, braided brake hoses, silicone fluid, motorsport clutch. Lotus Sport decals and Union flags.
Lotus Sport chassis plate.
2007 M.Y. & Elise S Introduction: June 2006
VIN character 10 = 7; Serial number restarts at 0001, common to all variants.
VIN character 4 identifies engine type. Elise S = Y
Differences between '07 Elise/Exige and '06 include: Elise 111R renamed Elise R; New sealed headlamp
units; raised LOTUS lettering on rear transom; additional screen pillar seal; Alpine audio; improved HVAC ducting. New model Elise S uses 1ZZ-FE engine producing 100 kW, with variable inlet timing but fixed valve lift,
plastic inlet manifold, revised intake snorkel, revised exhaust manifold and downpipe, smaller tailpipes within
standard trims. Elise S also uses new C56 5-speed transmission and 6-spoke roadwheels sharing styling of
standard '01 model wheels.
USA Exige S: October 2006
The specification of the USA Exige S is that of the standard USA Exige and option packs, apart from the
engine, which is as non-USA Exige S with the following exceptions: High flow port injectors, specific engine
programming, 223 PS, 223 Nm. Carry-over features from the non-USA Exige S include exhaust downpipe and
optimised muffler with single oval tailpipe, roof air intake funnel mouth.
Exige S British GT Special Edition: November 2006
Celebrating Lotus Sport Cadena’s 2006 British GT3 Team Championship victory.
Differences to standard Exige S include: Torsen LSD & Lotus Traction Control. Chassis rear brace kit.
T45 roof hoop & stays. Braided brake hoses. Level 1 sports exhaust. Forged 7-bifurcated spoke silver wheels.
Lotus Sport black metallic body colour with Sport yellow & Arctic silver quad stripes, supplier decals on sills,
Lotus Sport visor strip, Cadena decals on front wings, GT3 decal on rear clam, GT3 winners decal with unique
build number on rear quarter panel, Lotus Sport build plate with build number. 4-point harnesses, black/yellow
door trims and unique black/yellow trimmed seats. Optional a.c. Optional GT pack available as post registration
official factory conversion by Lotus Sport workshops at Hethel for U.K. and certain overseas territories, includes:
High flow injectors, different ECU & unique calibration for 243 bhp, Accusump, 2-way adjustable Ohlins dampers
with uprated springs, 308mm front discs & 4-piston A.P. callipers, Pagid pads, Castrol SRF brake fluid.
Page 5
Lotus Service Notes
Introduction
USA Low Speed Damage Mitigation: January 2007
From ‘07 USA VIN serial no. 1579.
To meet USA safety legislation, modifications made to Elise/Exige: Front; armatures and foam inserts
added between crash structure and clamshell. Rear; bumper panel housing foam pads either side of licence
plate, narrower rear grilles, reinforced boot floor and diffuser support panel, stiffened diffuser. Some elements
commonised for all markets.
Lotus Sport Exige Cup 255: January 2007
Produced as post registration official factory conversions of '07 Exige S by the Lotus Sport workshops at
Hethel for certain territories, excluding U.K. and USA. Not identifiable from VIN coding.
Based on Exige Cup 240 (see above) with following differences: Power increase to 255 PS by; unique
ECU calibration, enlarged chargecooler, extended roof duct, larger air cleaner and intake spout, uprated fuel
pump. A.P. Racing 4 piston alloy front callipers, 308mm front discs.
2-Eleven Introduction: May 2007
VIN character 6/7/8 = 123; Character 13 = 2
Extreme, minimalist, track focussed Elise variant based on Exige Cup 255 powertrain componentry, but
using new chargecooler arrangement. Produced in small numbers for U.K. and certain overseas territories. In
U.K. only, SVA road going version available. All other territories only for track use, in LHD or RHD.
New body with no doors or roof. Aeroscreen. Rear aerofoil in two versions. FIA compliant roll over bar.
Chassis rear brace, unique front top wishbones and steering arms, optional Ohlins suspension. Accusump,
twin front oil coolers. Standard LTC, optional variable LTC & Launch Control. Uprated clutch. Odyssey battery.
Limited warranty for SVA cars. Extensive options list.
USA Elise Limited Edition 'Type 72D'
Limited edition of 50 cars to commemorate the 35th anniversary of Lotus' F1 1972 World Championship
victory with the type 72D.
Phantom black body colour with hand painted gold pinstriping. Rear body spoiler, black diffuser. Gold
laurel leaf decal on front quarters, gold 'Elise' and 'Type 72D' decals, gold raised LOTUS lettering, gold/black
nosebadge, gold fuel filler cap. Gold Exige 8 split-spoke wheels with Yokohama A048 tyres and sports suspension. Black & gold seats and interior trim details with Limited Edition plaque. Scale model crash helmet.
Club Racer: September 2007
Limited edition of 25 for U.K. Unlimited for Europe.
For U.K., spec. based on '07 Exige S with Sport, Touring & Super Touring packs and a.c.. Sports exhaust
supplied for dealer fitment.
For Europe, spec. based on '08 Exige S (see below) with Sport and Performance packs. Forged
wheels.
All cars: Hethel track decal on rear transom, Le Mans blue body with Phantom black triple stripe. Black
leather and carbon effect trim with colour coded stitching.
Introduction of 2008 Model Year Elise/Exige: October 2007
VIN character 10 = 8. VIN serial number restarts at 0001. Exige N.A. built only to special order.
All cars now with dual airbags and start button in matt charcoal finish fascia. PFK 457 security system
with Lotus design transmitter key. Tyre pressure monitoring for USA only. High rpm sequential tell tales. CAN
bus diagnostics using laptop Lotus Techcentre. New paint colours. Performance Pack option (VIN character
4 = W) with 240 hp calibration, high flow injectors, big roof scoop, uprated clutch, 4-piston front brake callipers
and enlarged front discs, variable traction and launch control (excludes warranty).
Elise S Hethel 40th Limited Edition: October 2007
Commemorating 40 years of production at Hethel. All LHD.
'08 M.Y. Elise S in Burnt Orange with hardtop. Orange body grilles and centre console. Black diffuser
and wheels. Black leather seats and door trim with orange stitching. Build plaque. Country decals below side
repeater lamps. 7 Union Flag, 6 Swiss, 2 Belgium, 4 French, 10 German, 6 Italian.
Page 6
Lotus Service Notes
Introduction
Elise 'California' Limited Edition: October 2007
USA only. 25 off Ardent Red with cream/red leather and champagne trim; 25 off Saffron Yellow with black
leather and champagne trim.
Based on USA Elise with touring pack. Rear body spoiler. Silver front intake grilles, other grilles in body
colour. 16-spoke cast wheels in Hi-power silver, AD07 tyres. Lotus roundel and California decals on front
wings. Sports seats in cream & red or black leather. Other trim in cream & red or black leather. Hardtop lining
in Beige cloth. RHD footwell divider.
Exige Sprint: November 2007
Limited edition of 40 cars for U.K. market, one for each year from 1967 to 2006. +20 E.U. +2 Japan.
'08 M.Y. Exige S with Sport, Touring and Performance Pack, a.c., black forged wheels, 2-tone paint in
Aspen White and either Persian Blue or Saffron Yellow, with gold decal strip and 'Exige Sprint' logo. Union flag
on rear body, laurel decal on LHR quarter, colour coded leather seats and trim, embroidered footwell carpet
mats. Build plaque on chassis sill.
Introduction of Elise SC: February 2008 (final '07 M.Y. serial no. 3579)
Supercharged Elise without chargecooler.
VIN character 4 = Z
Based on Elise R, but using new Eaton M45 supercharger rotor pack integrated into inlet manifold, high
flow fuel injectors and unique calibration to produce 220 PS. Rear body spoiler, Lotus styled 12-spoke road
wheels in 6.0 and 8.0 front/rear widths, standard AD07 tyres. Wheelarch lips on non-USA cars. 'Elise Supercharged' decals on rear transom and front wings.
Lotus Sport Exige Cup 260: February 2008
Fully Type Approved version of Exige Cup 255 (see above).
VIN character 4 = A
Based on Exige S with: Big roof scoop, high output fuel pump, unique calibration to produce 260 PS.
Accusump, lightweight flywheel, uprated clutch, Torsen LSD, Variable Traction and Launch control (excludes
warranty). 4-piston front brake callipers and enlarged front discs, braided hoses, Bilstein or Ohlins adjustable
spring/dampers, stiff adjustable ARB in hard mounts, hi-power silver 16-spoke cast wheels, A048 tyres. FIA
compliant battery isolator and plumbed-in fire extinguisher. T45 seat belt anchorage frame. FIA compliant
cage and 4-point harnesses supplied separately. NO airbags and none pre-tensioner 3-point belts. No CDL.
Black Alcantara/carbon effect seats and door trim. Build plaque on dash, 'Lotus Sport' decal on front quarter
panels, 'Cup 260' decal on rear transom, black diffuser. Restricted warranty.
USA Elise SC '60th Anniversary': May 2008
Limited edition of 60 USA cars to commemorate 60th anniversary of Lotus Cars.
Based on Elise SC with hard and soft tops, Touring and Sport Packs, supersport suspension, forged
wheels, A048 tyres, T45 seat belt frame & harness bar. Body and double stripe paint in BRG/Saffron, Saffron/
Black, Black/Arctic, Storm Titanium/Canyon Red. Complimentary trim inserts and 60th Anniversary embroidery.
Anniversary decal on rear transom.
Clark Type 25 Elise SC: June 2008
Limited edition of 25 U.K./25 E.U./25 USA cars to commemorate 40th anniversary of Jim Clark's death.
Donation to the Jim Clark memorial fund.
Based on Elise SC with hard top and Sport Pack. BRG (B04) with Saffron single centre stripe, Lotus Sport
wheels with black spokes and silver rims, A048 tyres. Black & red leather themed interior, with sports seats,
wood gearknob and build plaque. Type 25 decal on rear transom, Jim Clark signature on LH buttress and inner
door panels, race roundels on doors with Type 25 decals. USA cars used 7-splitspoke black forged wheels,
alloy gear knob, black diffuser.
2009 M.Y. Introduction: September 2008 (final '08 cars: Elise 2308; Exige 2304; 2-Eleven 2292)
VIN character 10 = 9. VIN serial number restarts at 0001.
No changes apart from Cup 260.
Page 7
Lotus Service Notes
Introduction
2009 M.Y. Lotus Sport Exige Cup 260: October 2008
Lightweight body panels using carbon fibre, rear window deleted from rear bulkhead. Lightweight components incl. battery, c/c U-bends, billet flywheel, new forged 12-spoke roadwheels in 7 & 8 inch widths, rear
subframe with DeltaProtekt coating, deletion of footwell pads, interior mirror, sunvisors, tailgate strut. HANS
approved seats. Body coloured SBAF 'A' frame. Chassis drilled for front cage. New body graphics.
2010 M.Y. Introduction: May 2009 (final '09 cars: Elise TBA; Exige; TBA; 2-Eleven TBA; USA TBA)
VIN character 10 = A. VIN serial number restarts at 0001.
Elise range unchanged. Exige S (on USA & Gulf only from 0360): Front clamshell with restyled lower section including larger air intake ducts with a horizontal vane in each oil cooler duct. New full width body colour
front splitter. Wider, body mounted rear aerofoil, supported by end plates. All models: reduced emissions and
improved economy figures.
2010 M.Y. Lotus Sport Exige Cup 260: August 2009
Adoption of Exige S front clam and rear aerofoil (see above) using some carbon elements. Strengthened
engine bay undertray with new fixings to provide 'shear panel' stiffening of subframe suspension mounts. Ohlins
2-way adjustable dampers. Lightened Lotus Sport 5-spoke wheels. Carbon centre console.
Exige S Type 72: December 2009
Celebrates Type 72 F1 twenty GP victories. Limited edition of 20 for U.K., 20 for Europe, plus selected
RoW territories. Phantom Black with gold pin-striping, gold Exige S on rear, Type 72 on passenger 'B' panel.
Sport and Touring Packs. Machined forged 5-spoke wheels in black and gold. Black microfibre trim with gold
stitching. Build plaque with GP win.
Exige Scura/Stealth: January 2010
Limited edition of 35 cars for Europe and some RoW territories. Badged as 'Stealth' for Japan. Based
on Exige S with Cup 260 features including powertrain, suspension and body. Soft feel matt black paint finish
with gloss Phantom Black triple stripes. Forged 10-splitspoke wheels in matt black. Laquered carbon fibre
seat shells and centre tunnel. Anthracite gear knob and parking brake sleeve.
2011 M.Y. Introduction: March 2010
VIN character 10 = B. VIN serial number restarts at 0001.
Exige range unchanged. Changes to Elise range include: Revised front body with enlarged oil cooler intake
ducts and chin spoilers, restyled radiator outlet ducts, one-piece lift out access cover, aluminium mesh grilles.
Revised rear body with restyled bumper incorporating licence plate plinth, new engine/boot lid, aluminium mesh
grilles, separate rear transom panel without faux end grilles, new diffuser. New headlamp units incorporating
LED turn lamps and LED daytime running lamps. New 12-spoke cast roadwheels, or new 5-'Y'spoke forged
wheels. Elise S model replaced by base Elise with 1.6 ltr. IZR FAE engine, featuring inlet and exhaust cam
VVT-i, and VALVEMATIC inlet valve lift control, Lotus T6 controller; new 6-speed type EC60 transmission;
revised rear subframe; optional cruise control.
Page 8
Lotus Service Notes
Introduction
ENGINE BAY UNDERTRAY/DIFFUSER
For certain service operations, it may by necessary to remove the engine bay undertray and/or diffuser
panel. The panels contribute to the aerodynamic performance of the car, and also help to keep the engine bay
clean. Do not run the car without the panels fitted.
Typical model shown - others similar
3 screws to licence
plate plinth
1 screw each side
to grille panel
b275b
Diffuser panel
3 screws
each side
Single screw each to tank bay
side to clamshell panel
Undertray
front edge
M8 button head slots into
(2) to subframe 5 screws M8 button head chassis
undertray (2) to lower
to diffuser link brackets
Page 9
Lotus Service Notes
Introduction
JACKING POINTS
Care must be taken when using a lifting jack or hoist to position the device only in one of the the areas
shown in the illustration, with a suitable rubber or timber pad protecting the chassis from surface damage. If a
4-point lift is to be used, the engine bay undertray/diffuser panel (if fitted) must first be removed. When using
a 4-point lift, it is strongly recommended that for optimum stability and safety, positions B and D are used.
A; Identified by a blue sticker. Beneath crossmember ahead of fuel tank bay. To be used one side at a time
for wheel changing - lifts both wheels on one side. Do not use with a four point garage lift.
B; Beneath the front end of the right or left hand main chassis rail, behind the front wheelarch. Garage use
with 4-point lift in conjunction with (C).
C; The engine undertray/diffuser panel must first be removed. Beneath the outboard end of the chassis
crossmember ahead of the rear wheelarches. Take care to position the jack between the fixing screws
for the fuel tank bay perforated undershield. Garage use with 4-point lift in conjuction with (B).
D; The engine undertray/diffuser panel must first be removed. Beneath the rear subframe, close to the lower
wishbone rearmost mountings.
Jacking at any other point may damage the chassis or body structure and/or jeopardise safety.
Page 10
ohs49sn
Lotus Service Notes
TECHNICAL DATA - ENGINE
SECTION TDP
Section TDP
Page
General ....................................................................................................................
Cylinder Block ..........................................................................................................
Cylinder Head ..........................................................................................................
Valves & Springs ...................................................................................................... Camshafts ................................................................................................................
Pistons ..................................................................................................................... Connecting Rods ......................................................................................................
Crankshaft ...............................................................................................................
Oil Pump .................................................................................................................. Coolant Thermostat .................................................................................................. 2
3
3
3
3
3
3
3
3
4
Page 1
Lotus Service Notes
Section TDP
GENERAL (for supercharged cars see section Exige S/C)
Type designation - All nat. asp.except Elise S 2ZZ-GE
- Elise S 1ZZ-FE
- 2011 Elise
1ZR-FAE
Configuration & no. of cylinders in-line 4 - -
Capacity 1796 cm3 1794 cm³ 1598 cm3
Bore 82.00 mm 79.00 mm 80.50 mm
Stroke 85.00 mm 91.50 mm 78.50 mm
Camshafts Chain drv DOHC - Valves 4VPC in pentroof - chambers
Valve control - inlet Variable timing Variable timing Variable timing
& 2 stage lift & lift
- exhaust Variable lift - Variable timing
Valve timing - inlet - low & med speed- open 33°BTDC to 10° TDC
- close 15°ATDC to 58°ATDC
- high speed - open 58° BTDC to 15° BTDC
- close 54° ABDC to
97° ABDC
- all speeds - open 48°BT to 5°BT 10°BT to 70°AT
- close 12°AT to 55°AT 70°AB to 60°BB
- exhaust- low & med speed- open 14° BBDC
- close 34° ATDC - high speed - open 36° BBDC
- close 60° ATDC
- all speeds - open 42° BBDC 65°BB to 30°BB
- close 2° ATDC 1°BT to 34°AT
Compression ratio 11.5:1 10.0:1 10.7:1
Compression pressure (250 rpm) - new 1400 kPa 1500 kPa 1400 kPa
- service limit 1000 kPa - Firing order 1,3,4,2 - Spark plugs NGK IFR6A11 NGK BKR5EYA-11Denso 20HR11
Spark plug gap 1.1 mm 1.0 ± 0.05 mm 1.0 - 1.1 mm
Maximum continuous engine speed 8000 rpm 6,800 rpm 6,800 rpm
Maximum transient engine speed 8500 rpm 7,000 rpm 7,000 rpm
Idle speed 850 rpm 850 rpm 760 rpm
Ignition system Direct ignition - Plug top coils - -
Fuel system Fully sequential - indirect injection, - Lotus T4 ECU - Lotus T6 ECU
Fuel requirement (minimum) Unleaded 95 RON - Peak power (1999/99/EC) 141 kW (192 PS) 100 kW (136 PS) 100kW(136 PS)
@ 7,800 rpm @ 6,200 rpm @ 6,800 rpm
Peak torque (1999/99/EC) 181 Nm 172 Nm 160 Nm
@ 6,800 rpm @ 4,200 rpm @ 4,400 rpm
Exhaust emissions - CO 0.42 g/km 0.23 g/km 0.27 g/km
- HC (THC) 0.078 g/km 0.050 g/km 0.064 g/km
- NMHC 0.058 g/km
- NOx 0.0121 g/km 0.0217 g/km 0.025 g/km
- HC + NOx 0.0901 g/km 0.0717 g/km
- CO2 - pre '10 208 g/km 196 g/km
- 2010 on 196 g/km 179 g/km 155 g/km
Page 2
Lotus Service Notes
Section TDP
CYLINDER BLOCK
Material
Deck face flatness tolerance
Cylinder bore diameter (mm)
2ZZ-GE
1ZZ-FE
1ZR-FAE
Aluminium alloy, MMC bores
0.05 mm
82.000 - 82.013
Aluminium alloy,
cast iron liners
-
79.000 - 79.013
Aluminium alloy
cast iron liners
80.500 - 80.633
CYLINDER HEAD
Material
Head face flatness tolerance
Reface limit
Aluminium alloy
0.05 mm
No machining -
-
-
-
VALVES & SPRINGS
Valve seat angle in head Valve face angle
Cold valve clearance (cam & follower)- inlet
- exhaust
Valve guide standout - inlet
- exhaust
Valve spring free length - inlet
- exhaust
45°
44.5°
0.10 - 0.16 mm
0.24 - 0.30 mm
15.3 - 15.7 mm
15.3 - 15.7 mm
46.4 mm
46.5 mm
-
-
0.15 - 0.25 mm
0.25 - 0.35 mm
8.7 - 9.1 mm
8.7 - 9.1 mm
45.9 mm
45.9 mm
Hydraulic
Hydraulic
9.0 - 10.3 mm
11.15 - 11.55
53.4 mm
53.4 mm
- new 0.04 - 0.14 mm
- service limit 0.15 mm
0.04 - 0.10 mm
0.11 mm
0.06 - 0.16 mm
0.17 mm
CAMSHAFTS
End float
PISTONS
Diameter- @ 90° to pin, 12 mm from bottom edge 81.975 - 81.993
- @ 90° to pin, 25 mm from top edge 78.925 - 78.935
Ring gap- 110 mm from bore top - std. - no.1 0.25 - 0.35 mm - no.2 0.35 - 0.50 mm - oil rail 0.15 - 0.40 mm - max.- no.1 1.1 mm - no.2 1.2 mm - oil rail 1.1 mm - 50 mm from bore top -std. - no.1
- no.2
- oil rail
- max.- no.1
- no.2
- oil rail
Ring groove clearance 0.030 - 0.070 mm -
0.20 - 0.30 mm
0.30 - 0.50 mm
0.10 - 0.40 mm
0.50 mm
0.70 mm
0.70 mm
0.02 - 0.07 mm
CONNECTING ROD
Small end bush inside diameter
Big end side clearance
20.011 - 20.023 0.16 - 0.34 mm
20.012 - 20.021
-
20.012 - 20.021
-
CRANKSHAFT
Crankshaft endfloat - new
- service limit
Main journal diameter
Crankpin diameter
Max. taper & out of round, journals & crankpins
0.04 - 0.24 mm
0.30 mm
47.988 - 48.000
44.992 - 45.000
0.02 mm
0.04 - 0.24 mm
0.30 mm
-
43.992 - 44.000 0.02 mm
0.04 - 0.14 mm
0.18 mm
43.992 - 44.000
0.004 mm
OIL PUMP
Oil pressure
39 kPa min.
300 - 540 kPa 29 kPa min.
300 - 540 kPa
25 kPa min.
150 - 550 kPa
- idle, running temperature
- 3,000 rpm, running temperature
80.470 - 80.496
Page 3
Lotus Service Notes
Section TDP
Outer rotor to housing clearance - new
- service limit
Inner rotor tip clearance - new
- service limit
Rotor end float - new
- service limit
2ZZ-GE 1ZZ-FE
0.13 - 0.18 mm -
0.33 mm -
0.06 - 0.18 mm -
0.33 mm -
0.03 - 0.08 mm -
0.16 mm -
1ZR-FAE
0.12 - 0.19 mm
0.08 - 0.16 mm
0.09 - 0.14 mm
-
COOLANT THERMOSTAT
Valve opening temperature
Valve lift
Header tank pressure cap
Cap opening pressure
80 - 84°C
10 mm @ 90°C
108 kPa
93 - 123 kPa
10 mm @ 82°C
-
Page 4
-
-
-
Lotus Service Notes
Section TDQ
TECHNICAL DATA - VEHICLE
SECTION TDQ
Page
Dimensions ........................................................................................................ 2
Capacities .......................................................................................................... 3
Wheels & Tyres ................................................................................................... 3
Front Suspension ................................................................................................. 4
Rear Suspension ................................................................................................. 4
Electrical ............................................................................................................. 5
Transmission ....................................................................................................... 6
Clutch .................................................................................................................. 6
Brakes ................................................................................................................. 7
Steering ............................................................................................................... 7
Fuel Consumption ............................................................................................... 7
Page 1
Updated 9th June 2010
Lotus Service Notes
DIMENSIONS
Overall length - Elise - pre 2011
- 2011 on
- Exige
Overall width - exc. mirrors - Elise
- Exige
- inc. mirrors
Overall height (at kerb weight) - Elise
- Exige
Wheelbase
Track - front
- rear
Ground clearance (mid-laden) - except std. USA
- std. USA
Front overhang - Elise - pre '11
- '11 on
- Exige
Rear overhang - Elise - pre '11
- '11 on
- Exige
Approach angle (at kerb) - pre '11
- '11 on
Departure angle (at kerb)
Unladen weight - 111R/Elise R - total
(lightest) - front
- rear
- Elise S - total
(lightest) - front
- rear
- USA Elise - total
(heaviest) - front
- rear
- Elise 2011 - total
(lightest) - front
- rear
- non-USA Exige - total
- front
- rear
- non-USA Exige S- total
- front
- rear
- USA Exige - total
- front
- rear
Max. weight - 111R/R, Exige - total
- front
- rear
- Elise S - total
- front
- rear
- USA Elise - total
- front
- rear
- Elise 2011 - total
- front
- rear
- non-USA Exige S- total
- front
- rear
Section TDQ
3785 mm
3824 mm
3797 mm
1719 mm
1727 mm
1850 mm (approx.)
1117 mm
1159 mm
2300 mm
1457 mm
1507 mm
130 mm
135 mm
783 mm
805 mm
805 mm
702 mm
719 mm
692 mm
13.5°
12.5°
23°
860 kg >
327 kg > incl. full fuel tank
533 kg >
862 kg }
328 kg } incl. full fuel tank
534 kg }
912 kg )
344 kg ) incl. full fuel tank
568 kg )
876 kg ]
342 kg ] incl. full fuel tank
534 kg ]
875 kg >
328 kg > incl. full fuel tank
547 kg >
935 kg }
355 kg } incl. full fuel tank
580 kg }
920 kg )
350 kg ) incl. full fuel tank
570 kg )
1166 kg >
443 kg > incl. occupants & luggage
723 kg >
1126 kg }
428 kg } incl. occupants & luggage
698 kg }
1162 kg )
441 kg ) incl. occupants & luggage
721 kg )
1141 kg ]
429 kg ] incl. occupanta & luggage
712 kg ]
1199 kg >
456 kg > incl. occupants & luggage
743 kg >
Page 2
Updated 9th June 2010
Lotus Service Notes
Trailer towing
CAPACITIES
Engine oil - refill inc. filter - 2ZZ/1ZZ
(+ 3.5 litre if front mounted oil coolers are drained)
- 1ZR
High/low dipstick mark difference - 2ZZ/1ZZ
- 1ZR
Transmission oil - 2ZZ
- 1ZZ
- 1ZR
Fuel tank
Coolant
Refrigerant (R134a)
Rear luggage compartment
Section TDQ
Not permissible
4.4 litre
4.8 litre
1.5 litre
1.0 litre
2.3 litre
1.9 litre
2.4 litre
43.5 litre
12 litre
550 g
50 kg/112 litre
WHEELS & TYRES
Tyres
Type - Elise std. - prior '06
- from '06
- USA Elise
- Elise option, Exige
Size - front - Elise std.
- USA Elise
- Elise option, Exige
- rear - Elise std. - RE040
- AD07
- USA Elise - AD07
- Elise opt. Exige - A048
Pressure (cold) - front
- rear
Bridgestone Potenza RE040
Yokohama Advan Neova AD07
Yokohama Advan Neova AD07
Yokohama A048
175/55 R16 80W
175/55 R16 80W
195/50 R16 84W
225/45 R17 90W
225/45 R17 91W
225/45 R17 91W
225/45 R17 90W
1.8 bar (26 lb/in²)
2.0 bar (29 lb/in²)
Winter Tyres
Type - front
- rear
Size - front
- rear
Pressure (cold) - front
- rear
Tyre studding
Tyre chains
Pirelli 210 Snowsport
Pirelli 240 Snowsport
195/50 R16
215/45 R17
1.8 bar (26 lb/in²)
1.9 bar (27.5 lb/in²)
Not permitted
Pewag Brenta-C XMR69 fitted only on rear winter tyres
Wheels
Type - Elise 111R/R/USA
- Elise S
- Elise 2011
- Exige std. - Elise/Exige option
- Elise 2011 option
Size - front- Elise std.
- Elise option
- Elise option, Exige
- rear
Wheel bolt torque
Cast alloy, 8 spoke
Cast alloy, 6 spoke
Cast alloy, 12 spoke
Cast alloy, 8 Y-spoke
Forged alloy, 7 split-spoke
Forged alloy, 5 Y-spoke
5.5J x 16
6.0J x 16 (forged + AD07)
6.5J x 16 (forged + A048)
7.5J x 17
105 Nm (77 lbf.ft)
Page 3
Lotus Service Notes
FRONT SUSPENSION
Type
Steering axis inclination
Section TDQ
Independent. Upper and lower wishbone; co-axial coil spring/telescopic damper unit; anti-roll bar
12 ° nominal
Geometry specification - Standard Elise:
Mid-laden ride height (reference height for geometry check)
- USA Elise from VIN 3013 & 111R/R/S - front 130 mm below front end of chassis siderail - rear 130 mm below rear end of chassis siderail
- USA Elise prior VIN 3013 - front 135 mm below front end of chassis siderail
- rear 135 mm below rear end of chassis siderail
Castor - optimum + 3.8°
- tolerance range + 3.5° to + 4.1°; max. side/side 0.35°
Camber - optimum - 0.1°
- tolerance range + 0.1° to - 0.3°; max. side/side 0.2°
Alignment - optimum Zero
- tolerance range 0.5 mm toe out, to 0.7mm toe-in overall
Geometry specification - Elise option, Exige:
Mid-laden ride height (reference height for geometry check)
- front 130 mm below front end of chassis siderail - rear 130 mm below rear end of chassis siderail
Castor - optimum + 3.8°
- tolerance range + 3.5° to + 4.1°; max. side/side 0.35°
Camber - optimum - 0.3°
- tolerance range - 0.1° to - 0.5°; max. side/side 0.2°
Alignment - optimum Zero
- tolerance range 0.5 mm toe out, to 0.5 mm toe-in overall
Geometry specification - Elise option, Exige:
Mid-laden ride height (reference height for geometry check)
- front 120 mm below front end of chassis siderail - rear 120 mm below rear end of chassis siderail
Castor - optimum + 3.8°
- tolerance range + 3.5° to + 4.1°; max. side/side 0.35°
Camber - optimum - 0.2°
- tolerance range + 0.1° to - 0.3°; max. side/side 0.2°
Alignment - optimum Zero
- tolerance range 0.5 mm toe out, to 0.7 mm toe-in overall
REAR SUSPENSION
Type Independent. Upper and lower wishbone; co-axial coil spring/telescopic damper.
Geometry specification - Standard Elise:
Mid-laden ride height (reference height for geometry check)
- USA Elise from VIN 3013 & 111R/R/S - front 130 mm below front end of chassis siderail - rear 130 mm below rear end of chassis siderail
- USA Elise prior VIN 3013 - front 135 mm below front end of chassis siderail
- rear 135 mm below rear end of chassis siderail
Camber - optimum - 1.8°
- tolerance range - 1.6° to - 2.0°; max.side/side 0.2°
Alignment - optimum 1.2 mm toe-in each side
- tolerance range 1.2 to 1.8mm toe-in each side
max.side/side 0.3 mm
Page 4
Lotus Service Notes
Section TDQ
Geometry specification - Elise option, Exige:
Mid-laden ride height (reference height for geometry check)
- front 130 mm below front end of chassis siderail - rear 130 mm below rear end of chassis siderail
Camber - optimum - 1.8°
- tolerance range - 1.6° to - 2.0°; max.side/side 0.2°
Alignment - optimum 1.5 mm toe-in each side
- tolerance range 1.2 to 1.8 mm toe-in each side
max.side/side 0.3 mm
Geometry specification - Elise option, Exige:
Mid-laden ride height (reference height for geometry check)
- front 120 mm below front end of chassis siderail - rear 120 mm below rear end of chassis siderail
Camber - optimum - 2.5°
- tolerance range - 2.0° to - 2.7°; max.side/side 0.2°
Alignment - optimum 1.8 mm toe-in each side
- tolerance range 1.5 to 2.0 mm toe-in each side
max.side/side 0.3 mm
ELECTRICAL
Light Bulbs
Headlamps - prior '07 - main beam
- dip beam
- from '07 - main beam
- dip beam
2011 Elise - main beam
- dip beam
Driving lamps
Front side/parking lamps - except '11 Elise
- 2011 Elise
Side repeater lamps - except '11 Elise
- 2011 Elise
Front turn indicators - except '11 Elise
- 2011 Elise
Rear turn indicators - prior '06
- from '06
Stop/Tail lamps - prior '06
- from '06 Stop lamps (USA) - prior '06
- from '06
Tail lamps - prior '06
- from '06
Tail/turn lamps (USA) - prior '06
Rear fog lamps - except '11 Elise
- 2011 Elise
Reversing lamp - prior '06
- from '06
High mounted stop lamp - Elise
- Exige
Licence plate lamps
Interior lamp
Wattage
55
55
55
55
65 60
55
5
-
5
-
21
-
21
16
4/21
-
21
-
5
-
4/21
4/21
-
21
16
2.5
5
5
5
System voltage/polarity
Alternator
- 1ZR FAE
12V negative earth
85A
100A
Type
H7
H1
H7U
H7U
H9B
HB3A
H3
W5W
5 x LED
WY5W amber
LED
PY21w amber
11 x LED
H21
W16W capless
P21/4w
20 x LED
H21
20 x LED
R5W 20 x LED
P21/4w
P21/4w
10 x LED
H21
W16W capless
16 x LED
W5W capless
C5W
W5W
Page 5
Lotus Service Notes
Section TDQ
Battery - non USA - type Varta Blue Dynamic 544 402 044 3132
- short code B18
- capacity 44 Ah
- cold test current 440 A (EN)
- dimensions L 207, W 175, H 175mm
- USA - type Delco 19001598
- BCI code 26R-6YR
- cranking power 550 amps @ -18°C
- reserve capacity 80 minutes
TRANSMISSION
Gearbox - all except Elise S 6-speed manual transaxle incl. final drive
- Elise S 5-speed manual transaxle incl. final drive
Differential - standard Open, bevel gear
- option Torsen or plate type LSD combined with with Lotus Traction Control engine progamming
Transmission designation - expt Elise S & '11 Elise C64
- Elise S C56
- 2011 Elise EC60
Gear
Ratio
mph (km/h)/1000 rpm
C64
C56
EC60
C64
First
3.17
3.17
3.54
5.1 (8.2)
5.36 (8.62)
4.75 (7.64)
Second
2.05
1.90
1.91
7.7 (12.4)
8.73 (14.1)
8.79 (14.1)
Third
1.48
1.39
1.31
10.7 (17.2)
12.0 (19.2)
12.8 (20.6)
Fourth
1.17
1.03
0.97
13.6 (21.8)
16.2 (26.0)
17.3 (27.9)
Fifth
0.92
0.82
0.82
17.3 (27.8)
20.4 (32.8)
20.6 (33.1)
Sixth
0.81
-
0.70
19.4 (31.3)
Reverse
3.25
3.25
3.33
Final Drive
4.53
4.31
4.29
CLUTCH
Type
Friction plate diameter - 2ZZ/1ZZ
- 1ZR FAE
Diaphragm finger clearance - 2ZZ/1ZZ
Max. finger wear - 1ZR FAE - depth
- width
Diaphragm finger height - 2ZZ/1ZZ - new
- service limit
Max. finger tip non-alignment - 1ZR FAE
-
EC60
24.0 (38.6)
Single dry plate. Diaphragm spring cover. Hydraulic release.
215 mm
212 mm
1.00 mm
0.5 mm
6.0 mm
37.5 - 32.1 mm
42.75 mm
0.5 mm
Friction plate thickness 2ZZ/1ZZ
Rivet depth 2ZZ/1ZZ
1ZR FAE
- new
- service limit
- new
- service limit
- service limit
7.4 - 6.9 mm
5.6 mm
1.0 mm
0.2 mm
0.3 mm
Friction plate run-out 2ZZ/1ZZ
1ZR FAE
Pressure plate warp 2ZZ/1ZZ
- new
- service limit
- service limit
- service limit
0.8 mm
1.0 mm
0.8 mm
0.15 mm
Page 6
C56
Lotus Service Notes
BRAKES
Brake discs
Calipers - front
- rear
Disc size - front & rear
Operation
Parking brake
STEERING
Type
Turns, lock to lock
Gear ratio
Rack height plate
Turning circle - between walls (excl. mirrors)
- between kerbs
FUEL CONSUMPTION
1999/100/EC - urban - prior 2010
- Elise R, Exige
- - Elise SC
- Exige S
- from 2010
- Elise R
- - Elise SC
- Exige S
- extra urban - prior 2010
- Elise R, Exige
- Elise SC
- Exige S
- from 2010
- Elise R
- Elise SC
- Exige S
- combined - prior 2010
- Elise R, Exige
- Elise SC
- Exige S
- from 2010
- Elise R
- Elise SC
- Exige S
Page 7
Section TDQ
Cast iron, curved vane ventilated, cross-drilled discs on all four wheels.
A.P. Racing, aluminium alloy body, one pair of opposed pistons
Brembo, cast iron, single piston sliding rear calipers
288 mm
Tandem master cylinder with vacuum servo and Kelsey Hayes EBC430 Anti-lock system
Cable operation of rear calipers, self adjusting for pad wear.
Rack and pinion
2.8
15.8:1
6 notch
10 m
10.8 m
1ZZ-FE
11.3 l/100km
-
-
-
10.6 l/100km
-
-
-
-
6.5 l/100km
-
-
-
5.8 l/100km
-
-
-
-
8.3 l/100km
-
-
-
7.6 l/100km
-
-
-
-
2ZZ-GE
-
12.1 l/100km
11.6 l/100km
12.3 l/100 km
-
11.6 l/100km
11.8 l/100km
11.9 l/100 km
-
-
6.8 l/100km
6.7 l/100km
9.1 l/100 km
1ZR FAE
-
-
-
8.3 l/100km
-
6.2 l/100km
6.4 l/100km
6.5 l/100km
-
-
8.8 l/100km
8.5 l/100km
9.1 l/100km
-
8.2 l/100km
8.5 l/100km
8.5 l/100km
-
5.0 l/100km
6.28 l/100km
Lotus Service Notes
Section AH
CHASSIS
SECTION AH
Sub-Section
Page
General Description
AH.1
3
Chassis Straightness Check
AH.2
4
Rear Subframe
AH.3
5
Page 1
Page 2
Seat belt mounting
frame backstay
Sill extrustion
Steel rear subframe
a29b
Lotus Service Notes
Main siderail
Fuel tank bay
Door hinge
mounting
ELISE CHASSIS UNIT
Seat belt mounting
frame steel roof hoop
Composite Scuttle Seat mounting crash structure beam extrusion
Section AH
Lotus Service Notes
Section AH
AH.1 - GENERAL DESCRIPTION
The chassis frame of the Lotus Elise is constructed primarily from aluminium alloy extrusions and formed
alloy sheet, with the various sections bonded together using an epoxy adhesive with secondary drive-in fasteners. The basic chassis unit includes the passenger cell, front suspension mountings, fuel tank housing, and mid
mounted engine bay, with a fabricated sheet steel rear subframe bolting to the rear of the engine bay to provide
rear suspension mountings and rear body support. A tubular steel seat belt mounting frame is bolted to the top of
the chassis structure and incorporates a roof hoop for additional occupant protection. The cabin rear bulkhead,
body sills (inc. 'B' posts), front energy absorbing crash structure and scuttle/windscreen mounting frame, are all
constructed from glass fibre composite and are bonded to the chassis structure using an elastomeric adhesive.
The front and rear outer body clamshells are each constructed from glass fibre composite mouldings, fixed to
the body and chassis structure with threaded fasteners to facilitate service access and economic repair.
Two main chassis siderail extrusions, 210mm deep and 100mm wide, run along each side of the passenger
compartment between the front and rear suspension mountings, splaying outwards towards the rear before
curving inwards around the fuel tank bay and terminating at each side of the engine bay in a vertical section to
provide engine mounting platforms and a flange to which the rear subframe is attached. To enhance cockpit
access, the height of the siderails is reduced in the door area, and internal reinforcement added in order to
maintain beam strength and torsional rigidity.
Running along the underside of the siderails from the front suspension crossmember to the fuel tank bay
are sill extrusions which carry the cockpit floor panel. The single skin floor panel is swaged for stiffness, and
is reinforced by a ribbed transverse extrusion running across the inside of the tub, which also provides for the
seat mountings. Behind the passenger cell, the siderails are linked by a pair of transverse crossmembers
which are used in conjunction with a folded sheet upper panel to form an open bottomed fuel tank cell with a
detachable, screw fixed, closing panel with swaged lightening holes. Note that this lower panel contributes to
the structural integrity of the chassis, such that the vehicle should not be operated without it fitted.
The rear ends of the siderails are joined behind the engine bay by a galvanised sheet steel fabricated
subframe which provides mountings for the rear suspension pivots nad damper abutment, engine rear stabiliser
and exhaust muffler.
At the front of the passenger compartment, four transverse extrusion beams are used to provide mountings
for the front suspension pivots, and house the steering rack, with an upright section used each side to anchor
the top of the spring/damper unit. Five interlinked extruded floor sections together with additional extrusions,
connect the transverse beams to form an open topped space to house the heater/a.c. unit. An extruded scuttle beam links the tops of the siderails at the front of the cockpit, and is reinforced by a panel extending to the
steering rack crossmember. These elements are used to mount the steering column and pedal box, with a
vertical extrusion fixed to each end of the scuttle beam to carry the door hinge pillar.
To the front end of the chassis is bonded a glass fibre composite 'crash structure' which incorporates
tubular sections designed to dissipate collision energy and control the rate of deceleration sustained by the
occupants. Ducting and mountings for the horizontally positioned engine cooling radiator are also incorporated
in this structure.
The bonded and rivetted alloy chassis structure described above is considered a non-serviceable single
unit, jig built to fine tolerances, to which no structural repairs are approved. Superficial, cosmetic, or non-structural
localised damage may be cosmetically repaired as necessary, but in the case of accident damage resulting in
significant bending, tearing or distortion of the aluminium chassis, such that the specified suspension geometry cannot be achieved by the standard range of suspension adjustment provided, the recommended repair
is to renew the partial body assembly, which comprises the chassis, rear subframe and the seat belt mounting
frame together with jig bonded composite rear bulkhead, body sills, windscreen frame and crash structure.
Also included are the radiator feed and return pipes in the chassis siderails, and those pipes and cables routed
through the sills, including the heater and a.c. pipes, battery cable, clutch and brake pipes, and brake servo
and oil cooler hoses.
Page 3
Lotus Service Notes
Section AH
AH.2 - CHASSIS STRAIGHTNESS CHECK
In the absence of visual damage, the chassis may be checked for twist or distortion by utilising the tooling
holes in the underside of the main side rails. If computer processed laser measuring equipment is not available, manual checks can be made with reference to an accurately level ground plane, e.g. an accurately set
and maintained suspension geometry ramp/lift. Position the car on the lift, and proceed as follows:
1.
Identify the tooling holes in the lower surface of each chassis main side rail. At the front end, between the
suspension wishbone pivots, and at the extreme rear end of each rail.
2.
Measure the height of each tooling hole above the reference plane and use jacks to adjust the height of
the chassis in order to equalise any three of these dimensions.
3.
Measure the deviation of the fourth dimension from the other three.
Maximum service deviation = ± 2.0 mm.
4.
Repeat operations (2) and (3) for each combination of corners to result in four values for the 'fourth' dimension deviation. If any one of these exceeds the service specification, the chassis should be considered
damaged and replaced by a partial body assembly.
FRONT
REAR
Tooling hole
Tooling hole
Front wishbone Rear wishbone
Page 4
a27/27a
Lotus Service Notes
Section AH
AH.3 - REAR SUBFRAME
The rear ends of the chassis siderails are linked by a fabricated sheet steel subframe which provides
mountings for the rear body section, rear suspension pivots, engine rear stabiliser, exhaust muffler and seat
belt mounting frame struts. The subframe is secured to the siderails by two M12 bolts at each side, with an
anti-corrosion shim plate interposed.
To remove rear subframe
1. Remove the rear clamshell (see section BR).
2.
Remove exhaust heatshields, catalytic converter and muffler.
3.
Disconnect the parking brake cables, wheel speed sensor harnesses and rear brake hydraulics. Release
the driveshafts from the hubs, and remove both rear suspension assemblies complete, providing alternative support for the driveshafts.
4.
Disconnect the inertia switch, and release from the subframe the oxygen sensor harness, wheel speed
sensor harnesses and brake pipes.
5.
Release the engine rear stabiliser mounting from either the subframe or transmission.
6.
Release the roof hoop backstays from the subframe. Remove the two bolts each side securing the subframe
to the chassis flange and withdraw the subframe from the car.
Fitting rear subframe
When bolting the subframe at each side to the chassis rail rear flange, ensure that the anti-corrosion
shim plate is interposed. The lower fixing bolts should be inserted from the rear, using a washer and Nyloc nut
inside the chassis extrusion. Apply Permabond A130 (A912E7033V) to the threads of the upper bolts before
fitting from the front into the weldnuts in the subframe. Tighten all four bolts to 86 Nm. Continue re-assembly
in reverse order to disassembly.
Seat belt mounting
frame backstay
Backstay to subrame
fixing bolt
Subframe upper
mounting bolt
Rear subframe
Chassis
Anti-corrosion shimplate
Subframe lower mounting bolt
Page 5
a30
Lotus Service Notes
Section BQ
BODYCARE & REPAIR
SECTION BQ
Sub-Section Page
General Description
BQ.1
3
Lotus Composite Body Features
BQ.2
3
Bodycare
BQ.3
4
Accident Damage Assessment
BQ.4
5
Body Panel Bonding Materials
BQ.5
6
Replacement of Bonded-On Panels - General
BQ.6
9
Front Crash Structure
BQ.7
10
Windscreen Frame
BQ.8
12
Sill Panels
BQ.9
16
Rear Bulkhead
BQ.10
17
Page 1
Lotus Service Notes
Section BQ
Body Panels
Door
shell
Windscreen Sill panel
Front access frame
panel Rear
window
shroud
Engine
cover lid
Front
clamshell
Door hinge
cover panel
Cabin rear
bulkhead
Front crash
structure
Chassis frame
Page 2
Rear clamshell
b277b
Lotus Service Notes
Section BQ
BQ.1 - GENERAL DESCRIPTION
The body panels of the Lotus Elise are constructed of composite materials, with the external panels not
being required to contribute to chassis rigidity. The panels are attached to the aluminium chassis and/or other
body panels either by elastomeric polyurethane adhesive, or in the case of the front and rear clamshells, are
bolted on for ease of dis-assembly and access to chassis parts. The composite mouldings are manufactured
by one of several processes (see later) dependent on application, with a nominal thickness of 2.2 - 2.5 mm.
The windscreen frame incorporates foam beams to create closed box sections for optimum strength and a
‘crash structure’ bonded to the front of the chassis incorporates longitudinal box sections to provide specific
crush characteristics and absorb crash impact by progressive collapse. This structure also acts as a mounting
and duct for the engine cooling radiator which is mounted horizontally on its top surface.
BQ.2 - LOTUS COMPOSITE BODY FEATURES
Composite structures have the ability to absorb high impact loads by progressive collapse, with impact
damage being localised. In vehicle accidents this feature protects the occupants from injurious shock loads and
greatly reduces the danger of entrapment by deformation of steel body panels. This behaviour also facilitates
repair by either replacing the damaged bonded or bolt on panels, and/or integrating a replacement section
with the undamaged area, using recognised approved methods which restore the panel to its original condition
without residual strain or distortion.
The manufacturing process enables the thickness of composite mouldings to be varied in order to pro­vide
efficient structures of high strength and low weight. Composites will not corrode, so the strength of composite
components is retained regardless of age, unless physical damage is sustained. On the Elise, the body construction features an assembly of mouldings to form a single piece for the whole of the nose and front wings,
and a similar assembly for the whole of the rear body aft of the doors. These two 'clamshells' are fixed using
threaded fasteners to permit easy removal for access to chassis or powertrain components, or to allow simple
and economic accident repair. Other composite mouldings include the door shells, sills, front compartment
lid, windscreen frame and rear bulkhead, some panels being bonded to the aluminium alloy chassis with an
elastomeric adhesive.
A composite panel may return to its original shape after deflection, but beyond a certain level of flexibility,
such treatment may result in the formation of surface cracks which may not be immediately apparent due to
the masking effect of the paint film. A steel panel similarly treated would become dented or deformed. The
cracking may be confined to the surface layer with no reduction in panel strength, but if the damage is more
severe the composite structure below the surface may be weakened. Localised repairs can be made in either
case. Possible causes of surface cracking include:
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Vehicle collision;
Sitting, leaning heavily or pushing on the body or any composite panel;
Knocking doors against obstructions when opening;
Dropping objects onto a panel;
Allowing unrestrained items to roll about in a luggage compartment;
Fitting a front access panel or closing the engine cover onto projecting objects, e.g. luggage or tools;
Applying excessive force to parts attached to composite panels e.g. mirrors, locks, aerial etc. (inc. action
byvandals).
Incorrect jacking.
The composite body panels of the Elise are manufactured by one of several processes dependent on the
requirements of the panel concerned:
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The front and rear clamshells, sill panels, windscreen frame, door outer panels, hard top roof outer panel
and front crash structure are produced by Injection Compression System Resin Transfer Moulding (ICSRTM), whereby a mix of polyester resin and glass fibres is injected into a heated, chrome steel surfaced,
closed mould. After filling, the gap between the two halves of the mould is then reduced in order to compress the moulding and ensure complete material flow and consistent structural quality. Panel thickness
is a nominal 2.2 mm. The absence of the 'gel coat' used with other processes results in much greater
resistance to surface damage, and minimum surface preparation for before painting.
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Lotus Service Notes
Section BQ
The front access panels, engine cover lid, door hinge panels, door and roof inners and rear window shroud
are produced from Low Pressure Sheet Moulding Compound (LPSMC), whereby flat sheets of composite
material are formed using heated, chrome steel surfaced moulds to produce panels with a nominal thickness of 2.5 mm.
A third process is used for the cabin rear bulkhead, bootbox and radiator mounting panel where the panel
surface is not primarily visible. These panels are produced by a Polyurethane Structural Reaction Injection Moulding (PU SRIM) process.
Body panels unique to the Exige model, including front and rear clamshells, door hinge cover panels and
tailgate panel, are 'hand lay' composite mouldings with a nominal thickness of 2.5 mm.
Whichever production process applies, conventional composite repair techniques can be used to rectify
structural or surface damage whenever repairs can be determined as being more economic than panel replacement.
BQ.3 - BODYCARE
The acrylic enamel paint finish of the Elise is extremely resistant to all normal forms of atmospheric attack.
Following the simple maintenance procedure summarised below will help retain the gloss, colour and protective
properties of the paint throughout the life of the vehicle. However, car finishes are not immune to damage, and
amongst the more common causes of deterioration are:
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Atmospheric contaminants; dust, soot, ash, and acidic or alkaline aerosol mist can chemically attack
paint.
Abrasion; blowing sand and dust, or a dirty washing cloth.
Tree sap and insect fluids; can form a water‑insoluble polymer that adheres to the paint.
Bird excrement; highly acidic or alkaline, they can chemically etch the paint. Wash off immediately.
Leaves; contain tannic acid which can stain light finishes.
Impact damage; granite chippings thrown up from poor or recently dressed road surfaces can subject the
body to severe localised impact, and result in paint chips, especially around the vulnerable frontal panels.
Do not follow other vehicles too closely in such circumstances.
Washing
Lotus recommends that the car be hand washed, using the following instructions:
Many contaminants are water soluble and can be removed before any harm occurs by thorough washing
with plenty of lukewarm water, together with a proprietary car wash additive (household detergent and washing
up liquid can contain corrosive salts, and will remove wax and accelerate oxidation). Frequent washing is the
best safeguard against both seen and invisible contaminants. Wash in the shade, and use a cotton chenille
wash mitt or a sponge rinsed frequently to minimise entrapment of dirt particles. Use a straight back and forth
washing motion to avoid swirled micro scratches, and rinse thoroughly.
In order to minimise degradation from road salt, the underside of the chassis should be rinsed with clean
water as soon as possible after driving on treated roads. Many fuel filling stations offer pressure washing facilities ideal for this purpose, but to not use on the painted bodywork or soft top roof.
Soft Top Roof:
1. Careful vacuuming of the soft top before washing may be helpful in removing excess dust and other foreign
particles.
2. Wash in partial shade rather than strong sunlight, and wet the whole car before tackling the soft top.
3. Using only clean lukewarm water and a sponge (a chamois or cloth will leave lint, and a brush may abrade
the threads) wash the entire top uniformly. Do NOT use a detergent, which may affect the waterproofing
properties of the material.
4. Rinse the whole car to remove all soap from the fabric and to prevent streaking on the car bodywork.
5. Remove surface water with a sponge and allow to air dry in direct sunlight. Ensure that the roof is fully dry
before stowing, as prolonged stowage of a wet or damp roof will promote rotting of the fabric.
Keeping the soft top clean by regular washing will enhance the life and maintain the appearance of the
roof, and facilitate subsequent cleaning. The use of stronger cleansers should be left to professionals experi­
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Lotus Service Notes
Section BQ
enced in handling this type of fabric as discoloration and degradation of the special protective inner layer may
result. The application of wax finishes, dressings or preservatives will cause stains which are difficult to remove
and therefore should be avoided.
Paintwork Polishing
Eventually some loss of gloss, and an accumulation of traffic film, will occur. At this stage, after normal
washing, the application of a good quality liquid polish will restore the original lustre of the paint film. Higher
gloss of the paint finish, and added protection against contamination, can be obtained by the use of a wax
polish; however, this can only be used successfully on a clean surface, from which the previous application has
been removed with white spirit or a liquid polish cleaner.
Ventilation
Water lying on the paint surface for a lengthy period will eventually penetrate the paint film. Although the
effects will not be visible immediately, a deterioration in the protective properties of the paint film will ultimately
result. It is not recommended to store a wet car in a poorly ventilated garage. If good ventilation cannot be
provided, storage outside on a hard standing or under a carport is to be preferred.
BQ.4 - ACCIDENT DAMAGE ASSESSMENT
The repair method to be employed in the rectification of accident damage to composite panels, is to be
assessed reletive to the particular panel and its method of attachment:
Bolt-on Panels: - Front Clamshell;
- Rear Clamshell;
- Door Shells;
- Front Body Access Panels;
- Engine Cover Lid;
- Door Hinge Cover Panels;
- Rear Window Shroud;
- Hard Top Roof.
These panels are secured by threaded fasteners and are easily removed for access to the back of any
damaged area for repair by conventional composite techniques. Instructions for the removal and refitment of
these panels are contained in section BR.
Bonded-on Panels: - Windscreen Frame;
- LH & RH Sill Panels;
- Front Crash Structure;
- Rear Bulkhead
These panels are bonded to the chassis or to other panels using a flexible polyurethane adhesive which
must be cut before the panel may be removed. In some cases, it may be necessary to partially remove another
panel before the subject panel can be released. It is not generally economic to attempt to remove a bonded
panel intact for later re-fitment.
The integrity of the front crash structure is crucial to the safety of the car in a frontal collision, and it is recommended not to attempt any major repair of this component. The damaged structure should be cut from the
front of the chassis, and a new assembly bonded into position. The shape and positioning of the windscreen
frame is crucial to the fit of the windscreen and sealing of the soft top roof, such that the only repairs which
should be considered for this panel are cosmetic and superficial; any structural damage should entail panel
replacement.
The sill panels include the ‘A’ and ‘B’ posts, and involve much labour time to replace. Localised repairs
should be performed whenever possible, although access to the inside surface of some parts of the panels is
not freely available.
Note that if damage is such as to require replacement of the chassis, replacement chassis assemblies are
provided only as a 'partial body assembly' which includes jig bonded front crash structure, windscreen frame,
side sills and rear bulkhead. The roof hoop and rear subframe are also included, as are the pipes, hoses and
cables routed through the sills.
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Lotus Service Notes
Section BQ
BQ.5 - BODY PANEL BONDING MATERIALS
The materials used for bonding the body panels are manufactured by Dow Chemical, and in order to
main­tain the structural integrity of the vehicle, and in the case of the front crash structure, the safety, it is most
important to use only the specified materials. The surface preparation and cleaning and priming operations are
crucial to the performance of the adhesive, and must be followed in detail. The products to be used depend on
the surface (substrate) onto which they are applied, and the following list identifies each application:
Anodised aluminium (e.g. chassis and components)
Cleaner: Betawipe VP 04604 Lotus part no. A082B6150V
Primer: Betapnme 5404 Lotus part no. A082B6337V
Adhesive: Betaseal 1701 Lotus part no. A082B6281F
or Betamate E2400 Lotus part no. A082B8415V
Unpainted or painted composite
Cleaner: Betaclean 3900
Primer: Betaprime 5404 Adhesive: Betaseal 1701
or Betamate E2400 Lotus part no. A100B6008V
Lotus part no. A082B6337V
Lotus part no. A082B6281F
Lotus part no. A082B8415V
Zinc plated and passivated steel
Cleaner: Beatclean 3900
Primer: Betaprime VP 01706 A+B
Adhesive: Betaseal 1701
Lotus part no. A100B6008V
Lotus part no. A100B6070V
Lotus part no. A082B6281F
Glass
Cleaner: Betawipe VP 04604
Primer: Betaprime 5001
Adhesive: Betaseal 1701
or Betamate E2400
Lotus part no. A082B6150V
Lotus part no. A100B6009V
Lotus part no. A082B6281F
Lotus part no. A082B8415V
Uncoated Lexan/Perspex
Cleaner: Abrasion & dry wipe
Primer: Betapnme 5404 Lotus part no. A082B6337V
Adhesive: Betaseal 1701 Lotus part no. A082B6281F
or Betamate E2400 Lotus part no. A082B8415V
Residual adhesive (i.e. rebonding to surface after cutting off old panel)
Cleaner, primer
& re-activator: Betawipe 4000 Lotus part no. A082B6355V
Adhesive: Betaseal 1701 Lotus part no. A082B6281 F
or Betamate E2400 Lotus part no. A082B8415V
Applicator Bottle
An applicator bottle is available for use with some cleaners and primers, and has a disposable felt pad
which should be changed regularly to minimise surface contamination:
Applicator bottle: A000Z1071F
Cap: A082B6353S
Felt pad: A082B6354S
Product Usage
BETAWIPE VP 04604 (A082B6150V):
Description: Activator and cleaning agent used to promote adhesion to the substrate surface. Supplied in
a 250ml aluminium container with a YELLOW coloured cap.
Application: - Wipe on/wipe off type.
- Pour Betawipe VP 04604 into applicator bottle, and immediately refit the yellow cap onto the
container.
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Lotus Service Notes
- Push the applicator head onto the bottle, and fit the felt pad.
- Wet out the felt pan by inverting the applicator bottle and gently squeezing the sides.
- Wipe the pad over the substrate surface using minimal pressure to wet the surface.
- Immediately wipe off the activated/cleaned surface using a clean fibre free cloth, and dis­
card.
- If the substrate is very dirty, first wipe off the surface with a clean fibre free cloth and discard.
- Do not leave the caps off Betawipe containers. A milky colour indicates moisture absorption,
and the material should be discarded.
- Only decant a sufficient quantity of Betawipe for the job concerned, and never pour material
back into the container from the applicator bottle.
- Change the felt pad at regular intervals to reduce surface contamination.
Notes:
Section BQ
BETACLEAN 3900 (A100B6008V)
Description: Degreaser and cleaning agent used for the removal of contamination from the substrate surface.
Supplied in 1 litre aluminium container with a BLACK coloured cap.
Application: - Wipe on/wipe off type.
- When substrate is very dirty, first wipe off the surface with a clean fibre-free cloth and dis­
card.
- Dampen a fibre-free cloth with Betaclean 3900, and immediately replace the black cap.
- Thoroughly clean the substrate surface with Betaclean and discard the cloth.
- Wipe off the substrate with a clean fibre-free cloth and discard.
BETAWIPE 4000 (A082B6355V)
Description: Cleaning agent which acitvates the old adhesive layer to accept new adhesive. Supplied in 250
ml aluminium containers with a BLUE cap.
Application: - The residual adhesive bead should be cut with a scalpal to leave an even thickness of approximately 1 to 2 mm.
- Dampen a fibre-free cloth with Betawipe 4000 and immediately replace the blue cap.
- Thoroughly clean the substrate surface with Betawipe and discard the cloth. Do not wipe
off.
- Allow 2 - 3 minutes flash off time before applying adhesive.
BETAPRIME 5001 (A100B6009V)
Description: Adhesion promotor used to maximise the performance of the bonding between the cleaned
and/or activated surface and the adhesive compound. Supplied in 250 ml aluminium con­tainer
with GREEN coloured cap.
Application: - Two steel balls inside the container are provided to assist mixing of the contents when shaken.
Prior to decanting Betaprime 5001, shake the container for at least 60 seconds to disperse the
solid content of the material into suspension.
- Pour the primer into the applicator bottle and immediately replace the green cap.
- Wet out the felt pan by inverting the applicator bottle and gently squeezing the sides.
- Wipe the pad over the activated/cleaned substrate surface to apply a continuous film of
primer.
- Allow to dry for a minimum of 15 minutes before applying adhesive. If adhesive is not applied
with 72 hours, wipe on/wipe off with Betawipe VP 04604.
Notes: - The appearance of the primed areas should be deep black in colour with no streaks or
voids.
To achieve this appearance, apply in smooth continuous uni-directional movement, not short
backward and forward movements. The latter technique results in inconsistent film build.
Rework any poor areas after 5 minutes (tack time), applying in the same direction.
- Replace the felt pad if moisture absorption results in hardening.
- Never return unused Betaprime back into the aluminium container.
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Lotus Service Notes
Section BQ
BETAPRIME 5404 (A082B6337V)
Description: Adhesion promotor used to maximise the performance of the bonding between the cleaned
and/or activated surface and the adhesive compound. Supplied in 250 ml aluminium con­tainer
with RED coloured cap.
Application: - Two steel balls inside the container are provided to assist mixing of the contents when shaken.
Prior to decanting Betaprime 5404, shake the container for at least 60 seconds to disperse the
solid content of the material into suspension.
- Pour the primer into the applicator bottle and immediately replace the green cap.
- Wet out the felt pan by inverting the applicator bottle and gently squeezing the sides.
- Wipe the pad over the activated/cleaned substrate surface to apply a continuous film of
primer.
- Allow to dry for a minimum of 15 minutes before applying adhesive. If adhesive is notapplied
with 24 hours, re-activate by applying a further coat of Betaprime 5404.
Notes: - The appearance of the primed areas should be deep black in colour with no streaks or
voids.
To achieve this appearance, apply in smooth continuous uni-directional movement, not short
backward and forward movements. The latter technique results in inconsistent film build.
Rework any poor areas after 5 minutes (tack time), applying in the same direction.
- Replace the felt pad if moisture absorption results in hardening.
- Never return unused Betaprime back into the aluminium container.
BETAPRIME VP 01706 A+B (A100B6070V)
Description: Adhesion promotor used to maximise the performance of the bonding between the cleaned
and/or activated surface and the adhesive compound. Supplied in 250 ml aluminium con­tainers
of component A and component B.
Application: - Thoroughly shake component A container to disperse solid material. Remove the lid from the
component A container and scrape any sediment from the botton of the container. Re­place the
container lid and thoroughly shake again to disperse the solid content.
- Pour the required amount of component A into a clean container, and add the same volume
of component B. Replace lids immediately. Thoroughly mix the two components for 45 seconds
minimum.
- Leave the mixed components to stand for 30 MINUTES. (Discard if unused after 8 hours)
- Pour the pnmer into the applicator bottle and wet out the felt pan by inverting the bottle and
gently squeezing the sides.
- Wipe the pad over the cleaned substrate surface to apply a continuous THIN film of primer:
A thin, almost transparent film is all that is required. No attempt should be made to attain a
completely opaque covering.
- Allow to dry for a minimum of 4 HOURS, before applying adhesive.
Notes: - To achieve a continuous thin film of VP 01706, apply in a smooth continuous uni-directional
movement, not short backward and forward movements. The latter technique results in inconsistent film build.
- Replace the felt pad if moisture absorption results in hardening.
- Never return unused Betaprime back into the aluminium container.
BETASEAL 1701 (A082B6281F)
Description: One component moisture curing adhesive, providing high strength, permanently elastic bonds
between various substrates. Supplied in 300 ml aluminium cartridge.
Application: - Remove the cartridge end ensuring there is no damage to the reinforcing sleeve.
- Pierce the neck of the cartridge and screw on the applicator nozzle. Cut the nozzle end to the
required diameter and shape.
- Fit the cartridge into an air assisted gun, and extrude a smooth, even and continuous bead
of Betaseal to the previously prepared substrate.
- Assemble the joint within 5 MINUTES.
Notes: - If the adhesive has to be touched or manipulated for any reason, use only wetted fingers.
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Lotus Service Notes
Section BQ
BETAMATE E2400 (A082B8415V - 220ml, A100B6258V - 450ml)
Description: Two component chemically curing adhesive, providing high strength, permanently elastic bonds
between various substrates. Supplied in 220 and 450 ml aluminium cartridges.
Application: - An electrically driven Betagun Mk 11 is required to mix and extrude Betamate E2400. Refer
to the operating instructions supplied with the gun.
- Extrude a smooth, even and continuous bead of Betamate to the previously prepared substrate.
- Assemble the joint within 5 MINUTES.
Notes: - If the adhesive has to be touched or manipulated for any reason, use only wetted fingers.
Air gun
Betaseal cartridge
bj43
BQ.6 - REPLACEMENT OF BONDED-ON PANELS - GENERAL
Bonded body panels are secured using the Dow Chemical products ‘Betaseal’ or ‘Betamate’, which are
flexible polyurethane adhesives which must be cut in order for a panel to be removed. The recommended method
of adhesive cutting is with the use of a pneumatic tool such as the Chicago Pneumatic CP838 Pneu­Nife which
uses a range of differently shaped cutting knives to which is imparted a vibrating action. This tool may also be
used to remove windscreens.
Supplier:
Catalogue no.:
Recommended air pressure:
Tool air inlet:
Chicago Pneumatic, Utica, New York 13501, USA.
CP838 Pneu-Nife
60 - 90 PSIG (4.0 - 6.2 bar)
1/4” NPTF, 3/8” mm. hose size
Page 9
Lotus Service Notes
Section BQ
Operating handle
Compressed air inlet
Vibrating cutting blade
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It is not generally practical to remove a bonded panel intact, for later refitment. Consequently, when
necessary, the panel can be cut away for better access to the bonded joint. It is not necessary to remove all
traces of sealant from the joint faces on the remaining panels or chassis, but any remaining sealant must be
securely bonded and no thicker than 1 mm or the fit and joint gaps will be upset. It is essential always to follow
the cleaning/priming/bonding operations meticulously if sufficiently strong and durable bonds are to be obtained.
Always use the specified materials.
BQ.7 - FRONT CRASH STRUCTURE
The front crash structure consists of an upper and lower moulding bonded together and supplied only
as an assembly. It is bonded to the front face of the chassis, and is braced by an alloy undershield screwed
to the bottom front edge of the chassis, and to each lower side of the crash structure. The unit also acts as a
ducting for the engine cooling radiator and a.c. condenser (if fitted) which are mounted horizontally on its top
surface in a bolted-on composite radiator housing. Longitudinal tubes formed in the construction are designed
to produce a particular crush characteristic in order to control the rate of deceleration of the vehicle occupants
in a frontal collision.
Crush tubes
Radiator aperture
Crash structure
Airflow to
climate chamber
via cut outs
in tubes
Chassis front face
p84a
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Lotus Service Notes
Section BQ
To remove the crash structure:
Remove the front clamshell (see sub-section BR.5).
Remove the front undershield by releasing the three screws securing each lower side of the structure to
the shield, and the three screws securing the shield to the front lower edge of the chassis.
Drain the coolant and remove the radiator and pipework (see section KH).
Remove the driving lamps (if fitted) from the crash structure, along with the towing strut, horn, alarm siren
and wiring harness.
Use a seal cutting knife to cut the bond between the structure and the front face of the chassis. For access
to some of the bonding areas, it may be necessary to cut away some parts of the structure, rendering the
unit unsuitable for refitment. Take care not to damage the surface of the chassis when cutting the adhesive.
It is not necessary to remove all traces of old adhesive from the chassis, but a uniform surface must be
available for the new adhesive bead. The remaining adhesive must be securely bonded and be cut with
a scalpal blade to leave an even thickness of 1 - 2 mm.
Prepare the new structure for bonding:
Dry fit the new structure to the chassis, and check that a good fit is achieved. Fettle the structure or remove
old adhesive as necessary until the fit is satisfactory.
Re-activate the surface of the old adhesive on the chassis using Betawipe 4000 (see sub-section BQ.5),
and clean and prime the bonding area on the new crash structure using Betaclean 3900 and Betaprime
5404 (see sub-section BQ.5).
Bonding surface on chassis
Composite crash
structure
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Lotus Service Notes
Section BQ
Application of
adhesive bead
Betaseal bead
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Apply a bead of Betaseal/mate adhesive (see sub-section BQ.5) to the bonding surface in the manner
shown.
Fit the structure to the chassis and press into position to spread the adhesive. Use several clamps around
the joint flange to retain the structure until the adhesive has cured; This will take approximately 4 hours
dependent on atmospheric conditions, with a longer period required in dry atmospheres.
Fit the undershield, radiator (see sub-section KH.4), front clamshell (see sub-section BR.5) and remaining
parts.
BQ.8 - WINDSCREEN FRAME
The windscreen frame is a single ICSRTM moulding with hollow, foam filled sections, and incorporates a
forward extending buttress at each side to brace the frame against the front chassis. A separate dash baffle
panel is used to bridge the space between frame underside and chassis scuttle, and provide for the routing of
climate control pipework and air ducting, and other services.
Windscreen frame
Dash baffle panel
Demist air duct
Face level
vent duct
Chassis scuttle
Heater pipe
Page 12
b282b
Lotus Service Notes
Section BQ
The shape of the frame is critical to the windscreen fit, and structural repairs to the frame itself are not
recommended. It is not generally economic to attempt to remove the windscreen frame intact for refitment,
as the elastomeric adhesive bonding the frame to the chassis requires cutting with a reciprocating knife, and
access to the joints is sometimes ob­scured. The recommended procedure is to cut the frame as necessary to
allow its removal without damage to the dash baffle panel. If the sills are to remain fitted, it will be necessary
to carry out some minor work on the screen buttress to sill panel joint, where a panel overlap occurs.
To Replace Windscreen Frame
1. Remove the front wheelarch liners and front clamshell (see sub-section BR.5), and for improved access,
the two doors.
2.
Remove the windscreen (see sub-section BR.14).
3.
Remove the instrument binnacle and fascia top panel (see sub-section BR.13), and release the fixings
between dash upper extrusion and screen frame.
4.
Release the brake hose/pipe connector at the front end of each buttress on the windscreen frame. Release
all harnesses and other components from the windscreen frame buttresses as necessary.
5.
Remove the wiper motor mechanism from the windscreen frame.
6.
Use a sealant cutting tool to cut the bond between the windscreen frame buttresses and chassis, and
between the frame and 'B' posts, and between the frame underside and dash baffle panel. Remove the
windscreen frame.
7.
Cut the adhesive securing the drainage gutter around the front of the frame, to allow transfer to the new
frame.
8.
If the dash baffle panel is to be replaced, the clutch pipe and climate control cables must be released and
threaded through the panel before cutting the adhesive.
Primer band on chassis
Primer band on baffle
Dash baffle panel
Heater pipe grommet
Foam strip
Page 13
b283b
9.
Lotus Service Notes
Section BQ
To fit a new dash baffle:
- Ensure the heater feed and return pipes are fitted.
- Dry fit the panel and mark up the bonding surface on the chassis scuttle.
- Prepare and re-activate the surface of the old adhesive on the chassis using Betawipe 4000 (see
BQ.5).
- Clean and prime the upper and lower bonding faces on the new baffle panel using Betaclean 3900 and
Betaprime 5404 (see sub-section BQ.5).
- Apply a bead of Betaseal/mate adhesive (see sub-section BQ.5) to the baffle lower flange.
- Position the panel and press along the length of the joint to ensure sufficient spread of adhesive. Clamp
the panel in position until the adhesive cures.
- Apply self adhesive foam strip A082U6065V to each vertical end face of the baffle panel, wrapping over
onto the top edge and along to the primed surface. Apply a second strip up each vertical face.
10. Prepare the old adhesive bead on the chassis for fitment of the windscreen frame by removing excess
sealant from all the bonding areas on the chassis, sill panels and dash baffle to leave a consistent and
level bonding surface for the new frame. It is not necessary to remove all traces of old adhesive, but a
uniform surface must be available for the new adhesive bead. The remaining adhesive must be securely
bonded and be cut with a scalpal blade to leave an even thickness of 1 - 2 mm.
11. Fit the wiper motor assembly and windscreen washer jets to the windscreen frame.
12. If necessary, fit a new roof side rail latch plate to the windscreen header rail - it is not recommended to
refit a bracket due to the requirement for high surface quality on the bracket.
- If applicable, completely remove any old adhesive from the header rail taking care not to damage the composite substrate. Lightly abrade the bonding surface on the header rail but do not abrade the bracket.
- Clean the bonding surfaces on the header rail and bracket with Betaclean 3900 (see sub-section
BQ.5).
- Prime the header rail with Betaprime 5404, but do not prime the bracket.
- Generously coat the bonding surface of the bracket, with a 50/50 mix of Betamate 7064S (A116B0159V)
and Betamate 7014 (A116B0158V). Fit the bracket to the header rail and wipe off extruded adhesive with
Betaclean 3900. Position the bracket using tool T000T1422F (RH) or T000T1423F (LH), which sould be
taped to the header rail for at least 30 minutes.
13. Before fitting the windscreen frame, ensure that two setting rods are available for positioning the frame:
- Cut two 670mm lengths of locally sourced 10mm diameter steel rod.
14. - Prepare and re-activate the old adhesive bead on the chassis using Betawipe 4000 (see BQ.5).
- Clean and prime the bonding area on the new windscreen frame with Betaclean 3900 and Betaprime
5404 (see sub-section BQ.5).
- Apply a bead of Betaseal/mate adhesive (see sub-section BQ.5) to the whole of the bonding flange on the
windscreen frame and butresses, including the mating face between frame underside and baffle panel.
- Carefully fit the windscreen frame onto the chassis and press into position to ensure adequate adhesive
compression. Ensure the frame is positioned correctly in relation to the roll-over bar by fitting the two setting rods in the roof siderail locating slots. The rods should locate snugly in the slots with no end play.
- Clamp the frame into position until the adhesive cures.
- Ensure good adhesion between the frame and baffle panel.
- Use a spatula to smooth out or remove any excess or extruded adhesive.
15. Seal the frame panel to the top of the door hinge post at each side by extruding a bead of Betaseal, and
smoothing with a spatula to obtain a neat finish.
16. Examine the whole of the bonding jointline for sealing integrity, and if necessary apply additional adhe­sive
to seal any gaps. Use a spatula to smooth any visual areas to a neat finish.
17. Do not disturb the frame until the adhesive has fully cured (see sub-section BQ.5).
18. Fit the windscreen (see sub-section BR.14), dash panel and instrument pack (BR.13), front clamshell
(BR.5), and other components as necessary.
Page 14
Lotus Service Notes
Section BQ
Windscreen frame bonding (sills not shown)
Windscreen frame
Windsceen
frame
buttress
Dash
baffle
panel
Bonding path
Page 15
b281a
Lotus Service Notes
Section BQ
BQ.9 - SILL PANELS
The sill panels incorporate the ‘A’ and ‘B’ posts, and are bonded to the chassis, windscreen frame and
rear bulkhead panel. The sill bottom flange, and rear end of the will top flange are bonded into grooves in the
chassis main side rails and it is necessary to cut the sills in the course of their removal: It is not practical to
attempt to remove a sill panel intact for later refitment. If sill damage occurs which is not repairable ‘in situ’,
the sill panel should be renewed.
To Replace Sill Panel
A short section of sill flange underlaps the windscreen frame buttress flange in the front wheelarch area
and requires that some cutting and laminating of the new panel is required on assembly.
1.
Remove front and rear clamshells (see sub-sections BR.5, BR.6), dash panel (BR.13) and door hinge
bracket (BR.8).
2.
Remove the door latch striker pin and washers, noting the assembly sequence. Remove the door sill trim
panel from the chassis and the door ajar switch from the sill panel.
3.
Use a sealant cutting knife to cut the adhesive bead between sill and chassis/body panels.
Note:
-In the front wheelarch area, a short section of the sill flange underlaps the windscreen frame buttress
flange. Unless the windscreen is also to be removed, it will be necessary to cut the sill around this flange
in order to release the sill.
-The bottom edge of the sill, and the rear part of the top edge, locate in grooves in the chassis side frame,
and may not readily be cut out with the sill intact. Cut the sill as necessary to release the panel, and then
remove the remaining edges of the panel from the chassis using a suitable cutting knife.
-Cut the sealant around the door hinge post aperture.
-Cut the sealant between the panel and roll over bar.
Slots in chassis
Door hinge siderail
post
Bonding path
Cut flange
top corner Sill panel
if necessary
Page 16
bj47a
Lotus Service Notes
Section BQ
4.
Remove excess sealant from all the bonding areas on the chassis and body panels. It is not necessary to
remove all traces of old adhesive, but any remaining adhesive must be securely bonded and be cut with
a scalpal blade to leave an even thickness of 1 - 2 mm.
5.
If necessary, cut the top front corner of the sill flange to allow mating of the panel around the windscreen
butress flange. Dry fit the sill and fettle as necessary to achieve a good fit. Note that a new sill will require
an alloy right angle bracket (A120B0053F) riveting to the rear end of the sill panel to form a bonding surface.
Holes are pre-drilled, with two pairs of holes in the bracket to suit Rover and Toyota powertrain cars. For
Toyota powertrain cars, use the innermost holes in the bracket to pull the sill panel furthest inboard.
6.
Before preparing the surfaces for bonding, ensure that the necessary pipes and cables are fitted to the
chassis side rails:
RH side: - heater feed pipe
- brake pipe
- alloy spigot for side impact foam
LH side: - heater return pipe
- brake pipe
- clutch pipe
- servo vacuum hose
- main battery positive cable
- alloy spigot for side impact foam
Check that the following components are fitted into the composite sill:
RH side: - 2 a.c. pipes (if applicable)
- oil cooler return hose (if applicable)
- side impact foam
- foam baffle
LH side: - oil cooler feed hose (if applicable)
- side impact foam
- foam baffle
7.
Prepare the bonding surface of the new sill panel with Betaclean 3900 and Betaprime 5404 (see sub­
section BQ.5). Prepare surface of the old adhesive bead on the chassis and body panels Using Betawipe
4000 (see sub-section BQ.5).
8.
Apply a bead of Betaseal/mate adhesive (see sub-section BQ.5) to the bonding surface on the chassis and
body and fit the sill panel into position, first locating the sill bottom edge into its chassis slot, and press all
around the joint to ensure sufficient spread of adhesive. If necessary, use a spatula to smooth or remove
any extruded adhesive, and to neaten any visual areas. If necessary, add adhesive to the joint around
the door hinge post, and to the windscreen frame, and smooth with a spatula.
9.
Clamp the panel into position until the adhesive has cured (see sub-section BQ.5).
10. If the top front corner of the sill flange has been cut to fit around the windscreen butress flange, this area
should be reinforced as follows: Roughen the surface of the windscreen buttress flange and the adjacent
sill panel in the modified area, and lay up two pieces of chopped strand mat across the joint.
11. Refit the dash panel, front and rear clamshells, doors, both wheelarch liners and other components as
necessary.
BQ.10 - REAR BULKHEAD
The rear bulkhead is a Polyurethane Structural Reaction Injection Moulding (PU SRIM), incorporates the
rear window surround, and is bonded to the roll over bar and chassis fuel tank bay. A heat formed polyester
fibre heat/acoustic insulator panel is bonded to the rear side of the panel, and incorporates a glass fibre aluminised cloth heat reflector shield in the vicinity of the exhaust manifold. The rear window is bonded directly
to the bulkhead using the same materials and procedure as is used for the windscreen.
Page 17
Lotus Service Notes
Section BQ
To replace the rear bulkhead:
1.
Remove the rear clamshell (see sub-section BR.6).
2.
Remove both seats, and the bulkhead interior trim panel.
3.
Remove from the inside of the bulkhead the microwave sensor and immobiliser module. Release all wiring
harnesses from the bulkhead clips.
4.
Release all fittings from the roll-over bar backstays (air cleaner, roll over valve) and remove both backstays.
5.
Taking suitable precautions, remove the fuel filler hose and filler breather hose, and cap the tank apertures
to prevent dirt ingress and reduce fire risk.
6.
Release the evaporative emissions charcoal canister and fuel filter from their bulkhead mounting brackets.
7.
Release the aerial lead from the bulkhead.
8.
Using a long knife, cut the adhesive securing the insulator panel to the bulkhead, and remove the panel
to improve access to the bulkhead bonded joint.
9.
Using a sealant cutting knife, cut the adhesive bead between the top section of the bulkhead and the roll
over bar, and between the bottom of the bulkhead and the chassis. If the sill panels are fitted, cut the
bond between sill panel 'B' posts and the bulkhead panel.
10. Manoeuvre the bulkhead from the car.
To Fit Bulkhead Panel
Before fitting a bulkhead panel, ensure that the following parts are bonded to the panel:
- Header tank mounting bracket;
- Charcoal canister mounting bracket;
- Immobiliser module stud plate;
- Fuel filter mounting bracket;
- Rear window glass;
All the above components are bonded using elastomeric adhesive applied as follows. Refer also to subsection BQ.5:
Brackets & Studplates: Clean the bonding surfaces on the bracket and bulkhead with Betaclean 3900 (black
cap) and prime both surfaces with Betaprime 5404 (red cap). Apply Betaseal 1701 adhesive to the bracket,
and clamp in position until the adhesive has cured.
Rear Window: Clean the whole of the bonding surface on the glass with Betawipe VP 04604 (yellow cap), and
prime with Betaprime 5001 (green cap). Clean the corresponding surface on the bulkhead with Betaclean 3900
(black cap) and prime with Betaprime 5404 (red cap). Apply a bead of Betaseal 1701 to the periphery of the
glass, and press into position on the bulkhead to ensure sufficient compression of the adhesive. Use a spatula
to remove excess extruded adhesive and smooth any visual areas. Tape the glass into place if necessary to
retain position until the adhesive cures.
Bonding of Bulkhead Panel: Clean the mating surfaces of bulkhead, roll over bar and (if fitted) sill 'B' posts,
with Betaclean 3900 (black cap) and prime with Betaprime 5404 (red cap). Or, where applicable, use Betawipe
4000 to re-activate old adhesive (refer to sub-section BO.5). Clean the mating surface on the chassis with
Betawipe VP 04604 (yellow cap), and prime with Betaprime 5404 (red cap). Apply a bead of Betaseal 1701
to the bonding path on the bulkhead, and manoeuvre into postion, pressing all round the joint path to ensure
sufficient compression of the adhesive. Use a spatula to remove excess extruded adhesive and smooth any
Page 18
Lotus Service Notes
Section BQ
visual areas. Secure in position with tape until the adhesive has cured.
The heat/acoustic insulator panel is bonded to the bulkhead only at its centre section. Clean and prime
the centre section on the bulkhead with Betaclean 3900 and Betaprime 5404, and apply Betaseal 1701. Press
the insulator panel into position and ensure sufficient compression of adhesive. Tape in place until the adhesive
has cured.
Refit remaining components in reverse order to removal.
Page 19
Lotus Service Notes
Section BR
BODY FITTINGS
SECTION BR
Sub-Section Page
Removable Roof
BR.1
2
Rear Window Shroud (Elise only)
BR.2
6
Front Body Access Panels
BR.3
7
Engine Cover Lid
BR.4
7
Door Hinge Cover Panel
BR.5
9
Front Clamshell
BR.6
9
Rear Clamshell
BR.7
11
Door Mirrors
BR.8
12
Door Shell Brackets
BR.8a
13
Door Beam & Hinge
BR.9
14
Door Shell Assembly
BR.10
16
Door Glass, Guide Rails & Winder Mechanism
BR.11
17
Electric Windows
BR.12
21
Door Seals
BR.13
23
Door Latch Mechanism (without CDL)
BR.14
24
Central Door Locking
BR.15
27
Instrument Binnacle & Dash Panel
BR.16
28
Windscreen
BR.17
33
Page 1
Lotus Service Notes
Section BR
BR.1 - REMOVABLE ROOF
The Lotus Elise has been designed to exploit the pleasures of open top motoring, the better to enjoy
exposure to the natural environment, unencumbered by the restrictions and confinement bestowed by a cockpit roof. In order to provide some weather protection to the occupants and vehicle interior, and allow the
continued enjoyment of the car in unfavourable weather conditions, a simple hard or soft top roof may be fitted.
Due to the constantly changing dynamic and wind pressure loadings to which the roof structure is subject
when driving, and the tolerances required to allow for repeated removal and refitting of the roof, complete
weather sealing of the roof cannot be guaranteed, such that some wind noise and minor water leaks are
considered normal for this model. The Elise or Exige should not be subjected to an automatic car wash. Such
machines can induce water leaks caused by high pressure water jets which are not representative of conditions
encountered during normal use. The brushes used may also damage the fabric of the soft top roof.
Exige Hardtop Roof:
The Lotus Exige has been conceived and configured as a sports coupé with a removable roof. The
aerodynamic performance of the bodyshell including the front spoiler, rear aerofoil, roof panel and tailgate
have been tuned to provide the optimum handling balance with the roof scoop on supercharged cars providing
the cooling airflow for the chargecooler.
The roof panel may be removed for better access to the interior for servicing, and the car may be driven
without the roof fitted, but wind buffeting and increased noise levels will be experienced together with a slight
decrease in maximum power on supercharged cars.
Soft Top Roof
A hollow composite roof siderail is used on each side of the car to bridge each top corner of the windscreen frame to the roll over bar, and provide a mounting for a weatherstip seal, against which the top edge of
the door glass abuts. The soft top roof canopy is fixed to each siderail, which uses a spigot pin at the front and
rear to engage with a slot in a latch plate on the header rail and roll over bar. A second, spring loaded spigot pin
at each end of the siderails, is arranged to slide into a ramped hole on the latch plates and secure and tension
the soft top via steel cables running through the front and rear of the roof canopy.
Soft Top - Fitting
WARNING: The soft top roof should be fitted only whilst the vehicle is safely parked.
1.
2.
3.
From its stowage bag in the rear luggage
compartment, withdraw the roof assembly
and support stays. Lower both door windows, or open both doors.
Insert the two, identical, roof support stays,
with the arrows pointing forwards, into the
slots above the rear window, and in the windscreen header rail. Note that the slots are
keyed to prevent the stays being fitted the
wrong way round.
Lay the soft top roof across the centre of
the roof space with the arrows on the side
rails pointing forwards.
Page 2
FITTING ROOF STAYS
Arrows
point forward
Rear end keyway
b332
Lotus Service Notes
4.
5.
6.
Section BR
Roll out the left hand side of the roof, and
engage the fixed spigot pin on the front and
rear end of the rail, into the uppermost slot
in the latch blocks at the front and rear of
the roof aperture.
Ensure that the tensioning cables at the front
and rear edges of the roof canopy are correctly located in the channels between the
seal and body before rotating the left hand
side rail downwards.
Ensure that both spring loaded pins ‘click’
into their ramped slots indicating that latching is complete. If necessary, ease the latch
handles on the inside face of the side rails
inwards to facilitate latching. Pull up on the
side rail to check security.
Spigot
pin
Spring
loaded
pin
FITTING SIDERAIL
ohs111
On the right hand side of the car, repeat steps (4) and (5) for the second side rail, noting that greater
rotating force will be required as tension is applied to the canopy.
Note: Engaging the left hand roof side rail first, will minimise the possibility of the canopy tensioning
cable adjusters causing damage to the roof seals.
Soft Top - Removal
WARNING: The soft top roof should be removed only whilst the vehicle is safely parked.
1.
Open both doors or lower both door windows.
2.
On the inside face of the right hand roof
side rail, locate the two latch release levers:
Pull the two lever handles towards each
other to release the side rail latches (press
down on the side rail if necessary to relieve
the load on the latch pins), and rotate the
rail upwards to release the canopy tension.
3.
Repeat step (2) for the left hand side rail.
Note: Releasing the right hand roof side
rail first, will minimise the possibility of the
canopy tensioning cable adjusters causing
damage to the roof seals.
RELEASING ROOF SIDE RAIL
ohs112
4.
Carefully roll up each side of the roof canopy towards the centre, lift off the car, and stow in the roof bag.
5.
Unhook the two roof stays and stow in the roof bag.
Important Note: If the roof is not fully dry, it should be stowed for no longer than a few days before unrolling
or refitting and allowing to air dry completely. Prolonged stowage of a wet or damp roof will promote rotting of
the fabric.
Roof Cable - Front: The tension of the steel cable running through the front edge of the roof canopy should be
adjusted with the side rails latched. Hook a spring balance under the centre of the cable, and apply an upwards
force of 6 kgf. Adjust the cable tension to achieve a vertical gap of 6mm between the cable and top surface of
the windscreen surround.
Page 3
Lotus Service Notes
Section BR
Roof Cable - Rear: The roof rear cable tension should be sufficient only to maintain stability of the roof canopy
shape.
Side Rail Front Latch Plates: The latch plates on the windscreen header rail are secured using a two part
adhesive. If necessary, use Betaclean 3900 (A100B6008V), Betaprime 5404 (A082B6337V), and a 50/50 mix
of two part adhesive Betamate 7064S (A116B0159V) and Betamate 7014 (A116B0158V) to refix.
Hard Top Roof
Note
The hard top roof has been designed to provide a seasonal, rather than single trip option. Some owners
may prefer to entrust the fitting and removal of the hard top roof to their dealer.
When stowing the roof off the car, care should be taken to avoid damage to the roof corners; e.g. use a
suitable soft floor covering on which to stand the roof.
Fitment or removal of the hardtop is made considerably easier with the assistance of a second person.
Use only the ‘Torx’ tool supplied in the vehicle tool kit to tighten or release the roof fixing screws.
The hardtop roof fixings are made captive to the roof to prevent their loss.
Hard Top - Fitting
WARNING: The hard top roof should be fitted only whilst the vehicle is safely parked.
1.
Open both doors, and preferably with the
aid of an assistant, lower the roof onto the car
holding aside the loose tethered fixings to avoid
their entrapment or their causing paint damage.
Position the rear edge of the roof first before locating the front edge against the windscreen
header rail.
2.
Locate a front spigot bracket into its latch
plate lower slot (lifting the roof slightly to allow
this) and retain to the roof with the Torx bolt. Use
only the special tool supplied, and do not fully
tighten at this stage.
FRONT
SPIGOT
BRACKET
3.
Repeat step (2) for the opposite front spigot
bracket.
4.
Engage a rear cup bracket with the lower
tongue on its rear latch plate, and retain to the
roof with the Torx bolt. Use only the special tool
supplied, and do not fully tighten at this stage.
Ensure that the cup is fully located onto the
tongue.
5.
Repeat step (4) for the opposite rear cup
bracket.
FITTING REAR CUP BRACKET
6.
Push the roof fully forwards before tightening the front spigot brackets using only the special tool supplied. Hold each rear cup bracket in
alignment whilst tightening the single fixing screw
for each bracket. Do not overtighten.
7.
Fit the cover panels to each rear corner of
the roof, noting that the panels are handed for
left and right sides. Press the panels firmly into
position fully to engage the 'Velcro' fixing patches.
Page 4
REAR CORNER
COVER PANEL
b330
Lotus Service Notes
Section BR
8.
Using the special tool provided, install the
windscreen header cover panel by locating first
with the central screw, and then by the outer
screws before tightening in the same order.
9.
Check that the roof is secure by pulling upwards on each corner in turn. If any upward movement is evident, check the correct fitment of all
mounting brackets.
WINDSCREEN
HEADER TRIM
Hard Top - Removal
WARNING: The hard top roof should be removed only whilst the vehicle is safely parked.
1.
WINDSCREEN
HEADER TRIM
b331
Open both doors.
2.
Using the special tool supplied, release the
three Torx screws securing the windscreen header
trim panel, and remove the panel.
3.
Using the special tool supplied, slacken the
Torx screw securing each front corner spigot
bracket to the roof, but do not yet remove the
screws.
FRONT CORNER
SPIGOT BRACKET
b330
4.
Pull off the trim cover from each rear corner of the roof panel and remove the screw securing the hook bracket to the latch plate at each
rear corner.
REAR CUP BRACKET
5.
Remove the two front corner bracket fixing
screws and lift the front edge of the roof slightly
to release the front brackets from their latch plate
slots.
6.
With the aid of an assistant, lift the roof from
the car taking care to restrain the tethered brackets to avoid damaging the paintwork.
7.
If storing the roof vertically, take care to avoid damaging the panel corners by using a protective floor
covering.
Page 5
Lotus Service Notes
Section BR
BR.2 - REAR WINDOW SHROUD (Elise only)
The rear window shroud is a body colour composite panel which covers the seat belt mounting frame/roof
hoop, and forms a capping for the rear of the cockpit. The panel is secured by two brackets on its front edge
which are fixed each side by a single M6 screw to the top of the rear bulkhead panel and which are accessible
from within the cabin. On some cars it may be necessary first to remove a trim panel secured by five screws.
Note that Neoprene washers are used between the brackets and the bulhead.
Each rear leg of the shroud is fitted with a captive M6 stud, which locates through a hole in the clamshell
buttress, with the retaining nut accessible either from the engine bay, or wheelarch area. A foam gasket is used
to prevent chafing damage between the shroud and clamshell.
When removing the shroud, it is also necessary to peel off the rear weatherstrip from the front edge of the
panel, and to remove the two cant rail latch plates from their brackets on the roof hoop.
Note that on the Exige, the rear window shroud is an integral part of the rear clamshell moulding.
Roof/'B' post
weatherstip seal
Neoprene
washers
Fixing screw to
rear bulkhead
Fixing nut to
rear clamshell
Rear window shroud
Foam gasket
pl1020mt
Page 6
Lotus Service Notes
Section BR
BR.3 - FRONT BODY ACCESS PANELS
Elise
Two removeable, body colour composite panels are provided in the front body to
allow access to the front fusebox and brake
fluid reservoir.
To remove an access panel: Use the hexagonal key supplied in the vehicle tool kit (in the
battery cover rear pocket), to release the single threaded fastener securing the outboard
corner of the panel, and withdraw the panel
REMOVING ACCESS PANEL
from the two locating holes in the front body
spine. Guard against the lightweight panel
being blown away and damaged by a strong
wind.
To refit a panel: Hook the extended lip on the front edge of the panel beneath the rear edge of the louvre panel
before engaging the two locating pegs on the inboard side of the access panel with the grommeted holes in the
front body spine. Fit the single screw at the outboard corner of the panel into the captive nut in the body, taking
care not to cross-thread or overtighten the screw. Re-stow the hexagonal key in the tool kit.
Note that the outboard fastener uses a mounting plinth adjustable in height to allow optimum panel
alignment to be achieved.
ohs93
WARNING: Ensure the access panels are refitted and properly secured before driving.
Exige
The access panels on the Exige model are shorter front to back than those of the Elise, and are retained
by three socket head screws, the outermost of which features an adjustable plinth to allow panel height adjustment.
BR.4 - ENGINE COVER LID
Elise
The engine cover/boot lid is moulded from glass fibre composite and incorporates 4 engine cooling outlet
grilles secured by double sided tape and plastic rivets into recessed apertures. Two hinges are used to attach
the lid to the rear bulkhead, with stud plates fixing the hinges to the bulkhead from the engine bay side, and the
nuts accessible from the cabin after removal of the rear bulkhead trim panel. A single, key operated latch
mechanism secures the lid to a striker pin mounted on the clamshell engine/boot bulkhead. The latch is
released by inserting the ignition key into the lock and turning clockwise, the lock barrel being connected to the
latch mechanism by a short link rod. When the latch is released, a spring plunger will lift the lid sufficiently to
allow it to be raised fully by hand. Support the lid by inserting the prop provided on the boot bulkhead into the
slotted plate adjacent to the latch mechanism. The spring plunger also operates a micro-switch for the alarm
system, and is protected from exhaust manifold heat by a steel shield.
When closing the lid, fully engage the latch mechanism by pressing down on the cover only immediately
above the latch. Note that the lock mechanism plastic cover plate on the underside of the engine lid, serves
also to channel any water ingress from around the lock into the engine bay. Drain holes are provided in the
gutter surrounding the engine bay, with a collector and drain tube fitted at the rearmost extremity.
On USA models, an fluorescent emergency internal release handle is fitted on the underside of the lid to
facilitate the escape of a trapped child.
To remove the engine cover, release the cover from the two identical hinges. Note that the hinges also
serve to clamp the clamshell front edge to the cabin rear bulkhead.
Beware that the engine cover is locked whenever it is closed, and always requires the use of the ignition
key to release. Owners should be made aware of the importance of having a spare key available in case of
inadvertently locking the keys in the boot.
Page 7
Lotus Service Notes
Section BR
Theaded insert
in engine lid
Engine lid hinge
Studplate clamping hinge &
clamshell to bulkhead
b318
Nut inside cabin
Exige
On Exige models, the double skin, moulded composite tailgate panel, mates with an air intake duct in the
clamshell and roof panel to admit cooling air into the engine bay, and also features seven steel mesh grilles to
allow for the exhaustion of hot air. The tailgate panel uses extruded alloy hinges at its front edge, anchored to
the underside of the clamshell, and is provided with a gas spring strut to support the lid in the fully open
position. The latch mechanism is mounted on the boot bulkhead, where it, and an adjacent alarm plunger
switch are protected by a steel heat shield. The latch is operated by a cable release from a lever handle
mounted outboard of the driver's seat back.
A rear aerofoil with integrally moulded support struts, is secured to the rear end of the tailgate and
transfers loads via adjustable abutments into the boot bulkhead and body structure.
Tailgate release handle
ohs141
Page 8
Lotus Service Notes
Section BR
BR.5 - DOOR HINGE COVER PANEL
A separate glass fibre composite body panel is used to fill the area beween the door and wheelarch, and
uses threaded fasteners to attach to the rear of the clamshell, top of the sill and bottom inboard edge of the sill
panel.
To remove a door hinge cover panel:
From beneath the sill, remove the two fixings securing the bottom edge of the hinge panel to the sill.
Remove the filler panel concealing the fixing securing the hinge cover to the door sill recess, and remove
the fixing.
Remove the wheelarch liner and remove the single screw securing the door hinge cover panel to the
clamshell.
Release the repeater lamp harness and withdraw the panel.
No fixing used
in this position
Remove front
top fixing
Door
sill
filler
panel
Door hinge
cover panel
Hinge cover to
door sill fixing
Hinge cover to
sill underside
b231
BR.6 - FRONT CLAMSHELL
The front clamshell is a bonded assembly of several glass fibre composite mouldings incorporating both
front wings, the front access aperture, radiator air intake and headlamp housings. The clamshell is secured to
the windscreen frame, radiator mounting panel and other panels using threaded fasteners for ease of removal
and to facilitate service access and body repair.
To Remove Front Clamshell
1.
Remove both front body access panels.
2.
Remove both front wheelarch liners;
Page 9
Lotus Service Notes
Fixing inside
headlamp
housing
Section BR
Clamshell spine to
wiper motor bracket
Clamshell lower front
edge to undertray
Fixing to
windscreen
frame
Fixing to base of
windscreen pillar
Fixing to radiator mounting panel
(not used with oil coolers)
Fixing of door hinge
cover panel to clamshell
b316
3.
From inside each wheelarch, remove the single screw securing the top edge of the door hinge cover
panel to the clamshell. On cars fitted with front mounted oil coolers, release the hoses from any clamshell
clips around the top of the wheelarch.
4.
Via each door aperture, remove the single fixing securing a bracket at the top rear corner of the clamshell
to the base of the windscreen pillar.
5.
Remove the fixing at each side securing the clamshell to the bottom of the windscreen frame.
6.
Elise: Remove the two nuts securing the clamshell spine bracket to the wiper motor bracket extension.
Exige: Remove the two nuts and bolts securing the clamshell spine to the wiper motor extension bracket,
and the two screws each side securing the clamshell channel to the radiator air deflector panel.
7.
If fitted, remove the single fixing at the bottom front of each wheelarch, securing the clamshell to the
radiator panel extension (not used on oil cooler cars).
8.
Remove the headlamp cover/mask assembly from each side by releasing the three socket head screws
inside the wheelarch. Remove the clamshell fixing at the front of each headlamp housing. Release the
headlamp harnesses, and feed through the clamshell hole. Disconnect the aerial lead(s).
9.
Beneath the nose, release the screws fixing the front lower edge of the clamshell to the alloy undertray.
10.
Lift the clamshell from the car. Note any spacing washers or shims fitted at any fixing point.
Page 10
Lotus Service Notes
Section BR
BR.7 - REAR CLAMSHELL
The rear clamshell is a one piece composite moulding incorporating both rear wings, the engine bay
aperture, rear transom and integral luggage bay. The clamshell is secured to the chassis and other body
panels by threaded fasteners for ease of service access and body repair.
To Remove Rear Clamshell
1.
Remove the soft or hard top roof (including Exige) - see sub-section BR.1
2.
Remove both rear wheelarch liners;
3.
Elise: Remove the rear window shroud - see sub-section BR.2.
Exige: From within the cabin, remove the two screws above the rear window securing the top edge of the
clamshell to the rear bulkhead. Remove the two cant rail latch plates from their brackets on the roof
hoop. Peel off the weatherstrip seal from the clamshell flange.
Boot floor to subframe
Engine lid hinge
fixings
b317a
Fixings to sill
panel and grille
'B' post fixing
from inside
cabin
4.
From inside the cabin, remove both seats and the full width trim panel from the rear bulkhead. From the
access thus provided, remove the fixing securing the front end of the clamshell to the 'B' post above the
engine bay air intake.
5.
Elise: From inside the cabin, release the fixings securing the engine lid hinges to the rear bulkhead, and
withdraw the engine lid complete with hinges.
Page 11
Lotus Service Notes
Section BR
6.
Release the six (USA market) or eight (other cars) screws securing the fuel filler neck to the clamshell.
Withdraw the filler neck from the clamshell aperture, noting the earth braid secured to the roof hoop
backstay. Keep the filler cap fitted to minimise vapour hazard.
7.
Remove the air filter box intake scroll, and from inside each rear wheelarch, release the air intake grille
fixings, and the two screws securing the clamshell to the waistline joint of the sill panel. Withdraw each
grille from its retaining clip.
8.
Remove the battery and feed the battery cables through the clamshell grommet. Disconnect the rear
harness and rear lid switch harness from the area behind the battery, and feed through the clamshell
grommet.
9.
Remove the rear diffuser panel.
10.
From inside the luggage area, release the two screws each side securing the boot floor to the subframe.
11.
Unhook the washer bottle.
12.
Withdraw the clamshell from the car, noting any spacer pads fitted on the subframe.
13.
Refit in reverse order to disassembly with the following notes:
Shimming of clamshell floor mounting points:
It is most important to maintain a gap of at least 7mm between the phenolic resin heatshield rivetted to
the underside of the clamshell boot floor, and the exhaust muffler corrugated heat shield bolted to the subframe. The corrugated shield must touch neither the muffler, nor the clamshell mounted shield, or heat damage may be caused to the clamshell.
On factory build, the subframe is marked adjacent to each of the four clamshell mounting points with the
shim thickness required. Shim plates are available in 1mm and 2mm thicknesses. If a new subframe is being
fitted, or the markings are not visible;
Use a straight edge across the clamshell rear mounting points on the subframe, and measure down to the
muffler heatshield. Sufficient shims need to be used to bring this dimension to a minimum of 7mm.
With these shimplates fitted, trial fit the clamshell and if necessary add further shims to optimise the fit of
the clamshell with respect to sill and door shutlines.
Measure the shim gap at the boot floor front fixing point.
Remove the clamshell, fit the required shim plates onto the subframe and refit the clamshell.
BR.8 - DOOR MIRRORS
Mirror housing
The manually adjustable, plastic housed
door mirrrors, are mounted via an injection
moulded plinth to the door shell. A spring
loaded ball and socket arrangement provides
a means of mirror adjustment, and a sprung
attachment of the mirror housing to the pivot
socket allows for the mirror to move forwards
or backwards on accidental contact, in order
to reduce the potential for personal injury or
vehicle damage.
b240
Mirror glass & surround
Page 12
Lotus Service Notes
Replacement of mirror glass
The mirror glass is contained in a plastic
surround which is clipped into the housing in
order to provide for convenient and inexpensive replacement. To remove a glass, pull
back the boot between mirror and plinth, and
carefully prise the inboard edge of the mirror
surround from its retaining clips. Working
around the mirror periphery, continue to prise
the surround from the housing taking care not
to damage the paint on the housing. Press
the new glass/surround into the housing until
all the retaining clips are engaged, and reposition the convoluted boot.
Note that convex glass is normally fitted
to both sides, but certain markets, including
the USA, use flat glass in the driver's side,
and passenger side USA mirrors are convex
and etched 'Objects in mirror are closer than
they appear'.
Section BR
Mirror mounting plinth
Mirror assembly
b241a
Mirror fixing screw
Replacement of mirror assembly
The mirror assembly locates in the plastic injection moulded plinth via two spigots,
and is retained by a single screw tapping into
the lower spigot. To remove a mirror assembly, use a cross head cranked screwdriver, or
similar tool, to remove the screw recessed into
the inside face of the mirror plinth.
Replacement of mirror plinth
The mirror plinth incorporates tapping
plates to accommodate a single screw into the
top leg, and a pair of M5 screws into the bottom leg. The plinth is secured to the door outer
panel with access holes for the three screws
provided in the inner panel, cosmetically concealed by adhesive patches.
Note that a magnet may be required
when removing or refitting the rearmost screw.
b242b
Socket head screw
Adhesive patch
BR.8A - DOOR SHELL BRACKETS
The composite door shell is fitted with various steel brackets bonded to its inner surface in order to mount
the shell to the door beam and also to mount hardware components such as the latch and window lift mechanism. The brackets are bonded to the SMC door structure using ITW Plexus adhesive. If, for whatever reason
a bracket should become detached, the following procedure should be used to re-secure:
1.
Remove the failed component from the door.
2.
Prepare the bonding surface of the component using emery cloth.
3.
If the bracket does not already have holes drilled in the bonding surfaces, use the illustrated examples to
add 6mm holes to the relevent surfaces and provide the adhesive with a good keying feature.
Page 13
Lotus Service Notes
Exterior lock/finger
grip bracket
Window rear guide
channel bracket
6mm holes
Section BR
Shell to beam
front lower bracket
6mm holes
b347
4.
Prepare the bonding surface of the door panel using coarse emery cloth and clean with Betaclean 3900
(A100B6008V). It is not necessary to remove all existing adhesive if this is securely bonded.
5.
Apply a liberal quantity of ITW Plexus MA 920 adhesive (A117B0209V) to the door panel, and within a
maximum period of 4 Minutes (a longer open time will degrade adhesive performance) position the
bracket and ensure that the adhesive is extruded through the keying holes. Remove excess adhesive
which would interfere with any door functionality. Secure the bracket in position for a minimum of 30
minutes to allow adhesive to cure.
6.
Re-assemble door and check for correct function.
7.
If a latch mounting bracket needs to be rebonded, it is recommended to fit a cup washer A117W4192K
diagonally opposite (i.e. to the latch top mounting screw) to that already used on the inboard lower screw.
BR.9 - DOOR BEAM & HINGE
The door shell is bolted to a hollow section extruded aluminium alloy door beam, hinged at the front end
to the ’A’ post, and carrying the door latch mechanism, via steel brackets, at its rear end. The front end of the
door beam is welded to a second extrusion which forms the rotor of the door hinge. The hinge stator (or hinge
bracket) is bolted to an outrigger on the chassis, and incorporates two cylindrical bearing housings fitted with
maintenance free pivot bushes.
Door hinge adjustments
In order to provide for adjustment of door shutlines, the door hinge may be adjusted in two ways:
i)
Height of the hinge, its fore/aft position, and the pivot axis angle (to control the front/rear height alignment) may be adjusted after slackening the hinge bracket fixing bolts. The tapping plates for these bolts
are linked in vertical pairs and are captive, but loose, within the chassis outrigger, and allow for some
vertical movement. Horizontally slotted fixing holes in the hinge bracket allow for fore/aft movement.
ii)
Slotted shim plates fitted between the hinge bracket and chassis, allow the in/out door front edge alignment to be adjusted in steps of 1 rnm, and by varying the shim pack at the top and bottom pairs of fixings,
the vertical alignment, as viewed from the front, may be adjusted.
Ensure that the clamping load of the hinge bracket to the chassis is not corrupted by the shim plates
bearing against the body. If the surrounding body stands proud of the chassis door hinge outrigger, use a
suitably cut down shim plate to act as a spacer between the chassis and the adjustment shim pack or hinge
bracket.
Page 14
Lotus Service Notes
Door shell to
beam fixing
Section BR
Tapping plate
Shim plate
Chassis
outrigger
Dirt shield
Door beam
(hinge rotor)
Plastic shoe
Door restraint
spring plate
Hinge bracket
(stator)
b243b
Door beam pivot bearings
The door beam hinge uses two maintenance free ’top hat’ section synthetic bearings, pressed into the
hinge stator bracket. Inside each bearing, is fitted a ‘top hat’ section steel rotor bush, clamped to the door
beam extension by an M10 cap head screw threaded into the door beam.
The door beam extension also incorporates a cheek flange which abuts against a rubber strip on the
hinge bracket to limit door opening angle. A spring steel plate fixed to the front of the hinge bracket is designed
to engage around the profiled edge of the door beam abutment flange when the door is fully open, in order to
provide a sprung restraint for the door in this position. A plastic shoe is used over the sliding surface of the
spring plate to provide for maintenance free operation, with the shoe moulding clamped between the spring
plate and chassis. To help protect the hinge mechanism from water and dirt ingress, a plastic shield is push
fitted over the retaining nuts for the spring plate.
To remove the door assembly, or for access to the door pivot components, the two M10 cap head rotor
bush retaining screws should be removed, and the door assembly withdrawn from the hinge bracket. The rotor
bushes and/or bearings may then be withdrawn from the hinge bracket. On re-assembly, note that the bearings
and bushes are assembled dry from above and below the upper and lower housings respectively, and the cap
head screws tightened to 45 Nm. Insert the rubber bungs into the bush ends to inhibit dirt ingress and corrosion.
Page 14
Lotus Service Notes
Section BR
Rubber bung
Rotor bush
Plastic bearing
Door beam/
hinge rotor
Stator bracket
Cap head screw
Hinge bracket
fixings
b244
BR.10 - DOOR SHELL ASSEMBLY
The door shell is mounted on the door beam via three screws through a flange at the front end of the
beam, and by the door latch mounting bracket at the rear end. In order to provide fixing points for the beam,
lock mechanism and other components, the door shell includes various tapping plates and brackets jig bonded
to the inside of the shell, including fixing brackets for the accurate location of the window guide rails.
If a door is to be removed from the car, the preferred method is to release the M10 cap head screws
clamping the upper and lower bushes to the door beam. The beam and door shell assembly may then be
withdrawn from the hinge stator bracket without losing adjustment of the hinge alignment and door shutlines. If
the door shell has to be removed from the beam for repairs or replacement, the beam may be left ’in situ’ and
the door shell slid off the beam using the following procedure:
Removal of door shell from beam
The door shell is secured to the beam via three screws through a flange at the front end of the beam,
tapping into nut plates bonded into the door shell, and via two bolts at the rear end of the door to the door beam
extension bracket. Access to the two bolts securing the extension bracket to the door beam requires that the
door glass first be released:
1.
Remove the window winder handle and door trim panel (manual windows) or the door trim panel and
window switch (electric windows).
2.
Release the three screws securing the interior release handle, and unclip the control rod from the mechanism.
3.
Remove the two M6 and the single M8 screw securing the door beam flange to the front of the door shell
4.
Release the three M6 nuts securing the door glass to the lift channel, and separate the glass from the
channel. Tilt the glass as necessary to allow access to the two M8 bolts fixing the rear end of the door
beam to the extension bracket. Remove the bolts and withdraw the door assembly from the beam.
Note that it is necessary to remove the drop glass waist seal before the glass may be withdrawn from the
door.
Page 15
Lotus Service Notes
Beam to extension
bracket fixing
Door beam
extension
bracket
Section BR
Captive
fixing
Door beam
flange
Door
beam
Door shell to
extension
bracket fixing
Door shell to
beam fixing
b245a
When refitting the door, take care not to scratch the glass if this is contained in the door. Insert the two
rear bolts securing the beam to the latch bracket, but do not tighten until the three fixings securing the front of
the shell to the beam flange have been fitted and tightened.
BR.11 - DOOR GLASS, GUIDE RAILS & WINDER MECHANISM - Manual Windows
A manually operated door window scissor type lift mechanism is used in conjunction with two steel guide
rails and a ’frameless’ door design.
The operating principle of the window lift mechanism is that of a scissor linkage, with the front lower end
of the primary leg anchored to the door shell, the lower end of the secondary leg sliding in a horizontal channel
on the door shell, and the upper ends of both legs sliding in a channel fixed to the bottom edge of the window.
The geometry of the system provides for a parallel lift of the glass, where the angle of the bottom edge does not
change throughout the range of travel. An extension to the primary scissor leg carries a toothed sector which
is engaged by a pinion on the window winder. The front and rear edges of the glass are guided by steel rails
which engage with point contact Nylon guide blocks bonded to the glass. The bottom ends of the rails are
adjustable in/out to set the inward tilt of the glass, with the 'up' glass position controlled by an eccentric stop on
the winder mechanism.
Door glass adjustment
To adjust the door glass for optimum weather sealing and ease of operation:
1.
Fit the soft top roof and fully raise the window. Check the alignment of the top edge of the glass against
the seal, and the seal compression along the cant rail and up the 'A' and 'B' posts. A light compression is
required; just sufficient to ensure sealing, without imposing loads on the winder mechanism.
2.
To adjust the inward tilt of the glass, screw the adjusters at the bottom of each guide rail in or out as
necessary. Access is available without removing the door trim panel. Check that the window glass
moves freely throughout the range of travel.
Page 16
Lotus Service Notes
Section BR
Door glass
lift channel
Nylon guide
block
Door glass
tilt
Guide rail
top fixing
Scissor
linkage
Door
glass
Adjuster
screw
Handle pinion
Reaction
channel
Threaded
block fixed
to rail
Steel guide
rail
Toothed sector
Door
anchorage
point
b285a
Threaded block
fixed to door shell
Page 17
Lotus Service Notes
3.
Section BR
To adjust the alignment of the top edge of the glass, it is necessary to adjust the height of the reaction
channel. Remove the window winder handle and door trim panel, slacken the reaction channel fixings,
and move the channel up or down as required. Raising the channel will raise the rear edge of the glass.
Mesh friction washer
Winder spindle
Eccentric stop
Toothed sector
b274
4.
To adjust the fully up position of the glass, the eccentric stop on the toothed sector of the winder mechanism must be rotated as necessary. A mesh friction washer is fitted between the eccentric and the sector
to help retain adjustment.
To replace the door window glass
1.
Remove the window winder handle, and the door trim panel.
2.
Release the three fixings securing the slider channel to the bottom of the glass.
3.
Do not attempt to withdraw the glass from the door without first removing the door waist seal. Carefully
prise the one-piece seal off the door shell inner and outer flanges, and release the push fixing from the
seal moulding at the rear end of the door. Withdraw the glass from the door shell.
4.
Note that new door glasses are supplied complete with jig bonded Nylon sliders and stud plate.
5.
Fit the new glass into the door and re-assemble in reverse order to the above.
6.
Adjust the glass position as detailed above.
To replace door winder mechanism
1.
Remove the window winder handle, and the door trim panel.
2.
Release the interior release control rod from the door handle and unclip from the latch mechanism.
3.
Secure the door glass in the fully raised position, and release the three fixings securing the winder
mechanism to the door;
two fixings adjacent to the winder spindle;
on fixing through the static pivot of the primary scissor arm
4.
Manoeuvre the mechanism to free the winder spindle from the door, and to disengage the two upper
sliding bosses of the scissor arms from the window channel, and the lower sliding boss from the static
reaction channel. Withdraw the mechanism from the door.
5.
Before fitting a lift mechanism, lubricate the three slider bosses and the sector teeth with Century Luplex
M2 grease (or similar). Fit the mechasnism into the door and engage the three slider bosses in their lift
and reaction channels before securing with the three fixing screws. Note that a single M6 spacer washer
is used between the pivot of the primary scissor arm and the door shell.
Page 18
Lotus Service Notes
Section BR
Door glass
slider block
Winder mechanism
Lift channel
Door glass
stud plate
b321
Reaction
channel
6.
Scissor arm
pivot fixing
Winder
mechanism
fixing
Adjust the glass upstop postion, top edge alignment and inward tilt as detailed above.
Door glass guide rails
Two guide rails are used for door glass; one for the front and one for the rear edge. Each of the steel,
black zinc plated, guide rails, is secured by a single screw at the top end to a jig bonded bracket in the door
shell, and by a threaded adjuster at the lower end, engaging in a threaded block fixed to the door shell.
Screwing the adjusters in or out will set the inward tilt of the glass and the contact between glass and door
weatherseal.
To remove a guide rail, first remove the door glass (see above), before releasing the single screw at the
top, and releasing the threaded block from the door shell.
Page 19
Lotus Service Notes
Section BR
BR.12 - ELECTRIC WINDOWS (Parts List 11.02)
On cars so equipped, switches for the electric windows are mounted in the front of the door trim panels,
and are operative only with the ignition switched on. To help locate the switches in the dark, an illuminated dot
is provided in the ‘down’ button which glows amber when the lights are switched on.
To lower a window, switch on the ignition and press the lower, dished end of the switch in the relevent
door. Release the switch to stop window movement. To raise a window, press the upper, domed end of the
switch.
The electric operation of the door windows comprises;
An electric motor and winder drum assembly mounted on a bracket which is bolted to the door shell.
A guide channel for the window lift block, incorporating top and bottom cable pulleys, bolted to the door
shell.
A single drive cable running from the window lift block, around a guide channel pulley, through a flexible
conduit, around the motor driven winder drum, through another conduit, around the second guide channel
pulley and back to the window lift block.
An adaptor plate bolted to the stud plate on the lower edge of the door glass.
Viewed from outboard
Upper guide
pulley
Window upstop
Window lift block
Drive cable
Motor
mounting
plate
Adaptor plate fitted
to glass
Guide channel
Window
winder
drum
Bottom guide pulley
Window lift motor
b337
Door Glass Adjustment
The door glass guide channels and adjustment procedures are the same as used on manually operated
windows. Refer to sub-section BR.11.
The upstop for the door glass is fitted at the top end of the lift block guide channel in the form of an
adjustable stop screw against which a projection on the window lift bracket abuts.
The front/rear height of the top edge of the glass may be adjusted at the slot where the front of the window
lift bracket attaches to the door glass.
Page 20
Lotus Service Notes
Section BR
Replacement of Window Lift Mechanism
The window lift mechanism comprises the motor, drive cable and guide channel assembly as a complete
unit. To remove the mechanism:
1.
If possible, raise the window fully for optimum access.
2.
Remove the door trim panel and disconnect the window switch. Peel off the plastic water shielding.
3.
Release the window lift bracket from the door glass and secure the glass in the fully raised position taking
care not to damage the door waist seals in the top of the door shell.
Guide rail
top fixing
Motor mounting
bracket fixings
b339
Guide rail
bracket fixings
4.
Unplug the motor electrical connector. Release the three fixings securing the motor mounting bracket,
and the two remaining fixings securing the guide channel to the door shell.
5.
Carefully manoeuvre the lift mechanism from the door.
6.
Refit in reverse order to removal, noting that the motor mounting bracket is fixed directly against the door
shell, but that 4mm plastic spacers are used at each of the three guide rail fixings..
Door shell inner panel
Setscrew and washer
Window lift motor
4mm
plastic
spacer
Threaded
insert
Cable winder
drum
Motor mounting
bracket
Guide rail
bracket
Guide
rail
b340
Page 21
Lotus Service Notes
Section BR
Note that the door glass is common to manually operated windows, with slider blocks bonded to the front
and rear edges, and a studplate channel bonded to the lower edge. For electric window operation, an adaptor
studplate is used to provide two studs for the window lift bracket.
BR.13 - DOOR SEALS (Parts List 11.01)
Drop Glass 'Waist' Seal
The door drop glass waist seal is a single unit comprising inner and outer seal extrusions joined around
the rear end by a moulded capping piece. Each length of seal is pressed onto the top edge of the inner or outer
door panel, with a plastic rivet securing the capping piece. The seal should be removed before withdrawing the
door glass or guide channels from the door.
A 'cheater' seal is bonded to the front and rear faces of the door mirror mounting extension. To fit a new
seal:
- Clean the bonding surfaces on the door shell edges with Betaclean 3900 (A100B6008V).
- Apply Permabond A905 surface conditioner to the bonding surfaces of door shell and cheater seal.
- Apply Loctite 382 adhesive to the inside of the cheater seal and fit onto the door.
Door Weatherstrip
A hollow section rubber weatherstrip is bonded around the door aperture and roof landings to seal against
the door shell and roof. Different seal configurations are used for the door and roof areas, with specially
moulded sections to interface with the roof cantrails. The seal is divided into front and rear sections, with a joint
at the bottom front of each door aperture.
The weatherstrips are manufactured with a self adhesive backing strip. Before fitting a new seal, the
bonding area on the body must be thoroughly cleaned with Betaclean 3900 (A100B6008V). In the critical area
of the 'A' post to windscreen header rail corner, an adhesive promoter 3M 4298UV (A116B6000V) should be
applied along the seal path to to ensure optimum seal retention. Trial fit the seal before peeling off the
protective backing from the adhesive and applying the seal, ensuring that the moulded sections at the cant rail
interfaces are correctly positioned.
When fitting the rear section of the seal, remove the backing strip from the seal in the section around the
latch plate, and fully insert the weatherstrip nodule into the gap between the 'B' post and rear window shroud.
Weatherstip seal
Seal path
Weatherstrip nodule
Rear window shroud
'B' post
b335
Page 22
Lotus Service Notes
Section BR
Continue to remove the backing strip and stick the weatherstrip along the seal path down the 'B' post and
along the bottom of the door aperture. Cut the seal to mate with the end of the front weatherstrip. Repeat for
the opposite side, and then remove the top section backing strip and secure the seal along the roof shroud
flange. Use a roller wheel along the whole length of the seal to ensure full adhesion.
A secondary 'J' section seal is applied to the front vertical face of the door shell, linking to the cheater
seal.
BR.14 - DOOR LATCH MECHANISM - Without CDL (Parts List 10.17)
Interior release
handle
Interior release
control rod
Relay lever
assembly
Exterior release
button
Exterior
lock
control
rod
Door latch mechanism
Bracket, door beam rear
end to door shell
b251a
Page 23
Lotus Service Notes
Section BR
The door latch mechanism is fitted inside the rear face of the door, which is reinforced by a steel plate
bonded to the glass fibre composite door shell. The latch engages with a striker pin which passes through the
composite sill/'B' post moulding, into a captive nut on the roll over bar. An external locking door release button
is mounted via a reinforcing plate, in the top rear of the door outer shell, and transmits its motion around the
rear edge of the door glass to the latch mechanism via two short link rods and a relay lever.
The interior release handle is mounted in the front of the door inner shell, and is connected to the latch
mechanism by a control rod. No interior control of door locking is provided.
Interior Release Handle
Remove the window winder handle and door trim panel.
Remove the four screws securing the interior handle assembly and unclip the control rod end clip to allow
the rod to be unhooked from the handle.
On refitting, ensure that the control rod is located in the guide clips.
Trim panel
Door shell
Release
handle
Rod guide clips
b260a
Exterior Release Button
Remove the access disc from the rear
face of the door, and the rod access grommet
lower down.
Release the two screws securing the lock
assembly and angle bracket to the tapping
plate bonded in the door shell.
Unclip the link rod from the relay lever,
and withdraw the lock button from the door.
Exterior release
button fixings
(use Permabond A130
A912E7033V)
Control rod access
b255b
Page 24
Lotus Service Notes
Section BR
Latch Mechanism
Remove the window winder handle and door trim panel.
Unclip the control rod from the interior release handle, and unhook from the latch mechanism.
Unclip and disconnect the short link rod between the relay lever and the latch mechanism.
Remove the three M6 screws securing the latch mechanism to the door, and withdraw the latch.
Viewed through outer door skin
Plate bonded
inside
door shell
Control rod to
interior handle
Control rod
to relay lever
Rear
b261
Outboard
Control rod to latch
Relay Lever Mechanism
The relay lever components comprise a
Rod to
shaft with an integral lever on one end, which
exterior
connects to the exterior lock button, and a
button
second lever pinned to the other end, which
connects to the latch mechanism. The shaft
is supprted in two fibre bushes housed on the
bracket connecting the rear end of the door
Plain & spring
beam to the door shell. To remove the door
washers
beam extension bracket complete with relay
lever mechanism:
Pivot bush
Remove the window winder handle and
door trim panel.
Release the three M6 nuts securing the
Relay lever/shaft
door glass to the lift channel, and separate
the glass from the channel. Do not attempt to
b256
withdraw the glass from the door without first
removing the door glass waist seals.
Remove the access grommet from the rear face of the door, and unclip the exterior lock link rod from the
relay lever. Similarly disconnect the link rod between the relay lever and the latch mechanism.
Support the door shell before removing the two M8 bolts fixing the rear end of the door beam to the end
bracket, and the two screws securing the bracket to the door shell. Remove the bracket complete with
relay lever assembly from the door.
Refit the bracket in reverse order to removal.
Page 25
Lotus Service Notes
Section BR
BR.15 - CENTRAL DOOR LOCKING (Parts List 10.17)
On cars so equipped, the central door locking (CDL) operates on the driver’s and passenger’s doors in
conjunction with the Cobra 8185/8186 security alarm system. For full details of the alarm system, see subsection MP.1.
To lock the car, remove the ignition key, close both doors and check that the engine cover and front body
access panels are secure. Arm the security alarm in the usual way by pressing once, for a full second, the
larger of the two buttons on the transmitter key. This action will both arm the alarm and electrically lock the
driver’s and passenger’s doors.
If it is desired to lock the doors from inside the vehicle, for example to deter highjack attempts, a CDL
rocker switch is provided on the front of the gear lever shroud which should be pressed to the right to lock both
doors with or without the ignition switched on. Alternatively, the doors can be locked individually by depressing
the button at the rear end of each door sill. Note that whichever locking method is used, the doors will be
‘deadlocked’ such that the interior door release handles are inoperative.
To unlock the doors, press once, for a full second, the larger button on the transmitter key. The alarm will
be disarmed and both doors unlocked. Alternatively, from inside the car, press to the left the rocker switch on
the gear lever shroud to unlock both doors, or raise the sill button on each door. Note that in the event of a
vehicle collision which causes the safety inertia switch to be tripped, the doors will automatically be unlocked.
Notes:
- In the event of a flat vehicle battery, the central door locking will not operate. The doors can be unlocked
only after opening the boot lid and restoring power to the battery by substitution, re-charging or ‘jumping’ to
a second battery.
- To lock the car with a flat or disconnected battery, use the mechanical key in each exterior door button to
disconnect each release button from the latch. This technique does not 'deadlock' the interior release
handles, but does allow continued key access to the car until restoration of battery power.
- To deadlock the car with a flat vehicle battery, or without the use of the transmitter
or mechanical key, close and lock one door
using the sill button, and for the second
Door sill button
door, hold the exterior release button
b338
pressed in and depress the sill button before closing the door. Access is now available only on restoration of electrical power.
Door Locking Actuator
A CDL actuator is screw fixed to the door
shell below the latch mechanism, and uses a
link rod which passes through the rearmost
(shortest lever length) hole on the latch lever,
before continuing upwards to the door sill button. The latch mechanism within the door is
protected from tamper attempts by a plastic
security shield fixed with screws through the
door shut face. To remove an actuator, remove the door trim panel, security shield, release the two actuator fixing screws, unhook
the actuator from the link rod and disconnect
the harness.
Refit in reverse order to removal, noting
that no adjustment is required.
CDL
actuator
Rearmost
hole
Page 26
Lotus Service Notes
Section BR
BR.16 - INSTRUMENT BINNACLE & DASH PANEL (Parts List 14.10, 14.05, 14.05b)
The dash panel comprises interlinking alloy extrusions which join the chassis scuttle beam to the base of
the windscreen pillars, and also provide a mounting for the fascia top trip panel. The lowermost extrusion,
which incorporates a curved shelf, is keyed into a slot in the scuttle beam and is secured by rivets at each end
to the beam. On non-airbag cars, two interlinking extrusions are joined by self tapping screws to form the top
part of the dash panel, which is divided into two sections by the steering column. This upper dash is used to
house the face level vents and audio set. On airbag cars, the two upper extrusions are combined into a single
extrusion, which profile and function is similar to non-airbag cars, and which bridges the steering column area
and includes an aperture through which the passenger airbag is deployed.
The upper extrusion(s) slots behind the top edge of the lower dash, and is secured at each end by two
screws to threaded inserts in the base of the windscreen pillars. Additional location is provided by rivets
securing the speaker or door sill trim panel mounting brackets.
On non-airbag cars, a skinned foam fascia top panel, trimmed with suede material, joins the top of the
dash to the base of the windscreen and incorporates the demist ducting and four windscreen outlet vents, with
a moulded plastic capping panel around the front of the fascia top and surrounding the vents. At each end of
the fascia, a moulded plastic panel joins the fascia to the door sill finisher, and is used to mount the front
speakers and lighting switches.
On airbag cars, the untrimmed skinned foam panel incorporates the ducting to the six fixed demist outlet
vents, and also houses the front speakers. The face level vent outlets are housed in the moulded plastic
panels joining the fascia to the door sill finishers and in a central moulding also housing the audio set.
For access to the climate controls, or electrical components mounted on top of the chassis scuttle beam,
the fascia top panel must be removed.
To Remove Fascia Top Panel - non airbag cars
1.
Remove the steering column upper and
lower shrouds:
- Remove the four screws securing the
shroud upper section.
- Pull out the grommet from around the
ignition switch and remove the three
screws securing the lower
shroud to the column.
- Disconnect the trip reset button from
the lower shroud.
Column upper shroud
Lower shroud
mounting
bracket
Column lower
shroud
b258a
Page 27
Lotus Service Notes
2.
Section BR
Release the two fixings securing the binnacle mounting brackets to the column, and withdraw the instrument pack and cowl. Unplug the harness connector.
Instrument cowl
Instrument
pack
Binnacle
mounting
bracket
Mounting bracket
fixing screw
b259a
3.
Release the screws securing each fascia end (speaker) panel, disconnect the switch and speaker harnesses and withdraw the panels.
4.
Carefully prise each windscreen outlet vent from the fascia.
5.
Remove the screws at each end securing the fascia capping panel, and withdraw the panel.
6.
Remove the plastic finisher above the climate controls. Remove the four screws securing the top flange
of the dash extrusion to the underside of the fascia top.
7.
Lift the rear of the fascia top to release the two locating bosses from the keyhole slots in the dash, and pull
the fascia rearwards to withdraw the two front edge spigot pins.
8.
If the demist ducting is found to have become detached, or loose from the facia top foam moulding, the
duct should be refixed as follows:
- Remove any fixing screws, separate the duct from the fascia and remove any glue from the ducting.
- Roughen the bonding surface of the fascia with sand paper and clean and degrease with Betaclean 3900
or Acetone. Similarly clean and degrease the bonding surface of the demist duct.
- Prime bonding surfaces with Betaprime 5404 and bond with Betaseal 1701 or similar one component
polyurethane adhesive.
Page 28
Lotus Service Notes
Moulded plastic
capping panel
Section BR
Non-Airbag Type
pl1405mt
Capping panel fixing
Fascia top panel
Dash fixing
to screen
frame
Column
shroud
Fascia
to dash
fixing
Fascia top
recess finisher
FLV/climate
control
housing
Dash lower
extrusion
Keyhole slot
for fascia
Audio set
support
Dash upper
extrusion
Fascia top
Upper & centre
extrusions
Chassis
scuttle
beam
Lower
extrusion
b202a
Page 29
Lotus Service Notes
Section BR
Airbag Type
Instrument pack
mounting bracket
Column shroud
support leg
Fascia top panel
Column
shroud
Dash fixings
to screen
frame
FLV/audio
housing
Climate
control
housing
Airbag
door
Airbag shute
Dash upper
extrusion
Dash lower
extrusion
Audio set
support
Rivet to scuttle beam
Page 30
pl1405mtb
Lotus Service Notes
Section BR
To Remove Fascia Top Panel - airbag cars
WARNING: The airbag Sensor & Diagnositic Module can maintain sufficient voltage to cause an airbag
deployment for up to 20 seconds after the battery has been disconnected. Before working on the
airbag system, or in close proximity to an airbag, first take the following precautions to disable temporarily the airbag system:
a.
b.
c.
d.
e.
Turn off the ignition.
Before disconnecting the battery, use the Lotus Scan tool to read any stored trouble codes.
Disconnect the negative (earth) lead from the battery and tape back to ensure that no contact with the
battery negative terminal can be made.
Wait for 30 seconds.
If working on or near the steering wheel, locate the yellow harness connector alongside the steering
column near the column upper fixing. Unplug this connector. Note that the connector is fitted with
'shorting bars' which automatically interconnect the high and low terminals of the airbag to prevent accidental deployment caused by a voltage differential.
When service work has been completed, reconnect the harness plug and secure with its locking feature,
and reconnect the battery. Ensure the airbag tell tale lights for a few seconds with ignition and then goes out.
1.
Column shrouds: Remove the two screws retaining the top part of the shroud, and the four screws
retaining the lower part, and withdraw both parts from the column.
2.
Instrument shroud: Pull the instrument shroud backwards to release the four spring clips from their
apertures in the dash panel.
3.
Sill top trims: Release the two screws at the bottom of the coin pockets at the front of each sill, and pull
the sill top trim panels from the chassis.
4.
Dash end panels: Release the two screws within the top of each coin pocket, and withdraw the switch
panel (driver's side) and blanking panel (passenger side) from the dash end panel. Unplug the wiring
harness from the switch panel.
From within the aperture, release the two screws retaining each end panel to the dash, and pull the panel
rearwards to withdraw the spring clips in the top of the panel from the dash.
5.
Airbag door: Pull the airbag door away from the dash, which action will probably require the four retaining
clips to be renewed. Note that the door is constrained by two tether straps.
6.
Centre vent panel and radio surround: Release the two screws at each side of the panel and withdraw the
panel from its two spring clips.
7.
Fascia top panel: Remove the 5 screws securing the rear edge of the panel to the dash rail, and withdraw
the panel rearwards to disengage the two spigots from the base of the windscreen surround. Disconnect
the speaker cables.
8.
Refit in reverse order to removal.
Page 31
Lotus Service Notes
Section BR
BR.17 - WINDSCREEN (Parts List 11.01)
The laminated windscreen, together with self coloured synthetic finisher moulded around the top and side
edges, is bonded to the composite windscreen mounting frame using Betaseal flexible polyurethane adhesive.
It is not practicable to remove a windscreen from a car and then refit the same glass, as removal of the screen
will require cutting the surround finisher which is available only as part of a new windscreen assembly.
To Replace Windscreen
Parts required:
Windscreen
Betaseal Kit A075B6158F
Plinth, interior mirror mounting
Plinth Adhesive Kit A116U0194S
1.
On non-airbag cars, to minimise the possibility of trim damage, remove the fascia end (speaker) panels,
and the fascia top capping panel (around inside base of windscreen).
2.
Remove the front clamshell (see sub-section BR.6).
3.
Remove the wiper arm from its spindle, and the interior mirror from its plinth.
4.
Cut around the whole length of the windscreen surround finisher to allow access to the 'screen adhesive
joint. Apply suction handles to the outside surface of the screen.
5.
In order to incur the minimum risk of damage to the windscreen composite mounting frame, the preferred
method of cutting the windscreen adhesive is by the use of a 'cheese' wire. Protect the visual surface of
the windscreen frame with tape before commencing the cutting operation.
Screen removal tool
Cutting wire
b322
Page 32
Lotus Service Notes
Section BR
6.
After cutting out the screen, remove old adhesive from the windscreen frame sufficiently to leave a
consistent and flat surface for the new bond.
7.
Clean the whole of the inside surface of the windscreen with a 50% solution of water and isopropanol.
Allow to dry.
8.
Fit the interior mirror plinth to the inside of the windscreen using the adhesive kit and instructions supplied.
Windscreen top edge
Screen centreline
Obscuration
band
Mirror position on
RHD offset to left
79mm
63mm
63mm
Mirror position on
LHD offset to right
b263
9.
Clean the whole of the inside surface of the obscuration band, and the bonding surface on the windscreen
frame with the wipe cleaner.
10.
Apply a 25 mm wide band of Betaprime around the inside periphery of the glass. Similarly apply to the
whole of the bonding surface on the windscreen frame, and to the windscreen bottom laminated edge.
Allow to dry for a minimum of 5 minutes. If the screen is not fitted within 48 hours, the primer should be
re-applied.
11.
Cut the nozzle of the Betaseal cartridge
to the dimensions shown to produce a
triangular section bead. Holding the cartridge vertically, extrude a bead of adhesive around the screen, using the edge
of the finisher as a guide along the top
and sides, and following the centreline
of the primer band along the lower section.
8 mm
10 mm
60 mm
b264
Page 33
Lotus Service Notes
12.
Section BR
Cut three 4mm spacer blocks from the material supplied in the Betaseal kit, or from rubber or plastic
material, and position in the inside edge of the adhesive bead running along the bottom of the class.
These spacers are used to control the fitted height of the glass, and the wiper arm clearance.
Cartridge nozzle
Betaseal bead
Edge finisher
Obscuration
band
Primer band
Bead along centre of primer band
Spacer block in inside edge of bead
b265a
13.
Using the suction handles, carefully lower the windscreen onto the frame, with the edge finisher firmly
butted against the top and sides off the frame recess. Press around the periphery of the screen to
compress the adhesive until contact with the finisher spacers and bottom edge spacer blocks is felt.
Carefully examine the integrity of the whole length of the joint, if necessary using a spatula to force extra
adhesive into any suspect areas. Wipe off any excess adhesive extruded from the joint, or alternatively,
allow the adhesive fully to cure and cut away any excess using a scalpel blade.
14.
Use duct tape and/or support blocks to hold the screen in position and do not disturn until the Betaseal is
fully cured. This will take approximately 4 hours dependent on atmospheric conditions, with a longer
period required in dry atmospheres.
15.
Refit wiper arm, interior mirror and front clamshell.
Page 34
Lotus Service Notes
Section BR
Spillage of material
a)
Any spillage of Betaseal onto unprimed glass can be readily peeled off after it has cured.
b)
Any spillage onto the bldy can be removed with either Wipe Cleaner No.4, or white spirit.
Shelf life
a)
Betaseal primer has a useful life of about 24 hrs. after exposure to the air, after which it starts to become
spongy. If the material is spongy, DO NOT USE. Always use glass primer immediately on opening, and
replace the lid after use.
b)
Betaseal has a shelf life of over 6 months at ambient temperature in the original unopened package.
Page 35
Lotus Service Notes
Section CI
FRONT SUSPENSION
SECTION CI
Sub-Section
Page
General Description
CI.1
3
Geometry & Adjustments
CI.2
3
Anti-Roll Bar
CI.3
7
Suspension Disassembly/Assembly
CI.4
9
Front Wheel Bearings
CI.5
11
For Super Sport Suspension, see DH.6
Page 1
Lotus Service Notes
Section CI
GENERAL LAYOUT
Spring/damper unit
Top wishbone
Steering tie rod
Upper swivel
joint
Track rod
end
Steering
arm
Anti-roll bar
mounting
Anti-roll bar
Bottom wishbone
Hub carrier
Lower steering swivel joint
Page 2
Wheel hub
c34b
Lotus Service Notes
Section CI
CI.1 - GENERAL DESCRIPTION
The fully independent front suspension comprises, on each side of the car, upper and lower wishbones, a
concentric coil spring/telescopic damper unit, and a tubular anti-roll bar. A forged steel hub carrier, provides a
mounting for a the hub bearing unit to which the road wheel is attached via four spline socket bolts.
The upper and lower 'A' frame wishbones are fabricated from steel tube, the upper wishbone braced by
sheet steel gussets at its apex, and the lower wishbone braced by a tubular strut at its base. The inboard ends
of both wishbones use replaceable bonded rubber pivot bushes to provide maintenance free articulation, with
a specification providing accurate and responsive dynamic characteristics. The outer ends of both wishbones
incorporate housings into which the upper and lower steering swivel ball joints are pressed. The upper ball
pin is secured to the forged steel, rearward facing steering arm, itself fixed to the hub carrier by two M10 bolts.
The ball pin of the lower swivel joint is secured directly into a tapered hole in the bottom of the forged steel hub
carrier. The Bilstein spring/damper unit acts between the outer end of the lower wishbone and the chassis,
and is fitted with the damper rod lowermost in order to minimise unsprung weight.
A forward mounted tubular steel anti-roll bar, is supported in chassis mounted rubber or hard plastic pivot
bushes and is operated via short ball jointed drop links from the lower wishbones.
CI.2 - GEOMETRY & ADJUSTMENTS
Provision is made for the adjustment of wheel alignment, camber and castor. Under normal service conditions, no periodic scheduled check of the geometry is necessary, although a front wheel alignment check is
recommended when the front tyres are replaced. A full geometry check is required only after front suspension
repair, or if excessive tyre wear is evident, or if steering difficulties are encountered. Before any measurements
or adjustments are made it is essential first to set the vehicle to its ‘mid‑laden’ ride height, approximating to
driver and passenger and a half tank of fuel. This will require the vehicle to be ballasted, or tied down:
Standard Elise
Mid-laden ride height (reference height for geometry check);
- front 130 mm below front end of chassis siderail - rear 130 mm below rear end of chassis siderail
Camber - optimum - 0.1°
- tolerance + 0.1° to - 0.3°; Max side/side 0.2°
Castor - optimum + 3.8°
- tolerance + 3.5° to + 4.1°; max. side/side: 0.35°
Alignment - optimum Zero
- tolerance 0.5 mm toe-out to 0.7 mm toe-in overall
(0.07° toe-out to 0.10° toe-in overall)
Steering axis inclination 12° nominal
Sport Elise, Exige
Mid-laden ride height (reference height for geometry check);
- all except USA prior VIN 3013 - front 130 mm below front end of chassis siderail - rear 130 mm below rear end of chassis siderail
- USA prior VIN 3013 - front 135 mm below front end of chassis siderail - rear 135 mm below rear end of chassis siderail
Camber - optimum - 0.3°
- tolerance - 0.1° to - 0.5°; max. side/side: 0.2°
Castor - optimum + 3.8°
- tolerance + 3.5° to + 4.1°; max. side/side: 0.35°
Alignment - optimum Zero
- tolerance 0.5 mm toe-out to 0.5 mm toe-in overall
(0.07° toe-out to 0.07° toe-in overall)
Steering axis inclination 12° nominal
Page 3
Lotus Service Notes
Section CI
Alignment
Wheel alignment refers to the parallelism of the wheels when viewed from above and is crucial to vehicle
stability, handling and tyre wear.
Difference between
rim measurements
= overall toe out
FRONT
Individual
toe out angle
c26
Alignment is measured either by the angle a wheel makes with the vehicle centre line, or the difference in
dimension between the wheel rim to wheel rim measurement at the front and rear of the wheel at hub centre
height. The wheels are said to 'toe-in' when the wheel paths converge ahead of the vehicle, and 'toe-out' when
they diverge. Wheel alignment is designed to vary with both steering angle (Ackerman) and suspension travel
(bump steer) and should be measured only 'straight ahead' at the specified ride height.
Front wheel alignment is adjusted be screwing the track rods into or out of the track rod outer end ball
joints. In order to preserve the required bump steer characteristic and steering symmetry, the effective length
of each track rod must remain equal - adjust each track rod by a similar amount.
Track rod end flats
Steering rack gaiter
Track rod end
Steering arm
Steering track rod flats
Track rod end locknut
c28a
-
-
-
Hold the track rod end using the flats provided, and slacken the locknut. Repeat for the opposite side.
Turn each track rod a similar amount. As a guide, turning both track rods by one quarter of a turn will alter
overall toe-out by approx. 2.0 mm.
When adjustment is correct, hold each track rod end and tighten the locknuts to 80 - 82 Nm (58 - 60 lbf.
ft).
When slackening or tightening the track rod end locknuts, it is important that the torque reaction is resisted
using the track rod end flats, and that the ball joint itself is not allowed to be stressed.
Page 4
Lotus Service Notes
Section CI
Camber Adjustment
Camber is the angle from vertical of the wheel when viewed from the front, and is said to be negative when
the wheel leans inwards at the top (positive when leaning outwards). The primary purpose of camber is to
achieve the maximum efficiency of the tyre under cornering loads and body roll, with the specification closely
allied to a particular wheel/tyre combination. The camber angle changes with suspension travel, becoming
more negative on bump, and should be measured only at the specified ride height. Incorrect camber can result
in handling deficiencies and excessive tyre wear.
c29
Vertical
Camber angle
Wheel centreline
Camber adjustment is effected by adding or deleting shim plates between the steering arm (to which the
upper steering swivel joint is fixed) and the hub carrier.
Steering arm
-
-
-
-
Camber adjustment
shimplate
Hub carrier
c30a
Shimplates are available in 1mm and 3mm thicknesses.
Reducing the shim pack thickness will increase negative camber. Adding shims will reduce negative
camber.
A 1mm shim plate will alter camber by approximately 0.25°.
In March '04 the caphead bolts securing the ball joint plinth to the hub carrier were upgraded from 8.8 to
10.9 grade, with a corresponding increase in torque from 45 to 68 Nm. Before fitting these bolts, inspect
the cap head for the grade marking, apply Permabond A130 (A912E7033) to the threads, and torque
tighten to the appropriate figure.
Page 5
Lotus Service Notes
Section CI
Castor Adjustment
Castor is the angle from vertical of the steering axis of the wheel when viewed from the side. Its primary
purpose is to provide a natural straight running tendency of the steered wheels with forward vehicle motion.
Castor angles have a complex interaction with other steering geometries and if unbalanced or outside of specification, can result in various stability and handling deficiencies.
FRONT
Top &
bottom
steering
swivels
Castor angle
c27
The wishbone pivot bushes are bonded rubber type with a plastic flanged outer sleeve, a plain steel inner sleeve, and a plastic interleaf sleeve within the rubber bush to control the flexing characteristic. The top
wishbone rear bush, identified by a blue paint mark, has no interleaf sleeve.
The top wishbone pivots are sandwiched between the walls of transverse chassis box sections, the pick
up points in which are reinforced either with machined inserts, or in the case of the foremost position, a thick
alloy plate, each being bonded to the chassis with epoxy adhesive. Spacer washers are fitted ahead of and
behind each of the top wishbone pivot bushes to allow the wishbone to be displaced forwards or backwards,
with an associated change of castor angle. A rubber faced snubber washer fitted against the rear face of the top
wishbone front bush prevents metal to metal contact under extreme braking forces. The spacer washers may
be re-distributed between the front and rear of each pivot bush but the snubber washer position, and the total
shim pack thickness of 4 x 1.5mm at each pivot (inc. the 1.5mm snubber washer) must remain unchanged.
Top Wishbone Inboard Fixing
FRONT
Front leg
Rear leg
1.5mm shim 1.5mm shim
washers washers
Flanged plastic
outer sleeve
No interleaf Inner steel
Bonded Bonded on this bush sleeve
plate Rubber faced inserts
snubber washer
Page 6
c32
Lotus Service Notes
Section CI
Notes
-
Shim distribution at the front bush of either wishbone must be copied at the rear bush of that wishbone.
-
Transferring a 1.5mm shim washer from ahead of, to behind the pivot bushes, will reduce castor by approximately 0.4°.
-
Transferring a 1.5mm shim washer from behind, to ahead of the pivot bushes, will increase castor by
approximately 0.4°.
-
Ensure that the load spreading washers are correctly located beneath the bolt heads and nuts as shown
in the drawings.
-
Ensure that the pivot bolts are tightened only with the vehicle at ride height. Torque to 45 Nm.
CI.3 - ANTI-ROLL BAR
1.
Three types of anti-roll bar and chassis mounting have been used:
The standard tubular steel anti-roll bar is mounted in pivot bushes onto the front face of the chassis, and
is linked to the outboard ends of each lower front wishbone via short ball jointed links. The bar is mounted
to the chassis using rubber pivot bushes for noise isolation, retained by alloy clamp brackets. Washers
welded to the bar bear against the inner sides of the bushes to provide lateral location of the bar. Castrol
LMX rubber grease, or equivalent, should be used when fitting the rubber bushes onto the anti-roll bar.
Anti-Roll Bar Mounting - Rubber
Spacer plate
Rubber mounting
c40
2.
Clamp bracket
On Elise and Exige models built with 'Super Sport' suspension prior to August '06, a stiffer adjustable bar
is used with 5 holes in each end to allow some adjustment of roll stiffness to be made. Standard setting is
centre hole. Using a more forward hole increases stiffness. Two hard plastic clamping blocks secure the
bar to the chassis via the front lower wishbone inboard front pivot bolts, with 'top hat' section steel spacers
preventing the clamps from being crushed. An M5 bolt is used to close the bottom of each clamp.
Anti-Roll Bar Mounting - Hard 1
'Top hat' spacer
Clamping block
M5 bolt
Lower wishbone pivot bolt
Anti-roll bar
c40a
Page 7
Lotus Service Notes
Section CI
These hard type mountings provide optimum steering response but will transmit more noise and require
periodic lubrication with MoS2 grease at 3,000 mile (5,000 km) intervals. Noise from excessive clearance
may be ameliorated by judicious shaving of the clamping block faces.
2.
Elise and Exige models built with 'Super Sport' suspension from August '06, use a yellow painted, standard
rate, 5-hole adjustable bar, sharing the chassis mounting higher position of the standard bar but using
hard plastic bushes housed in alloy clamps. Each split pivot bush incorporates a raised shoulder around
its centre in order to engage with a groove in the two part clamp, and provide lateral location of the bush.
A pip on this shoulder locates in a hole in the clamp cap to prevent rotation of the bush. No lubrication is
required. These hard bushes benefit dynamic response at some penalty to refinement.
Anti-Roll Bar Mounting - Hard 2
Smaller washer Bearing clamp rear
Alignment
dowel Anti-rotation
pip
Cap head bolt
Chassis
front face
Anti-roll bar Synthetic split bush
Bearing
clamp cap Flat washer
c40b
Anti-Roll Bar Drop Link
Anti-roll bar
drop link
Anti-roll bar
Page 8
Lower wishbone
c31
Lotus Service Notes
Section CI
CI.4 - SUSPENSION DISASSEMBLY/ASSEMBLY
The suspension may be disassembled without the use of any special tools other than a 'Torx' socket for
the hub bearing carrier bolts, and a spring compressor, required only if the spring is to be removed from the
damper unit. With the car on a wheel free lift and with the front wheels removed:
1. Remove the wheelarch liner(s) as appropriate.
2.
Remove the two bolts securing the brake calliper to the hub carrier, release the flexible hose from the top
wishbone, and support the calliper aside without straining the brake hose. Release the single countersunk
screw, and remove the brake disc.
3.
Remove the nut securing the track rod end into the steering arm, and use a ball joint splitter to separate
the rod end from the arm.
4.
Remove the nut securing the top swivel joint to the steering arm, and use a ball joint splitter to separate
the joint from the arm. Remove the two M10 fixing bolts and remove the steering arm from the hub carrier,
taking care not to misplace the camber adjustment shim plates.
5.
Remove the nut securing the lower swivel joint to the hub carrier, and use a ball joint splitter to separate
the ball pin from the carrier.
6.
Remove the bolts securing the spring/damper unit to the lower wishbone and chassis anchor bracket, and
withdraw the unit, noting the spacer washers fitted at the top end.
7.
Disconnect the anti-roll bar drop link from the lower wishbone, and remove the lower wishbone front pivot
bolt.
8.
Remove the lower wishbone rear pivot bolt from within the cabin footwell, and withdraw the wishbone.
9.
Before removing the two pivot bolts for the top wishbone, take careful note of the distribution of castor
adjustment washers. Move the steering rack to full lock to provide clearance for the withdrawal of the
wishbone rear pivot bolt. Withdraw the wishbone.
10. The wishbone pivot bushes comprise a rubber bush bonded to a steel inner sleeve and a flanged plastic
outer sleeve. The bushes may be pressed out of the wishbone eyes, and new bushes fitted using suitable press tool dollies. Smear the outer surface of the new bush with IPC 'P-80' rubber lubricant emulsion
(A082C6042V) to ease fitment, and assemble as follows. If possible, warm the wishbone to 80 - 100°C.
Top wishbone - insert from the outside of both pivot eyes (from front of front eye, and rear of rear eye).
Lower wishbone - insert from the inside of both pivot eyes (from rear of front eye, and front of rear eye).
Note that all wishbone pivot bushes are common with the exception of the top wishbone rear pivot, which
contains no interleaf sleeve and is identified by a blue paint mark.
11. Top and bottom swivel joints are identical, and may be replaced if necessary using a suitable press.
12. If the anti-roll bar is to be removed; remove the front alloy undertray, and, by drilling out the rivets, the
small alloy closing panel at each side of the crash structure below the anti-roll bar. Release the a.r. bar
clamps and drop links, and withdraw the bar.
13. The road spring may be removed from the damper using a suitable spring compressor to allow the spring
lower slotted seat to be withdrawn. Note that spring upper seat is located by a square section circlip on
the damper body:
- Standard Elise: Use centre of 3 grooves for mid-laden ride height of 130mm.
- USA Elise: Use lower of 3 grooves for mid-laden ride height of 135mm.
- Elise with sports suspension package and non-USA Exige: Use the upper of 2 grooves for mid-laden
ride height of 130mm.
14. To remove the hub bearing unit from the hub carrier, release the three Torx head bolts and withdraw the
complete unit. The hub unit is not serviceable, and is replaced complete if faulty.
Page 9
Lotus Service Notes
Section CI
Reassembly
Re-assemble the suspension in reverse order to disassembly with the following notes:
-
Take care to assemble each pivot bolt with the correct washers/snubbers/spacers as shown in the diagrams.
-
Smear the shank of each pivot bolt with PBC grease, but do not allow contamination of the threads.
-
Take care to refit the original camber adjustment shimpack, and distribute the castor shims as noted on
removal.
-
Top ball joint plinth fixing bolts:
The bolts securing the steering arm/top ball joint plinth to the hub carrier were upgraded in March '04 at
VIN serial number 1537 (approx.) in order to commonise with motorsport applications. Earlier type 8.8
grade bolts should be tightened to 45 Nm; Later 10.9 grade bolts to 68 Nm. The bolt grade is stamped
around the head of the bolt. The thread of both bolt types should first be treated with Permabond A130
(A912E7033V).
-
After re-fitting a standard anti-roll bar, ensure that the crash structure closing panels are re-riveted.
-
Lubricate the rubber type anti-roll bar mountings with rubber grease and the Nylon type with MoS2
grease.
-
Apply Permabond A130 (A912E7033V) to the threads of the steering arm bolts.
-
Lubricate the ends of the damper top eye bush with rubber grease.
-
Press the brake pedal to reposition the pads before driving the car.
-
If the car suffers a suspension impact sufficient to damage a wheel rim, careful attention should be paid to
all related suspension components. Such forces can cause stretching of the lower ball pin and consequent
fixing nut torque loss. As a safety precaution, it is recommended that in all such cases, the lower ball joint
and the two bolts securing the upper ball joint plinth to the hub carrier are renewed.
The Service Schedule specifies that the security of the front and rear suspension is checked at each service.
For cars used on race tracks, or in similar conditions, suspension components and torque checks should be
carried out between sessions. This operation requires that all the principal suspension pivot bolts are torque
checked, noting the following points:
Where a bolt is tapped into a housing or weldnut, and relies on a thread locking compound for security, it
is important to appreciate that if the bolt is disturbed, the locking compound must be re-applied. The following
procedure should be adopted for all such fixings:
-
Check the torque of the fixing.
-
If the specified torque is attained without the fixing being disturbed (moving), take no further action.
-
If the bolt moves, the locking action of the thread adhesive will have been compromised. Remove the
bolt completely, clean off all old adhesive using a wire brush and acetone, and apply new adhesive as
specified.
-
Refit the bolt and tighten to the specified torque.
-
If for any reason a bolt is found to have become loose, and the car has been operated for any period in
this condition, the bolt should be renewed as a standard precaution and related components carefully
inspected for hole ovality or wear.
Torque Settings:
Upper and lower wishbone pivot bolts Upper swivel joint to steering arm
Lower swivel joint to plinth
Steering arm to hub carrier - 8.8 grade
- 10.9 grade
Track rod end to steering arm
Damper to lower wishbone
Damper to top anchor bracket
Damper anchor bracket to chassis
Hub bearing unit to hub carrier
Brake calliper to hub carrier
Anti-roll bar alloy mounting clamps
Anti-roll bar drop links
Page 10
Nm
45
55
55
45
68
30
45
45
25
90
45
25
45
Lotus Service Notes
Section CI
CI.5 - FRONT WHEEL BEARINGS
The sealed front wheel bearings are contained in a steel housing secured to the hub carrier with three
'Torx' bolts. The double row, angular contact, ball bearing is retained in the outer housing and also onto the
hub spigot by a shoulder and a peening operation, and is inseparable for service. Note that all four hub assemblies are common, and incorporate a wheel speed sensor in the bearing unit, with a flying lead terminating
in an electrical connector plug secured by a camber shim plate bracket. If there is found to be any discernible free play in the hub bearing, or any roughness or tight spots can be
felt, or any signs of lubricant expulsion are evident, the hub assembly should be replaced - there is no provision for adjustment.
To Replace Hub Bearing Assembly
1. With the wheel removed, release the two fixing bolts, and remove the brake calliper from the hub carrier.
Support clear of the brake disc without straining the flexible hose. Release the single countersunk screw
and withdraw the brake disc from the hub.
2.
Using a Torx socket, release the three bolts securing the hub bearing unit to the hub carrier.
3.
Fit the new hub bearing unit to the hub carrier and retain with the three Torx bolts. Torque tighten to 90
Nm.
4.
Refit the brake disc and calliper, using Permabond A130 (A912E7033) to the threads of the calliper fixing
bolts and torque tightening to 45 Nm. Pump the brake pedal to reposition the pads before driving the
car.
Hub
Steering arm
Hub carrier
Hub to carrier fixing bolt
Swaged bearing retention
Double row ball bearing
Page 11
c41a
Lotus Service Notes
Section DH
REAR SUSPENSION
SECTION DH
Sub-Section Page
General Description
DH.1
3
Geometry & Adjustments
DH.2
3
Suspension Disassembly/Assembly
DH.3
6
Rear Wheel Bearings
DH.4
9
Track Use Chassis Rear Brace Kit
DH.5
11
Super Sports Suspension Package
DH.6
14
Page 1
Lotus Service Notes
Section DH
Rear Suspension Layout
Damper top mount
Upper ball joint
Damper
Hub carrier
Top wishbone
Rear subframe
Rear
subframe
Lower wishbone
Wheel hub
Road spring
Toe control link
Lower ball joint
Page 2
Driveshaft
d20b
Lotus Service Notes
Section DH
DH.1 - GENERAL DESCRIPTION
The fully independent rear suspension comprises, on each side of the car, upper and lower tubular steel
wishbones, a toe control link, and a concentric coil spring/telescopic damper unit linked between the outboard
end of the lower wishbone and the chassis. A forged steel hub carrier, provides a mounting for the hub bearing
unit to which the road wheel is attached via four spline socket bolts.
The upper and lower 'A' frame wishbones are fabricated from steel tube, with the inboard ends of both
wishbones using replaceable bonded rubber pivot bushes to provide maintenance free articulation, with a
specification providing accurate and responsive dynamic characteristics, with some suppression of noise and
vibration. The two legs of the top wishbone pick up on the chassis rear subframe, and converge outboard
and forwards to a ball joint housing into which is pressed a ball swivel joint. The ball pin of this joint locates in
a forged steel plinth which is itself secured to the hub carrier using two horizontally disposed M10 bolts. The
braced, wide based, lower wishbone, is anchored at its front inboard end to the chassis rear crossmember via
a steel bracket, and at its rear inboard end to the chassis rear subframe. The two legs converge outboard and
rearwards to a ball joint housing which accommodates another swivel ball joint, the ball pin of which is secured
directly into a tapered hole in the forged steel hub carrier. The Bilstein telescopic damper with concentric coil
spring, is fitted with the damper rod lowermost to minimise unsprung weight, and acts between the outer end
of the lower wishbone and an anchorage on the steel subframe.
The adjustable length, double ball jointed, toe control link, shares a subframe anchorage with the rear pivot
of the lower wishbone, and at its outboard end, is secured directly into a tapered hole in a rearward integral
extension of the hub carrier.
The forged steel hub carrier provides a mounting for a hub bearing unit, which is secured by three 'Torx'
head bolts and incorporates a wheel speed sensor for the anti-lock brake system, engine management and
speedometer data.
DH.2 - GEOMETRY & ADJUSTMENTS
Provision is made for the adjustment of wheel alignment and camber. Under normal service conditions, no
periodic scheduled check of the geometry is necessary, with a full geometry check required only after suspension
repair, or if excessive tyre wear is evident, or handling deficiencies encountered. Before any measurements or
adjustments are made, it is essential first to set the vehicle to its ‘mid‑laden’ ride height, approximating to driver
and passenger and a half/full tank of fuel. This will require the vehicle to be ballasted or tied down:
Standard Elise
Mid laden ride height (reference height for geometry check);
- all except USA prior VIN 3013 - front 130 mm below front end of chassis siderail - rear 130 mm below rear end of chassis siderail
- USA prior VIN 3013 - front 135 mm below front end of chassis siderail - rear 135 mm below rear end of chassis siderail
Camber; - optimum - 1.8°
- tolerance - 1.6° to - 2.0°; max. side/side: 0.2°
Alignment; - optimum 1.2 mm (0.16°) toe-in each side
- tolerance 1.2 to 1.8 mm toe-in each side
(0.16° to 0.24° toe-in each side)
Max. difference side/side: 0.3 mm (0.04°)
Roadsport Elise, Exige (for Super Sport suspension see sub-section DH.6)
Mid laden ride height (reference height for geometry check);
- front 130 mm below front end of chassis siderail - rear 130 mm below rear end of chassis siderail
Camber; - optimum - 1.8°
- tolerance - 1.6° to - 2.0°; max. side/side: 0.2°
Alignment; - optimum 1.5 mm (0.20°) toe-in each side
- tolerance 1.2 to 1.8 mm toe-in each side
(0.16° to 0.24° toe-in each side)
Max. difference side/side: 0.3 mm (0.04°)
Page 3
Lotus Service Notes
Section DH
Alignment
Wheel alignment refers to the parallelism of the wheels when viewed from above and is crucial to vehicle
stability, handling and tyre wear. It is measured either by the angle a wheel makes with the vehicle centre
line, or the difference in dimension between the wheel rim to wheel rim measurement at the front and rear of
the wheel at hub centre height. The wheels are said to 'toe-in' when the wheel paths converge ahead of the
vehicle, and 'toe-out' when they diverge. Rear wheel alignment should be measured only using equipment
which measures individual rear wheel alignment reletive to the car centreline. Wheel alignment is designed
to vary with suspension travel ('bump steer') and the base setting should be measured only at the specified
mid laden ride height.
It is possible to accurately measure individual wheel alignment using a pair of long straight bars or round
section elastic in conjunction with 4 axle stands or similar. Any bars used must be longer than the length of the
car, and be suitably stiff and straight.
Set up the bars or elastic on each side of the car at wheel centre height as shown an the diagram, so that
A = A, B = B and C = C.
Straight
edge
FRONT
d21
Measure the distance from the bar to the rim of the wheel concerned at the front and rear of the centre line
of the wheel (D1, D2). If the front dimension, D1, is greater than the rear dimension, D2, the wheel has TOE-IN.
If the rear dimension is greater than the front dimension, the wheel has TOE-OUT. The difference between the
two measurements is the amount the wheel has toe-in or toe-out.
Wheel alignment is adjusted via the toe control link which is equipped with a left hand threaded ball joint at
the inboard end, and a right hand threaded ball joint at the outboard end. Slacken both ball joint locknuts, and
turn the link rod as necessary to increase or decrease the effective length of the link. As a guide, lengthening
the link rod by a turn of one 'flat' (one sixth of a turn) will increase toe-in by approximately 1mm.
After adjustment, tighten the two locknuts to 55 Nm taking care to ensure that the ball joint sockets are
aligned at 90° to each other to allow some free articulation.
Camber Adjustment
Camber is the angle from vertical of the wheel when viewed from the rear, and is said to be negative when
the wheel leans inwards at the top (positive when leaning outwards).
The primary purpose of camber is to achieve the maximum efficiency of the tyre under cornering loads and
body roll, with the specification closely allied to a particular wheel/tyre combination. The camber angle changes
with suspension travel, becoming more negative on bump, and should be measured only at the specified ride
height. Incorrect camber can result in handling deficiencies and excessive tyre wear.
Page 4
Lotus Service Notes
Section DH
Camber angle
-
-
-
-
-
-
-
Vertical
c29
Wheel centreline
Camber adjustment shim plates are fitted between the top wishbone ball joint plinth and the hub carrier,
and are available in 1.0 & 1.5mm thickness.
In June 2008, the shim material was upgraded and the slots deleted to enhance joint stability and commonise with motorsport applications. Retrofitment of the later type shims is recommended.
In all cases it is necessary to fit the plate supporting the wheel speed sensor harness.
Reducing the shim pack thickness will increase negative camber. Adding shims will reduce negative
camber.
A 1mm shim plate will alter camber by approximately 0.3°.
In March '04 the caphead bolts securing the ball joint plinth to the hub carrier were upgraded from 8.8 to
10.9 grade, with a corresponding increase in torque from 45 to 68 Nm. Before fitting these bolts, inspect
the cap head for the grade marking, apply Permabond A130 (A912E7033) to the threads, and torque
tighten to the appropriate figure. Retrofitment of the later type bolts is recommended.
Any attempt to adjust camber outside of Lotus specification, may result in inappropriate bolt thread engagement, and endanger security.
Top wishbone
Camber adjustment
shimplate
Hub carrier
Ball joint plinth
Shimplate with wheelspeed
sensor harness bracket
Page 5
d24a
Lotus Service Notes
Section DH
DH.3 - SUSPENSION DISASSEMBLY/ASSEMBLY
The suspension may be disassembled without the use of any special tools other than a 'Torx' socket for
the hub bearing carrier bolts, a spring compressor required only if the spring is to be removed from the damper
unit, and a ball joint splitter. If the hub carrier is to be removed, necessitating withdrawal of the driveshaft, it is
recommended first to release the driveshaft nut before dismantling the brakes.
With the car on a wheel free lift and with the rear wheels removed:
1.
Remove the split pin securing the driveshaft nut, and with the brakes firmly applied, remove the driveshaft
nut.
2.
Remove the engine bay undertray to provide access to the lower wishbone front pivot.
3.
Disconnect the parking brake cable from the caliper. Release the 'P' clip securing the brake hose to the
top wishbone and remove the two bolts securing the brake caliper to the hub carrier. Support the caliper
aside without straining the brake hose. Release the single retaining screw, and remove the brake disc
from the hub.
4.
Disconnect the wheel speed sensor cable from each hub unit, and release from routing clips.
5.
Release the nut securing the outer end of the toe link to the hub carrier, and use a ball joint separator to
release the joint from the carrier.
6.
Remove the nut securing the ball pin of the lower ball joint to the hub carrier, and use a ball joint separator
to release the joint from the carrier.
7.
Remove the two bolts securing the top swivel joint plinth to the hub carrier, noting and retaining the camber
adjustment shim pack.
8.
Withdraw the hub carrier assembly from the driveshaft, using a suitable puller tool if necessary to release
the shaft from the hub. Do not allow any pulling force to be applied through the driveshaft C.V. joints, or
damage to the joints will be caused.
9.
Remove the top and bottom mounting bolts for the spring/damper unit, and withdraw.
10. Remove the top wishbone pivot bolts, and withdraw the wishbone from the rear subframe.
Top wishbone front pivot
Tab washer
Top wishbone rear pivot
Plastic interleaf
FRONT Bush inserted Tab Tab washer Bush inserted Tab
from front washer from front washer
d22b
Page 6
Lotus Service Notes
Section DH
11. Remove the heatshield over the toe-link inboard ball joint, release the toe-link stud, remove the lower
wishbone front pivot bolt and withdraw the lower wishbone and toe link.
12. If necessary, remove the top swivel joint ball pin nut, and use a ball joint splitter tool to separate the joint
from its plinth. Either swivel joint may be replaced using suitable press tool dollies.
13. The wishbone pivot bushes are bonded rubber type with a plastic flanged outer sleeve, a plain steel inner
sleeve, and a plastic interleaf sleeve within the rubber bush to control the flexing characteristic.
The bushes may be pressed out of the wishbone eyes, and new bushes fitted using suitable press tool
dollies. Smear the outer surface of the new bush with IPC 'P-80' rubber lubricant emulsion (A082C6042V)
to ease fitment, and assemble as follows:
Top wishbone front pivot - insert a single 30mm long bush from the front end of the eye
Top wishbone rear pivot - insert a single 30mm long bush from the front end of the eye. Note: Prior to
January '06 this bush was inserted from the rear end. Inserting from the front provides greater restistance
to bush displacement from braking forces.
Lower wishbone rear pivot - insert a single 30mm long bush from the front end of the eye.
Lower wishbone front pivot - insert a 16mm long bush into each end of the front eye.
Lower wishbone front pivot
Lower wishbone rear pivot
FRONT Pivot mounting Plastic Rear bracket interleaf subframe
Tab
washer
Weldnut Short pivot Flange nut Long pivot bush bushes inserted from front
d19b/d
Toe
link
ball
joint
Anti-rotation
insert
14. The road spring may be removed from the damper using a suitable spring compressor to allow the spring
lower slotted seat to be withdrawn. Note that the spring upper seat is retained by a square section circlip
in a groove in the damper body:
- Standard Elise & USA from VIN 3013: Use centre of 3 grooves for mid-laden ride height of 130mm.
- USA Elise prior VIN 3013: Use lower of 3 grooves for mid-laden ride height of 135mm.
- Elise with Roadsports suspension package and non-USA Exige: Use the upper of 2 grooves for midladen ride height of 130mm.
15. To remove the hub bearing unit from the hub carrier, release the three Torx head bolts and withdraw the
complete unit. The hub unit is not serviceable, and is replaced complete if faulty.
Reassembly
Re-assemble the suspension in reverse order to disassembly with the following notes:
-
Take care to assemble each pivot bolt with the correct washers/snubbers/spacers as shown in the diagrams.
-
Smear the shank of each pivot bolt with PBC grease, but do not allow contamination of the threads.
-
Take care to refit the original camber adjustment shimpack.
Page 7
-
-
-
-
Lotus Service Notes
Section DH
Top ball joint plinth fixing bolts:
The bolts securing the top ball joint plinth to the hub carrier were upgraded in March '04 at VIN serial number
1537 (approx.) in order to commonise with motorsport applications. Earlier type 8.8 grade bolts should
be tightened to 45 Nm; Later 10.9 grade bolts to 68 Nm. The bolt grade is stamped around the head of
the bolt. The thread of both bolt types should first be treated with Permabond A130 (A912E7033V). Lubricate the ends of the damper top eye bush with rubber grease.
Tab washers are used for the bolt head of the lower wishbone forward pivot, and on both top wishbone
pivots. In each case, ensure that one end of the tab washer is folded around the chassis edge, and after
torque tightening the fixing, form the other end of the washer against the flats of the bolt head or nut. In
July '05, the thickness of the tab washer was increased from 1.2mm to 1.5mm.
If the lower wishbone front pivot brackets have been removed from the chassis, ensure that a spacer
is fitted on each of the four bolts securing each bracket, in order to allow the required bolt stretch to be
achieved.
Left hand bracket viewed from rear
Chassis
Wishbone pivot
bracket
Spacer tubes
d44
This bolt inverted for
parking brake cable
clearance
-
Note that on previous Elise models, there have been several variants of the toe-link inboard ball joint. The
correct joint for 2005 model year onwards has a ball pin thread pitch of 1.25mm (vs. 1.5mm). The flats
on the ball pin should be aligned with the channel in the subframe hardened insert. Note that the inboard
joint has a LH thread into the toe-link tube, and the outboard joint a RH thread into the toe-link tube with
a taper shank ball pin to fit into the hub carrier.
Hardened insert
Toe-link ball joint
Align ball joint flats
Rear subframe with insert channel
crossmember
Page 8
d43
-
-
-
Lotus Service Notes
Section DH
Do not operate the car without the exhaust silencer heatshielding correctly fitted, and incorporating heatshields for the toe-link inboard ball joints.
Press the brake pedal to reposition the pads before driving the car.
If the car suffers a suspension impact sufficient to damage a wheel rim, careful attention should be paid
to all related suspension components. Such forces can cause stretching of the lower ball pin and consequent fixing nut torque loss. As a safety precaution, it is recommended that in all such cases, the lower
ball joint and the two bolts securing the upper ball joint plinth to the hub carrier are renewed, together with
both toe-link ball joints.
The Service Schedule specifies that the security of the front and rear suspension is checked at each service.
For cars used on race tracks, or in similar conditions, suspension components and torque checks should be
carried out between sessions. This operation requires that all the principal suspension pivot bolts are torque
checked, noting the following points:
Where a bolt is tapped into a housing or weldnut, and relies on a thread locking compound for security, be
aware that if the bolt is disturbed, the locking compound must be re-applied. The following procedure should
be adopted for all such fixings:
-
Check the torque of the fixing.
-
If the specified torque is attained without the fixing being disturbed (moving), take no further action.
-
If the bolt moves, the locking action of the thread adhesive will have been compromised. Remove the
bolt completely, clean off all old adhesive using a wire brush and acetone, and apply new adhesive as
specified.
-
Refit the bolt and tighten to the specified torque.
If for any reason a bolt is found to have become loose, and the car has been operated for any period in
this condition, the bolt should be renewed as a standard precaution and related components carefully
inspected for hole ovality or wear.
At every service interval, the toe-link should be checked for free articulation by using a spanner on the flats
of the link and twisting in both directions. The torque required to articulate the joints should be little more
than may be applied by hand. If any joint is found to be seized or tight (or if any free play is evident), the
joint should be renewed. At each service, the toe-link inboard pivot should be torque checked to allow for
any settling of the ball joint orientation flats into the galvanised subframe groove.
Torque Settings:
-
Upper and lower wishbone pivot bolts -
Upper and lower swivel joint ball pins
-
Upper swivel joint plinth to hub carrier - 8.8 grade
- 10.9 grade
-
Toe-link outer ball joint to hub carrier -
Toe-link inner ball joint/wishbone to subframe
-
Toe-link ball joint lock nuts
-
Damper to lower wishbone
-
Damper to chassis
-
Brake caliper to hub carrier - upper M10
- lower M8
-
Hub bearing unit to hub carrier
-
Rear hub nut
Nm
45
55
45
68
55
60
45
45
45
45 - 50
26 - 30
90
220
DH.4 - REAR WHEEL BEARINGS
The sealed rear wheel bearings are contained in a steel housing secured to the hub carrier with three
'Torx' bolts. The double row, angular contact, ball bearing is retained in the outer housing and also onto the hub
spigot by a shoulder and a peening operation, and is inseperable for service. Note that all four hub assemblies
are common, and incorporate a wheel speed sensor in the bearing unit, with a flying lead terminating in an
electrical connector plug secured by a camber shim plate bracket. If there is found to be any discernible free play in the hub bearing, or any roughness or tight spots can be
felt, or any signs of lubricant expulsion are evident, the hub assembly should be replaced - there is no provision for adjustment.
Page 9
Lotus Service Notes
Section DH
To Replace Hub Bearing Assembly
1. With the wheel removed, apply the parking brake, remove the split pin from the nut retaining the driveshaft
in the hub, and release the nut.
2.
Release the two fixing bolts, and remove the brake caliper from the hub carrier. Support clear of the brake
disc without straining the flexible hose. Release the single countersunk screw and withdraw the brake
disc from the hub.
3.
Disconnect the wheel speed sensor harness from the hub unit.
4.
Using a Torx socket, release the three bolts securing the hub bearing unit to the hub carrier, and withdraw
the unit from the hub carrier and driveshaft. If necessary, use a suitable puller tool to press the shaft from
the hub, but on no account allow an extension force to be applied to the driveshaft.
5.
Fit the new hub bearing unit in reverse order to disassembly, with the following notes:
- Torque tighten the three Torx bolts securing the hub bearing assembly to the hub carrier to 90 Nm.
- Torque tighten the driveshaft nut to 220 Nm and retain using a new split pin.
- Pump the brake pedal to reposition the pads before driving the car.
Hub carrier
Top ball joint plinth
Hub to carrier fixing bolt
Hub
Split pin
Driveshaft
Castellated nut
Page 10
Double row ball bearing
d39
Lotus Service Notes
Section DH
DH.5 - TRACK USE CHASSIS REAR BRACE KIT - LOTAC05377
The purpose of the kit is to provide a 'double shear' mounting for the inboard ends of the rear toe-links and
spread the load distribution into the chassis over a wider base. New spherical joints are used on the inboard
ends of the toe-links, with a tubular steel crossbrace interconnecting the two pivot bolts and anchoring to the
rear engine steady mounting on the subframe. For cars used on closed circuits, this arrangement provides an
increased tolerance to abuse. It may be retrofitted on any Elise 111R/'04 Exige/USA Elise (i.e. Toyota powertrain cars).
The rear toe-links comprise the existing outboard taper shank ball joint and toe-link tube, but the inboard
joint is replaced by a new spherical joint with no integral stud. A bespoke spacer locates in the orientation
groove in the (unchanged) subframe and provides a flat surface against which to clamp the pivot ball of the new
joint. A flange head bolt passes through the ball joint and inboard pivot bush of the lower wishbone in a similar
manner to previously, but also locates a brace against the rear 'overhung' end of the ball joint. The tubular
crossbrace on factory built cars prior to December '05, links the two inboard joints via machined adaptor lugs
and turnbuckle adjusters, and is braced directly to the subframe by a welded bracket secured by the engine
rear steady mounting fixings. On later factory built cars using a brace kit, the crossbrace is a simple tubular
link (B120D0040H) without adjusters or subframe bracket. On these cars, a flat washer A120W4199F is used
beneath the head of the crossbrace bolts.
Kit Contents
Tubular Crossbrace, adjustable
Turnbuckle, crossbrace adjustment
Locknut, turnbuckle, M12, RH thread
Locknut, turnbuckle, M12, LH thread
Flange Nut, brace to subframe, M10
Adaptor Lug
Spherical Joint, toe-link inboard
Spacer, spherical joint to subframe
Pivot Bolt, toe link inboad, M10x120x1.25p
Locknut, pivot bolt, M10x1.25p
Fitting Instruction
Part Number
A120D0040H
A120D0039F
A111W3150F
A111W3149F
A111W3151F
A120D0037F
A120D0036F
A120D0035F
A120W2212F
A117W3189F
LSL489
Qty
1
2
2
2
2
2
2
2
2
2
1
Procedure (adjustable type crossbrace)
1. Remove the rear undertray and diffuser.
2.
At both sides, remove the toe-link inboard/lower wishbone rear pivot fixing nut, release the adjacent heatshield fixings and withdraw the ball joint.
3.
Cut a vertical slot in the ball joint heatshield at each side, to accommodate the crossbrace adaptor lug,
removing only as much material as necessary.
4.
Remove the two rearmost setscrews securing the engine mounting steady bracket to the subframe. If
these screws use weldnuts on the subframe, the nuts must be chiselled or ground off.
5.
Fit the locknuts onto the turnbuckles, and screw the LH thread of a turnbuckle into each end of the crossbrace
tube. Fit an adaptor lug onto the RH thread of each turnbuckle. Loosely assemble the crossbrace to the
underside of the subframe plinth using the original setscrews and new flange nuts.
6.
On each toe-link, measure the distance from the locknut to the centreline of the inboard pivot ball. Remove
the old joint from the link, and replace with a new spherical joint set to the same approximate position.
7.
Fit a new spacer into the orientation slot in the subframe before positioning the toe-link ball joint and sliding
the new pivot bolt through the crossbrace adaptor lug (adjusting the turnbuckle as necessary), ball joint,
spacer, subframe and wishone and retain with a new M10x1.25p locknut. Repeat for the opposite side.
Tighten the pivot bolts only at mid-laden ride height of 130mm to 50 Nm. Re-secure heatshield.
Page 11
8.
9.
Lotus Service Notes
Section DH
Tighten the turnbuckle locknuts to 45 Nm whilst holding the adjacent adaptor lug, and then tighten the
engine steady mountings to 45 Nm.
Adjust rear wheel alignment only at mid-laden ride height of 130mm to 1.5mm toe-in each side (±
0.3mm) and tighten the toe-link ball joint locknuts to 45 Nm. Ensure ball joints are phased at 90° to each
other to allow maximum joint articulation.
10. Refit undertray and diffuser.
Viewed from below
FRONT
Toe-link
Adaptor lug
Turnbuckle Adjustable type cross-brace tube
New spherical joint
Brace to
chassis
d48
Section A thro' lower
link inboard fixing
Heatshield
Lower wishbone
rear bush
Adaptor lug
Pivot bolt
FRONT
New spherical joint
Self-locking nut
Special spacer washer
Welded insert
Page 12
d46a
Lotus Service Notes
Section B thro' steady mounting attachment
(adjustable type crossbrace)
Chassis
Section DH
Engine steady mounting
Cross-brace
welded bracket
Cross-brace tube
FRONT
d47
General view
Cross-brace fixing Adaptor lug
to subframe
Turnbuckle
Cross-brace
Page 13
d45
Lotus Service Notes
Section DH
DH.6 - SUPER SPORT SUSPENSION
To provide customers for 6-speed Elise/Exige with a track optimised suspension choice, a 'Super Sport'
suspension specification was introduced in early 2006 as a factory build option package comprising:
-
Bilstein dampers with thread adjustable spring platforms and 10 position combined damping adjustment.
Remote reservoirs on front dampers.
Note: For 'Cup' and supercharged cars fitted with Ohlins spring/damper units, refer to Exige S/C supplement.
-
Road springs (Elise: 42.5/60 N/mm front/rear, Exige 47.5/65 N/mm front/rear) upgraded to dual rate specification; Front: 31.6/47.5 N/mm, Rear: 46.6/65 N/mm.
-
Front anti-roll bar gains 5-hole adjustment and hard plastic mountings.
-
Rear suspension chassis brace kit (recommended for track use and/or A048 tyres)
-
Lightweight forged wheels, 6.5J x 16 front, 7.5J x 17 rear.
-
Yokohama A048 tyres (standard fit on Exige), 195/50 R16 front, 225/45 R17 rear.
Ride Height
Cars factory built with Super Sport suspension are set at 130/130 ride height as standard cars, to provide
adequate road going ground clearance and ramp angles. To optimise the car for track use, it is recommended
to reduce ride height to 120/120mm.
To adjust the height, first load the car to the mid-laden condition with a full fuel tank and two 75 kg (12
stone) passengers. Then use the 'C' spanners supplied with the car to screw the spring collars upwards on
the damper body and drop the ride height as measured beneath the front and rear ends of each chassis main
siderail. To speed the attainment of this setting, the spring collars should be adjusted from the standard dimension of 110 mm front and rear, to an initial revised position of 104 mm front, and 102 mm rear as shown in the
illustration:
Rear shown. Front similar
Std. front: 110 mm. Lowered: 104 mm
Std. rear: 110 mm. Lowered: 102 mm
Locking ring
Spring seat
d49
After setting the ride height, the front wheel alignment should then be adjusted back to zero (tolerance
+0.7 to -0.5mm toe-in total). All other settings should remain within specification (see below).
Damper Adjustment
Note that the front dampers are equipped with remote gas reservoirs secured to the front face of the body
side panels and are protected by the wheelarch liners. Damper adjustment is common to front and rear dampers, and comprises a single knurled ring below the spring lower platform, with printed numbers 1 to 10 to be
viewed from outboard against an orange alignment dot on the damper body. 1 is fully soft, 10 fully stiff. Turn
the front wheels to full lock to view the front damper setting.
Page 14
Lotus Service Notes
Section DH
Recommended settings are as follows:
Road use: Front 3 Rear 2
Track use: Front 8 Rear 7
Rear Shown
Knurled
ring
Alignment
dot
d50
Anti-Roll Bar
An anti-roll bar with 5-hole adjustment is used, with cars built before August '06 using an uprated bar and
early type re-positioned hard mountings, whereas later cars use a yellow painted standard rate bar with revised
hard mountings in a position common with standard cars. Refer to sub-section CI.3.
Use the foremost hole P1 (shortest lever arm) for maximum stiffness and rearmost P5 for minimum. Increasing front roll stiffness will tend to promote understeer. Recommended position for road and track use is
central P3.
Chassis Rear Brace Kit
The chassis brace kit is fully described in sub-section DH.5 but is reduced in complexity for this application
by the use of a simple tubular brace to link the rear ends of the toe-link inboard fixing bolts. In this configuration, a flat washer A120W4199F (7/16 x 7/8) must be used between the head of the toe link pivot bolt and the
crossbrace tube.
Forged Wheels
The lightweight forged wheels offer a saving of 14.4 kg/car on Elise and 20.4 kg/car for Exige, and feature
a wider front rim width of 6.5J. Insets are unchanged.
Yokohama A048 Tyres
The Yokohama A048 tyres have been developed jointly by Lotus and Yokohama to suit the requirements
of the performance driver, with special emphasis on track use. Compared with the standard tyre, the front tyre
width is increased and the profile reduced from 175/55 to 195/50. The tyre tread design is directional, such that
each wheel/tyre assembly is dedicated to a single vehicle corner. Tyre pressures are unchanged.
The Lotus specific construction is identified by the letters 'LTS' moulded on the tyre sidewall. Ensure
that any replacement tyre is so marked. Note that an edging strip is applied around both front wheelarches to
provide the necessary tyre coverage.
Geometry
Front
Mid-laden ride height (reference height for geometry check)
- front 120 mm below front end of chassis siderail - rear 120 mm below rear end of chassis siderail
Castor - optimum + 3.8°
- tolerance range + 3.5° to + 4.1°; max. side/side 0.35°
Camber - optimum - 0.2°
- tolerance range + 0.1° to - 0.3°; max. side/side 0.2°
Page 15
Lotus Service Notes
Alignment - optimum
- tolerance range
Section DH
Zero
0.5 mm toe out, to 0.7mm toe-in overall
Rear
Mid-laden ride height (reference height for geometry check)
- front 120 mm below front end of chassis siderail - rear 120 mm below rear end of chassis siderail
Camber - optimum - 2.5°
- tolerance range - 2.0° to - 2.7°; max.side/side 0.2°
Alignment - optimum 1.8 mm (0.24°) toe-in each side
- tolerance range 1.5 to 2.0 mm (0.20 to 0.27°) toe-in each side
max.side/side 0.3 mm (0.04°)
Super Sport Suspension Retrofit
To retro-fit Super Sport suspension to a Toyota powertrain Elise/Exige, the following parts and procedure
may be used:
Parts Required
Front Damper
Rear Damper Front Spring
Rear Spring
OR
Front Spring/Damper Unit
Rear Spring/Damper Unit
Part Number A120C0018H
A120D0046H
A120C0019H
A120D0047H
Qty
2
2
2 31.5/47.5 N/mm
2 46.6/65 N/mm
A120C0017F
A120D0045F
2
2
'C' Spanner, spring seat adjust
Cradle, tie wrap, reservoir mounting
Tie Wrap, reservoir mounting
Screw, M5 x 20, cradle fixing
Rawlnut, M5, cradle fixing
Anti-Roll Bar, stiffened, adjustable
Mounting Clamp, Nylon
Spacer Sleeve, mounting clamp
Bolt, M5 x 45, cap head, clamp fixing
Washer, flat, M5, clamp fixing
Nyloc Nut, M5, clamp fixing
Pivot Bolt, M10 x 45, lower wishbone front
Washer, flat, M10, clamp to chassis
Anti-Roll Bar, std. rate, adjustable
Clamping Block, a.r.b. bush
Pivot Bush, a.r.b.
Bolt, skt cap, M8x65, clamp to chassis
Washer, flat, 25mm, clamp bolt
Washer, flat, 16mm, clamp bolt
Nut, Nyloc, M8, clamp bolt
A120C6001F
A082W6293F
A075W6038Z
A075W5084F
A075W6074F
A111C0134S
A111C0052F
A111C0060F
A082W2106F
A075W4011Z
A100W3113F
A075W2065F
A075W4024Z
A120C0020F
A120C0021F
A120C6002F
A125W7218F
B075W4021Z
A111W4175F
A075W3010Z
1
2
4
2
2
1
2
2
2
2
2
2
2
1
2
2
4
6
2
4
Black
>
>
>
> Use with bar A111C0134S
>
>
>
Yellow
)
)
) Use with bar A120C0020F
)
)
)
Optional Additions
Chassis Rear Brace Kit (recommended for track use and/or A048 tyres)
LOTAC05377 1
Forged wheels & A048 tyres Refer to Parts List
Edging Strip, front wheelarch A117B0559F 2
Page 16
Lotus Service Notes
Section DH
Procedure
1. Anti-Roll Bar - stiffened rate adjustable
Remove the anti-roll bar after first drilling out the rivets securing the reinforcing brackets between the
bottom of the crash structure and the chassis.
The adjustable anti-roll bar is secured by two Nylon clamps, fixed to the chassis via the front lower wishbone inboard front pivot bolt, with a 'top hat' section steel spacer preventing the clamp from being crushed.
These hard type mountings provide optimum steering response but will transmit more noise and require
periodic lubrication with MoS2 grease at 3,000 mile (5,000 km) intervals.
Modify the crash structure support bracket as necessary before refitting.
Anti-Roll Bar Mounting - Stiff adjustable
'Top hat' spacer
Clamping block
M5 bolt
Lower wishbone pivot bolt
Anti-roll bar
c40a
Anti-Roll Bar - standard rate adjustable
Remove the anti-roll bar after first drilling out the rivets securing the reinforcing brackets between the bottom of the crash structure and the chassis.
Each split pivot bush incorporates a raised shoulder around its centre in order to engage with a groove in
the two part clamp, and provide lateral location. A pip on this shoulder locates in a hole in the clamp cap
to prevent rotation of the bush. No lubrication is required.
Each bush housing is clamped to the front face of the chassis with two cap head bolts inserted from the
front, using large washers under their heads and lower fixing nuts, and a smaller washer beneath the upper fixing nut to fit within the chassis extrusion. Torque tighten the clamp bolts to 25 Nm.
Refit crash structure brackets.
Anti-Roll Bar - Standard rate adjustable
Bearing clamp rear
Alignment dowel Anti-rotation pip
Smaller washer
Cap head bolt
Chassis
front face
Anti-roll bar
Plastic split bush
Bearing clamp cap
Flat washer
Page 17
c40b
Lotus Service Notes
2.
Section DH
Modify Front Damper Bracket
Remove all four spring/damper units and front wheelarch liners (refer Service Notes section CI).
The upper eye of the alloy bodied Bilstein sport damper is larger than the standard steel eye and requires
that the front suspension upper clevis bracket (bolted to the chassis), is modified in order to provide the
necessary clearance.
File the bracket edge parallel with the damper eye axis as shown, and protect with a zinc rich anti-corrosion
paint.
New profile shown solid; Original condition dotted
3.
c45
Fit Spring/Damper Units
Unless fitting pre-assembled spring/damper units, use spring compressor clamps to assemble the new
springs and dampers, taking all appropriate safety precautions.
Mount the rear units with the red dot on the damper lower body facing outboard. Mount the front units in
similar manner and secure each front remote reservoir to the front face of the body side using a saddle
clip and two tie wraps as shown below. Fix the saddle clip using an M5 Rawlnut (drill panel to 9.5mm)
and screw. Ensure that the reservoir and hose are positioned to clear the wiring harness and oil cooler
pipe.
Damper reservoir
Ensure clearance
Oil cooler hose
Tie wraps
Saddle clip
Wiring harness
Front face of body side
Page 18
c46
Lotus Service Notes
Section DH
4.
Damper Adjustment
For damper adjustment, see above.
5.
Chassis Rear Brace Kit
The chassis brace kit is fully described in Section DH.5.
6.
Forged Wheels
The lightweight forged wheels offer a saving of 14.4 kg/car on Elise and 20.4 kg/car for Exige, and feature
a wider front rim width of 6.5J. Insets are unchanged.
7.
Yokohama A048 Tyres
The Yokohama A048 tyres, have been developed jointly by Lotus and Yokohama to suit the requirements
of the performance driver, with special emphasis on track use. Compared with the standard tyre, the
front tyre width is increased and the profile reduced from 175/55 to 195/50. The tyre tread design is directional, such that each wheel/tyre assembly is dedicated to a single vehicle corner. Tyre pressures are
unchanged.
The Lotus specific construction is identified by the letters 'LTS' moulded on the tyre sidewall. Ensure that
any replacement tyre is so marked.
8.
Front Wheelarch Edging Strip
In order to comply with tyre coverage regulations, fitment of A048 tyres requires that edging strip A117B0559F
is applied around both front wheelarches, and secured with Permabond C2 or similar adhesive.
9.
Geometry
For front and rear suspension geometry settings, see earlier in this section.
Page 19
Lotus Service Notes
Section EH
ENGINE
SECTION EH
Sub-Section
Page
General Description; 2ZZ-GE
EH.1
3
General Description; 1ZZ-FE
EH.2
9
Maintenance Operations; 2ZZ & 1ZZ
EH.3
10
Engine Removal/Replacement
EH.4
13
Special Tools
EH.5
15
Engine Management Component Location
EH.6
16
2010 Elise 1ZR FAE Supplement
EH.7
17
See also 2ZZ/1ZZ engine repair manual; E120T0327J (Toyota publication)
See also 1ZR FAE engine repair CD; T000T1523F (Toyota production)
Page 1
Lotus Service Notes
Section EH
Engine Sections (2ZZ-GE)
From LH side
From front
e226
Cylinder Head Section
Exhaust side
Inlet side
e227
Page 2
Lotus Service Notes
Section EH
EH.1 - GENERAL DESCRIPTION; 2ZZ-GE
The 1.8 litre, 16 valve four cylinder engine used in the Lotus 2005 model Elise is supplied by Toyota Motor Corporation, and is designated '2ZZ-GE'. The engine number is stamped on the rear end of the cylinder
block, exhaust side, and is followed by '2ZZ'. A full overhaul procedure for this engine family is contained in
the separate Toyota publication under part number E120T0327J.
The lightweight alloy cylinder block uses no separate cylinder liners, but has the integral cylinder walls
constructed from MMC (Metal Matrix Composite). The forged steel crankshaft is supported in five cast iron
main bearing caps which are integrated into a single piece alloy main bearing panel bolted to the bottom of the
block. A pressed steel sump is fitted below the main bearing panel. The iron and tin coated pistons, fitted with
three piston rings, are mounted via fully floating gudgeon pins to forged steel connecting rods which use two
bolt big end caps around the crankpins. The cylinder head houses four valves per cylinder, with inlets arranged
at 43° to the exhaust valves, and incorporates laser clad alloy valve seats welded into the cylinder head. At the
front of the engine, a single row chain, automatically tensioned by spring and oil pressure, is used to drive the
two overhead camshafts which incorporate VVTL-i (Variable Valve Timing and Lift-intelligent) to advance and
retard the inlet camshaft timing under electro/hydraulic control, and increase the lift of both inlet and exhaust
valves at high engine speed (see later).
A trochoid type oil pump, driven directly by the front end of the crankshaft supplies an oil gallery along the
left hand side of the crankcase, from which are fed the crankshaft main bearings, then the big ends, and via oil
jets, the underside of the pistons. The gallery also feeds a drilling up to the cylinder head for the two camshafts,
and the VVTL-i mechanism, with the chain tensioner fed from the exhaust cam drilling. The main gallery also
feeds the oil filter, vertically mounted on the left hand side of the cylinder block. The timing chain is lubricated
via an oil jet directly from the oil pump, and by oil draining down through the timing chest.
The water pump is mounted at the left hand front of the block and is driven by a multi-rib serpentine
auxiliary belt from the crankshaft. Coolant is pumped into the front of the cylinder block and head, and when
the thermostat is closed, returns to the pump via a by-pass gallery in the cylinder head and block. When the
thermostat opens, the by-pass route is closed off, and a greater volume of coolant flows via the heater matrix,
and throttle body as well as through the engine cooling radiator.
The die-cast aluminium intake manifold draws air from a single throttle body with cable controlled butterfly valve, into a plenum chamber from which the four intake ports are fed by individual tubes. A twelve hole
fuel injector is mounted in the top of each of the four intake ports in the cylinder head, with fuel supplied via
a one-way flow system with a pressure regulator contained inside the fuel tank. The Direct Ignition System
(DIS) uses separate high tension coils mounted directly onto each of the four spark plugs, with timing control
by the engine management ECU.
VVTL-i (Variable Valve Timing & Lift - intelligent)
This system features two elements:
Variable Valve Timing
In order to allow the inlet valve timing to be advanced or retarded to the benefit of particular running conditions, the inlet camshaft is provided with a hydraulic hub connecting the chain sprocket to the inlet camshaft.
The hub comprises a housing fixed to the sprocket and a four vane rotor fixed to the camshaft. The rotor is
contained within the housing with the rotor vanes dividing each of the four chambers in the housing into two
volumes, an advance and a retard side. Each of the chamber volumes is supplied with pressurised engine oil
from a spool valve under ECU control. By varying the relative pressure of the two oil volumes, the positional
relationship of the camshaft to the sprocket can be altered. The ECU monitors engine speed, intake air volume, throttle position and water temperature to determine the optimum cam phasing for the particular running
conditions, and modulates the duty cycle to the oil control (spool) valve until the desired timing is achieved,
as determined by reference to the crankshaft and camshaft sensors. Duty cycles greater than 50% cause the
timing to be advanced, and duty cycles less than 50% retard the timing. When the target timing is achieved, a
50% 'holding' duty cycle is applied. The oil control valve is mounted at the left hand front of the cylinder head
and feeds oilways within the head connecting with the inlet camshaft immediately behind the hydraulic hub.
When the engine is stopped, the inlet cam timing is set at full retard, to allow easy starting. To allow time
for oil pressure to build after engine start up, a spring loaded lock pin engages at full retard to mechanically
lock the hub, until normal oil pressure releases the pin automatically.
The table shows the basic timing strategy for different operating conditions:
Page 3
Lotus Service Notes
Section EH
e223
e222
e224
Page 4
Lotus Service Notes
Section EH
Note that compromises are involved in the programming of inlet cam timing, since advancing the valve
opening point also advances the valve closing point, when the ideal might be to advance the opening and retard
the closing points. For any particular engine running conditions, the timing is adjusted to optimise either the
valve opening point and overlap period, or the valve closing point, whichever provides the most benefit.
The range of inlet cam timing available is from:
Opening 33° BTDC, Closing 15° ABDC )
to; ) with standard (low speed) valve lift
Opening 10° ATDC, Closing 58° ABDC )
or;
Opening 58° BTDC, Closing 54° ABDC }
to; } with high speed valve lift (see below)
Opening 15° BTDC, Closing 97° ABDC }
Variable Valve Lift
Both inlet and exhaust camshafts are machined with two cams for each cylinder, a low lift cam and a high
lift cam. Each low lift cam actuates, via a low friction roller, a rocker arm which connects with a pair of inlet or
exhaust valves. The corresponding high lift cam actuates a spring loaded tappet housed within the rocker arm,
and under low speed conditions, has no effect on valve operation due to the clearance between the bottom of
the tappet and the rocker arm.
When engine speed reaches 6,000 rpm at normal running temperature, the ECU operates a spool valve
on the back of the cylinder head to close an oil return line, and raise oil pressure within the rocker pivot shaft
and passages within each rocker. This increased oil pressure is sufficient to overcome the spring loading of a
packer pin contained within each rocker arm, which is then forced between the bottom of the high speed cam
tappet and the rocker arm. Each high lift cam then controls valve operation, with the rocker being lifted clear
of the low speed cam. The higher valve lift for both inlet and exhaust valves in conjunction with the variable
valve timing, provides greater efficiency and power output at high engine speeds.
Standard (low speed) valve lift: - inlet; 7.25 mm
- exhaust; 7.25 mm
High speed valve lift: - inlet; 11.4 mm
- exhaust; 10.0 mm
Note that engine speed is limited to 6,000 rpm until normal running temperature has been attained.
Illustrations overleaf...............................
Page 5
Lotus Service Notes
Section EH
e225
Page 6
Lotus Service Notes
Section EH
Airbox Flap Valve
In order to reduce airflow restriction into the airbox at periods of high demand, and also to provide an
acoustic enhancement, the ECU, when switching to high valve lift mode, also opens a flap valve in the underside of the airbox body. This butterfly valve is sprung open, and is closed by a vacuum actuator supplied from
the inlet manifold. The vacuum supply uses an in-line non-return valve and a reservoir incorporated into the
front face of the airbox body to maintain flap closure during periods of low inlet depression. A solenoid valve
mounted on top of the airbox, and connected into the vacuum capsule line, is energised by the ECU when appropriate to ventilate the capsule and open the valve.
Airbox flap valve plumbing
Non-return valve
To inlet
manifold
Redundant
port capped
Intake flap solenoid valve
Air cleaner
Vacuum reservoir
Intake flap valve actuator
Page 7
em238
Lotus Service Notes
Section EH
Overhaul Notes
1.
Timing Marks (2ZZ only)
Take care when setting the engine to its 'timing' postion. Crankshaft at TDC, inlet cam pulley mark facing
inwards on centreline, exhaust cam pulley mark facing inwards but ONE TOOTH COUNTERCLOCKWISE
from centreline.
2.
Valve Clearances
a) It is unlikely that valve clearances will require adjustment unless components are replaced. A single
forked rocker arm is used to operate a pair of valves, which are shimmed during manufacture for equal
clearance. Routine service clearance checks should be made between the cam and roller follower. Only
if a valve or rocker arm is replaced need the clearance between individual valves and the rocker arm be
measured. Adjustment procedure is detailed in the text.
b) When using the shim adjustment special tool, before removing a shim from a valve stem, ensure that
the oil drain passages on the exhaust side of the head are blocked with paper towel. Shims are easily
dropped and may fall down the drain passages into an oil gallery in the crankcase, requiring engine removal
to retrieve.
3.
Stretch Bolts
The cylinder head bolts, big end bolts and main bearing cap bolts are 'stretch' type with an angular tightening procedure. The bolts should be measured to determine their suitability for re-use. Measure length
or diameter as specified in the text. Note that the big end bolts are 8.7 to 8.8 mm standard diameter, with
8.5 mm minimum.
4.
Timing Chain Tensioner
The maintenance free timing chain tensioner uses spring tension and engine oil pressure in conjunction
with a non-return ratchet mechanism to maintain chain tension. A pivotted hook on the tensioner body is
provided to aid assembly, by enaging with a pin on the spring plunger to hold the assembly retracted whilst
fitting. After fitment to the timing cover, the engine is then turned backwards so that the chain forces the
plunger into the tensioner body, which action pushes the hook into a disengaged position and allowing
tension to be applied on resumption of normal rotation. The ratchet mechanism prevents subsequent
plunger retraction.
5.
Bearing Shell Size Coding
Note that the main bearing shells and big end shells are selective thickness dependent on journal and
housing size. Pistons are one size only. No reboring or crankshaft grinding is permitted.
Main bearing housing size codes are stamped onto the cylinder block, and crankshaft journal size codes
on the crank. If necessary, Plastigage can be used to deterime oil clearance. Big end codes are stamped
only on the connecting rod caps. Service replacement shells will also be marked on the back with the size
code.
6.
Knock Sensor (2ZZ only)
The knock sensor used for Lotus applications is an annular type fitted over an M8 stud, with the retaining
nut tightened to 20 Nm. Note that the 1ZZ engine does not use a knock sensor.
7.
VVT Unit Refitment
The variable valve timing unit mounted on the front of the inlet camshaft, is secured in the fully retarded
position when the engine is stopped, by a spring loaded pin. When fitting the unit to the camshaft and
tightening the retaining bolt, it is essential that no torque is applied to the sprocket, or damage could be
caused to the locking pin. Ensure that the dowel pin in the camshaft front flange is correctly located in
the corresponding slot in the VVT hub before inserting the retaining bolt. Hold the camshaft only with a
spanner on the flats provided, and tighten the retaining bolt to 54 Nm.
Page 8
Lotus Service Notes
Section EH
eh.2 - General Description; 1ZZ-FE
The Elise S, introduced in May 2006 uses the Toyota '1ZZ-FE' engine instead of the '2ZZ-GE' fitted in the
Elise 111R. The two engines are similar in basic architecture, with the 2ZZ having been derived from the 1ZZ,
and whilst the overhaul procedures are largely common, many of the principal components are different. This
section identifies the main differences between the two engine types.
Valve Mechanism
The 1ZZ uses the same VVT-i 'intelligent' variable intake valve timing system as used on 2ZZ, but without
the intake and exhaust variable valve lift feature. Valve clearance adjustment via selective cam followers rather
than 'top hat' shims. Airbox flap valve programmed to open at 5,000 rpm. Lower rpm limits (see below).
Dimensions
The bore and stroke differ between the two engines, although the capacity difference favours the 2ZZ by
only 2cc. The 1ZZ is more undersquare with dimensions of 79.0 x 91.5mm producing 1794cc (2ZZ: 82.0 x 85.0
= 1796cc). The angle between intake and exhaust valves on the 1ZZ is 10° less at 33°, to permit a compact
cylinder head without the requirement to accommodate variable valve lift. The compression ratio is dropped
from 11.5 to 10.0:1.
Cylinder Block
The open deck alloy cylinder block of the 1ZZ uses dry, thin wall, non-replaceable, cast iron cylinder liners
(2ZZ uses integrated MMC cylinder walls).
Manifolds
The inlet manifold is moulded in plastic to reduce weight and heat transference, and incorporates a resonator feature to optimise gas pulsations for mid-range performance. A unique adaptor is used to link the manifold
to the electronic throttle body which differs from the 2ZZ and other 1ZZ types.
The simplified exhaust manifold and downpipe dispense with the divider plate used on the 2ZZ.
Cooling System
The cooling system is largely unchanged, with all 1ZZ cars using the oil/water heat exchanger and no
front mounted oil coolers. The throttle body is heated as previously, although the feed and return connections
differ in detail and no in-line throttle body thermostat is used.
Technical Data
1ZZ-FE
Capacity 1794 cc
Bore 79.0 mm
Stroke 91.5 mm
Valve control VVT-i
Compression ratio 10.0:1
Compression pressure (250 rpm, normal run temp.) - new 1500 kPa (218 psi)
- min.1000 kPa (145 psi)
Spark plugs - type NGK BKR5EYA-11
Denso K16R-U11
- gap 1.0 ± 0.05mm
Peak power (1999/99/EC) 100 kW (136 PS)
@ 6,200 rpm
Peak torque (1999/99/EC) 172 Nm
@ 4,200 rpm
Maximum continuous engine speed 6,800 rpm
Maximum transient engine speed 7,150 rpm
Exhaust emissions (Euro 4 & LEV 1) - CO 0.23 g/km
- HC 0.050 g/km
- NOx 0.0217 g/km
- HC + NOx 0.0717 g/km
- CO2 (combined) 196 g/km
2ZZ-GE (reference)
1796 cc
82.0 mm
85.0 mm
VVTL-i
11.5:1
1400 kPa (203 psi)
1000 kPa (145 psi)
NGK IFR6A-11
1.1 mm
141 kW (192 PS)
@ 7,800 rpm
181 Nm
@ 6,800 rpm
8,000 rpm
8,500 rpm
0.42 g/km
0.078 g/km
0.0121 g/km
0.07921 g/km
208 g/km
Page 9
Lotus Service Notes
Section EH
EH.3 - MAINTENANCE OPERATIONS - 2ZZ & 1ZZ
Engine Oil Level Check
The engine oil level should be checked regularly, such as every two or three fuel stops, and the oil level
maintained near the top mark on the dipstick. It is especially important to keep a check on the oil level during
the vehicle’s first 1,000 miles (1,600 km), as both the fuel and oil consumption will be prone to some variance
until the engine components have bedded in.
The best time to check the level is when the oil is warm, such as during a fuel stop. Ensure that the car is
parked on a level surface and that a few minutes have elapsed since stopping the engine to allow oil to drain
back into the sump. If the engine is stopped before reaching normal running temperature, the oil will not drain
back so readily, and the dipstick will display an artificially low reading.
Dipstick: The dipstick is identifiable by its yellow loop handle, and is located at the right hand front of the engine.
Withdraw the dipstick, and wipe with a paper towel. Replace the dipstick, if necessary feeding the blade into
the tube with the fingers, before pressing firmly to ensure that the handle is fully seated. Withdraw the dipstick
again to inspect the oil level, which should lie between the two dimples on the end of the stick.
The oil level should be maintained at the
OIL FILLER CAP
upper of these two marks in order to provide
optimum engine protection.
Topping Up: If topping up is necessary, unscrew the oil filler cap from the left hand end of
the cam cover. Add a suitable quantity of the
recommended engine oil (see ‘Recommended
Lubricants’) taking care not to spill any oil onto
engine or electrical components; use a funnel
if necessary.
The difference between high and low
dipstick marks is equivalent to 1.5 litre. Allow
DIPSTICK
several minutes for the oil to drain through to
the sump before re-checking the oil level.
Do NOT overfill, or lubrication will be degraded and consumption increased as the oil becomes aerated.
Refit the filler cap, turning clockwise until secure.
ohs131
ohs132
Engine Oil Change
The use of high quality oil, renewed at the specified intervals, is the key to engine longevity and sustained
performance. Adhere strictly to the engine oil and filter change intervals specified in the Maintenance Schedule.
For access to the engine sump and filter, the engine bay undertray must first be removed. This is most
easily achieved with the vehicle raised on a garage hydaulic lift, or alternatively, parked over an inspection pit.
The drain plug is located at the rear of the sump, and should be removed to drain the sump immediately after
a run when the oil is warm and the impurities are still held in suspension.
WARNING: - Take all suitable precautions to guard against scalding from the hot oil.
Allow the oil to drain completely before cleaning the drain plug, fitting a new sealing washer, and tightening securely. Refill with the recommended lubricant via the oil filler on the camshaft cover, to the top mark on
the dipstick, allowing several minutes for the oil to drain through to the sump before checking the level. Take
care not to overfill. Refit the oil filler cap securely, and check the oil level again when the engine is fully warm
(see above).
Oil Filter
The canister type oil filter is vertically mounted at the front of the engine, and is accessible from beneath
after removal of the engine bay undershield. The filter should be renewed along with the engine oil, at intervals
specified in the Maintenance Schedule.
WARNING: Take all suitable precautions to guard against scalding from the hot oil.
Page 10
Lotus Service Notes
Section EH
Remove the filter by turning in a counterclockwise direction, if necessary using an oil filter
OIL FILTER
wrench, and dispose of safely.
(Viewed
Ensure that only a Lotus specified filter is
from
fitted, as parts with identical outward appearbeneath)
ance can contain different internal features.
Before fitting a new filter, clean the mating
face on the engine, and smear the new seal
on the filter with clean oil. Add a small amount
of clean engine oil into the filter, screw onto
its spigot and tighten BY HAND sufficiently
to make a secure seal, typically 2/3 to 3/4
of a turn after the sealing faces have made
contact.
Overtightening using a filter wrench may damage the canister and/or complicate subsequent removal.
Start the engine and check for oil leaks. Re-check the security of the filter, further tightening by hand if
necessary. Check the oil level (see above) when the engine is fully warm.
ohs129
Oil Coolers
The foregoing oil change procedure does not disturb the oil quantity contained in the twin oil coolers and
associated pipework, but is considered perfectly satisfactory for routine maintenance operations. In instances
of major engine failure where the oil system may be contaminated with metallic debris, all oil cooler lines should
be thoroughly flushed out and the oil cooler radiators replaced.
If the oil cooler circuit is drained or replaced, the following procedure should be
adopted to fill the cooler system before starting
the engine: Oil cooler
1. Attach a tube to the bleed nipple on the
feed hose
sandwich plate between oil filter and
engine block, and lead into a catch tank.
Open the bleed nipple.
2. Disconnect the outlet hose from the top of
the LH oil cooler, and pour engine oil into
the cooler until oil reaches the bleed nipple (approx. 2.5 litres). Close the bleed
nipple, tightening to 8 Nm.
3. Connect the LH cooler outlet hose and
tighten to 40 Nm.
4. Add a further 0.7 litres of oil into the engine
to accommodate the volume of the return
hose between LH oil cooler and engine.
5. After starting the engine, restrict running to
idle speed for a minimum of 5 minutes, to
allow the oil cooler lines to be purged of
air. Stop engine and re-check oil level.
Oil cooler return hose
Sandwich plate
bleed nipple
Oil filter canister
e228
Note: For cars fitted with an Accusump pressurised oil storage canister, refer to section 'Exige SC'.
Page 11
Lotus Service Notes
Section EH
Air Cleaner Element
The air filter should be inspected at intervals dependent on the operating conditions. When the vehicle is
operated in a relatively clean environment, the element should be renewed at intervals specified in the Maintenance Schedule, but where a dusty or smog laden atmosphere prevails, or other factors contribute to filter
contamination, more frequent replacement will be required dependent on the level of pollution.
A disposable folded paper type air
cleaner element is fitted in a housing at the
left hand front of the engine bay. For access
to the element, the left hand rear wheel and
wheelarch liner must first be removed. Before
opening the air cleaner housing, the wheelarch
area should be cleaned to reduce the possibility of filter or housing contamination with road
dirt.
To open the filter housing, release the
two spring clips at the outboard end of the
housing, and hinge open sufficiently to allow
the element to be withdrawn.
AIR CLEANER
ELEMENT
ohs146
Clean the inside of the housing, including the joint faces, taking care not to contaminate the ‘clean’ engine
side of the assembly. Fit the new filter element into position with the shallow side facing the 'clean', engine
side of the housing. Ensure that the hinge lugs at the inboard end of the housing are correctly engaged before
closing the housing and securing with the two spring clips. Refit the wheelarch liner and rear wheel.
Auxiliary Drive Belt
A single multi-rib serpentine type belt is used to transmit drive from the crankshaft to the water pump,
alternator and a.c. compressor, with a slave pulley fitted in place of the power steering pump used in other
applications. A hydraulically damped, spring loaded tensioner arm applies tension to the back of the belt, and
is maintenance free. The belt itself should be inspected for condition at each service interval, and if it exhibits
any evidence of physical damage, cracking, fraying, perishing, abrasion or contamination, it should be replaced.
In the case of oil or coolant contamination, the cause must be identified and rectified, and each of the pulleys
must be thoroughly degreased before the new belt is fitted.
For further details, refer to section CH in the Engine Repair Manual, but note that only a six-sided socket
should be used on the cast boss on the tensioner arm. Due to the manufacturing draft angle of the casting, a
twelve point socket is liable to cause damage.
Spark Plugs
The ignition system uses a distributorless ignition system (DIS) which employs an individual high tension
coil for each of the four spark plugs. Each coil is mounted directly onto its spark plug using an integral connector
and is secured to the cam cover with a single screw. The spark plugs use small diameter centre electrodes made
of iridium for long life and high performance, and require changing only at 54,000 mile (90,000 km) intervals.
For further details, refer to section IG in the Engine Repair Manual.
Page 12
Lotus Service Notes
Section EH
EH.4 - ENGINE REMOVAL/REPLACEMENT
It is recommended to remove the rear clamshell prior to powertrain removal in order to improve access,
and to reduce the possibility of paint damage. The engine may be removed from above, with or without the
transmission. The following procedure applies to the engine/transmission assembly, but to avoid disturbing
the suspension, refer to sub-section FJ.5 to separate the engine from the transmission before withdrawing the
engine alone.
Fuel Pressure Relief Procedure
This procedure should be used prior to disconnecting any part of the fuel line.
‑
-
‑
-
-
‑
Pull out the fuel pump fuse (on the left
hand side of the engine bay bulkhead, as
shown), start the engine, and run until it
stops from starvation. Crank the engine
for a further few seconds.
If the engine is a non-runner, pull out the
fuel pump fuse, and crank the engine
for 20 seconds to minimise residual fuel
pressure.
Disconnect the battery.
It is recommended first to release the
quick fit connector located to the rear of
the coolant header tank:
Release the retaining clip securing the
pipe joint to the header tank bracket.
Slide the orange coloured safety lock to
allow access to the connector release
buttons.
Surround the pipe joint with a shop towel
to absorb fuel contained in the pipework
before pressing the release buttons and
separating the joint.
Fuel pump
fuse (20A)
WARNING: Be aware of the possibility of full pressure retention in the fuel line caused by a system
fault.
Orange
safety lock
Fuel pipe to
engine
-
-
-
Fuel pipe
from tank
-
L64
ohs136
Before re-making the joint, ensure that the orange safety lock is fitted onto the pipe connector
in the orientation shown in the illustration.
Push the male pipe end fully into the female
connector until a click is heard. Pull on the pipe
to ensure complete engagement.
Slide the orange safety lock over the connector
to prevent accidental pressing of the release
buttons.
Secure the pipe/connector using the pipe clip
on the header tank bracket.
Release
button
Page 13
Lotus Service Notes
Section EH
1.
Remove the engine bay undertray and diffuser, both rear road wheels and the rear clamshell (see subsection BR.7).
2.
On a.c. cars, recover refrigerant and disconnect both a.c. hoses from the pipes at the rear of the RH
sill.
3.
From beneath the car:
Drain coolant, transmission oil and, if necessary, engine oil. Diconnect the coolant inlet hose from the
thermosat housing and cap both apertures. Disconnect the two oil cooler hoses from the sandwich plate
and cap all ports and hoses.
4.
Disconnect the exhaust manifold from the downpipe.
5.
Release the gear cable routing clips from beneath the engine. Disconnect the earth braid between chassis and transmission.
6.
Release the clutch slave cylinder from the transmission housing and support aside.
7.
Release the steady mounting between the front of the engine and the chassis, and between the rear of
the engine and the subframe.
8.
From above:
Release the gearchange cables from the transmission by removing the 'R' clips retaining the inner cable
eyes, and the 'C' clips retaining the outer cables.
9.
Disconnect the air intake hose between air cleaner and intake plenum, and release the brake servo vacuum
hose from the intake plenum.
10. Disconnect the throttle cable. Disconnect the radiator feed hose and heater feed hose from the rear end of
the cylinder head. Disconnect the heater return hose from the water rail, and the two hoses and electrical
connector from the header tank. Disconnect the re-circ. pump hose to the chassis pipe, and release the
electrical connector. Unplug the engine harness. Release the header tank bracket from the subframe,
and remove the bracket complete with tank and recirc. pump. Release the purge pipe from the throttle
body.
11. Remove the LH driveshaft from the transmission:
Release the top ball joint plinth from the LH hub carrier noting and retaining the camber adjustment shims,
and separate the toe-link ball joint separated from the carrier. The driveshaft inboard joint is retained in
the transmission by a round section circlip. The joint may be removed by applying a shock pull to the C.V.
joint body using a slide hammer with a forked end. Take great care not to damage the output oil seal on
withdrawal.
CAUTION: Do NOT attempt to remove the inboard C.V. joint from the transmission by pulling on the
driveshaft. The balls of the inboard joint are restrained for transit purposes only, by a circlip at the end
of the ball tracks. Applying an extension force to the joint will damage the balls and require joint replacement. Apply pressure only to the outer body of the joint. Do not allow the brake hose to be stetched or
stressed, and support the driveshaft after withdrawal to protect the shaft joints and hub carrier. Cap the
driveshaft aperture in the transmission.
12. Remove the RH driveshaft from the transmission:
Release the top ball joint plinth from the RH hub carrier noting and retaining the camber adjustment shims,
and separate the toe-link ball joint separated from the carrier. The right hand driveshaft incorporates
a bearing for the extension shaft and it is this which retains the shaft in the transmission. Remove the
two bolts ecuring the bearing bracket, and withdraw the complete shaft assembly taking great care not
to damage the ouput oil seal. Do not allow the brake hose to be stetched or stressed, and support the
driveshaft after withdrawal to protect the shaft joints and hub carrier. Cap the driveshaft aperture in the
transmission.
Page 14
Lotus Service Notes
Section EH
13. Fit two engine lifting brackets T000T1437S to the left hand front and right hand rear of the cylinder head.
Sling support the power unit before releasing the RH and LH engine mounting brackets.
Engine lifting brackets
e229
17. Carefully hoist the power unit from the car, whilst monitoring for any remaining connections.
-
-
-
-
-
Refit the unit in reverse order to removal with the following notes:
Before re-fitting a driveshaft, first renew the round section circlip on the end of the left hand inboard joint
spigot shaft, and lubricate the circlip with grease. Also, check the condition of the transmission output seal,
and renew if necessary. Lubricate the lip of the seal with transmission oil, and grease the corresponding
shoulder on the driveshaft (C.V. joint) spigot, to reduce the danger of damaging the seal on assembly.
Carefully insert the driveshaft into the transmission, with, on the left hand shaft, the two ends of the circlip
positioned lowermost, and rotate the shaft if necessary to engage the splines. Press the inboard joint outer
until a click indicates the engagement of the retaining circlip, if necessary using a brass drift and hammer.
Pull on the body to ensure its security. On the right hand shaft, fit the bolts securing the extension shaft
bearing to the engine mounted bracket, and torque to 64 Nm.
Refer to section DH for rear suspension assembly details.
For coolant refilling procedure, refer to section KH.
For transmission details and gear cable adjustment, refer to section FJ.
EH.5 - SPECIAL TOOLS
The following engine special tools are available under Lotus part number:
Engine Lift Bracket
Bolt, engine lift bracket
Oil Filter Wrench
Valve Clearance Adjuster Set
Crankshaft Pulley Holding Tool
Flange Holding Tool
T000T1437S
T000T1440S T000T1441F T000T1442F T000T1443F T000T1444F 2 off
2 off
1 off
1 off
1 off
1 off
Page 15
Lotus Service Notes
Section EH
EH.6 - ENGINE MANAGEMENT COMPONENT LOCATION - 2ZZ
1
2
4
3
5
6
17
16
7
8
15
9
14
13
12
11
10
Key to engine management component location drawing
1. Electronic Control Unit (ECU).
2. Multi-function relay unit.
3. Oil control valve for variable valve lift.
4. Camshaft position sensor.
5. Fuel injector.
6. Knock sensor.
7. Oil control valve for variable valve timing.
8. Crankshaft position sensor.
9. Plug top coil.
10. Coolant temperature sensor.
11. Pre-catalyst oxygen sensor.
12. Post-catalyst oxygen sensor.
13. Oil pressure switch.
14. Throttle position sensor.
15. Vacuum solenoid for intake flap valve.
16. Mass airflow sensor.
17. Idle Air Control (IAC) valve (prior '06 M.Y.)
For component replacement procedures, refer to manual B120T0327J. For diagnostic codes, refer to Section
EMP.
Page 16
Lotus Service Notes
N
Section
EH
Reh.7- Elise IZR Supplement
S – 1Z
E
The 1.6 litre Elise announced. in January 2010 replaces the 1.8 litre Elise S model, and uses the Toyota
INE by a type T6 Lotus ECU (also used on Evora), programmed by Lotus. This
1ZR FAE engine,Ebut
Gcontrolled
N
Z
E
D HC
16 va v n line
yl dbutg gis
li
g
E
A in many respects
engine
to the 1ZZ and 2ZZ families
e nefurther optimised for fuel efficiency and
Ris- similar
e
Z
i
2
s
a4-cy
meets
Euro 5E emission
include
Timing
intelligent (VVT-i)
for both inlet
he 2 Ris a 1 8- standards
iter DOH Features
16-va ve
i Valve
der gas
in - engine
s em
de gVariable
i engine
y in-lin
n
e
T
4
e
A
and exhaust camshafts, in order to enhance
power
at
both
low
and
high
speeds,
and
a
VALVEMATIC
e
M
lin
se
lin
T eand
e g o ligent
lv in order
hese ento vary
nes use
he valve
ual
Vari
b e to
a ve
im
ng-inte
V
T iALnoxious
yV em,T VA
C syste
-i) EMAT
system
the inlet
lift
reduce
pumping
losses, minimise
emissions
optimise
n
v
S
i
m
N
6
e
y
1
c
y
Cthrottling is controlled
(E a single butterfly valve at
e
i
n
n
i
e
T
D
g
fuel
economy
Engine
by
a
combination
of
inlet
valve
lift
and
i
V
n
Direct I nitio
lec o i T (rVtt e o t ol
ll em- n elligent ETCS i) The
lite System (D S)lve in
i teSys
a 1 plenum
theisinlet
E
H
O
a h i er intake
D
is for a compact cylinder head, and a
Ti
Con narrowed
Other
a valve
29°
tle angle
leantoem
a veinclude
1 8 larchitectural features
c
o
V
h
a
crankshaft/cylinder
offsetEURO
(désaxé)
8mmon
to
aesiawith
h s en ine compl
regula
ions side thrust on the power stroke.
omy piston
l axis
ctroniVc ofemiss
o reduce
D
nEngine Sections
(
S stem
From LH
RO
EUside
From front
1ZR
The Acoustic Control Induction System (ACIS),
uses a bulkhead within the intake plenum to divide each
01
G
ZR
g etracts into two sections. For
of the four intake
each tract, an intake air control valve under common control,
provides either a long or short tract length dependent on engine speed and throttle opening. This feature optimises power output at both low and high engine speed ranges.
Page 17
Lotus Service Notes
Engine Data:
Capacity
Bore/stroke
Power/torque:
Combined fuel consumption:
Exhaust emissions CO2:
Engine management:
Valve control:
Engine speed control:
Max. engine speed:
Spark plugs:
Spark plug gap:
Compression - std
- min
- max. diff.
Section EH
1598 cm3
80.5 mm/78.5 mm
100 kW (136 PS, 134 hp) @ 6,800 rpm; 160 Nm (118 lbf.ft) @ 4400 rpm.
6.14 litres/100 km (46 mpg).
155 g/km
Lotus T6 controller (as Evora) with Lotus programming.
VVT-i variable timing of both inlet and exhaust cams;
VALVEMATIC variable lift system for the inlet valves.
Intake plenum throttling at low engine speeds; inlet valve lift and intake
plenum throttling at high speeds.
6800 rpm continuous; 7000 rpm transient.
Denso SC20HR11
1.0 to 1.1mm
1373 kPa (14.0 kgf/cm2, 199 psi) or higher
1079 kPa (11.0 kgf/cm2, 156 psi)
98 kPa (1.0 kgf/cm2, 14.2 psi)
Notes
- Valve lift actuator driven off tail of inlet camshaft. Vacuum pump driven off tail of exhaust camshaft to supply
brake servo and engine management functions.
- Long reach M12 spark plugs requiring 14mm socket wrench.
- New 'clip-on' cosmetic engine cover.
- No requirement or provision for oil coolers.
- The engine number is stamped on the left hand
front of the cylinder block, alongside the alternator,
and is prefaced by ‘1ZR’.
1ZR
Engine
Number
2
:
5
ohs176
Page 18
Lotus Service Notes
Section EH
VALVEMATIC System
The principle of the VALVEMATIC system is that a conventional inlet camshaft with a single (rotary) cam
for each cylinder operates a roller arm on a pivot shaft. On each side of the roller arm is an oscillating cam,
each of which opens, via a finger follower, one of two conventional inlet valves for that cylinder. The two valves
are operated at all times as a pair. The connection between the roller arm and the two oscillating cams is made
via a common pivot sleeve machined with three separate sections of helical splines, which correspond with
splines in the bores of the roller arm and oscillating cams. By sliding the sleeve axially, within the roller arm
and cams, the opposite helix angle used for the cams compared with that for the roller arm, results in a phase
shift between arm and cams.
Valves shown at full lift (camshaft omitted for clarity)
Pivot shaft
Roller arm
Oscillating cam
Camshaft
operates against
this roller
Finger follower
Inlet valves
Hydraulic
pivot post
A 'lost motion' damper ensures that the roller arm stays in contact with the rotary cam profile at all times.
The position of the oscillating cams at the start of a valve opening event however, is dependent on their phasing
with the roller arm. In the low lift mode, where the cams are phased counterclockwise in relation to the roller
arm as viewed from the rear, the finger follower roller is in contact with the base circle of the oscillating cam,
which must turn through a large part of its range before the cam starts to lift the valve, resulting in only the first
portion of the cam profile being used. In high lift mode, the oscillating cams are phased clockwise in relation to
the roller arms such that the cam profile immediately starts to lift the valve as soon as the roller arm is depressed
by the rotary cam, continuing then to utilise the full profile of the oscillating cam for maximum lift.
The concomitant variation in valve timing as the lift changes, is managed by the separate VVT-i system
(see earlier).
Page 19
Lotus Service Notes
Section EH
Auxiliary Belt Tension
The auxiliary belt tension on the 1ZR FAE engine is set manually by adjusting the alternator position. An
adjusting screw for this purpose is provided on the alternator strap, and may be utilised after slackening the
strap anchor and clamp bolts, and the alternator lower pivot bolt.
Belt tension should be set using a frequency meter between the water pump and alternator pulleys:
New belt; 110 Hz (± 5 Hz). Used belt; 90 - 100 Hz.
Alternatively, a force meter can be used on the lower belt run between the crankshaft and water pump:
New belt; 700 - 800 N. Used belt; 550 - 770 N.
If no meter is available, apply firm thumb pressure to the midpoint of the belt run between water pump and
alternator, and measure the deflection:
New belt; 7 - 8 mm. Used belt; 8 - 10 mm.
Engine Lubrication
For optimum engine protection, the oil level should be maintained towards the dipstsick top mark, not be
allowed to fall below the mid-point. If driving on a closed circuit track, or exploiting maximum cornering capability, it is especially important to maintain at the upper marking. Adding approximately ½ litre will raise the level
from the mid-point to the upper mark.­­
- The oil filter is a cartridge type paper element
similar in concept to the Evora, and is mounted
Paper
at the right hand rear of the engine, accessible
element
from beneath after removal of the engine bay
undertray.
- Make provision for collecting the small amount of
spilled oil before fitting adaptor tool T000T1441F
‘O’ ring
over the cap to release the security catch, and
allow it to be unscrewed using a 17mm wrench,
or 3/8 inch square drive. Release about 4 turns
Adaptor Align triple Filter cap
tool rib lowermost
before positioning the triple rib feature on the cap
to drain housing
lowermost; this will aid draining of the oil from the
OIL FILTER (1ZR)
filter housing. Then complete the removal of the
cap, and dispose of the paper filter element and
cap ‘O’ ring safely.
Clean the oil filter cap and inside of the filter housing. Carefully fit a new ‘O’ ring (supplied with the new
filter) into its groove on the cap and smear with clean engine oil before inserting a new filter element and refitting the cap, taking care to avoid cross-threading, and ensuring that the ‘O’ ring is not displaced. Using adaptor
tool T000T1441F, tighten the cap to 25 Nm.
ohs175
Engine Repair
An engine repair CD is available under part number T000T1523F. For a technical overview, choose:
-
New Car Features
-
2008/11 Update
-
New Features
-
1ZR-FAE and 2ZR-FAE Engine
Then select from the drop-down menu as required.
-
-
-
For repair procedures, choose:
Repair Manual
Engine
scroll down past diagnostic codes to find 1ZR-FAE ENGINE MECHANICAL in left hand column.
Page 20
Lotus Service Notes
Section EMP
ENGINE MANAGEMENT
SECTION EMP
Sub-Section Page
Diagnostic Trouble Code List
EMP.1
3
Diagnostic Scanner Tools
EMP.2
43
Engine Management Component Location
EMP.3
47
Mechanical Throttle Setting Procedure
EMP.4
48
2006 Model Year Electronic Throttle Control
EMP.5
49
Diagnostic Trouble Code Supplement - '06 M.Y.
EMP.6
50
Diagnostic Trouble Code Supplement - 2011 M.Y. Elise (Euro 5)
EMP.7
58
Page 1
Lotus Service Notes
Section EMP
EMP.1 - DIAGNOSTIC TROUBLE CODE LIST
DTC
Fault description
Page
P0011
P0012 P0076
P0077
P0101
P0102
P0103
P0106
P0107
P0108
P0111
P0112
P0113
P0116
P0117
P0118
P0121
P0122
P0123
P0128
P0131
P0132
P0133
P0134
P0135
P0137
P0138
P0139
P0140
P0141
P0171
P0172
P0201
P0202
P0203
P0204
P0300
P0301
P0302
P0303
P0304
P0324
P0327
P0328
P0335
P0340
P0351
P0352
P0353
P0354
P0420
P0441
P0442
Camshaft Position - Timing Over-Advanced or System Performance Camshaft Position - Timing Over-Retarded Intake Valve Control Solenoid Circuit Low
Intake Valve Control Solenoid Circuit High
Mass or Volume Air Flow Circuit Range/Performance Mass or Volume Air Flow Circuit Low Input
Mass or Volume Air Flow Circuit High Input
Manifold Absolute Pressure/Barometric Pressure Circuit Range/Performance Manifold Absolute Pressure/Barometric Pressure Circuit Low Input
Manifold Absolute Pressure/Barometric Pressure Circuit High Input
Intake Air Temperature Sensor 1 Circuit Range/Performance Intake Air Temperature Sensor 1 Circuit Low Intake Air Temperature Sensor 1 Circuit High Engine Coolant Temperature Circuit Range/Performance Engine Coolant Temperature Circuit Low Engine Coolant Temperature Circuit High Throttle Position Sensor 'A' Circuit Range/Performance Throttle Position Sensor 'A' Circuit Low Throttle Position Sensor 'A' Circuit High Coolant Thermostat (Coolant Temperature Below Thermostat Regulating Temperature)
O2 Sensor Circuit Low Voltage (Pre Catalyst)
O2 Sensor Circuit High Voltage (Pre Catalyst)
O2 Sensor Circuit Slow Response (Pre Catalyst)
O2 Sensor Circuit No Activity Detected (Pre Catalyst)
O2 Sensor Heater Circuit (Pre Catalyst)
O2 Sensor Circuit Low Voltage (Post Catalyst)
O2 Sensor Circuit High Voltage (Post Catalyst)
O2 Sensor Circuit Slow Response (Post Catalyst)
O2 Sensor Circuit No Activity Detected (Post Catalyst)
O2 Sensor Heater Circuit (Post Catalyst)
System Too Lean
System Too Rich
Injector Circuit/Open – Cylinder 1
Injector Circuit/Open – Cylinder 2
Injector Circuit/Open – Cylinder 3
Injector Circuit/Open – Cylinder 4
Random/Multiple Cylinder Misfire Detected
Cylinder 1 Misfire Detected
Cylinder 2 Misfire Detected
Cylinder 3 Misfire Detected
Cylinder 3 Misfire Detected
Knock Control System Error
Knock Sensor 1 Circuit Low Knock Sensor 1 Circuit High Crankshaft Position Sensor “A” Circuit Range/Performance
Camshaft Position Sensor “A” Circuit
Ignition Coil “A” Primary/Secondary Circuit
Ignition Coil “B” Primary/Secondary Circuit
Ignition Coil “C” Primary/Secondary Circuit
Ignition Coil “D” Primary/Secondary Circuit
Catalyst System Efficiency Below Threshold
Evaporative Emission System Incorrect Purge Flow
Evaporative Emission System Leak Detected (small leak)
4
4
4
4
5
5
5
7
7
7
8
8
8
10
10
10
12
12
12
14
15
15
15
15
15
18
18
18
18
18
20
20
21
21
21
21
22
22
22
22
22
24
24
24
25
26
27
27
27
27
28
29
29
Page 2
Lotus Service Notes
Section EMP
DTC
Fault description
Page
P0444
P0445
P0446
P0447
P0448
P0451
P0452
P0453
P0455
P0456
P0461
P0462
P0463
P0480
P0481
P0500
P0506
P0507
P0508
P0509
P0562
P0563
P0601
P0606
P0627
P0646
P0647
P1301
P1302
P2602
P2603
P2646
P2647
P2648
P2649
Evaporative Emission System Purge Control Valve Circuit Open
Evaporative Emission System Purge Control Valve Circuit Shorted
Evaporative Emission System Vent Control Circuit
Evaporative Emission System Vent Control Circuit Open
Evaporative Emission System Vent Control Circuit Shorted
Evaporative Emission System Pressure Sensor/Switch Range/Performance
Evaporative Emission System Pressure Sensor/Switch Low Evaporative Emission System Pressure Sensor/Switch High Evaporative Emission System Leak Detected (large leak)
Evaporative Emission System Leak Detected (very small leak)
Fuel Level Sensor “A” Circuit Range/Performance
Fuel Level Sensor “A” Circuit Low Fuel Level Sensor “A” Circuit High Fan 1 Control Circuit
Fan 2 Control Circuit
Vehicle Speed Sensor “A”
Idle Air Control System RPM Lower Than Expected
Idle Air Control System RPM Higher Than Expected
Idle Air Control System Circuit Low
Idle Air Control System Circuit High
System Voltage Low
System Voltage High
Watchdog
Checksum
Fuel Pump Control Circuit /Open
A/C Clutch Relay Control Circuit Low
A/C Clutch Relay Control Circuit High
Misfire level causing emissions increase
Misfire level causing catalyst system damage
Coolant Pump Control Circuit Low
Coolant Pump Control Circuit High
A Rocker Arm Actuator System Performance or Stuck Off
A Rocker Arm Actuator System Stuck On
A Rocker Arm Actuator Control Circuit Low
A Rocker Arm Actuator Control Circuit High
31
31
31
31
31
31
31
31
29
29
32
32
32
33
33
34
35
35
35
35
36
36
37
37
38
39
39
40
40
41
41
42
42
42
42
When applicable, reference may be made under the 'Notes' heading to a page in the Toyota service manual.
This information should be used only for diagnosis and connection detail of the sensor. The Elise/Exige uses
a Lotus ECU, the connections for which may be found in circuit diagrams in Section MP. Diagnostic Trouble
Codes should be read using a Lotus Scan tool T000T1418F.
For 2006 M.Y. Trouble Codes see Section EMP.6
Page 3
Lotus Service Notes
Camshaft Timing Control (VVT)
P0011 P0012 P0076
P0077
Section EMP
P0011
P0012
P0076
P0077
Camshaft Position – Timing Over-Advanced or System Performance
Camshaft Position – Timing Over-Retarded
Intake Valve Control Solenoid Circuit Low
Intake Valve Control Solenoid Circuit High
Description
The Variable Valve Timing system (VVT) on the intake camshaft can vary the timing by approximately 25°. The
camshaft relative position is varied by a system of vanes mounted on the drive end of the camshaft. The VVT
oil control valve modulates a spool valve position in accordance with the drive signal duty cycle, this in turns
controls the oil pressure applied to the vanes. A 50% duty cycle applied to the valve will hold the valve current
timing by preventing oil flow from the VVT controller housing, a duty cycle less than 50% will retard the valve
timing, a duty cycle greater then 50% will advance the valve timing.
Component connections
Sensor Connector Description
1 Battery Voltage
2 VVT Oil Control Valve
P0011, P0012
ECU Pin
-
49(J3)
ECU Connector
52 Way (Right)
Monitor: Continuous
Enable Criteria:
• Engine running > 30 secs
• Coolant temperature > 60°C (140°F)
Disable Criteria:
P0116, P0117, P0118 – Coolant temperature fault codes
Potential failure modes:
• Static valve timing is incorrect
• VVT camshaft actuator failure
• VVT valve stuck open / closed
P0076, P0077
Monitor: Continuous
Enable Criteria: Engine running
Disable Criteria: None
Potential failure modes:
• VVT valve open circuit
• VVT valve short to ground
• ECU output circuit failure
Notes:
The MIL will be illuminated if the faults are present for 2 consecutive trips
Page 4
'06 M.Y. in brackets
Lotus Service Notes
Intake Air Flow
P0101
P0102
P0103
Section EMP
P0101
P0102
P0103
Mass or Volume Air Flow Circuit Range/Performance
Mass or Volume Air Flow Circuit Low Input
Mass or Volume Air Flow Circuit High Input
Description
The Mass Air Flow (MAF) sensor is incorporated into the airbox, and measures both intake air flow rate and
Intake Air Temperature (IAT). The MAF sensor uses a platinum hot wire and a cold wire element. By controlling the current flow through the hot wire to maintain a constant temperature, and therefore known resistance,
any change in air flow and therefore temperature, will be detected by a change in resistance. This change of
resistance is the output signal from the sensor.
Sensor connections
Sensor Connector
1
2
3
4
5
Description
Battery Voltage
MAF Ground
MAF Signal
IAT Signal
IAT Ground
ECU Pin
-
31(D2)
45(B4)
44(B3)
18(D2)
ECU Connector
52 Way (Right)
52 Way (Right)
52 Way (Right)
52 Way (Right)
'06 M.Y. in brackets
Sensor characteristics
0 – 655 g/sec
Typical values: 1.5 – 5.0 g/sec (idle), 5.0 – 15.0 g/sec (2500rpm elevated idle no load)
Monitor: Continuous.
P0101
Enable Criteria:
• Engine running
• Engine speed >2490rpm
• TPS > 80% (P0101 – MAPS* too low)
• TPS < 5% (P0101 – MAPS* too high)
*(MAPS – Mass Air Per Stroke)
Disable Criteria:
P0122, P0123, P0222, P0223 – Throttle/Pedal position fault codes
Potential failure modes:
• MAF sensor battery voltage open circuit (MAF value (g/sec) = 0.0)
• MAF sensor signal open circuit or short to ground (MAF value (g/sec) = 0.0)
• MAF sensor ground open circuit (MAF value (g/sec) > 229.0)
P0102
Enable Criteria: Engine running
Disable Criteria: None
Potential failure modes:
• MAF sensor battery voltage open circuit (MAF value (g/sec) = 0.0)
• MAF sensor signal open circuit or short to ground (MAF value (g/sec) = 0.0)
• MAF sensor ground open circuit (MAF value (g/sec) > 229.0)
Page 5
Lotus Service Notes
Section EMP
P0103
Enable Criteria: Engine running
Disable Criteria: None
Potential failure modes:
• MAF sensor battery voltage open circuit (MAF value (g/sec) = 0.0)
• MAF sensor signal open circuit or short to ground (MAF value (g/sec) = 0.0)
• MAF sensor ground open circuit (MAF value (g/sec) > 229.0)
Notes:
• The MIL will be illuminated if the faults are present for 2 consecutive trips
• Further information on the sensor may be found in Toyota 1ZZ-FE, 2ZZ-GE manual RM733E (B120T0327J)
Page DI-26 to DI-32
Page 6
Lotus Service Notes
Barometric Pressure
P0106
P0107
P0108
Section EMP
P0106
P0107
P0108
Manifold Absolute Pressure/Barometric Pressure Circuit Range/Performance
Manifold Absolute Pressure/Barometric Pressure Circuit Low Input
Manifold Absolute Pressure/Barometric Pressure Circuit High Input
Description
The barometric pressure sensor is located internally within the ECU, and measures atmospheric pressure. This
parameter is required to compensate the mass air flow when the vehicle is operated at higher altitudes.
Monitor: Continuous
P0106
Enable Criteria:
• Engine running
• Engine speed 2190 – 3510rpm
• TPS > 80%
Disable Criteria:
P0101, P0102, P0103 – MAF Sensor fault codes
P0121, P0122, P0123, P0222, P0223, P2135 – Throttle/Pedal position fault codes
Potential failure modes:
Sensor failure
P0107, P0108
Enable Criteria: Engine running
Disable Criteria: None
Potential failure modes:
Sensor failure
Notes:
The MIL will be illuminated if the fault is present for 2 consecutive trips
Page 7
Lotus Service Notes
Intake Air Temperature
Section EMP
P0111
P0112
P0113
P0111Intake Air Temperature Sensor 1 Circuit Range/Performance
P0112Intake Air Temperature Sensor 1 Circuit Low
P0113Intake Air Temperature Sensor 1 Circuit High
Description
The combined sensor which measure both Mass Air Flow (MAF) and Intake Air Temperature (IAT) is incorporated into the airbox. The IAT sensor is a thermistor device which changes resistance with temperature. As
air intake temperature decreases the thermistor resistance value increases, and conversely as air temperature
increases so the thermistor resistance value decreases.
Sensor connections
Sensor Connector
1
2
3
4
5
Description
Battery Voltage
MAF Ground
MAF Signal
IAT Signal
IAT Ground
ECU Pin
-
31 (D2)
45(B4)
44(B3)
18(D2)
ECU Connector
52 Way (Right)
52 Way (Right)
52 Way (Right)
52 Way (Right)
Sensor characteristics
IAT -20°C (-4°F) 12.5 – 16.9 kΩ
IAT 20°C (68°F) 2.19 – 2.67 kΩ
IAT 60°C (140°F) 0.50 – 0.68 kΩ
Monitor: Continuous
P0111
Enable Criteria:
• Engine running < 30 secs
• Coolant temperature < 30°C (86°F)
Disable Criteria:
P0116, P0117, P0118 – Coolant temperature fault codes
Potential failure modes:
• P0112 – signal short circuit
• P0113 – signal open circuit
• Sensor failure
P0112
Enable Criteria: Engine running
Disable Criteria: None
Potential failure modes:
• Signal short circuit (IAT = –40°C (–104°F) < 0.049 V)
• Sensor failure
Page 8
'06 M.Y. in brackets
Lotus Service Notes
Section EMP
P0113
Enable Criteria: Engine running
Disable Criteria: None
Potential failure modes:
• Signal open circuit (IAT > 140°C (284°F) > 4.932 V)
• Sensor failure
Notes:
• The MIL will be illuminated if the fault is present for 2 consecutive trips
• Further information on the sensor may be found inToyota 1ZZ-FE, 2ZZ-GE manual RM733E (B120T0327J)
pages DI-33 to DI-38
Page 9
Lotus Service Notes
Engine Coolant Temperature
P0116
P0117
P0118
Section EMP
P0116
P0117
P0118
Engine Coolant Temperature Circuit Range/Performance
Engine Coolant Temperature Circuit Low
Engine Coolant Temperature Circuit High
Description
The engine coolant temperature sensor is a thermistor device which changes resistance with temperature. As
coolant temperature decreases the thermistor resistance value increases, and conversely as coolant temperature increases so the thermistor resistance value decreases.
Sensor connections
Sensor Connector Description
1 Ground
2 Signal
ECU Pin
7 (H1)
33(C3) ECU Connector
52 Way (Right)
52 Way (Right)
Sensor characteristics
0°C (32°F) = 3.279 V
19.4°C (67°F) = 2.186 V
42.5°C (108.5°F) = 1.249 V
80°C (176°F) = 0.469 V
P0116
Enable Criteria:
Engine running > 800 seconds
Disable Criteria: None
Potential failure modes:
• P0117 – signal short circuit
• P0118 – signal open circuit
• Sensor failure
P0117
Enable Criteria: Engine running
Disable Criteria: None
Potential failure modes:
• Signal short circuit (Coolant Temperature = –40°C (–104°F) < 0.029 V)
• Sensor failure
P0118
Enable Criteria: Engine running
Disable Criteria: None
Potential failure modes:
• Signal open circuit (Coolant Temperature > 140°C (284°F) > 4.892 V)
• Sensor failure
Page 10
'06 M.Y. in brackets
Lotus Service Notes
Section EMP
Notes:
• The MIL will be illuminated if the fault is present for 2 consecutive trips
• Further information on the sensor may be found inToyota 1ZZ-FE, 2ZZ-GE manual RM733E (B120T0327J)
page DI-39 to DI-45
Page 11
Lotus Service Notes
Throttle Position
P0121
P0122
P0123
Section EMP
P0121
P0122
P0123
Throttle Position Sensor 'A' Circuit Range/Performance
Throttle Position Sensor 'A' Circuit Low
Throttle Position Sensor 'A' Circuit High
Description
The Throttle Position Sensor (TPS) is a potentiometer device, which is connected to a 5V reference source, a
ground and an input signal to the ECU.
Sensor connections
Sensor Connector
1
2
3
4
Description
Ground
5V Ref.
TPS1 Signal
TPS2 Signal
ECU Pin
34 (D1)
8 (M4)
20(D3)
(E3)
ECU Connector
52 Way (Right)
52 Way (Right)
52 Way (Right)
(Right)
Sensor characteristics
0% = 0.595 V ± 5%
100% = 4.148 V ± 5%
Monitor: Continuous.
P0121
Enable Criteria:
Rationality check – throttle not too high at low engine load:
• Engine running
• TPS > 80%
• Engine speed >1500rpm
• MAPS* < 40%
• Vehicle Speed > 30 km/h (18.6mph)
OR
Rationality check – throttle not too low at high engine load:
• Engine running
• TPS < 10%
• Engine speed 1500 – 2010rpm
• MAPS* > 65%
*(MAPS – Mass Air Per Stroke)
Disable Criteria:
P0101, P0102, P0103
P0500 P0016
– MAF Sensor fault codes
– Vehicle Speed sensor
– Crankshaft/Camshaft position correlation error
Potential failure modes:
• Sensor short or open circuit
• Sensor failure
Page 12
'06 M.Y. in brackets
Lotus Service Notes
Section EMP
P0122
Enable Criteria: None
Disable Criteria:
P0016 – Crankshaft/Camshaft position correlation error
Potential failure modes:
• Signal short circuit (< 0.283 V)
• Reference voltage open circuit
• Reference voltage short to ground
• Sensor failure
P0123
Enable Criteria: None
Disable Criteria:
P0016 – Crankshaft/Camshaft position correlation error
Potential failure modes:
• Signal open circuit (> 4.487 V)
• Reference voltage open circuit
• Reference voltage short to ground
• Sensor failure
Notes:
• The MIL will be illuminated if the fault is present for 2 consecutive trips
• Further information on the sensor may be found inToyota 1ZZ-FE, 2ZZ-GE manual RM733E (B120T0327J)
page DI-45 to DI-52
Page 13
Lotus Service Notes
Coolant Thermostat
P0128
Section EMP
P0128
Coolant Thermostat (Coolant Temperature Below Thermostat Regulating Temperature)
Description
The thermostat diagnostic is enabled after each cold engine start, and monitors the rate of temperature rise
during warm up relative to the measured engine air flow.
Monitor: Continuous
Enable Criteria:
• Engine running
• Coolant Temperature > -10°C (14°F)
• Coolant Temperature < 70°C (158°F)
Disable Criteria:
P116, P117, P118 – Engine Coolant Temperature sensor faults
Potential failure modes:
Thermostat failure
Notes:
The MIL will be illuminated if the fault is present for 2 consecutive trips.
Page 14
Lotus Service Notes
O2 Sensor (Pre Catalyst)
P0131
P0132
P0133
P0134
P0135
Section EMP
P0131
P0132
P0133
P0134
P0135
O2 Sensor 1 Circuit Low Voltage
O2 Sensor 1 Circuit High Voltage
O2 Sensor 1 Circuit Slow Response
O2 Sensor 1 Circuit No Activity Detected
O2 Sensor 1 Heater Circuit
Description
The oxygen sensor monitors the oxygen content in the exhaust gases. The sensor consists of a zirconia electrode between two platinum plates. When zirconia comes into contact with oxygen, it becomes an electrical
conductor. The exhaust gases pass through louvers in the sensor. One plate is in contact with the outside air
and the other plate is in contact with the exhaust gases. The platinum plate in contact with the air is electrically
negative due to the oxygen in the atmosphere and the plate in contact with the exhaust gases is electrically
positive. This will cause a difference in electrical potential to develop between the two plates. Thus the voltage
across the platinum plates ranges approximately from 100 millivolts to 900 millivolts, depending on the oxygen
content of the exhaust gases. Thus when the air/fuel mixture is rich, the oxygen sensor output will be high. If
the air/fuel mixture is lean, the oxygen sensor output will be low.
Sensor connections
Sensor Connector
1
2
3
4
Description
Signal
Ground
Heater Battery Voltage
ECU Pin
15 (A3)
41(F4)
1 (K3)
-
ECU Connector
52 Way (Left)
52 Way (Left)
52 Way (Left)
-
'06 M.Y. in brackets
Sensor characteristics
Normal operating range is 0 – 1000mV
Malfunction Criteria
P0131
Set when the sensor operates below 5mV for more than 1.5 seconds consecutively for a specified number of
times.
Monitor: Continuous
Disable Criteria: DFCO (Deceleration Fuel Cut Off)
Potential failure modes:
• Low fuel pressure (Lean mixture)
• Malfunctioning sensor
• External water on sensor
• Sensor wire shorted to ground
P0132
Set when the sensor operates above 1200mV for more than 1.5 seconds consecutively for a specified number
of times.
Monitor: Continuous
Page 15
Lotus Service Notes
Section EMP
Potential failure modes:
• High fuel pressure (Rich mixture)
• Leaking or shorted injector
• Purge valve fault
• Oxygen sensor contamination
• Engine oil contamination
• Sensor wire
P0133
Set when the sensor fails to switch from a Lean to a Rich condition or switch from a Rich to a Lean condition
in a sufficiently timely manner. A selection of switches is used to determine the average times.
Enable Criteria:
• Vehicle speed between 0 – 255 km/h (158.5 mph)
• MAF per stroke between 15 – 70 mg
• Engine speed between 2600 – 3511rpm
• Engine run time > 200 seconds
• Coolant temperature > 60°C (140°F)
• Closed loop fuelling enabled
Disable Criteria:
P0116, P0117, P0118 – Coolant temperature sensor faults
P0131, P0132, P0134, P0135 – Pre catalyst oxygen sensor faults
P0101, P0102, P0103 – MAF sensor faults
Monitor:
Monitored until the required amount of switches in both directions has been achieved (Approx. 150 sec)
Potential failure modes:
• Sensor connector and wiring should be checked for corrosion and loose connections
• Sensor contaminated, possibly from fuel, improper use of RTV, engine oil or coolant
P0134
Set when the sensor fails to switch above 557mV ('06 M.Y.; 675mV) and below 400mV within a 5.1 second
period for 5 consecutive checks ('06 M.Y.; within 60 sec).
Enable Criteria:
• Engine run time > 30 seconds
• Engine is not at idle
• Engine is in closed loop fuel control
Monitor:
Until either passed or failed (5.1 x 5 = 25.5 sec + initial 30 sec = 55 sec maximum).
Potential failure modes:
Sensor connector and wiring should be checked for corrosion and loose connections.
P0135
Set when the sensor output is greater than 1900mA or less than 250mA for 1.5 seconds, for 40 consecutive
checks.
Enable Criteria:
Engine run time > 60 seconds
Monitor:
Continuous
Page 16
Lotus Service Notes
Section EMP
Potential failure modes:
Sensor connector and wiring should be checked for corrosion and loose connections.
Notes:
• The MIL will be illuminated if the fault is present for 2 consecutive trips.
• Further information on the sensor may be found inToyota 1ZZ-FE, 2ZZ-GE manual RM733E (B120T0327J)
pages DI-53 to DI-62
Page 17
Lotus Service Notes
O2 Sensor (Post Catalyst)
P0137
P0138
P0139
P0140
P0141
Section EMP
P0137
P0138
P0139
P0140
P0141
O2 Sensor Circuit Low Voltage
O2 Sensor Circuit High Voltage
O2 Sensor Circuit Slow Response
O2 Sensor Circuit No Activity Detected
O2 Sensor Heater Circuit
Description
The oxygen sensor monitors the oxygen content in the exhaust gases. The sensor consists of a zirconia electrode between two platinum plates. When zirconia comes into contact with oxygen, it becomes an electrical
conductor. The exhaust gases passes through louvers in the sensor. One plate is in contact with the outside air
and the other plate is in contact with the exhaust gases. The platinum plate in contact with the air is electrically
negative due to the oxygen in the atmosphere and the plate in contact with the exhaust gases is electrically
positive. This will cause a difference in electrical potential to develop between the two plates. Thus the voltage
across the platinum plates ranges approximately from 100 millivolts to 900 millivolts, depending on the oxygen
content of the exhaust gases. Thus when the air/fuel mixture is rich, the oxygen sensor output will be high. If
the air/fuel mixture is lean, the oxygen sensor output will be low. The post catalyst oxygen sensor performance
is a good indicator of catalyst efficiency.
Sensor connections
Sensor Connector
1
2
3
4
Description
Signal
Ground
Heater Battery Voltage
ECU Pin
3 (B3)
29(F4)
27(H3)
-
ECU Connector
52 Way (Left)
52 Way (Left)
52 Way (Left)
-
'06 M.Y. in brackets
Sensor characteristics
Normal operating range is 0 – 1000mV
Malfunction Criteria
P0137
Set when the sensor operates below 5mV for more than 1.5 seconds consecutively for a specified number of
times.
Monitor: Continuous
Disable Criteria: DFCO (Deceleration Fuel Cut Off)
Potential failure modes:
• Check and rectify any pre catalyst sensor fault code, as they may be causing the fault code to be set
• Sensor wire shorted to ground
• Catalyst
P0138
Set when the sensor operates above 1200mV for more than 1.5 seconds consecutively for a specified number
of times.
Monitor: Continuous
Page 18
Lotus Service Notes
Section EMP
Potential failure modes:
• Check and rectify any front sensor fault code, as they may be causing the fault code to be set
• Catalyst
P0139
Set when the sensor fails to reach 650mV after 1.9 seconds of P.E or when the sensor fails to drop below
150mV after 5 seconds of DFCO ('06 M.Y.; Set when sensor fails to switch between 250mV and 650mV with
sufficient rapidity).
Enable Criteria:
• Engine run time > 200 seconds
• Coolant temperature > 60°C (140°F)
• Open loop fuel control
• DFCO (Deceleration Fuel Cut Off) followed by idle operation for 'lean to rich' switch
• DFCO for 'rich to lean' switch
Disable Criteria:
P0116, P0117, P0118 – Coolant Temperature Sensor faults
P0201, P0202, P0203, P0204 – Injector faults
P0300, P0301, P0302, P0303, P0304 – Misfire faults
P1301, P1302 – Misfire faults causing emission or catalyst damage
Monitor: Continuous, until the test is either passed or failed
Potential failure modes:
• Check and rectify any pre catalyst sensor fault code, as they may be causing the fault code to be set
• Catalyst
P0140
Set when the sensor fails to switch above 557mV and below 400mV within 60 seconds.
Enable Criteria:
• Engine run time > 30 seconds
• Engine is not at idle
• Engine is in closed loop fuel control
Monitor: Continuous
Potential failure modes:
• Check and rectify any front sensor fault code, as they may be causing the fault code to be set
• Sensor connector and wiring should be checked for corrosion and loose connections
• Catalyst
P0141
Set when the sensor output is greater than 1900mA or less than 250mA for 1.5 seconds, for 40 consecutive
checks.
Enable Criteria: Engine run time > 60 seconds
Monitor: Continuous
Potential failure modes:
Sensor connector and wiring should be checked for corrosion and loose connections
Notes:
• The MIL will be illuminated if the fault is present for 2 consecutive trips.
• Further information on the sensor may be found in Toyota 1ZZ-FE, 2ZZ-GE manual RM733E (B120T0327J)
pages DI-63 to DI-66
Page 19
Lotus Service Notes
Fuel Control System Too Lean Or Rich
P0171 System Too Lean
P0172 System Too Rich
Section EMP
P0171
P0172
Description
The oxygen sensor sends a signal to the ECU corresponding to the exhaust gas oxygen content enabling the
ECU to maintain a 14.7:1 air/fuel ratio under normal driving conditions. The ECU can make fuel corrections
of ± 17% to the calculated fuel demand. If the ECU determines a rich condition exists (oxygen sensor above
0.450mV), it will decrease the calculated fuel demand to maintain a 14.7:1 ratio. If the ECU determines a lean
condition exists (oxygen sensor below 0.450mV), it will increase the calculated fuel demand to maintain a
14.7:1 ratio.
Enable Criteria
• Fuel Trim condition enabled
• Closed loop fuelling enabled
• Engine speed > 1100 rpm
• MAF > 6 g/sec
• Engine load < 70 %
• Altitude < 8000 ft (2438 m), Baro > 756 mbar
• Inlet air temperature > -10°C (14°F)
Disable Criteria
P0106, P0107, P0108 – Baro sensor faults
P0111, P0112, P0113 – Air Intake Sensor faults
P0131, P0132, P0133, P0134, P0135 – Oxygen sensor faults
P0300, P0301, P0302, P0303, P0304 – Misfire faults
P0441, P0442, P0443, P0447, P0448, P0450, P0451, P0455, P0456 – EVAP faults
Monitor: Continuous
Malfunction Criteria
P0171
This code is set when the calculated fuel demand has been increased to its maximum limit of 17% and the
system still cannot maintain an air/fuel ratio of 14.7:1 under normal driving conditions.
Potential failure modes:
• Fuel Pressure too low
• Air leak in system
• Water in fuel
• Exhaust leak / crack before front oxygen sensor
• Injector fault
• Sensor connector and wiring for signs of corrosion or loose connections
P0172
This code is set when the calculated fuel demand has been decreased to its minimum limit of -17% and the
system still cannot maintain an air/fuel ratio of 14.7:1 under normal driving conditions.
Potential failure modes:
• Fuel Pressure too high
• Leaking fuel injector
• Restriction in the exhaust system or air intake / filter
• Erratic throttle position sensor
Notes:
• The MIL will be illuminated if the fault is present for 2 consecutive trips.
• Further information on the sensor may be found inToyota 1ZZ-FE, 2ZZ-GE manual RM733E (B120T0327J)
pages DI-67 to DI-72
Page 20
Lotus Service Notes
Fuel Injection System
P0201
P0202
P0203
P0204
Section EMP
P0201
P0202
P0203
P0204
Injector Circuit/Open – Cylinder 1
Injector Circuit/Open – Cylinder 2
Injector Circuit/Open – Cylinder 3
Injector Circuit/Open – Cylinder 4
Description
The ECU has four injector driver circuits, each of which controls an injector. When the engine is running the
ECU continuously monitors the injector circuit feedback signals. The feedback signal should be low when the
injector is ON and high voltage when the injector is OFF.
Component connections
Injector ECU Pin ECU Connector
1 25(J1) 52 Way (Right)
2 51(K4) 52 Way (Right)
3 14(K3) 52 Way (Right)
4 40(K2) 52 Way (Right)
'06 M.Y. in brackets
Malfunction Criteria
The operation of all the injector codes is the same, the last digit relates to the injector involved i.e. a code P0203
indicates there is a problem with injector number 3.
Enable Criteria: Engine running
Monitor: Continuous
Limp home:
• Limit maximum engine speed to 6000rpm
• Return the fuel system to open loop fuel control
Potential failure modes:
Sensor connector or wiring corroded or loose connections
Notes:
• The MIL will be illuminated if the fault is present for 2 consecutive trips.
• If an injector goes short circuit it is likely that the ECU injector driver will be damaged.
Page 21
Lotus Service Notes
Misfire
P0300
P0301
P0302
P0303
P0304
Section EMP
P0300
P0301
P0302
P0303
P0304
Random/Multiple Cylinder Misfire Detected
Cylinder 1 Misfire Detected
Cylinder 2 Misfire Detected
Cylinder 3 Misfire Detected
Cylinder 4 Misfire Detected
Description
A misfiring cylinder can be detected by analysing crank speed variation. As a result of a combustion event there
will be a net acceleration of the crankshaft. Subsequent to a misfire event the engine will decelerate over the
period following the missed cylinder event.
Speed changes can be characterised by observing changes in the time period for a fixed angle of rotation after
firing events. A significant change in this period, assessed by comparison to previous periods, may be attributed
to misfire on a known cylinder.
Component connections '06 M.Y. in brackets
Connector Description ECU Pin ECU Connector
1 Supply Voltage Coil 1 Coil 2 Coil 3 Coil 4
2 Ignition Coil Feedback 22 (F3) 22 (F3) 22 (F3) 22 (F3) 52 Way (Right)
3 Coil Output (Logic) 52(G1) 26 (G4) 47 (G3) 48 (G2) 52 Way (Right)
4 Ground
Malfunction Criteria
The operation of all the misfire codes is the same, the last digit relates to the misfire involved i.e. a code P0303
indicates there is a problem with coil number 3. P0300 indicates the misfire is random and not linked to one
particular cylinder.
Enable Criteria:
• Battery voltage between 10 – 16 V
• Coolant temperature between -10 – 120°C (14 – 248°F)
• Engine speed between 660 – 8010rpm
• Engine speed transient > 15rpm
• Altitude < 8000 ft (2438 m) / Baro > 756mbar
• Fuel level > 5 litres (1.3 US gallons)
• Engine load between 15 – 48% depending on engine speed
Disable Criteria: DFCO enabled (Deceleration Fuel Cut Off)
Monitor: Continuous
Limp home:
• Limit maximum engine speed to 6000 rpm
• Return the fuel system to open loop
• ECU may deactivate two cylinders, the misfiring cylinder and it’s matched other i.e. 1 & 4 or 2 & 3.
Potential failure modes:
• Injector related codes, as these can cause misfire codes to be set.
• VVT or VVL codes set
• Sensor connector and wiring for signs of corrosion or loose connections
• Spark plug / Cylinder compression
• Cam timing / Damage to rocker arm assembly
Page 22
Lotus Service Notes
Section EMP
Notes:
• The MIL will be illuminated if the fault is present for 2 consecutive trips.
• Further information on the sensor may be found inToyota 1ZZ-FE, 2ZZ-GE manual RM733E (B120T0327J)
pages DI-73 to DI-78
Page 23
Lotus Service Notes
Knock Control System
P0324
P0327
P0328
Section EMP
P0324
P0327
P0328
Knock Control System Error
Knock Sensor 1 Circuit Low
Knock Sensor 1 Circuit High
Description
The knock sensor contains a piezoelectric element which generates a voltage when it becomes deformed. The
piezoelectric element sends the signal to the ECU, when the cylinder block vibrates due to engine knocking.
If knock is detected then the ECU will retard the ignition to suppress it. The knock control sensor cannot differentiate between spark knock and other similar sounding noises.
Sensor connections
Sensor Connector Description
1 Sensor input
2 Ground
ECU Pin
43(C4)
13(A4)
ECU Connector
52 Way (Right)
52 Way (Right)
'06 M.Y. in brackets
Malfunction Criteria
P0327 – This code is set when the knock sensor signal is < 0.586 V
P0328 – This code is set when the knock sensor signal is > 2.928 V
Potential failure modes:
• Abnormal engine noise, i.e. damaged engine or exhaust system contacting vehicle
• Knock sensor fixing too tight
• Sensor connector / wiring corroded or loose connections
Notes:
• The MIL will be illuminated if the fault is present for 2 consecutive trips.
• Further information on the sensor may be found inToyota 1ZZ-FE, 2ZZ-GE manual RM733E (B120T0327J)
pages DI-79 to DI-81
Page 24
Lotus Service Notes
Engine Speed / Position Sensors
P0335
Section EMP
P0335
Crankshaft Position Sensor “A” Circuit Range/Performance
Description
Engine speed is calculated by measuring the time between the ‘teeth’ of the crankshaft sensor trigger disc. The
disc has 34 ‘teeth’ and 2 missing ‘teeth’, spaced at 10 degree intervals around the disc. The 2 missing ‘teeth’
are positioned at 225 degrees before cylinder No.1 and 4 TDC. The crankshaft sensor signal is also used to
determine misfires events.
Sensor connections
Sensor Connector Description
1 Sensor input
2 Ground
ECU Pin
4 (E1)
30(E4)
ECU Connector
52 Way (Right)
52 Way (Right)
'06 M.Y. in brackets
Monitor: Continuous
Enable Criteria: Engine running
Disable Criteria: None
Potential failure modes:
• Sensor signal open circuit or short to ground
• Sensor ground open circuit
• Sensor failure
Notes:
• If a sensor or sensor circuit failure occurs, the engine will not fire or start.
• The MIL will be illuminated if the fault is present for 2 consecutive trips
• Further information on the sensor may be found inToyota 1ZZ-FE, 2ZZ-GE manual RM733E (B120T0327J)
pages DI-82 to DI-83
Page 25
Lotus Service Notes
Engine Speed / Position Sensors
P0340
Section EMP
P0340
Camshaft Position Sensor “A” Circuit
Description
The camshaft position input to the ECU is used to determine engine phase, enable sequential fuel injection
control and to determine camshaft position for the VVT system. The inlet camshaft has three ‘teeth’ spaced 90°
apart, which are detected by the electromagnetic sensor. The valve timing setting is measured in the ECU by
measuring time from a (fixed position) crankshaft tooth to a (variable position) camshaft tooth. As the engine
speed and the position is known from the crankshaft sensor signal, the camshaft position can be calculated.
Sensor connections
Sensor Connector Description ECU Pin
1 Signal(VR Input) 16(C1)
2 Ground 42(E2)
ECU Connector
52 Way (Right)
52 Way (Right)
'06 M.Y. in brackets
Monitor: Continuous
Enable Criteria:
• Engine running
• Engine speed > 600rpm
Disable Criteria: None
Potential failure modes:
• Sensor signal open circuit or short to ground
• Sensor ground open circuit
• Sensor failure
Notes:
• The MIL will be illuminated if the fault is present for 2 consecutive trips.
• Further information on the sensor may be found in Toyota 1ZZ-FE, 2ZZ-GE manual RM733E (B120T0327J)
pages DI-84 to DI-85
Page 26
Lotus Service Notes
Ignition System
P0351
P0352
P0353
P0354
Section EMP
P0351
P0352
P0353
P0354
Ignition Coil “A” Primary/Secondary Circuit
Ignition Coil “B” Primary/Secondary Circuit
Ignition Coil “C” Primary/Secondary Circuit
Ignition Coil “D” Primary/Secondary Circuit
Description
A Direct Ignition System (DIS) is used on the engine. The DIS improves the ignition accuracy, reduces highvoltage loss, and enhances the reliability of the ignition system. The DIS is a 1-cylinder system that ignites one
cylinder with one ignition coil. The ECU determines the ignition timing and outputs the ignition signals (IGT) for
each cylinder. Based on IGT signals, the power transistors in the igniter cuts off the current to the primary coil,
which induces a spark at the spark plug connected to the secondary coil. The igniter will also send an ignition
confirmation signal (IGF) as a fail-safe measure to the ECU.
Component connections '06 M.Y. in brackets
Connector Pin Description ECU Pin ECU Connector
1 Supply Voltage Coil 1 Coil 2 Coil 3 Coil 4
2 Ignition Coil Feedback 22 (F3) 22 (F3) 22 (F3) 22 (F3) 52 Way (Right)
3 Coil Output (Logic) 52(G1) 26(G4) 47 (G3) 48 (G2) 52 Way (Right)
4 Ground
Malfunction Criteria
No IGF signal to ECM while engine is running
Potential failure modes:
• Open or short in IGF1 – IGF4 circuit from ignition coil to ECU
• Coil failure
Notes:
• The MIL will be illuminated if the fault is present for 2 consecutive trips.
• Further information on the sensor may be found inToyota 1ZZ-FE, 2ZZ-GE manual RM733E (B120T0327J)
pages DI-97 to DI-103
Page 27
Lotus Service Notes
Catalyst System Efficiency
P0420
Section EMP
P0420
Catalyst System Efficiency Below Threshold
Description
The ECU compares the waveform of the oxygen sensors located before and after the catalyst to determine
whether or not the catalyst has deteriorated. If the catalyst is functioning normally the front oxygen sensor will
be switching between rich and lean whilst the rear oxygen sensor should also be switching between rich and
lean but more slowly. When both the oxygen sensor waveforms change at the same rate, it indicates that the
catalyst performance has deteriorated. The ECU counts the number of pre and post catalyst oxygen sensor
switches and divides one by the other to determine a ratio number. If the ratio number is greater than 0.6 ('06
M.Y.; 0.165) the code is set.
Sensor connections
Pre catalyst oxygen sensor
Sensor Connector Description
1 Signal
2 Ground
3 Heater Supply
4 Battery Voltage
ECU Pin
15 (A3)
41(F4)
1 (K3)
-
ECU Connector
52 Way (Left)
52 Way (Left)
52 Way (Left)
-
'06 M.Y. in brackets
Post catalyst oxygen sensor
Sensor Connector Description
1 Signal
2 Ground
3 Heater Supply
4 Battery Voltage
ECU Pin
3 (B3)
29(F4)
27(H3)
-
ECU Connector
52 Way (Left)
52 Way (Left)
52 Way (Left)
-
'06 M.Y. in brackets
Malfunction Criteria
• Closed loop fuel control enabled
• Coolant temperature > 60 °C (140 °F)
• Baro > 756 mbar
• Vehicle speed < 130 km/h (81 mph)
• MAF < 40 g/sec
• Air inlet temp > -10°C (14°F)
Disable Criteria:
P0101, P0102, P0103 – MAF faults
P0107, P0108 – MAP / Baro Faults
P0116, P0117, P0118 – Coolant temperature faults
P0131, P0132, P0133, P0134, P0135, P0137, P0138, P0139, P0140, P0141– Oxygen sensor faults
P0171, P0172 – Fuelling faults
P0300, P0301, P0302, P0303, P0304 – Misfire faults
Potential failure modes:
• Exhaust system leak
• Oxygen sensor faults
• Oxygen sensor heater failure
• Catalyst failure
Notes:
• The MIL will be illuminated if the fault is present for 2 consecutive trips.
• Further information on the sensor may be found inToyota 1ZZ-FE, 2ZZ-GE manual RM733E (B120T0327J)
pages DI-86 to DI-88
Page 28
Lotus Service Notes
Evaporative Emission Control – Leak Detection System
P0441
P0442
P0455
P0456
Section EMP
P0441
P0442
P0455
P0456
Evaporative Emission System Incorrect Purge Flow
Evaporative Emission System Leak Detected (small leak)
Evaporative Emission System Leak Detected (large leak)
Evaporative Emission System Leak Detected (very small leak)
Description
During an Evaporative Emission System Leak Detection check, the vacuum in the system is monitored by ECU
using the fuel tank pressure sensor. At the appropriate time, the test starts with the ECU closing the canister
closure value and opening the purge solenoid with the appropriate duty cycle. This allows the engine to draw
a vacuum on the entire evaporative emission system. After a calibrated vacuum level is achieved the purge
solenoid is closed, sealing the system. A leak is detected by monitoring any decrease in vacuum level over a
calibrated period of time.
Sensor / component connections
Vapour Pressure sensor
Connector Pins Description
1 Ground
2 Signal
3 5V V. Ref.
ECU Pin
78 (L4)
75(C1)
55(M4)
ECU Connector
28 Way (Left)
28 Way (Left)
28 Way (Left)
Purge Canister Closure Valve
Connector Pins Description
A Battery Voltage
B ECU ground
ECU Pin
-
9 (H2)
ECU Connector
52 Way (Left)
'06 M.Y. in brackets
Purge Solenoid
Connector Pins
A
B
ECU Pin
-
38 (F4)
ECU Connector
52 Way (Right)
'06 M.Y. in brackets
Description
Battery Voltage
ECU ground
'06 M.Y. in brackets
Enable Criteria:
• Altitude < 8000 ft (2438 m), Baro > 700 mbar
• Coolant > 45°C (113°F)
• Air temp < 80°C (176°F)
• Fuel level between 8 – 35 litres (2.1 – 9.24 US gallons)
• Vehicle must be stationary
• Closed loop fuelling control enabled
• Closed loop idle speed control enabled
• Ignition on
Disable Criteria:
P0171, P0172 P0441, P0444, P0445 P0446, P0447, P0448 P0451, P0452, P0453 P0461, P0462, P0463
P0500 – Fuel trim too rich or lean soft code
– Purge faults
– Canister closure faults
– Tank Pressure sensor faults
– Fuel level sensor faults
– Vehicle speed faults
Malfunction Criteria
P0441
This code can be caused by the purge value being either stuck closed or open.
Page 29
Lotus Service Notes
Section EMP
Purge valve stuck open
A purge valve that is unable to seal correctly will result in a tank evacuation during the sealing phase of the
leak check sequence. In this phase, a pressure rise would normally be expected but when the purge valve
is not sealing this causes depression in the tank. When the pressure is below -1.7mbar a purge valve fault is
detected.
Purge valve stuck closed
A purge valve that is unable to open will not be able to achieve the required depression during the evacuation
phase. A positive pressure rise during the leak check evacuation phase will be detected. Additional purge checks
will set a purge valve fault code.
Monitor: Until leak check is completed
P0442
This code is set during the evaporative leak check process if the system calculates the measure of leak is above
a specified value (determined by a table related to fuel level) after the 6.3 second timer has expired.
Monitor: Until leak check is completed
Potential failure modes:
• Leak from pipes or connections
• Leaking or damaged seal on filler cap / not fitted correctly
• Canister Closure valve not fully closing
P0455
This code is set if during the evaporative leak check the system fails to reach the evacuation target pressure.
The system will perform additional purge checks to determine the nature of the problem. The additional purge
checks will also run if the leak check fails to complete because the calculated vapour concentration is above
the limit.
Additional Purge Check Enable Criteria:
• Vehicle not stationary
• Load between 30 – 35%
• Purge value >= 75%
Monitor: Until leak check is completed
Potential failure modes
• Fuel filler cap not fitted
• Leak from pipes or connections
• Canister Closure valve stuck open
P0456
This code is set during the evaporative leak check process if the system calculates the measure of leak is above
a specified value (determined by a table related to fuel level) after the 19.7 second timer has expired.
Monitor: Until leak check is completed
Potential failure modes:
• Leak from pipes or connections
• Leaking or damaged seal on filler cap / not fitted correctly
• Canister Closure valve not fully closing
Notes:
• The MIL will be illuminated if the fault is present for 2 consecutive trips.
• Further information on the sensor may be found in Toyota 1ZZ-FE, 2ZZ-GE manual RM733E (B120T0327J)
page FI-53
Page 30
Lotus Service Notes
Evaporative Emission Control – Purge, Open / Closed Circuit
P0444
P0445
P0446
P0447
P0448
P0451
P0452
P0453
Section EMP
P0444
P0445
P0446
P0447
P0448
P0451
P0452
P0453
Evaporative Emission System Purge Control Valve Circuit Open
Evaporative Emission System Purge Control Valve Circuit Closed
Evaporative Emission System Vent Control Circuit
Evaporative Emission System Vent Control Circuit Open
Evaporative Emission System Vent Control Circuit Closed
Evaporative Emission System Pressure Sensor/Switch Range/Performance
Evaporative Emission System Pressure Sensor/Switch Low
Evaporative Emission System Pressure Sensor/Switch High
Description
When the engine is running the ECU continuously monitors the feedback signals from the evaporative emission
components. The feedback signal should be low when the turned ON and high when turned Off. The following
codes will be set if the above conditions are not met.
P0444, P0445, P0447, P0448, P0452, P0453
P0446
This code can be caused by the canister closure valve (CCV) being either stuck closed or open.
CCV stuck open:
A CCV is stuck open then there will be minimal tank depression when the leak test is performed. Addition check
will be performed when the vehicle is being driven before the code is set.
CCV stuck closed:
Detection of a stuck closed CCV is implemented by detecting an excessively low tank pressure during normal
purge. Detection of this fault will disable further purging
Additional checks for stuck CCV closed:
• Vehicle not stationary
• Load between 30 – 35%
• Purge Value >= 75%
Monitor: Until leak check is completed.
P0451
This code is set when the ECU detects abnormalities in the fuel tank vapour pressure sensor signal. The ECU
analyses the filtered and unfiltered pressure signal at idle after a de-slosh period to determine if there is any
difference, a big difference indicates as fault. The ECU also monitors the signal on gear changes to see if there
is any pressure rise as a result of the fuel sloshing around.
Disable Criteria:
P0500 – Wheel speed sensor fault
Monitor: Until leak check is completed
Notes:
The MIL will be illuminated if the fault is present for 2 consecutive trips.
Page 31
Lotus Service Notes
Fuel Level Sensor
P0461
P0462
P0463
Section EMP
P0461
P0462
P0463
Fuel Level Sensor “A” Circuit Range/Performance
Fuel Level Sensor “A” Circuit Low
Fuel Level Sensor “A” Circuit High
Description
When the engine is running the ECU continuously monitors the fuel level sensor feedback signals. The feedback
signal should be low when turned ON and high when turned OFF. The following codes will be set if the above
conditions are not meet.
Sensor connections
Sensor Connector Description
1 Vapour pressure and fuel level ground
2 Fuel level sensor
3 Vapour pressure & fuel level V ref. '06 M.Y. in brackets
ECU Pin ECU Connector
78 (L4) 28 Way (Left)
76(E3) 28 Way (Left)
55(M4) 28 Way (Left)
Enable Criteria:
• P0462 & P0463 – Condition not met as above
• P0461 – Checks for three conditions, stuck when full, stuck when empty or stuck midway. The ECU determines
if the sensor is stuck by calculating the amount of fuel used during the test period with the engine conditions
as listed below.
• RPM > 2800rpm
• Load > 40%
• Minimum Fuel level > 2 litres (0.5 US gallons)
• If the ECU calculates that no fuel has been used during these tests it indicates that the sensor is not working correctly. The ECU also monitors the filtered and unfiltered signal at idle after a 10 second de-slosh period
and compares the differences. Gear changes cause the fuel to slosh around so the ECU monitors the signal
to see if there is any pressure rise.
Disable Criteria:
P0500 – Wheel speed sensor fault
Notes:
The MIL will be illuminated if the fault is present for 2 consecutive trips.
Page 32
Lotus Service Notes
Engine Cooling Fan Control
P0480
P0481
Section EMP
P0480
P0481
Fan 1 Control Circuit
Fan 2 Control Circuit
Component connections
Sensor Connector Description
2 (ACCM 2*) Relay #1 3 (ACCM 2*) Relay #2 ECU Pin
67 (J2) 60(J3) ECU Connector
28 Way (Left) 28 Way (Left)
'06 M.Y. in brackets
*ACCM – A/C Control Module
Monitor: Continuous
Enable Criteria: Engine running
Disable Criteria: None
Potential failure modes:
• A/C Control Module failure
• ECU output circuit failure
Notes:
No MIL will be illuminated for this failure.
Page 33
Lotus Service Notes
Vehicle Speed Sensor
P0500
Section EMP
P0500
Vehicle Speed Sensor “A”
Description
The ECU uses the left rear wheel speed sensor to determine vehicle speed. This output to the ECU is via the
ABS module.
Sensor connections
ABS Control Unit Description
3 Wheel Speed 3 from ABS (LR)
ECU Pin
77(B4)
ECU Connector
28 Way (Left) '06 M.Y. in brackets
Sensor characteristics
Hall Effect sensor
Malfunction Criteria
• TPS < 0.8
• Engine speed > 1800rpm and < 5010rpm
• Baro > 756 mbar
Monitor: Continuous
Potential failure modes:
• Open or short in vehicle speed sensor circuit
• Build up of debris in the sensing plate on the wheel hub
Notes:
The MIL will be illuminated if the fault is present for 2 consecutive trips.
Page 34
Lotus Service Notes
Idle Speed Control
P0506
P0507
P0508
P0509
Section EMP
P0506
P0507
P0508
P0509
Idle Air Control System RPM Lower Than Expected
Idle Air Control System RPM Higher Than Expected
Idle Air Control System Circuit Low (prior '06 M.Y.)
Idle Air Control System Circuit High (prior '06 M.Y.)
Description
Prior to '06 M.Y. the ECU controls the air entering the engine with an idle air control (IAC) valve. To increase the
idle the ECU commands the IAC to open up. This allows more air to bypass the throttle blades. To decrease
the idle speed the ECU commands the IAC to close up. This will reduce the amount of air bypassing the throttle
body. The ECU performs low and high circuit checks when it is activating the component.
For '06 M.Y. onwards, the electronically controlled throttle needs no IAC, as the ECU commands the throttle
valve itself to control idle speed.
Component connections (prior to '06 M.Y.)
Connector Description ECU Pin
1 Idle air control value 35
2 Battery Voltage -
3 Ground -
ECU Connector
52 Way
-
Malfunction Criteria
P0506 – This code is set if the engine fails to achieve the desired idle speed by more than 100 rpm.
P0507 – This code is set if the engine fails to achieve the desired idle speed by more than 200 rpm.
P0508 – This is set when the ECU does not get the expected feedback (prior to '06 M.Y.).
P0509 – This is set when the ECU does not get the expected feedback (prior to '06 M.Y.).
Enable Criteria:
• Engine at idle speed
• Battery Voltage between 10 – 16 V
• Idle speed learn limit ± 15%
• Timer expired 5 seconds
Monitor: Continuous
Potential failure modes:
• Throttle body sticking (not fully closing) (prior to '06 M.Y.)
• Connector / wiring corroded or loose connections (prior to '06 M.Y.)
• Throttle linkage / cable binding (prior to '06 M.Y.)
• Induction system air leak
• Excessive engine load from front end accessory drive system, e.g. water pump seizing
Notes:
The MIL will be illuminated if the fault is present for 2 consecutive trips.
Page 35
Lotus Service Notes
Battery Voltage
P0562
P0563
P0562
P0563
System Voltage Low
System Voltage High
Monitor: Continuous
Enable Criteria:
• Engine running
• P0562 – Voltage Too Low < 10V
• P0563 – Voltage Too High > 16V
Disable Criteria: None
Potential failure modes:
• Alternator fault
• Battery fault
Notes:
The MIL will be illuminated if the fault is present for 2 consecutive trips.
Page 36
Section EMP
Lotus Service Notes
ECU Integrity
P0601
P0606
Section EMP
P0601
P0606
Checksum
Watchdog
Description
These codes are used by the ECU to check the integrity of the software and calibration data. P0601 checks
that on power up the checksum for calibration data is the same as checksum saved on power down. P0606
checks the watchdog timer after a defined period to see if it has reset. If the watchdog timer has not reset then
the code has entered an unplanned loop or condition stopping it resetting the timer.
Monitor
• P0601 at ECU power up
• P0606 continuously while the engine running
Notes:
The MIL will be illuminated if the fault is present for 2 consecutive trips.
Page 37
Lotus Service Notes
Fuel Pump
P0627
Section EMP
P0627
Fuel Pump Control Circuit /Open
Description
The fuel system is of the non-return type. The pump is incorporated into the fuel tank module which also contains the level sensor, regulator and vapour pressure sensor.
Component connections
Connector Description
4 (RMC 1 – MFRU*) Inertia Switch (Pin 1) 2 (RMC 2 – MFRU*) Fuel Pump Relay *MFRU – Multi Function Relay Unit
Monitor: Continuous
Enable Criteria: Ignition on
Disable Criteria: None
Potential failure modes:
• Pump open circuit or short to ground
• Multi Function Relay Unit failure
• Pump failure
• ECU output circuit failure
Notes:
No MIL will be illuminated for this failure.
Page 38
ECU Pin
- 68 (J4) ECU Connector
28 Way (Left) '06 M.Y. in brackets
Lotus Service Notes
Air Conditioning System
P0646
P0647
Section EMP
P0646
P0647
A/C Clutch Relay Control Circuit Low
A/C Clutch Relay Control Circuit High
Component connections
Connector Description
5 (ACCM 2*) AC Clutch Relay ECU Pin
53(J1) ECU Connector
28 Way (Left) '06 M.Y. in brackets
*ACCM – A/C Control Module
Monitor: Continuous
Enable Criteria: Engine running
Disable Criteria: None
Potential failure modes:
• A/C compressor clutch open circuit or short to ground
• A/C Control Module failure
• A/C compressor clutch failure
• ECU output circuit failure
Notes:
No MIL will be illuminated for this failure.
Page 39
Lotus Service Notes
Misfire
P1301
P1302
Section EMP
P1301
P1302
Misfire level causing emissions increase
Misfire level causing catalyst system damage
Description
When the engine misfire reaches a high enough percentage the engine emission output levels can exceed the
allowed limits, this will produce the fault code P1301. If the misfire percentage is high enough and there is a
possibility that the catalyst may be damaged then code P1302 will be set.
See misfire faults P0300, P0301, P0302, P0303, P0304
Notes:
• The MIL will flash for a 1302 fault code
• The MIL will be illuminated if the 1301 fault is present for 2 consecutive trips.
Page 40
Lotus Service Notes
Coolant Recirculation Pump
P2602
P2603
Section EMP
P2602
P2603
Coolant Pump Control Circuit Low
Coolant Pump Control Circuit High
Description
During a hot shutdown of the engine, the recirculation pump can continue to pump coolant around the engine.
The recirculation pump will run after the engine has been turned off if the enable criteria are matched.
Component connections
Connector Description
2 (RMC 1 – MFRU*) Fuse box 5 (RMC 2 – MFRU*) Recirc Pump Relay
ECU Pin
- 69(K1) ECU Connector
28 Way (Left) '06 M.Y. in brackets
*MFRU – Multi Function Relay Unit
Monitor: Continuous
Enable Criteria:
P2602 - engine not running
P2603 - engine running
Disable Criteria: None
Potential failure modes:
• Pump open circuit or short to ground
• Multi Function Relay Unit failure
• Pump failure
• ECU output circuit failure
Notes:
No MIL will be illuminated for this failure.
Page 41
Lotus Service Notes
Camshaft Lift Control (VVL)
P2646
P2647
P2648
P2649
Section EMP
P2646
P2647
P2648
P2649
A Rocker Arm Actuator System Performance or Stuck Off
A Rocker Arm Actuator System Stuck On
A Rocker Arm Actuator Control Circuit Low
A Rocker Arm Actuator Control Circuit High
Description
Intake and exhaust camshaft lift can be changed by means of the Variable Valve Lift (VVL) system, which varies
the amount of maximum lift of the intake and exhaust valves. The mechanism uses dual element rocker arms to
provide cam changeover, with both the intake and exhaust camshafts having high and low speed cam profiles.
The system is ECU controlled, using an oil control solenoid which, when activated, uses hydraulic pressure to
push a rocker arm locking pin into engagement to activate the high-speed cam profile. A signal from the VVL
oil pressure switch provides feedback to the ECU that VVL activation has taken place. VVL activation* to the
high lift camshaft profile occurs at 6200rpm when engine speed is increasing, and returns to the low lift camshaft
profile at 6000rpm when the engine speed is decreasing.
*Coolant temperature must be >60°C (140°F).
Component connections
Connector Description ECU Pin ECU Connector
1 Battery Voltage - 2 VVL Oil Control Valve 12(H3) 52 Way (Right)
- VVL Oil Pressure Switch 21 (B2) 52 Way (Right)
Monitor: Continuous
Enable Criteria: Engine running
Disable Criteria: None
Potential failure modes:
• VVL valve stuck open / closed
• VVL valve open circuit
• VVL valve short to ground
• Rocker arm failure
• Rocker shaft location pin failure
• ECU output circuit failure
Notes:
The MIL will be illuminated if the fault is present for 2 consecutive trips.
Page 42
'06 M.Y. in brackets
Lotus Service Notes
Section EMP
EMP.2 - Diagnostic scanner tools
In order to provide for communication with the engine management system electronic control module, a
hand held electronic scanner ‘Lotus Scan’ (part number T000T1418F), may be plugged into a special 16 terminal
harness connector socket, known as a Data Link Connector (DLC), located at the front of the passenger footwell.
Note that this tool may also be used on previous Elise models (excluding Exige, 340R and 160 models).
-
-
-
-
-
-
Amongst the operations available using the ‘Lotus Scan’ tool are:
Reading of Trouble Codes
Clearing of Trouble Codes
Reading live data
Test operation of individual solenoids
Running engine history report
Reprogramming ECU
Operating instructions are provided with the tool.
Important Note
The power supply transformer is used for overnight charging of the printer, and also for powering the
Scan tool during software downloading from a PC (personal computer). For the software download operation,
the Scan tool requires a power supply from the mains via the transformer and an inverter. Two types of inverter
have been used; early kits used an adaptor lead to plug into the bottom end of the Scanner tool. Later kits use
an adaptor plug fitting into the top end of the scanner.
When charging the printer, it is most important that the inverter is NOT used, or damage to the transformer may be caused. Incorrect connection is possible only with the early type adaptor lead, with which extra
care should be exercised.
1. Reading data from vehicle
Data Link Connector (DLC) Scan tool
(front of passenger footwell)
Printer
Page 43
em192a
Lotus Service Notes
Section EMP
2. Downloading software from P.C.
With early type adaptor lead
Connect to COM port on PC Adaptor lead used
to connect to
transformer
Power
supply
transformer
em192c
With later type adaptor
Connect to COM port on PC Power supply adaptor
T000T1436F
Power
supply
transformer
em192f
3. Charging printer
Power supply
transformer
Do NOT use adaptor
lead for this application
Printer
Page 44
em192b
Lotus Service Notes
Section EMP
Lotus TechCentre - 2008 model year
All USA market cars from ’08 model year onwards, are required by legislation to use a CAN compliant
on-board diagnostic system. This has been commonised for all Elise/Exige models. The Lotus Scan 3 tool is
replaced by a ‘stand alone’ lap top PC loaded with ‘Lotus TechCentre’ software to allow the CAN based serial
data to be read.
Controller Area Network (CAN) is an electronic standard to allow high speed communication between
modules and controllers, via a serial data bus. The bus is a circuit linking the modules to the controller, consisting of a pair of cables, twisted together to reduce electromagnetic interference, and carrying a square wave
voltage signal corresponding to ‘0’s and ‘1’s, coded in such a way as to identify and prioritise the individual
messages. On the Elise/Exige, CAN based systems for 2008 onwards include; engine management, anti-lock
braking and related features, tyre pressure monitoring and onboard diagnostics.
A Vehicle Communication Device (T000T1472F) introduced for the Europa model is used to connect the
vehicle to the laptop Lotus TechCentre. All system interrogation and diagnosis are carried out via the Lotus
TechCentre.
The minimum specification of the laptop computer for installation of the Lotus TechCentre is as follows:
-
-
-
-
-
-
-
Processer 1.70 Ghz;
1 GB RAM;
40 GB HDD;
CDRW DVD ROM;
WIN XP PRO or VISTA;
USB interface;
Ethernet or Wireless LAN
Note that this laptop should be dedicated soley to the Lotus TechCentre, with no other software installed.
This diagnostic software is designed primarily for use by trained Lotus technicians, and is available as a CD
under part number T000T1510F (version 4) or later supercessions. A monthly (Lotus Dealers) or annual (nonLotus dealers) licence and support fee will also be levied, providing access to Lotus TechCentre Technical
Support phoneline on 0870 9493 668, and e-mail on [email protected]
Also required is a unique 18 character licence/registration key without which Techcentre will not function.
This key is non transferable to other PC’s.
Scope of Lotus TechCentre
Model
Elise
Exige
Europa
2-11
Evora
Esprit
2004 on
2004 on
2006 on
2007 on
2009 on
V8
Type of Electronic Control Unit
Communication compatible
EMS
ABS
SRS
TPMS
Y
Y
Y
Y
Y
Y
Y
Y
N
Y
Y
N/A
Y
Y
N/A
N/A
Y
Y
Y
Y
Y
Y
N
N
IP
N
N
N
N
Y
N
Engine ECU
Reprogrammable
08 MY on
Y
Y
N
Y
Y
N
Note that TechCentre has no connectivity to Rover powertrain Elise/Exige variants, and that only limited
diagnostics are available for the V8 Esprit. No communication is available with the Europa powertrain. Diagnostics for these vehicles are accessible using the Lotus Scan 3 tool T000T1467F (U.K./EU).
Page 45
Page 46
Lotus Service Notes
Section EMP
Lotus Service Notes
Section EMP
EMP.3 - ENGINE MANAGEMENT COMPONENT LOCATION
1
2
4
3
5
6
17
16
8
15
9
14
13
12
11
10
Key to engine management component location drawing
1. Electronic Control Unit (ECU).
2. Multi-function relay unit.
3. Oil control valve for variable valve lift.
4. Camshaft position sensor.
5. Fuel injector.
6. Knock sensor.
7. Oil control valve for variable valve timing.
8. Crankshaft position sensor.
9. Plug top coil.
10. Coolant temperature sensor.
11. Pre-catalyst oxygen sensor.
12. Post-catalyst oxygen sensor.
13. Oil pressure switch.
14. Throttle position sensor.
15. Vacuum solenoid for intake flap valve.
16. Mass airflow sensor.
17. Idle Air Control (IAC) valve - prior '06 M.Y.
For component replacement procedures, refer to manual B120T0327J.
Page 47
7
Lotus Service Notes
Section EMP
EMP.4 - MECHANICAL THROTTLE SETTING PROCEDURE (Prior '06 M.Y.)
To avoid throttle cable strain, and ensure correct idle control and pedal operation, the following adjustments
must be maintained. If the pedal downstop is incorrectly set, overloading of the throttle body cable quadrant
can occur, resulting in quadrant distortion, closed throttle position error and engine stalling:
1.
Check the throttle body cable quadrant for distortion and mis-alignment. If necessary, repair or replace
the quadrant.
2.
Check that there is 2 - 3 mm free play at the throttle pedal, adjusting at the throttle body cable abutment
bracket if necessary.
3.
If an idle control problem has been reported, reset the closed throttle stop screw on the throttle body:
With ignition off, use a hexagonal key in the bottom end of the throttle stop screw to allow the throttle butterfly valve to fully close, and introduce clearance between the screw and quadrant stop bracket. Screw
upwards until contact is just made, and then a further ½ turn upwards. Secure with the locknut. Recheck
cable adjustment as above.
4.
Adjust the throttle pedal downstop such that vigorous full depression of the pedal achieves full opening of
the throttle butterfly without allowing the cable or mechanism to be strained.
5.
If the throttle stop screw was adjusted, allow the engine to idle for 15 minutes to relearn settings.
6.
An alternative pedal position which may be preferred for 'heel and toeing', may be achieved by replacing
the rubber upstop buffer with an M5x15 hex. head setscrew, with three flat washers beneath the head for
a total thickness of around 7mm. The cable must then be re-adjusted at the engine abutment as above.
The foopad downstop bolt should then be replaced by an M8x20 setscrew and reset as above.
Throttle cable
Closed throttle
stop bracket
Cable quadrant
Throttle stop screw
Page 48
sb77
Lotus Service Notes
Section EMP
emp.5 - 2006 model year electronic throttle control (ETC)
For '06 model year, the 2ZZ-GE engine is equipped with an electronic 'drive by wire' throttle in order to
meet Low Emissions Vehicle 2 emissions standards as dictated by California Air Resources Board. This is
achieved by allowing fuel pre-scheduling and consistency of load demand.
The mechanical throttle control cable is replaced by a pedal actuated potentiometer unit which feeds
pedal movement and position information to the engine management ECU. The ECU compares this demand
information with existing engine throttle position data, and outputs a suitable command signal to the DC stepper motor which operates the throttle valve. For optimum safety, two output curves are produced by the pedal
unit and are fed into two processors contained within the ECU. Similarly, two streams of engine throttle valve
positional information are fed back into these processors, which are then compared by the ECU software. Any
discrepancies are analysed and appropriate safety oriented commands outputed to the throttle valve which may
be limited to a maximum 15% opening, or to a 7% mechanically sprung setting for 'limp home', or in extreme
cases, the injectors may be shut off.
Note that no IAC valve is required, as the idle air control function is incorporated into the electronic throttle system.
ECU Communication
2006 model year cars with ETC have the VIN included in the ECU memory, without which the MIL will
be illuminated, and a fault code stored. The Lotus Scan tool requires an updated operating programme which
includes VIN download facility and is available on CD under part number T000T1466/2. This programme must
be downloaded on to a PC before being transferred to the Scan tool. The ECU progamme is also specific to
ETC, with an i.d. of A120E0030H (non USA) or A121E0010H (USA) .
Page 49
Lotus Service Notes
Section EMP
EMP.6 - DIAGNOSTIC CODE SUPPLEMENT - '06 M.Y.
New fault codes for '06 M.Y. cars with electronic throttle control are as follows:
DTC
Fault Description
P0016 Crankshaft Position – Camshaft Position Correlation Error
(P0121/P0122/P0123 Throttle Position Sensor 'A' - see page 12)
P0222 Throttle Position Sensor 'B' Circuit Low
P0223 Throttle Position Sensor 'B' Circuit High
P0630 VIN Not Programmed or Incompatible – ECU
P0638 Throttle Actuator Control Range/Performance
P2100 Throttle Actuator Control Motor Circuit/Open
P2102 Throttle Actuator Control Motor Circuit/Low
P2103 Throttle Actuator Control Motor Circuit/High
P2104 Throttle Actuator Control System – Forced Idle
P2105 Throttle Actuator Control System – Forced Engine Shutdown
P2106 Throttle Actuator Control System – Forced Limited Power
P2107 Throttle Actuator Control Module Processor
P2108 Throttle Actuator Control Module Performance
P2122 Pedal Position Sensor 'D' Circuit Low
P2123 Pedal Position Sensor 'D' Circuit High
P2127 Pedal Position Sensor 'E' Circuit Low
P2128 Pedal Position Sensor 'E' Circuit High
P2135 Throttle Position Sensor 'A'/'B' Voltage Correlation
P2138 Pedal Position Sensor 'D'/'E' Voltage Correlation P2173 Throttle Actuator Control System – High Airflow Detected
Page 50
Page
49
49
49
50
50
51
51
51
51
52
52
52
53
53
53
54
54
54
55
55
Lotus Service Notes
Crankshaft Position–Camshaft Position Correlation Error
Section EMP
P0016
Description
The crankshaft position sensor is used to identify engine position and speed via a pole wheel mounted on the
front end of the crankshaft. The camshaft position sensor is used to determine camshaft position from a three
vane reluctor on the rear end of the inlet camshaft. The Variable Valve Timing system (VVT) on the inlet camshaft can vary the timing by up to 25°, with fault codes P0011 and P0012 allocated to errors with the variable
timing. Fault code P0016 indicates a mechanical timing error such as incorrectly set, or 'jumped' cam timing.
Enable Criteria:
# Engine running (for up to 4 seconds)
Disable Criteria: None
Potential failure modes:
# Crankshaft/Camshaft alignment
Throttle Position Sensor 'B' Circuit Low
P0222
Description
Two potentiometers are built into the throttle valve actuator unit in order to provide a throttle position signal to
the ECU. Note that the sensors operate on 5 volts.
Enable Criteria: None
Disable Criteria: None
Potential failure modes:
# Signal short circuit (< 0.283 V)
# Reference voltage open circuit
# Reference voltage short to ground
# Sensor failure
Notes: A maximum throttle opening of 15% may be imposed due to this single code. In the case of multiple
codes, a mechanically sprung 7% opening may be applied.
Throttle Position Sensor 'B' Circuit High
P0223
Enable Criteria: None
Disable Criteria: None
Potential failure modes:
# Signal open circuit (> 4.487 V)
# Reference voltage open circuit
# Reference voltage short to ground
# Sensor failure
Notes: A maximum throttle opening of 15% may be imposed due to this single code. In the case of multiple
codes, a mechanically sprung 7% opening may be applied.
Page 51
Lotus Service Notes
VIN Not Programmed or Incompatible – ECU/PCM Section EMP
P0630
Description
The ECM programming includes the Vehicle Identification Number (VIN). This operation is performed using
the Lotus Scan tool.
Enable Criteria:
# Engine running (for up to 4 seconds)
Disable Criteria: None
Potential failure modes:
# VIN not programmed
# Incompatible VIN programmed
Throttle Actuator Control Range/Performance
P0638
Description
The single throttle butterfly valve, mounted at the inlet to the intake plenum, is operated by a stepper motor
under the command of the engine ECU. The valve moves through a range of nearly 90° and should display
100% at full throttle and around 2% at idle.
Monitor: Continuous
Enable Criteria:
# Engine running
Disable Criteria:
# Electronic throttle fault(s) present
Potential failure modes:
# Blocked throttle body
# Damage to throttle actuator
Notes: A mechanically sprung 7% throttle opening may be imposed.
Page 52
Lotus Service Notes
Throttle Actuator Control Motor Circuit/Open
Section EMP
P2100
Description
The throttle actuator stepper motor operates on 12 volts.
Monitor: Continuous
Enable Criteria: None
Disable Criteria: None
Potential failure modes:
#Throttle actuator control motor open circuit
Throttle Actuator Control Motor Circuit/Low
P2102
Monitor: Continuous
Enable Criteria: None
Disable Criteria: None
Potential failure modes:
# Throttle actuator control motor short to ground
Throttle Actuator Control Motor Circuit/High
P2103
Monitor: Continuous
Enable Criteria: None
Disable Criteria: None
Potential failure modes:
# Throttle actuator control motor short to supply voltage
Throttle Actuator Control System – Forced Idle
P2104
Description
If a problem is detected which could result in faster engine speed than commanded by the pedal, the actuator
is switched out, allowing the throttle valve to default to a 6% mechanically sprung setting. This provides a fast
idle speed which may be used to effect a 'limp home' mechanism.
Monitor: Continuous
Enable Criteria: Engine running
Disable Criteria: None
Potential failure modes:
# Electronic throttle fault
Note: This code indicates action taken by the ECU, and will always be accompanied by another code which
has caused this action.
Page 53
Lotus Service Notes
Throttle Actuator Control System – Forced Engine Shutdown
Section EMP
P2105
Description
If a problem is detected which could result in engine speed runaway, or if sufficient control of engine speed is
lost, the ECU switches off the fuel injectors in order to stop the engine.
Monitor: Continuous
Enable Criteria: Engine running
Disable Criteria: None
Potential failure modes:
# Electronic throttle fault
Note: This code indicates action taken by the ECU, and will always be accompanied by another code which
has caused this action.
Throttle Actuator Control System – Forced Limited Power
P2106
Description
If a problem is detected which could result in engine speed control difficulties, the ECU will limit throttle opening
to a maximum of 15%.
Monitor: Continuous
Enable Criteria: Engine running
Disable Criteria: None
Potential failure modes:
# Electronic throttle fault
Note: This code indicates action taken by the ECU, and will always be accompanied by another code which
has caused this action.
Throttle Actuator Control Module Processor P2107
Description
The ECU contains two processors dedicated to the throttle pedal and throttle valve potentiometers.
Monitor: Continuous
Enable Criteria: Engine running
Disable Criteria: None
Potential failure modes:
# ECU internal fault
# Incorrect ECU programming
Page 54
Lotus Service Notes
Throttle Actuator Control Module Performance
Section EMP
P2108
Monitor: Continuous
Enable Criteria: Engine running
Disable Criteria: None
Potential failure modes:
# ECU internal failure
# Short circuit to throttle actuator
Pedal Position Sensor 'D' Circuit Low
P2122
Description
Two potentiometers are built into the throttle pedal unit in order to provide a throttle demand signal to the ECU.
Note that the potentiometers operate on 5 volts.
Enable Criteria: None
Disable Criteria: None
Potential failure modes:
# Signal short circuit (< 0.283 V)
# Reference voltage open circuit
# Reference voltage short to ground
# Sensor failure
Notes: A maximum throttle opening of 15% may be imposed due to this single code. In the case of multiple
codes, a mechanically sprung 7% opening may be applied.
Pedal Position Sensor 'D' Circuit High P2123
Enable Criteria: None
Disable Criteria: None
Potential failure modes:
# Signal open circuit (> 4.487 V)
# Reference voltage open circuit
# Reference voltage short to ground
# Sensor failure
Notes: A maximum throttle opening of 15% may be imposed due to this single code. In the case of multiple
codes, a mechanically sprung 7% opening may be applied.
Page 55
Lotus Service Notes
Pedal Position Sensor 'E' Circuit Low
Section EMP
P2127
Description
Two potentiometers are built into the throttle pedal unit in order to provide a throttle demand signal to the ECU.
Note that the potentiometers operate on 5 volts.
Enable Criteria: None
Disable Criteria: None
Potential failure modes:
# Signal short circuit (< 0.283 V)
# Reference voltage open circuit
# Reference voltage short to ground
# Sensor failure
Notes: A maximum throttle opening of 15% may be imposed due to this single code. In the case of multiple
codes, a mechanically sprung 7% opening may be applied.
Pedal Position Sensor 'E' Circuit High
P2128
Enable Criteria: None
Disable Criteria: None
Potential failure modes:
# Signal open circuit (> 4.487 V)
# Reference voltage open circuit
# Reference voltage short to ground
# Sensor failure
Notes: A maximum throttle opening of 15% may be imposed due to this single code. In the case of multiple
codes, a mechanically sprung 7% opening may be applied.
Throttle Position Sensor 'A'/'B' Voltage Correlation
P2135
Description
Two potentiometers are built into the throttle actuator unit in order to provide a throttle position signal to the
ECU. Two processors within the ECU compare the two output signals, which should match within a defined
tolerance. Note that the potentiometers operate on 5 volts.
Enable Criteria: None
Disable Criteria: Throttle position greater than 60%
Potential failure modes:
# TPS1 reading incorrectly
# TPS2 reading incorrectly
Notes: A maximum throttle opening of 15% may be imposed.
Page 56
Lotus Service Notes
Pedal Position Sensor/Switch 'D'/'E' Voltage Correlation Section EMP
P2138
Description
Two potentiometers are built into the throttle pedal unit in order to provide a throttle demand signal to the ECU.
Two processors within the ECU compare the two output signals, which should match within a defined tolerance.
Note that the potentiometers operate on 5 volts.
Enable Criteria: None
Disable Criteria: None
Potential failure modes:
# PPS1 reading incorrectly
# PPS2 reading incorrectly
Notes: A maximum throttle opening of 15% may be imposed.
Throttle Actuator Control System – High Airflow Detected
P2173
Description
The mass air flow is compared with the throttle position to determine whether an incorrect correlation exists.
Enable Criteria: None
Disable Criteria: MAF fault(s) present
Potential failure modes:
# Throttle plate damage
# Air leak in intake system
Notes: A mechanically sprung 7% throttle opening may be imposed, or the injectors may be shut off to stop
the engine.
Page 57
Lotus Service Notes
Section EMP
EMP.7 - DIAGNOSTIC CODE SUPPLEMENT - 2011 M.Y. ELISE (Euro 5)
DTC
Fault Description
Page
P0011A Camshaft Position - Timing Over-Advanced or System Performance P0012 A Camshaft Position - Timing Over-Retarded P0014 B Camshaft Position - Timing Over-Advanced or System Performance
P0015 B Camshaft Position - Timing Over-Retarded
P0016 Crankshaft Position - Camshaft Position Correlation - Bank1 Sensor A
P0017 Crankshaft Position - Camshaft Position Correlation - Bank1 Sensor B
P0076 Intake Valve Control Solenoid Circuit Low P0077 Intake Valve Control Solenoid Circuit High P0079 Exhaust Valve Control Solenoid Circuit Low P0080 Exhaust Valve Control Solenoid Circuit High
P0101 Mass or Volume Air Flow Circuit Range/Performance P0102 Mass or Volume Air Flow Circuit Low Input
P0103 Mass or Volume Air Flow Circuit High Input
P0107 Manifold Absolute Pressure/Barometric Pressure Circuit Low Input
P0108 Manifold Absolute Pressure/Barometric Pressure Circuit High Input
P0112 Intake Air Temperature Sensor 1 Circuit Low P0113 Intake Air Temperature Sensor 1 Circuit High P0116 Engine Coolant Temperature Circuit Range/Performance P0117 Engine Coolant Temperature Circuit Low P0118 Engine Coolant Temperature Circuit High P0122 Throttle Position Sensor 'A' Circuit Low P0123 Throttle Position Sensor 'A' Circuit High P0131 O2 Sensor Circuit Low Voltage (Pre Catalyst) P0132 O2 Sensor Circuit High Voltage (Pre Catalyst) P0133 O2 Sensor Circuit Slow Response (Pre Catalyst) P0134 O2 Sensor Circuit No Activity Detected (Pre Catalyst) P0135 O2 Sensor Heater Circuit (Pre Catalyst) P0137 O2 Sensor Circuit Low Voltage (Post Catalyst) P0138 O2 Sensor Circuit High Voltage (Post Catalyst)
P0139 O2 Sensor Circuit Slow Response (Post Catalyst) P0140 O2 Sensor Circuit No Activity Detected (Post Catalyst) P0141 O2 Sensor Heater Circuit (Post Catalyst)
P0171 System Too Lean P0172 System Too Rich P0222 Throttle Position Sensor 'B' Circuit Low
P0223 Throttle Position Sensor 'B' Circuit High
P0261 Cylinder 1 Injector Circuit Low
P0262 Cylinder 1 Injector Circuit High
P0264 Cylinder 2 Injector Circuit Low
P0265 Cylinder 2 Injector Circuit High
P0267 Cylinder 3 Injector Circuit Low
P0268 Cylinder 3 Injector Circuit High
P0270 Cylinder 4 Injector Circuit Low
P0271 Cylinder 4 Injector Circuit High
P0300 Random/Multiple Cylinder Misfire Detected
P0301 Cylinder 1 Misfire Detected
P0302 Cylinder 2 Misfire Detected
P0303 Cylinder 3 Misfire Detected
P0304 Cylinder 4 Misfire Detected
P0327 Knock Sensor 1 Circuit Low P0328 Knock Sensor 1 Circuit High
P0335 Crankshaft Position Sensor “A” Circuit Range/Performance Page 58
Lotus Service Notes
Section EMP
DTC
Fault Description
P0341
P0351
P0352
P0353
P0354
P0366
P0420
P0444
P0445
P0461
P0462
P0463
P0480
P0481
P0500
P0506
P0507
P0537
P0538
P0562
P0563
P0565
P0567
P0568
P0571
P0601
P0606
P0610 P0616
P0617
P0628
P0629 P0630 P0638 P0661
P0662
P0685
P0703
P0806
P0807
P0808
P1045
P1046
P1047
P1049
P1055
P1107
P1108
P1301
P1302
P1645
P2100
P2102
P2103
P2104
Camshaft Position Sensor “A” Circuit Range/Performance
Ignition Coil “A” Primary/Secondary Circuit
Ignition Coil “B” Primary/Secondary Circuit
Ignition Coil “C” Primary/Secondary Circuit
Ignition Coil “D” Primary/Secondary Circuit
Camshaft Position Sensor “B” Circuit Range/Performance
Catalyst System Efficiency Below Threshold
Evaporative Emission System Purge Control Valve Circuit Open
Evaporative Emission System Purge Control Valve Circuit Shorted
Fuel Level Sensor “A” Circuit Range / Performance
Fuel Level Sensor “A” Circuit Low Fuel Level Sensor “A” Circuit High Fan 1 Control Circuit – Non-MIL
Fan 2 Control Circuit – Non-MIL
Vehicle Speed Sensor “A”
Idle Air Control System RPM Lower Than Expected
Idle Air Control System RPM Higher Than Expected
A/C Evaporator Temperature Sensor Circuit Low – Non-MIL
A/C Evaporator Temperature Sensor Circuit High – Non-MIL
System Voltage Low
System Voltage High
Cruise Control On Signal – Non-MIL
Cruise Control Resume Signal – Non-MIL
Cruise Control Set Signal – Non-MIL
Brake Switch “A” Circuit – Non-MIL
Watchdog
Checksum
Variant Code not Programmed
Starter Relay Circuit Low – Non-MIL
Starter Relay Circuit High – Non-MIL
Fuel Pump Control Circuit Low
Fuel Pump Control Circuit High
VIN not Programmed or Incompatible
Throttle Control Error
Intake Manifold Tuning Valve Control Circuit Low
Intake Manifold Tuning Valve Control Circuit High
ECM/PCM Power Relay Control Circuit/Open
Brake Switch “B” Circuit – Non-MIL
Clutch Position Sensor Circuit Range/Performance – Non-MIL
Clutch Position Sensor Circuit Low – Non-MIL
Clutch Position Sensor Circuit High – Non-MIL
Valvematic SDOWN Circuit Malfunction
Valvematic ECU Detected Difference Between Target and Actual Valvematic Angle
Valvematic Driver Learned Value Error / Power Source Circuit Malfunction
Valvematic Driver Internal Circuit Malfunction
ECU Detected Difference Between Target and Actual Valvematic Angle
Manifold Absolute Pressure Circuit Low Input
Manifold Absolute Pressure Circuit High Input
Misfire level causing emissions increase
Misfire level causing catalyst system damage
“A” Rocker Arm Actuator Position Sensor Circuit
Throttle Actuator Control Motor Circuit/Open
Throttle Actuator Control Motor Circuit Low
Throttle Actuator Control Motor Circuit High
Throttle Actuator Control System – Forced Idle
Page 59
Page
Lotus Service Notes
Section EMP
DTC
Fault Description
P2105
P2106
P2107
P2108
P2119
P2122
P2123
P2127
P2128
P2135
P2138
P2173
P2612
P2613
P2646
P2647
P2648
P2649
Throttle Actuator Control System – Forced Engine Shutdown
Throttle Actuator Control System – Forced Limited Power
Throttle Actuator Control Module Processor
Throttle Actuator Control Module Performance
Throttle Actuator Control Throttle Body Range / Performance
Throttle/Pedal Position Sensor/Switch "D" Circuit Low
Throttle/Pedal Position Sensor/Switch "D" Circuit High
Throttle/Pedal Position Sensor/Switch "E" Circuit Low
Throttle/Pedal Position Sensor/Switch "E" Circuit High
Voltage Correlation Error (Sensors “A” & “B”).
Voltage Correlation Error (Sensors “D” & “E”).
Throttle Actuator Control System – High Airflow Detected
A/C Refrigerant Distribution Valve Control Circuit Low – Non-MIL
A/C Refrigerant Distribution Valve Control Circuit High – Non-MIL
“A” Rocker Arm Actuator System Performance or Stuck Off
“A” Rocker Arm Actuator System Stuck On
“A” Rocker Arm Actuator Control Circuit Low
“A” Rocker Arm Actuator Control Circuit High
U0115
Lost communication with ECM/PCM “B” (Valvematic controller)
Page
Note; Fault code P1047
If the power supply to the VALVEMATIC controller is lost during normal vehicle operation, code P1047 will
be stored and a limphome mode initiated. This will result in limited engine torque being available for the remainder
of the ignition cycle. Re-instatement of the power supply will not automatically eradicate the code, and neither
will clearing of the code via Lotus TechCentre be effective until a learing process has been completed.
After rectification of the power supply fault, proceed as follows:
1.
Ignition off and allow ECU to power down (wait for 30 seconds).
2.
Start engine and allow to idle for 30 seconds. Idle speed may increase during this recovery process.
3.
Ignition off for 30 seconds.
4.
Start engine and allow to idle for 30 seconds.
5.
Ignition off for 30 seconds.
6.
Ignition on and use Lotus TechCentre to reset code P1047 (and any other VALVEMATIC related fault
codes).
Process complete.
Page 60
Lotus Service Notes
Section EMP
Page 61
Page 62
Lotus Service Notes
Section EMP
Lotus Service Notes
Section FJ
TRANSMISSION
SECTION FJ
Sub-Section Page
Introduction
FJ.1
2
Gearchange Mechanism
FJ.2
6
Lubrication
FJ.3
13
Driveshafts
FJ.4
14
Transmission Replacement
FJ.5
17
Transmission Overhaul & Special Tools
FJ.6
18
See also Toyota transmission repair manual:
1ZZ / 2ZZ - C64/C56 repair manual E120T0327J
1ZR - EC60 repair manual CD T000T1523F
Page 1
Updated 17th May 2010
Lotus Service Notes
Section FJ
FJ.1 - INTRODUCTION
The Elise S 5-speed transmission, the 2ZZ powered Elise/Exige 6-speed transmission, and the 1ZR
powered Elise 6-speed, are all of similar construction, being 'end on' type, mounted on the left hand end of the
engine unit, and comprising the clutch housing, gearbox, final drive gears, and differential. All units are supplied by Toyota, and are designated correspondingly 'C56', 'C64' and EC60 (C = series; 5 or 6 = no. of gears;
6, 4 or 0 = ratio set). Publication E120T0327J covers the repair of the C56 and C60, with CD T000T1523F
covering the EC60.
Two control cables, running along the centre of the cabin and beneath the power unit, are used to transmit
the movement of the gearchange lever to the transmission selector mechanism.
C56 Five Speed
(reverse idler omitted Clutch housing
for clarity)
Clutch splines
5 4 3 2 R 1
End cover
(casting on
Lotus)
Gearbox casing
LH driveshaft
inboard CV joint
Final drive
output gear
Page 2
Bevel gear
differential
f138
Lotus Service Notes
C64 Six Speed
(reverse idler omitted
for clarity) Input shaft
Output shaft
6
5
4
3
2
R
Section FJ
1
End cover
Centre support
bearing
Clutch/Diff
housing
Gearbox
casing
EC60 Six Speed
Input shaft
Output shaft
6
5
4
3
Reverse idler
2
R
1
f145
Clutch/Diff
housing
Gearbox casing
Page 3
f146
Lotus Service Notes
Section FJ
The two shaft, all indirect gearbox, is housed within a two or three part cast alloy casing, including the dry
chamber clutch housing, and secured by threaded fasteners to the back of the engine block. The clutch friction
plate is splined to the gearbox input shaft from which the power flows to the output shaft mounted below it, and
thence to the final drive and differential into which are fitted the driveshafts.
In the C56 5-speed gearbox, ratios 1 to 4 including reverse, are contained within the main case, with the
5th gearset overhung at the rear within an end cover. The input shaft uses a front roller bearing and a rear
ball bearing, as does the output shaft, albeit with a much larger front roller to accommodate the final drive gear
forces. Needle roller bearings are used for each of the free spinning gears, and a pair of taper roller bearings
support the differential assembly. Sychroniser assemblies for 3rd/4th and 5th speeds are mounted on the input shaft, and that for 1st/2nd on the output shaft, with the latter also providing the reverse gear driven pinion
incorporated on its periphery. A reverse gear idler pinion is mounted on its own stub shaft, and may be slid into
engagement with both a gear integral with the input shaft, and the ring gear on the 1st/2nd synchroniser. The
housing for the final drive and differential is shared between the clutch housing and gearbox case, with taper
roller bearings supporting the differential.
The C64 six-speed transmission is a development of the C56, with both shafts extended at the rear to
accommodate the additional ratio. Extra ball bearings are included in the end case to support the tails of each
shaft.
The EC60 6-speed transmission is a further evolution of the C64, but dispenses with the separate end
casing and shaft centre support bearings, using instead, front and rear ball bearings for the input shaft, and
a pair of opposed taper roller bearings for the output shaft. A reverse gear engagement aid is provided by a
mechanism which applies a loading to the 6th gear synchroniser cone, to help stop input shaft rotation, before
the reverse idler gear teeth are slid into engagement.
Page 4
Lotus Service Notes
Section FJ
C64 Gear Clusters (other variants similar)
6th gear 5th gear 4th gear 3rd gear
2nd gear
Output shaft
1st gear
Reverse
Input shaft
Double cone 2nd
gear synchromesh
f130
Final drive gear
The input shaft includes integral drive pinions for 1st, 2nd and reverse gears, and carries the clutch driven
plate, the 3rd/4th synchroniser and the 5th/6th synchroniser. The output shaft features an integral final drive
gear, spline fixed 3rd/4th/5th/6th driven pinions, and carries the 1st/2nd gear synchroniser. All forward gears
are constant mesh with inertia lock type synchromesh, with reverse gear attained by sliding a spur idler pinion
into engagement with both a gear on the periphery of the 1st/2nd synchroniser and a drive gear integral with
the input shaft. All gears, with the exception of reverse, use a helical tooth form for quiet running.
Sychromesh: For each gear ratio, one of the shafts has a fixed gear, and meshes with a freely revolving pinion
on the other shaft. To engage a particular gear, the freely revolving pinion must be connected to its shaft via the
sychroniser hub. This connection is made by sliding a sleeve splined to the outside of the synchroniser hub,
to engage the sleeve's internal teeth with a ring of external teeth integral with the adjacent drive pinion.
As an example, third gear selection operates as follows: Under normal road driving, when the clutch is
depressed as a precurser to a gear change, the input shaft with the third gear synchroniser are de-coupled from
the engine, but will continue to turn under decaying inertia, clutch windage, and oil drag from the drive pinions
(which are being driven from the roadwheels via the output shaft). Before the outer sleeve of the synchroniser
may be slid on its axial splines to engage with the spline ring integral with 3rd drive gear, the speeds of the two
parts must be commonised. For this purpose, a baulk (or synchroniser) ring is fitted between the two parts,
being rotationally driven by the synchroniser hub, and equipped with a female conical surface to mate with a
male cone integral with the gear. Teeth on the outside of the baulk ring, over which the synchro sleeve must
slide before engaging the third gear splines, perform a baulking function described below:
When the gear lever is operated, the outer sleeve of the synchroniser is moved towards third gear, and
pushes three spring detent plates which press the baulk ring onto the gear cone. As the input shaft train is
turning faster than third gear, the baulk ring is dragged to one end of its rotational constraint slots in the synchroniser hub, in which position the internal spline teeth of the synchroniser sleeve are mis-aligned with the
teeth on the baulk ring. When further pressure is applied via the gearlever, the detent plates are overidden, and
the synchroniser sleeve splines are pressed against the ends of the baulk ring teeth, increasing the pressure
on the conical surfaces. The bevelled ends of the sleeve splines and baulk ring teeth tend to turn the ring into
alignment, but whilst a speed differential between the ring and the gear remains, the cone drag force (caused
Page 5
Lotus Service Notes
Section FJ
by gear inertia) is dominant and maintains spline mis-alignment. This is the 'baulk' function.
When the speed of the input train becomes synchronised to that of third gear, there ceases to be a force
dragging the baulk ring to the end of its slots, so that the force at the bevelled ends of the splines is now dominant, allowing the baulk ring to move back in its slots to align the splines and for the synchroniser sleeve to be
slid over the ring teeth towards the spline teeth on third gear. These spline teeth, whose position in relation to
those on the baulk ring is entirely random when speed synchronisation occurs, are unlikely to align, but once
the synchroniser sleeve has slid over the baulk ring teeth, there is no longer any pressure applied to the cones,
so the bevelled ends of the teeth may now complete the alignment process. Gear engagement occurs when
the sleeve completes its mating with the gear spline teeth.
On 6-speed C64 transmissions, in order to cater for the heavy demands made on the second gear synchroniser, and provide high durability, this gear is fitted with a double cone mechanism to increase the conical
surface area within a small space. This process is carried further on the EC60 transmission to provide triple
cone synchromesh for 1st and 2nd speeds.
The selector mechanism cross shaft uses Teflon bushes to minimise friction, and a mass damper to improve
gearchange feel. An interlock mechanism allows the selector finger to operate only one selector shaft at a time.
In order to inhibit the unintended selection of reverse gear, a spring detent mechanism is arranged to act on the
cross-shaft, in conjunction with, on 6-speed versions, a lift collar below the gear lever knob, and on 5-speeders,
a mechanism allowing selection of reverse gear only on approach from the central neutral position.
Differential
Standard cars use a conventional 'open' two bevel gear differential contained in a carrier to which is bolted
the final drive output gear, and which is supported in two taper roller bearings. Optional on some C64 equipped
models, in conjunction with electronic Lotus Traction Control (LTC), is a Torsen type limited slip differential (LSD)
in an otherwise unchanged transmission housing (Character 3 of 7 digit code on bar code label: 'O' = open; 'L'
= LSD). The LSD uses worm wheels to interconnect the two output shafts and uses the poor torque reversal
efficiency of this type of gearing to ensure that both wheels are always supplied with driving torque.
Driveshafts
On C64 models, an output extension shaft supported in a ball bearing mounted on the cylinder block, is
used on the right hand side to allow equal length drive shafts to be used. The driveshafts use Rzeppa type
joints on their outboard ends and plunging joints at the inboard ends to accommodate the driveshaft length
variation concomitant with suspension travel.
FJ.2 - GEARCHANGE MECHANISM
6-Speed
The gear lever is spring biased towards
the 3rd/4th gear plane, and must be moved
against light spring pressure to the left before
selecting first or second gear, or against similar
pressure to the right before selecting 5th or
6th speed.
LIFT
COLLAR
6-SPEED CHANGE PATTERN
ohs15a
Engaging Reverse Gear:
With the vehicle at a complete standstill, pause for a moment with the clutch pedal fully depressed before moving the lever to the left, raising the lift collar beneath the knob, and then further to the left over a spring
detent before finally pushing forwards to engage the gear.
Page 6
Lotus Service Notes
Section FJ
5-Speed
The gear lever is spring biased towards
the 3rd/4th gear plane, and must be moved
against light spring pressure to the left before
selecting first or second gear, or against similar
pressure to the right before selecting 5th.
Engaging Reverse Gear:
With the vehicle at a complete standstill, pause for a moment with the clutch
pedal fully depressed before moving the lever
against spring pressure fully to the right, and
then rearwards to engage the gear. Note that
an inhibit mechanism requires that the lever
approaches reverse gear only from the central
neutral position. Direct access from 5th gear
is blocked.
5-SPEED CHANGE PATTERN
ohs15b
A two cable mechanism is used to connect the gearchange lever with the transmission, one cable ('shift')
to transmit the fore/aft movement of the lever, and a second ('crossgate') cable for the sideways movement.
The gearchange lever is pivotted at its base and operates the shift cable directly via a ball joint half way up the
lever. The base of the lever has an extended ball pin on the right hand side which engages with a crossgate
bellcrank lever, the other leg of which operates the crossgate cable. An inhibit mechanism prevents the gear
lever being moved into the reverse gear plane unless a collar beneath the gear knob is lifted. Prior to May '07,
the collar is connected by control cable to a pivotted stop arm sprung to an 'up' position. In this position, a stop
pin on the crossgate bellcrank lever abuts against the end of the stop arm and prevents gearlever movement
into the reverse gear plane. When the collar is lifted, the stop arm is pulled down against its spring, to clear the
stop pin and allow reverse gate selection. From May '07 on 6-speed cars , lifting the collar raises a boss at the
base of the lever above a curved inhibitor block, allowing the lever full leftward movement.
Crossgate
Gearchange Cable Schematic (prior May '07)
Shift
Reverse gate lift collar
Reverse
gate Crossgate Crossgate cable
release bellcrank lever
cable
Shift cable
Gear lever
ball pivot Reverse gate
stop arm
Abutment
block
Page 7
f133
Lotus Service Notes
Section FJ
The front end of both inner cables are equipped with socket joints which may be clipped on and off the ball
pins provided on the gearchange mechanism. The outer cables are retained by a forked plastic block bolted
into the gearlever/handbrake mounting frame.
The gear cables are routed along the centre of the cabin floor, beneath the fuel tank bay, and loop under
the engine to an abutment bracket on the top of the transmission housing. Both cables are retained in the
abutment bracket by spring 'C' clips. The shift cable is fitted on the left, and uses a bellcrank lever and ball
jointed link to connect with the transmission cross-shaft lever, in order to rotate the shaft. The cross-shaft lever
incorporates an inertia weight to smooth the gearchange action and improve feel. The crossgate cable is fitted
on the right and uses a centre pivotted lever arm to impart an axial motion to the transmission cross-shaft. The
ends of both inner cables threaded into alloy eyes which are retained on the lever pins by 'R' clips.
C56/C64 Transmission 'R' clip 'C' clip
External Levers
Shift bellcrank lever
Crossgate cable
Crossgate
Inertia lever Shift cable
weight
Transmission
cross-shaft
housing
f132
Gearchange Cable Adjustment
Prior May '07:
Under normal circumstances, no adjustment to the gear cables should be required. If a cable is replaced
in service, it may be necessary to make minor adjustments via the threaded ball joint at the front of the cable
in order to accommodate lever movement within the shroud aperture. From May '07: 6-speed:
In order to ensure smooth selection of 1st/2nd gears, it is important to set the crossgate cable adjustment in
relation to the reverse inhibitor block.
-
Push the lever to the left to abut against the reverse inhibitor block, and check selection of 1st and 2nd
gears. There should be no obstruction to fore/aft movement of the lever.
-
If fore/aft baulking occurs, remove the gear lever shroud. Release the ball pin from the crossgate bellcrank
lever, release the locknut and screw the ball joint socket one turn up or down the cable end before reattaching to the bellcrank and testing. Once a setting is found which allows smooth fore/aft lever movement
whilst abuting against the inhibitor block, secure the ball joint socket with the locknut.
-
Raise the reverse inhibit gear lever collar and check that reverse gear can be engaged.
-
Refit the shroud and check that all gears can be selected without the lever fouling the shroud aperture. If
necessary, fit shim washers behind the reverse inhibitor block to move the lever away from the LH side of
Page 8
-
Lotus Service Notes
Section FJ
the aperture and re-adjust the crossgate cable as necessary.
If other adjustments have been made, check the alignment of the 3rd/4th lever plane. From the spring
loaded neutral position, it should be possible to smoothly engage 3rd and 4th gears without moving the
lever across the gate. If necessary, the ends of the centralising hairpin spring may be reprofiled to reset
the neutral plane.
Gearchange Cable Replacement
For access to the gear cables, the gear lever shroud and parking brake lever trim must be removed: Unscrew the gear lever knob, remove the single screw each side of the shroud, and withdraw the shroud over the
gear and parking brake levers. Remove the engine bay undertray.
At the front end of the cables, unclip the inner cable ball joint sockets from the ball pins on the mechanism
levers. Release the outer cable plastic abutment block from the mounting frame. At the rear end of the cables,
remove the 'R' clips retaining the inner cable eyes to the levers, and the 'C' clips securing the outer cables to
the abutment bracket. Release the 'P' clips and cable ties as necessary to allow the cables to be withdrawn
from the car, noting the routing of the cables past the parking brake lever and wiring harness.
Refit in reverse order to removal, paying particular attention to the routing through or alongside the parking brake lever mounting frame.
Page 9
Gear Lever
Page 10
Lift tube
Crossgate cable
Reverse
selector
cable
(6-speed only)
Transmission
abutment
bracket
Lotus Service Notes
Fixing to p40
l 5mxt
seat front Reverse gate crossmember stop arm Gear lever
mounting frame
Fixing to seat
rearcrossmember
Lift tube
adaptor
Inertia weight
Shift cable
Gearchange Mechanism & Mounting Frame (prior May '07)
Section FJ
Lotus Service Notes
Section FJ
Gearlever Mounting Frame
The gear lever/parking brake lever mounting frame is common to right and left hand drive cars, but is
mounted offset towards the passenger side of the car in order to allow sufficient room for fore/aft adjustment of
the driver's seat. The frame is secured to thread inserts in the seat mounting crossmembers by two M8 screws
at the rear, which also secure the seat runner/frame, and two M8 screws at the front. All fixings using captive
nuts in the seat mounting crossmembers.
Gearlever Replacement (prior May '07)
The gear lever alone may be replaced if necessary using the following procedure. Note that fabrication
of the gear lever was changed in February 2005 from using a hexagonal section bar to a thicker round section
bar, the better to resist operator abuse. Only the later type will be supplied in service, which if being used to
replace the hexagonal type will require fitment of the following parts as a set:
Parts Required
Gear Lever - RHD
Gear Lever - LHD
Lift Tube, reverse select
Lift Tube Adaptor
Spring Clip, lift tube to adaptor
Knob, gear lever, M10
Grub Screw, M5 x 16, gear knob
Tool, gear lever bush guide
Part Number
A120F0008S
A120F0009S
B120U0017F
B120F6259S
B120W6770F
C120U0012F
A120W5292F
A120U0054S
Qty
1
1
1
1
1
1
1
1
Procedure
1. Release the grub screw (if applicable) in the front face of the gear lever knob, and unscrew the knob. For
knobs without grub screws, gentle heat may help to soften the thread adhesive. Prise off the spring clip
from the top of the lift tube adaptor.
2.
Release the two grub screws in the underside of the parking brake lever sleeve and withdraw the
sleeve.
3.
Remove the two screws securing the front of the gear lever shroud and carefully withdraw the gear/park
brake shroud, disconnecting the window switch and hazard lamps switch (if applicable). Take care to
prevent scratching the shroud on seat belt fixings or seat runners.
4.
Release the reverse selector cable from the gear lever and unhook from the lift tube adaptor. Discard the
adaptor.
5.
Prise off the gear selector cable socket from the gear lever (use a 10mm spanner).
6.
From the LH side of the unit, remove the screw securing the gear lever pivot to the mounting frame. Push
the top of the gear lever to the right to help disengage the crossgate selector ball at the bottom of the lever
from the bellcrank lever socket. Take care not to damage the socket plastic bush which should remain in
the bellcrank lever. Discard the gear lever.
7.
To allow fitment of the bush guide tool, unhook the main harness from the 'P' clip at the front of the frame,
temporarily hook over the outside of the shroud fixing leg and rotate the 'P' clip 90°. Locate the guide tool
in the hole at the RH side of the mounting frame and secure in position using a 'G' clamp as shown, but
do not crush or distort the frame.
Note: Attempting to fit the gear lever ball into the socket and bellcrank lever without the use of the special
guide tool, is likely to result in damage to one or more components and/or personal injury, physical or
psychological.
Page 11
Lotus Service Notes
Section FJ
Bellcrank lever plastic socket
'G' clamp
Use suitable bolt to
push back socket
Special tool
A120U0054S
(Some components omitted for clarity)
f135
8.
Push the plastic socket in the bellcrank lever fully into the guide tool to facilitate installation of the gear
lever. Apply a dab of mineral oil based lithium grease (e.g. Molykote Longterm W2) to the socket.
9.
Fit the gear lever, feeding the crossgate ball into the bellcrank lever and position the lever upright. Using
a suitable screwdriver or pry bar, push the base of the lever over to the right to engage the crossgate ball
into the plastic socket (should click home).
10. Remove the 'G' clamp and guide tool, and push the crossgate socket to the left to engage the 'D' feature
on the gearlever pivot ball with the matching hole in the LH side of the frame. Apply Permabond A130
(A912E6033V) to the fixing screw and torque tighten to 10 Nm. Restore harness position.
'D' spigot on lever
pivot ball
'D' hole in mounting frame
Page 12
f136
Lotus Service Notes
Section FJ
11. Fit the new lift tube adaptor onto the gear lever and ensure it is free to slide up and down. Hook in the
reverse selector cable and secure to the gear lever abutment. Temporarily fit the new lift tube onto the
adaptor and screw on the new gear knob. Adjust the cable to allow correct reverse gear selection and
tighten adjuster nuts. Remove gear knob and lift tube. Clip the selector cable onto the gear lever ball.
12. Cut the tie strap securing the old lift tube in the gear lever gaiter and fit the new lift tube using a suitable tie
strap. Fit the shroud over the parking brake and gear lever, taking care not to scratch the surface finish,
and aligning the flats on the lift tube with those on the lift tube adaptor. Connect the electrical switches as
necessary, and retain the shroud with the two screws.
13. Use the new spring clip to secure the lift tube to the adaptor, and fit the new gear knob, tightening the grub
screw to orientate the graphic correctly. Fit and secure the parking brake lever sleeve.
14. Check gear selection and reverse inhibit function. Ensure the lift tube returns freely under spring action.
FJ.3 - LUBRICATION
The transmission should be checked for oil leaks, for the correct oil level, and the oil renewed, at intervals
specified in the Maintenance Schedule.
Transmission oil viscosity; SAE 75W/90
Specification; API GL-4 or GL-5
C64 filler/level
Quantity;- 6 speed C64 2.3 litres
plug
- 6 speed EC60 2.4 litres
- 5 speed 1.9 litres
To check the oil level:
-
Remove the engine bay undertray.
-
Wipe clean the area around the socket
headed level plug on the front face of the
transmission main casing.
-
Remove the plug, and check that the oil
is level with the bottom of the hole. Note
that the release of oil trapped by the plug,
should not be confused with an indication
of correct oil level.
-If necessary, add only the specified
lubricant (see above) via the level plug hole
until the oil level stabilises at the bottom of the
plug hole.
Alternatively, oil may be added into the
top of the transmission via a mechanical
speedo drive (not used in this application)
cover at the right hand top of the transmission,
after removing the single screw.
-Refit the level plug with a new sealing
washer, and tighten securely.
C64
Drain
plug
f131
f147
EC60
filler/level
plug in end case
EC60
drain plug
in underside
To renew transmission oil:
-
The hexagon headed drain plug located at the bottom of the final drive casing, should be removed immediately after a run when the oil is warm, taking suitable precautions against scalding.
-
Clean the plug, fit a new sealing washer and refit securely.
-
Refill to the level plug hole as detailed above.
Page 13
Lotus Service Notes
Section FJ
FJ.4 - DRIVE SHAFTS
Each of the two driveshaft assemblies comprises a steel shaft with a constant velocity joint at each end,
and is used to transmit the drive from each differential output gear to the rear wheel hub. The two driveshaft
assemblies are similar, but on C64 transmissions, the inboard joint of the right hand shaft is supported in an
outrigger bearing bolted to the right hand side of the cylinder block, and uses an integral extended shaft to
reach into the transmission housing. The inboard joints are of a plunging 6-ball double offset design to accommodate driveshaft length variation with suspension travel, whereas the outboard joints are high efficiency
8-ball fixed type.
Replacement outboard joints include the main driveshaft (longer on the RH side), outboard C.V. joint and
gaiter. Replacement inboard joints include the inner C.V. joint and gaiter kit, with the C64 type extended stub
shaft of the RH joint also including the support bearing and mounting bracket.
The joints themselves are packed with grease on initial assembly, and are maintenance free. It is however
vitally important that the protective gaiters are carefully inspected at service intervals, to check for splits, tears
or punctures, since the joint will deteriorate very quickly once contaminated with dirt or water. Damaged gaiters
should be renewed immediately, once the servicibility of the joint has been established.
CAUTION: The outboard C.V. joint gaiter can suffer 'pinch' damage if the joint is subjected to extreme articulation off the car, or during driveshaft removal/refitment.
RH Driveshaft Assembly
Outboard joint Main shaft Inboard joint
LH Driveshaft Assembly
Outboard joint
Page 14
Extension shaft
(C64 only)
Support bearing
Main shaft
f128
Inboard joint
Circlip
f129
Lotus Service Notes
Section FJ
Clicking noises, torque reversal 'clonks', or shudder and vibration when accelerating are all possible symptoms of worn C.V. joints. It should not be possible to discern any free play in a joint, but care must be taken not
to confuse this with transmission backlash, which will certainly be evident. Any symptoms that could be due to
worn driveshaft joint assemblies, should be investigated and rectified without delay, since a broken driveshaft
can cause considerable damage. Safety considerations should always be accorded the highest priority.
The inboard C.V. joint is equipped with a male splined spigot shaft which engages with the female splines
of the differential output sun gear, with the LH shaft retained by a round section spring circlip on its end, and
the RH shaft retained by the extension shaft support bearing. Each of the two transmission output oil seals
runs on a stepped shoulder on the C.V. joint spigot shaft. The stub shaft of each outboard joint is splined into
the wheel hub, and retained by a nut on the threaded end of the shaft.
Driveshaft Assembly Replacement
Removing a driveshaft assembly from the transmission will result in some loss of transmission lubricant.
It may be preferred to drain off some oil via the transmission drain plug beforehand.
1. Remove transmission drain plug and drain off approx. 1 litre of oil into a clean container for re-use.
2.
Remove the rear road wheel.
3.
Remove the split pin from the hub nut and remove the nut and washer (right hand thread on both sides).
Before the shaft can be withdrawn from the hub, the top ball joint plinth must be released from the hub
carrier (note camber shims fitted), and the toe-link ball joint separated from the carrier. This will allow the
hub carrier to be pulled away sufficiently for the driveshaft to be withdrawn, but take care not to strain the
brake hose or wheel speed sensor harness.
4.
Except C64 RH Driveshaft: The driveshaft inboard joint is retained in the transmission by a round section
circlip. The joint may be removed by applying a shock pull to the C.V. joint body using a slide hammer
with a forked end.
CAUTION: Do NOT attempt to remove the inboard C.V. joint from the transmission by pulling on the
driveshaft. The balls of the inboard joint are restrained for transit purposes only, by a circlip at the end of
the ball tracks. Applying an extension force to the joint will damage the balls and require joint replacement.
Apply pressure only to the outer body of the joint.
C64 RH Driveshaft: This driveshaft incorporates a bearing for the extension shaft and it is this which
retains the shaft in the transmission. Remove the two bolts securing the bearing bracket, and withdraw
the complete shaft assembly.
When withdrawing either driveshaft from the transmission, take care not to damage the output oil seal.
6.
Before re-fitting a driveshaft, first renew the round section circlip on the end of the inboard joint spigot shaft,
and lubricate the circlip with grease. Also, check the condition of the transmission output seal, and renew
if necessary. Lubricate the lip of the seal with transmission oil, and grease the corresponding shoulder
on the driveshaft (C.V. joint) spigot, to reduce the danger of damaging the seal on assembly.
7.
Carefully insert the driveshaft into the transmission, with the two ends of the circlip positioned lowermost,
and rotate the shaft if necessary to engage the splines. Press the inboard joint outer until a click indicates
the engagement of the retaining circlip, if necessary using a brass drift and hammer. Afterwards, pull on
the joint body to check its security. On the C64 right hand shaft, fit the bolts securing the extension shaft
bearing to the engine mounted bracket, and torque to 64 Nm.
8.
Fit the outer end of the shaft into the hub, and refit the top ball joint plinth to the hub carrier with the camber adjustment shim pack in position. Apply Permabond A130 (A912E7033V) to the threads of the two
socket head bolts and torque to 45 Nm.
9.
Refit the toe-link into the hub carrier and torque the retaining nut to 55 Nm.
10. Fit the washer and castellated nut to the driveshaft, apply the parking brake and tighten the nut to 220
Nm. Fit a new split pin to lock the nut.
11. With the car on a level surface, top up the transmission oil to the filler/level plug hole.
Page 15
Lotus Service Notes
Section FJ
Driveshaft C.V. Joint and/or Gaiter Replacement
The outboard C.V. joint is supplied complete with main driveshaft to which it is fixed by a spline with a small
helix angle to eliminate any potential backlash. Separation of the shaft from the joint should not be attempted.
Note that the RH main shaft is 22mm longer than the LH shaft. Replacement of the outboard joint gaiter entails
removal of the complete driveshaft assembly from the car, and removal of the inboard joint from the shaft.
1. Remove the driveshaft assembly from the car (see above).
2.
Remove the clips securing the inboard joint gaiter without damaging the gaiter if it is to be re-used. Pull
the gaiter off the joint outer body, remove the circlip in the end of the joint outer body and match mark the
body to the joint inner race before sliding the body off the shaft assembly.
3.
Remove the circlip from the end of the shaft and match mark the inboard joint inner race to the shaft before
pulling or pressing the race from the shaft. Slide the inboard gaiter off the shaft.
4.
Remove the clips securing the outboard gaiter, and slide the gaiter off the shaft.
5.
Inspection & Cleaning: Complete disassembly of either joint is NOT recommended. The separate components are a precision fit and develop their own individual wear patterns, such that any interchanging or
re-orientation of parts is likely to result in premature failure.
If the grease in the joint is contaminated with dirt or water, it is likely that the joint is damaged, and should
be replaced. If the grease is not contaminated, the joint should be degreased by soaking in a suitable
solvent (NOT petrol), and then carefully inspected. Tilt the inner race to one side to expose each ball.
Severe pitting, galling, play between ball and its cage window, any cracking or damage to the cage, or
pitting, galling or chips in raceways, call for joint replacement.
If the joint is found to be serviceable, it must be repacked with the special grease provided. Pack the
grease into the joint itself and also into the inside of the new gaiter.
NOTE: The grease provided in the kits is specially formulated for wear resistance and durability. DO NOT
use substitutes or mix with other lubricants. The grease specification and quantity also differs for inboard
and outboard joints:
Inboard: 140g NKG 205 99-1089#BJ95
Outboard: 130g NTG 2218M 99-729#BJ100 (inboard grease is also supplied as the inboard joint must
be removed before fitting outboard gaiter)
6.
Slide the new outboard gaiter and smaller retaining clip onto the shaft. Fit the gaiter into the grooves on
the outboard joint body and the driveshaft, and secure with the clips provided.
7.
Slide the new outboard gaiter and retaining clip onto the driveshaft and press the joint inner race onto the
driveshaft splines with the match marks aligned (if re-using joint). Retain with a new circlip.
8.
Fit the inboard joint body to the shaft assembly with the match marks aligned (if re-using joint), and fit a
new circlip into the end of the housing to retain the joint.
9.
Fit gaiter into the grooves on the joint outer body and driveshaft and secure with new gaiter clips.
10. Refit the driveshaft to the car (see above).
Extension Shaft Support Bearing - C64
The ball bearing supporting the RH driveshaft extension shaft to the engine block is mounted in a housing
which is bolted to a bracket on the engine block. The bearing is sealed and maintenance free, and is included
as part of the inboard C.V. joint assembly, but may if necessary be renewed by the following procedure:
1.
Remove the RH driveshaft assembly (see above).
2.
Using a press, remove the dust shield from the inboard end of the shaft.
3.
Remove the circlip from the outboard face of the bearing housing, and press or pull the housing from the
bearing.
Page 16
Lotus Service Notes
Section FJ
4.
Prise or pull the bearing dust shield off the shaft.
5.
Remove the circlip retaining the bearing and press or pull the bearing from the shaft.
6.
Press a new bearing into the housing,
and retain with a new circlip. Then use
special press tool T000T1438F to press
the inner race of the bearing up to the
shoulder on the shaft, and retain with a
new circlip.
f125
7.
Use special press tool T000T1439F to
press the bearing dust shield onto the
shaft and position as shown in the illustration.
8.
Press the inboard dust shield onto the
end of the shaft to the dimension shown
in the illustration.
9.
Refit the driveshaft to the car (see
above).
f126
86.5 ± 0.5mm
f127
FJ.5 - TRANSMISSION REPLACEMENT
The transmission may be removed from below after removing the left hand rear suspension assembly,
both driveshaft assemblies and the exhaust system. Release the clutch release fork, gearchange cables, earth
braid and reverse light switch.
The engine must be supported to allow the engine and transmission mountings to be disconnected and
the power unit tilted as necessary to allow the transmission to be withdrawn. The clutch bell housing is secured
to the engine by 8 bolts as shown overleaf.
Page 17
Lotus Service Notes
Section FJ
Clutch housing to engine fixings - viewed from gearbox side (2ZZ shown)
M12x55 flange head bolts to block; 64 Nm
M10x65 bolts also secure
starter motor; 37 Nm M10x55 bolts to
block; 37 Nm
f134
M10x30 bolts to sump; 23 Nm
FJ.6 - TRANSMISSION OVERHAUL
The overhauling of the Toyota supplied type C64/C56 transmission, is detailed in separate publication
E120T0327J.
For the EC60 transmission, a CD under part number T000T1523F is available; choose:
-
Repair Manual
-
Transmission
-
scroll down to find EC60 MANUAL TRANSAXLE in left hand column.
When applicable, select '2010/01 -'
Page 18
Lotus Service Notes
Transmission Special Tools
Description Press Dolly, driveshaft bearing
Press Dolly, driveshaft bearing shield
Oil Seal Puller
Differential Preload Adaptor
5th/6th Gear Puller Kit
comprises:
Upper Plate
Centre Bolt
Arm (x3)
Adaptor
5th/6th Synchro Hub Puller Kit
comprises
Hanger
Slide Arm (x2)
Centre Bolt
Claw no.2 (x2)
Holder
Output Shaft Seal Replacer Dolly, LH
Output Shaft Seal Replacer Dolly, RH
Output Shaft Seal Replacer Handle
Section FJ
Lotus Part No. T000T11438F
T000T1439F
T000T1445S
T000T1446S
T000T1447
T000T1447/1
T000T1447/2
T000T1447/3
T000T1447/4
T000T1448
T000T1448/1
T000T1448/2
T000T1448/3
T000T1448/4
T000T1448/5
T000T1459F
T000T
T000T1460F
Transmission Overhaul Notes
1. Removing and installing 5th and 6th driven gears from the end of the ouput shaft requires considerable
force. The specified puller tools should be used, but when pulling 5th speed driven gear, the claws of the
tool may require some grinding to allow complete and proper fitment, and an anti-spreading device is recommended to be fitted around the three claws. Striking the puller bolt with a hammer in between tightening
steps will help shock the gear from its interference fit, and engaging two gears to lock the transmission
will also aid the process.
2.
The preload on the differential carrier taper roller bearings is controlled by shims between the bearing
outer race and the clutch housing, and is determined by installing the final drive assembly in an otherwise
empty casing, and measuring the steady rotation torque.
3.
If the input shaft oil seal is to be replaced, the bearing should also be renewed since this is likely to be
damaged during oil seal removal.
4.
The transmission cross-shaft reverse select compression spring shown in the Toyota Repair Manual is
removed for the Lotus application. When fitting a replacement transmission, compare the cross shaft
spring loading of the old and new units to determine whether this modification has been carried out.
Page 19
Lotus Service Notes
Section FJ
Torque wrench
5.
-
-
-
-
-
-
f143
For cars fitted with a limited slip differential, note the following:
Apart from the taper roller bearings supporting the differential assembly in the transmission case, the unit
is not serviceable.
The tightening torque of the bolts securing the final drive gear to the differential assembly = 101 Nm (Std.
diff. = 77 Nm).
When setting the differential bearing preload (see page 41-28 in Toyota manual D120T0327J) note that a
different procedure must be used due to the construction of the LSD. Instead of fitting only the differential
assembly into the transaxle/transmission case, and then measuring the turning torque directly at the differential, LSD versions require that the differential and output shaft be assembled into the casings, and
the turning torque measured by using a torque wrench (27mm socket) on the end of the output shaft.
Bearing preload (at starting):
New bearings: 0.17 - 0.35 Nm (1.7 - 3.6 kgf.cm)
Used bearings: 0.11 - 0.22 Nm (1.1 - 2.2 kgf.cm)
Adjustments are made as for non-LSD.
There is no special oil requirement for the LSD.
Page 20
Lotus Service Notes
Section GH
WHEELS & TYRES
SECTION GH
Sub-Section Page
General Description
GH.1
2
Wheels GH.2
2
Tyres
GH.3
4
Winter Tyres & Snow Chains
GH.4
5
Punctured Tyre Emergency Inflator GH.5
6
Tyre Pressure Monitoring System (TPMS) - '08 onwards USA only
GH.6
7
Page 1
Lotus Service Notes
Section GH
GH.1 - GENERAL DESCRIPTION
The single piece, light alloy roadwheels are factory fitted with tyres engineered to provide the optimum
balance of ride and handling characteristics. In order fully to exploit the dynamic qualities and packaging
opportunities, the wheel and tyre sizes are different front and rear, so that interchanging of wheels and tyres
between axles is not permissible. Note that the tyre tread pattern of both tyre types is directional, and must be
fitted on the wheel with sidewall arrow pointing in the direction of forward rotation.
The tyres should be inspected frequently by the vehicle user, and also at every service, for signs of cuts,
abrasions or other damage, and for any uneven tread wear patterns. Uneven treadwear may indicate that the
suspension geometry or dampers require attention. Care should be taken when parking to avoid tyre contact
with high or sharp edged kerbs, as mistreatment of this nature can cause internal damage to the tyre structure
which may not readily be apparent. The alloy wheel rims may also be distorted or damaged by careless parking, and result in wheel imbalance or loss of tyre pressure. Safety considerations should always be paramount
when assessing tyre condition and serviceability, and the tyres replaced if any doubt exists, or if the legal tread
depth limits are approached.
The cold tyre pressures should be checked every week, or every 1,000 miles (1,700 km), whichever is the
sooner, and corrections made as necessary. Under‑inflation will cause excessive wear, rapid deterioration of
the tyre sidewalls and heavy steering, whereas overinflation results in a hard ride and increased susceptibility
to tyre damage. Both conditions will cause a degradation in the vehicle handling qualities. It is important that
the tyre pressures are adjusted only when the tyres are cold (driven less than one mile), as the pressures may
increase by 0.3 ‑ 0.5 bar (4 ‑ 8 lb/in²) when the tyres are warmed to normal running temperature. The tyre
valve dust cap should always be replaced in order to prevent the ingress of dirt and moisture into the valve,
which could cause leakage.
When balancing the wheel and tyre assemblies, the wheels should be located by the centre spigot ‑ NOT
by the wheel bolt holes. In order to maintain the correct handling feel and minimum steering wheel shake, it is
very important that the radial and lateral run out of the tyres are to the high standard required by Lotus Cars.
If any difficulty is experienced with replacement tyres, refer to the tyre manufacturer.
The Bridgestone Potenza, Yokohama AD07 or Yokohama A048 tyres fitted to the Elise are suitable for all
normal weather conditions, but are optimised for dry road sports driving. The tyre characteristics include good
feedback (‘feel’) from the road surface to the steering wheel, a high level of steering linearity and response,
and little performance degradation with the high temperatures which may be reached on track. However, tyre
performance will decrease at low ambient temperatures, resulting in reduced levels of grip and an increased
susceptibility to damage from impacts. In these conditions, especially below 15°F (-10°C), it is recommended
to fit a vehicle set of the recommended winter tyres (see below).
GH.2 - WHEELS
Elise: Standard wheels on the Elise 111R and Elise for North America, are the same style and rim sizes as
used on the Rover powertrain Elise 111S; Cast alloy 8-spoke in 'high power' silver, 5.5Jx16 and 7.5Jx17. The
rear wheels of Toyota powertrain cars however have a greater inset (38mm vs. 17.75mm) to compensate for the
suspension pick up points having been moved further outboard. In addition, the wheels have been tested and
approved to a higher load rating, and whereas Rover powertrain cars may use the later 'B' level front wheels,
no Toyota powertrain model should be fitted with the earlier type 'A' level front wheel. For identification, refer
to the 'max. load' rating marked on the inside of a wheel spoke: 'A' level = 230 kg; 'B' level = 255kg.
Exige: These models use unique, black finished wheels featuring 8 Y-spokes, and are fitted with wider, 6.5J
front wheel rims to accommodate the wider A048 front tyres.
Option: Optional wheels include unique a lightweight forged alloy, 7split-spoke design, using the wider front rim
size. These wheels are available in either painted or natural anodised finishes, but it is important to be aware
that the natural anodised surface finish may be attacked by some proprietary wheel cleaning products. Wash
only using hot soapy water or car bodywork shampoo. Advise tyre fitting companies accordingly. From '06 M.Y.
these forged wheels were also made available in a 6.0J front size to allow the use of standard tyre sets with
175 width front tyres, as well as accommodating the 195 section A048s. Colours and finishes of road wheels
are subject to marketing factors and may differ from the above.
Page 2
Lotus Service Notes
Section GH
Type - Std. - Elise
- Exige
- Option
Front wheel max. load rating
Size - front - Elise std
- Elise option
- Elise option
- Exige
- Exige option
- rear - std
- Exige option
Inset - front - 5.5J, 6.5J, 7.0J
- front - 6.0J
- rear
PCD
Wheel bolt torque
Centre spigot hole diameter
Radial run-out at bead seat
Lateral run-out at bead seat
Rimstock, cast alloy, 8 spoke, Hi-power Silver )
Rimstock, cast alloy, 8 Y-spoke, Black ) see parts list
Rimstock, lightweight forged alloy, 7 split-spoke,) for details
Silver painted or natural anodised finish. )
255 kg
5.5J x 16 (cast)
6.0J x 16 (forged + AD07 or A048)
6.5J x 16 (forged + A048)
6.5J x 16
7.0J x 16
7.5J x 17
8.0J x 17
+ 31.3 mm
+ 25.0 mm
+ 38.0 mm
100 mm
105 Nm (77.5 lbf.ft)
56.5 mm
0.3 mm max.
0.3 mm max.
Note that the inset figure is the displacement of the wheelrim centreline relative to the INSIDE OUTSIDE
wheel/hub mounting face. A positive inset face of face of
indicates that the wheelrim centreline lies in- wheel wheel
board of the wheel mounting face, whereas a
negative inset means the wheelrim centreline
is outboard of the mounting face.
Wheelrim centreline Wheel mounting face
Wheel Bolts
The wheel bolts used are of a special
design to suit the small diameter fixing tunnels in the wheel centres. The bolts have an
M12x1.5 thread, 60° conical seat, and a 10
spline socket head for which a special extension tool is supplied with the car.
A 17 mm a/f deep socket and 1/2 inch
square drive wrench should be applied to the
extension tool, with a tightening torque of 105
Nm required.
Note that on models fitted with early type
upgraded, 4-piston, front brake callipers, with
11mm thick disc mounting bells, longer wheel
bolts are required which use the standard
spline head, and no coded security bolts:
Inset (positive shown)
g02
Standard wheelbolt
Standard tool
Coded
wheelbolt
Coded
tool
17mm socket, extension
& torque wrench ohs114a
Standard bolt; B117G6000F 26mm thread length Head outside diameter: 22mm
Long bolt; A120G6004F 28mm thread length Head outside diameter: 19mm
To protect against wheel theft, one of the four bolts securing each wheel is key coded, and requires a
corresponding coded extension tool. Rotate the tool until full engagement into the bolt head is ensured before
applying release torque. Note that an alignment mark is provided on the coded bolt head and tool to aid refitting. Both the standard and coded spline drive extension tools are stowed in the vehicle tool kit, and should
remain with the car at all times to allow servicing to be performed.
Page 3
Lotus Service Notes
Section GH
A sticker with the code number is supplied with the vehicle for safe keeping by the vehicle owner. This
code will enable dealers to order a replacement coded extension tool if necessary. It is the responsibility of the
dealer to verify the legitimacy of any customer request for a coded tool. Typical security code; FEOR17025
GH.3 - TYRES
Elise 111R prior '06 M.Y.: Lotus engineers worked with the tyre manufacturer Bridgestone, to produce a version
of the ‘Potenza RE040’ tyre specifically for the Lotus Elise 'Mk.2' including Elise 111R, to optimise performance
on both road and track. This tyre is identified by the construction code element of the DOT code moulded on
one of the tyre sidewalls, and it is most important that ONLY this version is fitted if the correct handling characteristics are to be maintained.
D O T # # # #
***
Front tyre code = CFE
####
Rear tyre code = DCK
Bridgestone
Potenza
RE040
At the introduction of the 111R, the speed
rating of the tyres was uprated from 'V' to 'W',
without any physical change to the construction. For legal reasons, only tyres marked with
a 'W' rating should be used on the 111R.
Wear indicators are moulded into the bottom of the tread grooves at intervals around
the tyre, indicated by small pointers on the
outer tread blocks.
The tyres should be replaced before being worn to this minimum legal tread depth. Note that the ‘Potenza’
tread pattern is directional, so that the tyre must be fitted onto the wheel with regard to which side of the car the
wheel is to be fitted. A direction of rotation arrow is included in the tyre sidewall markings.
Tyre type
Size - front
- rear
Identification code (see above) - front
- rear
Pressure (cold) - front
- rear
Bridgestone Potenza RE040
175/55 R16 80W 225/45 R17 90W
CFE
DCK
1.8 bar (26 lb/in²)
2.0 bar (29 lb/in²)
Exige & Elise Option: These models are
Yokohama
fitted with Yokohama A048 tyres, which have
A048
been developed jointly by Lotus and Yokohama
to suit the requirements of the performance
driver, with special emphasis on track use.
Compared with the standard tyre, the
front tyre width is increased and the profile
reduced from 175/55 to 195/50. The tyre tread
design is directional, such that each wheel/
tyre assembly is dedicated to a single vehicle
corner. The Lotus specific construction is
identified by the letters 'LTS' moulded on the
tyre sidewall. Ensure that any replacement
tyre is so marked.
On Elise models, in order to maintain sufficient vehicle stability with these track based tyres, Lotus approves
of A048s only in conjunction with sports suspension. The tyres should not be fitted on standard specification
wheels, or with standard suspension.
g20
Page 4
Lotus Service Notes
Type
Size - front
- rear
Pressure (cold)- front
- rear
Yokohama A048 'LTS'
195/50 R16 84W 225/45 R17 90W
1.8 bar (26 lb/in²)
2.0 bar (29 lb/in²)
Elise 111R from '06 & R + USA Elise: These
cars are fitted with Yokohama AD07 tyres developed specifically for the Elise, and are optimised for dry road sports driving. The Lotus
specific construction is identified by the letters
'LTS' moulded on the tyre sidewall. Ensure that
any replacement tyre is so marked.
Note that the AD07 tread pattern is directional, so that the tyre must be fitted onto the
wheel with regard to which side of the car the
wheel is to be fitted. A direction of rotation arrow is included in the tyre sidewall markings.
Type
Size - front
- rear
Pressure (cold)- front
- rear
Section GH
Yokohama
AD07
ohs115b
Yokohama Advan Neova AD07
175/55 R16 80W 225/45 R17 91W
1.8 bar (26 lb/in²)
2.0 bar (29 lb/in²)
Tyre Characteristics: All standard equipment tyres fitted on the Elise and Exige are suitable for all normal
weather conditions, but are optimised for dry road sports driving. The tyre characteristics include good feedback
('feel') from the road surface to the steering wheel, a high level of steering linearity and response, and little performance degradation with the high temperatures which may be reached on track. However, tyre performance
will decrease at low ambient temperatures, resulting in reduced levels of grip and an increased susceptibility to
damage from impacts. If the car is to be used in winter, or in cold conditions, it is recommended to fit a vehicle
set of the recommended winter tyres (see below).
GH.4 - WINTER TYRES & SNOW CHAINS
If the car is to be used in winter or in cold conditions, or driven on snow covered roads, it is recommended
to fit winter tyres developed specifically for such conditions.
Winter Tyres
Type - front
- rear
Size - front
- rear
Pressure (cold)- front
- rear
Pirelli 210 Snowsport
Pirelli 240 Snowsport
195/50 R16 225/45 R17
1.8 bar (26 lb/in²)
1.9 bar (27.5 lb/in²)
WARNING:
- When winter tyres are fitted, a maximum speed of 118 mph (190 km/h) must be observed.
- The tyres are NOT suitable for studding.
Snow Chains
In extreme conditions, Lotus approves the fitment of Pewag Brenta-C XMR69 snow chains, used only in
conjunction with winter tyres (see above) and fitted on only the rear wheels. Close attention should be paid to
the fitting and tensioning instructions supplied with the chains, and the chains should be removed as soon as
road conditions allow.
Page 5
Lotus Service Notes
Section GH
GH.5 - PUNCTURED TYRE EMERGENCY INFLATOR (If fitted)
In order fully to exploit the benefits of light
weight, and to maximise stowage space, no
spare wheel is included in the Elise specification, but a temporary puncture repair facility is
provided in the form of a tyre inflator aerosol.
The aerosol is mounted in spring clips at the
extreme right hand front corner of the rear
luggage compartment.
When the aerosol is connected to the
tyre valve, and the button pressed, a mixture
of liquid latex and propellant is injected into
the tyre, such that the solidifying latex is forced
into the puncture site at the same time as the
tyre is inflated, effecting a temporary repair
and enabling the car to be driven at moderate
speed to the nearest tyre depot.
TYRE INFLATOR AEROSOL
ohs118
WARNING:
- Use of the aerosol does not constitute a permanent repair, but is designed to allow the car to be
driven to the nearest tyre depot. At the earliest opportunity, the tyre should be professionally
repaired or replaced dependent on the severity of the damage.
- Until the tyre is repaired or replaced, the car should be driven in a moderate manner, not exceeding 30 mph (45 km/h).
- Do not use the aerosol for large holes or repairs, or when the tyre sidewall has been damaged, or
if the tyre has been displaced from the rim.
- For safety reasons, the aerosol should be carried at all times in the designated stowage position.
Never carry in the passenger compartment.
As soon as a puncture is suspected, the car should be stopped at the first safe opportunity. Continued
driving on a deflated tyre will cause irreparable damage to the tyre.
Directions for use of the aerosol: Before using, carefully read all the instructions on the canister, or on any
literature accompanying the product. The following instructions apply to the use of Holts Tyreweld:
1. Remove the object causing the puncture, and position the wheel with the puncture site lowermost. Deflate
tyre fully.
2. Shake the can vigorously. In cold conditions, warm the can using the car's heater outlets, or by body
warmth.
3. Screw the aerosol tube onto the tyre valve, remove the cap, hold the can upright and press the button
until the tyre is firmly inflated.
4. Immediately drive for 6 - 12 miles (10 - 20 km) (or to the tyre depot if nearer) in a moderate manner and
not exceeding 30 mph (45 km/h), to allow the sealant to spread. Then check and adjust the tyre pressure
as necessary.
5. Have the tyre professionally repaired or replaced at the earliest opportunity, and until such time, limit
speed to 30 mph (45 km/h) with a moderate driving manner. Note that some tyre repairers may make an
additional charge for cleaning the sealant off the tyre before repair, and that any subsequent repairs may
not be guaranteed. If the vehicle is equipped with low tyre pressure monitoring equipment, be aware that
the pressure sensor mounted inside the tyre, could be obstructed by the sealant, and should be replaced
at the next opportunity.
6. Renew the emergency inflator aerosol.
Page 6
Lotus Service Notes
Section GH
GH.6 - Tyre pressure monitoring system (tpms) - USA only
All USA Elise/Exige models from ‘08 model year onwards are fitted with a tyre pressure monitoring system.
A sensor incorporated into each of the tyre valves monitors the air pressure inside the tyre, and supplies an
onboard control module with this data by radio transmission. If any tyre pressure should fall below 75% of the
recommended value, an alert message is sent to the instrument panel, and the tyre pressure tell tale
will light up amber. The fuel gauge display will then be overwritten with a message to indicate which tyre is
concerned, with text such as: LF Low (left hand front tyre low pressure). This message will show for 5 seconds
before the display reverts to the fuel level bar graph, but will repeat for 5 seconds at 30 second intervals.
The TPMS incorporates self-malfunction recognition, and if a fault is detected, the tell tale will flash for one
minute and then remain constantly lit. The LCD panel will also flash ‘TPMS FAULT’ for 5 seconds, and repeat
at 30 second intervals; no indication of low tyre pressure will be displayed.
Tyre fitters and service technicians should be made aware that TPMS is fitted, and that the tyre valves
include pressure sensors. If the emergency tyre inflator aerosol has been used, it will be necessary to renew
the tyre valve/pressure sensor. If a fault is indicated after wheel or tyre replacement, it is likely that a sensor
has been incorrectly fitted or damaged. If a tyre valve is renewed, or is moved to a different wheel position, the
TPMS will automatically identify the new configuration.
Note that the pressure sensors are powered by integral batteries, with an average service life of 10 years.
It is recommended to renew all pressure sensors at this time interval.
If renewing a wheel, ensure that only a TPMS compatible wheel is used, as the installation angle of the the
tyre valve is modified to accommodate the pressure sensor. Compatible cast wheels are identified by 'TPMS'
within one of the recesses in the hub mounting face. On TPMS compatible forged wheels, the profile of the
wheel rim outboard of the central well, is modified in order to allow local machining around the valve hole on
the inside of the rim to provide a shallower installation angle. If no machining is evident, the wheel is not TPMS
compatible. In addition, a batch code is engraved onto the inner rim in the form of 'PS123456'. The first three
numbers indicate the week and year of manufacture, and any wheel with a code of PS267### (week 26 of
2007) or later, will be TPMS compatible. TPMS type wheels may be fitted on all cars.
Page 7
Lotus Service Notes
Section HG
STEERING
SECTION HG
Sub-Section
Page
General Description
HG.1
2
Steering Wheel
HG.2
2
Upper Column Assembly
HG.3
5
Intermediate Column HG.4
9
Front Wheel Alignment & Rack Gaiters
HG.5
9
Rack & Pinion Assembly Removal/Replacement
HG.6
10
Adjustment of Rack Bar Thrust Pad
HG.7
12
Page 1
Lotus Service Notes
Section HG
General Layout
Upper column mountings
Track rod
end
Intermediate
column
Lower
u/j
Upper u/j
Upper column
assembly
Rack mounting
plinth
Thrust pad
adjuster
Rack housing
Gaiter
hg.1 - general description
Track rod
h55
The steering system of the Elise comprises a telescopically collapsible upper column assembly, connecting
to a rigidly mounted rack and pinion assembly via a universally jointed intermediate shaft. The steering rack
tie rods connect to rearward facing steering arms bolted to the forged steel front hub carriers, with geometry
providing 30% Ackermann effect, and a toe-out on bump characteristic. No power assistance is provided.
Prior to June '04, the steering rack assembly used a one-piece, alloy, pinion/rack housing, superseded
after that time by a cast alloy pinion housing mated to a tubular steel rack housing.
The upper column is fixed to the scuttle beam, with the column upper bearing carrier also providing
mountings for the steering lock and column switches. 'Break out' inserts fitted in the column upper mounting
flanges, allow for telescoping of the column in a frontal collision. The steering rack assembly, which provides
2.4 turns from lock to lock at a 15.8:1 ratio, is rigidly mounted inside a chassis transverse extrusion behind the
top wishbone rear pivots.
HG.2 - STEERING WHEEL
Non Airbag Type: The alloy three spoke steering wheel, has a leather trimmed rim and moulded rubber covered spokes, and is secured to the column via a 36 spline boss. The horn button is mounted in the steering
wheel centre pad which is supported by a collapsible steel spider bolted to the hub of the wheel. The positive
feed to the horn button is supplied via a spring loaded contact housed in the column switch carrier, and a slip
ring mounted on the forward side of the wheel. The earth contact of the button is connected to a terminal on
the spider.
Airbag Type: The alloy three spoke steering wheel has a leather trimmed rim and moulded rubber covered
spokes which incorporate horn buttons in the outer ends of each of the nominally horizontal spokes. An airbag
Page 2
Lotus Service Notes
Section HG
module is incorporated in the centre of the wheel, and uses a rotary coil unit to maintain cable continuity to the
airbag and horn buttons.
To Remove Steering Wheel (non airbag)
1. Pull off the centre trim pad with horn button, and disconnect the two horn leads.
2. To allow access for a steering wheel
puller tool, it is necessary first to remove
the column shroud:
-
Release the four screws securing the
shroud upper section, turning the steering
wheel as necessary to permit access.
-
Pull out the grommet from around the
ignition switch, and remove the three
screws securing the lower shroud.
-
If necessary, disconnect or remove the
trip/panel lights control button from the
lower shroud.
Column upper shroud
Lower shroud
mounting
bracket
Column lower
shroud
b258a
3.
Remove the nut securing the steering wheel boss to the column. Match mark the boss and column to
enable alignment to be maintained on re-assembly.
4.
Use a suitable steering wheel puller tool to locate behind the steering wheel boss and bear against the
end of the column.
CAUTION: If excessive force is applied to either the wheel or column without an appropriate puller,
the telescoping mechanism of the outer column may be overridden, necessitating column replacement.
5.
If necessary, unclip the slip ring from the steering wheel boss and withdraw with the horn lead. Withdraw
the column bearing preload spring.
6.
-
To refit the steering wheel, reverse the above procedure with the following notes:
Clip the horn slip ring to the steering wheel boss with the turn indicator cancelling vane on the left hand
side.
Ensure that the column bearing preload spring is fitted over the inner column before fitting the wheel with
the match marks aligned. If re-alignment is necessary, see later.
Torque tighten the steering wheel to column nut to 25 Nm.
-
-
Page 3
Lotus Service Notes
Section HG
To Remove Steering Wheel (airbag type)
WARNING: The driver's airbag is housed in the hub of the steering wheel. Precautions need to
be taken for personal safety when working with airbags and associated componentry. Do not attempt
to remove the airbag or steering wheel without first referring to section WD.
On the back of the airbag type steering wheel hub, is mounted a 'rotary connector', being a device which
allows the steering wheel to turn whilst maintaining electrical continuity to the airbag module and horn buttons.
This device needs to be centralised before fitting, or breakage will result. Follow instructions below carefully.
1.
Column shrouds: Remove the two screws retaining the top part of the shroud, and the four screws retaining
the lower part, and withdraw both parts from the column, if necessary disconnecting the trip/panel lights
control button from the lower shroud.
2.
Refer to section WD to remove the airbag module from the wheel.
3.
Disconnect the horn harness plug.
4.
The steering wheel may be released from the hub by removing the four attaching screws.
5.
To remove the hub, or wheel and hub assembly from the column, first ensure the front wheels are pointing
straight ahead. Bend back the locking tabs and release the nut securing the hub to the column. Before attempting to remove the hub, match mark the position of the hub against the column to aid re-assembly.
6.
Using a suitable steering wheel puller tool, position the legs to reach through the holes in the wheel hub
and bear directly against the hub, without intefering with the rotary connector on the back of the hub. The
centre screw should bear against the end of the column. Withdraw the wheel/hub/rotary connector assembly from the column splines.
Alternatively, for better puller access, the steering wheel can first be removed from the hub by releasing
the four retaining screws.
CAUTION: If excessive force is applied to either the wheel/hub or column without an appropriate
puller, the telescoping mechanism of the outer column may be overridden, necessitating column
replacement.
7.
Refitment
If the hub is already fitted to the column, refit the steering wheel to the hub and tighten the four fixing
screws. Mate the horn buttons harness connector plug.
8.
If fitting the wheel/hub/rotary connector assembly to the column, the rotary connector must first be centralised: Turn the connector centre element fully counterclockwise until tight, then turn clockwise approximately
2.5 turns until the arrow marks on the two parts of the rotary connector are aligned. Make sure the front
wheels are pointing straight ahead, and fit the assembly onto the column with the hub to column match
marks (made on disassembly) aligned, and engage the spring loaded pin on the column switch housing
with the slot in the rotary connector.
9.
Fit a new locking tab washer, followed by the steering wheel nut, and torque tighten to 25 Nm (18.5 lbf.ft).
Bend up the locking tabs to secure.
10. Refer to section WD to refit the airbag module, and verify the system.
Steering Wheel Alignment
Ideally, the steering wheel should align in the straight running position, with the steering rack centralised
and with equal track rod lengths. In practice, a minor compromise to track rod lengths may have to be made.
To arrive at the optimum setting, proceed as follows:
Note that only one splined joint in the steering system allows a choice of position, this being the lower
joint to rack pinion shaft.
1. Set the front wheel alignment to specification with equal track rod lengths (see sub-section CI.2).
Page 4
Lotus Service Notes
2.
Section HG
Turn the steering to each full lock in turn and set the steering wheel on the column splines such that its
orientation in one full lock position is the nearest possible mirror image of its position at the opposite full
lock.
Mirror image
wheel positions
3.
h53
Secure the steering wheel before road testing the car and marking the actual 'straight ahead' position of the
steering wheel which should deviate from the ideal position by less than 5°. Final alignment is achieved
by asymmetric adjustment of the track rods, retaining the overall toe-out setting.
HG.3 - UPPER COLUMN ASSEMBLY
Non-airbag steering wheel shown
Instrument
pack support
bracket
'Break out' insert
Column lower
mounting bracket
Column support bracket
Turn & flasher switch
Intermediate
column
Trim pad
collapsible
spider
Column lock
assembly
Upper
Chassis
bearing
scuttle
housing
Wiper
beam
Horn button
Trim pad
switch
Page 5
h49a
Lotus Service Notes
Section HG
The upper steering column assembly comprises an inner column which connects the steering wheel to the
intermediate shaft, and a tubular steel outer column which, with its alloy upper bearing housing, supports the
inner column and carries the column lever switches for lighting and wiper control, and also the ignition switch/
steering lock.
Both inner and outer columns are of fixed length, but are telescopically collapsible when subjected to
crash forces. The two parts of the inner column are fixed together by plastic pins designed to shear and allow
telescoping to occur beyond a specified axial load. The two part outer column tube uses gripper rings to retain
the column length, with the lower part mounted by a single fixing to the chassis scuttle beam via a three point
fixing steel bracket. The upper part of the outer column has two open slotted mounting flanges each of which
is fitted with a 'break out' alloy insert, bolted through to an extruded alloy plinth fixed to the scuttle beam. In
the event of an extreme axial load being applied to the column via the steering wheel, as may occur during a
vehicle frontal collision, the plastic retaining pins in the column flange inserts will shear and allow the upper
part of the column to break free of the upper fixings and telescope forwards, reducing the potential for column
induced injury.
Column slotted 'Break out'
flange
insert
Column
lower
fixing
Normal
Condition
Chassis
scuttle
beam
h50a
Column flange broken
out of insert
Collapsed
Condition
h51a
Dimensional Check
If the vehicle is involved in an accident, or any part of the column is subjected to an abnormal load including airbag deployment, the column should be carefully examined to establish if any telescoping has occurred.
Perform the following checks, and replace the complete upper column assembly if any of the dimensions are
outside specification:
1.
Outer Column:
Measure the length of the lower part of the outer column as shown:
Specification = 80 ± 1mm
2.
Inner Column Lower:
Measure the length of the exposed part of the inner column as shown:
Specification = 58 ± 1mm
Page 6
Lotus Service Notes
Section HG
Outer column
assembly
3.
80 ± 1 mm
Inner
column
lower end
58 ± 1 mm
h52
Inner Column Upper
With the steering wheel removed, measure the length of the exposed part of the upper column as
shown:
Specification = 76 ± 1mm
Inner column
upper end
76 ± 1 mm
4.
'Break out' Inserts
Remove the column shrouds and the
column flange fixing bolts, and check
that each of the alloy 'break out' inserts
is securely attached to the column flange.
If the plastic pins are sheared, the column
assembly must be replaced.
h52a
Alloy 'break
out' insert
Nylon
shear
pins
h48
Page 7
Lotus Service Notes
Section HG
To Remove Upper Steering Column Assembly
WARNING: On cars so equipped, the driver's airbag is housed in the hub of the steering wheel. Precautions need to be taken for personal safety when working with airbags and associated componentry. Do
not attempt to remove the airbag, steering wheel or column without first referring to section WD.
1.
Disconnect the battery, and remove the column shrouds (see sub-section HG.2).
2.
Disconnect the column lever switches, or release the retaining pawls and slide the switches out of the
carrier. Disconnect the horn contact pin. On airbag equipped cars, refer to section WD and unplug the
yellow airbag harness connector.
3.
To disconnect the ignition switch: prise open the terminal cover, and use a small screwdriver to release
the retaining barb located between the white and yellow cables. Withdraw the connector.
4.
If necessary, remove the steering lock/ignition key barrel: Turn the key to position 'I', depress the spring
pin accessible via a hole in the column switch carrier, and withdraw the lock barrel.
5.
If necessary, remove the ignition switch: First remove the steering lock/ignition key barrel (see above).
Remove the retaining grub screw and withdraw the switch.
6.
If necessary, remove the steering lock assembly: Remove the spline head screw securing the column
switch carrier, and drill or chisel out the two shear head bolts fixing the lock assembly to the column.
7.
Remove the pinch bolt securing
the upper universal joint to the
intermediate column.
Non-airbag type shown
8.
On non-airbag cars, remove the
two fixings for the instrument pack
mounting brackets, and remove
the instrument pack and cowl assembly after unplugging the single
harness connector.
On airbag equipped cars, withdraw
the instrument surround and cowl
straight rearwards from the dash
panel to release the spring clips.
Remove four screws to release
the instrument pack mounting
bracket from the dash and unplug
the two harness connectors
Instrument
pack
9.
Instrument cowl
Instrument
& cowl
mounting
bracket
Release the two bolts securing the
upper column clamp to the dash
brackets, and remove the switch
pack.
10. From the access provided by
the removal of the switch pack,
release the upper column single
lower fixing and withdraw the
column assembly from the scuttle
and off the intermediate steering
column.
Page 8
b259a
Lotus Service Notes
Airbag Type
Section HG
Instrument pack
Instrument cowl
Upper column clamp fixings
Instrument
mounting bracket
fixings (4 off)
b343
11. Refit the column in reverse order to removal with the following notes:
-
The groove for the pinch bolt allows assembly of the universal joint to the intermediate column in only one
orientation. Torque tighten the pinch bolt to 35 Nm.
-
Torque tighten the column lower fixing bolt to 45 Nm
-
Torque tighten the two column upper fixing bolts to 22.5 Nm.
-
If applicable, use new shear bolts to secure the steering lock assembly, and tighten until sheared.
HG.4 - INTERMEDIATE COLUMN
The intermediate steering column consisted of a symmetrical splined shaft and two different Hookes type
universal joints, but has now been replaced by a shaft with an integral lower u/j. The lower joint uses an unindexed 36 spline connection to the steering rack pinion shaft, and the upper joint accommodates a double flatted
boss on the end of the upper column, with a pinch bolt groove allowing assembly in only one orientation. The
intermediate shaft itself, uses a splined joint, and, on early type shafts, a lower indexed pinch bolt groove.
To remove the intermediate column assembly, the upper column must first be removed (see sub-section
HG.3), after which the rack pinion shaft pinch bolt may be removed and the column assembly withdrawn. Match
marking the lower u/j to the pinion shaft will aid steering wheel alignment on re-assembly. Torque tighten the
pinch bolts to 35 Nm.
HG.5 - TRACK ROD ENDS & RACK GAITERS
Front Wheel Alignment
Alignment is measured either by the angle a wheel makes with the vehicle centre line, or the difference in
dimension between the wheel rim to wheel rim measurement at the front and rear of the wheel at hub centre
height. The wheels are said to 'toe-in' when the wheel paths converge ahead of the vehicle, and 'toe-out' when
they diverge. Wheel alignment is designed to vary with both steering angle (Ackermann) and suspension travel
(bump steer) and should be measured only 'straight ahead' at the specified ride height.
Page 9
Lotus Service Notes
Section HG
Provision is made for the adjustment of front wheel alignment at the joint between the steering rack track
(tie) rods, and the outer ball joints ('track rod ends'). The required ride height and alignment specification is
detailed in sub-section CI.2.
Gaiter
Track rod end flats
Steering arm
Steering track rod flats
Track rod end locknut
c28a
Note that in order to preserve the required bump steer characteristic and steering symmetry, the effective
length of each track rod must remain equal - adjust each track rod by a similar amount:
-
-
-
Hold the track rod end using the flats provided, and slacken the locknut. Repeat for the opposite side.
Turn each track rod a similar amount. As a guide, turning both track rods by one quarter of a turn will alter
overall toe-out by approx. 2.0 mm.
When adjustment is correct, hold each track rod end and tighten the locknuts to 45 Nm (33 lbf.ft).
When slackening or tightening the track rod end locknuts, it is important that the torque reaction is resisted
using the track rod end flats, and that the ball joint itself is not allowed to be stressed.
Track Rod Ends
The track rod ends are sealed for life and maintenance free, but if replacement is required; remove the
ball pin nut and use a ball joint splitter tool to separate the joint from the steering arm. Unscrew the joint from
the track rod. On re-assembly, tighten the ball joint to steering arm nut to 30 Nm, and set the front wheel alignment as detailed in sub-section CI.2.
Steering Rack Gaiters
The convoluted gaiters sealing each end of the steering rack housing to the track rods, should be inspected
at service intervals and replaced immediately if found to be torn, cracked or otherwise damaged. The ingress
of dirt or water into the rack housing will cause rapid deterioration of the track rod inner ball joints and rack and
pinion mechanism.
To replace a gaiter, remove the track rod end (see above), release the gaiter clips, and slide the gaiter off
the housing and track rod. Check for consequent damage or wear and replace the steering gear assembly if
necessary. Fit the new gaiter into position, and secure with new retaining clips.
HG.6 - RACK & PINION ASSEMBLY REMOVAL/REPLACEMENT
The rack and pinion assembly is mounted inside an extruded chassis box section crossmember at the
top front of the footwell. Each of the two rack housing mounting plinths uses an M10 (upper) and M8 (lower)
fixing bolt to secure the housing to the vertical rear face of the crossmember. A steel reinforcement channel is
bonded to the outside of the crossmember, with a riveted height setting plate to define the vertical position of the
housing. Note that the only approved repairs or adjustments to the steering rack assembly are the replacement
of the track rod ends and rack housing gaiters, and the adjustment of the rack pressure pad.
Page 10
Lotus Service Notes
Section HG
Steering rack Steel reinforcement channel (bonded)
assembly
Height setting plate
M10 fixing bolt
M8 fixing bolt
Pop rivet
Chassis
crossmember
h54
To Remove/Replace Steering Assembly
1. Remove the nut securing each track rod end to the steering arm, and use a ball joint splitter to separate
the joint.
2.
From inside the footwell, match mark the pinion shaft against the u/j yoke to aid steering wheel alignment
on re-assembly, and remove the pinch bolt.
3.
From inside the footwell, remove the two M8 and M10 bolts securing the rack housing.
4.
Draw the housing forwards to disengage the intermediate shaft u/j, and manoeuvre the assembly out of
the chassis crossmember.
5.
On re-assembly, check that the correct rack height setting plate is fitted. For the standard ride height of
130/130 or 135/135, the '6 notch' plate A111H0017 should be fitted. Fitment of the wrong plate (identified
by the number of notches in the vertical edges) will result in an incorrect bump steer characteristic and
degraded handling. The plate is secured to the chassis by a single pop rivet.
6.
Feed the rack assembly into the chassis crossmember and engage the pinion shaft into the lower u/j with
the match marks aligned. If a new assembly is being fitted, follow the 'Steering Wheel Alignment' procedure in sub-section HG.2.
7.
New fixing bolts for the steering rack housing are precoated with thread locking compound. If existing
bolts are to be re-used, wire brush the threads before re-applying a suitable thread locking compound and
torque tightening the M8 bolts to 22.5 Nm, and the M10 bolts to 45 Nm.
Page 11
Lotus Service Notes
Section HG
8.
Fit the lower u/j pinch bolt, and tighten to 35 Nm.
9.
Fit the track rod ends into the steering arms, and tighten the nuts to 30 Nm.
10. Check and adjust the front wheel alignment as detailed in sub-section CI.2.
HG.7 - ADJUSTMENT OF RACK BAR THRUST PAD
The following information applies to one-piece alloy bodied steering rack units:
A thrust pad backed by a pair of belleville washers, is used to control the preload between the rack bar
teeth and the pinion gear, and is adjustable via a threaded backstop plug. The correct preload allows the horizontally mounted rack bar (column disconnected) to be pulled through its full travel by a steady force of 50 - 70
N (12 - 16 lbf). The rack and pinion assembly must be removed from the chassis before any adjustment may
be carried out.
To adjust the thrust pad, release the locknut (36mm socket) and use a 5.5mm hexagonal bit to adjust the
backstop as required before tightening the locknut. For an approximate initial setting, screw in the backstop
plug until solid, then back off ½ turn.
Rack housing
'O' ring
Threaded plug
Thrust pad
Belleville washers
h56
Locknut
The following information applies to alloy/steel tube type steering rack units:
A thrust pad backed by a coil spring, is used to control the preload between the rack bar teeth and the pinion
gear, and is adjustable via a threaded backstop plug. The correct preload allows the horizontally mounted rack
bar (column disconnected) to be pulled through its full travel by a steady force of 50 - 100 N (12 - 20 lbf). The
rack and pinion assembly must be removed from the chassis before any adjustment may be carried out.
To adjust the thrust pad, release the locknut (36mm socket) and use a 19mm hexagonal bit to adjust the
backstop as required before tightening the locknut. For an approximate initial setting, screw in the backstop
plug until solid, then back off ¼ turn.
Page 12
Lotus Service Notes
Section HG
Exploded View
Oil seal
Ball bearing
Pinion
Circlip
Thrust pad
Locknut
Coil spring
Threaded plug
h59
Sectional View
Pinion shaft
Oil seal
Thrust pad
Locknut
Circlip
Ball bearing
Rack bar
Threaded
plug
Pinion
Needle roller bearing
Coil spring
Page 13
h60
Lotus Service Notes
Section JJ
BRAKING SYSTEM
SECTION JJ
Sub-Section
Page
General Description
JJ.1
3
Tell Tale Lamps
JJ.2
4
Brake Fluid Check & Change
JJ.3
4
Front Brake Pad Replacement
JJ.4
5
Rear Brake Pad Replacement
JJ.5
6
Parking Brake Adjustment
JJ.6
9
Brake Discs
JJ.7
11
Brake Callipers
JJ.8
12
'08 M.Y. Upgrade Option
JJ.8A
13
Brake Master Cylinder
JJ.9
15
Vacuum Servo
JJ.10
16
Pedal Box
JJ.11
21
ABS Theory of Operation
JJ.12
24
ABS Electro-Hydraulic Unit
JJ.13
31
Wheel Speed Sensors
JJ.14
32
Data Link Connector (DLC)
JJ.15
32
Special Tools
JJ.16
33
Lotus Scanner Tool Checking Procedures
JJ.17
37
Page 1
Page 2
Master
cylinder
Vacuum
servo
ABS controller
Pedal
box
Front calliper
Fluid
reservoir
Parking brake
lever
Brake pipe
along sill
Brake pipe
along subframe
GENERAL LAYOUT
Parking brake
primary cable
Parking brake
secondary cable
Rear brake calliper
j161a
Lotus Service Notes
Section JJ
Lotus Service Notes
Section JJ
JJ.1 - GENERAL DESCRIPTION
The Lotus Elise, when fitted with anti-lock brakes, comprises ventilated discs all round with AP Racing 2piston fixed callipers on the front and Brembo single piston sliding callipers on the rear. A tandem master
cylinder, with vacuum servo assistance, operates the callipers via a front/rear split hydraulic circuit with antilock control by a Kelsey-Hayes microprocessor based system. The centrally mounted parking brake lever,
operates the rear calliper pistons by control cables.
The AP Racing front callipers, have lightweight alloy bodies housing two opposed pistons, and are mounted
via two bolts directly to the rear of the forged steel hub carriers. The rear brakes use Brembo cast iron, single
piston callipers, sliding on pins mounted directly to the forged steel hub carriers. A ventilated cast iron brake
disc with curved internal vanes and cross drilling is common to all four wheels, and is sandwiched between the
road wheels and hubs, retained for convenience by a single countersunk screw.
The tandem master cylinder is made by FTE, and incorporates a front section to supply both front brakes,
and a rear section to supply the rear brakes. A translucent fluid reservoir is mounted on a bracket above the
master cylinder, and has separate compartments connected to the front and rear cylinder sections by flexible
hose. A third hose connects the rear reservoir compartment with the clutch master cylinder to supply that
system's needs. A fluid level sensor in the filler cap will light a fascia tell tale lamp if the level becomes
dangerously low.
The parking brake ratchet lever is mounted between the seats and uses a short primary cable and balancing yoke to actuate a single control cable linked to each rear calliper. Adjustment of the calliper mechanism to
compensate for brake pad wear is automatic. The parking brake should be applied by pulling up the lever with
high effort, and engaging the highest ratchet setting attainable. When parking the car on a slope, the additional
precaution should be taken of leaving the transmission in first or reverse gear and steering the wheels towards
the kerb. If the parking brake is applied when the brakes are hot (e.g. after prolonged or vigorous braking),
special care should be taken to ensure that the parking brake is securely engaged in order to allow for any
potential affect on brake performance as the discs cool.
The braking system is designed to enhance brake performance during high speed driving, with good fade
and pad wear characteristics, and have a higher friction level when heated to normal working temperature than
when cold. Required pedal effort will reduce as cold brakes become heated to normal working temperature,
and the braking efficiency will increase significantly as new discs or pads become 'bedded in'. After fitting new
brake components, maximum braking efficiency will be achieved if, for the first few hundred miles, needless
heavy braking is avoided, and the brake pads are allowed to 'bed in' fully before being used to their full
potential.
A Kelsey-Hayes Antilock Brake System (ABS) is used to optimise brake performance in extreme conditions and reduce the tendency of any wheel to lock up. Under most conditions, the maximum braking force is
provided by a wheel which is rotating at about 90% of road speed. Apart from the likelihood of increasing the
stopping distance, a locked wheel provides no steering force, such that with both front wheels locked, movement of the steering wheel has no effect on vehicle direction. With the antilock system, even panic braking
results in controlled deceleration and the retention of steering response and is especially advantageous when
braking on slippery road surfaces and in bad driving conditions. The ABS control system is self monitoring and
has the capability of switching itself off if a fault is detected, allowing the base brake system to operate without
anti-lock control.
Under normal circumstances, the hydraulic power brake system of the vehicle operates without input
from the ABS, with brake pressures governed by the force applied to the brake pedal. The ABS microprocessor
receives signals from wheel speed sensors at each of the four wheel hubs, and interprets this data to determine
if any wheel is tending to lock up. If imminent lock up is determined, the microprocessor commands solenoid
valves in an electro-hydraulic unit to reduce the pressure in that particular brake circuit in order to restore wheel
speed to that providing the maximum braking force consistent with continued wheel rotation.
When the ABS is operating, indication to the driver is provided by a 'pulsing' sensation felt at the brake
pedal as fluid is pumped between the master cylinder and hydraulic control unit, and also by audible clicking of
the relays and switches. These signals indicate to the driver that maximum retardation is being approached,
and that driving style should be modified to suit the conditions. The minimum stopping distance is achieved by
applying the brakes firmly and steadily, and allowing the ABS to modulate hydraulic pressure. The driver
should not attempt to emulate this process by ‘pumping’ the brake pedal, as modulation at the pedal will treat
all four wheels similarly, rather than the individual wheel control allowed by the electronics.
During ABS operation, the wheels may appear to lock momentarily as the wheel speed changes rapidly,
and some tyre noise (intermittent screeching) may be heard. This noise is normal and will vary with road and
Page 3
Lotus Service Notes
Section JJ
tyre conditions. However, a wheel that completely locks and stays locked for more than one or two seconds is
not normal, and indicates that the vehicle should be serviced as soon as possible. The ABS cannot operate
properly if the base brake system is faulty, and will also be affected by dragging brakes, faulty wheel bearings
or other related faults.
The ABS controller constantly monitors the anti-lock system for faults, and lights a fascia tell tale if a
problem is detected. Information stored in the computer's memory may be accessed via a hand held electronic
scanner, in order to facilitate diagnosis of system faults (see later).
JJ.2 - TELL TALE LAMPS
Two tell tale lamps are provided in the instrument cluster to warn of problems in the brake system.
Brakes Tell Tale
As a bulb check function, this tell tale will glow red for about six seconds after ignition switch on, and then
go out unless one of the following conditions applies:
i) The parking brake is applied.
ii) The brake fluid level in the master cylinder reservoir is low.
Under normal circumstances, the tell tale should light when the ignition is switched on, and go out when
the parking brake is released. If the lamp stays on, or comes on whilst driving, the car should be stopped
immediately, as this may be an indication of low brake fluid level caused by a hydraulic leak. A button on the
reservoir cap allows the tell tale circuit to be tested.
Euro spec.
'Brakes' tell tale
USA spec.
'Brakes' tell tale
m252
'ABS' tell tale
'ABS' tell tale
ABS Tell Tale
The ABS tell tale warns the driver of problems in the anti-lock system. The lamp should light for about 6
seconds following ignition switch on, and then go out. If the lamp remains lit, or comes on whilst driving, a fault
in the ABS is indicated. The base brake system will continue to operate normally, but without ABS regulation.
The car can be driven but should be checked and repaired at the earliest opportunity.
JJ.3 - BRAKE FLUID CHECK & CHANGE
Before checking the brake fluid level, ensure that the car is parked on a level surface, and remove the
driver's side front body access panel. The level of fluid in the reservoir may be inspected without disturbing the
filler cap, and should be level with the top of the 'MAX' mark moulded on the translucent reservoir body. The
level will fall progressively as the brake pads wear in service, and should be checked at each service interval.
A sensor incorporated into the filler cap will light a tell tale lamp in the instrument cluster if the level drops
significantly. As a bulb check, the tell tale should light for about six seconds when the ignition is first turned on,
but may also be tested by pressing the button on the filler cap, which action should light the tell tale with the
ignition switched on.
The reservoir is mounted on a bracket over the master cylinder to which it is connected by flexible hoses.
An internal baffle divides the reservoir into two compartments, with one section supplying the front brake
circuit, and a second section supplying the rear brakes in addition to, via another flexible hose, the clutch
master cylinder. Service wear of the clutch friction plate will cause fluid to be displaced from the self adjusting
clutch slave cylinder, back to the reservoir, and will counteract to some extent the dropping of the level due to
brake pad wear.
Page 4
Lotus Service Notes
Section JJ
If the reservoir needs topping up, first clean around the cap to reduce the possibility of contamination
before unscrewing the cap; it is not necessary to disconnect the level sensor cables. Take suitable precautions
to guard against damage to paintwork caused by brake fluid dripping from the level sensor. Use only a fresh
supply of DOT 4 non-mineral type fluid, identified by a yellow and black symbol.
BRAKE FLUID
RESERVOIR
CAP
Non-mineral type
brake fluid symbol
(Yellow & Black)
ohs139
j146
Do NOT use DOT 5 silicone fluid, or any
fluid which has been exposed to the atmosphere for more than a brief period, or any fluid
suspected of being wet, dirty or contaminated.
Do not overfill. Replace the filler cap securely.
Some service operations, such as replacing brake pads, will result in the displacement of fluid from the
hydraulic circuit back into the reservoir. In order to prevent fluid overflowing from the reservoir, it may be
necessary to remove some fluid using a syringe.
Renewal of Brake Fluid
Brake fluid absorbs water from the atmosphere over a period of time (hygroscopical), resulting in a
lowering of the boiling point of the fluid, and corrosion of the hydraulic system. For optimum safety and brake
performance, the brake fluid should be renewed every twelve months (including clutch release system).
Brake Bleeding Procedure
If the brake fluid is to be renewed, or an hydraulic component replaced, the system should be bled of air
using the following procedure:
1.
Using conventional manual techniques, or low air pressure applied to the reservoir, bleed the system
from each calliper bleed nipple in turn until no air bubbles can be seen.
2.
Connect the Lotus Scan tool and select ABS and follow the brake bleeding instructions. Whilst this
automatic process is taking place (with all 4 calliper nipples open), gently cycle the brake pedal up and
down whilst keeping the reservoir topped up, to move any air bubbles displaced from the ABS unit down
the hydraulic lines. Finish by closing each nipple with the pedal down.
3.
Repeat step (1) to purge each calliper feed line in turn.
JJ.4 - FRONT BRAKE PAD REPLACEMENT
Pad thickness may be checked with the wheel removed without disturbing the calliper.
Standard pad thickness (excluding backplate);
Minimum pad thickness (excluding backplate);
9.0 mm
2.5 mm
If the thickness of any pad is below the specified minimum, the axle set of pads should be renewed. Note
that the pad backplates are factory fitted with anti-squeal overlays, and are identified with T 4139 on the
backplate.
For cars used on track, where sustained hard use and extreme brake temperatures are likely to occur,
'Motorsport' pads made by Pagid may be fitted in complete vehicle sets under part number A111J0150S (front)
and A111J0151S (rear).
1.
To remove the brake pads; Remove the 'R' clip from the lower of the two pad retaining pins, and withdraw
the lower of the pin taking care to restrain the anti-rattle spring. Remove the second retaining pin together with the anti-rattle spring plate. Withdraw the pads from the calliper. Measure the lining thickness
and renew the axle set of pads if any lining is below 2.5 mm.
Page 5
Lotus Service Notes
Section JJ
2.
Before replacing the pads, inspect the calliper for any signs of fluid leakage from a piston seal or joint,
and replace the calliper if any such signs are evident. Clean the pad recess in the calliper taking suitable
precautions to protect from dust inhalation.
3.
If refitting the existing brake pads, refit each pad in the same position as originally fitted.
'R' pin
Brake pad
Pad securing pin
Anti-rattle spring plate
j164
4.
If fitting new pads, the pistons must be pushed back into the calliper to provide the necessary clearance.
This action will return fluid to the master cylinder such that some fluid may need to be removed in order
to prevent overflowing. Take care to avoid damaging the brake disc surface, or distorting the disc.
5.
Position the pads in the calliper, and insert the upper pad retaining pin from the outboard side. Secure
with the split pin.
6.
Fit the anti-rattle spring into position with the side tangs pressing against the top end of the pad backplates,
and the centre tang beneath the retaining pin. Insert the second pad retaining pin into the calliper,
passing over the lower central anti-rattle spring tongue.
7.
Before driving the car, press the brake pedal several times to bring the pads to their correct running
position. Top up the master cylinder reservoir if necessary to bring the level to the top of the 'MAX' mark.
8.
Ensure the customer is made aware that maximum braking efficiency will be achieved if, for the first few
hundred miles, needless heavy braking is avoided, and the brake pads are allowed to 'bed in' fully before
being used to their full potential.
JJ.5 - REAR BRAKE PAD REPLACEMENT
Pad thickness may be checked after removing the road wheel, without disturbing the calliper.
Standard pad thickness (excluding backplate);
6.5 mm
Minimum pad thickness (excluding backplate);
2.5 mm
If the thickness of any pad is below the specified minimum, the axle set of pads should be renewed. Note
that the pad backplates are marked T 4139 and are factory fitted with anti-squeal overlays.
Page 6
Lotus Service Notes
Tools Required:
Piston Retraction Tool T000T1242
1.
Remove the rear road wheels.
2.
At each rear corner: using a suitable pin
punch, knock the pad retaining pin out
of the calliper towards the outside, taking precautions as necessary to restrain
the anti-rattle spring from flying off as
the pin is withdrawn.
Section JJ
Pad retaining pin
Retaining
pin snap
ring
3.
Remove the anti-rattle spring, and withdraw both brake pads from the calliper.
Measure the thickness of the lining material, and renew the axle set of pads if
any are below 2.5 mm.
4.
Anti-rattle spring
j123
Before refitting the pads, inspect the piston boot for splits, cracks or other damage, and for any signs of fluid leakage
or wetness.
If any such signs are apparent, the complete calliper should be replaced as Brembo do not recommend
that this calliper be dismantled.
5.
If refitting the existing brake pads, refit each pad in the same position as originally fitted.
6.
Before fitting new rear pads, the calliper piston must be screwed back into the calliper down the parking
brake actuation mechanism. This operation requires the use of special tool T000T1242 and the removal
of the brake disc:
Remove the single socket head screw retaining the brake disc, and remove the disc.
Fit special tool T000T1242 into the holes in the calliper piston, and screw the piston back down
the parking brake mechanism screwthread until fully bottomed.
Refit the brake disc, and tighten the countersunk retaining screw to 12 Nm.
7.
In order to minimise brake squeal from new pads during the bedding-in period, a copper based (PBC)
paste (e.g Renolit) should be used on the pad contact surfaces of the rear callipers in the areas shown:
Contact face of piston
Calliper outboard fingers
188
Page 7
Lotus Service Notes
Top surface of bridge including
inner surface in contact with
pad backplate
Section JJ
Bottom surface of bridge
including inner surface
in contact with pad backplate
j188
8.
Slide the brake pads into the calliper. Position the pad anti-rattle spring in the calliper aperture, with the
spring ends located in the recesses provided. Ensure that the spring is fitted the correct way up, w i t h
the turned spring end in the longer recess. Press the spring eyes into alignment whilst the pad retaining
pin is inserted through the calliper from the outside. Ensure that the pin passes through both eyes of the
anti-rattle spring, and both brake pads, and that the pin is fully installed with the snap ring seated in the
outboard side of the calliper.
Anti-rattle spring
Inboard pad
Turned spring end
in longer recess
Outboard pad
Pad retaining pin
j124
9.
Refit the roadwheels and press the brake pedal several times to set the brake pad position. Before
switching on the ignition, check the fluid level in the reservoir and top up if necessary.
10.
Ensure the customer is made aware that maximum braking efficiency will be achieved if, for the first few
hundred miles, needless heavy braking is avoided, and the brake pads are allowed to ‘bed in’ fully before
being used to their full potential.
Page 8
Lotus Service Notes
Section JJ
JJ.6 - PARKING BRAKE MECHANISM
Operation of the parking brake lever applies a pull to a short link cable which connects via a horseshoe
compensator to the centre of a single cable linking the two rear callipers. At each calliper, the cable connects
to a lever which operates the hydraulic piston by mechanical means:
Movement of the calliper lever causes rotation of one of a pair of steel discs, rotation of the other being
restrained by a stop bolt in the cylinder. Hardened balls housed in ramps machined in the discs, force the discs
apart, and in so doing, apply an axial force to the piston via a screwthread and nut. The nut is restrained in the
piston by a one way clutch which grips the nut when the parking brake is applied, but allows it to turn when the
mechanism relaxes, or when the piston is operated hydraulically by the footbrake. In this way, the mechanical
mechanism is adjusted automatically to compensate for pad wear.
Needle roller
thrust bearing
Piston
assembly
Driven
disc
Return
spring
Stop
bolt
Operating
lever
Balls
in ramps
Lever
return
spring
Driving
disc
j126
Calliper park brake lever
For the auto adjustment system to
function correctly, it is essential that each
calliper parking brake lever is allowed to return
fully when the brake is released, and is not
prevented from doing so by maladjustment of
the parking brake cable. To check that the
calliper levers are fully returned; with the
parking brake ‘off’, measure the distance
between the cable abutment and calliper lever
as shown.
76 mm
Cable abutment
139
Page 9
Lotus Service Notes
Section JJ
After verifying this dimension, any slack in the rear cable may be adjusted out at the left hand outer cable
abutment, which is integral with the pivot bracket for the front leg of the lower wishbone. Remove the engine
bay undertray for access. After adjustment, re-check the calliper lever ‘off’ dimension.
LH lower wishbone
front pivot bracket
Horseshoe compensator
Parking brake cable adjuster
j169
The parking brake lever is mounted in a steel bracket which also houses the gearchange lever, and is
bolted to the seat mounting crossmember at the front, and to the floor rear crossmember. The parking brake
lever is secured by two bolts fixing the ratchet quadrant to the bracket. Access to the lever is available after
removing the cockpit centre trim panel:
Parking brake lever
Ratchet quadrant
Primary cable
Parking brake tell tale switch
Mounting bracket
Fixing point to
seat rear
crossmember
j189
Page 10
Lotus Service Notes
-
Section JJ
Unscrew the gear lever knob.
Release the fixing screw at either side of the gear lever shroud base.
Remove the single screw retaining the rear bulkhead centre pocket, and then the two screws securing the
rear shroud. Disconnect the auxiliary power socket.
Lift the centre trim panel, label and disconnect the CDL switch and (if fitted) hazard switch, and release
the gear lever gaiter.
Note that the parking brake/gearchange lever mounting bracket is not drive handed, but is offset, via
alternative fixing holes in the chassis, towards the passenger side. The ratchet pawl operates a micro switch
to light the 'brakes' tell tale lamp in the instrument panel whenever the ignition is switched on and the parking
brake is applied. The short front cable is connected to the lever assembly by a clevis pin with spring retaining
clip. When carrying out any work in this area, take care not to damage or misroute the electrical main harness.
JJ.7 - BRAKE DISCS
All four wheel brakes use a brake disc which is sandwiched between the wheel and its hub flange, being
centralised by the hub spigot, and transmitting torque via the clamping force of the road wheel bolts. A
countersunk screw is used to retain the discs for convenience when servicing.
The same disc is used at each corner of the car, and features cast iron construction with internal curved
vane cooling and cross-drilling. The opposite direction of rotation of the curved vanes on each side of the car
does not significantly affect the cooling performance of the disc. The condition of the brake disc friction
surface is a major factor in brake performance and feel, with a good surface quality and minimal run-out and
thickness variation being required. After an extended lay up, some surface corrosion may develop on the discs
which will cause a degradation in braking quality until the surfaces are cleaned up by normal brake action.
Excessive run-out or thickness variation as a result of overheating or extended wear, may cause brake judder
and/or extended pedal travel due to pad 'knock off'. Scoring and ridging of the braking surfaces will be exacerbated by operation in dusty or unmetalled road environments, and will reduce braking performance.
No skimming or re-surfacing of the brake discs is recommended. If the disc becomes badly scored, or is
out of specification in any way, it should be renewed. NOTE: Ensure that there is no discernible free play in the
wheel bearings before attempting to measure brake disc run-out. If disc run-out exceeds the service maximum,
check the hub run-out before replacing the disc.
Brake disc thickness:
New
26.0 mm (1.02 in)
Service minimum
24.0 mm (0.98 in)
Runout:
New maximum
0.03 mm (0.001 in)
Service maximum
0.10 mm (0.004 in)
Hub:
Disc mounting face run-out max.
0.04 mm (0.0015 in)
Front Disc Replacement
1.
Remove the road wheel.
2.
Remove the two bolts securing the brake calliper to the hub carrier, and withdraw the calliper from the
disc. Secure clear without straining the flexible hose.
3.
Remove the single countersunk screw, and withdraw the disc from the hub.
4.
Before re-fitting a disc, ensure that the mating face between disc and hub is scrupulously clean. Mount
the disc onto the hub and align the wheel bolt holes.
5.
Apply Permabond A130 (Blue - A912E7033) to the threads of the calliper fixing bolts. Fit the calliper over
the disc and secure to the hub carrier with the two bolts. Tighten to 45 Nm (33 lbf.ft).
6.
Refit the road wheel and operate the brakes before driving the car to set the brake pad position.
Rear Disc Replacement
Replacement of the rear discs is similar to that for the front discs, except that if the brake pads are
removed, it is not necessary to remove the brake calliper to enable the disc to be withdrawn from the hub.
Page 11
Lotus Service Notes
Section JJ
JJ.8 - BRAKE CALLIPERS
The front brake callipers are manufactured by A.P. Racing, and are to be dismantled or overhauled only
by their factory at Wheeler Road, Seven Stars Industrial Estate, Coventry, CV3 4LB.
Torque settings:
Flexible hose to front caliper: 22 Nm
Front caliper to hub carrier: 45 Nm
The Brembo rear brake callipers may have the sliding pins overhauled as detailed below, but any signs of
hydraulic leakage from the cylinder indicate that the unit should be replaced.
Rear Calliper Sliding Pins
The sliding bushes and sleeves of the Brembo rear callipers may be replaced without disturbing the
hydraulic connection:
a)
Disconnect the parking brake cable from the calliper.
b)
Remove the cap head bolt securing the bottom guide bush to the hub carrier.
Top guide bush boots
Top guide bush
Lower guide
boot
j163
Split plastic bush
Lower guide sleeve
c)
Remove the hex. head bolt securing the top guide bush to the hub carrier, and withdraw the calliper from
the car with the brake hose still connected.
d)
Slide out the lower steel guide sleeve and withdraw the bush/boot from the calliper. Pull the boots off the
top steel guide bush and slide out the bush from the calliper.
e)
Clean the guide bores in the calliper body with brake cleaner. Lubricate the new bushes and boots with
silicone grease provided in the repair kit, and reassemble into the calliper in reverse order to disassembly.
f)
Refit the calliper to the hub carrier using Permabond A134 on the threads of both bolts, torque tightening
the two fixings to:
Upper M10 bolt;
45 - 50 Nm (33 - 37 lbf.ft)
Lower M8 caphead; 26 - 30 Nm (19 - 22 lbf.ft)
g)
Reconnect the parking brake cable and operate the footbrake to reposition the pads before driving the
car.
Page 12
Lotus Service Notes
Section JJ
JJ.8A - '08 MODEL YEAR UPGRADE OPTION
Introduced as an option for some '08 models, is an uprated front brake kit, comprising 4-piston front
callipers, larger diameter front discs and steel braided hoses.
Front Callipers:
At each front corner, the A.P. Racing, alloy, 4-piston front calliper is radially mounted to the front hub
carrier via an alloy adaptor bracket. Two reduced head capscrews secure the adaptor bracket to the hub
carrier, with two capscrews with washers securing the calliper to the adaptor. Two retaining pins are used to
locate the Pagid RS14 brake pads, and also secure an anti-rattle spring plate which incorporates a direction of
rotation arrow.
Torque figures: Adaptor to hub carrier; 58 Nm. Calliper to adaptor; 58 Nm. Caliper bleed screw; 17 Nm.
Front Discs:
The front discs are increased in diameter from 288mm to 308mm, and are cooled by internal curved
vanes which trail the normal direction of rotation, to result in distinct RH and LH components. Each disc is
mounted to its hub via an adaptor 'bell' from which it should not be separated under normal circumstances.
Torque of disc to bell mounting bolts; 14 Nm. Note that these discs are fitted only on the front, with standard
discs on the rear.
New thickness of the front discs is 26.00mm; minimum service thickness 25.00mm
Wheel bolts:
In order to provide sufficient clearance between the 4-piston brake callipers and all road wheel options,
the thickness of the disc mounting bell at the hub face is increased from the standard 7mm disc thickness to
11mm. This requires the use of 2mm longer wheel bolts (C117G6000F) to maintain sufficient thread engagement. To reduce the possibility of incorrect fitment, both front and rear wheels are secured with the longer
bolts, with no coded security bolts fitted. Note that these bolts use the standard spline type socket heads, but
have a reduced outside diameter of the head.
Standard bolt;
Long bolt;
B117G6000F
C117G6000F
26mm thread length
28mm thread length
Head outside diameter: 22mm
Head outside diameter: 19mm
Braided hoses:
The steel braided front hoses are connected to the front callipers using a banjo fitting tightened to 25 Nm.
**************************************************************
Introduced in June 2008, at approx. ’08 M.Y. VIN serial number 1742, the ‘big brake’ kit fitted to all Exige
S models with the Performance Pack option, has been revised to a Fast Road specification. The differences
may be summarised as follows:
Single piece iron front brake discs replace separate iron discs and alloy mounting bells;
Bespoke single piece front callipers replace callipers with separate adaptor brackets;
Brake pad material change, front and rear;
Revised braided hoses front and rear;
Standard wheel bolts (incl. security coding) replace longer versions without security bolt;
For Cup 260 cars, a new Sport brake specification combines the Fast Road front callipers with 2-piece
front discs for marginally better disc cooling, in conjunction with Pagid pad material.
In general, the Fast Road brakes offer significant benefits over standard brakes where full vehicle performance is exploited, primarily through reduced brake fade in conditions of repeated or prolonged heavy
application. Trade offs include a greater susceptibility to noise generation. The Sport brakes, have marginally
better disc cooling via the alloy mounting bells, and use the competition type Pagid pad material. Note that the
new calliper requires a new reduced thickness version of the Pagid pad (A128J0003S). Trade offs include a
greater susceptibility to noise generation, and reduced response when the brakes are cold.
Page 13
Lotus Service Notes
Section JJ
The new callipers do not require the thicker disc bells formerly used to provide wheel/calliper clearance,
or the corresponding increased length wheelbolts. Consequently, a new version of the two piece disc assembly
uses the standard 8 mm flange thickness and standard wheelbolts.
Be aware that erroneously fitting a new 2-piece disc on an original ‘Big Brake’ car will result in
the road wheel fouling the brake calliper.
Comparison chart:
Feature
Front calliper pistons
Piston diameter (mm)
Calliper housing
Pad material
New pad thickness
Front disc size
Front disc features
Wheelbolts
Standard
(reference)
2
44.45
Alloy. Bolts
directly to hub
carrier.
Textar T4139
14.5
288 x 26
Curved internal
vanes, cross
drilled.
Common RH LH
Single piece.
26mm long
+ coded bolt
‘Big Brake’
Fast Road
(discontinued)
4
4
Leading 31.75
Leading 31.75
Trailing 36.00
Trailing 36.00
Alloy. Uses
Alloy. Bolts
separate adaptor directly to hub
bracket.
carrier.
Pagid RS14B
Ferodo DS25HP
16.5
14.5
308 x 26
308 x 26
Curved internal
Curved internal
vanes, cross
vanes, cross
drilled.
drilled.
Handed RH LH
Handed RH LH
Separate 11mm Single piece.
thick alloy
mounting bell.
28mm long
26mm long
+ coded bolt
Sport
4
Leading 31.75
Trailing 36.00
Alloy. Bolts
directly to hub
carrier.
Pagid RS14B
14.5
308 x 26
Curved internal
vanes, cross
drilled.
Handed RH LH
Separate 8mm
thick alloy
mounting bell.
26mm long
+ coded bolt
Brake pad bedding-in
Fast Road brakes should be bedded-in according to standard handbook advice; avoid needless heavy
braking for the first 100 miles (160 km). Thereafter, the first time the brakes are used aggressively, some loss
of brake feel may be evident as the brake pads undergo a final conditioning phase. After the brakes have
cooled, full brake performance will be restored.
For cars built with Sport Brakes, and any car fitted with ‘big brakes’ using Pagid RS14B pads, an extended
bedding-in procedure is required, detailed in LSL534b (see S/B 2008/05).
Whichever brake equipment is fitted, it is vital that the brake pad material is matched at all four
wheels - do not mix front and rear pad materials.
The braided brake hoses have been revised on introduction of the Fast Road brakes to optimise hose
length and improve ‘P’ clip security. These hoses may be used as service replacement on all cars.
Page 14
Lotus Service Notes
Section JJ
JJ.9 - BRAKE MASTER CYLINDER
The tandem brake master cylinder is mounted in the front compartment and is secured to the brake servo
by two studs with M8 nuts. The cylinder uses two pistons to supply the independent front and rear brake
circuits. The cross-section below is provided for information, but the master cylinder manufacturer does not
recommend any dismantling of the unit, and supplies no replacement parts or internal components. If the
cylinder is faulty it should be renewed as a complete assembly.
j187
Key to Cross-Section
1.
2.
3.
4.
5.
6.
7.
8.
9.
Body
Passage to rear cylinder
Rear cylinder inlet port
Guide bush
Rear piston
Lip seal
Stop washer
Primary seal
Washer
10.
11.
12.
13.
14.
15.
16.
17.
18.
Spring plate
Retaining screw
Stop sleeve
Rear piston spring
Front piston
Secondary seal
Transfer passage
Front piston stop
Front piston spring
To remove the unit, proceed as follows:
1.
On Exige models, remove the front clamshell (see sub-section BR.6).
2.
Syphon fluid from the reservoir to reduce spillage.
3.
Release the two hoses connecting the master cylinder to the fluid reservoir, and the single hose connecting to the clutch master cylinder, and plug all hoses. Disconnect the electrical cables from the reservoir
cap, cut the tie wrap and withdraw the reservoir from the mounting bracket.
4.
Release the two brake pipes from the master cylinder, and plug the pipes and ports.
5.
Release the two nuts securing the master cylinder to the brake servo and remove the cylinder.
6.
Refit the master cylinder in reverse order to removal, using NEW locknuts (supplied with a new cylinder)
and tighten to the following torques:
Master cylinder fixing nuts; 25 Nm
Brake pipes to cylinder; 17.5 Nm
7.
Fill the reservoir with DOT 4 non-mineral type brake fluid, and bleed the complete brake system of air
using standard vacuum assisted, pressure assisted or manual techniques.
Page 15
Lotus Service Notes
Section JJ
JJ.10 - VACUUM SERVO UNIT
The FTE brake vacuum servo is, with the exception of the air filter and non return valve, a non-servicable
sealed unit which if found to be faulty, must be replaced as an assembly. The air filter (surrounds the input push
rod) should be replaced whenever the brake system is overhauled, and cleaned or replaced more frequently if
the vehicle is operated in dusty conditions. A vacuum non-return valve is incorporated into the vacuum hose
elbow connector in the front case of the servo unit, and a second in-line non-return valve is fitted into the supply
line close to the engine. The elbow connector valve is a push fit into a grommet in the servo shell, and is
supplied complete with the grommet.
The servo is fitted between the brake pedal and master cylinder and is of the 'suspended in vacuum' type,
wherein a flexible diaphragm divides the space inside a steel shell into two chambers. The front chamber is
connected, via a non-return valve, to the vacuum produced in the engine's inlet plenum chamber. When the
brakes are 'off', this vacuum is also applied to the rear side of the diaphragm, which is held towards the rear of
the shell by a spring. The brake pedal is connected to the brake servo control rod, which operates a control
valve before pressing against the output rod via a pliant reaction disc.
Brakes Off
In the simplified schematic diagram, with the brakes off, the diaphragm and driving piston are pushed to
the left by the main spring, and the input rod is pushed to the left by its own spring, causing the control valve to
close off the atmospheric port. Engine vacuum admitted to the right hand side of the diaphragm is also
communicated to the left side of the diaphragm, and the unit is stable.
Diaphragm
Rear chamber
Engine
vacuum
Servo control rod
Front
chamber
Brake pedal
connection
Output
rod
Air filter
Diaphragm
Main
spring
Reaction disc
j147a
Page 16
Lotus Service Notes
Section JJ
Initial Movement
Initial movement of the brake pedal causes the input rod to move to the right, and allows the control valve
under the action of its spring, to close off the vacuum port in the driving piston. The atmospheric port remains
closed.
Driving piston
Vacuum port
closed off
Brake pedal
input
Atomospheric
port closed
147b
Page 17
Lotus Service Notes
Section JJ
Pressure Balance
Further pressure on the brake pedal opens the atmospheric port and bleeds atmospheric pressure into
the left hand chamber. This pressure imbalance causes the driving piston to move to the right, adding assistance
to the force applied directly to the output rod (and the master cylinder) via contact between the input and output
rods. When the force produced by the pressure differential across the diaphragm balances the reaction force
of the main spring and master cylinder, movement of the driving piston ceases, with both control valve ports
closed, and the system once again in equilibrium.
From this position of equilibrium, further pressure on the pedal will tend to open the atmospheric port and
allow pressure in the left hand chamber to increase, and move the driving piston to the right before again
stabilising. Any reduction in pedal pressure will tend to open the vacuum port and allow the higher pressure in
the left hand chamber to bleed off into the right hand chamber, whose depression is kept constant by its
connection with the intake plenum. The pressure imbalance is reduced, and the driving piston will move to the
left under the action of the main spring, until equilibrium is again restored.
Higher pressure
balances manifold
pressure plus
spring
Low pressure
from intake
manifold
Vacuum port
Input from
brake pedal
Output to
master
cylinder
Atmospheric port
j 47c
Page 18
Lotus Service Notes
Section JJ
Maximum Assistance
If the pedal is pressed hard, the atmospheric port will be held open, so that the left hand chamber will be
subject to full atmospheric pressure. This is full servo assistance which will, with 0.8 bar of vacuum available
from the engine, increase the force applied to the master cylinder pushrod by approximately four times.
Atmospheric
pressure
Intake manifold
depression
Input from
brake pedal
Output to
master
cylinder
Contact between
input and output rods
via reaction disc
Atmospheric
port open
j147d
When pedal pressure is relaxed, the vacuum port in the driving piston will open and bleed the higher
pressure from the left side of the diaphragm into the right hand chamber and thence into the engine plenum,
collapsing the pressure differential across the diaphragm. The driving piston is moved fully to the left by the
main spring.
The pliant reaction disc fitted between the input and output rods ensures a graduated application of servo
assistance and provides pedal feedback and 'feel' to the driver.
Page 19
Lotus Service Notes
Section JJ
Operational Check
As a quick check of servo operation proceed as follows: With the engine stopped, press the brake pedal
several times to exhaust the servo unit of vacuum. Keeping the pedal pressed (which should be 'hard' and
'high'), start the engine; The pedal should drop slightly as the servo vacuum builds up, and extra force is
produced. If the pedal does not drop, it is most likely that there is a fault in the vacuum supply line. Check the
vacuum hose, all connections and the non-return valve. If the vacuum supply is not defective, the servo unit
should be replaced.
Setting brake pedal: It is essential that the servo piston (and master cylinder piston) is allowed to return fully
when the brakes are released, and is not pre-loaded by mal-adjustment of the input pushrod. See sub-section
JJ.11.
Stop light switch: The stop switch is mounted in a right angle bracket fixed to the underside of the scuttle, and
abuts directly against the pedal. The switch is retained in the bracket by a quarter turn mechanism.
To Replace Brake Servo Unit
1.
Remove the brake master cylinder (see sub-section JJ.9).
2.
From within the footwell, disconnect the servo pushrod from the brake pedal.
3.
Disconnect the brake servo vacuum hose, and release the four nuts securing the servo to the pedal box
extension plinth. Withdraw the servo assembly.
4.
Replace the servo in reverse order to the above, tightening the servo mounting nuts to 25 Nm, and the
new master cylinder fixing nuts to 25 Nm. Check pushrod adjustment (see sub-section JJ.11) and bleed
the hydraulic system.
Pedal box
Servo mounting bracket
to pedal box fixing
Brake servo
Servo to mounting
bracket fixing nut
j191
Page 20
Lotus Service Notes
Section JJ
JJ.11 - PEDAL BOX
PRIOR TO '06 M.Y.
The extruded and welded aluminium alloy pedal box is bonded and rivetted to an aperture in the chassis
scuttle. A hollow steel pivot shaft serving all three pedals is bolted to a steel mounting plate, itself bolted to the
inside of the pedal box. Each pedal is machined from a common alloy extrusion, with the throttle pedal being
of a narrower section than that used for the brake and clutch. An extruded footpad is keyed, bonded and
rivetted to the clutch and brake pedals, and is bolted to the throttle pedal. All the pedals use synthetic bushes
for maintenance free articulation on the steel pivot shaft, and the clutch pedal uses a cylindrical steel trunnion
supported in synthetic bearing rings to actuate the master cylinder pushrod.
In order for the required pedal spacing to be achieved within the packaging constraints of the vehicle, the
brake pedal uses a relay lever to move the output plane inboard of the pedal line. A steel relay lever pivots on
the common pedal shaft, and is equipped with two legs, one of which is used to connect to the brake pedal via
an integral trunnion, whilst the other leg is connected to the brake servo pushrod by a clevis pin.
The throttle pedal actuates the throttle cable directly, which is routed along the cockpit centre, beneath the
gear lever and parking brake lever trim panels, beneath the fuel tank bay and up to the front of the engine bay
to the throttle body.
Adjustment
Throttle cable:
The pedal is pulled against a rubber buffer on a steel upstop bracket by an extension spring.
Adjust the cable outer length at the engine end abutment bracket to allow 2 - 3mm of pedal movement
before the throttle is actuated.
Set the downstop in the pedal footpad such that vigorous full depression of the pedal achieves full
opening of the throttle butterfly without allowing the cable to be strained.
An alternative pedal position which may be preferred for 'heel and toeing' may be achieved by replacing
the rubber upstop buffer with a M5x15 hex. head setscrew, with three flat washers beneath the head for a
total thickness of around 7mm. The cable must then be re-adjusted at the engine abutment as above.
The footpad downstop bolt should then be replaced by an M8x20 setscrew and reset as above.
Brake pedal:
The pedal is pulled 'off' by an extension spring anchored to a bracket rivetted to the scuttle beam.
There is normally a gap of approximately 3mm between the brake pedal and the pedal box upstop flange
with the pedal released. If preferred, the brake pedal can be raised slightly by adjusting the effective
length of the pushrod at its connection to the clevis, but the master cylinder must never be preloaded, i.e.
there must always be a small clearance between the pedal and upstop bracket to ensure that the master
cylinder piston is allowed fully to return and open the reservoir port.
After any adjustment, tighten the clevis locknut and check operation of the brake light switch.
Clutch pedal:
The pushrod, which is captive in the master cylinder, is screwed fully into the pedal trunnion, and controls
the pedal height. Rubber buffers are provided to cushion the pedal at full travel.
Pedal Removal
To remove a pedal from the pivot shaft, the pedal shaft mounting plate must be removed from the pedal
box complete with all three pedals:
1.
Remove the intermediate steering column (see Section HG).
2.
Disconnect the brake servo clevis pin from the pedal relay lever, and release the throttle cable from the
pedal.
3.
Remove the two bolts securing the clutch master cylinder assembly to the pedal box and unscrew the
pushrod from the pedal trunnion.
4.
Remove the two bolts securing the brake servo mounting plinth to the pedal box and provide alternative
support for the servo/brake master cylinder assembly.
Page 21
Lotus Service Notes
Section JJ
5.
Release the pedal return springs and remove the stop lamp switch.
6.
From above, release the six M6 screws securing the pedal shaft mounting bracket to the top of the pedal
box, and the single screw in the front face of the pedal box. Withdraw the pedal shaft assembly from
inside the pedal box.
7.
Remove the three M5 screws securing the pedal shaft to its mounting bracket, and disassemble the
pedals from the shaft taking careful note of spacers and washers.
8.
On re-assembly, note that the pivot bushes of the brake pedal and relay lever should be lubricated with
Syntheso GLK1, or equivalent. Check pedal pushrod and stop switch operation as detailed above.
Pedal shaft mounting
plate fixing
Pedal box
Throttle
cable
Pedal
shaft
mounting
plate
Throttle cable
abutment on
scuttle
Pedal
footpad
Pedal pivot
bush
Clutch
pedal
trunnion
Downstop
pl1401mt
Pedal shaft
Page 22
Alloy clutch
pedal
Brake pedal
steel relay lever
Throttle cable
abutment on
engine plenum
Lotus Service Notes
Section JJ
FROM '06 M.Y.
Introduced for the 2006 model year, was electronic throttle control (ETC), which dispensed with the mechanical throttle cable linking the accelerator pedal to the throttle body. The ‘drive by wire’ throttle actuation
uses a throttle pedal fabricated from steel rod which is pivotted in a plastic housing bolted to the pedal box.
The plastic housing incorporates two pedal position potentiometers operated by rotation of the pedal pivot, and
provide signals to the engine ECU, which then interprets driver commands allied to emission and engine
management requirements, and drives the throttle butterfly stepper motor to the appropriate position, or rate of
change of position.
Other changes to the pedal box include fabricated steel, silver painted brake and clutch pedals fitted
with alloy pedal pads. Some markets, principally Canada, are fitted with a pedal actuated 'clutch down' switch
to inhibit engine cranking unless the clutch pedal is fully depressed.
The throttle pedal assembly may be removed by disconnecting the harness plug from the module and
releasing the three M8 bolts and nuts securing the unit to the pedal box.
- The throttle pedal upstop is set internally within the electronic housing, with a downstop moulded into the
housing itself.
- The brake pedal is pulled 'off' by an extension spring anchored to a bracket rivetted to the scuttle beam.
- There is normally a gap of approximately 3mm between the brake pedal and the pedal box upstop flange
with the pedal released. If preferred, the brake pedal can be raised slightly by adjusting the effective
length of the pushrod at its connection to the clevis, but the master cylinder must never be preloaded, i.e.
there must always be a small clearance between the pedal and upstop bracket to ensure that the master
cylinder piston is allowed fully to return and open the reservoir port.
- After any adjustment, tighten the clevis locknut and check operation of the brake light switch.
- The clutch pushrod uses an integral plastic clevis to connect to the pedal and control the pedal up position
as the master cylinder tops out. A downstop buffer is provided on the pedal box flange.
Pedal box
Pedal shaft mounting
plate fixing
Module to pedal
box fixing
Throttle
pedal
electronic
module
Pedal shaft
mounting
plate
Module
connector
socket
Pedal pivot bush
Steel pedal
Pedal shaft
Alloy footpad
pl1401mt6
Page 23
Lotus Service Notes
Section JJ
JJ.12 - ABS THEORY OF OPERATION
The Kelsey-Hayes antilock brake system is an 'add on' type used to supplement the dual circuit, tandem
master cylinder, vacuum servo assisted brakes fitted to the Elise. A single electro-hydraulic unit comprising a
hydraulic modulator, hydrauliic pump, microprocessor and solenoid valve bank, is mounted in the front services compartment and plumbed into the front and rear brake circuit lines from the tandem master cylinder.
The microprocessor (ECM) receives signals from magnetic wheel speed sensors integrated into each of
the four road wheel hubs, and interprets the individual wheel acceleration, deceleration, and comparative
wheel speeds. From this data, the ECM is able to determine if any wheel is tending to lock up, and if imminent
lock up is sensed, the microprocessor commands the relevant solenoid valves firstly to reduce pressure in that
particular brake circuit in order to restore wheel speed, and then to modulate pressure to that providing the
maximum braking force consistent with continued wheel rotation. The system is able to monitor and independently control each of the four wheel brakes, and is referred to a 4-channel system.
In order to achieve the required pressure modulation, three basic modes are used:
Pressure hold;
Pressure reduction;
Pressure increase;
In order to maintain the safety provision of two entirely independent hydraulic circuits, one for the front
brakes, and one for the rear, the hydraulic elements of the control unit are doubled up, with no part of the
system shared between the two circuits. For the pressure hold function, four isolation solenoid valves are
used, one in the hydraulic circuit for each wheel brake. The pressure reduction function is achieved by a
separate dump solenoid valve in each of the four wheel brake circuits, and the pressure increase provided for
by a single electric motor operating two hydraulic pumps, one serving the front, and on the rear brake circuit.
Separate low pressure accumulators are used for the front and rear circuits.
Electro-Hydraulic Control Unit
The electro-hydaulic control unit comprises an alloy valve block containing the four isolation valves, four
dump valves, two hydraulic pumps and two accumulators, with the single pump motor screwed to the housing,
and with a solenoid block and ECM unit attached to the topside. The complete assembly is flexibly mounted
via three rubber isolator bushes to a steel cradle, which is itself mounted on three rubber bobbins to the
passenger side front chassis. The eight solenoid valves are grouped in two rows, with the valve plungers
protruding in sealed canisters from the topside of the unit where each one is surrounded by a solenoid coil. The
isolation and dump valves share a similar construction, but the spring loaded isolation valves are normally
open, and the dump valves normally closed.
Anti-lock ECM
Valve block
Control unit
mounting cradle
ECM isolator grommet
Cradle mounting bobbin
Passenger side damper bracket
Page 24
j190
Lotus Service Notes
Section JJ
Anti-Lock Braking
Maximum braking force is provided from a tyre when there is around 15% slippage, dependent on road
surface conditions and tyre characteristics. The function of the ABS is to limit tyre slippage when braking to
around this figure in order to provide optimum grip, and also, by preventing wheel lock, to ensure that steering
control of the vehicle is retained.
A high brake pedal pressure (or low road surface friction) may initiate the locking of one or more wheels.
In the diagram below, a typical control strategy is shown:
1.
Normal braking occurs until, as the applied pressure increases, the wheel speed signals received by the
ECM indicate that the left hand front wheel (for example) is tending to lock. i.e. its deceleration is too
rapid, with too great a speed differential with the other wheels.
2.
The connection between the master cylinder and the LH front brake circuit is interrupted (by the isolation
valve), and the rate of slip increase is reduced.
3.
If the wheel speed continues to depart significantly from vehicle speed, the dump valve is energised to
reduce pressure in the LH front circuit until wheel speed begins to increase. The dump valve is then
closed, as is the isolation valve.
4.
As wheel speed approaches that providing optimum grip, the isolation valve is pulsed open to allow a
stepped pressure increase.
5.
As wheel speed begins to drop off and depart from vehicle speed again, a new cycle starts, repeating
steps (1) to (4).
6.
When wheel speed increases sufficiently to meet vehicle speed, ABS intervention ceases, although
monitoring is continued throughout each braking event.
Page 25
Lotus Service Notes
Section JJ
Sequence of Operation
In the following diagrams, one half of the hydraulic modulator is shown schematically, representing the
front brake control circuit, with the sequence of operation described for the left hand front wheel brake. This
sequence would be similar for any of the other three wheel brakes. A typical emergency braking event is
described where, in this example, the left hand front wheel tends to lock. Note that the complete system is
duplicated for the rear brake circuit, which remains completely independent of the front circuit.
Normal Braking
During normal braking, when the wheel speed sensors indicate no imminent wheel locking, the ABS is
inactive. The solenoids are unenergised, so that the isolation valves are sprung open, and the dump valves
sprung closed.
Hydraulic fluid from the master cylinder enters the modulator via the inlet port, by-passes the attenuator
orifice, passes through the open isolation valve and out to the LH front wheel brake.
LHF
Isolation
valve
To LHF
circuit
LHF
Dump
valve
RHF
Dump
valve
RHF
Isolation
valve
To RHF
circuit
Inlet from
master
cylinder
Pump
Low pressure
accumulator
Pump motor
149a
Page 26
Lotus Service Notes
Section JJ
Pressure Isolation (Pressure Maintain)
If signals received from the wheel speed sensors indicate imminent lock up of the LH front wheel, the first
step in the anti-lock sequence is to isolate that wheel brake circuit from the master cylinder. The ECM energises the isolator valve solenoid, which closes the valve against spring pressure and maintains existing pressure in the left hand front brake circuit regardless of any increase in pedal pressure.
Isolation valve
energised and
closed
Pressure
trapped
in LHF
brake
line
Inlet from
master
cylinder
j149b
Page 27
Lotus Service Notes
Section JJ
Pressure Reduction
Once the LH front wheel brake circuit has been isolated from the master cylinder, the pressure must be
reduced in order to allow wheel speed to be restored. This pressure reduction is achieved by the ECM energising the dump valve solenoid, which then opens against spring pressure and bleeds off some of the fluid into the
low pressure accumulator shared with the RH front circuit. Very short activation pulses are used to maintain
close control of the pressure reduction, and to limit the reduction to that required to restore wheel speed. Fluid
displaced from the wheel brake circuit is stored in the front brake accumulator against spring pressure, and is
also used to prime the hydraulic pump.
Isolation valve
energised and
closed
Dump valve
energised and
open
Fluid
bleeds
off from
LHF circuit
Inlet from
master
cylinder
Pump is
primed
Low pressure
accumulator
charged
j149c
Page 28
Lotus Service Notes
Section JJ
Pressure Increase (Re-apply)
As soon as imminent wheel lock is detected by the ECM, and the ABS control system is activated, the
pump motor is energised. When the dump valve is opened, and fluid is allowed to bleed off from the wheel
brake circuit into the low pressure accumulator, this fluid is scavenged by the pump and returned back into the
input circuit through an attenuator orifice. This action is the origin of the 'pedal pushing back' sensation felt by
the driver, with the pressure pulsations from the pump damped and quietened by the restriction of the orifice.
When wheel speed has been restored and the brake pressure is required to increase, the isolation valve is
momentarily opened, to allow master cylinder/pump pressure to raise the pressure in the wheel brake circuit in
increments. If imminent locking is again sensed, the isolation valve closes, the dump valve opens and the
cycle repeats, with the whole process occuring several times a second.
Isolation valve
pulsed open
Increasing
pressure
to LHF
brake
Inlet from
master
cylinder
Pump
operating
Attenuator
orifice
Accumulator
discharges into
pump
j149d
Page 29
Lotus Service Notes
Section JJ
Brake Release
When no further wheel locking is sensed by the ECM, the ABS becomes inactive with the isolation valve
open (solenoid de-energised) to allow direct communication between the master cylinder and wheel brake
circuit, and the dump valve closed (solenoid de-energised) to seal off the pressure relief circuit. The pump will
remain running for a short time to help drain any fluid from the accumulator, whose piston is returned to its start
position under the action of the spring, and return the fluid to the master cylinder reservoir.
Isolation valve
de-energised
and open
Output
to LHF
brake
Inlet from
master
cylinder
Pump runs
for short
period
Fluid scavenged from
low pressure accumulator
j149e
Page 30
Lotus Service Notes
Section JJ
JJ.13 - ELECTRO-HYDRAULIC UNIT
The electro-hydraulic unit is located on the driver's side in the front services compartment, and is flexibly
mounted in a support frame via three isolator rubber bushes. The support frame itself is fixed to the front
suspension damper top mounting bracket and windscreen frame butress via another three rubber bobbins. A
single 27 pin electrical connector plug is provided with a sliding retainer to aid its mating with the vehicle
harness.
CAUTION: Do not disconnect or connect the main connector plug with the ignition switched on. Switch
off the ignition and disconnect the main connector plug before carrying out any electrical welding operations on
the car.
Hydraulic pipe connections to the unit comprise two input pipes from the master cylinder (one for the front
circuit, one for the rear) and four output pipes, one for each of the wheel brakes. Note that all hydraulic
connections are identified by engraved markings on the unit, with further protection against incorrect connection provided by the use of two different brake pipe union sizes: M10 x 1.0 and M12 x 1.0.
To Remove Electro-Hydraulic Unit
When removing the unit, beware of dripping brake fluid and take appropriate precautions to prevent
damage to paintwork.
1.
Remove the driver's side front access panel, radiator outlet louvre and wheelarch liner.
2.
Switch off the ignition before drawing out the retainer slide from the connector plug to release the harness
from the unit.
3.
Label each of the hydraulic pipes before disconnecting from the unit and immediately capping the pipes
and plugging the ports to reduce the spillage of brake fluid, and to prevent the ingress of dirt.
4.
Release the three fixings securing the controller mounting bracket to the damper bracket and windscreen
frame butress, and withdraw the unit and mounting cradle.
5.
To remove the controller from the cradle, unscrew the two socket head pins supporting the sides of the
unit, and withdraw the unit from the third grommet at the end of the motor casing.
Mounting
grommet
Mounting
bobbin
Electrohydraulic
unit
Controller
mounting
bracket
Socket
head pin
Damper bracket
j190
Page 31
Lotus Service Notes
6.
Section JJ
To refit, reverse the removal procedure, tightening the two socket head mounting pins to 9 Nm, and the
brake pipe unions (both sizes) to 16 Nm, taking care to connect the brake pipes to the correct ports on the
hydraulic block - see diagram. Press in the retainer slide to connect the harness plug.
RH rear
LH rear
RH front
LH front
MC rear
MC front
Hydraulic
control
unit
Master
cylinder
j192
7.
Bleed the unit using the procedure detailed in sub-section JJ.3.
8.
Verify correct connection by using the 'Lotus Scan' tool in actuator tests with the car on a wheel free lift.
Check that operation of each solenoid valve affects the appropriate wheel.
Service Breakdown of Electro-Hydraulic Unit
Service parts for this unit are limited to; the hydraulic modulator with pump motor; and the coil integrated
module which comprises the ECM and solenoid pack.
To separate the module from the hydraulic block, release the 'Torx' screws and withdraw the module from
the solenoid valve spigots. When refitting, check that the gasket is correctly located around the solenoid coil
cluster, before mating with the hydraulic block and fitting the screws.
Note that component parts are calibrated specifically for the Lotus Elise. Do not use parts from other sources.
JJ.14 - WHEEL SPEED SENSORS
A wheel speed sensor is integrated into each of the four hub bearing assemblies and supplies a signal to
the ABS control module. The module outputs a road speed signal to the engine ECM, and also to the instrument pack for speedometer operation.
Output from each wheelspeed sensor can be checked using Lotus scanner tools, and if found to be faulty
or absent, the complete hub assembly should be renewed - refer to sub-section CI.5 (front) or DH.4 (rear).
JJ.15 - DATA LINK CONNECTOR (DLC)
The Data Link Connector (DLC) is a 16 terminal electrical connector plug, complying with SAE J 1962, which
provides a means of communication with the ABS and engine management electronic control units. The connector
is used in service to connect electronic diagnostic equipment such as the Lotus scanner tools which allows system
interrogation including the reading of trouble codes.
The DLC is either tied to the main harness at the front
of the passenger footwell, or secured to the centre underside of the scuttle beam.
Page 32
Data Link
Connector
em235
Lotus Service Notes
Section JJ
JJ.16 - SPECIAL TOOLS
Retraction Tool, Rear Calliper Piston T000T1242
Used to retract the rear calliper pistons and
enable fitment of new brake pads.
j157
Lotus Scan Tool T000T1418F
In order to provide for communication with the engine management system electronic control module, a
hand held electronic scanner 'Lotus Scan' (part number T000T1418F), may be plugged into a special 16
terminal harness connector socket, known as a Data Link Connector (DLC), located at the front of the passenger footwell. Note that this tool may also be used on previous Elise models (excluding Exige '00 M.Y, 340R and
160 models).
-
Amongst the operations available using the 'Lotus Scan' tool are:
Clear fault codes
View fault codes/wheel speeds/valve activities
Generate valve/motor activities
Read EEPROM contents
Read ECU identification
Operating instructions are provided with the tool.
Important Note
The power supply transformer is used for overnight charging of the printer, and also for powering the
Lotus Scan tool during software downloading from a PC (personal computer). For the software download
operation, the Scan tool requires a power supply from the mains via the transformer and an inverter. Two types
of inverter have been used; early kits used an adaptor lead to plug into the bottom end of the Scanner tool.
Later kits use an adaptor plug fitting into the top end of the scanner.
When charging the printer, it is most important that the inverter is NOT used, or damage to the
transformer may be caused. Incorrect connection is possible only with the early type adaptor lead, with which
extra care should be exercised.
1.
Reading data from vehicle
Data Link Connector (DLC)
(front of passenger footwell)
Scan 3
Printer
em192a
Page 33
Lotus Service Notes
2.
Section JJ
Downloading software from P.C.
With early type adaptor lead
Connect to COM
port on PC
Power
supply
transformer
Adaptor lead used
to connect to
transformer
em192c
With later type adaptor
Connect to COM
port on PC
Power
supply
transformer
Power supply adaptor
3.
Charging printer
Power supply
transformer
Do NOT use adaptor
lead for this application
Printer
Page 34
em192f
Lotus Service Notes
Section JJ
Lotus TechCentre - 2008 model year
All USA market cars from ’08 model year onwards, are required by legislation to use a CAN compliant onboard diagnostic system. This has been commonised for all Elise/Exige models. The Lotus Scan 3 tool is
replaced by a ‘stand alone’ lap top PC loaded with ‘Lotus TechCentre’ software to allow the CAN based serial
data to be read.
Controller Area Network (CAN) is an electronic standard to allow high speed communication between
modules and controllers, via a serial data bus. The bus is a circuit linking the modules to the controller,
consisting of a pair of cables, twisted together to reduce electromagnetic interference, and carrying a square
wave voltage signal corresponding to ‘0’s and ‘1’s, coded in such a way as to identify and prioritise the individual messages. On the Elise/Exige, CAN based systems for 2008 onwards include; engine management,
anti-lock braking and related features, tyre pressure monitoring and onboard diagnostics.
A Vehicle Communication Device (T000T1472F) introduced for the Europa model is used to connect the
vehicle to the laptop Lotus TechCentre. All system interrogation and diagnosis are carried out via the Lotus
TechCentre.
The minimum specification of the laptop computer for installation of the Lotus TechCentre is as follows:
-
Processer 1.70 Ghz;
1 GB RAM;
40 GB HDD;
CDRW DVD ROM;
WIN XP PRO or VISTA;
USB interface;
Ethernet or Wireless LAN
Note that this laptop should be dedicated soley to the Lotus TechCentre, with no other software installed.
This diagnostic software is designed primarily for use by trained Lotus technicians, and is available as a CD
under part number T000T1510F (version 4) or later supercessions. A monthly (Lotus Dealers) or annual (nonLotus dealers) licence and support fee will also be levied, providing access to Lotus TechCentre Technical
Support phoneline on 0870 9493 668, and e-mail on [email protected]
Also required is a unique 18 character licence/registration key without which Techcentre will not function.
This key is non transferable to other PC’s.
Scope of Lotus TechCentre
Model
Elise
Exige
Europa
2-11
Evora
Esprit
2004 on
2004 on
2006 on
2007 on
2009 on
V8
Type of Electronic Control Unit
Communication compatible
EMS
ABS
SRS
TPMS
Y
Y
Y
Y
Y
Y
Y
Y
N
Y
Y
N/A
Y
Y
N/A
N/A
Y
Y
Y
Y
Y
Y
N
N
IP
N
N
N
N
Y
N
Engine ECU
Reprogrammable
08 MY on
Y
Y
N
Y
Y
N
Note that TechCentre has no connectivity to Rover powertrain Elise/Exige variants, and that only limited
diagnostics are available for the V8 Esprit. No communication is available with the Europa powertrain. Diagnostics for these vehicles are accessible using the Lotus Scan 3 tool T000T1467F (U.K./EU).
Page 35
Lotus Service Notes
Section JJ
TechCentre Connection
TechCentre connection to the car is made via the Vehicle Communication Device (VCD) and the Data
Link Connector (DLC) located at the front of the passenger footwell. The yellow connector lead is used to
connect the VCD to the car, and a USB lead connects the VCD to the laptop PC.
Power for the VCD is taken from the vehicle battery via the DLC and when powered, a blue tell tale on
the unit will light. Should updated firmware be available for the VCD (usually downloaded as part of an online
update) TechCentre will automatically update the VCD and display a message to confirm.
The VCD, under part number T000T1472F is supplied in a black plastic carry case containing the following:
VCD
16 Pin Yellow connector lead (VCD to Vehicle)
USB lead (VCD to PC)
USB extension lead (VCD to PC)
Use of TechCentre
Instructions for using the TechCentre are available in the ‘Technical Information’ section displayed on
programme start up.
Page 36
Lotus Service Notes
Section JJ
JJ.17 - LOTUS SCANNER TOOL CHECKING PROCEDURES
1.
Trouble Codes
i)
ii)
iii)
When the ABS controller detects a fault in the system, the following events occur;
The ABS tell tale is lit;
The anti-lock system is switched out;
A trouble code is stored in the non volatile random access memory i.e. memory which is retained when
the power supply is interrupted, or the battery disconnected.
Trouble codes may be either Condition Latched, or Ignition Latched:
Condition Latched; With this type of fault, which is generally low or high voltage, the ABS tell tale will light, and
the anti-lock system switch out, until such time as conditions return to normal, at which point the light will be
extinguished, and the anti-lock be reinstated. The trouble code will be stored only whilst the fault is present.
Ignition Latched; This type of fault, of which are most categories, will cause the tell tale to be lit and the antilock to be inhibited until such time as the fault is no longer detected at the moment of a subsequent switching
on of the ignition. At this point, the lamp will be extinguished, and the ABS restored, but the trouble code will
be retained in the memory for the next 20 drive cycles i.e. ignition switched on and a minimum road speed of
5 mph attained.
Access to the diagnostic codes is available only by using the 'Lotus Scan' tool connected to the DLC (see
JG.15). The ‘Lotus Scan’ is a hand held electronic scanner tool with an LCD display panel which is able to
display any stored trouble codes and sensor readings as well as allowing manual operation of actuators.
The facilities available include:
View fault codes/wheel speeds/valve activities
Clear fault codes
Generate valve/motor activities
Read EEPROM contents
Read ECU identification
Important Notes
Whenever the Lotus Scan tool is connected, the ABS tell tale is lit and the anti-lock function is inoperative.
Never connect or disconnect the DLC to/from the control unit with the ignition switched on.
Before charging or quickcharging, disconnect the battery from the vehicle electrical system.
Never disconnect the battery from the vehicle electrical system with the engine running.
Never use a quick-charger for starting.
Take care when touching energised parts of the ignition system.
ECMs must be removed prior to welding operations, or subjecting to oven temperatures above 80°C.
When voltage testing, use only a high-resistance type meter.
During test steps which involve the connection of contacts from harness plugs or control units with ground
or battery voltage (+12V), exercise great care as incorrect contact can cause permanent damage to the
ECM internal circuits.
When measuring resistance from ground bearing wires to vehicle ground, the nominal value of 'less than
2 ohms' sometimes cannot be achieved. In this case, disconnect the negative (ground) post of the battery
and measure the resistance to the vehicle earth lead.
Always erase trouble codes from any control unit after a test is done.
Page 37
Lotus Service Notes
2.
Abbreviations & Definitions
BATTERY VOLTAGE
BRAKE LIGHT SW.
FL WHEEL SPEED
FR WHEEL SPEED
RL WHEEL SPEED
RR WHEEL SPEED
FRONT WHL SPEEDS
REAR WHL SPEEDS
VALVE RELAY CMD
VAVLE RELAY FDBK
RETURN PUMP CMD
RETURN PUMP FDBK
FL HOLD SOL. CMD
FL HOLD SOL. FDBK
FL REL. SOL. CMD
FL REL. SOL. FDBK
FR HOLD SOL. CMD
FR HOLD SOL. FDBK
FR REL. SOL. CMD
FR REL. SOL. FDBK
RL HOLD SOL. CMD
RL HOLD SOL. FDBK
RL REL. SOL. CMD
RL REL. SOL. FDBK
RR HOLD SOL. CMD
RR HOLD SOL. FDBK
RR REL. SOL. CMD
RR REL. SOL. FDBK
3.
Section JJ
System voltage
Brake light switch
Front left wheel speed
Front right wheel speed
Rear right wheel speed
Rear right wheel speed
Front wheel speed
Rear wheel speed
Valve relay command
Valve relay feedback
Return pump command
Return pump feedback
Front left solenoid hold command
Front left solenoid hold feedback
Front left solenoid release command
Front left solenoid release feedback
Front right solenoid hold command
Front right solenoid hold feedback
Front right solenoid release command
Front right solenoid release feedback
Rear left solenoid hold command
Rear left solenoid hold feedback
Rear left solenoid release command
Rear left solenoid release feedback
Rear right solenoid hold command
Rear right solenoid hold feedback
Rear right solenoid release command
Rear right solenoid release feedback
ECU Identification
The ECU identification number for the Elise/Exige is: A120J6000F
Supplier ECU Hardware Number: EBC 430
Supplier ECU Software Number: LCFWDQ04K2K
Page 38
Lotus Service Notes
4.
Section JJ
Circuit Diagram
5.
Diagnostic Trouble Codes
Page 39
Lotus Service Notes
5.
Section JJ
Diagnostic Trouble Codes
DTC
Diagnostic Trouble Code Storage Condition
C0035
...
...
C0040
...
...
C0045
...
...
C0050
...
...
C0060
C0065
C0070
C0075
C0080
C0085
C0090
C0095
C0110
...
C0121
C0161
C0232
...
C0245
C0245
C0252
C0550
C0550
C0556
C0561
C0563
C0564
C0800
...
Front left wheel speed sensor: Short circuit or circuit
No signal;
Incorrect signal;
Front right wheel speed sensor: Short circuit or circuit
No signal;
Incorrect signal;
Rear left wheel speed sensor: Short circuit or circuit
No signal;
Incorrect signal;
Rear right wheel speed sensor: Short circuit or circuit
No signal;
Incorrect signal;
Front left outlet solenoid valve circuit malfunction;
Front left inlet solenoid valve circuit malfunction;
Front right outlet solenoid valve circuit malfunction;
Front right inlet solenoid valve circuit malfunction;
Rear left outlet solenoid valve circuit malfunction;
Rear left inlet solenoid valve circuit malfunction;
Rear right outlet solenoid valve circuit malfunction;
Rear right inlet solenoid valve circuit malfunction;
Return pump:
circuit open or shorted;
locked or shorted;
Valve relay circuit malfunction;
Brake light switch fault;
Brake system telltale voltage: high or open circuit;
low;
Wheel speed:
sensor erratic signal;
error;
Replace electronic control unit;
Replace electronic control unit;
Brake system or electronic control unit malfunction;
Replace electronic control unit;
Replace electronic control unit;
Replace electronic control unit;
Replace electronic control unit;
Switched battery voltage:high (valve relay)
low (valve relay)
For remedial procedures, see Lotus Scan tool display.
Page 40
Remedy
open;
open;
open;
open;
C-04
C-04
C-04
C-05
C-05
C-05
C-06
C-06
C-06
C-07
C-07
C-07
C-12
C-12
C-12
C-12
C-12
C-12
C-12
C-12
C-10
C-10
C-09
C-11
C-13
C-13
C-08
C-08
C-02
C-02
C-12
C-02
C-02
C-02
C-02
C-03
C-03
Lotus Service Notes
Section KH
ENGINE COOLING
SECTION KH
Sub-Section Page
General Description
KH.1
3
Maintenance
KH.2
3
Drain/Refill Procedure
KH.3
4
Radiator & Cooling Fan
KH.4
5
Radiator Fan Control
KH.5
7
Radiator Feed & Return Pipes
KH.6
8
Water Pump & Thermostat
See Section EH
Oil Coolers
KH.7
8
Page 1
Lotus Service Notes
Section KH
Coolant Flow Circuits
Thermostat closed
Heater feed
pipe in sill
Throttle
body
Thermostat
housing
Heater matrix
in climate
chamber
k74b
Heater
return
pipe
Heater return
pipe in sill
Heater feed from
back of cylinder head
Header tank
Radiator by-pass
Recirculation pump
Thermostat open
Radiator on
crash
structure
Radiator return pipe
in chassis side rail
Throttle body
thermostat
Heater matrix
in climate
chamber
k74a
Return to
thermostat
housing
Radiator feed pipe
in chassis side rail
Heater feed from
back of cylinder head
Header tank
Recirculation pump
Page 2
Lotus Service Notes
Section KH
KH.1 - GENERAL DESCRIPTION
The engine cooling system comprises an engine driven water pump, a front mounted radiator with electric cooling fan(s), a header tank, re-circulation pump and associated ducting, pipework and controls.
The centrifugal water pump is mounted on the front face of the cylinder block, and is driven by the smooth
'back' side of the multi-rib auxiliary drive belt. Water is discharged from the pump into the front of the cylinder
block, around the cylinder liners and up into the cylinder head, before exiting the engine via an outlet spigot on
the rear of the head.
Radiator open circuit:
From the main outlet on the rear face of the cylinder head, a moulded hose connects with the main
radiator feed pipe which runs inside the left hand chassis side rail, before feeding the front mounted radiator.
The engine cooling radiator is of aluminium construction with plastic end tanks and is horizontally mounted on
top of the glass fibre composite 'crash structure' which also serves as a duct to direct airflow from the body
nose air intake, to the underside of the radiator. Twin 100 mm diameter electric cooling fans are fitted to the
underside of the radiator to supplement, when required, the ram air flow, and a moulded deflector panels direct
air exhausting from the top of the radiator through outlet grilles in the front bonnet. On cars equipped with air
conditioning, the condenser is sandwiched between the radiator and crash structure, with the cooling fans
attached to underside of the condenser.
The right hand, outlet spigot on the radiator feeds a return pipe routed down the inside of the chassis right
hand side rail, which is then connected to the thermostat housing on the left hand side of the block. Coolant
flowing through the open thermostat enters the water pump to commence another circuit.
Heater circuit:
A second outlet spigot on the rear of the head is used to supply the heater circuit. Water flows via a recirculation pump, into an aluminium pipe routed along the outside of the right hand chassis siderail, within the
composite sill member. The front end of this pipe rises over the end of the scuttle, penetrates the plenum/
scuttle baffle panel, and connects to the heater matrix mounted in the chassis front climate chamber. The
heater return circuit is similarly routed along the left hand side of the chassis, to join a steel heater return pipe
at the back of the cylinder head, and running beneath the inlet manifold to the engine side of the thermostat
housing.
In conditions of 'heat soak', after stopping a hot engine, the re-circulation pump is energised under engine
ECU control to pump coolant through the heater circuit and limit the potential for localised boiling within the
cylinder head.
Radiator by-pass circuit:
When the thermostat is closed, the radiator return circuit is shut off, and coolant leaving the cylinder head
is forced to flow through a by-pass circuit which links the engine outlet hose to the header tank and then to the
heater return pipe.
Header tank:
The top RH spigot on the header tank is connected to an air bleed on the back of the cylinder head; the
top rear spigot to the engine outlet hose; and the bottom port to a hose joining the heater return pipe immediately before its termination at the thermostat housing.
Throttle body and oil/water heat exchanger
The throttle body is water heated to prevent icing, drawing a supply from the back of the cylinder head,
and returning via an in-line thermostat, into the heater return pipe. On cars not fitted with front mounted air/oil
coolers, an oil/water heat exchanger is sandwiched between the oil filter and cylinder block. Coolant is fed
from a water jacket spigot on the left hand side of the cylinder block into the exchanger, with the outlet pipe
connecting into the heater return pipe.
KH.2 - MAINTENANCE
Under normal operating conditions, the engine cooling system, being a closed circuit, should not require
any topping up between services. As a precaution however, every week, the level of coolant in the engine
cooling header tank should be checked. The header tank is mounted at the left hand side of the engine bay,
with a hose from its underside connecting with the heater return rail near the thermostat housing. An air bleed
hose connects the header tank air space with the radiator by-pass circuit and a cylinder head spigot at the front
end of the inlet manifold. The tank is fitted with a 110 kPa (15 lb/in²) pressure cap to raise the boiling point of
the coolant to over 120°C. The transluscent header tank is marked with both cold and hot level indicators. The
Page 3
Lotus Service Notes
Section KH
level of coolant will rise as the engine warms up and the coolant expands, and will fall again as it cools down.
WARNING: Do NOT remove the cap or bleed plug from the engine cooling header tank when the
engine is warm, as serious scalding could result from boiling water and/or steam.
When fully cold, the level of coolant should be up to the ‘cold’ mark moulded on the header tank. If
overfilled, the excess coolant will be ejected when the engine is warm, and if the level is allowed to fall too low,
overheating may result. If necessary, top up the system using an approved coolant mixture (see below) to
maintain full protection from freezing damage and corrosion.
Anti-Freeze/Corrosion Inhibitor
It is necessary that the coolant contains an anti-freeze with corrosion inhibitor to protect the engine and
heat exchangers from both frost damage, and corrosion of the metallic elements. In order to protect against
these dangers as well as raising the boiling point of the coolant, the Elise is factory filled with a 50% concentration of Havoline XLC, which is a mono-ethylene glycol coolant using organic acid technology (OAT) to provide
increased corrosion protection compared with conventional coolant additives. A yellow label around the header
tank neck identifies the coolant type used. The corrosion inhibiting carboxylic acids in the OAT coolant tend to
remain in solution rather than being deposited on the internal surfaces of the cooling system, thus improving
heat transfer and extending service life. Havoline XLC is the only recommended coolant product, and at 50%
concentration provides freezing protection down to approximately - 40°C. Even in warm climates it is recommended that the concentration is not allowed to fall below 25%, in order to maintain full corrosion protection.
The simplest means of checking the antifreeze concentration is to measure the specific gravity (density)
of the coolant at a known temperature, using a hydrometer. The following table provides a general guide:
Concentration
25%
33%
50%
Density @
20°C
60°C
1.039
1.020
1.057
1.034
1.080
1.057
The coolant density reflects the effective level of mono-ethylene glycol, and not the level of corrosion
inhibitors present, whose effectiveness diminishes over a period of time. The coolant should therefore be
renewed every 4 years to ensure optimum corrosion protection.
In areas where the tap water is extremely hard (exceeding 250 parts per million), use of this water will
lead to 'furring up' of the system over a period of time. In such areas, distilled, de-ionised or filtered rain water
should be used.
Radiator Fin Cleaning
At service intervals, the matrix of the engine cooling radiator should be checked for clogging by insects,
leaves and other debris. If necessary, use a water jet from both above and below to clean the fins, taking care
not to damage the fragile tubes or distort the finning. At the same time, check the integrity of all cooling system
joints, and the condition of all flexible hoses. In snowy conditions, ensure the radiator air exit is cleared of snow
before driving the car.
KH.3 - DRAIN/REFILL PROCEDURE
1.
To drain the engine cooling system:
Remove the undertray from beneath the nose of the car.
2.
Disconnect the radiator feed and return hoses from the front ends of the thro' chassis pipes, and collect
the draining coolant. Remove the header tank cap to speed the operation.
3.
Open the drain tap at the right hand rear of the cylinder block.
Note that draining of the heater matrix is not easily possible with the unit 'in situ', and that if draining for
the purpose of coolant change, this volume should be disregarded.
Page 4
Lotus Service Notes
1
Section KH
To refill the system:
Refit the hoses to the feed and return pipes and close the cylinder block drain tap.
2.
Remove the right hand front wheelarch liner and open the air bleed plug on the radiator outlet hose. From
within the engine bay, open the air bleed plug in the heater return hose at the left hand rear of the engine
bay.
3.
Fill with the recommended coolant mix via the header tank and close the bleed plugs when a steady
stream of coolant is expelled.
4.
Start the engine and allow to idle, and periodically open the bleed plugs to allow any trapped air to be
expunged. Top up the header tank when necessary, and fit the pressure cap when required to prevent
overflow. When the cooling fans have cut in and then out, stop the engine and allow to cool. Recheck
coolant level when fully cold.
KH.4 - RADIATOR & COOLING FAN
The aluminium cored radiator is positioned horizontally on top of the composite 'crash structure' in the
front services compartment. A composite moulding is used to mount the radiator, and also, via extensions at
each side, to provide a mounting point for the inside front of the clamshell wheelarch. The radiator must be
removed for access to the cooling fans.
To Remove Radiator
1.
Remove the front clamshell (see section BR).
2.
Drain the coolant and disconnect the feed and return hoses from the radiator.
3.
If the car is equipped with air conditioning, de-pressurise the system and recover the refrigerant via the
service ports near the evaporator.
4.
Remove the two radiator outlet air deflector panels, release all tie wraps and fixings securing wiring
hanesses and pipes to the radiator mounting panel, and disconnect the radiator fan harness plugs.
5.
If the car is fitted with front mounted oil coolers, disconnect the feed and return hoses from both coolers
and plug all ports to limit oil spillage. Remove the mounting brackets from the coolers and crash structure.
6.
Release the single fixing at the bottom of each side extension securing the mounting panel to the bottom
flange of the crash structure.
7.
Release the three fixings securing the back edge of the mounting panel to the vertical flange on the crash
structure, and the three fixings along the front edge of the panel.
8.
Withdraw the radiator mounting panel with radiator/(condenser)/cooling fans assembly.
9.
Each cooling fan is secured two studs and nuts to either the radiator flange bracket, or, on a.c. cars to the
condenser. The condenser is secured to the radiator lower flange by two studs at the front edge, and by
two pairs of screws at the rear edge. The radiator is fixed to the mounting panel by brackets at the front
and rear. Note the foam packing used between the radiator and mountign panel to ensure that all ducted
air flows through the radiator matrix.
10.
Refit the radiator in reverse order to removal, ensuring that the foam packing is re-installed. Refill with
coolant and bleed as detailed in sub-section KH.3. Re-charge refrigerant system.
Page 5
Lotus Service Notes
Section KH
Radiator Mounting
Front mounting
spreader plate
Rear mounting
spreader plate
Radiator
mounting
panel
Front
mounting
bracket
Access to this
clip available
via turn lamp
aperture
Rear
mounting
bracket
Fan fixing
Engine
cooling
radiator
Air conditioning
condenser
(if fitted)
Cooling fan
p105
Page 6
Lotus Service Notes
Section KH
Engine cooling radiator
Front spreader plate
Front mounting
bracket
a.c. condenser
Rear
mounting
bracket
Radiator
mounting
panel
Cooling fan
p106
KH.5 - RADIATOR FAN & RE-CIRC. PUMP CONTROL
The two cooling fans are fitted beneath the radiator or (with a.c.) condenser/radiator package, and the
coolant re-circulation pump is mounted below the header tank. Both the fans and pump are controlled by the
engine management ECU using data provided by the engine coolant temperature sensor mounted in the back
of the cylinder head.
The cooling fans are switched as a pair, and will operate at half speed (connected in series) when coolant
temperature reaches 98°C on rise, and switch off at 94°C on fall. The fans will also operate at half speed
irrespective of coolant temperature if the a.c. is switched on and the compressor is running. If coolant temperature rises to 103°C, the fans will switch to full speed (connected in parallel), reverting to half speed at 98°C.
The fans will also run at half speed, unless high coolant temperature dictates otherwise, when the a.c. is
switched on and the compressor is running, or if the engine management system detects a fault with the inlet
air temperature or coolant temperature circuits.
At road speeds in excess of 85 mph (135 km/h), equating to the fan stall speed, all fan functions are
switched off.
Heat Soak
In order to help control engine temperature after switching off an engine whose temperature is over 88°C,
the ECU will remain powered for a period of 20 minutes to allow heat soak management.
A coolant re-circulation electric pump is mounted below the coolant header tank and is plumbed into the
heater supply line. When energised, the pump circulates coolant through the engine and heater system,
drawing coolant from the back of the cylinder head, and pumping it through the heater matrix to the heater
return pipe and back into the thermostat housing. The pump functions only with ignition off in conditions where
the ECU remains live. The pump is then activated at coolant temperatures over 110°C, switching off at 100°C
on fall. If temperature should rise to 115°C, the pump will be supplemented by the two cooling fans running at
half speed, switching off at 110°C on fall.
Fan Control Module
The cooling fans, re-circ. pump and a.c. compressor are controlled by a relay module mounted to the top
of the passenger side wheelarch liner. Important Note: The a.c. relay module is identical in appearance to the
engine relay module, but the function of the two modules is different and they must not be transposed. The a.c.
relay module A117M0038F has a brown label marked YWB100800 and a blue connector moulding; The
engine relay module A111E6024F has a white or brown label marked YWB100970 and a black connector
moulding. If necessary, use a scalpal blade to slim the centre spigot of a new module connector housing to
allow its fitment on an earlier car.
Page 7
Lotus Service Notes
Section KH
If the ECM receives a signal voltage outside of the acceptable range, a default setting equating to 60°C
will be substituted, and the cooling fan energised.
KH.6 - RADIATOR FEED & RETURN PIPES
The radiator feed and return pipes are routed through the chassis main side rails, feed on the left, and
return on the right. Each pipe is located by a grommet in the chassis front closing panel, and by a pair of
shaped foam blocks inserted into the rear end of each chassis rail.
On initial build, the water pipes are fitted before the crash structure is bonded to the front of the chassis.
A new chassis assembly is supplied with both water pipes and the crash structure pre-fitted. If a pipe is to be
replaced in service without the crash structure being removed:
WARNING: The machined edges of the chassis extrusions and the ends of the drive fasteners can
present sharp edges and points representing a potentially serious health hazard. It is strongly recommended that industrial gloves are worn, and other suitable precautions taken to provide protection
from cuts and abrasions.
1.
Drain the coolant and remove the front clamshell (see section BR).
2.
To release the hoses from the rear ends of the water pipes requires that the fuel tank be removed. Access
is available only via apertures in the inner walls of the chassis siderails within the fuel tank bay. To
remove the tank refer to sub-section LJ.4. The hoses are secured to the rear ends of the water pipes by
spring clamps requiring a suitable tool to release.
3.
Release the hoses from the front end of the water pipe.
4.
Using the access provided from within the fuel tank bay, push the water pipe forwards until obstructed by
the crash structure. It is recommended that a suitable hole be cut in the flat vertical face of the crash
structure, adjacent to the fog lamp harness grommet, in order to allow the pipe to be withdrawn forwards.
5.
To refit, retrieve the two support foams from inside the chassis rail. Fit the grommet into the hole in the
chassis front closing plate, and smear with rubber grease. Feed the pipe through the access hole and
grommet, and position with 35 - 40 mm of pipe protruding.
5.
At the rear end of the pipe, fit two foam support blocks onto the pipe, and push into the chassis rail ahead
of the fuel tank bay aperture.
6.
Refit the hoses to the front and rear ends of the pipes and manipulate the pipe to check for absence of
chassis contact 'knock'.
7.
Blank off the access hole in the crash structure with a suitable grommet.
KH.7 - OIL COOLERS
Depending on market territory and date of build, cars may be fitted with either an engine mounted water/
oil heat exchanger, or a single LH front mounted air/oil cooler, or twin front mounted air/oil coolers. The water/
oil heat exchanger or single front mounted oil cooler is entirely adequate for all normal conditions of road use,
but for cars used on closed circuit tracks or driven in a competitive manner (note; such use may invalidate
vehicle warranty), or if full vehicle performance is to be exploited for an extended period (especially in hot
ambient temperatures), it is recommended that twin front mounted coolers be fitted for optimum control of oil
temperature.
Water/oil Heat Exchanger (if fitted)
On cars so fitted, the oil/water heat exchanger is sandwiched between the oil filter and cylinder block.
Water hoses connect a tapping on the left hand side of the cylinder block to the heat exchanger, and from the
Page 8
Lotus Service Notes
Section KH
exchanger to the heater water return pipe. This device transfers heat from the engine coolant to the oil after a
cold start, and conversely, in conditions of high oil temperature transfers heat from the oil to the coolant.
Front Mounted Air/Oil Coolers
On cars so fitted, front mounted oil/air radiators are mounted ahead of each front wheel arch and fed with
air from intakes either side of the main engine radiator intake in the body nose. 'Single oil cooler’ cars are
equipped with an oil cooler ahead of only the LH front wheel, but use the same hoses as twin oil cooler cars,
with a joiner union attached to a bracket in place of the symetrically opposite RH cooler.
On all cars with front mounted oil cooler(s), the oil/water heat exchanger is replaced by a sandwich plate
incorporating oil take-off feed and return unions, with the redundant coolant hoses interconnected by a 'U' pipe.
A thermostat incorporated into the sandwich plate begins to close at 72ºC, and is fully closed at 80ºC. When
open, oil can by-pass the oil cooler circuit, but when fully closed, all oil is directed from the sandwich plate via a
flexible hose within the RH sill panel, over the front wheel arch liner to the top connection on the RH oil cooler (or
joiner union on single oil cooler cars). From an outlet union at the bottom front of the cooler (or joiner union),
another hose runs beneath the crash structure to the bottom of the LH cooler, from the top of which oil is returned
via a third hose, running through the LH sill, back to the return union on the sandwich plate.
Oil Cooler Layout
Oil cooler
sandwich plate
Cooler feed hose
in RH sill
Oil cooler
thermostat
Heat exchanger
hoses or by-pass
Cooler
mounting
plate
Cooler return hose
in LH sill
Nut plates
Cooler
interconnection
hose
Air deflector
panel
pl4603mt
LH oil
cooler
Oil/water
heat exchanger
Each cooler is secured by a two stud bracket to the side of the crash structure, and positioned immediately ahead of the engine radiator mounting panel side extensions, which incorporate airflow apertures and
additional deflector panels on their front surfaces. Louvres in the wheelarch liner front sections allow air to
exhaust from the coolers into the wheelarches.
Page 9
Lotus Service Notes
Section KH
Procedure for conversion from single to twin front mounted oil coolers
Parts Required
Oil Cooler, RH, incl. foam seal
Duct, oil cooler, RH
- Elise
- Exige
Big Head Pop Rivet, duct fixing
Part Number
A120K0020F
A120B0090F
A122B0194F
A089W6297F
Qty
1
1
1
3
1.
Remove the front clamshell (refer to sub-section BR.6).
2.
Disconnect oil cooler hoses from joiner union ahead of RH front wheel using 2 off 1 1/8" spanners, and
plug hose ends to minimise oil loss.
3.
Remove hose joiner bracket and secure new oil cooler, with its pre-applied sealing foam, to mounting
bracket using existing fixings. Torque tighten to 22 Nm.
4.
Fit hoses to oil cooler. When tightening the union nut it is essential that the oil cooler union is held
using a 15/16 in. open end spanner whilst torque tightening the hose union nut (1 1/8") to 40 Nm.
Failing to follow this procedure may result in damage to the oil cooler.
5.
Start the engine and check for oil leaks.
6.
Secure the new cooler duct with the three big head rivets to the radiator duct and refit the front clamshell.
Oil Cooler Circuit Bleeding
When carrying out routine oil changes,
the oil quantity contained in the twin oil coolers and associated pipework is not disturbed
and is considered perfectly satisfactory for
routine maintenance operations. In instances
of major engine failure where the oil system
may be contaminated with metallic debris, all
oil cooler lines should be thoroughly flushed
out and the oil cooler radiators replaced.
If the oil cooler circuit is drained or replaced, the following procedure should be
adopted to fill the cooler system before starting the engine:
1.
Attach a tube to the bleed nipple on the
sandwich plate between oil filter and
engine block, and lead into a catch tank.
Open the bleed nipple.
2.
Disconnect the outlet hose from the top
of the LH oil cooler, and pour engine oil
into the cooler until oil reaches the bleed
nipple (approx. 2.5 litres).
Close the bleed nipple, tightening to 8 Nm.
Sandwich
plate bleed
nipple
e228
3.
Connect the LH cooler outlet hose and tighten to 40 Nm.
4.
Add a further 0.7 litres of oil into the engine to accommodate the volume of the return hose between LH
oil cooler and engine.
5.
After starting the engine, restrict running to idle speed for a minimum of 5 minutes, to allow the oil cooler
lines to be purged of air. Stop engine and re-check oil level.
Page 10
Lotus Service Notes
Section LJ
FUEL SYSTEM
SECTION LJ - ELISE 111R, EXIGE 2004 M.Y. On (non USA)
Sub-Section Page
General Description
LJ.1
3
Fuel Filling
LJ.2
3
Precautions
LJ.3
4
Fuel Tank
LJ.4
5
Fuel Pump/Sender Assembly
LJ.5
7
Charcoal Canister
LJ.6
8
Page 1
Page 2
Fuel feed
pipe
Tank breather
connection
Fuel pump
Quick fit
connector
Fuel rail
Fuel tank
Charcoal canister
Tank breather pipe
Filler breather hose
em208c
Vapour management
valve
Roll-over valve
Purge line to inlet manifold
Fuel filler neck
Vapour purge line
Lotus Service Notes
Section LJ
Lotus Service Notes
Section LJ
LJ.1 - GENERAL DESCRIPTION
The 43.5 litre fuel tank is fabricated from Neotec coated steel, and is externally powder coated for further
corrosion resistance. The tank is mounted within the chassis crossmember between the passenger compartment and engine bay, and is secured by two support brackets from beneath. The fuel filler neck connects with
the right hand top of the tank, with the filler breather pipe routed to the centre, and the fuel pump/fuel gauge
sender unit mounted into the left hand top surface. The modular fuel pump/sender assembly includes a
submerged turbine type pump with non-return valve, integrated fuel filter and a pressure regulator valve, to
supply a single line fuel rail for the four fuel injectors at a pressure of around 325 kPa. The single line fuel
supply eliminates fuel circulation back to the tank, thus reducing fuel tank temperature and evaporative emissions.
When the ignition is switched on, the engine management ECU energises the fuel pump for a period of
about 3 seconds to prime the system before switching off. If a signal from the crankshaft sensor indicates that
the engine is being cranked or is running, the fuel pump feed will be maintained. The pump is switched off
immediately when the ignition is switched off, or about 3 seconds after a stall. Note that if coolant temperature
at the time of ignition switch off is over 88°C, the ECU remains powered for a period of 20 minutes to allow for
heat soak management (see sub-section KH.5). Re-energising the ignition during this period will not run the
fuel pump until a crank signal is received.
A safety inertia switch is incorporated into the fuel pump electrical circuit, and operates in a severe impact
(indicative of a vehicle collision) to switch off the fuel pump feed and minimise the fire risk. The switch is
located in the engine bay on the inner face of the left hand chassis siderail, and is reset once tripped, by
pressing the rubber button on the top of the switch.
An evaporative emissions 'charcoal' canister is mounted at the right hand front of the engine bay and is
connected to the air space inside the fuel tank via a port in the top plate of the fuel pump assembly. The
connecting pipe is routed through a roll over shut off valve mounted by the canister, to protect against fuel
spillage in case of vehicle inversion. The purge port of the canister is routed through a solenoid valve mounted
on top of the canister, to a port on the inlet manifold. The evaporative emissions control system prevents
untreated fuel vapour from the tank reaching the atmosphere, by absorbing the tank vapour in a bed of activated charcoal in the canister. When the engine is running, the engine management ECM opens the purge
solenoid valve and allows intake manifold depression to draw fresh air through the canister, purging absorbed
fuel from the charcoal, and consuming the resultant vapour in the normal combustion process. In this way, the
charcoal bed is 'cleaned' ready to absorb more tank vapour.
LJ.2 - FUEL FILLING
Fuel Requirement
Use only UNLEADED fuel with a minimum octane rating of 95 RON (‘Premium’ unleaded in U.K.) or
higher for optimum engine performance. Using fuel with a lower octane rating may cause knocking (pinking)
which, if severe, can cause serious engine damage. Light knocking may occasionally be heard for short
periods when accelerating or driving up hills, and this should cause no concern, although using a lower gear
would be advised. If, however, persistent heavy knocking is heard when using the specified fuel, diagnosis of
the cause should be undertaken without delay.
Note that the filler neck is restricted in size so that only the smaller diameter nozzle used on unleaded
petrol pumps may be inserted. The use of leaded fuel or lead replacement petrol (LRP) would cause irreparable
contamination of the catalytic converter and of the exhaust gas sensor used by the computer controlled engine
management system.
Fuel Filling
WARNING: - Be aware of the danger of explosion when dealing with petrol and its attendant fumes.
Before stopping at a filling station, switch off mobile phones, ensure that all cigarettes are extinguished
and that no naked flames or other potential ignition sources are present. Switch off the engine before
refuelling.
- Remove the filler cap slowly to allow any pressure to bleed off gradually. Hasty removal may result
in a small amount of fuel spray with a possible health or fire hazard.
Filler Cap: The key locking filler cap is located in the right hand rear quarter panel:
Page 3
Lotus Service Notes
-
-
Section LJ
To unlock the cap, insert the key (same key as ignition), turn ¼ counterclockwise and withdraw the cap
with the key. As the cap is unlocked, any slight pressure differential between the tank and atmosphere will
be released, and a brief hiss may be heard, which is completely normal. Note that the key can withdrawn
only from a locked cap.
To refit, engage the ears on the cap with the slots in the neck, turn the key ¼ clockwise to lock and
withdraw the key.
Filling Procedure: Insert the pump nozzle fully into the neck, and fill until the first time the auto-shut off mechanism is triggered. Do not attempt to ‘brim’ the tank to the top of the filler neck, as expansion of the fuel due to
temperature change (especially in hot weather - the temperature in underground storage tanks is significantly
colder) may cause flooding of the charcoal canister, or spillage of fuel.
The total usable fuel capacity is 43.5 litres.
LJ.3 - PRECAUTIONS
The fuel line between pump and injector rail, and the injector rail itself, contain pressurised fuel both when
the ignition is switched on, and for a period after switching off. This feature aids engine starting by reducing the
time needed to build up operating fuel pressure, and by inhibiting the formation of vapour pockets in the supply
line of a stopped hot engine.
WARNING:
i)
To minimise the risk of fire and personal injury, relieve the fuel system pressure before servicing
any part of the fuel supply circuit. See ‘Fuel Pressure Relief Procedure’ below.
ii)
To reduce the possibility of sparks occurring when a fuel line is disconnected, or when fuel
vapour is present, the negative battery cable should be disconnected before work is commenced.
iii) When fuel lines are disconnected, absorb any escaping fuel in an absorbent cloth and dispose of
safely.
Fuel Pressure Relief Procedure
This procedure should be used prior to disconnecting any part of the fuel line.
-
-
-
-
-
Pull out the fuel pump fuse (on the left
hand side of the engine bay bulkhead,
as shown), start the engine, and run until
it stops from starvation. Crank the
engine for a further few seconds.
If the engine is a non-runner, pull out the
fuel pump fuse, and crank the engine for
20 seconds to minimise residual fuel
pressure.
Disconnect the battery.
It is recommended first to release the
quick fit connector located to the rear of
the coolant header tank:
Release the retaining clip securing the
pipe joint to the header tank bracket.
Slide the orange coloured safety lock to
allow access to the connector release
buttons.
Surround the pipe joint with a shop towel
to absorb fuel contained in the pipework
before pressing the release buttons and
separating the joint.
Fuel pump
fuse (20A)
ohs136
WARNING: Be aware of the possibility of full pressure retention in the fuel line caused by a
system fault.
Page 4
Lotus Service Notes
Orange
safety lock
Section LJ
Fuel pipe to
engine
Fuel pipe
from tank
-
-
Release
button
L64
-
Before re-making the joint, ensure that the orange safety lock is fitted onto the pipe connector in the orientation shown in the illustration.
Push the male pipe end fully into the female
connector until a click is heard. Pull on the
pipe to ensure complete engagement.
Slide the orange safety lock over the connector
to prevent accidental pressing of the release
buttons.
Secure the pipe/connector using the pipe clip
on the header tank bracket.
LJ.4 - FUEL TANK
The 43.5 litre fuel tank is fabricated from Neotec coated steel, and is externally powder coated for further
corrosion resistance. The tank is mounted within the chassis crossmember between the passenger compartment and engine bay, and is secured by two support cradles from beneath. The fuel filler neck connects with
the right hand top of the tank, with the filler breather pipe routed to the centre, and the fuel pump/fuel gauge
sender unit mounted into the left hand top surface. A removeable panel is provided in the top of the chassis
crossmember in the cabin, which provides access to the fuel pipe connections and harness connector. If the
pump/gauge sender unit is to be replaced, the tank must be removed from the chassis.
To Remove Fuel Tank
If necessary, syphon fuel from the tank to reduce the weight before removal.
1.
WARNING: The fuel line between pump and engine remains pressurised after switching off the
ignition. Before disconnecting the fuel line, carry out the fuel pressure relief procedure detailed
in sub-section LJ.3.
Carry out the fuel pressure relief procedure detailed in sub-section LJ.3.
Disconnect the battery.
It is recommended first to release the quick fit connector located to the rear of the coolant header tank:
Release the retaining clip securing the pipe joint to the header tank bracket.
Slide the orange coloured safety lock to allow access to the connector release buttons.
Surround the pipe joint with a shop towel to absorb fuel contained in the pipework before pressing
the release buttons and separating the joint.
WARNING: Be aware of the possibility of full pressure retention in the fuel line caused by a
system fault.
2.
Remove the left hand seat and rear bulkhead trim panel. From the left hand rear corner of the cabin,
remove the access panel on the top of the chassis rear crossmember for access to the fuel pump
connections. Release the quickfit type connector on the fuel vapour line connection to the pump/sender
unit top plate. Prise out the retaining spring clip and withdraw the fuel feed pipe. Disconnect the wiring
harness plug from the pump unit, and from the pressure sensor.
3.
Remove the RH rear wheel and wheelarch liner to provide access to the filler hose connections. Release
the filler hose and filler breather hose from the tank spigots, and cap both orifices to prevent debris
ingress and reduce the fire hazard.
4.
Remove the engine bay undertray/diffuser.
Page 5
Lotus Service Notes
Section LJ
5.
Disconnect control cables:
Release the two gearchange cables from the transmission levers and abutment bracket.
Release the parking brake cable from the horseshoe compensator and abutment brackets.
Release the throttle cable from the engine.
Release the gearchange cable and throttle cable 'P' clips from the perforated 'shear panel' below
the fuel tank.
6.
From beneath the fuel tank, release the fixings securing the 'shear panel' front and rear edges to the
chassis, and those at each side securing the composite sills to the panel. Note that this panel is a
structural part of the chassis, and that the car should not be used without the panel fitted.
l58b
Fixing to chassis
Fixing to sill
Fuel tank 'shear panel'
7.
Support the tank before removing the two support cradles from the chassis. Each cradle uses two bolts
at the front end of the bracket, and a single bolt at the rear, all threading into Rivnuts in the chassis.
8.
Carefully lower the tank from the chassis.
8.
Before re-fitting the tank, ensure that all the clamping pads are in place:
- EPDM foam sponge block on upper and lower edges of both tank side faces;
- Expanded Polypropylene saddles on top face of tank;
- Neoprene isolating strip between tank and support cradles;
- EPDM rubber wedge between front bottom edge of tank and support cradles;
- Neoprene sponge foam between upper front of tank and chassis.
Page 6
Lotus Service Notes
Section LJ
Polypropylene saddles
Fuel tank
Foam sponge
Rubber wedge
Earth braid
Support
cradle
L59b
9.
Ensure the pump/sender unit is fitted into the into the tank, with the earth braid fitted onto the '10 O'clock'
position pump mounting stud.
10.
Loose fit the LH tank mounting cradle ensuring that the earth braid is fitted beneath the head of the
horizontally disposed front fixing bolt.
11.
Feed the LH end of the tank into the cradle, and raise the tank into position taking care not to trap or pinch
the fuel pipes or wiring harness. Retain with the RH cradle, noting that no washer is fitted at the horizontally disposed front fixing point. Torque tighten the cradle fixing bolts to 24 Nm.
12.
Continue the installation in reverse order to removal, and ensure that the 'shear panel' is fitted beneath
the fuel tank bay before driving the car.
LJ.5 - FUEL PUMP/SENDER ASSEMBLY
The combined fuel pump/gauge sender unit is mounted in the left hand end of the tank top surface. A
removeable panel is provided in the top of the chassis crossmember in the cabin, which provides access to the
fuel pipe connections and harness connector, but if the pump/gauge sender unit is to be replaced, the tank
must be removed from the chassis (see sub-section LJ.4).
For fuel pump test procedures, refer to Toyota 2ZZ-GE Engine Repair Manual, publication RM733E.
Page 7
Lotus Service Notes
Section LJ
To Remove Pump/sender Assembly
1.
Remove the fuel tank (see sub-section LJ.4).
2.
Release the eight nuts securing the clamping ring, and carefully withdraw the pump assembly from the
tank. Immediately seal the tank aperture to reduce the fire hazard and prevent dirt ingress.
3.
For permitted disassembly of the pump unit, refer to Toyota 2ZZ-GE Engine Repair Manual, publication
RM733E.
To refit the pump assembly, renew the rectangular section sealing ring before carefully feeding the sender
float arm in through the tank aperture. Orientate the unit with the breather spigot pointing inboard, and fit
the clamping ring with the location tab engaged with the recess in the pump top moulding. Fit and secure
the eight M6 washers and nuts.
4.
5.
Refit the fuel tank into the car (see sub-section LJ.4).
6.
Connect the fuel feed pipe and retain with the spring clip. Connect the breather pipe to the spigot on the
pump top plate. Fit the harness plugs to the pump/sender connector, and to the pressure sensor.
LJ.6 - CHARCOAL CANISTER
In order to prevent fuel vapour venting from the fuel tank to atmosphere, the breather pipe from the tank
is routed to a canister filled with activated-charcoal, which absorbs and stores the fuel vapour when the engine
is stopped. When the engine is running, the canister is connected to the depression in the intake plenum via a
port on the inlet manifold such that fresh air is drawn through the canister to purge the charcoal of its absorbed
fuel, with the resultant gas then consumed by the engine in the normal combustion process.
Charcoal Canister
This is mounted at the right hand front corner of the engine bay via a bracket fixed to the bulkhead. Fuel
vapour from within the tank and collected from a spigot on the fuel pump/sender top plate, is routed via a
roll-over valve (to prevent fuel spillage if the car is inverted) mounted on the charcoal canister bracket, to the
canister port labelled ‘tank’. This port is extended within the canister to the underside of the charcoal bed,
below which is a reservoir to collect any liquid fuel. A second port on the canister ('vent') connects the top side
of the charcoal bed to atmosphere. In this way, vapour from the fuel tank is cleansed of fuel by the charcoal
bed before venting to atmosphere.
The third, 'purge' port, controlled by a solenoid valve mounted on the air cleaner housing, connects the
underside of the charcoal bed with a port on the engine inlet manifold. The solenoid valve is opened during
certain engine running conditions in order to allow intake depression to draw fresh air through the vent pipe and
charcoal bed, cleansing the charcoal of fuel before consuming the resultant vapour in the normal combustion
process. In this way, the charcoal is prepared for further vapour absorption.
Control System
The canister purge valve is controlled by the engine management ECU, which keeps the valve closed
(unenergised) when the engine is cold or idling in order to protect the catalyst and maintain idle quality. At
normal running temperatures and engine speeds above idle, the ECU monitors other running conditions and
management system stati, and when appropriate conditions pertain, the ECU will apply a duty cycle to the
valve in order to regulate the amount of purging allowed dependent on the amount of vapour in the canister.
Page 8
Lotus Service Notes
Section MP
ELECTRICS
SECTION MP
Sub-Section
Page
Cobra Vehicle Security Alarm (prior '08 M.Y.)
MP.1
2
Central Door Locking
MP.2
6
Electric Windows
MP.3
7
Switches & Instruments - Driver's Information
MP.4
8
Component Location & Fuse Ratings
MP.5
14
Audio Equipment
MP.6
16
Battery, Battery Cables & Earthing Points
MP.7
17
Wiper Mechanism
MP.8
20
Harness Routing
MP.9
21
Front Lamp Assemblies
MP.10
22
2006 M.Y. Supplement
MP.11
25
2008 M.Y. Supplement (incl. PFK alarm system)
MP.12
28
2011 M.Y. Supplement
MP.13
36
Page 1
Updated 1st June 2010
Lotus Service Notes
Section MP
MP.1 - COBRA VEHICLE SECURITY ALARM
The Lotus Elise/Exige prior to '08 M.Y. is fitted as standard with a Cobra 8186 immobiliser/alarm which
includes the following features:
•
Elise 111R U.K. approval to Thatcham category 1.
•
'Dynamic coding' of the transmitter keys; Each time the transmitters are used, the encrypted rolling code
is changed to guard against unauthorised code capture.
•
Automatic (passive) engine immobilisation to prevent the engine from being started.
•
Ingress protection using sensing switches on both doors, both front body access panels, and the engine
cover.
•
Personal protection by ‘on demand’ activation of the siren.
•
Selectable cockpit intrusion sensing using a microwave sensor.
•
Self powered siren to maintain protection if the vehicle battery is disconnected.
•
Alarm/owner transmitter programming using a Personal Identification Number (PIN).
Transmitter Fobs
Two transmitter fobs are provided with
the car to operate the immobiliser/alarm
system. The two transmitters should be
kept separate, and a replacement obtained
immediately after any loss to ensure that a
spare is always available.
Each individual alarm system has a
unique serial number and an owner’s Personal
Identification Number (PIN), both of which
are printed on a code card supplied with
the vehicle. In order to allow replacement
transmitters to be ordered, it is essential
that these numbers are recorded and kept
safely with the vehicle documents. If the
code card is not available on receipt of the car,
enquire with the dealer immediately.
S/N 99999999
PIN CODE = 9999
Large button
Key tell tale
Small button
COBRA TRANSMITTER & CODE NUMBERS
Engine Immobiliser
In order to provide a measure of automatic vehicle security, independent of any driver initiative, the system
will ‘passively’ immobilise the engine’s cranking and running circuits after the first occurring of the following
approximate time delays:
i) Four minutes after switching off the ignition.
ii) Two minutes after a mobilising command (see below).
iii) One minute after switching off the ignition and opening the driver’s door.
The immobilised state is indicated by the security tell tale in the tachometer upper face flashing continuously.
To mobilise the engine, press once, and for a full second, the larger of the two buttons on the transmitter
fob. The security tell tale will be extinguished.
Valet Mode
If leaving the car for servicing or parking, the passive immobilisation feature may be switched off by; switching on the ignition, pressing the transmitter small button, and switching off the ignition. Two beeps will confirm
‘valet’ activation, and the security tell tale will flash continuously, even with the engine running.
At the next arming command, the valet mode will be switched off.
Arming the Alarm
Remove the ignition key, close (and lock) both doors, and check that the engine cover and front body access panels are secure. The roof may be either closed or open. Press once, and for a full second, the larger
of the two buttons on the transmitter fob (on cars with CDL, this action will automatically lock both doors - see
later). This command will be acknowledged by:
Page 2
-
-
Lotus Service Notes
Section MP
Two flashes of the hazard warning lamps;
Continuous flashing of the security tell tale.
Check that these indications occur. If not, press the button a second time, as the first press may have
only switched off the passive immobilisation (see above).
Note that if the system is armed when a door or engine cover/front access panel is not fully closed, a
continuous buzz will be heard as warning. If still open after expiry of the arming period, (see below) the alarm
will be armed with that switch group (both doors, or front/rear access lids) excluded from the circuit.
After arming the system, the engine is immediately immobilised, but a period of approximately 45 seconds
must elapse before all functions and sensors become fully active. After this time, the alarm will be triggered
by any of the following actions:
-
Interruption of the vehicle battery power supply.
-
Energising the ignition circuit (‘hot wiring’).
-
Opening a door;
-
Opening the engine cover or a front access panel.
-
Movement detected within the cabin.
When triggered, the hazard warning lamps will flash and the electronic wailing siren will sound for a
period of approximately 30 seconds before closing down and resetting, ready for any further triggering input.
If a trigger is continuously present, the alarm will repeat after a short delay, and continue in this sequence for
about ten cycles.
To silence the siren when triggered, press once, and for a full second, the larger button on the transmitter
fob. This will not affect the status of the alarm which will remain armed.
Disarming the Alarm
To disarm the alarm, press once, and for a full second, the larger button on the transmitter fob. This command will be acknowledged by:
-
One flash of the hazard warning lamps;
-
Extinguishing of the security tell tale.
If the alarm had been triggered during the last armed period, the disarm command will be acknowledged
by the hazard lamps flashing 4 times, and the buzzer sounding 4 times. The security tell tale will then flash a
code to indicate the triggering source:
-
One pulse flashing: door, engine cover/boot lid or body front access panel. On USA cars, check that the
interior lamp is not switched off.
-
Two pulse flashing: movement detected in cabin by microwave sensor.
-
Four pulse flashing: tampering with ignition circuit.
-
Five pulse flashing: voltage drop.
-
Six pulse flashing: interruption of battery supply.
-
Seven/Eight pulse flashing: serial data fault; alarm harness including microwave sensor cables and immobiliser fuse in engine bay.
The coding will be deleted when the ignition is next turned on.
'Chirping'
'Chirping' is enabled/disabled by disconnecting power to the alarm controller, then re-connecting and
pressing the transmitter button within 5 seconds.
Emergency Disarming/Mobilising
If the transmitter fobs are lost or damaged, the alarm system owner’s unique PIN may be used to disarm
the alarm and/or mobilise the engine provided that access is available to the cabin. Follow the transmitter fob
programming instructions (see later) from step 3.
Intrusion Sensing
A microwave sensor is mounted behind the cabin rear bulkhead trim panel, and is able to detect substantial
physical movement within the cockpit, and trigger the alarm. Microwave transmissions are blocked by metal
objects, so it is important not to corrupt the signal by placing such items on the bulkhead ledge.
If desired, the alarm may be armed without the intrusion sensor or battery interruption circuits being active
by arming the system in the usual way with the transmitter larger button, and within 20 seconds, pressing the
smaller button twice.
Page 3
Lotus Service Notes
Section MP
Manual Activation of Horn/Siren
To enhance personal security, with the system in an armed state, the siren may be manually triggered by
pressing the transmitter smaller button. The horn/siren will sound and the turn lamps flash for 15 seconds. To
stop the alarm, press either of the two buttons.
Transmitter Fob Battery Replacement
The transmitter fobs will normally operate within a range of 5 metres from the car, but this may be reduced
by the presence of other radio signals in the vicinity. A small LED tell tale on the transmitter fob will flash whilst
the button is held down to indicate correct operation, but if the lamp flashes irregularly or only once, transmitter
battery replacement is required.
The transmitters are powered by a long life 3V Lithium battery, type CR2032, which with normal use should
last for 3 years. To ensure continuity of operation, it is recommended to renew the batteries every 12 months:
-
Using a small screwdriver, prise open the case in the areas marked ‘open’.
-
Remove the old battery and wait for 10 seconds before inserting the new battery with +ve sign uppermost,
and holding the battery only by the periphery.
-
Align the locating studs, and firmly press the case together.
-
The transmitter should now operate normally, but may require re-synchronisation with the control unit.
Transmitter Re-synchronisation
If at any time the transmitter does not function, and the battery is known to be good, carry out the following re-synchronisation procedure:
-
Stand close to the car and hold down both buttons on the transmitter until the LED on the fob is extinguished
(approx. 10 seconds).
-
Release both buttons; the fob tell tale should come on constantly.
-
Press the larger button for one second (the fob tell tale will flash). Synchronisation is complete.
Programming Additional Transmitter Fobs
Two transmitter fobs are provided with the new vehicle. If a transmitter is lost or damaged, a replacement
should be obtained immediately from your dealer, and programmed to the vehicle alarm controller using the
system owner’s unique Personal Identification Number (PIN). Up to four transmitter fobs can be matched with
the alarm system, but all fobs must collectively undergo the single programming operation:
a). Before programming the transmitters, the PIN should first be verified. If the PIN is incorrect and a working
fob is prepared for reprogramming, all fobs may be disabled. To verify the PIN;
With the car immobilised (tell tale flashing), follow steps (3i) to (3iii) below (i.e. do not prepare any fobs).
If the PIN is correct, the tell tale should be extinguished, and the system mobilised. If not, the PIN is incorrect.
b). Having verified the PIN as above, proceed as follows:
1.
2.
3.
4.
Press, simultaneously, both buttons on a transmitter fob until the fob tell tale stops flashing (approx. 10
seconds). On release of the buttons, the fob tell tale will light.
Repeat operation (1) for ALL the transmitter fobs required to operate the system.
If the system is immobilised (security tell tale flashing):
i)
Turn the ignition on and off 3 times within 7 seconds; the security tell tale in the tachometer will light
for 3 seconds.
ii) Enter the PIN: Immediately the tell tale goes out, switch ON the ignition and count the number of
security tell tale flashes until equal to the first number of the PIN, then turn the ignition OFF, then back ON
again.
iii) Repeat operation (ii) for the remaining 3 digits of the PIN, remembering to turn the ignition OFF and
back ON after each code number.
Note: If at any time a mistake is made when entering the PIN, turn the ignition OFF for 10 seconds and
re-commence entering the PIN.
iv). If the PIN is correct, the security tell tale will be out. Carry on with step 4.
With the system mobilised (security tell tale out):
i)
Turn the ignition on and off 3 times within 7 seconds; the security tell tale in the tachometer will light
for 3 seconds.
Page 4
5.
6.
7.
Lotus Service Notes
Section MP
ii) Enter the PIN: Immediately the tell tale goes out, switch ON the ignition and count the number of
security tell tale flashes until equal to the first number of the PIN, then turn the ignition OFF, then back ON
again.
iii) Repeat operation (ii) for the remaining 3 digits of the PIN, remembering to turn the ignition OFF and
back ON after each code number.
Note: If at any time a mistake is made when entering the PIN, turn the ignition OFF for 10 seconds and
re-commence entering the PIN.
After finishing step (4) with the ignition on, within 7 seconds, press once the large button of each transmitter fob.
Turn off the ignition.
Test operation of each transmitter fob.
Location of Components
The alarm system components are located as follows:
-
Electronic Controller: Mounted on top of the scuttle beam at LH extreme end. Accessible after removal
of fascia top.
-
Siren Unit: Mounted on front of radiator duct LH extension, beneath LHF turn lamp. Accessible only after
removal of front clamshell.
-
Immobiliser Module: Mounted on left hand end of cabin rear bulkhead. Accessible after removal of rear
bulkhead trim panel.
-
Microwave Sensor: Mounted centrally on cabin rear bulkhead, beneath trim panel.
-
Engine Lid Sensor: Mounted on luggage compartment bulkhead, alongside latch.
-
Front Access Panel Sensors: Mounted on brackets fixed to topshell at outboard edge of aperture.
Front access cover sensor
Electronic controller
Microwave sensor
Siren unit
Door switch
Engine lid sensor
Immobiliser module
m240a
Identification of alarm controller
Note that earlier Elise variants have used versions of the alarm controller with and without CDL functionality. For Elise 111R and Exige models with CDL, the controller should be printed with the identification 8185
4C8170AIB.
Page 5
Lotus Service Notes
Section MP
MP.2 - CENTRAL DOOR LOCKING (if fitted)
The central door locking (CDL) operates on the driver’s and passenger’s doors in conjunction with the
security alarm system, which includes CDL circuitry in the Cobra 8186 alarm controller.
To lock the car, remove the ignition key, close both doors and check that the engine cover and front body
access panels are secure. Arm the security alarm in the usual way by pressing once, for a full second, the
larger of the two buttons on the transmitter key. This action will both arm the alarm and electrically lock the
driver’s and passenger’s doors.
If it is desired to lock the doors from inside the vehicle, for example to deter highjack attempts, a CDL
rocker switch is provided on the front of the gear lever shroud which should be pressed to the right to lock both
doors with or without the ignition switched on. Alternatively, the doors can be locked individually by depressing the button at the rear end of each door sill. Note that whichever locking method is used, the doors will be
‘deadlocked’ such that the interior door release handles are inoperative.
To unlock the doors, press once, for a full second, the larger button on the transmitter key. The alarm will
be disarmed and both doors unlocked. Alternatively, from inside the car, press to the left the rocker switch on
the gear lever shroud to unlock both doors, or raise the sill button on each door. Note that in the event of a
vehicle collision which causes the safety inertia switch to be tripped, the doors will automatically be unlocked.
Notes:
-
In the event of a flat vehicle battery, the
central door locking will not operate. The
doors can be unlocked from outside only
after:
Elise; opening the engine cover and
restoring power to the battery by
substitution, re-charging or ‘jumping’ to
a second battery.
Exige; removing the front body passenger
side access panel and providing a 12 volt
supply to the auxiliary power point.
-
-
EXIGE AUXILIARY BATTERY POSTS
ohs142
To lock the car with a flat or disconnected battery, use the mechanical key in each exterior door button
to disconnect each release button from the latch. This technique does not 'deadlock' the interior release
handles, but does allow continued key access to the car until restoration of battery power.
To deadlock the car with a flat vehicle battery, or without the use of the transmitter or mechanical key,
close and lock one door using the sill button, and for the second door, hold the exterior release button
pressed in and depress the sill button before closing the door. Access is now available only on restoration
of electrical power.
Door Locking Actuator
A CDL actuator is screw fixed to the door shell below the latch mechanism, and uses a link rod which
passes through the innermost hole on the latch lever, before continuing upwards to the door sill button. For
replacement details, refer to sub-section BP.17.
Modules, Fuses & Relays
A CDL module is mounted on the top of
the scuttle beam at the extreme end on the RH
side, accessible after removal of the fascia top
trimmed panel and face level vent trunking (if
fitted). A battery feed for the CDL system is
provided from fuse A22 (7.5A).
m251
Page 6
CDL module
Lotus Service Notes
Section MP
MP.3 - ELECTRIC WINDOWS (if fitted)
On cars so equipped, switches for the electric windows are mounted in the front of the door trim panels,
and are operative only with the ignition switched on. To help locate the switches in the dark, an illuminated dot
is provided in the ‘down’ button which glows amber when the lights are switched on.
Illuminated
dot
Window up
Window down
ohs124
To lower a window, switch on the ignition and press the lower, dished end of the switch in the relevant
door. Release the switch to stop window movement. To raise a window, press the upper, domed end of the
switch. The electric window lift mechanismuses an electric motor and winder drum driving a steel cable around
top and bottom guide pulleys to a lift block. The window glass is fixed to the lift block which is guided by a
vertical rail.
The door harnesses to support CDL and electric windows are routed to the scuttle area via a grommet in
the 'A' post area ahead of the door hinge post. Two 20A fuses for the window motors are tie wrapped to the
harness above the passenger footwell. Modules for the hazard lamps and wash/wipe functions, and relays for
the horn and inertia switch door open command, are mounted on the scuttle beam in the same area.
Page 7
Lotus Service Notes
Section MP
MP.4 - SWITCHES & INSTRUMENTS - DRIVER'S INFORMATION
Ignition Switch/Steering Lock
The switch/lock is located on the right hand side of the steering column.
I ‑ Insert the key into the slot, and turn clockwise to position ‘I’ to unlock the steering column. If the key is
reluctant to turn, wriggle the steering wheel to ease the load on the steering lock.
II ‑ Turn to position ‘II’ to switch on the ignition and operate auxiliary equipment. III ‑ Turn further clockwise to ‘III’ against spring pressure to operate the starter motor. As soon as the engine
starts, allow the key to return to position ‘II’. For the correct starting procedure, see the later chapter
‘Starting Procedure & Running In’. To stop the engine, turn the key back to ‘I’.
Passive Immobilisation: If the ignition has been switched off for longer than four minutes, or longer than
one minute after switching off the ignition and opening the driver’s door, the passive immobilisation security
feature will operate and disable the ignition and starter circuits. This condition is indicated by the security
tell tale flashing continuously. To mobilise the engine, press once, and for a full second, the larger of the
two buttons on the transmitter fob. The security tell tale will be extinguished.
B ‑ To remove the key, turn fully counterclockwise to ‘B’ and withdraw. The steering column lock will be activated when the key is withdrawn but may not engage until the steering is turned and the mechanism is
aligned.
DO NOT leave the ignition switched on for long periods without the engine running, since although the
engine ignition system itself draws no current when the engine is stopped, a battery drain will occur through
other circuits even when auxiliary equipment is not being used.
For security reasons, and to guard against battery drain, always remove the key when leaving the car.
WARNING:
‑
Do not push or tow the car unless the key is first used to unlock the column and is then left in the
lock.
‑
Never withdraw the key until the vehicle is stationary.
‑ To reduce the risk of theft, or danger to a child remaining in the vehicle, always remove the key
when leaving a parked car.
Tell Tale Lamps
A block of tell tale lamps is incorporated
into the instrument cluster to indicate the
operational status of various systems.
Bulb Check
In order to check that the warning systems
are operative, all the tell tale lamps (except the
‘security’ tell tale; see Vehicle Security Alarm)
should light for about six seconds following
ignition switch on. If any lamp should fail to
light, it is possible that the bulb or warning
circuit may be faulty.
Euro
f
USA
f
a
b
c
d
e
g
a h
b
i
c
j
d
k
e
g
h
i
j
k
S.I.R. (Airbag) Tell Tale (USA h)
The Supplementary Inflatable Restraint system has a self-diagnostic facility which lights the red tell tale
if a fault is detected. As a bulb and circuit check, the tell tale will light briefly when the ignition is switched on,
and then go out. If the lamp lights at any other time, a fault in the S.I.R. system is indicated, which should be
rectified without delay.
Turn Tell Tale (a)
When the left hand or right hand turn indicators are operating, this green tell tale flashes in unison. The
flasher relay may also be heard to operate. If the tell tale fails to light, or flashes at an unusual or irregular rate,
check the operation of the turn indicator lamps immediately.
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Lotus Service Notes
Section MP
Seat Belt Tell Tale (b)
The red seat belt tell tale is provided as a reminder that both driver and passenger should always wear the
seat belts, no matter how short the journey. The lamp will light for about 8 seconds following ignition switch on,
before being extinguished. On USA market cars, and other markets from December 2005, the lamp will flash
until the driver's seat belt is fastened, accompanied for the first eight seconds by an audible chime.
Brakes Tell Tale (c)
This tell tale will glow red with the ignition switched on whenever the parking brake is applied. Driving
the car with the brake not fully released will cause overheat damage to the rear brakes. Each time the parking
brake is released, check that the tell tale is extinguished.
With the parking brake released, if the tell tale should light at any time after the check period, stop the car
immediately, as the circuit has detected a dangerously low level of brake fluid in the master cylinder reservoir,
possibly caused by a hydraulic leak in one of the separate front or rear brake circuits. There is a danger that
air may enter the hydraulic system and cause spongy operation and extended pedal travel. The divided brake
circuit should ensure that emergency braking remains, but the car should not be driven until the fault has been
identified and rectified.
Oil Pressure Tell Tale (d)
This red tell tale warns of low engine oil pressure. The lamp will be lit whenever the ignition is on and
the engine is stopped, but should extinguish as soon as the engine is started. If the lamp fails to go out after
engine start up, or comes on when the engine is running, stop the engine immediately and do not restart until
the cause has been investigated and rectified. Continuing to run the engine with little or no oil pressure could
cause major internal damage, possibly resulting in seizure.
Low Fuel Level Tell Tale (e)
When only a single segment of the fuel gauge bar graph remains, representing approximately 5 litres, this
amber tell tale will flash. Refuel at the next opportunity.
ABS Tell Tale (f)
This amber tell tale should light for about four seconds following ignition switch on, and then go out. If
the lamp remains lit, or comes on whilst driving, a fault in the ABS is indicated. The base brake system will
continue to operate normally, but without ABS regulation. The car can be driven but should be checked and
repaired at the earliest opportunity.
Main Beam Tell Tale (g)
This lamp glows blue whenever the headlamp main beams are operating.
Rear Fog Lamps Tell Tale (Euro h)
This lamp glows amber whenever the rear fog lamps are operating (see ‘Rear Fog Lamp Switch’).
Battery Charging Tell Tale (i)
This red tell tale will light whenever the ignition is on and the engine is stopped. If it lights any time that
the engine is running, the battery is not being charged, which may be due to a broken alternator drive belt, or
an electrical fault. Urgent attention is required, but as the engine coolant pump is independently driven, the
car need not be stranded, subject to battery condition and local circumstances.
Malfunction Indicator Lamp (k)
The engine Malfunction Indicator Lamp (MIL) is provided to warn the driver that the engine management
system has detected a fault which may result in increased noxious emissions from the exhaust. In order to minimise emissions and potential engine damage, various operational limitations may automatically be applied.
i) If the MIL lights continuously whilst driving, immediately reduce speed and adopt a moderate driving style.
Seek dealer advice without delay and avoid all unnecessary journeys.
ii) If the MIL flashes, an engine misfire has been detected which is likely to cause overheat damage to the
catalytic converter. Slow down immediately and be prepared to stop.
-
If the MIL then stops flashing, and is lit continuously, proceed with caution and seek dealer advice.
-
If the MIL continues to flash, stop the vehicle as soon as it is safe to do so, and switch off the engine. Seek
dealer advice.
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Lotus Service Notes
Section MP
Note:
Continuing to drive the car with a flashing MIL may cause overheat damage to the catalytic converter and
increased noxious emissions.
In order to comply with emissions regulations, data regarding activation of the MIL is recorded in the engine
electronic controller, and may be downloaded by Lotus dealers.
Security/RPM Tell Tale
The security tell tale is located at the top of the tachometer display, and indicates the status of the immobiliser and alarm.
-
Tell tale out; engine is mobilised, and the alarm is off.
-
Tell take flashing; engine is immobilised, or alarm is armed and engine immobilised.
For full details of the vehicle security system, refer to the earlier section ‘Vehicle Security’. Note that the
tell tale also functions as a high engine speed (rpm) warning - see ‘Tachometer’.
Instruments
Speedometer
This instrument displays road speed in either MPH (with a secondary scale in km/h), or km/h according
to market.
Tachometer
The tachometer indicates engine speed in revolutions per minute. A safeguard in the engine management
system limits the maximum continuous engine speed to 8000 rpm once normal running temperature has been
attained. Very short bursts up to 8500 rpm are allowed during maximum acceleration through the lower gears.
A 6000 rpm limit is imposed on a cold engine in order to reduce possible damage from unsympathetic use.
The use of wide throttle openings and/or high rpm before normal running temperature has been reached will
result in premature wear and should be avoided. Do not run the engine continuously at its maximum speed,
or allow overspeeding to occur on the overrun by changing down through the gears too early, as this imposes
very high loads on engine components, resulting in premature wear and possible failure.
A red tell tale lamp in the top of the tachometer face lights at high rpm (dependent on gear engaged) to
warn that maximum engine speed is being approached. When exploiting full acceleration, gearchange upshifts
should be made immediately the tell tale lights. Note that this lamp also functions as a security system tell
tale (see ‘Vehicle Security’). Recalibration of the tachometer needle position will occur during a three second period following ignition
switch on, but if a needle becomes 'stranded' outside of the re-calibration range, the following procedure should
be followed:
With the vehicle stationary;
-
On airbag equipped cars, first remove
Security/RPM tell tale
fuse C3 (beneath fascia);
Tachometer Speedometer
-
Open driver's door;
-
Press and hold trip reset button on
column shroud;
-
Turn on ignition;
-
Turn off ignition and refit fuse C3.
If this procedure should fail to zero the
needles, the battery should be disconnected
for 10 seconds.
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INSTRUMENT POD
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Lotus Service Notes
Section MP
LCD Panel
A liquid crystal display (LCD) panel is provided below the instruments in order to display fuel level, coolant
temperature, total mileage and trip functions. The panel is blank until the ignition is switched on.
Fuel Contents Display
An indication of the level fuel in the tank is
displayed in the form of a bar graph at the right
hand top of the LCD panel in the instrument
cluster. When completely full (approximately
43.5 litres (9.6 U.K. gal), the display will show
six black segments. As the fuel level falls,
a white band will extend from the right to
represent the empty portion.
When only a single segment remains,
representing approximately 5 litres, the amber
low fuel tell tale will flash. Refuel at the next
opportunity.
Trip distance Proportion of fuel remaining
Odometer
LCD DISPLAY PANEL
Coolant temperature
m253
Coolant Temperature Display
The engine coolant temperature will be displayed at the bottom right hand corner of the panel as soon
as the temperature reaches 72°C. The running temperature will fluctuate a certain amount as the operating
conditions change, and during periods of idling or in heavy traffic, the temperature may rise to over 100°C, with
the cooling fans switching on at half speed at approximately 98°C and at full speed at approximately 103°C.
The display will flash at temperatures over 110°C in order to prompt closer monitoring of high temperatures,
but as the pressurised cooling system has a boiling point of over 120°C, only if the temperature approaches
this level need there be any cause for concern. If this should occur, allow the engine to idle for a few minutes
whilst monitoring the temperature, and if it continues to rise, switch off and seek qualified assistance.
After a heavy snowfall, ensure that the radiator cooling outlet grilles in the front body are cleared of snow
before driving the car, or overheating may occur.
Odometer
An odometer (total distance recorder) reading is displayed at the bottom left hand corner of the panel, and
is calibrated in the same units (miles or kilometres) as is the speedometer.
Trip Recorder
A trip recorder is provided at the top left hand corner of the panel, calibrated in the same units as is the
speedometer.
In order to zero the trip display, switch on the ignition, and press for a moment (less than 1 second), the
small button on the steering column shroud between the ignition switch and steering wheel. This dual function
button also controls the panel illumination - see ‘Instrument & Switch Illumination’.
Fascia Switches
Lighting functions are controlled by a vertical row of three push button switches mounted in the fascia
outboard of the steering column. Each switch is pressed once to switch on, and pressed a second time to
switch off. A symbol is positioned alongside each switch to indicate its function, and is backlit orange when
the lights are switched on.
Sidelamp Switch
The topmost switch functions with or without ignition, and switches on the sidelamps. A tell tale in the
switch button lights up green to indicate when the circuit is active. Note that the headlamps must be off before
the sidelamps can be switched off.
Headlamp Switch
The centre switch functions with or without ignition, and switches on the headlamps together with the sidelamps if not already selected by the sidelamps switch. A tell tale in the switch button lights up green to indicate
when the circuit is active. The steering column lever switch (see later) is used to select main beam or dip.
Pressing the switch a second time will switch off the headlamps, but leave on the sidelamps.
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Lotus Service Notes
Section MP
Lights On’ Buzzer
A ‘lights on’ reminder buzzer will sound if the lights are on when the ignition is switched off and the driver’s
door is opened.
Sidelamps
Headlamps
Rear Fog
ohs109a
Rear Fog Lamp Switch
The lowermost switch controls the two rear fog lamps (where fitted), and may be selected only after first
switching on the ignition, and then the headlamps. A tell tale in the switch button lights up amber to indicate
when the circuit is active.
Note that the switch will default 'off' whenever the headlamps or ignition are switched off, requiring reselection if lamp acivation is again desired.
In some territories, rear fog lamps may be used legally only in conditions of ‘seriously reduced visibility’. Be aware that indiscriminate or forgetful use of the rear fog lamps can cause distraction and discomfort to following traffic.
Hazard Warning Lamps Switch
The hazard warning switch is located immediately ahead of the gear lever in the centre shroud, and has
an icon in the switch button which is back lit when the ignition is switched on. The switch is operative at all
times, and when pressed flashes all the turn indicator lamps, and the switch tell tale, in unison. Press a second
time to switch off.
This facility should be used when the vehicle has to be stopped on the highway in abnormal circumstances,
where a warning to other traffic would be judicious. Use of the hazard warning lamps may be subject to local
traffic laws, with which drivers should familiarise themselves.
Instrument Illumination
A small button is provided on the steering column shroud, between the ignition switch and steering wheel,
by which the brightness of the instrument illumination may be adjusted. To cycle through the range of brightness, press and hold the button, and release at the desired setting.
This dual function button also resets the trip distance recorder - see ‘Trip Recorder’.
Auxiliary Power Socket
An auxiliary power socket is fitted in the
centre trim shroud below the oddments pocket
on the rear bulkhead. The socket is operative
at all times, and is provided with a protective
hinged flap and an illumination ring which is
backlit red when the lights are switched on.
The format of the socket allows a
standard cigarette lighter element to be used,
or other electrical accessories requiring this
type of fitting. Maximum current draw should
not exceed 15 amps.
Page 12
AUXILIARY
POWER
SOCKET
ohs144
Lotus Service Notes
Section MP
WARNING: Do not leave small children unattended in the car since careless interference with the power
socket could be dangerous.
Headlamp Dipswitch/Flasher/Turn Indicators
The steering column left hand lever switch controls the headlamps main beam/dip, headlamp flash and
turn indicators.
Headlamp Dipswitch: To switch on the headlamps,
press the headlamp switch in the fascia outboard
Right
of the steering column. The left hand lever switch
turn
is then used to select main or dip beam. Main
beam is obtained with the lever furthest forward,
away from the steering wheel, and dip beam with
the lever moved back towards the wheel. The
main beam tell tale lamp in the instrument panel
Main beam
lights when main beam is operating.
Left
Note: i) When main beam is selected, the dip
turn Dip beam
beam lamps remain lit. ii) On cars equipped with
optional auxiliary main beam lamps mounted in
Flash
the radiator air intake, the auxiliary lamps operate
in conjunction with the body mounted headlamp
main beams.
Headlamp Flasher: The headlamp flasher is operative at all times. If the lever is pulled towards the steering
wheel against spring pressure, the headlamp main beams will light.
Turn Indicators: The turn indicators operate only with the ignition switched on. Move the lever down to indicate
a left hand turn, and up for a right hand turn. The switch will be cancelled when the steering wheel is returned
to the straight ahead position.
For convenience, when signalling a lane change, lightly pressing the switch up or down will allow its return
under spring action.
ohs32
Windscreen Wiper/Washer
The steering column right hand lever switch controls the windscreen wiper and washer, and is operative
only with the ignition switched on. Never use the wiper on a dry screen.
Windscreen Wiper: The wiper is controlled by
Wiper
the up/down position of the lever switch, which
operates as follows:
Moved fully down, the wiper is
switched off.
Move up to the first position for
intermittent wipe. The wiper will make
one sweep about every five seconds.
Select the next position for normal wiper
operation.
Move fully upwards for quick wipe, to
be used only in heavy rain.
Washer
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Windscreen Washer: Two windscreen washer jets are provided, one each side of the wiper spindle. Pulling
the control lever towards the steering wheel will operate both the washer pump and the wiper. When the switch
is released, the wiper will continue for a further four sweeps.
Horn
The windtone horn, which functions at all times, is operated by a central button in the steering wheel
boss.
Interior Lamp
An interior lamp is mounted centrally in the rear bulkhead trim panel and is equipped with a three position
rocking lens:
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Lotus Service Notes
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Section MP
Lens rocked upwards; lamp is switched off. NOTE: On USA cars, arming the alarm with the interior
lamp switched off may exclude the doors from activating the alarm.
Lens central; lamp is switched on, with or without ignition.
Lens rocked downwards; a courtesy mode applies, where the lamp is switched on whenever a door is
opened, and goes out when the doors are closed. In addition, the alarm disarm command will also light
the interior lamp for a period of 30 seconds, or until the ignition is switched on.
Inertia Switch
The safety inertia switch is designed to
operate on impact, typified by vehicle collision,
to switch off the fuel pump, and thus minimise
any fire hazard. The inertia switch is mounted
at the left hand rear corner of the engine bay,
and is reset by pressing the rubber diaphragm
button on the top of the unit.
INERTIA
SWITCH
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MP.5 - COMPONENT LOCATION & FUSE RATINGS
Main Fusebox
The main fusebox is located in the front services compartment, on the passenger side, and is protected
by a plastic cover. For access, remove the passenger side front body access panel, and unclip the fusebox lid.
Twenty two slots are provided for ‘Littel’ type fuses which are numbered, and coloured according to their amperage rating, and may be pulled out from their slots using the fuse extractor tool provided on the fusebox lid.
m254
As viewed from in front of Elise:
Fuse 1
Fuse 11
MAIN FUSEBOX
Slot Rate
1 20A
2 2A
3 20A
4 20A
5 7.5A
6 7.5A
7 10A
8 7.5A
9 10A
10 7.5A
11 10A
12 10A
Slot Rate
Circuit
Aux. power socket
non USA: Alarm siren
USA: Reverse lamps
Driver window
Passenger window
Stoplamps
non USA: Reverse lamps
Turn indicators
Ignition services
Battery services
Hazard lamps
Horn
Alarm power,interior lamp
ABS
Circuit
Page 14
Fuse 12 Fuse 22
13 3A
14 20A 15 7.5A
16 10A
17 10A
18 10A
19 20A
20 15A
21 15A
22 7.5A
ECU ignition
Rad. fans;
1&2 slow, 1 fast
Radio, switch pack module
Sidelamps
non USA: Rear fog
Dip beam LH
Dip beam RH
A.C. comp. relay, rad fan 2 fast
Main beam LH
Main beam RH
CDL m255
Lotus Service Notes
Engine Compartment
Fuses and relays associated with the
engine management system are contained
in two 4-position fuse holders located at the
front of the engine bay on the cabin bulkhead,
adjacent to the engine ECM. To access the
fuses, unclip rear edge of the cover.
Fuse no.
R1
R2
R3
R4
R5
R6
R7
R8
Rating
20A
3A
5A
5A
5A
7.5A
10A
5A
Circuit
Fuel pump
Immobiliser
Alternator sense
ECU battery feed
O2 heaters
VSV's VVT, VVL, IAC
Injectors, ignition coils
Re-circ. pump
Interior Fuses & Relays
The wash/wipe module, turn/hazard
flasher relay, horn relay and a relay for inertia
switch activation of the central door locking,
are mounted on the scuttle beam above the
passenger footwell, with four fuses secured to
the harness in that area.
Fuse no.
C1
C2
C3
C4
Rating
20A
15A
7.5A
10A
Circuit
Interior fan
Wiper motor
Audio key-in
A.C. compressor
Section MP
ENGINE BAY FUSES
4
3
2
1
8
7
6
5
ohs136
Front

Fusebox ‘C’
Viewed
from
beneath
m248a
A 60A Maxi fuse protecting the ABS circuit is located beneath the passenger side fascia top, adjacent to
the positive post.
A multi-function relay unit containing the engine control relay, fuel pump relay and starter relay is mounted
in the engine bay near the ECU. A similar relay unit is mounted in the front services compartment alongside
the fusebox, and operates the a.c. compressor and radiator fans. Important Note: Although the two modules
are identical in appearance, their function is different and they must not be transposed. The a.c. relay module
A117M0038F has a brown label marked YWB100800; The engine relay module A111E6024F has a white label
marked YWB100970.
For the location of the vehicle alarm system components, see sub-section MP.1.
Fuse colours:
2A ‑ Black
3A - Violet
15A ‑ Light Blue20A - Yellow
4A - Pink
25A - Clear
Relay Position
RHD:
Inboard top; Inboard bottom;
Outboard top;
Outboard bottom;
LHD:
Inboard top; Inboard bottom;
Outboard top;
Outboard bottom; Wiper
Flasher
CDL trip
Horn
Flasher
Wiper
Horn
CDL trip
5A ‑ Orange
7.5A - Brown
10A - Red
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Lotus Service Notes
Section MP
Component Location
CDL module Engine bay fuseboxes
Horn mounted
on crash structure ECU
mounting
plate
Fusebox
Inertia
switch
Radiator fan/a.c.
control module
Fuse
ABS block
fuse
Switch Horn relay pl1703mt
controller CDL trip relay
Flasher unit
Wiper delay
MP.6 - AUDIO EQUIPMENT
Front speaker
The Elise may be specified with various
audio equipment options. All cars are fitted
with a main wiring harness which includes:
an ISO 16-way connector located behind the
standard ISO size audio aperture in the dash
panel; speaker wiring terminating behind
the cabin LH rear corner trim panel; and an Speaker
analogue di-pole aerial routed inside the front grille
body. On cars factory built with a digital audio
set, this aerial is supplemented by a digital dipole aerial routed in a similar manner.
Speakers
'Two speaker' cars are fitted with a
speaker in each cabin rear corner in a sound
deadening full width rear bulkhead trim panel.
An upgraded audio option uses the same
rear speakers, in conjunction with a pair of
front speakers, mounted one in each dash
end panel. USA cars have the front speakers mounted in the fascia top panel.
Page 16
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Lotus Service Notes
Section MP
Speaker specifications are as follows:
Rear: Blaupunkt GTX 542 2-way co-axial; 90W max; 30W RMS; 4 ohms impedance.
Front: Blaupunkt TSX 402 2-way co-axial; 105W max; 35W RMS; 4 ohms impedance.
To remove the rear bulkhead trim panel, remove the four screws securing the top edge of the panel to the
bulkhead plinth, and ease the panel from behind the seat belt mounting frame at each side.
MP.7 - BATTERY, BATTERY CABLES & EARTHING POINTS
Battery
WARNING: POISON/DANGER ‑ CAUSES SEVERE BURNS ‑ KEEP OUT OF REACH OF CHILDREN.
Contains sulphuric acid ‑ avoid contact with skin, eyes or clothing. If in contact with skin or eyes; flush
with copious amounts of water. Remove contaminated clothing. Seek immediate medical attention. If
ingested; seek immediate medical attention . Do not induce vomiting or give fluids to drink.
Batteries produce explosive gases. Keep sparks, flames and cigarettes away. Ventilate when charging
or using in enclosed space. Always shield eyes when working near batteries.
Battery Access
The 45 Ahr Yuasa type 063/3 battery is located at the left hand front of the rear luggage compartment.
No routine inspection or topping up of the electrolyte is required, but at intervals specified in the Maintenance
Schedule, the battery terminals should be checked for security and condition, and protected with petroleum
jelly.
To remove the battery, unhook the plastic cover, disconnect both battery cables (see below), and pull
off the breather pipe (if applicable). Release the single screw securing the clamp bracket at the rear base of
the battery, and manoeuvre the battery from the base retaining shoes at the front and right hand side. When
lifting out the battery, be aware of the considerable weight, and take all appropriate precautions to safeguard
personal health.
Refit the battery, with its terminals inboard, by reversing the above procedure. Remember to push on the
breather pipe (if applicable), and reconnect the battery cables as detailed below.
Battery
clamp
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Disconnecting the Battery
If the battery is to be disconnected, the following precautions should be taken:
i) Wait for at least ten seconds after switching off the ignition to allow the engine management system to
adjust the setting of some components ready for re‑starting.
ii) If the car is fitted with the upgraded security alarm, immediately before disconnection, mobilise the engine
using the transmitter button with ignition off, and disconnect the battery within 25 seconds. If disconnected
after this time, or when immobilisation is in effect, the alarm will be triggered.
iii) Ensure that all electrical loads (e.g. lights) are switched off.
iv) Disconnect the negative (earth; black; ‘‑’) battery cable first, and re‑connect last. If the battery positive
terminal is inadvertently earthed (e.g. when using a spanner) whilst the negative terminal is still connected,
the resultant short circuit with heavy sparking and current flow could cause serious burns.
v) If the vehicle is fitted with security coded audio equipment, check that the code is available for entering
after battery reconnection.
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Lotus Service Notes
Section MP
Battery Reconnection
i)
Check again that all electrical loads are switched off.
ii) Connect the positive battery cable first, followed by the negative (earth) cable.
iii) Be aware that the vehicle security alarm may be triggered by the action of battery re-connection. Have
the alarm transmitter key ready to disarm the alarm (see ‘Vehicle Security Alarm’).
iv) After reconnection, a change in the engine performance characteristics may be noted for a period whilst
the computer controlled engine management system ‘re‑learns’ some of its settings.
v) If necessary, enter the security code into audio equipment.
Battery Charging
Under conditions of normal daily use, it should not be necessary to use external battery charging equipment. In a low usage regime, however, it is important to maintain the charge state of the battery using a trickle
charger, or an automatic battery management charger such as that available through Lotus After Sales. Such
devices, when connected to a vehicle battery, continuously monitor battery charge state and switch on and
off automatically in order to maintain the battery in a fully charged state without danger of damage through
overcharging.
If the battery becomes discharged to the extent that the vehicle cannot be started, the recommended
course of action is to fit a substitute battery whilst the original battery is trickle charged. If, in an emergency,
the vehicle has to be ‘jump’ started, the subsequent conditions of vehicle use may not allow for sufficient alternator charging of the battery to achieve a fully charged state. The battery should be trickle charged until 12.8
volts is recorded, which process may take 24 hours or longer. Putting the battery into service at a lower state
of charge will reduce the time period for which the vehicle can be parked. A battery left in a fully discharged
state for a prolonged period, may not be recoverable to its original condition.
Unless using an automatic battery management charger, the battery should be removed from the car for
recharging, to a well ventilated area to avoid a build up of fumes in the luggage compartment and to prevent
damage to the car's electrical system. Observe the safety precautions listed above when removing the battery and take care to avoid sharp knocks or shocks, keeping the battery as upright as possible. Beware of the
considerable weight of a battery, and take necessary precautions against personal injury.
Check that the electrolyte level is between the upper and lower markers on the battery case, and if necessary add distilled water. The recommended bench charge rate is 4 amps. When the battery is fully charged
(12.8 volts), allow the battery to stand for an hour before refitting into the battery well and reconnecting the
leads - see above.
Quiescent Drain
With a fully charged battery, the current drain with all electrical equipment switched off (no radio fitted)
should be as follows;
Immobiliser active
15 mA
Alarm set
20 mA
If current drain is found to be significantly in excess of these figures, the cause must be established by
isolating components (e.g. at fusebox) and rectifying faults as necessary.
Battery Cables
The main battery positive cable runs from the battery to a binding post mounted on the engine ECU plate,
itself fixed to the engine bay bulkhead. From this post, one cable loops to the starter motor and then to the
alternator, and another is routed through the LH sill, fixed to the outside of the chassis LH side rail together with
the heater return pipe, clutch hydraulic hose and servo vacuum hose, and penetrates the scuttle baffle panel
to a second positive post mounted on the top of the scuttle beam. This post is used to distribute power to the
main fusebox and other front end circuits.
The battery earth cable connects to a chassis earth point on the inside surface of the LH chassis rail at the
side of the engine bay, accessible from beneath. From here, an earth braid connects with the ECU plate and
also with the transmission casing. A second earth point is used at the front of the chassis to provide for front
mounted components, and is located within the front services compartment on the inside surface of the chassis
LH siderail. Each chassis earth point uses an M8 threaded insert and on some cars, a special stepped washer
which must be fitted the correct way round in order to contact the chassis (anodisation removed around insert).
The chassis and cable earth terminals should be coated with petroleum jelly to protect from corrosion.
On the Exige, positive and negative posts are provided on the passenger side in the front services compartment in order to allow for jumper cable connection on a car with a flat battery, when release of the engine
cover is not available.
Page 18
Lotus Service Notes
Section MP
Battery cables; positive & negative posts
Positive binding post
on scuttle
Chassis front
earthing point
Starter
solenoid
Battery
negative
Battery
positive
Chassis rear earth point
m191b
Positive post on bulkhead
Chassis Chassis front
earth To ECU earth point
stud plate To transmission Positive binding
housing post on scuttle
Page 19
m191b
Lotus Service Notes
Section MP
MP.8 - WIPER MECHANISM
The windscreen wiper mechanism comprises a uni-directional motor with an external rotary link, a connecting rod, and a pair of actuating links which join the connecting rod to the arms of the wiper spindle. This
mechanism provides the wiper with a motion which is slowed at each end of its travel in order to ease the
inertia loads during direction changes, to the benefit of refinement and durability. The motor and wheelbox are
mounted on a single fabricated steel bracket which is bolted to the windscreen scuttle panel.
To remove the wiper mechanism:
1. Remove the front clamshell (see sub-section BP.5).
2.
Remove the wiper motor protective cover by releasing the two screws into the windscreen buttress, and
the patch of adhesive between the inboard end and the screen gutter. Disconnect the harness plug from
the motor. Disconnect the washer tubing.
3.
Remove the wiper arm from the spindle, and the spindle rubber surround.
Spindle rubber surround
Wiper arm
Wiper motor
mounting bracket
Clamshell
mounting
plinth
bolt
Bracket
fixing
bolts
Bracket fixing
Wiper motor assembly
m208
4.
Release the three screws securing the motor mounting bracket to the windscreen frame - one at each side
of the spindle, one at the motor end, and withdraw the complete mechanism from the car.
5.
If the motor is separated from the mechanism, the position of the rotary link should be marked against
the motor shaft for reference when re-fitting. The motor should be in the 'park' position before fitting, and
the mechanism at full travel so that the rotary link and connecting rod are aligned in the fully extended
position.
Page 20
Lotus Service Notes
Section MP
RHD Shown
(LHD symmetrically
opposite)
Wiper linkage
in full travel
position
6.
m209
Re-assemble in the reverse order to removal, torque tightening the bracket bolts to 20 Nm.
MP.9 - HARNESS ROUTING
The main harness runs from the main fusebox/relay station at the passenger side of the front services
compartment, and divides into three branches; one running forwards across the front of the chassis well to feed
the interior fan motor, heater/a.c. functions, radiator fans and ABS controller, and then round the front of the
crash structure to supply the horn and front lights. A second branch connects to the radiator fans/a.c. control
module mounted on the passenger side wheelarch liner. The third brance runs rearwards through the scuttle
where it divides again to run across the dash top, picking up on the positive post, and supplying the instrument
pack and switchgear. The harness then runs along the cockpit centre tunnel to the rear of the cabin, over the
top of the fuel tank bay, and through a grommet at the left hand rear corner of the cabin.
At the left hand front corner of the engine bay, one branch continues rearwards through a rear clamshell
grommet to connect with the rear lighting harness routed inside the clamshell. Another branch runs across the
engine bay/cabin bulkhead to the multi-function relay module and engine ECU. The engine harness connects
to the ECU on the bulkhead.
Front section fixed Routed along dash top to crash structure Engine harness
Wheel speed
sensor
Fusebox &
rad. fan/a.c. Routed along
module centre tunnel
Rear
harness
Positive Engine ECU
post
pl1701mt
Page 21
Lotus Service Notes
Section MP
MP.10 - FRONT LAMP ASSEMBLIES
Headlamp Units - Prior '07 M.Y.
The front clamshell incorporates, at each side, a headlamp housing, in each of which are mounted a halogen projector type dip beam lamp (upper), and a halogen main beam lamp (lower), which also incorporates the
sidelamp bulb. A moulded plastic mask and clear acrylic cover are bonded together and are fitted over each
headlamp housing, with a rubber surround finisher, with the unit retained by three slotted thumbscrews accessible from within the front wheelarch. For access to the headlamps, release the three socket head screws and
withdraw the headlamp cover assembly.
Dip beam lamp
Main beam
lamp
HEADLAMP COVER UNIT SOCKET BOLTS
ohs105a
Sidelamp bulb
ohs107
Headlamp bulbs may be replaced after disconnecting the cables (Dip; blue/yellow, black. Main; blue/
black, black) and releasing the spring clip. Both the 55W H1 dip beam bulb, and the 55W H7 main beam bulb
incorporate orientation features which must be correctly located on re-fitting. The holder for the T4W bayonet
fitting sidelamp bulb may be twisted to release from the main beam headlamp.
If the car is to be used temporarily in an opposite drive hand territory, a masking lever incorporated in each
dip beam headlamp should be moved to provide a horizontal cut off and prevent dazzle.
Headlamp Beam Alignment
1. Using beam setting equipment compatible with ECE Regulation No.48 for 76/756/EEC, position the machine
between 300 and 700mm in front of the LH headlamp, and parallel with the two headlamp units using the
sight bar or similar device dependent on the machine design, to ensure cross car match. Use the guides
provided on the machine to ensure the correct height and lateral setting.
2.
Switch on the headlamp dip beams (uppermost lamps), and check the lateral beam alignment. The ‘knee
point’ of the beam cut off line must lie within a tolerance of 2% to the passenger side, and 0%.
Check the vertical alignment of the dip beam which must lie within a tolerance of -0.5% and -2%.
3.
If adjustment is required, from within each front wheelarch, using a 5mm hexagonal key, remove the three
socket head screws securing the headlamp cover/masks, and withdraw the covers complete with rubber
seal.
4.
To adjust the dip beam laterally, adjust the dome headed screw at the upper inboard side of the dip beam
(uppermost) lamp, accessed from the front of the lamp. Turn clockwise to adjust the beam to the right.
Optimum setting is 0%.
To adjust the vertical aim of the dip beam, adjust the dome headed screw at the lower outboard side of
the lamp, accessed from the front. Turn clockwise to raise the beam. Optimum setting is -1.5%.
5.
Repeat for the RH lamp.
6.
Centralise the machine on the LH main beam (lowermost) lamp, and switch on the main beams. Check the
main beam alignment which should be centralised with the marker dot on the machine screen or slightly
below the horizontal. Optimum setting is 0%.
- To adjust the main beam laterally, adjust the dome headed screw at the upper inboard side of the lamp,
Page 22
Lotus Service Notes
Section MP
accessed from behind the lamp. Turn clockwise to adjust the beam to the right.
- To adjust the vertical aim of the main beam, adjust the dome headed screw at the lower outboard side
of the lamp, accessed from behind the lamp. Turn clockwise to raise the beam.
7.
Repeat for the RH lamp.
8.
Re-fit the cover/mask assemblies complete with edge seal to the body, and secure with the three socket
head screws and washers.
Vertical adjuster Lateral adjuster
Lateral adjuster High beam lamp
Vertical adjuster
Low beam
lamp
m257
Headlamp Cover Seal
The headlamp cover/mask is sealed to the body aperture by an extruded synthetic moulding, supplied in
straight lengths. The seal needs to be cut to length to be a snug fit around the periphery of the lamp and the
two ends bonded together using a suitable adhesive such as Permabond C2 or similar. The seal is then fitted
to the headlamp cover with the narrower face uppermost, and with the longer leg of the lower face against the
mask.
Headlamp cover
Cover/mask seal
Body
Mask
b342
Headlamp Units - '07 M.Y. Onwards
New headlamp assemblies introduced for '07 model year are unchanged in styling, but are redesigned
as sealed units to comply with legislative demands, and comprise main/dip/sidelamps with integral reflectors,
mask and cover. An optical feature in the centre of the cover is designed to gather refracted light and prevent
scatter above the dip beam cut off. Certain atmospheric conditions may result in some condensation inside
the lamp unit, but this should disperse with the lamps in operation and cause no concern.
The main beam lamp is mounted lowermost as previously, and uses a free-form reflector and 55W H7U
bulb. Above that is the projector type dip beam lamp with 55W H7U bulb, and at the top of the unit is the side/
parking lamp with W5W bulb, the latter function formerly incorporated into the main beam lamp. Each complete
lamp unit with hard coated polycarbonate cover is fitted to the body via a remodeled clamshell housing and is
secured by three M10 and one M6 fixing. Note that the clamshell construction renders retrofitment of the new
lamps to earlier models impracticable.
Access to the bulbs is available after removing the wheelarch liner front section, and then the appropriate
grommet over the main or dip beam bulbs. The alignment relationship between main and dip beam lamps is
fixed, but two cross-head adjusters are provided on the back of the headlamp housing by which the whole lamp
unit may be adjusted. The outboard screw adjusts vertical alignment, and the inboard screw horizontal.
Page 23
Lotus Service Notes
Section MP
To remove a lamp unit from the car, remove the three M10 nuts and the single M6 nut securing the lamp
assembly to the clamshell. On re-assembly, note that the jointline between lamp and body may be optimised
via threaded collars on three of the lamp fixing studs.
Opposite Drive Hand Beam Masking: If the car is temporarily to be used in an opposite drive hand territory,
the dip beam bias should be masked to prevent dazzle. The '07 model year lamps incorporate a masking lever
within each dip beam lamp, accessible after removing the wheelarch liner front section and upper grommet.
The lever incorporates a slot for a small flat bladed screwdriver, but is located in one of four different sites
dependent on handing and market.
On RHD cars, the lever in both lamps should
be turned clockwise to mask. The lever turns Masking lever
only a few degrees, requiring little force.
Applying too much force or movement will damage the system. Feel for a slight click.
RH 3°
LH
On LHD cars, the lever in both lamps should
be turned counterclockwise to mask. The
lever turns only a few degrees, requiring little force. Applying too much force or
movement will damage the system. Feel for
a slight click.
RH LH
Front Turn Lamps
For access to the front turn indicator bulb,
the lamp unit must be released from the body.
Using a suitable stiff rod, via an access hole in
the outer top corner of the air intake aperture,
push backwards the retaining clip at the front
corner of the turn lamp, and withdraw the lamp
from the body. Introduced for the '06 M.Y. was
a secondary security device in the form of an
'O' ring anchored to the crash structure and
looped through the lamp front retaining clip.
m263
RELEASING FRONT
TURN LAMP
ohs117
Twist the bulb holder counterclockwise to release from the lamp, and replace the bayonet fitting amber
bulb.After replacing the bulb and holder, fit the seal around the periphery of the lamp, and engage the lamp
unit top corner lip in the body aperture, before pressing the bottom corner until the spring clip is heard to engage. Ensure the lamp is securely fitted by attempting to extract the lamp from above, which should not be
possible.
Page 24
Lotus Service Notes
Section MP
mp.11 - 2006 m.y. supplement
Lotus Traction Control
Lotus Traction Control (LTC) is a software programme within the engine electronic control unit (ECU)
which uses inputs from the wheel speed sensors to determine the degree of wheelspin occurring, and when
necessary, modulate fuel injector delivery to control engine power output until grip is restored. If an LSD is
fitted, the LTC also operates to stabilise high speed vehicle behaviour under high cornering loads or extreme
manoeuvres.
An LTC tell tale is provided in the
instrument panel, and if this lamp, together
with the tell tale light in the LTC button (see
below) is seen to flicker, this is an indication
that traction control has been triggered and
electronic intervention is taking place; the
tractive limit has been reached and driving
style should be modified accordingly. If the
lamp is continuously lit, this is an indication
that the LTC has been manually switched off
(see below).
LTC tell tale (Euro shown)
WARNING: The enhanced vehicle control that this feature provides should not induce any relaxation
of caution or vigilance by the driver. Physical limits of cornering and braking still apply, and excessive
speed may result in loss of control and an accident. The driver is at all times responsible for the
judgement of appropriate speed.
Lotus Traction Control ‘Off’ Button
In certain unusual circumstances, such
as loose surfaces, deep snow or when
‘rocking’ the vehicle free from mud, it may be
desirable temporarily to switch off the traction
control. An LTC ‘off’ button is provided on the
gear lever shroud, and should, with the ignition
switched on, be held pressed for 2 seconds.
Both the button tell tale and the LTC warning
lamp in the instrument panel will light up amber
to confirm system de-activation.
LTC 'off'
button
ohs140c
WARNING:
• When an LSD is fitted, Lotus Traction Control should always be active when driving on the public
highway in normal conditions.
• If the system is switched off when driving off-highway, be aware of the consequent change in
vehicle behaviour and modify driving style accordingly.
To re-activate LTC, press (momentarily) the button a second time and check that the tell tale lamps in both
the switch button and instrument panel go out. Irrespective of the system status when the ignition is turned off,
LTC will automatically be activated next time the ignition is switched on.
ECU Programming
The ECU progamming for '06 M.Y. cars includes Electronic Throttle Control (ETC) and Lotus Traction
Control (LTC), and may be identified by interrogation using the Scan tool; Non-USA: A120E0030H. USA:
A121E0010H.
In order for LTC to be operative, a new ECU must detect the presence of the LTC 'off' switch within the
first 5 ignition cycles. If no switch is detected (the switch does not need to be activated), the LTC programme
will be locked out indefinately, and can only be reset by Lotus Cars.
Page 25
Lotus Service Notes
Section MP
Fuses
m254
As viewed from in front of Elise:
Fuse 1
Fuse 11
Fuse 12 Fuse 22
MAIN FUSEBOX
Slot Rate
1 20A
2 5A
3 20A
4 20A
5 10A
6 7.5A
7 10A
8 7.5A
9 15A
10 7.5A
11 10A
12 10A
13 3A
Circuit
Aux. power socket
Reverse lamps
Driver window
Passenger window
Stoplamps
Turn indicators
Ignition services
Battery services
Hazard lamps
Horn
Alarm power,interior lamp
ABS
ECU, starter switch, immobiliser
Supply
Battery
Ignition
Ignition
Ignition
Ignition
Ignition
Ignition
Battery
Battery
Battery
Battery
Ignition
Ignition
Slot Rate
14 20A 15 7.5A
16 10A
17 10A
18 10A
19 20A
20 15A
21 15A
22 7.5A
Engine Compartment
Fuses and relays associated with the
engine management system are contained
in two 4-position fuse holders located at the
front of the engine bay on the cabin bulkhead,
adjacent to the engine ECM. To access the
fuses, unclip rear edge of the cover.
Fuse no. Rating
R1
20A
R2
3A
R3
5A
R4
5A
R5
5A
R6
7.5A
R7
10A
R8
5A
Page 26
Circuit
Fuel pump
Immobiliser
Alternator sense
ECU battery feed
O2 heaters
VSV's VVT, VVL, IAC
Injectors, ignition coils,
ECU main pwr, ac module
Re-circ. pump
Circuit
Rad. fans; 1&2 slow, 1 fast
Radio, switch pack module
Sidelamps, rear fog
Dip beam LH
Dip beam RH
A.C. comp. relay, rad fan 2 fast
Main beam LH
Main beam RH
CDL m255
Supply
Battery
Battery
Battery
Battery
Battery
Battery
Battery
Battery
Battery
ENGINE BAY FUSES
4
3
2
1
8
7
6
5
ohs136
Supply
Battery
Battery
Battery
Battery
ECU
ECU
ECU
ECU
Lotus Service Notes
Interior Fuses & Relays
The wash/wipe module, turn/hazard
flasher relay, horn relay and a relay for inertia
switch activation of the central door locking,
are mounted on the scuttle beam above
the passenger footwell, with two 4-slot fuse
holders secured to the harness in that area.
Relay Position
RHD:
Inboard top; Inboard bottom;
Outboard top;
Outboard bottom;
LHD:
Inboard top; Inboard bottom;
Outboard top;
Outboard bottom; Fuse no.
C1
C2
C3
C4
C5
Rating
20A
15A
7.5A
7.5A
15A
Wiper
Flasher
CDL trip
Horn
Flasher
Wiper
Horn
CDL trip
Circuit
Interior fan
Wiper motor
Audio key-in
A.C. compressor
Aux. Driving lamps
Front

Section MP
Fuseboxes ‘C’
Viewed
from
beneath
m248b
Supply
Start drop out
Start drop out
Key in
Ignition
Battery
LED Rear Lamps
Introduced on all 6-speed Elise variants for ’06 M.Y. are new rear lamp clusters incorporating LEDs in the
annular segments of the lamps. The central elements continue to use filament bulbs. The non-USA Elise also
adopts the USA centre high mounted stop lamp (CHMSL) featuring red LEDs behind a white lens. The light
emitting diodes are extremely durable and are serviced only by lamp cluster replacement. The turn indicators in
the centre of the outboard lamps, and the reverse lamps in the centre of the inboard units, use W16W bayonet
fitting filament bulbs in twist release holders. Note that on USA cars, the outboard lamps are fitted with ballast
modules secured by the lamp fixing nuts.
Lamp Configuration - filament bulb & LED types (LH lamps shown)
Non-USA Tail
Stop
Turn
Rear
Fog
Additional segment used on LED lamps
Not used
USA
Tail
Stop
Turn
Additional segments used on LED lamps
Reverse
Reverse
Not used
Page 27
Lotus Service Notes
Section MP
MP.12 - 2008 M.y. supplement
VEHICLE SECURITY ALARM
The Lotus Elise/Exige for ‘08 model year onwards is fitted as standard with a PFK 457 immobiliser/alarm
which includes the following features:
•
Lotus branded transmitter key.
•
U.K. approval to Thatcham category 1.
•
‘Dynamic coding’ of the transmitter keys; Each time the transmitters are used, the encrypted rolling code
is changed to guard against unauthorised code capture.
•
Passive activation of immobiliser, central locking and alarm system.
•
Ingress protection using sensing switches on the latches of both doors, the front body access panels, and
the engine lid/tailgate.
•
Selectable cockpit intrusion sensing using a microwave sensor.
•
Self powered siren to maintain protection if the vehicle battery is disconnected.
•
Personal protection by ‘on demand’ activation of the siren.
•
Emergency alarm override and transmitter key programming using an alarm/owner specific Personal
Identification Number (PIN).
Transmitter Keys
Manual siren, aux.
Two new Lotus designed and badged
transmitter keys are provided with the car, and
Disarm, mobilise, unlock
combine a mechanical key blade with a three
button transmitter unit incorporated into the
Arm & Lock
key head. The mechanical key operates the
ignition switch, emergency manual door locks,
fuel filler cap (not USA) and Elise engine/boot
lid. The transmitter operates the electronic
immobiliser, alarm system and the central
locking. The two transmitter keys should be
TRANSMITTER KEY
kept separate, and a replacement obtained
immediately after any loss to ensure that a
spare is always available.
The 4-digit code for the mechanical key, the unique serial number of the immobiliser/alarm, and the vehicle
owner’s 5-digit alarm Personal Identification Number (PIN), are supplied on plastic tags attached to the key ring
of a new vehicle. In order to allow replacement transmitter keys to be programmed, it is essential that these
numbers are recorded and kept safely by the owner with the vehicle documents. It is also recommended that
the dealer stress this issue to their customers and, in the interests of customer service, keep a record in their
own database.
Replacement Keys: Additional or replacement transmitter keys may be purchased uncut/uncoded from Lotus
under part number A120H0008S and will be supplied with a blank mechanical blade for copy cutting to an existing
key. Alternatively, a cut key may be ordered from Bolton Lock Company, quoting the 4 digit ‘L’ key code, under
part number A120H0009S (using form LSL482c). In either case, the transmitter will then need matching to
the vehicle using the vehicle owner's 5-digit PIN, as described later in this bulletin.
ohs128c
Disarming the Alarm/Unlocking
When approaching the car, it is likely that the vehicle is locked and the alarm armed. The alarm red tell
tale lamp in the speedometer face will be triple flashing. To disarm the alarm and unlock the doors:
-
Press the central, unlock, button on the transmitter key. The first press will unlock just the driver’s door. Two presses in quick succession will unlock both the driver and passenger doors.
-
This command will be acknowledged by a double flash of the hazard lamps.
-
The engine will be mobilised (see below).
-
The interior lamp will fade on, and remain lit for up to 2 minutes (if set to the 'courtesy' position).
-
The alarm tell tale will be extinguished.
If a door is not opened within 2 minutes, the doors will passively re-lock and the alarm system re-arm.
Page 28
Lotus Service Notes
Section MP
Passive Immobilisation
In order to provide a measure of automatic vehicle security, independent of any driver initiative, the system will ‘passively’ immobilise the engine’s cranking and fuel pump circuits after the ignition has been turned
off for 40 seconds, or a similar period has elapsed since the last mobilising command. With the ignition off,
the alarm tell tale will indicate that immobilisation is in effect by briefly flashing every second. With ignition on,
immobilisation is indicated by a continuously lit tell tale.
To mobilise the car (i.e. allow engine starting) with ignition on or off, press once the transmitter centre
button; the alarm tell tale will be extinguished.
Arming the Alarm/Locking the Doors
To lock the doors and arm the alarm, remove the ignition key, close both doors, and check that the engine
lid/tailgate and body front access panels are secure:
-
Press once the raised logo button on the transmitter fob.
-
This command will be acknowledged by a single flash of the hazard lamps.
-
Both doors will be locked, the engine immobilised and the alarm system armed. A settling period of 40
seconds must expire before the ingress sensors become active.
-
The alarm tell tale will repeatedly triple flash.
Note:
i) If the system is armed when a door is not fully shut, three triple beeps will sound as a warning and the
doors will not be locked. Opening a door will not trigger the alarm.
ii) If the system is armed when the engine lid/tailgate or a front access panel is not fully closed, three warning
double beeps will be heard, and the doors will not be locked. Opening a door in this instance will trigger
the alarm.
iii) If one transmitter is used to disarm the alarm, and a second transmitter to re-arm, a system test mode will
be initiated, and operational variations will occur. Allow an undisturbed period of 2 minutes to elapse to
restore normal operation.
When fully armed, and after the settling period of 40 seconds has expired, the alarm will be triggered by
any of the following actions:
-
Interruption of the car battery power supply or siren cables.
-
Energising the ignition circuit (‘hot wiring’).
-
Opening a door;
-
Opening the engine lid/tailgate or a front access panel.
-
Movement detected within the cabin (unless de-selected).
If the alarm is triggered, the hazard warning lamps will flash and the wailing siren sound for a period of
approximately 30 seconds before closing down and resetting, ready for any further triggering input. If a trigger
is continuously present (e.g. door left open), the alarm will repeat for a maximum of eight 30 second cycles
before excluding the triggering sensor for the remainder of the armed period.
To silence the siren, press once the central, disarm button on the transmitter key. If necessary, press a
second time to disarm the alarm.
Alarm Tell Tale Summary
Tell tale off; Alarm disarmed, engine mobilised.
Tell tale on; Immobilised with ignition on.
Brief flash every second; Immobilised with ignition off.
Repeating triple flash; Alarm armed.
Interior Movement Sensor
A microwave sensor is mounted behind the cabin rear bulkhead trim panel, and is able to detect substantial
physical movement within the cockpit, and trigger the alarm. Microwave transmissions are blocked by metal
objects, so it is important not to shield the signal by placing such items on the bulkhead ledge.
If an animal is to be left in the vehicle, or if for any other reason it is desired to exclude the interior movement sensor when the alarm is set, press once the transmitter logo button in the normal way to set the alarm,
and then press a second time (within 2 seconds) to exclude the interior movement sensor. A single beep will
be heard as confirmation. This exclusion will be automatically cancelled when the alarm is disarmed.
Page 29
Lotus Service Notes
The sensitivity of the sensor is factory
set for the Elise/Exige, and should never need
any adjustment. Such a faciltity is, however,
provided on the unit, and is accessible after
removal of the cabin rear bulkhead trim panel.
Turning the adjustment screw clockwise
will increase sensitivity. Be aware that the
adjustment movement is extremely short, with
only a fraction of a turn being needed.
Section MP
1
-)#2/
Adjuster screw
5
7!6%
3%.
3/2
INGRESS SENSOR
m267
Manual Activation of Siren
If, for personal security reasons, it is desired to manually activate the siren at any time when the ignition
is off, press for 3 seconds the transmitter auxiliary (3rd) button. The wailing siren will sound, and the hazard
lamps flash for a period of 30 seconds. To stop the siren, press once any of the transmitter buttons.
Manual siren activation will not affect the status of the alarm arming.
Transmitter Key Battery Replacement
The transmitter keys will normally operate
Back panel
within a range of 5 metres from the car, but this
Retaining
may be reduced by the presence of other radio
tongue
signals in the vicinity. The transmitters are
CR2032
powered by a long life 3V Lithium battery, type
battery
CR2032, which with normal use should last for
3 years. To ensure continuity of operation, it
is recommended to renew the batteries every
12 months:
TRANSMITTER BATTERY
-
Using a small screwdriver, prise open the
REPLACEMENT
back panel of the key case using the slot
by the keyring hole.
-
Remove the old battery and wait for 10 seconds before inserting the new battery with +ve sign uppermost,
and holding the battery only by the periphery.
-
Refit the back panel, engaging the retaining tongue, and pressing firmly to engage the clip.
-
The transmitter should now operate normally.
oh102b
Disconnecting the Vehicle Battery
In order to prevent the alarm being triggered, before disconnecting the vehicle battery, ensure that the
alarm is disarmed.
Emergency Disarming/Mobilising
If the key head transmitters are lost or damaged, the alarm system owner’s 5-digit PIN may be used to
disarm the alarm and start the engine provided that the cabin is accessible, and a correct mechanical key
blade is available. Note that if the alarm is armed, accessing the cabin, or turning on the ignition will trigger the
alarm until completion of this emergency process.
-
Turn on the ignition. The alarm tell tale will light.
-
Within 10 seconds, turn the ignition off; the tell tale will begin to flash.
-
After a number of flashes corresponding to the first digit of the PIN, turn on the ignition. Note that the first
flash may not be of full duration (but is still to be counted) dependent on the waveform position at time of
ignition switch off.
-
Turn off the ignition and after a number of flashes corresponding to the second digit of the PIN, turn on
the ignition. Repeat this process until all 5 digits have been completed. Note that 10 flashes correspond
to a zero digit.
-
If the PIN is entered correctly, the alarm will now be overridden and the engine mobilised. However, passive immobilisation will still occur after an ignition off time of 40 seconds, requiring a repeat of the above
procedure to mobilise. Passive arming and passive door locking cannot occur until a transmitter is used
to operate the alarm.
Page 30
Lotus Service Notes
Section MP
If, at any stage of the process, a number is entered incorrectly, the system will immediately revert to the
start, so that the whole PIN must be re-entered.
Programming Additional Transmitters
A maximum of 6 transmitters may be programmed to the car, any thereafter overwriting the first to have
been programmed.
- With the engine immobilised (tell tale flashes briefly once per second), turn on the ignition.
-
Enter the PIN as detailed above, followed by the additional two digits 1, 1.
-
The tell tale will flash rapidly for one second, then turn off.
-
Within 8 seconds, press any button on the transmitter to be programmed. The tell tale will then pulse
rapidly and the siren will beep.
-
Within 10 seconds press any button on the next transmitter to be programmed (if applicable), and repeat
this process for all remaining transmitters.
-
When all transmitters have been programmed, wait for 10 seconds, or turn off the ignition.
To disable a lost or stolen transmitter from the system, use the above procedure to programme 6 transmitters, if necessary repeatedly reprogramming the same transmitter if less than 6 programmed transmitters
are to be used.
Trigger Report Back and Feature Selection
A facility is provided to identify the source of an alarm triggering event (trigger report back), as well as
allowing certain features of the system to be selected or de-selected. The same procedure described above
to input a PIN is used, but in this case to input the programming code '123'; the tell tale will then flash rapidly
for 1 second, then remain lit. Commencing within 10 seconds, continue this procedure to input the two digits
of the feature code, after which the tell tale will flash rapidly for 1 second then beep once or twice to indicate
the new status of that feature; one for 'ON', twice for 'OFF'. Selection will alternate each time that feature code
is entered. Note that within 10 seconds, a second feature code (or repeat) may be selected from this point by
entering only the 2-digit code. To exit programme mode, simply wait for 10 seconds.
Feature
Revert to defaults
Trigger report back
Unlock with ignition
Lock with ignition
Selective door unlock
Audible tones*
Lock with auto re-arm
Door open audible warning
Code
123 00
123 11
123 33
123 34
123 41
123 61
123 87
123 88
Default
1 Beep
2 Beeps
see below
OFF
OFF
ON
OFF
ON
ON
ON
ON
ON
ON
ON
ON
OFF
OFF
OFF
OFF
OFF
OFF
* When selected, a single beep will sound when the alarm is armed, and a double beep when disarmed. To
silence for a single activation, press briefly the transmitter auxiliary (3rd) button prior to pressing the arm or
disarm button.
Trigger report back: After the code 12311 has been entered, the tell tale flashes out a code(s) to indicate the
source of the alarm trigger:
No. of flashes Triggering sensor
1 Microwave movement sensor
2 Door, bonnet or boot lid
3 Ignition energisation
4 Manual siren activation
Quick Test
To facilitate testing of the alarm system, the unit can be placed into a 'Quick Test' mode by arming the
alarm with one transmitter key, and disarming with another. In this mode, the system will shorten the siren time
to 2 seconds, the immobiliser arm time to 5 seconds, and the settling time to zero. To exit this mode, simply
wait for 2 minutes without any further inputs.
Note that in Quick Test mode, any movement detected by the microwave sensor will trigger only the tell
tale and not the siren. The 2 minute timer will not be extended.
Page 31
Lotus Service Notes
Section MP
Component Location
The location of the PFK alarm components is unchanged from the equivalent earlier Cobra parts; the
controller is mounted on top of the scuttle beam at the LH extreme end. Access requires removal of the fascia
top. The immobiliser is incorporated into the controller as a single unit. The siren is mounted on the front of the
radiator duct LH extension, beneath the LHF turn lamp. Accessible only after removal of the front clamshell.
The microwave sensor is fixed to the cabin rear bulkhead, requiring removal of the rear bulkhead trim panel
for access.
CDL Module; The Central Door Locking module is different on PFK cars, but is mounted in the same position
as previously, on top of the scuttle beam at the RH extreme end. Note that this unit is specific to PFK cars, and
does not require the inverter relay (on underside of scuttle beam) for inertia switch operation of the CDL.
TYRE PRESSURE MONITORING SYSTEM (TPMS) - USA ONLY
All USA Elise/Exige models from ‘08 model year onwards are fitted with a tyre pressure monitoring system. A sensor incorporated into each of the tyre valves monitors the air pressure inside the tyre, and supplies an
onboard control module with this data by radio transmission. If any tyre pressure should fall below 75% of the
recommended value, an alert message is sent to the instrument panel, and the tyre pressure tell tale
will light up amber. The fuel gauge display will then be overwritten with a message to indicate which tyre is
concerned, with text such as: LF Low (left hand front tyre low pressure). This message will show for 5 seconds
before the display reverts to the fuel level bar graph, but will repeat for 5 seconds at 30 second intervals.
The TPMS incorporates self-malfunction recognition, and if a fault is detected, the tell tale will flash for one
minute and then remain constantly lit. The LCD panel will also flash ‘TPMS FAULT’ for 5 seconds, and repeat
at 30 second intervals; no indication of low tyre pressure will be displayed.
Tyre fitters and service technicians should be made aware that TPMS is fitted, and that the tyre valves
include pressure sensors. If the emergency tyre inflator aerosol has been used, it will be necessary to renew
the tyre valve/pressure sensor. If a fault is indicated after wheel or tyre replacement, it is likely that a sensor
has been incorrectly fitted or damaged. If a tyre valve is renewed, or is moved to a different wheel position, the
TPMS module (at LH front of boot) will automatically identify the new configuration.
Note that the pressure sensors are powered by integral batteries, with an average service life of 10 years.
It is recommended to renew all pressure sensors at this time interval.
WARNING ‘TELL TALE’ LAMPS
The instrument panel tell tales and LCD functionality have been revised for '08 M.Y. New features are
described below:
Security Tell Tale
The security function is separated from the combined security/rpm tell tale and is moved into the face of
the speedometer.
High RPM Tell Tales
Three red tell tales are incorporated into the tachometer face to warn that maximum engine speed is being
approached. Maximum transient engine speed in all gears at normal running temperature, is 8,500 rpm (7150
rpm for Elise S), at which point the engine is governed, but as the rate of rpm increase is potentially greater in
the lower gears, the tell tale trigger points are tailored to accommodate the reaction time available. As maximum
rpm is approached, the tell tales will light in the following left to right sequence:
-
one red light
-
two red lights
-
three rapidly flashing lights
When exploiting maximum acceleration, gearchange upshifts should be made immediately the three
flashing lights appear.
NOTICE:
-
A 6,000 rpm limit is imposed on a cold engine to reduce possible damage and wear from an unsympathetic
driving style.
-
At normal running temperature, maximum continuous engine speed is 8,000 rpm (6,800 rpm Elise S).
-
Using maximum rpm and the above tell tale facility should be restricted to occasions when maximum acceleration is required. Overuse will compromise powertrain service life.
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Lotus Service Notes
Tachometer
Service tell tale
Speedometer
High rpm tell tales
LCD panel
-
Section MP
Security tell tale
!
Traction control Low tyre pressure
tell tale tell tale
ohs127b
The engine is not protected from overspeeding caused by erroneous or premature downchanging. Such
misuse could result in catastrophic failure, not covered by the vehicle warranty.
SCHEDULED SERVICE TELL TALE (IF FITTED)
Under normal usage conditions, a routine maintenance service should be performed at the first occurring
of 9,000 miles (15,000 km) or 12 months from the previous service (USA; 7,500 miles/6 months). The approved
service period extends to 500 miles before/after or one month before/after the stipulated distance/time.
As a driver aid to distance servicing, an amber wrench icon in the face of the speedometer will flash for 10
seconds following each ignition turn on, when within 500 miles (800 km) of the service period, allowing plenty
of time for booking arrangements to be made. Once the service period is reached, the tell tale will remain
constantly lit with ignition until reset by your dealer.
Note that this feature is provided only as a secondary aid, and uses only distance criteria, and not the
time factors which may predominate. It is the owner’s responsibility to ensure that servicing is carried out at
the prescribed intervals..
TRIP DISTANCE/DIGITAL SPEED DISPLAY/TIME CLOCK
The top left portion of the LCD panel may be cycled through the following displays:
-
Trip distance (in same units as analogue speedometer).
- Digital road speed in alternative units to those indicated by the analogue instrument (either mph or
km/h).
-
Digital time clock (if fitted - this feature will not be available initially).
To cycle, one at a time, through these three displays, briefly press the small button on the right hand side
of the steering column shroud. (Note that this button also adjusts the brightness of the instrument and HVAC
panel illumination if held pressed when road speed is selected).
Trip distance: Units displayed are miles, and range from 000.0 to 999.9. To reset to zero; when the trip function
is displayed, press the button on the column shroud for longer than 1 second.
Time Clock Setting: To adjust the 24 hour time clock (if fitted);
-
when the time function is displayed, press the button on the column shroud for longer than 1 second. The
hour display will then flash.
-
Repeated brief presses of the button will increment the hour figure. Pressing the button for longer then 1
Page 33
-
-
Lotus Service Notes
Section MP
second will store the hour setting and start the minute display flashing.
Further brief button presses will increment the minute figure.
When the correct time is displayed, press the button for longer than 1 second to store the setting and start
the clock.
Instrument pack version check
An improved calibration for the 2008 M.Y. Elise/Exige instrument packs was introduced at '08 M.Y. VIN
serial number 0880. Improved tolerancing and CAN BUS filtering reduces the potential for frozen displays and
enhances the accuracy of displayed data. To check the software version installed:
-
Open the driver's door;
-
Push in and hold the trip reset button on the column shroud;
-
Still pressing the trip button, turn on the ignition (position 'll');
-
Note the version number displayed at the top left hand side of the instrument pack LCD.
Early software is named VER.0.04 or VER.0.07. Latest software is VER.0.08.
The software and instructions are available on a CD part number T000T1501F, for downloading via the
Lotus TechCentre.
VARIABLE TRACTION & LAUNCH CONTROL (IF FITTED)
Exige S models specified with the ‘Performance Pack’ option, include variable Lotus Traction Control
(LTC), allied with Variable Launch Control (see below) and have a rotary control knob mounted on the left hand
side of the steering column shroud.
Each time the ignition is turned on, normal full LTC is activated. To enable variable traction control, turn
on the ignition and hold the LTC ‘off’ button pressed for 2 seconds. Check that the tell tale in the switch button
is lit. Start the engine. Note that if the ignition is switched off (e.g. prior to a second start attempt), the above
procedure must be repeated in sequence.
With the switch button tell tale lit and the engine running, the rotary knob may then be used to select the
degree of traction control desired, with the setting shown on the instrument panel LCD in the form ‘#% SLIP’, with
a possible range between 0 and 9%. The display will revert to showing the fuel level after a few seconds.
•
For maximum traction control (0% slip) turn the knob fully counterclockwise to ‘MAX’.
•
To reduce traction control (to allow up to 9% slip), turn the knob progressively clockwise. •
Fully clockwise (‘0’), traction control is disabled, as indicated by the lighting of the instrument panel tell
tale, and an LCD message of ‘LTC OFF’.
If at any time during that ignition cycle, the control knob is turned, the LCD will again show the traction
control setting for a few seconds.
When the ignition is next turned on, normal full LTC will be activated unless the above procedure is repeated.
Variable Launch Control
CAUTION: This feature is designed for competition use, and as such, its employment will invalidate
vehicle warranty on any components subject to the extreme loads associated with racing starts.
Variable Launch Control allows the engine rpm to be limited during a competition start in order to balance
engine power against available grip and provide a controlled degree of wheelspin for the first moment of acceleration, until superseded by the traction control system at around 6 mph.
To enable this feature, turn on the ignition and hold the LTC ‘off’ button pressed for 2 seconds. Check that
the tell tale in the switch button is lit. Then;
•
With ignition on, engine stopped, fully depress the throttle pedal for 5 seconds.
•
Tacho will now show launch rpm. Turn the rotary knob as necessary to select any desired launch rpm
between 2000 and 8000.
•
Release throttle and start engine.
•
Turn the rotary knob to select the desired level of traction control (see above), noting that the launch control
setting will not be affected.
•
Engage first gear, apply full throttle (ECU limits engine speed to selected launch rpm), and rapidly ‘drop’
clutch.
•
Maintain full throttle throughout the transition from launch to traction control (at around 6 mph) until the
Page 34
•
Lotus Service Notes
Section MP
first gear change is required.
To disable launch control when variable traction control is still required, reset launch rpm to 8,000.
NOTE
•
Do not attempt to slip the clutch during this process, as overheating or damage to the clutch mechanism
may occur. An instant clutch engagement is required to ‘break’ rear tyre traction and initiate wheelspin. Note that an hydraulic damper valve is incorporated into the clutch release pipework to protect the driveline
from excessive shock loading when using this technique.
•
Do not attempt LC starts in any gear other than first.
•
Do not hold the engine at or near maximum rpm for more than a few seconds.
•
Under no circumstances should this track feature be employed on the public road.
•
Use of Launch Control is an ultimate technique designed to produce the fastest possible race start.
Always allow the clutch to cool and recover before repeating a launch controlled start. The extreme
loads associated with such starts will result in reduced transmission component life cycles.
•
At the next key-on, the system will default to full LTC and Launch Control off. Turning on the ignition and
holding the LTC 'off' button pressed for 2 seconds will restore the previous traction and launch settings.
Adjustment Tips
Note that the optimum settings for variable traction and launch control will differ for each set of track surface, tyre and ambient conditions. A suggested adjustment logic follows:
•
Set the traction control to a mid position.
•
Start with a low launch rpm e.g. 4,000 rpm.
•
Trial launch and assess initial wheelspin control and transition into traction control.
•
If launch control is set too low, the engine may ‘bog down’ and fall out of the power band. If set too high,
too much initial wheelspin may result, with poor step off from the line.
•
Similar logic applies to traction control adjustment when this system takes over above about 6 mph.
REAR LAMP CLUSTERS
A running change to the LED tail lamp clusters will occur shortly after '08 introduction. The new 'B' level
lamps incorporate features allowing the previously separate radio supression inductor jump harnesses and (for
USA cars) the ballast resistors to be deleted. The new lamps are identified by using a grey moulding for the
lamp rear body instead of the previous black colour. If replacing black body lamps on any car with 'B' level grey
body lamps, the inductor jump harnesses and ballast resistors (as applicable) may be discarded.
CAN BUS DIAGNOSTICS - LOTUS TECHCENTRE
Controller Area Network (CAN) is an electronic standard to allow high speed communication between modules and controllers, via a serial data bus. The bus is a circuit linking the modules to the controller, consisting
of a pair of cables, twisted together to reduce electromagnetic interference, and carrying a square wave voltage
signal corresponding to '0's and '1's, coded in such a way as to identify and prioritise the individual systems.
On the Elise/Exige range, CAN based systems include; engine management system, instrument pack and tyre
pressure monitoring system (USA).
All USA market cars from '08 model year are required by legislation to use a CAN compliant on-board
diagnostic system. This has been commonised for all Elise/Exige models. The Lotus Scan 3 tool is replaced
by a 'stand alone' lap top PC loaded with 'Lotus TechCentre' software to allow the CAN based serial data to be
read. The Vehicle Communication Device (T000T1472F) introduced for the Europa model is used to connect
the vehicle to the laptop Lotus TechCentre. Engine programming, live data display, diagnostics of engine, ABS
and airbag systems, and service tell tale lamp resetting are all carried out via the Lotus TechCentre.
The minimum specification of the laptop for installation of the Lotus TechCentre is as follows:
Processer 1.70 Ghz
1 GB RAM
40 GB HDD
CDRW DVD ROM
WIN XP PRO
USB interface
Ethernet or Wireless LAN
Note that this laptop should be dedicated totally to the Lotus TechCentre, with no other software loaded.
Page 35
Lotus Service Notes
Section MP
MP.13 - 2011 m.y. supplement
Cruise Control - optional fitment on 1.6 ltr Elise; not available on other models.
Caution: Cruise control should be used only when conditions are favourable; on straight, dry, open roads with
light traffic.
The cruise control system is incorporated into the engine ECU programme, and allows the maintenance
of a selected vehicle speed above 30 mph (50 km/h), without having to use the accelerator pedal. The tell tale
lamp in the gear lever shroud is lit whenever cruise control is active.
Operating cruise control
Two switch buttons are provided on the
end of the left hand steering column stalk;
an upper rocker switch to set the speed, and
a lower push button to switch off the cruise
control.
CRUISE CONTROLS
(if fitted)
Setting the vehicle speed
Set, or increase
To engage cruise control, the vehicle
speed
R
must be travelling at 30 mph (50 km/h) or
Reduce speed
more. Accelerate to the desired cruising speed
and then press once the ‘I’ end of the rocker
Switch off
switch with the raised pip. Cruise control will
engage and the set speed maintained when
the accelerator is released (road gradient and
winds permitting). The accelerator may be
used to increase speed temporarily without
affecting the setting.
Cruise control automatically disengages when; the foot or parking brakes are applied, a gearchange is
made, or when the vehicle’s speed falls below 30 mph (50 km/h). To disengage it manually, press once the
‘O’ button.
ohs177
Resuming a set speed
Caution: The resume function should be used only if the driver is aware of, and wants to return to, the set
speed.
To resume cruising after braking, changing gear or slowing below 30 mph (50 km/h), press once the ‘R’
switch.
Changing the set speed
When cruise control is operating, press and hold the ‘I’ end of the rocker switch to accelerate the car. Release the switch when the desired new speed is attained. Alternatively, repeated brief presses of the switch
will increase the setting by 1 mph (1.5 km/h) increments. Pressing the ‘R’, dimpled end of the switch will reduce
the set speed in like manner.
Otherwise, the car may manually be accelerated or braked to the desired new speed, and the ‘I’ switch
pressed once to set cruise at that speed.
Set speed cancellation
The set speed will be reset to zero when:
-
The vehicle is stopped or;
-
The parking brake is applied or;
-
Reverse gear is selected or;
-
The ignition is turned off.
Programming
Programming for the cruise control is incorporated into the 1ZR engine ECU programme.
Page 36
Lotus Service Notes
Section MP
Daytime Running Lamps (DRL) - Elise
The 2011 Elise is fitted with headlamp assemblies incorporating amber LED string turn indicators, and
dual intensity white LED string parking/daytime running lamps.
1.8 litre cars: When the ignition is turned on, the front and rear sidelamps will automatically be activated as
daytime running lamps.
1.6 litre cars: When the engine is started, the front and rear sidelamps will automatically be activated as daytime
running lamps, with the front sidelamps operating with an increased intensity.
When the ignition is turned off, the DRLs will switch off automatically unless they were manually selected.
Main Fusebox
Fuse 1
Fuse 11
As viewed
from
in front
Fuse 12
SlotRate
Circuit SlotRate
Circuit
1 20A
2 5A
3 20A
4 20A
5 10A
6 7.5A
7 10A
8 7.5A
9 15A
10 7.5A
11 10A
12 10A
13 3A
Aux. pwr. socket
Reverse lamps
Driver’s window
Pass. window
Stop lamps
Turn indicators
Ignition services
Battery services
Hazard lamps
Horn
Alarm pwr.,
interior lamp
ABS
ECU ignition
14 20A
15 7.5A
16 10A
17 10A
18 10A
19 20A
20 15A
21 15A
22 7.5A
Rad. fans;
1&2 slow, 1 fast
Radio, switch pack module
Sidelamps; rear fog
Dip beam LH
Dip beam RH
A.C. comp. relay rad fan 2 fast
Main beam LH
Main beam RH
CDL m255
Fuse 22
Footwell Sited Fuses
Eight fuses are secured to the main wiring harness just ahead of the scuttle beam and accessible from
the passenger footwell.
FuseRating
C1 20A
C2 15A
C3 7.5A
C4 7.5A
C5 15A
C6 5A
C7 5A
C8 5A
Circuit
Interior fan
Wiper motor
Audio key-in
A.C. compressor
Auxiliary driving lamps
1.6 ltr.; Alternator ign.
1.6 ltr.; Alternator sense
Daytime running lamps
Page 37
Lotus Service Notes
Section MP
Engine Compartment Fuses
Fuses associated with the engine management system are contained in two 4-position fuse holders located at the front of the engine bay on the cabin bulkhead, adjacent to the engine ECM. To access the fuses,
unclip rear edge of the cover.
FuseRating
R1 20A
R2 10A
3A
R3 5A
R4 25A
5A
R5 7.5A
5A
R6 7.5A
R7 10A
R8 5A
Circuit
Fuel pump
1.6 ltr.; Coils
1.8 ltr.; TPMS
1.8 ltr.; Alternator sense
1.6 ltr.; Valve lift motor
1.8 ltr.; ECU battery feed
1.6 ltr.; O2 heaters
1.8 ltr.; O2 heaters
VSVs, VVT, VVL, purge
Injectors, coils, ECU power, a.c.`
Re-circ. pump
Lighting - Elise;
-
New headlamp assemblies featuring Halogen main and dip beam lamps, LED amber string direction indicators, and LED white string daytime running lamps (for all markets). Headlamp units fitted from clamshell
underside.
-
Evora style side repeater lamps.
If adjustment to headlamp alignment
is required, remove the access cover in the
wheelarch liner. The alignment relationship
between high and low beam lamps is fixed,
but two adjusters are provided on the back
of the headlamp housing by which the whole
lamp unit may be adjusted.
To adjust the beam laterally, turn the
outboard hexagonal adjuster screw. Optimum
setting is 0%. To adjust the beam vertically, turn the
inboard adjuster screw. Optimum setting is
-1.2%. To replace the dip beam bulb, remove the
protective boot from the back of the outboard
lamp, twist the bulb holder counterclockwise,
and withdraw from the lamp. Prise open the
retaining barbs to allow the harness plug to
be disconnected. Replace the 12V 60W type
HB3A bulb, and reassemble in reverse order
to disassembly.
Replacing the main beam bulb from the
inboard lamp is similar to the above except
that the harness connection uses separate
spade terminals (may be connected either
way round). The main beam bulb is 12V 65W
type H9B.
Vertical
adjuster
ELISEHEADLAMP ADJUSTERS
ohs179
Main beam
bulb
Dip beam
bulb
ELISE HEADLAMP BULBS
Note that retrofitment of the new headlamps to earlier models is not possible.
Page 38
Lateral
adjuster
ohs180
Lotus Service Notes
Section MP.14e
ELECTRICS
SECTION MR.14e CIRCUIT DIAGRAMS
2011MY ELISE WITH 1ZR POWERTRAIN
Contents List Circuit Diagrams
-
2
Circuit Diagrams
-
3 - 47
Fuse Layout
-
48
Colour Codes & Abbreviations
Updated 19th May 2010
-
49
Page 1
Lotus Service Notes
Section MP.14e
MP.14e - CIRCUIT DIAGRAMS
Circuit
Sheet
Battery Supply
Accessory Key In
Accessory Supply
Ignition Supply
Charging System
CAN Network
Diagnostic Link Connector
Grounding Structure
Cranking
Alarm & Immobiliser
Central Locking
EMS Power & Ground
EMS Fuel Injection
EMS Ignition Coils
EMS, TMAF, Purge, Oil Pressure SW & Knock Sensors
EMS Cam & Crank Sensors EMS Coolant Sensing & Fan Contol
EMS Throttle Actuation
EMS Fuel Pump & Fuel level Sensing. Clutch Potentiometer
EMS O2 Sensors
EMS CVCV Cruise Control
EMS Valvetronic
Daytime Running / Side Lamps, Non - USA Daytime Running / Side Lamps, USA
Headlamps
Driving Lamps
Fog Lamps Non USA
Direction Indicators & Hazard Lamps, Non - USA
Direction Indicators & Hazard Lamps, USA
Brake Lamps , Non - USA
Brake Lamps , USA
Reverse Lamps & Parking Sensors, Non - USA
Reverse Lamps & Parking Sensors, USA
Airbags
Anti-Lock Brakes & Traction Control Instrument Cluster HVAC System Part 1
HVAC System Part 2
HVAC System Part 3 GCC - Aux HVAC
Wash Wipe System.
Window Lift
Tyre Pressure Monitoring
I.C.E. Horn & Power Socket
Page
A1
A2
A3
A4
A5
A6
A7
A8
B1
B2
B3
C1
C2
C3
C4
C5
C6
C7
C8
C9
C10
C11
C12
D1A
D1B
D2
D3
D4
D5A
D5B
D6A
D6B
D7A
D7B
E1
E2
E3
E4A
E4B
E4C
E5
E6A
E7
E8
E9
Page 2
3
4
4
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
Lotus Service Notes - 2011MY Elise Circuit Diagrams - All Markets Section MP.14e
1ZR Powertrain
Page 3
Lotus Service Notes - 2011MY Elise Circuit Diagrams - All Markets Section MP.14e
1ZR Powertrain
Page 4
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1ZR Powertrain
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1ZR Powertrain
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1ZR Powertrain
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1ZR Powertrain
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1ZR Powertrain
Page 9
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1ZR Powertrain
Page 10
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1ZR Powertrain
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1ZR Powertrain
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1ZR Powertrain
Page 13
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1ZR Powertrain
Page 14
Lotus Service Notes - 2011MY Elise Circuit Diagrams - All Markets Section MP.14e
1ZR Powertrain
Page 15
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1ZR Powertrain
Page 16
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1ZR Powertrain
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1ZR Powertrain
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1ZR Powertrain
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1ZR Powertrain
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1ZR Powertrain
Page 21
Lotus Service Notes - 2011MY Elise Circuit Diagrams - All Markets Section MP.14e
1ZR Powertrain
Page 22
Lotus Service Notes - 2011MY Elise Circuit Diagrams - All Markets Section MP.14e
1ZR Powertrain
Page 23
Lotus Service Notes - 2011MY Elise Circuit Diagrams - All Markets Section MP.14e
1ZR Powertrain
Page 24
Lotus Service Notes - 2011MY Elise Circuit Diagrams - All Markets Section MP.14e
1ZR Powertrain
Page 25
Lotus Service Notes - 2011MY Elise Circuit Diagrams - Non USA
1ZR Powertrain
Section MP.14e
Page 26
Lotus Service Notes - 2011MY Elise Circuit Diagrams - USA Only Section MP.14e
1ZR Powertrain
Page 27
Lotus Service Notes - 2011MY Elise Circuit Diagrams - All Markets Section MP.14e
1ZR Powertrain
Page 28
Lotus Service Notes - 2011MY Elise Circuit Diagrams - All Markets Section MP.14e
1ZR Powertrain
Page 29
Lotus Service Notes - 2011MY Elise Circuit Diagrams - Non USA
1ZR Powertrain
Section MP.14e
Page 30
Lotus Service Notes - 2011MY Elise Circuit Diagrams - Non USA
1ZR Powertrain
Section MP.14e
Page 31
Lotus Service Notes - 2011MY Elise Circuit Diagrams - USA Only Section MP.14e
1ZR Powertrain
Page 32
Lotus Service Notes - 2011MY Elise Circuit Diagrams - Non USA
1ZR Powertrain
Section MP.14e
Page 33
Lotus Service Notes - 2011MY Elise Circuit Diagrams - USA Only Section MP.14e
1ZR Powertrain
Page 34
Lotus Service Notes - 2011MY Elise Circuit Diagrams - Non USA
1ZR Powertrain
Section MP.14e
Page 35
Lotus Service Notes - 2011MY Elise Circuit Diagrams - USA Only Section MP.14e
1ZR Powertrain
Page 36
Lotus Service Notes - 2011MY Elise Circuit Diagrams - All Markets Section MP.14e
1ZR Powertrain
Page 37
Lotus Service Notes - 2011MY Elise Circuit Diagrams - All Markets Section MP.14e
1ZR Powertrain
Page 38
Lotus Service Notes - 2011MY Elise Circuit Diagrams - All Markets Section MP.14e
1ZR Powertrain
Page 39
Lotus Service Notes - 2011MY Elise Circuit Diagrams - All Markets Section MP.14e
1ZR Powertrain
Page 40
Lotus Service Notes - 2011MY Elise Circuit Diagrams - All Markets Section MP.14e
1ZR Powertrain
Page 41
Lotus Service Notes - 2011MY Elise Circuit Diagrams - All Markets Section MP.14e
1ZR Powertrain
Page 42
Lotus Service Notes - 2011MY Elise Circuit Diagrams - Gulf States Section MP.14e
1ZR Powertrain
Page 42
Lotus Service Notes - 2011MY Elise Circuit Diagrams - All Markets Section MP.14e
1ZR Powertrain
Page 43
Lotus Service Notes - 2011MY Elise Circuit Diagrams - All Markets Section MP.14e
1ZR Powertrain
Page 44
Lotus Service Notes - 2011MY Elise Circuit Diagrams - All Markets Section MP.14e
1ZR Powertrain
Page 45
Lotus Service Notes - 2011MY Elise Circuit Diagrams - All Markets Section MP.14e
1ZR Powertrain
Page 46
Lotus Service Notes - 2011MY Elise Circuit Diagrams - All Markets Section MP.14e
1ZR Powertrain
Page 47
Lotus Service Notes - 2011MY Elise Circuit Diagrams - All Markets Section MP.14e
1ZR Powertrain
Page 48
Lotus Service Notes
Section MP.14e
Colour Code
B = Black
P = Purple
R = Red
S = Slate (Grey)
U = Blue
W = White
Y = Yellow G = Green
K = Pink
LG = Light Green
N = Brown O = Orange
Abbreviations
ABS Anti-lock Brake System
ACCM Air Conditioning Control Module
ACC Accessory
ACHC Air Conditioning Harness Connector
ACIS Acoustic Control Induction System
CAN Controller Area Network
CDL Central Door Locking
CHMSL Centre High Mounted Stop Lamp
CVCV Canister Vent Close Valve
DDHC Driver's Door Harness Connector
DI Direction Indicator
DRL Daytime Running Lights
ECU Electronic Control Unit
EHC Engine Harness Connector
FL Fog Lamp
FLSW Brake Fluid Switch
FSM Front Side Marker
FTC Fuel Tank Connector
GND Ground
IP Instrument Pack
I/P Input
LF Left Front
LIHC Left Inner Harness Connector
LOHC Left Outer Harness Connector
LR Left Rear
MB Main Beam
NPL Number Plate Lamp
O2 Oxygen (sensor)
O/P Output
PDHC Passenger's Door Harness Connector
RF Right Front
RIHC Right Inner Harness Connector
RIL Rear Outer Lamp
RMC Rear Module Connector
ROHC Right Outer Harness Connector
ROL Rear Outer Lamp
RR Right Rear
RSM Rear Side Marker
SL Side Lamp
SNR Sensor
SPL Splice
SPMC Switch Pack Module Connector
SRS Supplementary Restraint System (Airbag)
SSWHC Starter Switch Harness Connector
TMAF Temperature & Mass Air Flow
TPMS Tyre Pressure Monitoring System
VSV Vacuum Solenoid Valve
VVT Variable Valve Timing
VVTLi Variable Valve Timing & Lift - intelligent
WS Wheel Speed
WSS Wheel Speed Sensor
YMC Yazaki Module Connector
Page 49
Lotus Service Notes
Section OI
MAINTENANCE & LUBRICATION
SECTION OI
Page
Recommended Lubricants
2
Maintenance Schedule
- Elise 111R & '04 Exige (non-USA)
- Elise/Exige North America
Pre-Delivery Inspection
3
6
9
Body Paint Inspection
- Elise
- Exige
11
12
Licence Plate Fitment
13
Page 1
Lotus Service Notes
Section OI
RECOMMENDED LUBRICANTS
Engine
In order to ensure the longevity and reliability of the vehicle, it is most important that only the specified
lubricants are used. It is an entirely false economy to try to save money by using lower quality oils, which
may break down before the next change interval and provide inadequate protection before the end of the term.
High oil consumption may also result.
Factory fill on the Elise/Exige range is Texaco Havoline Synthetic 5W/40 (also known as Texaco Havoline
Ultra 5W/40), which is a top quality semi-synthetic oil meeting the API SL standard. If it is necessary to top up
the oil during the running-in period, this product should be used if possible, or one with the same specification.
Note that a semi-synthetic oil is preferred over a fully synthetic oil for initial fill to aid the bedding in process of
the engine.
At the First After Sales Service and completion of the running-in period, and for all servicing thereafter, a
fully synthetic 5W/40 oil such as Texaco Havoline Fully Synthetic should be used. This oil has been tested in
all climatic conditions likely to be encountered, and offers advantages in ease of cranking, smooth cold running
and fuel economy at low temperatures, in combination with good wear protection at elevated temperatures and
at high engine speeds. If Texaco/Havoline products are not available, an oil meeting the specification below
should be used, but note that in general, lubricants described as 'synthetic' are likely to be only semi or part
synthetic. Use only oils confirmed as being 'fully synthetic'. Note also that no oil additives have been recommended by Lotus.
Viscosity:
Quality Standard:
Capacity- refill inc. filter - 2ZZ
- 1ZR
Difference between high
& Low dipstick marks - 2ZZ
- 1ZR
Oil change interval
5W/40
API SL/CF, SJ/CF; ACEA A3
4.4 litre (cars fitted with front mounted oil coolers contain an additional 3.5 litres, but this oil is not drained during routine servicing)
4.8 litre
1.5 litre
1.0 litre
Refer to Maintenance Schedule
Transmission (gearbox & final drive)
Viscosity - 2ZZ SAE 75W/90
- 1ZR SAE 75W
Quality Standard - 2ZZ API GL-4 or GL-5
- 1ZR API GL-4
Capacity - 2ZZ 2.3 litre (2.4 US qt)
- 1ZR 2.4 litre
Oil change interval Refer to Maintenance Schedule
Brake & Clutch System
Type
Specification
Capacity- brake
- clutch
Fluid change interval
Non-mineral (non-petroleum) hydraulic fluid
DOT 4
1.5 litre
0.5 litre
12 months
Engine Coolant Additive
Only approved product
Type
Colour
Concentration
Quantity reqd. @ 50%
Coolant change interval
Havoline XLC
Ethylene glycol antifreeze with OAT corrosion inhibitors
Orange
50%
6 litres
4 years
Air Conditioning Refrigerant
550g R134a
Page 2
Lotus Service Notes
Section OI
MAINTENANCE SCHEDULE - ELISE/EXIGE (NON USA)
LSL501c
Job no.: ........................ Owner's name: .....…………....................... Vehicle: ..............………...………..
Vehicle registration no.: ......………................... V.I.N.: ......………................................................…
Recorded mileage: ........………...…….………… Mileage at last service.: ..............………………
Today's date: ………………..………...…………… Date of last service: ………………………
EXPLANATORY NOTES:
Required Maintenance
In order to maintain warranty validation and help ensure proper safety, emissions performance and dependability
of the vehicle, Lotus Cars Ltd. requires that the vehicle be serviced in accordance with this schedule. Each
service should be performed within 9,000 miles (15,000 km) or 12 months of the previous service, whichever first
occurs.
Any necessary repairs should be completed without delay.
A cross ( X ) in the following table indicates an operation to be performed. The corresponding box should be
ticked when the operation has been satisfactorily performed, or the X circled if extra work and time is required.
The approval of the customer should be obtained before any extra work is undertaken, details of which should be
recorded in the space provided at the end of the schedule.
Inspect' means assess condition and test for correct operation. Extra time is required to adjust or repair - advise
customer beforehand if necessary.
Check' means test and adjust/fill or tighten as necessary. Labour time is included.
Special Operating Conditions
If the car is subjected to one of the following 'special operating conditions', additional servicing is required (see
additional servicing notes below):
- Regular use on unpaved or dusty roads (1,2)
- Use in mountainous areas with severe or prolonged brake usage (3)
- Frequent short trips with cold engine (esp. in cold weather/climates); and/or frequent or prolonged idling (1)
- Occasional circuit use, with repeated high rpm, wide throttle openings and high oil temperatures (1,3,4)
- Competition, or timed track use (5)
Additional servicing:
1. Oil & filter change @ 4,500 m (7,500 km) intervals.
2. Inspect air cleaner @ 9,000 m (15,000 km) intervals, or as required.
3. Inspect brake pads & discs @ 1,000m (1,500 km) intervals, or as required.
4. Thorough safety check including wheels, tyres, suspension, steering and brake systems.
5. The Lotus Elise/Exige is designed as a road going sports car. It is recognised that owners may wish to use
the car occasionally on closed circuit tracks to experience the car's full range of dynamic capabilities. However,
use of the car in a competitive manner, including timed runs or laps, is not endorsed by Lotus. This type of timed,
competitive use will invalidate warranty and require appropriate levels of expert vehicle preparation and servicing
over and above that specified in the Maintenance Schedule.
After Sales Service
To be performed by the selling dealer within 1,000 - 1,500 miles (1,500 - 2,500 km) or 12 months of vehicle sale,
whichever first occurs.
If carried out by the selling dealer, there is no charge to the vehicle owner for the labour content of the After Sales
Service. Only for materials used will a charge be made. To maintain warranty validation, an Engine History and
Performance Report print out via the Lotus TechCentre must be submitted to the Warranty Department.
Page 3
2
2a
3
4
5
6
7
8
9
9a
9b
9c
10
11
12
13
14
15
16
17
17a
18
19
20
21
22
23
23a
24
25
26
27
28
29
30
30a
31
32
33
34
35
Section OI
Service Type
Op.
No.
1
Lotus Service Notes
Operation Description
After
Sales
9,000m
(15,000km)
or 12 months
Fit covers to seats, footwells, steering wheel and rear body
Lubrication
Renew engine oil and filter - normal conditions
Renew engine oil and filter - special conditions
Inspect engine & transmission for oil leaks
Check transmission oil level
Renew transmission oil
Engine
Inspect air cleaner element - special conditions
Renew air cleaner element
Renew spark plugs
Inspect auxiliary drive belt condition (X* Elise SC only)
Inspect auxiliary drive belt condition - special conditions
Renew auxiliary drive belt - Elise SC only
If applicable: Check Accusump pressure/operation and system for
leaks. Renew in-line filter gauze
Inspect integrity of fuel system
Connect 'Lotus TechCentre'; inspect fault codes & ECU programme le
Print Engine History & Performance data and return to Lotus
Cooling System
Inspect water radiator & oil cooler hoses & pipework for damage or
leaks. Clean radiator & oil cooler finning
Check coolant level
Renew coolant
Braking System
Inspect parking brake adjustment
Inspect brake pad thickness & disc condition - normal cndts.
Inspect brake pad thickness & disc condition - special cndts.
Inspect brake hoses, pipes & hydraulic units
Check brake fluid level
Renew brake/clutch fluid
Steering & Suspension
Check security and condition of front & rear suspension inc. free
articulation of rear toe link ball joints
Check torque of rear toe link inboard fixing (60 Nm)
Inspect dampers for leaks and performance
Where applicable: Check security of damper reservoirs, check
adjuster settings, lubricate adjusters and spring platforms
Inspect front and rear wheel bearings for play
Inspect condition of drive shaft gaiters
Inspect steering ball joints and gaiters
Inspect free play at steering wheel
Wheels & Tyres
Inspect tyre condition & set pressures
Electrical
Check battery & terminals for security & condition
Inspect operation of all lights
Body
Check hardtop air intake for obstructions (supercharged)
Inspect adjustment of hinges and latches
Inspect operation & condition of seat belts
Lift footwell mats, clean & dry floor
Inspect wiper operation & top up windscreen washer reservoir
Renew alarm transmitter batteries (check with customer)
X
X
lsl501c
Page 4
Other
Intervals
X
4,500m (7,500km)/6 mth
X
X
27,000m (45,000km)
54,000m (90,000km)/6 yr
X
X
27,000m (45,000km)
54,000m (90,000km)/6 yr
X
X*
4,500m (7,500km)/6 mth
18,000m (30,000km)/24 mth
X
X
X
X
X
X
X
X
X
X
X
X
X
1,000m (1,500km)
X
X
4 yr
2 yr
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
1 yr
Lotus Service Notes
Section OI
Road Test Performance
Engine performance ...........................…..................
Tailpipe CO ...........................................................
Clutch operation ......................................................
Gearbox operation ................................................
Brake performance ...................................................
Steering performance ...........................................
Driveline & suspension noise/vibration .......................
Wheel balance ......................................................
General comments ……………………………………………………………………………………………………
...........................................................................................................……………………….............
…………………………………………………………………………………………………………………………..
Additional Work Performed or Required
…………………………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………......
Work completed by ............................................… Owner's Maintenance Booklet stamped: …………
Recommended Service Times
After Sales Service: 1.9 hr
Regular Service:
2.8 hr
Op. 2a:
0.6 hr
Op.4:
0.1 hr
Op.5:
0.7 hr
Op.7:
0.6 hr
Op.8:
0.5 hr
Op.9a:
0.1 hr
Op.9b:
0.6 hr
Op.9c:
0.3 hr
Op.15:
0.6 hr
Op.17a:
0.3 hr
Op.20:
0.6 hr
Op.23a
0.2 hr
Op.35:
0.1 hr
Dealer Stamp:
Date:
Page 5
Lotus Service Notes
Section OI
MAINTENANCE SCHEDULE - ELISE/EXIGE (North America)
LSL462d
Job no.: ........................ Owner's name: .....…………....................... Vehicle: ..............………...………..
Vehicle registration no.: ......………................... V.I.N.: ......………................................................…
Recorded mileage: ........………...…….………… Mileage at last service.: ..............………………
Today's date: ………………..………...…………… Date of last service: ………………………
EXPLANATORY NOTES:
Required Maintenance
In order to maintain warranty validation and help ensure proper safety, emissions performance and
dependability of the vehicle, Lotus Cars Ltd. requires that the vehicle be serviced in accordance with this
schedule. Each service should be performed within 7,500 miles or 6 months of the previous service, whichever
first occurs.
Any necessary repairs should be completed without delay.
A cross ( X ) in the following table indicates an operation to be performed. The corresponding box should be
ticked when the operation has been satisfactorily performed, or the X circled if extra work and time is required.
The approval of the customer should be obtained before any extra work is undertaken, details of which should
be recorded in the space provided at the end of the schedule.
'Inspect' means assess condition and test for correct operation. Extra time is required to adjust or repair advise customer beforehand if necessary.
'Check' means test and adjust/fill or tighten as necessary. Labour time is included.
Special Operating Conditions
If the car is subjected to one of the following 'special operating conditions', additional servicing is required:
- Regular use on unpaved or dusty roads (1,2)
- Use in mountainous areas with severe or prolonged brake usage (3)
- Frequent short trips with cold engine (esp. in cold weather/climates); and/or frequent or prolonged idling (1)
- Occasional circuit use, with repeated high rpm, wide throttle openings and high oil temperatures (1,3,4)
- Competition, or timed track use (5).
Additional servicing:
1. Oil & filter change @ 4,000 m intervals.
2. Inspect air cleaner @ 7,500 m intervals, or as required.
3. Inspect brake pads & discs @ 4,000 m intervals, or as required.
4. Thorough safety check including wheels, tyres, suspension, steering and brake systems.
5. The Lotus Elise/Exige is designed as a road going sports car. It is recognised that owners may wish to use
the car occasionally on closed circuit tracks to experience the car's full range of dynamic capabilities. However,
use of the car in a competitive manner, including timed runs or laps, is not endorsed by Lotus. This type of
timed, competitive use will invalidate warranty and require appropriate levels of expert vehicle preparation and
servicing.
After Sales Service
To be performed within 1,000 - 1,500 miles or 12 months of vehicle sale, whichever first occurs.
To maintain warranty validation, an Engine History Report print out from the Lotus TechCentre tool must be
submitted to the Warranty Department.
Page 6
Op.
No.
1
2
2a
3
4
5
6
7
8
9
9a
9b
9c
10
11
12
13
14
15
16
17
17a
18
19
20
21
22
23
23a
24
25
26
27
28
29
30
30a
31
32
33
34
35
Lotus Service Notes
Section OI
Service Type
Operation Description
After
Sales
7,500 miles
or 6 months
(soonest)
Fit covers to seats, footwells, steering wheel and rear body
Lubrication
Renew engine oil and filter -normal conditions
Renew engine oil and filter -special conditions
Inspect engine & transmission for oil leaks
Check transmission oil level
Renew transmission oil
Engine
Inspect air cleaner element -special conditions
Renew air cleaner element
Renew spark plugs
Inspect auxiliary drive belt condition (X* Elise SC only)
Inspect auxiliary drive belt condition -special conditions
Renew auxiliary drive belt - Elise SC onl
If applicable: Check Accusump pressure/operation and system for
leaks. Renew in-line filter gauze
Inspect integrity of fuel system
Connect 'Lotus TechCentre'; inspect fault codes & ECU programme
Print Engine History & Performance data and return to Lotus
Cooling System
Inspect water radiator & oil cooler hoses & pipework for damage or
leaks. Clean radiator & oil cooler finning
Check coolant level
Renew coolant
Braking System
Inspect parking brake adjustment
Inspect brake pad thickness & disc condition -normal cndts.
Inspect brake pad thickness & disc condition -special cndts.
Inspect brake hoses, pipes & hydraulic units
Check brake fluid level
Renew brake/clutch fluid
Steering & Suspension
Check security and condition of front & rear suspension inc. free
articulation of rear toe link ball joints
Check torque of rear toe link inboard fixing (60 Nm)
Inspect dampers for leaks and performance
Where applicable: Check security of damper reservoirs, check
adjuster settings, lubricate adjusters and spring platforms
Inspect front and rear wheel bearings for play
Inspect condition of drive shaft gaiters
Inspect steering ball joints and gaiters
Inspect free play at steering wheel
Wheels & Tyres
Inspect tyre condition & set pressures
Electrical
Check battery & terminals for security & condition
Inspect operation of all lights
Body
Check hardtop air intake for obstructions (supercharged)
Inspect adjustment of hinges and latches
Inspect operation & condition of seat belts
Lift footwell mats, clean & dry floor
Inspect wiper operation & top up windscreen washer reservoir
Renew alarm transmitter batteries (check with customer)
X
X
X
X
Other
Intervals
X
4,000 miles/6 months
X
22,500 miles
45,000 miles/6 years
X
30,000 miles
30,000 miles/6 years
X
X*
4,000 miles/6 months
15,000 miles/12 months
X
X
X
X
X
X
X
X
X
X
X
X
X
1,000 miles
X
X
4 yr
2 yr
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
1 yr
lsl462d
Page 7
Lotus Service Notes
Section OI
Road Test Performance
Engine performance ...........................…..................
Tailpipe CO ...........................................................
Clutch operation ......................................................
Gearbox operation ................................................
Brake performance ...................................................
Steering performance ...........................................
Driveline & suspension noise/vibration .......................
Wheel balance ......................................................
General comments ……………………………………………………………………………………………………
...........................................................................................................………………………..........…….
…………………………………………………………………………………………………………………………..
Additional Work Performed or Required
…………………………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………......
Work completed by ............................................… Owner's Maintenance Booklet stamped: …………
Recommended Service Times
After Sales Service: 1.9 hr
Regular Service:
2.8 hr
Op. 2a:
0.6 hr
Op.4:
0.1 hr
Op.5:
0.7 hr
Op.7:
0.6 hr
Op.8:
0.5 hr
Op.9a:
0.1 hr
Op.9b:
0.6 hr
Op.9c:
0.3 hr
Op.15:
0.6 hr
Op.17a:
0.3 hr
Op.20:
0.6 hr
Op.23a
0.2 hr
Op.35:
0.1 hr
Page 8
Dealer Stamp:
Date:
Lotus Service Notes
Section OI
PRE-DELIVERY INSPECTION
LSL345E
MODEL
COLOUR
VIN
SCC _ _ _ _ _ _ _ _ _ _ _ _ _ _
9
OPERATION DESCRIPTION
Fit protective covers to seats, footwells & steering wheel.
Engine Bay
Check engine, transmission & PAS oil levels.
Check coolant fill level.
Start Engine
Inspect engine & transmission for oil leaks.
Inspect cooling system for leaks.
Fill fuel tank and inspect entire fuel system for leaks.
Use Lotus TechCentre to check for stored codes.
Wheels & Tyres
Check cold tyre pressures.
Check torque of wheel bolts.
Check tyreweld canister is fitted in rear luggage compartment.
Electrical
Check security of battery terminals and voltage. Below 12.4V recharge. Below 11.7V replace*.
Inspect operation of alarm system, CDL & fuel flap release.
Inspect operation of all exterior & interior lamps.
Inspect operation of horn & hazard switch.
Inspect wiper operation at all speeds & park position.
Inspect screen washer & powerwash operation, jet alignment & reservoir level.
Inspect operation of all instrumentsl, mirror adjustment & fold.
Inspect operation of heater / air conditioning & blower fan.
Inspect operation of audio equipment & set time clock (if applicable).
Body
Check brake / clutch fluid level.
Inspect operation of doors, door locks & tailgate release (incl. Evora cable).
Inspect operation of electric window lift mechanism.
Inspect fit of hard & soft top roofs.
Inspect seat adjustment latching & operation of front & rear seatbelts.
Inspect interior trim for damage & cleanliness.
Inspect all paint work for damage (Elise LSL407a; Exige LSL409a; Europa LSL514; Evora LSL544).
Check presence of toolkit & literature pack.
Fit number plates and tax disc holder.
Complete Warranty Literature
Check presence of vehicle handbook, audio booklet & other documentation.
Complete pages 2, 3, 4a & 4c in "Maintenance Record" booklet.
Cut out pages 4a & 4c for return to Lotus Cars Warranty Department.
Copy alarm installation certificate, PIN & key details (inc. locking wheel bolts). Originals to customer.
U.K.: Complete Lotus Roadside Assistance card (expiry date 2 years from reg. date).
* Battery claims will not be accepted unless correct trickle charging has been maintained.
Page 9
Lotus Service Notes
Section OI
Road Test Performance Check - Add comments as necessary
Engine performance:
Brake performance:
Clutch operation:
Gearbox operation:
Steering performance:
Check wheel balance:
Driveline/suspension noise/vibration:
General Comments
Additional Work Required
Additional Work Completed by:
Valet
Undertake complete vehicle valet.
Notes - The PDI is subject to the following conditions:
Dealer stamp:
a) It is the responsibility of the supplying dealer to ensure that
the car is delivered to the customer in the best possible condition.
b) All costs incurred during the inspection process are the responsibility of the dealer.
c) Failure to return a signed copy of this inspection to Lotus
Cars Ltd. by the dealer, may result in warranty claims on
the particular car being rejected.
Pre-Delivery Inspection Completed by:
Date:
ONCE COMPLETED, SEND ORIGINAL COPY OF PDI FORM, OWNER'S HANDBOOK MAINTENANCE RECORD
PAGES "P.D.I & REGISTRATION OF SALE", AND NEW CAR HANDOVER CHECKLIST (LSL486) TO:
WARRANTY DEPARTMENT,
LOTUS CARS LTD.
POTASH LANE,
HETHEL,
NORFOLK,
NR14 8EZ,
ENGLAND
lsl501
Page 10
Lotus Service Notes
Section OI
PRE-DELIVERY PAINT MARK UP - ELISE 2
PAINT DEFECT CODE
VIN
COLOUR
OWNER
DATE OF PDI
Page 11
lsl407a
B
C
D
F
G
H
K
M
BLISTERING
CHIPS
DISTORTION
FLAKING
GEL CRAZING
PIN HOLES
SINKAGE
MAT CREASES
N
O
P
R
S
T
U
V
SHADING
OVERSPRAY
PRE-RELEASES
RUN
SCRATCHES
THIN PAINT
DIRT UNDER PAINT
VOIDS
Lotus Service Notes
Section OI
PRE-DELIVERY PAINT MARK UP - EXIGE
VIN
COLOUR
OWNER
DATE OF PDI
lsl409a
PAINT DEFECT CODE
B
C
D
F
G
H
K
M
BLISTERING
CHIPS
DISTORTION
FLAKING
GEL CRAZING
PIN HOLES
SINKAGE
MAT CREASES
N
O
P
R
S
T
U
V
SHADING
OVERSPRAY
PRE-RELEASES
RUN
SCRATCHES
THIN PAINT
DIRT UNDER PAINT
VOIDS
Page 12
Lotus Service Notes
Section OI
Licence Plate Fitment - Except North America
Front
The mounting plinth for the front licence plate is moulded into the front clamshell, and is slightly curved
in plan. Typically, double sided tape in conjunction with two fixing screws are used to secure the plate which
should not project above the top edge of the plinth by more than 40mm, or cooling performance will be inhibited.
Conversely, too low a position may result in damage from grounding on ramps and kerbs.
Proprietary threaded blind fixings such as Pulserts, Rivnuts, Rawlnuts or Jacknuts may be used, or alternatively, using the limited access available from beneath the nose of the clamshell, any non-captive fixing
may be used.
Licence Plate Fitment on North American Elise
LSL480
Front
The Elise front clamshell incorporates a moulded plinth for the front licence plate. A licence plate mounting
frame is supplied loose with the car for those States which require front plates. The aluminium frame has four
M6 threaded studs, and should be fitted to the clamshell plinth by marking and drilling the four 6mm clearance
holes symmetrically about the vertical and horizontal centrelines of the plinth. A template is attached for your
convenience.
Fit the frame with the longer legs uppermost, and remove the air intake grille to allow access to secure
the frame with flat washers and M6 Nyloc nuts. Do not overtighten. Refit the grille and fit the licence plate to
the mounting frame.
Rear
The rear licence plate plinth is provided with two sets of four M6 threaded inserts positioned in different
configurations to suit various State requirements.
Page 13
Align edge of paper with end of plinth
Top edge of plinth
Mark hole centres and drill to 6mm
Bottom edge of plinth
Align edge of paper with end of plinth
Section OI
Page 14
Lotus Service Notes
Section PL
AIR CONDITIONING, HEATING & VENTILATION
SECTION PL
Sub-Section Page
General Description
PL.1
3
Controls Operation & Airflow Distribution
PL.2
5
Cooling Fans & Re-circulation Pump
PL.3
11
Refrigerant Handling
PL.4
13
Refrigerant Pipework Precautions
PL.5
13
Refrigerant Oil
PL.6
15
Compressor
PL.7
16
Condenser
PL.8
18
Receiver-Drier
PL.9
20
Expansion Valve
PL.10
20
Heater/Evaporator/Fan Unit
PL.11
21
Air Distribution Unit
PL.12
22
Refrigerant Pipes
PL.13
23
Air Blender & Re-circ. Flap Actuators
PL.14
23
Page 1
Updated 9th June 2010
Lotus Service Notes
Section PL
Heater Circuit
Water feed pipe along outside
of RH chassis siderail
Heater
matrix
Water return pipe
along outside of
LH chassis siderail
Water return to
engine side of
thermostat
p77c
Coolant re-circulation pump
Refrigerant Circuit
Receiver-drier
Feed & return pipes
along outside of RH
chassis siderail
Condenser
Expansion valve
Compressor
Evaporator casing
p78c
Page 2
Lotus Service Notes
Section PL
PL.1 - GENERAL DESCRIPTION
Heater System
The heater system uses engine coolant to provide a heat source transferred to the interior airstream via
a heat exchanger matrix mounted in an 'air blend' unit housed within the chassis well, ahead of the cabin
footwell. The coolant is fed from an outlet on the left hand side of the cylinder head, and via an alloy pipe
running along the outside of the RH chassis side rail to the matrix. Coolant is returned via a similar pipe along
the outside of the LH chassis rail to a by-pass return pipe on the left hand side of the engine.
Air temperature is controlled by a pair of air blend flaps within the heater housing which direct a varying
proportion of the airflow through, or around the matrix as determined by the position of the temperature selector knob. Note that no water valve is fitted, such that the matrix is always 'hot' when the engine is running.
Air Conditioning (If fitted) - Basic Principles
The air conditioning unit uses a cycling clutch system with a thermostatic expansion valve to provide
refrigerated air to the vehicle interior. The system comprises:
a closed circuit containing refrigerant R134a;
a compressor mounted on the front side of the engine, driven by multi-vee belt from the front end of the
crankshaft via an electromagnetic clutch;
a condenser mounted horizontally at the front of the car, beneath the engine cooling radiator;
an evaporator unit (cooler) fitted in the chassis well ahead of the cabin footwell;
a thermostatic expansion valve fitted at the inlet connection to the evaporator;
a receiver-drier unit mounted above the heater/a.c. unit
Closed Circuit
The closed refrigerant circuit should not be opened unless absolutely necessary, and only then using
appropriate refrigerant recovery equipment. Never allow the refrigerant to vent to atmosphere. Refer to subsection PL.5. Failure to observe these precautions may result in personal injury.
Expansion
valve
Trinary switch
Service ports
Condenser
Compressor
connections
Receiver-drier
High pressure
relief valve
Sill pipes
p75c
Page 3
Lotus Service Notes
Section PL
Compressor
When the engine is running, and the refrigeration controls demand it, the electromagnetic clutch incorporated in the compressor pulley is energised, which then locks the pulley to the shaft and drives the compressor.
The rotary vane type compressor operates to discharge refrigerant vapour at high pressure and temperature
into the condenser. The compressor is lubricated by a quantity of special refrigerant oil, most of which is
retained in the compressor, with the remainder being circulated with the refrigerant. An integral thermal cut-out
switch is designed to prevent overheating damage by interrupting the compressor clutch circuit if an excessively high temperature is detected.
A thermostat, sensing the temperature of the refrigerated air as it leaves the evaporator, signals the
compressor to cycle on and off. In order to avoid engine stalling and to maintain idle speed when the compressor driving load is placed on the engine, the a.c. request and compressor command signals are processed by
the engine management ECU, which amends the idle air control valve position as necessary.
Condenser
The aluminium condenser is horizontally mounted beneath the engine cooling radiator, and is of parallel
flow construction. The hot vapour received by the condenser from the compressor, releases heat to the
surrounding air via the condenser finning, with airflow boosted by two electric fans mounted below the condenser, and ram air flow caused by vehicle movement.
Evaporator
The evaporator is a tube and fin type heat exchanger mounted in a plastic housing fitted into the chassis
well ahead of the passenger compartment footwell. All incoming airflow is directed through the evaporator,
before being directed through or past the heater matrix, and then into the air distribution chamber.
The low pressure liquid refrigerant flowing into the evaporator via the expansion valve, begins to boil
(evaporate) and in so doing, draws the necessary heat for this process from the airstream passing through the
evaporator. This airstream is consequently cooled, and is directed through the various outlet vents to the
passenger compartment.
When the a.c. switch is pressed by the driver, and other parameters allow it (i.e. ignition on, blower fan
speed selected, a.c. pressure switch closed), the a.c. circuit is activated and the compressor clutch is engaged.
A thermostat, using a sensor inserted into the outlet side of the evaporator finning, monitors the temperature of
the refrigerated air and signals the compressor to cycle on and off in order to maintain outlet air temperature
just above freezing.
The inlet and outlet pipes connect to the evaporator via the expansion valve block, into which they are
sealed using 'O' rings and a clamp plate. The inlet is supplied from the receiver-drier, and the outlet feeds the
compressor.
Expansion Valve
The expansion valve block is fitted into the high and low pressure lines at the evaporator, and provides a
restriction to the flow of high pressure liquid into the evaporator, such that the consequent pressure drop
causes a change of state from a high temperature, high pressure liquid, to a low pressure, low temperature
atomised liquid.
By sensing the temperature and pressure of refrigerant leaving the evaporator, the expansion valve is
able to modulate the flow of refrigerant into the unit to optimise the cooling performance.
Receiver-Drier
The receiver-drier unit is fitted into the refrigerant line between the condenser and evaporator expansion
valve, and houses a screen sack filled with desiccant to absorb traces of moisture and other contaminants from
the refrigerant. The unit is mounted in the chassis well above the heater/a.c. unit. A sight glass built into the
top of the receiver-drier allows a visual assessment of refrigerant charge to be made - a clear sight glass may
indicate that the system is correctly charged, or completely empty, although the latter situation is usually
accompanied by oil streaks. If refrigerant charge is low, a stream of bubbles will be visible at the sight glass.
A trinary switch fitted into the top of the receiver-drier senses the pressure of refrigerant and allows
system operation only within a pressure range of 2 to 32 bar in order to prevent system damage from too high
a pressure, or from compressor oil starvation damage caused by too low a pressure. A third switching point is
used to engage the two condenser fans at half speed at pressures over 17.5 bar (see also sub-section KH.5).
An additional safeguard is provided in the form of a high pressure relief valve in the condenser inlet pipe, which
opens at 38 - 41 bar.
Page 4
Lotus Service Notes
Section PL
PL.2 - HEATER/A.C. AIRFLOW OVERVIEW
The major units of the Heating Ventilation and Air Conditioning (HVAC) system comprise a dual intake
blower fan, an evaporator housing (with no evaporator fitted for non a.c. cars), a heater housing and an airflow
distribution unit. The fan blower unit and the combined evaporator/heater unit are mounted in the chassis
climate chamber ahead of the cabin footwells, with the airflow distribution unit mounted on the top of the
chassis scuttle area. Ambient air is collected from the radiator air intake duct via two ports in the radiator
ducting, which mate to apertures in the chassis front crossmember. Moulded ducting on the rear side of the
chassis front face directs this air, via a shut off butterfly flap valve on a.c. cars (to provide a recirc. function), to
the blower fan front intake. The rear intake of the double sided fan housing is connected to perforated ports in
the front wall of each footwell.
The fan blower unit directs all airflow through the a.c. evaporator (if fitted), after which a pair of linked air
blender flaps, control the proportion of air which flows through the heater matrix. The upper flap is driven by a
stepper motor from the cockpit temperature selector, with the lower flap linked to the upper by toothed belt.
After leaving the HVAC chamber, air is ducted to a distribution chamber mounted on the top of the chassis
scuttle which distributes air to screen, face level vents and footwell vents. The distribution chamber contains
a horizontal, three vane, rotary flap, driven by a stepper motor, and controlling outlets to the screen and face
level vents. A link rod connects this flap to a second flap controlling airflow to the footwells. Ducting for the
windscreen vents is incorporated into the underside of the fascia top panel.
Schematic Airflow
Face level
vent
Windscreen
vent
Footwell vent
Re-circ. ports in
footwell
Blower fan
Heater matrix
A.C. evaporator
Re-circuation flap
(a.c. cars only)
Stepper motor for
re-circ. flap
Chassis front wall
Crash structure
Fresh air in
p101
Page 5
Lotus Service Notes
Section PL
Airflow through a.c./heater unit
Cold air
Trunking to
distribution unit
Ambient or re-circulated
air inlet
p110b
Heater
matrix
Fan blower
a.c. evaporator (if fitted)
Warm air
Flap in full
warm position
p110a
Butterfly flap open
Page 6
Lotus Service Notes
Interior Climate Controls
The interior climate controls consist of
two push switches (if fitted) for air conditioning and air re-circulation, and three rotary controls for heater temperature, fan speed, and
air distribution.
Air Conditioning (if fitted)
The left hand push button switch requests
air conditioning, but the engine must be running and a fan speed selected before the system will operate. The a.c. switch receives its
feed from the fan speed switch and energises
the a.c. request relay. When closed, the request relay supplies, via the a.c. thermostat
and trinary switch, an ECM input. The ECM
processes a valid request input, and if other
parameters allow (e.g. not wide open throttle,
not excessive coolant temperature), the ECM
will open the IAC valve before energising the
a.c. clutch relay. Note also that ambient air
temperature must be above 3°C.
With a fully cold temperature setting,
refrigerated air will be supplied. For dehumidified air, select air conditioning in conjunction with a warm temperature setting.
The tell tale in the switch button lights
up green when the circuit is active.
Section PL
INTERIOR CLIMATE CONTROLS
p98b
Temperature
Air conditioning
(if fitted)
Fan Speed
Distribution
Re-circulation
(if fitted)
p99
Air Re-circulation (with a.c.)
Air supply for the interior climate system is normally drawn from both the intake duct ahead of the engine
cooling radiator, and the vehicle interior. When the re-circulation button is pressed, a stepper motor is activated to close a butterfly flap in the fresh air intake, in order to provide a 90% recirculation supply to the blower
fan. The re-circulation facility should be used when maximum refrigeration is desired. The tell tale in the
switch button lights up green when the circuit is active.
Heater Temperature
With the left hand rotary electrical control turned fully counterclockwise, the air blender flaps are positioned to direct all the airflow to by-pass the heater chamber so that no air heating is provided. If air cooling is
required, use this temperature position in conjunction with air conditioning. Turning the control progressively
clockwise operates the stepper motor attached to the upper flap spindle, and via toothed belt to the lower flap,
to direct airflow through the heater matrix and provide an increasing level of air heating until at the fully
clockwise position, maximum heat is supplied.
Fan Speed
The centre rotary switch provides three fan speeds to boost air circulation. Turned fully counterclockwise,
the fan is off; Turning the switch progressively clockwise operates the blower fan at increasing speed in three
steps. Note that the fan operates only with the ignition switched on. The fan speed resistors are mounted in the
top of the evaporator housing.
Air Distribution
The right hand electrical rotary control operates a stepper motor on the air distribution unit to direct airflow
to the windscreen, face level and footwell vents. The following diagrams indicate airflow for the different
control positions:
Page 7
Lotus Service Notes
Section PL
Face Level):
Turned fully counterclockwise, the stepper motor on the air distribution unit (ADU)
operates the rotary flap to close off the windscreen vents, and direct all airflow to the four
face level vents, each of which may be manipulated to adjust volume and direction. The
footwell flap is closed.
Windscreen
Scuttle
baffle
panel
To face
level
vents
Air distribution unit
From
climate
chamber
Chassis scuttle
Rotary flap
Connecting link
p102a
Footwell flap closed
Page 8
Lotus Service Notes
Section PL
Footwell:
As the control is turned clockwise from
the face level vents symbol towards the
footwell symbol, the stepper motor turns the
rotary flap to progressively close off the face
level vents. A rod connecting the rotary flap
to the footwell flap is arranged to open the
footwell vents in opposite proportion, until at
the footwell symbol, all airflow is directed to
the footwells.
.
Footwell flap open
From
climate
chamber
Screen & footwell
ports closed off
To footwells
p102b
Page 9
Lotus Service Notes
Section PL
Demist:
As the control is turned clockwise from
the face level vents symbol towards the
footwell symbol, the stepper motor turns the
rotary flap to progressively open the windscreen vents. The rod connecting the rotary
flap to the footwell flap is arranged to close
the footwell vents in opposite proportion, until
at the screen symbol, all airflow is directed to
the windscreen. Select a warm temperature
setting and a suitable fan speed.
Full Defrost Performance
For maximum defrost performance, turn
the distribution knob fully clockwise and select maximum temperature and fan speed. On
cars with adjustable windscreen vents, direct
the centre pair of screen vents slightly rearwards, and the end pair of vents forwards as
shown in the illustration.
Ventilation Shut-Off
To close off the ventilation, which may
be desirable in heavy traffic to reduce the induction of fumes into the car, turn off the fan,
turn the distribution control fully
counterclockwise to the face level vent position, and manually shut off each of the face
level vents.
Inner
vent
direction
Outer
vent
direction
FULL DEFROST
PERFORMANCE
ohs98
Windscreen vent
Demist duct in
fascia top panel
Scuttle baffle panel
Windscreen port open
From
climate
chamber
Face level port closed
Footwell flap closed
p102c
Page 10
Lotus Service Notes
Section PL
PL.3 - COOLING FANS & RE-CIRCULATION PUMP
The two cooling fans are fitted beneath the radiator or (with a.c.) condenser/radiator package, and the
coolant re-circulation pump is mounted below the header tank. Both the fans and pump are controlled by the
engine management ECU using data provided by the engine coolant temperature sensor mounted in the back
of the cylinder head.
The cooling fans are switched as a pair, and will operate at half speed (connected in series) when coolant
temperature reaches 98°C on rise, and switch off at 94°C on fall. If coolant temperature rises to 103°C, the
fans will switch to full speed (connected in parallel), reverting to half speed at 98°C.
The fans will also run at half speed, unless high coolant temperature dictates otherwise, when the a.c. is
switched on and the compressor is running, or if the engine management system detects a fault with the inlet
air temperature or coolant temperature circuits.
At road speeds in excess of 85 mph (135 km/h), equating to the fan stall speed, all fan functions are
switched off.
Heat Soak
In order to help control engine temperature after switching off an engine whose temperature is over 88°C,
the ECU will remain powered for a period of 20 minutes to allow heat soak management.
A coolant re-circulation electric pump is mounted below the coolant header tank and is plumbed into the
heater supply line. When energised, the pump circulates coolant through the engine and heater system,
drawing coolant from the back of the cylinder head, and pumping it through the heater matrix to the heater
return pipe and back into the thermostat housing. The pump functions only with ignition off in conditions where
the ECU remains live. The pump is then activated at coolant temperatures over 110°C, switching off at 100°C
on fall. If temperature should rise to 115°C, the pump will be supplemented by the two cooling fans running at
half speed, switching off at 110°C on fall.
Fan Control Module
The cooling fans, re-circ. pump and a.c. compressor are controlled by a relay module mounted to the top
of the passenger side wheelarch liner. Important Note: The a.c. relay module is identical in appearance to the
engine relay module, but the function of the two modules is different and they must not be transposed. The a.c.
relay module B117M0038F has a purple label marked YWB100801 and a blue connector moulding; The
engine relay module A111E6024F has a white or brown label marked YWB100970 and a black connector
moulding. If necessary, use a scalpal blade to slim the centre spigot of a new module connector housing to
allow its fitment on an earlier car.
If the ECU receives a coolant temperature sensor signal voltage outside of the acceptable range, a
default setting equating to 60°C will be substituted, and the cooling fans activated at half speed as an engine
protection strategy.
Note that a blockage in the a.c. system may result in the cooling fans running at full speed.
Page 11
Lotus Service Notes
Section PL
Seat belt mouting
frame backstay
Outlet from pump to heater
Coolant
header tank
Wiring
harness
Coolant re-circulation pump
p109b
Heater return hose
Heater feed from cylinder head
Fans/compressor relay module
Shelf on driver's side
wheelarch liner
p108
Page 12
Lotus Service Notes
Section PL
PL.4 - REFRIGERANT HANDLING
The system is charged with 0.55 kg of refrigerant HFC R134a, and the following precautions MUST
ALWAYS BE OBSERVED.
1.
On no account should refrigerant ever be discharged to atmosphere - use a refrigerant recovery/recycling
station in accordance with the manufacturer's instructions. Filling points on early Elise are located in the
front services compartment, and on the Exige and later Elise, ahead of the RH rear wheel, accessible
after removal of the wheelarch liner.
2.
Standard R134a 'quick fit' connectors are provided in the compressor suction and discharge pipes at the
right hand front of the engine bay;
- the low pressure vapour line port is fitted in the pipe between the evaporator and compressor.
- the high pressure liquid line port is fitted in the pipe between the compressor and condenser.
3.
Heavy concentrations of refrigerant vapour can produce toxic gas if exposed to a naked flame. The gas
can also attack metal.
4.
Refrigerant drums must never be left open - always ensure the caps are securely fitted.
5.
Never transport drums of refrigerant in the passenger compartment of a car.
6.
Never expose refrigerant drums to high temperature.
7.
Never weld or use a steam cleaner in close proximity to any part of the air conditioning system.
8.
Never expose the eyes to vapourised or liquid refrigerant - ALWAYS wear safety goggles and gloves
when handling refrigerant.
PL.5 - REFRIGERANT PIPEWORK PRECAUTIONS
The following precautions must be observed when carrying out any work on the refrigerant pipework:
Before disconnecting any refrigerant pipework, the refrigerant must first be recovered using suitable equipment connected to the service valves at the right hand front of the engine bay. Ensure that the equipment is
suitable for R134a.
1.
All replacement components and flexible end connections are sealed when new, and should only be
opened IMMEDIATELY PRIOR TO FITTING, AND AT ROOM TEMPERATURE, to prevent condensation
of any moisture which may enter when the sealing is removed.
2.
Pipes, flexible end connections and components, must be capped immediately they are opened to prevent the ingress of moisture and/or dirt.
3.
The receiver-drier should be the LAST component to be connected, to ensure optimum dehydration and
maximum moisture protection of the system.
4.
All joints should be coated with refrigeration oil before making any connections, to aid seating.
5.
Great care must be taken to prevent damage to the pipe fittings and connections, since due to the high
pressures involved, a leak can be caused by the slightest imperfection. Always use two spanners of the
correct size when releasing or tightening any pipe joint so that the fixed part of the union may be prevented from twisting and damaging the component. This is especially important with the aluminium
condenser.
6.
All pipes and hoses must be free from any kinking. The efficiency of the system can be impaired by a
single kink, or restriction. Flexible hoses should not be bent to a radius which is less than ten times the
diameter of the hose.
Page 13
Lotus Service Notes
Section PL
Refrigerant Pipework Fixing Torques
Key
1
2
3
4
5
6
7
8
9
10
Description
Qty
Thread
Pitch
Compressor to engine
3
M8
A.C. hoses to compressor
2
M6
Bulkhead connector, high pressure
2
3/4 - 16 UNF
1.6
Bulkhead connector, low pressure
2
1 1/16 - 14 UNS
1.8
High pressure blow off valve
1
3/8 - 24 UNF
1.1
High pressure pipe to condenser
1
3/4 - 16 UNF
1.6
Liquid line to condenser
1
5/8 - 18 UNF
1.4
Receiver-drier inlet/outlet pipes
2
5/8 - 18 UNF
1.4
Trinary switch to pipe
1
7/16 - 20 UNF
1.27
Clamp plate, pipes to expansion valve
1
M6
1
# Use refrigeration oil only, smear on "o" rings and threads prior to assembly
(Gloves should be worn when handling refrigeration oil - see data sheet)
Torque
35 Nm
10 Nm
25-30 Nm
35-40 Nm
10-13 Nm
25-30 Nm
20-25 Nm
20-25 Nm
15-20 Nm
7-9 Nm
Refrigerant Pipework 'O' Rings
Key
Description
A Suction line to compressor
B High pressure line to compressor
Suction line bulkhead connectors and expansion valve to
C
suction line
High press. line bulkhead connectors, cond. inlet, exp. valve to
D
evaporator
High pressure valve, condenser outlet, rec. drier, inlet pipe to
E
exp. valve
F Evaporator to expansion valve
Size
18mm o.d.
15 mm o.d.
Part Number
A120P6002H
A120P6001H
17mm i.d.
A082P6081F
11mm i.d.
A082P6079F
7.5mm i.d.
13.5mm i.d.
A082P6078F
A082P6080F
10
F
9
C
E
1
4
C
D
2
B
8
E
2
A
3
D
3
D
4
C
7
E
5
E
6
D
p75b
Page 14
Lotus Service Notes
Section PL
PL.6 - REFRIGERANT OIL
The internal working parts of the compressor are lubricated by refrigerant oil. This is a special type of oil
which has an affinity with the refrigerant, such that a proportion of the oil circulates with the refrigerant, around
the whole system. Under normal operating conditions, the oil never needs changing or replenishing, and if the
correct procedure for system depressurisation and re-charging is followed, minimal oil will be lost from the
system during these operations. If, however, the system suffers a major leak or sudden de-pressurisation,
most of the oil held in suspension will be lost as the refrigerant escapes, necessitating the addition of a specified quantity of oil to the compressor on re-assembly (see section PL.7).
If a refrigeration component is to be replaced, the removed item will contain a certain amount of oil, and
a corresponding amount of new oil must be added to the system on re-assembly:
Condenser;
30 cm³
Evaporator;
30 cm³
Any major pipe or hose;
10 cm³
Receiver-drier;
30 cm³
Compressor 2ZZ & 1ZZ Powertrain; 60 cm³ (See additional information in section PL.7)
Compressor 1ZR Powertrain;
95 cm³ (See additional information in section PL.7)
Approved Oils
Use only Denso ND-OIL 8 low viscosity (ISO46) PAG oil or equivalent (Sanden SP10; Four Seasons 59007).
Refrigerant oil absorbs water and should not be exposed to the atmosphere for any longer than is strictly
necessary to perform the operation. Never return decanted oil back into the storage container.
Page 15
Updated 9th June 2010
Lotus Service Notes
Section PL
PL.7 - COMPRESSOR
The a.c. compressor is mounted on the left hand side of the cylinder block, beneath the alternator, and is
accessible from below.
A single multi-rib serpentine type belt is used to transmit drive from the crankshaft to the water pump,
alternator and a.c. compressor, with a slave pulley fitted in place of the power steering pump used in other
applications. A hydraulically damped, spring loaded tensioner arm applies tension to the back of the belt, and
is maintenance free. The belt itself should be inspected for condition at each service interval, and if it exhibits
any evidence of physical damage, cracking, fraying, perishing, abrasion or contamination, it should be replaced. In the case of oil or coolant contamination, the cause must be identified and rectified, and each of the
pulleys must be thoroughly degreased before the new belt is fitted.
For further details, refer to section CH in the Engine Repair Manual, but note that only a six-point socket
should be used on the cast hexagonal boss on the tensioner arm. The manufacturing draft angle on this
component may result in damage being caused by a twelve point socket.
Compressor Removal
1.
Remove the compressor drive belt by applying a six-sided socket to the cast boss on the tensioner arm
to relieve the tension, and slip the belt off the compressor pulley.
2.
Recover the refrigerant using equipment connected to the service ports at the right hand front of the
engine bay.
2.
Remove the engine bay undertray.
3.
From beneath the car, release the suction and discharge pipes from the compressor and immediately cap
the pipes and compressor ports to prevent ingress of dirt and moisture.
4.
Disconnect the compressor clutch harness.
5.
Release the three compressor fixing bolts, and remove the compressor from the engine. Retain the
compressor for oil quantity measurement if a new unit is to be fitted.
Oil Quantity Adjustment Prior to Compressor Refitment
Refitting Existing Compressor
i)
If the existing compressor is to be refitted after normal refrigerant recovery has been performed, a quantity of oil equivalent to that recovered must be added to that already held in the compressor.
ii)
If the system has suffered a rapid discharge, caused for example by accident damage, most of the
refrigerant oil will have been lost. Drain the remaining oil from the compressor by removing the drain
plug and rotating the clutch plate. For 2ZZ and 1ZZ powertrains add 60 cm³ of new refrigerant oil for 1ZR
powertrains add 95 cm³ of new refrigerant oil (see above) to the compressor before refitment.
Fitting New Compressor
New compressors are sealed and pressurised with nitrogen gas. The sealing caps should be removed
only immediately prior to compressor fitment, at which time the gas pressure should be heard to escape as a
cap is slowly released. New compressors are supplied with an oil fill of 60 cm³ (2ZZ & 1ZR) and 95 cm³ (1ZR).
iii) If normal refrigerant recovery has been performed, the new compressor oil should be drained off, and the
required oil quantity in the new compressor calculated and added:
Drain and measure the oil quantity in the OLD compressor by removing the drain plug and rotating
the clutch plate. Quantity = X cm³
Oil quantity to be added to new compressor = X + 10 cm³
iv) If the system has suffered a rapid discharge, caused for example by accident damage, most of the
refrigerant oil will have been lost. In this case, drain the new compressor of oil and refill with 60 cm³.
Page 16
Updated 9th June 2010
Lotus Service Notes
Section PL
Compressor Fitment
1.
Fit the compressor to the engine and secure with the three M8 bolts; Tighten to 25 Nm (18 lbf.ft). Using
a six-sided socket on the tensioner arm, fit the drive belt onto the compressor pulley.
2.
Using new 'O' rings lubricated with an approved refrigerant oil, fit the two refrigerant pipes to the compressor and tighten the fixing screws to 10 Nm (7 lbf.ft).
3.
Connect the compressor clutch harness.
4.
Recharge the system with R134a refrigerant.
Compressor
harness
connector
High pressure
outlet connection
Low pressure
suction inlet
connection
p113
Compressor fixing bolts
Note
The 1ZR-FAE engine used in the 1.6 litre Elise, is a variable displacement compressor, instead of the
cycling clutch type used on the 1ZZ and 2ZZ engines. A safety feature in the pulley hub allows the pulley drive
to shear in the event of compressor seizure, without jeopardising other ancillaries.
Page 17
Lotus Service Notes
Section PL
PL.8 - CONDENSER
The engine cooling radiator, a.c. condenser and cooling fans are secured together as a package and are
mounted horizontally, with fans lowermost, on top of the crash structure. The all aluminium condenser is of
parallel flow construction, with tanks at each side which direct the refrigerant flow from the front inlet connection successively through 10, 7, 5 and 4 rows, before it emerges from the rear outlet union. Bonded to the front
and rear of the condenser are steel channels which incorporate mounting brackets to attach the unit to the
lower flanges of the engine cooling radiator, and also to provide mountings for the two cooling fans.
For access to the condenser or cooling fans, the front clamshell must be removed followed by the radiator
mounting panel with the complete cooling pack.
1.
Remove the front clamshell (see sub-section BR.6).
2.
Remove the two air deflector/water shields.
3.
Drain the coolant and disconnect the feed and return hoses from the radiator.
4.
Unplug the fan harness connector(s).
5.
Recover the refrigerant using suitable equipment connected to the service ports at the right hand front of
the engine bay.
6.
Using two spanners on each connection to avoid twisting the union, release the two refrigerant pipes from
the condenser and immediately cap both the pipes and the condenser unions to prevent the ingress of dirt
and moisture.
Engine cooling radiator
Front spreader plate
Front mounting
bracket
a.c. condenser
Rear
mounting
bracket
Radiator
mounting
panel
Cooling fan
p106
Page 18
Lotus Service Notes
Front mounting
spreader plate
Section PL
Rear mounting
spreader plate
Radiator
mounting
panel
Front
mounting
bracket
Rear
mounting
bracket
Engine
cooling
radiator
Air conditioning
condenser
Fan fixing
Cooling fan
p105
Page 19
Lotus Service Notes
Section PL
7.
Release the radiator mounting panel from the crash structure and lift away the complete assembly.
8.
To remove the radiator pack from the mounting panel, pull out the sealing foam, release the three bolts
securing each rear bracket to the panel, and the two bolts fixing each front bracket to the panel. Separate
the fans, condenser and radiator as necessary.
9.
On re-assembly, note that the two angle brackets securing the rear of the condenser to the radiator duct,
are positioned below the condenser flange, and use a spacer washer at the adjacent fixing point to
replicate the flange thickness. Ensure that the sealing foam is refitted around the sides and rear of the
condenser, and that the spreader plates are fitted on top of the housing at the front fixing points.
10.
-
If a new condenser is fitted, add 30 cm³ of approved refrigerant oil to the system.
Use new 'O' rings on the pipe connections, and lubricate with refrigerant oil.
Using two spanners, tighten the condenser inlet connection to 25 - 30 Nm.
Using two spanners, tighten the condenser outlet connection to 20 - 25 Nm.
Recharge the system with 0.55 kg of R134a.
Refill the cooling system (see sub-section KH.3).
Radiator mounting panel
PL.9 - RECEIVER-DRIER
If the system has been open to atmosphere for any length of time, e.g. following accident damage or a burst hose or
damaged component, the receiver-drier
unit must be renewed, and should be the
last component to be fitted, and uncapped
only immediately prior to connection and
recharging.
The receiver-drier is clamped to a
mounting bracket at the front of the climate
chamber. If the receiver-drier is to be replaced, the refrigerant must first be recovered using suitable equipment connected
to the service ports at the right hand front
of the engine bay.
Cap all pipes and ports immediately
after disconnection to prevent the ingress of dirt and moisture.
When reconnecting the pipes, use
new 'O' rings coated in an approved
refrigerant oil, and tighten to 20 - 25
Nm.
Inlet connection
Trinary switch
p107
Outlet
connection
Mounting
bracket
Receiver
drier
Windscreeen
PL.10 - EXPANSION VALVE
The expansion valve is fitted onto the evaporator inlet and outlet pipes above the climate chamber, and
is accessible from within the front services compartment. To replace the valve:
1.
Recover the refrigerant using suitable equipment connected to the service ports at the right hand front of
the engine bay.
2.
Release the single M6 screw securing the clamp plate to the top of the expansion valve, and withdraw the
plate and both pipes from the valve. Immediately cap the pipes and ports to prevent the ingress of dirt
and moisture.
Page 20
Lotus Service Notes
3.
Section PL
Release the two M5 screws from the counterbored holes in the top of the valve, securing the valve to the
evaporator pipes, and withdraw the valve from the pipes. Immediately cap the pipes and ports to prevent
the ingress of dirt and moisture.
Outlet to compresser
Inlet from receiver-drier
M6 clamp screw
'O' ring seal
Top clamp plate
M5 clamp screw (x2)
Expansion valve body
Lower clamp plate
(tapped)
'O' ring seal
Evaporator outlet pipe
Evaporator inlet pipe
p71
4.
Before refitting, renew all the connector 'O' rings, and coat with an approved refrigerant oil.
5.
Fit the threaded clamp plate around the evaporator pipes, and secure the expansion valve onto the pipes
with the two M5 screws tightened to 5 - 6 Nm.
6.
Use the second clamp plate to secure the two pipes to the expansion valve, tightening the single M6
screw to 7 - 9 Nm.
7.
Recharge the system with 0.55 kg of R134a.
PL.11 - HEATER/EVAPORATOR/FAN UNIT
The heater matrix and a.c. evaporator are contained within a single housing together with the air blender
temperature control flaps. The housing is mounted in the chassis climate chamber where it is clipped to the fan
blower unit, and retained by a simple clamp bracket.
Note that the heater/a.c./blower unit is fitted the opposite way round between Rover and Toyota powertrain
cars: On 'Rover' cars, the blower unit is on the passenger side, and the air blend actuator on the rear of RHD
installations, and in front on LHD. On 'Toyota' cars, the blower is on the driver's side, and the air blend actuator
on the front of RHD cars and the rear of LHD.
Page 21
Lotus Service Notes
Section PL
To remove heater/evaporator/fan unit:
1.
Remove the front clamshell (see sub-section BR.6).
2.
3.
Remove the two air deflector/water shields, windscreen washer reservoir and ducting between heater/
a.c. unit and air distribution unit.
Recover the refrigerant using suitable equipment connected to the service ports at the right hand front of
the engine bay.
4.
Disconnect the refrigerant pipes as necessary and remove the receiver-drier unit and mounting bracket.
Disconnect the outlet pipe from the expansion valve. Cap all pipes and ports immediately to prevent the
ingress of dirt and moisture.
5.
Disconnect the hoses from the heater matrix and collect escaping coolant.
6.
Unplug the wiring harness from the temperature flap motor, a.c. thermostat and fan motor.
7.
Remove the clamping bridge retaining the unit into the chassis and release the overcentre clips securing
the unit to the fan blower housing. Withdraw the unit from the chassis together with the drain tube.
To refit heater/evaporator/fan unit:
Before refitting the unit, first ensure that the following components are fitted in the chassis:
Fresh air intake ducting/re-circulation valve assembly, retained in channel at front of chamber by single
clamp bracket. Check that re-circ. flap stepper motor harness is connected, and that the moulded plastic
water shield is fitted over the actuator.
Recirc. ducting is fitted in rear of chassis climate chamber
Earth cables are connected to chassis negative post at the left hand side of the chamber.
Rear circuit brake pipe is fitted between master cylinder and bulkhead connector.
Position the fan housing into the passenger side of the chassis chamber. Fit the drain tube into the base
of the heater/evap. unit and use a guide wire or similar to aid routing of the tube through the chassis crossmember
via the central aperture at the back of the chamber, as the unit is fitted into the chamber. Engage the lower
edges of the fan unit and heater/evap. unit before clamping together with the two overcentre latches. Retain
the assembly by fitting the bridging clamp bracket.
Continue re-assembly in reverse order to removal.
PL.12 - AIR DISTRIBUTION UNIT
The airflow distribution unit is mounted on top of the chassis scuttle, sandwiched between the underside
of the fascia top/demist duct and the chassis. The unit comprises several plastic mouldings bonded and
rivetted together to contain the rotary flap for windscreen/face level vents, and also the footwell flap. The
stepper motor for the rotary flap is mounted on the side of the unit.
To Remove
1.
Remove the front clamshell (see sub-section BR.6) and washer bottle and wiper mechanism (see subsection MP.8).
2.
Remove the air trunking between the heater/a.c. unit and the distribution unit.
3.
Release the fixings securing the heater water pipe to the chassis scuttle.
4.
Drill out the rivets securing the distribution unit retaining bracket to the chassis scuttle.
5.
Withdraw the unit from beneath the scuttle baffle panel, disconnecting the stepper motor harness plug
when access allows.
Page 22
Lotus Service Notes
6.
Section PL
Refit in reverse order to removal, ensuring that the sealing foam between the unit and baffle panel and on
the chassis scuttle is present and in good condition. Secure by re-rivetting the retaining bracket.
PL.13 - REFRIGERANT PIPES
The main feed and return (high pressure liquid and low pressure suction) lines to the compressor take the
form of aluminium pipes routed along the outside of the RH chassis rail, such that removal of the body sill panel
is required for access to the pipes. Replacement of the pipes is unlikely to be necessary other than as a result
of accident damage, in which case the body sill will be replaced in accordance with Service Notes Section BQ.
PL.14 - AIR BLENDER & RE-CIRC. FLAP ACTUATORS
The stepper motor (actuator) for the air temperature blender flap is mounted on the side of the heater/a.c.
casing and is secured by two screws. A moulded plastic cover is hooked over the actuator to provide protection
from direct water contamination. On installations where the actuator is on the rear of the unit (RHD Rover
powertrain; LHD Toyota powertrain), access to the actuator requires the unit to be removed from the chassis
(see sub-section PL.12).
With the heater/a.c. unit removed, pull off the moulded water shield and release the two fixings securing
the actuator to the casing. The nuts are accessible inside the casing via the air outlet aperture, but the air
blender flap may need to be moved to allow access to both nuts. In order to allow flap movement, the flap must
be mechanically disconnected from the motor by unclipping the actuator outer cover and sliding a drive gear
off its shaft.
On installations where the actuator is on the front of the unit (LHD Rover powertrain; RHD Toyota powertrain),
and the car is not fitted with air conditioning, the actuator is accessible with the unit 'in-situ'. Remove the front
clamshell (sub-section BR.6), release the harnesses from the the front edge of the climate chamber and tie
back the harnesses and water hoses to allow optimum access to the actuator. Pull off the moulded water
shield, unclip the actuator outer cover and slide off a drive gear to allow the flap to be moved for access to the
two fixing nuts inside the casing. To aid reassembly, it is recommended to glue the two fixing spacers in
position.
The re-circulation flap actuator on both RHD and LHD cars is accessible only with the heater/a.c. unit
removed. If this should occur, the re-circ. flap actuator water shield should be fitted (if not already present) by
withdrawing the re-circ. flap assembly from the channel in the front of the climate chamber, hooking the water
shield over the actuator and refitting into the chassis, noting that the actuator lead is looped downwards to
prevent water tracking along the lead and into the actuator.
Early cars built before May 2004 will benefit from the fitment of an extended clamshell gutter (if not
already fitted). On later cars, the fettling of the clamshell was revised to prevent water spilling directly into the
actuator area.
Parts Required
Gutter Extension Panel, RHD
Gutter Extension Panel, LHD
Part Number
A117B0703K
A117B0704K
Qty
1
1
1.
Remove both front body access panels, and the two louvre panels. Remove the two air deflector panels
to which the louvre panels attach.
2.
The rear of the radiator is secured by two pairs of screws along the top rear edge. Release the inboard
screw on each side.
3.
Before attempting to install the new gutter extension panel, protect the top surface of the radiator with a
rigid plastic sheet or similar to avoid damage to the delicate finning. Manoeuvre the gutter extension
panel into the underside of the clamshell spine, and retain with the two radiator fixing screws. Note that
the panel incorporates a hot air dam for the spine area.
4.
Refit the two air deflector panels, the louvres and the access panels.
Page 23
Lotus Service Notes
Section PL
Hot air dam
Gutter extension panel
Radiator
inboard fixing
sb79
Page 24
Lotus Service Notes
Section QH
CLUTCH
SECTION QH
Sub-Section
Page
General Description
QH.1
3
Clutch Pedal
QH.2
3
Hydraulic Release System
QH.3 3
Clutch Assembly
QH.4
6
Supplement for 2011 Elise
QH.5
9
Page 1
Updated 9th June 2010
Clutch cover
Steel pipe
Hose abutment
brackets
pl4701mt
Flexible hose
Lotus Service Notes
Page 2
Updated 9th June 2010
Pipe adaptor
Steel pipe
Fork
gaiter
Release
fork
Master cylinder
Slave
cylinder
Release bearing
Bleed nipple
Bearing retaining spring
GENERAL LAYOUT
Friction plate
Section QH
Lotus Service Notes
Section QH
QH.1 - GENERAL DESCRIPTION
The driving element of the clutch assembly consists of the rear face of the engine flywheel, and a pressure plate fixed to the flywheel via the spring diaphragm clutch cover assembly. The driven element, is a single,
dry, double sided friction plate, splined to the gearbox input shaft, and interposed between the flywheel and
pressure plate. The diaphragm spring in the clutch cover clamps the friction plate between the pressure plate
and flywheel to provide the drive connection between engine and gearbox. The gearbox input shaft, on which
the friction plate is free to slide axially, is 'overhung' from the gearbox, with no spigot bearing in the rear end
of the crankshaft.
The hydraulic clutch release mechanism uses a master cylinder fixed to the pedal box, and a slave cylinder bolted directly to the transmission case. The master cylinder is connected to the fluid reservoir of the brake
master cylinder, and uses a steel pipe routed along the outside of the LH chassis side rail to connect with the
slave cylinder via a flexible hose. The slave cylinder operates a release fork which pivots on a ball end fulcrum
pin and presses the release bearing against the inner ends of the diaphragm spring fingers, which pivot about
their fulcrums and relieve the clamping force applied to the pressure plate via the diaphragm outer edge. The
release bearing slides on a guide sleeve surrounding the gearbox input shaft. A preload spring inside the slave
cylinder applies light pressure to the release lever in order to ensure that contact between the release bearing
and diaphragm spring fingers is maintained.
No routine adjustment of the clutch or release mechanism is required. The clutch slave cylinder is self
adjusting, with the 'rest' position of the piston dependent on the thickness, or degree of wear, of the friction
plate. As wear of the friction plate takes place, and its thickness is reduced, the slave cylinder piston is pushed
progressively further back on the return stroke with fluid being returned to the master cylinder reservoir.
QH.2 - CLUTCH PEDAL
The clutch pedal is machined from an aluminium alloy extrusion which is common to the brake and
throttle pedals, with an extruded footpad keyed, bonded and rivetted to the bottom of the pedal. Synthetic 'top
hat' bushes are used to provide maintenance free articulation on the steel pivot shaft, with a pair of synthetic
bearing rings supporting a cylindrical steel trunnion to actuate the master cylinder pushrod. Note that the two
synthetic bearing rings may be replaced with the pedal 'in-situ', by using a suitable bolt with clamp washers to
press the rings into position. Each bush has an outer diameter chamfer at one end to aid insertion.
The master cylinder pushrod is captive in the end of the master cylinder and is screwed fully into the
pedal trunnion. With the clutch pedal released, there should be a clearance between the pedal and the pedal
box in order to allow the master cylinder to 'top out'. Conversely, the pedal should contact the floor before the
cylinder 'bottoms out'.
QH.3 - HYDRAULIC RELEASE SYSTEM
Master Cylinder
The clutch master cylinder is mounted on the pedal box, and is accessible from within the front services
compartment. The cylinder is not equipped with its own fluid reservoir, but instead is linked via hose to the
adjacent brake fluid reservoir. There is no provision for any servicing of the master cylinder, and if found to be
faulty, the unit should be replaced.
-
-
-
-
-
To replace the master cylinder:
Clean the master cylinder and surrounding area with methylated spirit. Do not use petrol or paraffin.
Take all necessary precautions to guard against contamination of painted surfaces with brake fluid.
Disconnect and immediately plug and cap the hose connection to the fluid reservoir, and the output pipe
connection.
From inside the footwell, remove the two bolts securing the cylinder to the pedal box. Withdraw the
cylinder from the front services compartment.
To refit, reverse the removal procedure, taking care to feed the pedal pushrod through the dust boot and
into the end of the master cylinder as the cylinder is positioned. Tighten the outlet pipe connection to
20 - 24 Nm and bleed the hydraulic system of air.
Page 3
Updated 9th June 2010
Lotus Service Notes
Section QH
Pedal box
Connection to fluid
reservoir
Clutch master cylinder
Mounting bolt
Pedal pushrod
Clutch pipe
connector
q51
Slave Cylinder 2ZZ & 1ZR Powertrain
The slave cylinder is secured by two bolts directly to the clutch housing on the forward side of the unit,
and operates the clutch fork by a fixed length pushrod. A bleed nipple is provided by which to bleed air from
the hydraulic system.
Mounting bolts
Slave cylinder
Clutch fork
Bleed nipple
Steel pipe
Hose connection
Page 4
Updated 9th June 2010
q52
Lotus Service Notes
-
-
-
-
-
-
-
-
-
-
-
-
Section QH
To replace the slave cylinder:
Clean the slave cylinder and surrounding area with methylated spirit. Do not use petrol or paraffin.
Take all necessary precautions to guard against contamination of painted surfaces with brake fluid.
Unscrew the pipe union nut from the slave cylinder and drain the hydraulic fluid into a suitable container.
Cap both pipe and cylinder port to limit fluid loss and prevent dirt ingress.
Remove the two cylinder retaining bolts and withdraw the cylinder and pushrod assembly.
Remove the cylinder boot and pushrod.
Tap the cylinder or use a low pressure airline to remove the piston and spring from the cylinder.
CAUTION - Use a workshop towel to protect against hydraulic fluid spray, and protect painted surfaces
from contamination.
Thoroughly clean the cylinder bore using hydraulic fluid. If any scoring, corrosion, damage or wear is
evident, the cylinder assembly should be renewed.
When refitting the piston and spring, use Lithium soap based glycol grease on the piston and seal before
carefully inserting the spring and piston into the cylinder.
Fit the pushrod into the boot and the boot to the cylinder.
Fit the cylinder with the tie wrap bracket to the clutch housing, and torque the two fixing bolts to 12
Nm.
Fit the hydraulic pipe to the slave cylinder and torque to 15 Nm.
Bleed the hydraulic system and tighten the bleed nipple to 8.4 Nm.
Bleed nipple Slave cylinder Spring
Piston
Pushrod
Fixing bolts Tie wrap bracket
Boot
q53
Hydraulic Pipe
A rigid steel pipe is used to convey the hydraulic fluid from the master cylinder to the left hand front corner of the engine bay. The pipe is routed through the dash baffle panel and down the LH 'A' post to run along
the outside of the chassis LH main siderail, within the composite sill member, clipped to the heater pipe. The
pipe terminates at a bracket rivetted to the rear end of the chassis siderail, where it connects to a flexible hose
secured at its other end to a bracket on the clutch housing. A short steel pipe links this joint to the clutch slave
cylinder, which uses a 'quickfit' push-in connector to aid production line assembly.
Page 5
Updated 9th June 2010
Lotus Service Notes
Clutch master cylinder
Section QH
Dash baffle panel
Steel pipe clipped
to heater pipe
Steel pipe
Slave cylinder
q46a
Flexible hose
to engine
QH.4 - CLUTCH ASSEMBLY 2ZZ & 1ZR POWERTRAIN
The clutch assembly comprises the friction plate, clutch cover assembly (pressure plate/diaphragm
spring/cover) and release bearing. For access to the clutch assembly, the engine and transmission must be
separated.
Removal of clutch assembly:
The transmission may be removed from below: 1.
Remove the LH rear suspension assembly (refer to sub-section DH.3), both driveshaft assemblies (refer
to sub-section FJ.4) and the exhaust system.
2.
Disconnect the clutch release fork, gearchange cables, earth braid and reverse light switch.
3.
The engine must be supported to allow the engine and transmission mountings to be disconnected and
the power unit tilted as necessary to allow the transmission to be withdrawn. The clutch bell housing is
secured to the engine by 8 bolts as shown overleaf.
4.
Matchmark the clutch cover to the flywheel before progressively loosening each clutch cover bolt half a
turn at a time until clutch cover spring pressure is released. Withdraw the cover from the flywheel dowels
taking care not to allow the friction plate to drop.
5.
Pull the release fork off the fork pivot ball, and withdraw fork and release bearing from the transmission.
Inspection
1.
Clutch cover: Check the surface of the pressure plate for scoring or discolouration through overheating.
Check the fingers of the diaphragm spring for excessive wear at the release bearing contact surface. If
any fingers are indented to a width greater than 6mm, or a depth of 0.5mm, the cover assembly should be
renewed. If the cover is accidentally dropped, the setting or balance of the assembly could be disturbed.
Replacement of the cover is recommended.
Page 6
Updated 9th June 2010
Lotus Service Notes
2.
Section QH
Friction plate: Check the cush drive springs for breakage or cracking of the hub. Examine the condition
of the friction material for signs of oil contamination, scorching, or any other damage. Using vernier callipers, measure the depth of the rivet heads below the surface of the friction material.
Minimum depth: 0.3mm.
With the friction plate mounted on its splines, check the run-out at the outer edge of the friction surface:
Maximum run-out: 0.8mm.
If addressing symptoms of clutch judder, or if any of the above inspections are not passed, renew the
friction plate.
3.
Release bearing: Check the bearing for discernible play, noise or rough feeling, and renew if there is any
doubt.
4.
Flywheel: Using a dial test indicator, measure the axial run-out at the outer edge of the flywheel drive
surface.
Maximum runout: 0.1mm.
If necessary, renew the flywheel. When fitting the flywheel:
- progressively tighten the eight fixing bolts in a diametrically opposite sequence, to 49 Nm.
- mark the angular position of each bolt head, and further tighten each bolt in a diagonally opposite sequence an additional 90°.
Refitting clutch assembly
1.
Using a universal type centralising mandrel, position the friction plate with the 'flatter' side towards the
flywheel, and fit the clutch cover onto the flywheel dowels with the match marks aligned (if applicable).
2.
Fit the clutch cover retaining bolts finger tight and monitor friction plate centralisation as the bolts are
progressively tightened in a diagonally opposite sequence to 19 Nm.
3.
Using a dial test indicator, measure the diaphragm spring tip height variation. Maximum variation:
0.5mm.
If necessary, use a special clutch tool to achieve the specification.
4.
If the release fork pivot ball had been removed, refit and tighten to 37 Nm.
5.
Apply sparing quantities of Molybdenum Disulphide (MoS2) grease to the contact points of the release
fork fingers, release fork pivot, fork retaining spring and pushrod socket. Also apply sparingly to the
transmission input shaft splines.
6.
Fit the release bearing and fork together, and position in the clutch housing with the fork retained on the
pivot ball by its retaining spring. Fit the dust boot into the housing aperture.
7.
Refit the engine to the transmission in reverse order to removal, tightening the clutch housing bolts as
follows:
M12 x2; Upper
64 Nm
M10 x2; RH side
37 Nm
M10 x2; Starter Motor 37Nm
M10 x2; Sump
23 Nm
Illustration overleaf.
Page 7
Updated 9th June 2010
Lotus Service Notes
Section QH
Clutch housing to engine fixings - viewed from gearbox side (2ZZ shown)
M12x55 flange head bolts to block; 64 Nm
M10x65 bolts also secure
starter motor; 37 Nm
M10x55 bolts to
block; 37 Nm
M10x30 bolts to sump; 23 Nm
Page 8
Updated 9th June 2010
f134
Lotus Service Notes
Section QH
QH.5 - SUPPLEMENT FOR 2011 ELISE - 1ZR POWERTRAIN
The 2011 model Elise is fitted with a conventional single dry plate clutch with diaphragm spring cover,
but the 1ZR powertrain uses a concentric type clutch release slave cylinder mounted inside the clutch housing
and surrounding the transmission input shaft.
Diaphragm spring
clutch cover
Transmission
input shaft
Concentric
slave cylinder
Engine crankshaft
Flywheel
f148
The hydraulic pipe enters the housing from above, via a union equipped with a bleed nipple for the
expulsion of air from the system. Access to the slave cylinder is available only after separation of the engine
from the transmission.
For overhaul and repair procedures refer to CD T000T1523F and select:
-
New Car Features
-
2008/11 Update
-
New Features
-
Clutch
Page 9
Updated 9th June 2010
Lotus Service Notes
Section WD
AIRBAG SYSTEM
SECTION WD - ELISE/EXIGE
Sub-Section Page
General Description
WD.1
3
Airbag Tell Tale
WD.2
3
Data Link Connector
WD.3
3
Trouble Codes
WD.4
4
Diagnostic Scanner Tools
WD.5
4
Safety Precautions, Shipping, Storage & Disposal
WD.6
8
Theory of Operation
WD.7
11
Sensor & Diagnostic Module (SDM)
WD.8
13
Driver Airbag Module
WD.9
14
Rotary Connector
WD.10
15
Passenger Airbag Module
WD.11
16
Seat Belt Pre-tensioners
WD.12
18
Page 1
Lotus Service Notes
Section WD
WD.1 - GENERAL DESCRIPTION
The airbag Supplementary Restraint System (SRS) was introduced on the Lotus Elise for USA markets,
first produced for 2005 model year. This was then offered as an option for other LHD markets, and later for
RHD. From 2008 model year, all cars were so equipped. The SRS comprises driver and passenger frontal
airbags and pyrotechnic seat belt pre-tensioners for both the driver and passenger. The airbag system is
supplemental to the seat belts, and does not render the seat belts redundant. Seat belts have proven to be the
single most effective safety device, and should be worn at all times by both driver and passenger, no matter
how short the journey. Properly worn seat belts also ensure that the seat occupant is in the best position for full
effectiveness of the airbag.
WARNING: Airbags inflate with great force, in a fraction of a second, and if a vehicle occupant is too
close to the airbag (less than 10 inches {250 mm}) or incorrectly positioned, they could be killed or
seriously injured.
The SRS is designed to operate when the vehicle is involved in a frontal, or near frontal collision, and the
impact (rate of deceleration) as detected by a vehicle mounted sensor, is sufficient to warrant airbag and seat
belt tensioning protection to both occupants. The airbag for the driver is housed in the centre of the steering
wheel, and that for the passenger in the front of the fascia. When triggered, both bags inflate in a fraction of a
second to form a cushion for the driver's and passenger's upper bodies. The bags then deflate very rapidly to
minimise any obstruction to the driver. Initiated at the same time as the airbags is a pyrotechnic device on
each seat belt reel assembly, which uses a rack and pinion mechanism in order to apply a tightening force to
the belt reel and remove any slack from the belt. The force sustained by the belt and its user is then controlled
by a torsion bar within the belt reel to limit the deceleration force to which the occupant is subjected.
Note that the SRS will deploy only in moderate to severe frontal and near frontal collisions, and is not
designed to be triggered in rollover, rear or low speed frontal collisions, or in some types of side impacts.
The system incorporates a self-diagnostic facility, which continuously monitors the SRS electrical circuits
for faults, and if necessary, lights a tell tale lamp in the instrument cluster. Most components of the SRS will
require replacement after an airbag deployment.
WD.2 - AIRBAG TELL TALE
A tell tale lamp in the instrument cluster will light for a few seconds following ignition switch on, and then
go out. If the lamp remains lit, or comes on at any other time, a fault in the airbag system is indicated.
WARNING: If the airbag tell tale does not operate as described above, a fault in the SRS system is
indicated. The airbags may not inflate correctly or at all, or may inflate without warning. The system
should be interrogated using Lotus Scanner tools, and diagnosed and rectified without delay.
Main harness
WD.3 - DATA LINK CONNECTOR (DLC)
In order to provide for communication
with the SRS Sensing and Diagnostic Module
(SDM), Lotus Scanner tools may be plugged
into the special 16 terminal harness connector socket, known as a Data Link Connector,
located off the main harness and accessible
from the passenger footwell. Communication
with engine management and anti-lock brakes
is also available via this connector.
em235a
Data Link Connector (DLC)
Page 3
Lotus Service Notes
Section WD
WD.4 - TROUBLE CODES
All the time the ignition is switched on, the Sensing and Diagnostic Module (SDM) continuously monitors
the resistance of various parts of the SRS electrical circuit, and compares these values with pre-programmed
tolerance bands to enable it to recognise 'faults' in the system and light the airbag tell tale lamp in the instrument cluster. If such a fault is detected, the SDM stores a 'Trouble Code' for that particular type of fault in its
memory.
i).
Current (Present) Codes - Faults that are currently being detected. Current codes are stored in the SDM
Random Access Memory (RAM), which will be cleared if the vehicle battery is disconnected.
ii). History (Not present) Codes - All faults detected since the last time faults were cleared from the memory
using the Lotus Scan tool. History codes are stored in the SDM Electronically Erasable Programmable
Read Only Memory (EEPROM) and are not cleared if the battery is disconnected.
Vehicle crash data is also stored in coded form in the SDM and is not erasable. New SDMs are supplied
only against V.I.N. and on exchange with the old unit.
WD.5 - DIAGNOSTIC SCANNER TOOLS
In order to provide for communication with the airbag SDM, engine management system ECU and antilock brake system, a hand held electronic scanner 'Lotus Scan 3' (part number T000T1418F), may be plugged
into the Data Link Connector (see earlier)
Amongst the operations available using the 'Lotus Scan 3' tool are:
Reading of Trouble Codes
Clearing of Trouble Codes
Reading live data
Operating instructions are provided with the tool.
Important Note
The power supply transformer is used for overnight charging of the printer, and also for powering the
Scan 3 tool during software downloading from a PC (personal computer). For the software download operation, the Scan tool requires a power supply from the mains via the transformer and an inverter. Two types of
inverter have been used; early kits used an adaptor lead to plug into the bottom end of the Scanner tool. Later
kits use an adaptor plug fitting into the top end of the scanner.
When charging the printer, it is most important that the inverter is NOT used, or damage to the
transformer may be caused. Incorrect connection is possible only with the early type adaptor lead, with which
extra care should be exercised.
1.
Reading data from vehicle
Data Link Connector (DLC)
(front of passenger footwell)
Scan tool
Printer
em192a
Page 4
Lotus Service Notes
2.
Section WD
Downloading software from P.C.
With early type adaptor lead
Connect to COM
port on PC
Power
supply
transformer
Adaptor lead used
to connect to
transformer
em192c
With later type adaptor
Connect to COM
port on PC
Power
supply
transformer
Power supply adaptor
3.
em192f
Charging printer
Power supply
transformer
Do NOT use adaptor
lead for this application
Printer
Page 5
Lotus Service Notes
Section WD
Lotus TechCentre - 2008 model year
All USA market cars from ’08 model year onwards, are required by legislation to use a CAN compliant onboard diagnostic system. This has been commonised for all Elise/Exige models. The Lotus Scan 3 tool is
replaced by a ‘stand alone’ lap top PC loaded with ‘Lotus TechCentre’ software to allow the CAN based serial
data to be read.
Controller Area Network (CAN) is an electronic standard to allow high speed communication between
modules and controllers, via a serial data bus. The bus is a circuit linking the modules to the controller,
consisting of a pair of cables, twisted together to reduce electromagnetic interference, and carrying a square
wave voltage signal corresponding to ‘0’s and ‘1’s, coded in such a way as to identify and prioritise the individual messages. On the Elise/Exige, CAN based systems for 2008 onwards include; engine management,
anti-lock braking and related features, tyre pressure monitoring and onboard diagnostics.
A Vehicle Communication Device (T000T1472F) introduced for the Europa model is used to connect the
vehicle to the laptop Lotus TechCentre. All system interrogation and diagnosis are carried out via the Lotus
TechCentre.
The minimum specification of the laptop computer for installation of the Lotus TechCentre is as follows:
-
Processer 1.70 Ghz;
1 GB RAM;
40 GB HDD;
CDRW DVD ROM;
WIN XP PRO or VISTA;
USB interface;
Ethernet or Wireless LAN
Note that this laptop should be dedicated soley to the Lotus TechCentre, with no other software installed.
This diagnostic software is designed primarily for use by trained Lotus technicians, and is available as a CD
under part number T000T1510F (version 4) or later supercessions. A monthly (Lotus Dealers) or annual (nonLotus dealers) licence and support fee will also be levied, providing access to Lotus TechCentre Technical
Support phoneline on 0870 9493 668, and e-mail on [email protected]
Also required is a unique 18 character licence/registration key without which Techcentre will not function.
This key is non transferable to other PC’s.
Scope of Lotus TechCentre
Model
Elise
Exige
Europa
2-11
Evora
Esprit
2004 on
2004 on
2006 on
2007 on
2009 on
V8
Type of Electronic Control Unit
Communication compatible
EMS
ABS
SRS
TPMS
Y
Y
Y
Y
Y
Y
Y
Y
N
Y
Y
N/A
Y
Y
N/A
N/A
Y
Y
Y
Y
Y
Y
N
N
IP
N
N
N
N
Y
N
Engine ECU
Reprogrammable
08 MY on
Y
Y
N
Y
Y
N
Note that TechCentre has no connectivity to Rover powertrain Elise/Exige variants, and that only limited
diagnostics are available for the V8 Esprit. No communication is available with the Europa powertrain. Diagnostics for these vehicles are accessible using the Lotus Scan 3 tool T000T1467F (U.K./EU).
Page 6
Lotus Service Notes
Section WD
TechCentre Connection
TechCentre connection to the car is made via the Vehicle Communication Device (VCD) and the Data
Link Connector (DLC) located at the front of the passenger footwell. The yellow connector lead is used to
connect the VCD to the car, and a USB lead connects the VCD to the laptop PC.
Power for the VCD is taken from the vehicle battery via the DLC and when powered, a blue tell tale on the
unit will light. Should updated firmware be available for the VCD (usually downloaded as part of an online
update) TechCentre will automatically update the VCD and display a message to confirm.
The VCD, under part number T000T1472F is supplied in a black plastic carry case containing the following:
VCD
16 Pin Yellow connector lead (VCD to Vehicle)
USB lead (VCD to PC)
USB extension lead (VCD to PC)
Use of TechCentre
Instructions for using the TechCentre are available in the ‘Technical Information’ section displayed on
programme start up.
Page 7
Lotus Service Notes
Section WD
WD.6 - SAFETY PRECAUTIONS, SHIPPING, STORAGE & DISPOSAL
WARNING: The SDM can maintain sufficient voltage to cause an airbag deployment for up to 20
seconds after the battery has been disconnected. Before working on the airbag system, or in close
proximity to an airbag, first take the following precautions to temporarily disable the airbag system:
1.
2.
3.
4.
5.
Turn off the ignition.
Before disconnecting the battery, use the Lotus Scan tool to read any stored trouble codes.
Disconnect the negative (earth) lead from the battery and tape back to ensure that no contact with the
battery negative terminal can be made.
Wait for 30 seconds.
If working on or near the steering wheel, locate the yellow harness connector alongside the steering
column near the column upper fixing. Unplug this connector. Note that the connector is fitted with
'shorting bars' which automatically interconnect the high and low terminals of the airbag to prevent accidental deployment caused by a voltage differential.
When service work has been completed, reconnect the harness plug and secure with its locking feature,
and reconnect the battery. Ensure the airbag tell tale lights for a few seconds with ignition and then goes out.
Storage
Airbag modules and SDMs should not be stored at temperatures above 176°F (80°C).
Airbag modules and SDMs should not be stored in damp conditions.
Do not store airbag module or SDM boxes more than two high.
Always store and handle airbag modules and SDMs in an upright position. Never store SDMs upside
down.
Sensor & Diagnostic Module (SDM)
The SDM is calibrated specifically to the Elise/Exige, and is mounted on a dedicated bracket to the scuttle
beam. Never use an SDM from another vehicle, or modify its mounting to the Elise/Exige.
WARNING:
•
Handle the SDM with great care. Never strike or jar the SDM as this could cause airbag deployment and result in personal injury or improper operation of the SRS.
•
All module and mounting bracket bolts must be correctly installed and tightened to assure proper
security and operation.
•
Never power up the SRS when the SDM is not properly mounted and secured, since the SDM is
easily triggered when not attached, and could result in deployment causing personal injury.
•
Do not use or attempt to repair a damaged SDM.
Inflator Module
Live (Undeployed) Inflator Modules: Special care is necessary when handling and storing a live (undeployed)
inflator module. In the unlikely event of accidental deployment, the rapid gas generation produced during
deployment of the air bag could cause violent movement of the inflator module or surrounding objects, and
result in personal injury.
WARNING:
•
When carrying a live inflator module, make sure the bag and trim cover are pointed away from
you. In case of an accidental deployment, the bag will then deploy with minimal chance of injury.
•
When placing a live inflator module on a bench or other surface, always face the bag and trim
cover upwards, away from the surface. This is necessary so that a free space is provided to allow
the air bag to expand in the unlikely event of accidental deployment. Otherwise, personal injury
may result.
•
Never carry the inflator module by the wires or connector on the underside of the module.
•
Do not use or attempt to repair a damaged inflator module, and NEVER apply any electrical power
to the module except as specified in the diagnostic procedures.
Inflator Module Shipping Procedures for Live (Undeployed) Inflator Modules
The transportation of uninstalled inflator modules is regulated by the Hazardous Materials Regulations of
Page 8
Lotus Service Notes
Section WD
the U.S. Dept, of Transportation (DOT) and most state governments. Special procedures are required for
transportation. Lotus recommends that the dealers and repair shops check with the hazardous material section
of their respective state police authority for applicable shipping requirements.
For all shipments on public roads, the DOT has classified the uninstalled inflator module as a flammable
solid under a special exemption process. It should always be shipped and stored in the approved cardboard
container in which it is purchased. The container should be marked with “Flammable Solid , n.o.s., UN1325,
DOT-E8236” and labelled with the specified red and white flammable solid label. Each shipping location must
have a copy of the exemption on file. A shipping paper (e.g., a customer receipt) must accompany each
shipment and identify the module as “Flammable Solid, n.o.s., UN1325, DOT-E8236”. Transportation, storage
and handling of the module should be in accordance with the exemption and the requirements for a DOT
flammable solid. Do not expose the module to heat, open flame, impact, friction, or electrical charge.
Inflator Module Scrapping Procedures
WARNING: Failure to follow proper SRS inflator module disposal procedures can result in airbag
deployment which may cause personal injury. Undeployed inflator modules must not be disposed of
through normal refuse channels. The undeployed inflator module contains substances that can cause
severe illness or personal injury if the sealed container is damaged during disposal. Disposal in any
manner inconsistent with proper procedures may be a violation of federal, state and/or local laws.
Reference should be made to the local State authority for the correct disposal procedures for deployed
inflator modules.
Vehicle Scrapping Procedures
Some vehicles equipped with SRS that have live (undeployed) inflator modules may have to be scrapped
because they have completed their useful life, or have been severely damaged in a non-deployment type
accident. The following procedure should be followed when scrapping a vehicle with an undeployed module.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Follow the safety procedure detailed in sub-section WD.6 to turn off the ignition, disconnect the battery
and unplug the yellow 4-way connector to the inflator module, alongside the steering column.
Follow the procedure detailed in sub-section WD.11 to gain access to the passenger airbag module.
At the driver's airbag harness alongside the steering column, cut the harness side of the SRS wiring
approx. 3 to 6 inches from the yellow connector.
Splice 2 wires at least 20 feet long to the red/blue and the red/green coloured cables in this connector
block.
Reconnect the yellow 4-way connector block now equipped with 2 x 20ft long cables.
Check that the inflator module is secured to the steering wheel.
Remove all loose objects from the front seat.
Ensure no one is in the vehicle.
Stretch wires away from car to their full length.
Apply 12 volts across the wires to deploy the air bag.
Do not touch the inflator module area for 20 minutes due to the heat generated during deployment.
Wear gloves and safety glasses to handle the deployed air bag. Wash your hands with mild soap and
water afterwards.
Repeat steps 3 to 12 for the passenger airbag, splicing the 20ft cables into the two wires connecting the
SDM to the airbag.
Deployed Inflator Modules
WARNING: Safety precautions must be observed when handling a deployed inflator module. After
deployment, the air bag surface may contain a white packing powder used to ease deployment, together with a small amount of sodium hydroxide dust, a by-product of the sodium azide reaction
during deployment that can be irritating to the skin if left on for an extended period of time. Always
wear gloves and safety glasses when handling a deployed inflator module, and wash your hands with
a mild soap and water afterwards.
Page 9
Lotus Service Notes
Section WD
Airbag Activation/Disposal Procedure
Items Required
2
People.
2 Pairs
Heat proof gloves.
2 Pairs
Eye protection glasses.
2 Pairs
Ear defenders.
Explosion container – a container to constrain the sudden inflation of the bag, may be mesh e.g. metal stillage,
but requires a lid.
Sandbags, - to keep lid closed.
12 volt power supply.
Various air bag & seat belt wiring connectors / small crocodile clips.
10 meters Detonation wire
Paint marker pen
Dustbin / recycling container.
Weather Conditions.
Calm, clear, dry day with very little wind.
Place power supply upwind of explosion.
Location.
Any isolated area.
Detonation Wires
Procedure.
·
Circuit diagram as shown.
·
Make sure the power supply is turned off
and is situated the length of the detonation wires away from the airbag.
Airbag
·
Only detonate ONE at a time.
·
Ensure the detonation wires are disconnected from the power supply.
·
Place 1 airbag into the explosion conCage
tainer and connect the detonation wires.
Do not snag wires.
·
Secure lid with sandbags.
·
Put on your Eye & Ear protection.
·
Connect the detonation wires to the power supply, doesn’t matter on polarity.
·
Turn the power supply on.
·
AIRBAG WILL DETONATE AND INFLATE.
·
Turn power supply off and disconnect detonation wires from the power supply.
·
Put on your heatproof gloves.
·
Remove the airbag from the explosion container and disconnect the detonation wires.
·
Mark-up and place the detonated airbag into the recycling container.
·
Repeat this procedure as many times as required.
Page 10
Switch
Battery
Page 6a
Lotus Service Notes
Section WD
Inspections Required After an Accident
All SRS system components, including harnesses and brackets, must be inspected after an accident. If
any are damaged or bent, they must be replaced even if a deployment did not occur. If the SRS was deployed,
the following components MUST be renewed even if there is no visible damage to the parts:
Driver airbag module;
Passenger airbag module;
Sensor & Diagnostic Module (SDM);
Driver and passenger pyrotechnic seat belt assemblies;
Rotary connector;
Passenger airbag mounting brackets (2);
Passenger airbag shute (2);
Passenger airbag door assembly (trim panel);
Dash panel upper extrusion.
Inspect the steering column for damage or telescoping (see Section HG) and column mounting brackets
for damage. Inspect the chassis scuttle beam in the area of the passenger airbag mounting brackets for
damage or distortion. Inspect the SRS wiring harness and connectors for damage or any signs of overheating.
Do not attempt to repair the steering column or chassis or any of the above mentioned components. Service
is by replacement only.
WARNING: Proper operation of the SRS system requires that any repairs to the vehicle structure
return it to its original production configuration. Deployment, or any visible damage to the SRS components and/or their respective mounting brackets requires replacement, not repair.
WD.7 - THEORY OF OPERATION
•
•
•
•
•
The key components of the Supplementary Restraint System (SRS) are the following:
Sensor & Diagnostic Module (SDM);
Driver airbag module;
Passenger airbag module;
Rotary connector;
Seat belt pre-tensioners.
Sensor & Diagnostic Module (SDM)
The SDM is the main electronic control unit (ECU) of the SRS, whose function is to detect rates of forward
deceleration, and when interpreted as a collision accident requiring supplementary occupant protection, the
SDM triggers as a single set, the driver and passenger airbags and both seat belt pre-tensioners. Additional
functions are to maintain an energy reserve in case of vehicle battery power interruption, operation of a dash
mounted tell tale lamp, and a electronic diagnostic and event recording facility accessible via a workshop
scanner tool.
The unit is mounted by a dedicated bracket to the top of the passenger side scuttle beam, accessible after
removal of the fascia top.
•
•
•
The following functionality is provided by the SDM;
Sensing of frontal impact crash events and vehicle specific discrimination between non-deployment and
deployment-requiring events as well as the deployment of the frontal airbags and seat belt pre-tensioners.
In case of a required deployment, timely activation of the activation current for the deployment loops.
Detection of electrical system faults which may influence the readiness of the system to deploy, or increase the probability of an inadvertent deployment by:
- continuous electrical monitoring of all deployment circuits (without any effect on the readiness of the
system);
- continuous monitoring of the supply voltage and the lamp circuitry (dependent on lamp driver activation
status);
- SDM self test;
- activation of a tell tale lamp in case of a detected system fault.
Page 11
Lotus Service Notes
•
•
Section WD
Fault storage and 'Crashrecording' within EEPROM ('crashrecording': recording of system parameters
(e.g. fault status in deployment events).
Diagnostic communication using an ISO9141 protocol.
Frontal Impact Sensing and Deployment
The SDM contains an integrated accelerometer which provides a nearly linear proportional electrical
representation of the acceleration experienced by the vehicle along the longitudinal axis. This signal is amplified and filtered to reduce unwanted electronic noise and to compensate for offset drifts. The filtered signal is
then digitized to provide an input for evaluation by the crash algorithm. As soon as the crash algorithm detects
that pre-defined thresholds have been exceeded, the SDM activates both airbags and both seat belt pretensioners.
To enhance system reliability under normal driving conditions, an additional electromechanical 'safing'
sensor is included to ensure that the SRS is armed only when significant deceleration occurs. In order to
protect against undesired deployments in case of severe EMI, humidity or accelerometer fault, the deceleration condition monitoring by the safing sensor occurs in addition to, and independent of, the crash algorithm.
Neither the seat belt pre-tensioners nor the airbags will be activated by the SDM as long as the diagnostic
mode is active.
Fault Display
The following conditions lead to a fault display in the form of continuous illumination of the airbag tell tale.
•
One or more trouble codes requiring tell tale lamp activation in the 'historic' and 'present' condition are
stored in the SDM's EEPROM.
•
One or more trouble codes requiring tell tale lamp activation in the 'present' condition only are stored in
the SDM's EEPROM, the condition of which is, or has been, 'present' in the current operating cycle. For
all faults requiring four consecutive incidents for a trouble code to be set, the 'present' condition and fault
display will be activated already after two consecutive events if the related trouble code has already been
stored in a previous operating cycle.
•
Faults concerning the voltage supply (overvoltage/undervoltage) will lead to tell tale activation only until
the regular voltage range has been reached again (turn-off delay max. 5s after return from undervoltage
and max. 20s after return from overvoltage). There are no related trouble codes.
•
The airbag tell tale will not be activated due to SRS warning lamp related faults.
•
The tell tale will be activated immediately after entering the diagnostic mode, or on deployment of the
SRS.
Excluding the exceptions stated above, it is not possible to switch off the tell tale other than by resetting
the fault codes stored in the EEPROM. This is not possible after an airbag deployment - the SDM must be
renewed.
The following delays apply for the detection and display of faults. The delays apply from the extinguishing
of the tell tale, following the ignition switch on bulb check period:
1 to 5 secs
- for external deployment circuit faults and overvoltage supply.
12 to 20 secs - for undervoltage supply.
up to 15 secs - for SDM internal faults.
•
•
•
The tell tale will be activated without SDM intervention in the following situations:
the minimum voltage of 8.0 V has not been exceeded after switching on the ignition.
the energy reserve (in SDM) has run low, which may be caused by supply voltages below 7.8 V.
the watchdog has interfered.
A trouble code readout using tell tale blink codes is not implemented.
Power Supply & Grounding
The nominal supply voltage of +12 volts is derived from terminal 5 when the ignition is switched on. The
SDM internal ground (terminal 7) must be securely connected to the vehicle chassis ground. To provide
redundant grounding, the SDM housing is internally connected to the ground connector pin.
Supply Voltage Range
The SDM is designed to operate within the following voltage ranges:
Page 12
Lotus Service Notes
Section WD
System fault detection, SDM self test: min. 8.0 V; max. 16.0 V
Below 10.0 V system readiness may be delayed by 3 s.
Below 9.0 V system readiness may be delayed by 10 s.
System fault detection and SDM self test are reduced as long as an undervoltage condition is detected, which
could already apply for supply voltages below 10.5 V.
Activation of airbags: min. 8.0 V; max. 16.0 V.
Activation of seat belt pre-tensioners: min. 10.0 V; max. 16.0 V.
Energy Reserve
Energy reserve capacitors within the SDM are provided to allow SRS deployment if the vehicle battery
power supply is interrupted during the time of vehicle impact. The capacitors provide full support of the
acceleration sensing and airbag initiation capability for a minimum of 150 ms after a loss of external power
supply, provided that before the loss, the SDM had been supplied with:
at least 10.0 V for at least 10 s; or
at least 9.0 V for at least 13 s; or
at least 8.0 V for at least 20 s.
The capacitors will be discharged down to a point where no initiation of airbags is possible within a max.
of 20 s after removal of the power supply.
WD.8 - SENSOR & DIAGNOSTIC MODULE (SDM)
To Replace SDM
WARNING: The SDM must be replaced after SRS deployment. Do not attempt to repair or reuse.
The SDM is mounted on a bracket riveted to the top of the passenger side scuttle beam, and is accessible
only after removal of the fascia (dash) top panel.
1.
Follow the safety procedure detailed in sub-section WD.6 to turn off the ignition, disconnect the battery
and unplug the yellow 4-way connector to the inflator module, alongside the steering column.
2.
Column shrouds: Remove the two screws retaining the top part of the shroud, and the four screws
retaining the lower part, and withdraw both parts from the column.
3.
Instrument shroud: Pull the instrument shroud backwards to release the four spring clips from their
apertures in the dash panel.
4.
Sill top trims: Release the two screws at the bottom of the coin pockets at the front of each sill, and pull
the sill top trim panels from the chassis.
5.
Dash end panels: Release the two screws within the top of each coin pocket, and withdraw the switch
panel (driver's side) and blanking panel (passenger side) from the dash end panel. Unplug the wiring
harness from the switch panel.
From within the aperture, release the two screws retaining each end panel to the dash, and pull the panel
rearwards to withdraw the spring clips in the top of the panel from the dash.
6.
Airbag door: Pull the airbag door away from the dash, which action will probably require the four retaining
clips to be renewed. Note that the door is constrained by two tether straps.
WARNING:
•
The only permitted repair to the airbag door and tether strap assembly is the replacement of the
plastic retaining clips which secure the door to the dashboard. If the clips are broken, they MUST
be replaced ONLY by the correct Lotus supplied parts. Do not attempt to fix the door in position
by any other means.
•
After SRS deployment, the airbag door assembly MUST be replaced even if there is no visible
damage.
Page 13
Lotus Service Notes
Section WD
7.
Centre vent panel and radio surround: Release the two screws at each side of the panel and withdraw.
8.
Fascia top panel: Remove the 5 screws securing the rear edge of the panel to the dash rail, and withdraw
the panel rearwards to disengage the two spigots from the base of the windscreen surround. Disconnect
the speaker cables.
9.
SDM: Unplug the harness connector from the SDM. Release the four retaining nuts, and withdraw the
sensor and diagnostic module from its mounting bracket.
Refitment of the SDM is a reversal of the removal procedure, but remember to check that the tether strap
bracket for the airbag trimmed door has been secured before the fascia top panel is fitted, and that new push
fasteners for the airbag door will be required. Use Scan 3 tool or Lotus TechCentre to configure airbag system.
WD.9 - DRIVER AIRBAG MODULE
WARNING: Safety precautions must be observed when handling a deployed airbag. After deployment, the airbag surface may contain a white packing powder used to ease deployment, together with
a small amount of sodium hydroxide dust, a by-product of the sodium azide reaction during deployment that can be irritating to the skin if left on for an extended period of time. Always wear gloves and
safety glasses when handling a deployed inflator module, and wash your hands with a mild soap and
water afterwards.
The driver's airbag (or inflator module) is housed in the hub of the steering wheel, beneath a moulded trim
cover designed to hinge open in the event of deployment. The module comprises:
an inflatable fabric bag;
an inflator (canister of gas generating material)
an initiator (or 'squib')
When the vehicle suffers a forward deceleration of sufficient magnitude to close both the safing sensor
and integrated accelerometer within the SDM, current flows through the deployment loop of both the driver and
passenger airbag module initiators and ignites the gas generating material. Each bag inflates in a fraction of a
second, the driver's bag bursting open the steering wheel centre trim cover, and then deflates via vents in the
bag, with the whole cycle taking less than one second. The airbag is designed for a single deployment, and
must then be renewed.
In order to help prevent unwanted deployment of the driver's airbag when servicing the steering column or
other SRS components, a shorting bar is incorporated in the airbag side of the 4-way harness connector plug
located alongside the steering column. The shorting bar operates when the connector is unplugged, to short
across the feed and return connections to the airbag. Thus, if a positive feed, or earth is inadvertently applied
to the connector terminals, both sides of the inflator module will be subject to the same electrical potential, and
no deployment will occur.
To replace driver's airbag
WARNING: The following procedures must be followed in the order listed to temporarily disable the
airbag system whilst working in the immediate vicinity of an airbag. Failure to follow this procedure
could cause unintended airbag deployment, resulting in personal injury and unnecessary airbag system
repairs.
a). Turn off ignition.
b). Disconnect the negative battery cable, and tape back to ensure that it cannot contact the battery terminal.
c). From alongside the steering column, in the area of the column upper fixing, locate and disconnect the
driver's airbag yellow 4-way harness connector plug.
1.
Column shrouds: Remove the two screws retaining the top part of the shroud, and the four screws
retaining the lower part, and withdraw both parts from the column.
2.
On the reverse side of the steering wheel, locate and remove the two socket head screws, accessible via
holes in the plastic shroud around the steering wheel hub. Withdraw the airbag module and disconnect
Page 14
Lotus Service Notes
Section WD
the yellow harness connector.
WARNING: When carrying a live airbag module, make sure the bag and trim cover are pointed away
from you. In case of an accidental deployment, the bag will then deploy with minimal chance of injury.
When placing a live airbag module on a bench or other surface, always face the bag and trim cover
upwards, away from the surface. This is necessary so that a free space is provided to allow the airbag
to expand in the unlikely event of accidental deployment.
3.
If a driver's airbag is deployed, refer to steering section HG to determine whether the steering column
telescoping mechanism has been activated, and if necessary, renew the column assembly.
4.
Mate the new airbag yellow connector plug with the harness plug in the steering wheel hub, and locate the
module into the steering wheel. Fit the two socket head retaining screws and tighten to 7Nm.
5.
When all service work is complete, connect the harness plug alongside the steering column, and reconnect the battery. Turn on the ignition and check that the airbag tell tale lights for a few seconds and then
goes out.
WD.10 - ROTARY CONNECTOR
WARNING: The rotary connector MUST be replaced after SRS deployment even if there is no visible
damage.
The rotary connector is a device which fits between the steering wheel and column, and allows the
steering wheel to turn whilst maintaining electrical continuity to the airbag module and horn buttons. The
assembly consists of an annular housing fitted over the top end of the steering column, and containing a coil of
four wires. The wires are:
+ve feed to the inflator module (switched by the safing sensor);
ground to the inflator module (switched by the microprocessor accelerometer);
input to the horn buttons;
output from the horn buttons.
The steering column side of the device is fitted with a 4 way connector block which plugs into the SRS
harness. The steering wheel side of the device has two 2-way connector plugs, one for the airbag module, and
one for the horn buttons. The coil housing is constructed in two parts, with the outer part fixed to the outer
(stationary column, and the inner part keyed to the inner (rotating) column.
The two parts of the coil housing slide inside of each other in such a way as to allow the steering wheel
to be rotated through its full travel, lock to lock, whilst maintaining an unbroken feed to each of the four circuits
in the steering wheel hub, via the continuous wires in the coils.
In order to help prevent unwanted deployment of the air bag when servicing the steering column or other
SIR components, a shorting bar is incorporated in the rotary connector side of the 4-way SRS harness connector plug. This shorting bar operates when the connector is unplugged, to short across the feed and return
connections to the inflator module. Thus, if a positive feed, or earth is inadvertently applied to the connector
terminals, both sides of the inflator module will be subject to the same potential, and no deployment will occur.
When servicing the rotary connector, it is most important that the correct orientation of the connector is
maintained on refitment, or the connector will run out of travel and be broken.
To replace the rotary connector
1. Remove the airbag module from the steering wheel (see sub-section WD.8).
2.
Disconnect the horn harness plug.
3.
Bend back the locking tabs and release the nut securing the wheel to the column. Before attempting to
remove the wheel, ensure the front wheels are pointing straight ahead, and match mark the position of
the steering wheel hub against the column to aid re-assembly.
4.
Using a suitable steering wheel puller tool, position the legs to reach through the holes in the wheel hub
Page 15
Lotus Service Notes
Section WD
and bear directly against the hub, without interfering with the rotary connector. The centre screw should
bear against the end of the column. Withdraw the wheel/hub/rotary connector assembly from the column
splines.
Alternatively, for better puller access, the steering wheel can first be removed from the hub by releasing
the four retaining screws.
CAUTION: If excessive force is applied to either the wheel or column without an appropriate
puller, the telescoping mechanism of the outer column may be overridden, necessitating column
replacement.
5.
Release the two countersunk screws retaining the rotary connector to the steering wheel hub.
6.
On refitment, feed the airbag and horn connector plugs on the rotary connector through the hole in the
steering wheel hub, and secure the unit to the hub with the two countersunk screws. If necessary, refit the
steering wheel to the hub and secure with the four screws. Mate the horn buttons harness connector plug.
7.
Before fitting the wheel/hub/rotary connector assembly to the column, the rotary connector must be
centralised: Turn the connector centre element fully counterclockwise until tight, then turn clockwise
approximately 2.5 turns until the arrow marks on the two parts of the rotary connector are aligned. Make
sure the front wheels are pointing straight ahead, and fit the assembly onto the column with the hub to
column match marks (made on disassembly) aligned, and engage the spring loaded pin on the column
switch housing with the slot in the rotary connector.
8.
Fit a new locking tab washer, followed by the steering wheel nut, and torque tighten to 25 Nm (18.5 lbf.ft).
Bend up the locking tabs to secure.
9.
Mate the airbag harness connector plug and fit the airbag module into the steering wheel. Retain with the
two socket head screws and tighten to 7Nm.
10.
Refit the column shrouds, and when all service work is complete, mate the horn/airbag connector to the
vehicle harness (clipping the connector to the column) and reconnect the battery. Check that the airbag
tell tale lights for a few seconds with ignition, and then goes out.
WD.11 - PASSENGER AIRBAG MODULE
WARNING: Safety precautions must be observed when handling a deployed airbag. After deployment, the airbag surface may contain a white packing powder used to ease deployment, together with
a small amount of sodium hydroxide dust, a by-product of the sodium azide reaction during deployment that can be irritating to the skin if left on for an extended period of time. Always wear gloves and
safety glasses when handling a deployed inflator module, and wash your hands with a mild soap and
water afterwards.
The passenger's airbag (or inflator module) is housed within the passenger side of the fascia, mounted on
a bracket to the scuttle beam, and arranged to deploy via an aperture in the dash panel covered by a trimmed
'door'. The door is designed to break away in the event of airbag deployment, but is tethered to the dash by two
restraining straps. The airbag module comprises:
an inflatable fabric bag;
an inflator (canister of gas generating material)
an initiator (or 'squib')
When the vehicle suffers a forward deceleration of sufficient magnitude to close both the safing sensor
and integrated accelerometer within the SDM, current flows through the deployment loop of both the driver and
passenger airbag module initiators and ignites the gas generating material. Each bag inflates in a fraction of a
second, the passenger's bag bursting through the dash panel 'door', and then deflates via vents in the bag, with
the whole cycle taking less than one second. The airbag is designed for a single deployment, and must then be
renewed.
Page 16
Lotus Service Notes
Section WD
WARNING: The harness connector for the passenger's airbag is accessible only after removing the
fascia top panel, so care should be taken to avoid working in close proximity to the airbag door in case
of unintended deployment.
To replace passenger's airbag
WARNING: The following procedures must be followed in the order listed to temporarily disable the
airbag system whilst working in the immediate vicinity of an airbag. Failure to follow this procedure
could cause unintended airbag deployment, resulting in personal injury and unnecessary airbag system
repairs.
a). Turn off ignition.
b). Disconnect the negative battery cable, and tape back to ensure that it cannot contact the battery terminal.
c). From alongside the steering column, in the area of the column upper fixing, locate and disconnect the
yellow driver's airbag harness connector plug.
1.
For access to the passenger's airbag module, the fascia top panel must first be removed. Refer to subsection WD.8.
2.
From the right hand end of the airbag module, pull out the security tag and unplug the harness connector.
3.
Release the two nuts and remove the airbag door tether strap bracket from the module mounting bracket.
4.
Release the four nuts and the dash steady brackets securing the airbag module, and withdraw the module
from its mounting bracket.
WARNING: When carrying a live airbag module, make sure the bag and trim cover are pointed away
from you. In case of an accidental deployment, the bag will then deploy with minimal chance of injury.
When placing a live airbag module on a bench or other surface, always face the bag and trim cover
upwards, away from the surface. This is necessary so that a free space is provided to allow the airbag
to expand in the unlikely event of accidental deployment.
5.
If an airbag deployment has occurred, the chassis scuttle beam, airbag mounting bracket, dash extrusions and all associated parts must be carefully examined for distortion and renewed where necessary.
WARNING: Proper operation of the SRS system requires that the vehicle structure remains in its
original production configuration. Any damage to the SRS components and/or their respective mounting
brackets, including the chassis, requires replacement, not repair.
6.
If necessary, fit the airbag mounting brackets to the scuttle beam, and tighten the four M8 fixing bolts to
15 Nm.
7.
Fit the airbag module to the mounting brackets, together with the dash steady brackets. Tighten the four
M6 nuts to 6 Nm.
8.
Fit the airbox door tether strap bracket to the airbag module mounting bracket, and tighten the two nuts to
10 Nm.
9.
Plug in the harness connector into the RH side of the module and retain with the security tag.
10.
Refit the fascia top panel (see sub-section WD.8).
11.
Refit the column shrouds, and when all service work is complete, mate the horn/airbag connector to the
vehicle harness (clipping the connector to the column) and reconnect the battery. Check that the airbag
tell tale lights for a few seconds with ignition, and then goes out.
Page 17
Lotus Service Notes
Section WD
WD.12 - SEAT BELT PRE-TENSIONERS
WARNING:
•
Failure to comply with the instructions, safety standards and operating procedures as described
in this section, may cause vehicle damage and/or personal injury.
•
Both driver and passenger seat belt assemblies must be replaced after SRS deployment. Do not
attempt to repair or reuse.
Device Operation
The seat belt pre-tensioners are triggered together with the airbags, and use a pyrotechnic device on each
seat belt reel assembly, to operate a rack and pinion mechanism which applies a tightening force to the belt
reel to remove any slack from the belt. Under normal operation, the rack is fully raised and disengaged from
the pinion, allowing normal spooling of the reel for belt withdrawal and retraction.
When airbag/pre-tensioner triggering conditions apply, the SDM signals ignition of the gas generator, the
pressure from which forces the piston and toothed rack downwards, causing rotation of the pinion gear and a
re-winding of the seat belt webbing. The force sustained by the belt and its user is then controlled by a torsion
bar within the belt reel to limit the deceleration force to which the occupant is subjected during the crash event.
The belt pre-tensioning mechanism is designed to operate only once, such that both belt assemblies
should be renewed after airbag/seat belt pre-tensioner deployment. Activation of the pyrotechnic mechanism
is indicated by the belt reel being locked, and allowing neither extraction nor retraction of the belt.
WARNING: Following an impact in which the pre-tensioning element is activated, the seat belt assembly is rendered inoperable. The car should not be driven until the belt assembly has been renewed.
Electrical connector
Gas generator
Belt reel
Piston
w62
Pinion
Page 18
Rack
Lotus Service Notes
Section WD
Removal of Seat Belt Assembly
WARNING: Before removing or refitting a pyrotechnic seat belt assembly, the ignition key should be
withdrawn, and the battery leads disconnected from both positive and negative terminals, and isolated to ensure that accidental contact cannot occur.
Each seat belt reel assembly is secured, via a spacer block, to the seat belt mounting bracket/roof hoop
by a single bolt. Note that an orientation tang is incorporated on the belt reel which engages with a hole in the
spacer, and that the spacer is keyed to the mounting bracket by a roll pin.
1.
Check that the key is removed from the ignition switch.
2.
Disconnect both battery cables, and insulate to ensure that accidental contact cannot occur.
3.
Remove both seats by releasing the seat belt from the seat (noting the 10mm spacer), and the seat
runners or frame from the floor.
4.
Remove the centre tunnel rear cup holder liner after removing the single screw from inside the base.
Remove the two screws then exposed securing the cup holder, and remove the holder, disconnecting the
auxiliary power socket.
5.
Remove the 4 fixings along the top of the cabin rear bulkhead trim panel, and withdraw the panel,
disconnecting the speakers and interior lamp.
Hinge up the plastic cover and release the belt slide from the roof hoop, noting the 5mm spacer.
6.
7.
Allow at least one minute from disconnecting the battery before disconnecting the electrical connector
from the gas generator on the seat belt assembly. Release the Torx head fixing bolt and withdraw the belt
reel assembly and spacer block.
Fitment of Seat Belt Assembly
WARNING: Before removing or refitting a pyrotechnic seat belt assembly, the ignition key should be
withdrawn, and the battery leads disconnected from both positive and negative terminals, and isolated to ensure that accidental contact cannot occur.
Each seat belt reel assembly is secured, via a spacer block, to the seat belt mounting bracket/roof hoop
by a single bolt. Note that an orientation tang is incorporated on the belt reel which engages with a hole in the
spacer, and that the spacer is keyed to the mounting bracket by a roll pin.
1.
Fit the seat belt reel assembly and alloy spacer to the bracket on the mounting frame, with the spacer
block located by its roll pin into the hole in the bracket, and the belt reel tang located in the upper hole in
the spacer. Fit and tighten the single Torx head fixing bolt (discarding the cardboard retaining washer if
fitted) to 45 Nm (33 lbf.ft). Plug the harness connector plug into the gas generator on the belt assembly.
2.
Fit the belt slide to the roof hoop with the 5mm spacer interposed, and tighten the special shouldered bolt
to 45 Nm (33 lbf.ft). Check that the hoop is free to pivot. Clip the plastic cover into position.
3.
Refit the cabin rear bulkhead trim panel, connecting the interior lamp and speakers, and retain with the
four screws.
4.
Refit the cup holder, connecting the power socket, and liner.
5.
Refit the seats and fit the seat belt to the seat frame with the 10mm spacer between belt and seat. Tighten
the special shouldered bolt to 33 Nm (24 lbf.ft). Check that the belt eye is free to pivot.
6.
Reconnect the battery, turn on the ignition, and check that the airbag tell tale lamp lights for a few seconds
and then goes out.
Page 19
Lotus Service Notes
Section WD
Safety Standard
The pre-tensioning function is energised via pyrotechnic materials, therefore manipulation, handling and
storage MUST be performed to the specified procedures as described to avoid any occurrence of injury to the
operator or damage to the pre-tensioning unit.
In normal conditions, the pre-tensioner assembly can only be activated through the action of the electric
ignition control during impact. During the activation phase of the pyrotechnic charge, small gas quantities are
developed. The main constituent of the gases is Nitrogen:
Note! This gas is not toxic.
The pre-tensioner assemblies must be protected against exposure;
To temperatures over 90°C (195°F) at contact with surfaces
90°C during 106 hrs.
From sparks and naked flames.
WARNING: If exposed to temperatures in excess of 140°C, self-ignition of the pyrotechnic charge of
the gas generator may occur. Exposure to temperatures in excess of 165°C, self-ignition of the
pyrotechnic charge will occur.
Also, if exposed to temperatures between 90°C (285°F) and 165°C (330°F), deterioration of the pyrotechnic
charge ignition is possible. The consequences of this could be failure to activate at prescribed levels. The pretensioner must be protected against stresses, shocks and dropping. Pre-tensioners that have been subjected
to such treatment must be discarded and returned to the supplier with accompanying paperwork describing the
reasons for return.
Never store pre-tensioner assemblies with other flammable or combustible materials. Gas generators
MUST be prevented from coming into contact with acid, water, grease and heavy metals: Contact with these
substances may cause toxic or dangerous gases, or explosive mixtures.
Any residual fuel of the gas generator, not burned during ignition, is slightly flammable. The unit, therefore, must never be disassembled, damaged or the parts manipulated. Any advertising or demonstrations of
the pre-tensioner assembly should only be carried out using inert pre-tensioners (without the pyrotechnic charge).
The base of the pre-tensioner must be painted green, with visible and indelible wording, stating ‘Inert Assembly’. It must incorporate the KSS logo, signed with indelible ink by the person responsible for the supply of the
product.
WARNING: Never disassemble the pre-tensioner or any of it’s components!
Transportation of belt with pre-tensioner
Transport on road vehicles should be carried out with the assemblies stored in the luggage compartment.
Never transport in the passenger compartment. Never transport the pre-tensioner manually or holding it by the
webbing: this can result in damage to the assembly.
Storage of belt with pre-tensioner
Belts with pre-tensioning elements should be stored in containers or boxes that can be locked with a key,
and ventilated. They MUST be stored in an area free from flames and heat sources. On completion of work, or
during work break periods, pre-tensioner belts should be returned to the storage container and locked with a
key.
Disposal of belts with pre-tensioner
Charged pre-tensioners to be scrapped and not fitted to a car must be activated. This should be carried
out only by the belt manufacturers, or specialised workshops.
Vehicle disposal
Charged pre-tensioners fitted to a vehicle MUST be removed before the vehicle is dismantled for scrapping. If the pre-tensioner is not activated during an accident, the device must be considered as still to be in a
'charged' condition.
General safety instructions/dangers for health
When handling activated pre-tensioners, use safety glasses and vinylic or nitrylic protection gloves.
After handling a loaded pre-tensioner, wash hands with soap and water.
Page 20
Lotus Service Notes
-
Section WD
There is no danger of exposure to propellants in the sealed system. The propellant mix is in a solid state,
therefore no inhalation is possible, even if the gas generator cartridge is broken.
Avoid skin contact and do not ingest the propellant.
First aid
Ingestion: Help the person vomit if conscious. Call a physician.
Skin contact: Wash immediately with soap and water. Call a physician.
Eyes: Wash the eyes immediately with running water for a minimum of 10 minutes. Call a physician.
Inhalation: Take the person immediately to fresh air. Call a physician.
General notice
Storage, transport, dismantling and/or recycling of the pre-tensioner shall be carried out according to the
legal and local regulations, taking account also of directives for masonry, fire fighting, transport, environmental
protection and the safety and health of all staff.
WARNING: The seat belt pre-tensioner devices fitted on the Lotus Elise are designed and calibrated
specifically for this particular model. Pre-tensioners must not be adapted, re-used or installed on any
other vehicle - they must only be fitted to the prescribed vehicle with specific homologation continuity.
Any attempt to re-use, adapt or install pre-tensioners on a different vehicle can cause severe or
fatal injuries to the occupants during normal operation as well as the result of an accident.
Page 21
Lotus Service Notes
Exige S/C
SUPPLEMENT
EXIGE SUPERCHARGED (S/C)
Sub-Section
Page
Concept & Overview
Exige S/C.#
2
Technical Data
Exige S/C.TD
3
Body
Exige S/C.B
4
Front Suspension
Exige S/C.C
5
Rear Suspension
Exige S/C.D
5
Engine
Exige S/C.E
5
Wheels & Tyres
Exige S/C.G
11
Brakes
Exige S/C.J
11
Cooling
Exige S/C.K
11
Maintenance & Lubrication
Exige S/C.O
12
Clutch
Exige S/C.Q
12
Miscellaneous
Exige S/C.Z
12
Page 1
Lotus Service Notes
Exige S/C
EXIGE S/C.# - CONCEPT & OVERVIEW
In February 2005, Lotus announced the Lotus Sport Exige 240R (243 bhp) to provide discerning customers
with an exclusive very high performance derivative of the Exige, to be built in a global limited edition of 50 units.
The cars to be produced to customer order as post registration official factory conversions of the '05 Exige by
the Lotus Sport workshops at Hethel, and available for the U.K. and certain overseas territories where regulations allow. In November 2005, Lotus Sport commenced build of a limited number of Exige Cup 240 cars in
road or race specification for selected markets, and differing in detail to the 240R. Then in January 2006, an
official production version of the supercharged car, Exige S, was introduced with a simplified specification.
The performance of the standard Exige is uprated by the fitment of a Magnuson supercharger belt driven
from the crankshaft, feeding through an air/air chargecooler into a new plenum/intake manifold, and featuring a
supercharger integral by-pass valve. The 240R engine uses a mechanical throttle and a 5th injector mounted
in the intake manifold plenum, whereas the '06 M.Y. Cup cars use an electronic throttle, larger port injectors
and no 5th injector, and the Exige S utilises standard injectors.
Chassis dynamics on 240R and Cup cars are uprated by the fitment of Ohlins 2-way adjustable dampers,
with adjustable spring platforms for the uprated springs, and new lightweight forged 5-spoke roadwheels of
slightly wider section to accommodate optional track use only slick tyres.
This supplement describes the features of the supercharged variants which differ from the standard '05
Exige model. For information on any subject matter not included here, refer to the main manual.
Lotus Sport Exige 240R
240Rint
Page 2
Lotus Service Notes
Exige S/C
EXIGE S/C.TD - TECHNICAL DATA
Where different to standard Exige:
Engine
Forced induction
Maximum boost pressure
Max. power
- 240R & Cup
- Exige S
Max. torque
- 240R & Cup
- Exige S
Power to weight ratio - 240R & Cup
Specific power output - 240R & Cup
Lubrication system supplement - 240R & Cup
Oil cooling
Wheels & Tyres
Wheels - type
- size - front
- rear
- 240R
Lightweight forged alloy 5-spoke, satin
black or high power silver
7J x 16
8J x 17
- 240R
- 240R
Suspension
Ride height, mid laden, front/rear
Spring rate
- front
- rear
Front anti-roll bar
Dampers
Magnuson MP62 supercharger with
integral by-pass valve.
Air/air chargecooler.
0.5 bar (7 psi)
181 kW (243 bhp; 247 PS) @ 8000rpm
162.5 kW (218 bhp; 221 PS) @ 7800rpm
236 Nm (174 lbf.ft; 24 kgf.m) @ 7000rpm
215 Nm (158.6 lbf.ft; 22 kgf.m) @
5500rpm
195 kW/t (261 hp/t; 266 PS/t)
100.78 kW/l (136.97 hp/l; 137.4 PS/l)
Accusump oil storage reservoir
Twin front mounted oil coolers
- 240R & Cup
- 240R & Cup
- 240R & Cup
- 240R & Cup
- 240R & Cup
120/120 (2 x 75 kg pass., ½ tank fuel)
325 lb/in
425 lb/in
5-position adjustable
Ohlins gas pressurised with remote
reservoirs, 2-way damper adjustment,
adjustable spring top platforms.
Fuel Consumption (1999/100/EC)
Urban
Extra urban
Combined
12.3 l/100 km
7.2 l/100 km
9.1 l/100 km
CO2
Urban
Extra urban
Combined
292 g/km
172 g/km
216 g/km
Page 3
Lotus Service Notes
Exige S/C
EXIGE S/C.B - BODY
Exterior
All 50 of the 240R cars are finished in high metallic content paint in either Sport Yellow or Sport Black,
reflecting the brand colour scheme of Lotus Sport. Yellow cars are complemented by black roadwheels, and
black cars with high power silver wheels.
A Lotus Sport 240R decal is applied to the RH side of the rear transom.
Paint Codes:
Sport Yellow: Lotus code B112 Du Pont code X3454
Sport Black: Lotus code B111 Du Pont code X3453
240 Cup and Exige S models were offered in the complete range of colours with the front splitter, side
intake scoops and the rear aerofoil (excluding support struts) finished in body colour rather than satin black.
Exige S cars feature an 'Exige S' decal on the rear trabnsom, and an 'S' decal on each fron quarter panel. Both
decals available in grey or silver dependent on body colour.
The chargecooler air intake scoop on the roof of Exige S models is fitted with an enlargement funnel mouth
(without grille) for increased airflow and enhanced chargecooler efficiency.
Interior
Each Lotus Sport Exige 240R is individually numbered from 001 to 050, and identified by a Lotus Sport
build plate styled after those used by Team Lotus for the Formula One cars. The plate is riveted to the chassis
main side rail on the passenger side, and is engraved with the unique Limited Edition number.
The 240R features black leather sports seats embroidered on the head restraints with Exige branding in
yellow, with further Lotus Sport yellow highlights on the seat sides, door trim inserts, gear lever gaiter and parking brake lever gaiter. Cup cars use black leather/suede/carbon effect trim with '06 M.Y. Probax sports seats.
240R and Cup cars are fitted with four point seat belt harnesses, with the shoulder straps anchored to a
seat belt mounting frame (roll hoop) cross bar. The roll hoop and back stays on these cars are manufactured
in T45 steel to allow easy conversion to U.K. motorsport MSA approval by the addition of an 'A' frame and
diagonal brace.
All 240Rs are equipped with air conditioning, but is optional on other models.
Page 4
Lotus Service Notes
Exige S/C
EXIGE S/C.C - FRONT SUSPENSION - 240R & CUP
Stiffened road springs front and rear are fitted on new Ohlins dampers featuring remote gas reservoirs,
adjustable spring platforms and separate adjustments for compression and rebound damping. The spring platforms allow for lowering of the car to 120/120mm mid-laden ride height for track use, and the 22 compression
and 60 rebound damper settings allow the characteristics to be fine tuned to individual requirements. The gas
reservoir is mounted on the inboard crossbrace of the lower wishbone, and is connected to the damper body
by a steel braided hose.
Compression (bump) damping is adjusted by turning the knob on the end of the gas reservoir canister: Turn
clockwise to increase damping, and couterclockwise to decrease. Recommended settings are as follows:
Road use: 11 clicks from full hard
Track use: 11 clicks from full hard
Rebound damping is adjusted via a ribbed collar below the bottom spring seat: Turn clockwise (as viewed
from below) to increase damping, and counterclockwise to decrease. Recommended settings are as follows:
Road use: 8 clicks from full hard
Track use: 8 clicks from full hard
The motorsport stiffened and 5-position adjustable front anti-roll bar provides further opportunity for fine
tuning. To stiffen the bar, use a more forward hole, and to soften, use a more rearward hole. Recommeded
setting:
Road use: Central hole
Track use: Central hole
Suspension geometry is unchanged - refer to Section TDQ.
EXIGE S/C.D - REAR SUSPENSION - 240R & CUP
Stiffened road springs front and rear are fitted on new Ohlins dampers featuring remote gas reservoirs,
adjustable spring platforms and separate adjustments for compression and rebound damping. The spring
platforms allow for lowering of the car to 120/120mm mid-laden ride height for track use, and the 22 compression and 60 rebound damper settings allow the characteristics to be fine tuned to individual requirements. On
240R models the gas reservoirs are mounted on the roll over bar backstays, and on Cup cars, on the toe-links.
Each reservoir is connected to its damper body by a steel braided hose.
Compression (bump) damping is adjusted by turning the knob on the end of the gas reservoir canister: Turn
clockwise to increase damping, and couterclockwise to decrease. Recommended settings are as follows:
Road use: 15 clicks from full hard
Track use: 10 clicks from full hard
Rebound damping is adjusted via a ribbed collar below the bottom spring seat: Turn clockwise (as viewed
from below) to increase damping, and counterclockwise to decrease. Recommended settings are as follows:
Road use: 15 clicks from full hard
Track use: 12 clicks from full hard
Suspension geometry is unchanged - refer to Section TDQ. The Track Use Chassis Rear Brace Kit is
fitted as detailed in sub-section DH.5.
EXIGE S/C.E - ENGINE
The 1.8 litre 2ZZ-GE engine with VVTL-i (Variable Valve Timing and Lift - intelligent) of the standard Exige
is fitted with a low pressure Roots type Magnuson MP62 supercharger to provide up to 0.5 bar (7 psi) of boost
pressure. The supercharger is mounted on the left hand side of the block and driven by a lengthened version
of the multirib auxiliary belt. The unit is self contained and features helix twisted rotors to minimise output
pressure variations, and maintenance free gearing and bearings, requiring no externally sourced lubrication.
An integral by pass valve under ECU control, operates to recirculate air from the compressor outlet back to the
inlet under conditions of idle and part throttle to the benefit of economy and quiet operation.
The supercharger is hung off the new intake manifold by two bolts in conjunction with eccentric sleeves in
order to ensure stress free alignment. An alloy bracket supports the nose of the unit to the RH engine mounting
plinth, and a tubular strut braces the intake end of the unit to the clutch slave cylinder mounting point.
Page 5
Page 6
Chargecooler
outlet duct
Alternator anchor
Fixing point
to manifold
Mounting lug for
supercharger
Supercharger
outlet adaptor
Supercharger outlet elbow
Connection to chargecooler inlet
New inlet manifold
Fixed to engine
mounting plinth
Connection to chargecooler outlet
Supercharger & Ducting
Strut to clutch
slave cylinder mounting
By-pass valve
capsule
pl4207ls/pl4209lr
Swan neck
adaptor fixings
(supercharger
inlet)
Supercharger outlet connector
Chargecooler
inlet duct
Lotus Service Notes
Exige S/C
Lotus Service Notes
Chargecooler outlet duct
Inlet manifold
Exige S/C
Chargecooler
Chargecooler
inlet duct
Boss
for 5th
injector
(240R)
Standard
airbox
Supercharger
outlet elbow
Supercharger
outlet adaptor
Electronic
throttle body
Supercharger
FRONT
Adaptor to chargecooler
Chargecooler
radiator
Throttle body
adaptor
le2047a
Flexible bellows
Air duct
from roof
scoop
FRONT
Rubber mounting
Bracket to
inlet manifold
Rubber mounting
Bracket to inlet manifold
and cam cover
Fixing to inlet manifold
pl4610mx
Page 7
Lotus Service Notes
Exige S/C
Air is drawn from the standard air cleaner through the throttle body and adaptor and into the supercharger
axial intake port. From the outlet port on the compressor top surface, the air is directed through a 'U' bend duct
to the LH end of an air/air chargecooler rubber mounted above the engine, where airflow gathered from the roof
duct is used to cool the compressed intake charge. The chargecooler uses four rubber bobbins attached to two
mounting brackets themselves secured to the inlet manifold and cam cover. A charge air temperature sensor
is mounted in the outlet tank of the chargecooler. The cooled air exiting from the RH end of the chargecooler
flows via another 'U' bend duct into a cast alloy intake plenum/manifold. The whole intake tract has been kept
as short as possible, and uses large diameter ducting and generously radiused bends to optimise airflow and
efficiency to the particular benefit of throttle response and fuel economy.
A re-shaped breather pipe is used to connect the crankcase breather spigot to the cam cover and circumnavigate the supercharger.
On the 240R and Cup cars, a stainless steel 'level one' sports exhaust muffler (LOTAC05334) is fitted to
provide an acoustic enhancement and features enlarged, slash cut tailpipes and a near 20% weight saving
over the standard system. Exige S models use a stainless muffler with a single, oval shaped, tailpipe design.
240R models use 4 standard port fuel injectors together with an additional 5th injector mounted in the
intake end of the inlet manifold. Other 240 and upwards versions, and all USA cars, use 4 special high-flow
port injectors. The Lotus engine management system is reprogrammed to suit each engine specification and
incorporates additional functions to control the fifth injector (240R) and supercharger by-pass valve. The boost
characteristics have allowed the switching point from low to high lift cam profile to be modulated between 4,500
and 6,200 rpm (at normal running temperature). The airbox flap valve opens at 4,500 rpm. 240R models use
a mechanical cable operated throttle body, whereas the Cup and Exige S cars use '06 model electronic throttle.
Twin front mounted oil/air coolers are fitted to all supercharged Exige.
Accusump - 240R & Cup 240
To provide protection against the possibility of oil starvation caused by the extreme g-forces possible with
track use on slick tyres, the 240R and Cup cars are fitted with an Accusump oil storage system.
A 2-litre Accusump reservoir is mounted in the rear luggage compartment, plumbed into the LH oil cooler
return hose at the front of the engine bay, with the connecting hose routed over the RH rear wheelarch. The
device comprises an alloy cylinder divided by a sliding piston, one side of which is connected to the engine
oil supply, with the other containing pressurised air. With the engine running, the cylinder is charged with oil
provided by the engine oil pump, but if the pressure should drop for a short period due to oil pump pick up pipe
exposure during extreme braking or cornering events, the accumulator air pressure forces the stored oil into
the engine lubrication system to maintain continuity of oil supply until normal conditions are resumed.
A one-way valve at the oil cooler connection of the 'T'- piece ensures that the oil discharged from the Accusump is directed into the oil pump and not the cooler. An Electric Pressure Control (EPC) non-return valve is
fitted at the connection to the Accusump cylinder, to allow cylinder charging when oil pressure is above 35 - 40
psi, and cylinder discharging at engine oil pressures below 35 - 40 psi. The EPC is also linked to the ignition
switch such that with the ignition switched on the valve is open to allow oil flow, and with ignition off the valve
is closed to retain oil within the reservoir.
Normal Operation
When the ignition is turned on, the EPC valve is opened, allowing the pressurised oil stored in the reservoir to flow out into the engine and prime the oil galleries and bearings ready for start up. When the reservoir
has been emptied, the pressure gauge on the end of the reservoir will indicate the pre-charge pressure which
should be 7 - 15 psi.
When the engine is started, engine oil pressure will force the reservoir piston back, such that the reservoir
air pressure gauge will indicate engine oil pressure. At pressures above 40 psi, the electric valve is switched
off, enabling the non-return function to allow oil flow only from the engine to the Accusump. The pressure of
stored oil will accord with the highest engine oil pressure achieved until either; a) pressure falls below 40 psi,
at which point the valve opens, or b) the ignition is switched off, and then on again, opening the valve as described above.
With cold oil, 80 psi may be generated, but idling at normal running temperature should produce around
30 - 40 psi. Note that the pressure reading on the reservoir gauge is damped and will lag behind the actual
instantaneous pressure. A pressure relief valve in the end of the reservoir protects the equipment from overpressure damage. If oil is seen to escape from this valve, a fault in the lubrication system is indicated, or
excessive rpm have been used with cold oil.
When the ignition is switched off, the electric valve closes and the oil stored in the Accusump at that time
is retained in the cylinder ready for re-starting.
Page 8
Lotus Service Notes
Exige S/C
Accusump reservoir
Air pressure gauge
EPC valve
assembly
FRONT
Mounting clamp to
boot floor
In-line
filter
To LH port
on sandwich
plate
From oil
cooler
pl4015cLR
Routine Checks
Be aware that the indicated oil level on the dipstick will depend on the amount of oil stored in the Accusump, which itself is dependent on the both the Accusump pre-charge air pressure and the engine oil pressure
when the ignition was switched off.
Before checking the oil level, the Accusump pre-charge pressure should first be checked; turn on the
ignition to open the EPC valve and allow the stored oil to be discharged from the Accusump. The pressure
gauge reading will drop during this discharge, but should then register 7 - 15 psi representing the pre-charge.
If necessary, adjust the air pressure using tyre inflator equipment on the Schraeder valve adjacent to the gauge
and set to 15 psi.
The oil level should now be above the top mark on the engine dipstick. To check for correct oil level, the
engine should be started at idle to charge the Accusump until the pressure gauge registers 40 psi. If idle oil
pressure is below 40 psi, increase rpm until 40 psi is achieved and then switch off. This pressure should then
be retained in the cylinder. If idle oil pressure is over 40 psi, the engine must be run to normal running temperature before switching off and then re-starting as above.
After a suitable oil drainback pause, the sump oil level may then be inspected on the disptick, and the
level corrected to the top mark. It is important to maintain oil at this level to accommodate the oil transfer into
the Accusump at pressures greater than 40 psi. Be aware that checking the oil level under any conditions other
than 15 psi pre-charge and 40 psi oil pressure will produce inconsistent results.
Oil Changing
Before draining the sump, the ignition should first be switched on to open the EPC valve and allow the
Accusump to discharge the stored oil into the sump. Check that a pressure of 7 - 15 psi remains in the Accusump at the end of this process, and if necessary top up the pressure using tyre inflating equipment on the
Schraeder valve next to the gauge and set to 15 psi.
The oil can then be drained in the usual way, with the quantity contained in the oil cooler lines disregarded
for the purposes of routine maintenance. If an engine failure has occurred, with possible debris contamination
of oil hoses and coolers, it is recommended to replace both oil coolers, and to replace or thoroughly flush the
feed and return hoses. At each service interval the in-line filter gauze in the hose between the Accusump and
'T'- piece, should be renewed.
After renewing and pre-filling the engine oil filter, and replacing the in-line filter gauze (see above), refill the
sump to about 10mm above the top mark on the dipstick. Start the engine and allow to idle. Do NOT rev the
engine or drive the car. The Accusump will take up to 2 litres of oil from the sump to store within the cylinder.
Page 9
Lotus Service Notes
Exige S/C
Continue to idle the engine until normal running temperature is reached, then check the level on the dipstick (with
40 psi showing on the Accusump gauge) as detailed above. Top up the oil to the top mark on the dipstick.
Supercharger Remove/Refit
To remove:
1. Remove the chargecooler together with inlet and outlet 'U' shaped ducts.
2.
Remove the throttle body and vacuum/breather hose plumbing.
3.
Using a 6-point socket, relieve auxiliary belt tension and remove the auxiliary belt. Remove the alternator
top mounting bolt, slacken the lower, and swing down the alternator. Release the dipstick tube from the
supercharger.
4.
Using a strap wrench, remove the supercharger pulley retaining nut, and slide off the pulley.
5.
Remove the support strut between the throttle body adaptor and the clutch slave cylinder. Slacken the
pinch bolt securing the supercharger to the nose bracket. Remove the two bolts supporting the supercharger to the inlet manifold and withdraw the supercharger.
To refit:
1. With the supercharger nose bracket bolted to the engine mounting plinth, fit the upper fixing on the alternator to the nose bracket outer end (with 13.5mm spacer). This defines the position of the nose bracket.
Tighten bracket to engine mounting plinth to 50 Nm. Remove alternator top bolt and swing down to allow
supercharger to be fitted.
2.
Prepare supercharger: Clean mating faces of supercharger and outlet adaptor using Betaclean 3900. Fit
'O' ring into groove in outlet adaptor and fit to supercharger using 6 off M8 x 25 setscrews with Permabond
A130. On the fixing located inside the adaptor, Permabond should be applied over the entire thread length.
Orientate the adaptor with the outlet pointing towards the rear of the car when fitted. Torque tighten all
fixings to 25 Nm.
Clean mating faces of outlet adaptor and outlet elbow using Betaclean 3900. Fit 'O' ring into groove in
outlet adaptor face. Fit outlet elbow to point to LH side of car using 4 off M8 x 25 setscrews with a pipe
clip bracket secured by both rearmost fixings. Tighten to 25 Nm.
3.
Fit M8 stud B111E6081S into RH top (as viewed on face) fixing position in supercharger inlet flange. Clean
mating face on supercharger and inlet adaptor using Betaclean 3900. Fit 'O' ring into groove in adaptor
face and fit adaptor to supercharger using 2 off M8 x 30 flange head bolts in top positions and M8 flange
nut on stud - all 25 Nm. Disregard 4th position at this stage.
4.
Mount supercharger: With the pulley removed from the supercharger, slide the nose into the nose bracket
until hard against the machined step. Support to the inlet manifold sliding bushes using M10 x 50 flange
head bolts and Permabond A130, but do not tighten. Tighten the nose bracket socket head pinch bolt to
25 Nm.
5.
Loosley fit the supercharger support strut between the inlet adaptor (M8 x 55 bolt with A130) and the clutch
slave cylinder fixings (M8 x 25 with A130). Tighten the three support strut bolts to 25 Nm. Carefully tighten
the two M10 x 50 flange head bolts to pull in the two spacers evenly to clamp against the supercharger.
6.
Refit the alternator upper bolt and spacer and tighten to 25 Nm. Tighten the lower bolt to 25 Nm.
7.
Fit the pulley to the supercharger with the longer boss towards the 'charger. Fit the nut onto the shaft, and
use a strap wrench to hold the pulley whilst the nut is tightened to 61 Nm.
Page 10
Lotus Service Notes
8.
Exige S/C
Use a 6-point socket on the tensioner arm to allow fitment of the multirib accessory drive belt around the
pulleys as shown, ensuring that the belt is correctly seated in all the ribbed pulleys.
Slave pulley
Water pump
Supercharger
Belt tensioner
Alternator
Crankshaft pulley
A.C. compressor
e232
9.
Refit other components in reverse order to removal.
#
#
#
#
Note areas of change compared with standard models;
Engine dipstick tube altered to avoid supercharger.
Crankcase breather pipe altered to avoid supercharger.
Relays on engine bulkhead move to avoid supercharger by-pass capsule
Charcoal canister moved from bulkhead to bracket on top of chassis right hand rear upright member to
avoid alternator.
EXIGE S/C.G - WHEELS & TYRES
240R cars use lightweight forged alloy 5-spoke roadwheels at 7x16 and 8x17 are ½ inch wider, front and
rear, than standard Exige wheels, but retain the standard insets of + 31.3 mm and + 38.0 mm. The wheels
are finished in either Satin Black or High Power Silver dependent on body colour (see above). 'Lotus Sport' is
moulded into one of the spokes of each wheel. Cup and Exige S models use standard Exige wheels finished
in hi-power silver.
The Lotus specific, regular Exige Yokohama A048 tyres, identified by 'LTS', are fitted as standard.
EXIGE S/C.J - BRAKES
-
For 240R and Cup models, the braking system is uprated in the following respects:
Motorsport brake pads are fitted front and rear;
Steel braided brake hoses fitted all round;
Front and rear brake callipers are finished in 'Sport Yellow';
Hydraulic system filled with Castrol 'SRF' synthetic racing brake fluid. Over 500°F boiling point. Dot 4.
EXIGE S/C.K - COOLING
Twin front mounted oil/air coolers (std. Exige hot climate spec.) are fitted to all supercharged Exige models. An engine intake air chargecooler radiator is rubber mounted to the engine, with cooling airflow collected
by the roof duct and directed via the tailgate panel and flexible bellows to the radiator, after which the hot air
exhausts through the tailgate louvres.
Page 11
Lotus Service Notes
Exige S/C
EXIGE S/C.O - MAINTENANCE & LUBRICATION
-
A Maintenance Schedule for supercharged cars is available under part number LSL460b.
Recommended lubricants are unchanged apart from:
240R & Cup cars: Brake Fluid; Castrol SRF
Fuel; Unleaded 98 RON
Spark plugs are part number ALS3E6015F (NGK PFR7G) with 0.8mm (- 0.1, + 0) gap.
EXIGE S/C.Q - CLUTCH
240R and Cup cars use an uprated clutch cover assembly and a competition specification sintered metal friction plate. No routine maintenance is required other than annual renewal of the Castrol SRF hydraulic fluid.
EXIGE S/C.Z - MISCELLANEOUS
#
#
#
Supercharged models also differ from standard Exige in the following respects:
Engine dipstick tube altered to avoid supercharger.
Relays on engine bulkhead moved to avoid supercharger by-pass capsule.
Charcoal canister moved from bulkhead to bracket on top of chassis right hand rear upright member.
Page 12
Lotus Service Notes
2-Eleven
SUPPLEMENT
2-Eleven
Sub-Section
Page
Concept & Overview
2-Eleven.#
2
Technical Data
2-Eleven.TD
3
Chassis
2-Eleven.A
5
Body
2-Eleven.B
5
Front Suspension
2-Eleven.C
9
Rear Suspension
2-Eleven.D
9
Engine
2-Eleven.E
11
Wheels & Tyres
2-Eleven.G
17
Brakes
2-Eleven.J
17
Cooling
2-Eleven.K
18
Fuel System
2-Eleven.L
19
Electrical
2-Eleven.M
20
Maintenance & Lubrication
2-Eleven.O
26
Miscellaneous
2-Eleven.Z
26
Circuit Diagrams Index
-
27
Page 1
Lotus Service Notes
2-Eleven
2-ELEVEN.# - CONCEPT & OVERVIEW
In March 2007, Lotus announced the Lotus 2-Eleven (255 PS) designed for the motorsport enthusiast, and
aiming to provide a high fun factor from a lightweight, high performance, distinctively styled vehicle, suitable
as a basis for various sporting disciplines, as well as offering U.K. customers the option of a unique road going
experience. The cars to be produced in small numbers for the U.K. and certain overeas territories tailored to
customer specification from an extensive options list.
The running gear is based on the Exige S, and shares that car's basic chassis and supercharged powertrain
componentry, but uses a new chargecooler arrangement and peripheral systems. Unique engine programming
is used in conjunction with 4 high flow fuel injectors as used on Exige Cup cars. The open top lightweight body
is designed to be amenable to economic accident repair and is supplemented by an FIA compliant roll over
bar, and strut mounted rear aerofoil acting directly onto the rear subframe. Options include a race specification carbon fibre adjustable rear aerofoil combined with an enlarged front splitter for enhanced aerodynamic
balanced downforce, and Ohlins fully adjustable spring/damper units with remote reservoirs.
This supplement describes the unique features of the 2-Eleven, and refers to other models where componentry is shared.
Lotus 2-Eleven (road spec.)
2-11 fq road black
Page 2
Lotus Service Notes
2-Eleven
2-ELEVEN.TD - TECHNICAL DATA (Where different to standard naturally aspirated Exige)
Identification
The VIN coding of the 2-Eleven includes the following identifying characters:
Character 4 (engine type); 2-Eleven 2ZZ supercharged 255 bhp = N
Character 6/7/8 (vehicle type); 2-Eleven = 123
Character 12 (chassis specification); U.K. SVA RHD = F
U.K. SVA LHD = G
Track only LHD = H
Track only RHD = J
Character 13 (model); 2-Eleven = 2
Dimensions
Overall length - SVA
Overall width - excluding mirrors
- including mirrors
Overall height (at kerb weight)
Ground clearance
Dry weight - base car
Unladen weight - SVA
Maximum weight
Note that the VIN label on the
2-Eleven is located on the cabin
rear bulkhead, behind the
driver's seat.
3822 mm
1709 mm
1735 mm (approx.)
1112 mm
95 mm
670 kg
745 kg. incl. full fuel tank
895 kg. incl. occupants
Capacities
Engine oil; refill incl. filter & Accusump
6.4 litre
(The oil cooler circuit contains an additional 3.5 litres, but this volume is not normally drained during routine
servicing)
Engine
Forced induction
Power to weight ratio - base car
Specific power output
Lubrication system supplement
Oil cooling
Magnuson MP62 supercharger with
integral by-pass valve.
Air/air chargecooler.
0.5 bar (7 psi)
255 PS (252 bhp; 188 kW) @ 8000rpm
242 Nm (179 lbf.ft; 24.7 kgf.m) @
7000rpm
376 bhp/tonne
142 PS/l (140 bhp/l; 105 kW/l)
Accusump oil storage reservoir
Twin front mounted oil coolers
Clutch
Spring cover assembly
Friction plate
Uprated diaphragm spring
Uprated cush drive springs
Maximum boost pressure
Max. power
Max. torque
Wheels & Tyres
Wheels - type
- size
- std.
- option
- std.
- front
- rear
- option - front
- rear
- rear
Cast alloy, 8 x Y-spoke (as Exige)
Lightweight forged alloy 5-spoke
6.5J x 16
7.5J x 17
7J x 16
8J x 17
Page 3
Lotus Service Notes
Suspension
General
Ride height, mid-laden, front/rear
Option
Suspension Geometry (at mid-laden ride height)
Front
Castor
2-Eleven
Unique front top wishbones and steering
arms. Chassis rear brace
100/110 (2 x 75 kg pass., ½ tank fuel)
Siffened, 5-position adjustable front antiroll bar with Ohlins gas pressurised,
2-way adjustable, remote reservoir damp
ers, with adjustable spring top platforms.
Alignment
Steering axis inclination
+ 3.5° to + 4.5° (+ 3°30’ to + 4°30’)
max. side/side 0.4° (0°24’)
- 1.5° to - 1.3° (- 1°30’ to - 1°18’)
max. side/side 0.4° (0°24’)
- 0.4 mm to zero
11°54’ to 12°06’
Rear
Camber
Alignment
- 2.75° to - 2.48° (- 2°45’ to - 2°29’)
1.2 to 1.5 mm toe-in each side
Camber
Electrical
Battery
- type
- rating
- capacity (20 hr)
- cold cranking
- reserve capacity
- dimensions
- weight
Page 4
Odyssey PC680
PHCA 5 second 680 amps
17 ah
220 amps
24 minutes
L185; W 79; H 187 mm
7 kg
Lotus Service Notes
2-Eleven
2-ELEVEN.A - CHASSIS
-
The 2-Eleven uses the basic chassis 'tub' of the Elise/Exige with minor revisions including;
Deletion of door hinge upright extrusions on each end of scuttle beam.
Full height side members (no cabin access cut down).
Revised pick up points for the roll over bar.
Addition of a body side attachment panel to the lower edge of each chassis rail sill extension.
The front crash structure is as Elise/Exige with minor fettling revisions, and the galvanised steel rear
subframe differs only in respect of incidental fixings.
Roll-Over Bar
The tubular steel roll-over bar is substantially cross-braced, including provision for shoulder harness
anchorage, and features integral bracing struts to both front and rear. The feet of the main hoop are bolted to
tapping plates riveted into the top surface of the chassis side rails, with the front bracing struts locating against
the joint between the side rail top and scuttle cross-beam and secured by similar riveted tapping plates. The
rear bracing struts use a single fixing bolt at each side to secure to the rear subframe.
The roll-over bar complies with FIA requirements for international motorsport, but note that any additions
or modifications to the 'bar may invalidate such compliance.
2-ELEVEN.B - BODY
On the 2-Eleven, the rear transom/bumper, body exterior side panels, ‘A’ panels, front splitter and splitter
end support panels and the single panel comprising the whole of the nose section and front wings, are secured
by threaded fasteners to permit easy removal for access to chassis or powertrain components, and allow simple
and economic accident repair. The composite body inner sides, together with the alloy sheet front and rear
cabin bulkheads and rear scuttle panel, are secured with an elastomeric adhesive.
Screw fixed body panels
Front body section
'A' panel
Rear scuttle panel (also bonded)
Body side
Rear transom/bumper
pl1001cc
Page 5
Lotus Service Notes
Bonded Body Panels
2-Eleven
Body inner side panel
Front bulkhead
pl1002cc
Body inner side panel
Rear bulkhead
(also bonded to rear
scuttle panel)
All composite panels on the 2-Eleven are designed for light weight consistent with aerodynamic function,
with some panels featuring core mat technology to provide a sandwich construction for enhanced stiffness.
All panels are nevertheless vulnerable to damage caused by inappropriate subjection to bodyweight or other
misapplied forces.
Note: The 2-Eleven is not equipped with conventional shock absorbing bumpers, so extra care should be taken
when parking to guard against body damage. The Lotus 2-Eleven does not offer the same kind and degree of
impact resistance or energy absorption afforded by normal bumper systems. Some panels, including the front
quarter panels and ‘A’ panels, have sacrificial functions to help reduce repair costs and damage to the front
body section in minor accidents.
Care is also required, due to the low ground clearance, to guard against chassis underside damage caused
by ramps, kerbs and road humps. Note that the front splitter panel is constructed from timber composite,
sealed by a layer of resin, and that the occasional grounding of this panel, which is a normal occurrence under
track conditions, will cause erosion of the outer layer, requiring periodic repair (water absorption may promote
eventual de-lamination) or replacement.
Engine Lid
A removable panel in the rear body is secured by two recessed ‘Aerocatches’ and provides access to the
engine for maintenance operations.
To remove the cover, at each latch, press the smaller section of the flush fitting latch plate to allow the
latch plate lever to spring up. Fully raise the lever to release the latch. Lift the rear of the panel, and then draw
rearwards to disengage the front flange from beneath the rear scuttle, before lifting the panel forwards and over
the rear aerofoil. Park the panel where it is unlikely to be damaged or blown away by wind.
To refit, rest the panel on the two rubber buffers at the front of the body aperture and slide forwards to
engage the tang bracket at each side of the panel, beneath the body edge adjacent to the roll bar backstays,
and the panel front flange beneath the rear scuttle edge. Press down the two latch levers to engage the retaining pins, finally pressing the small buttons to allow the lever ends to be captured. Ensure that each lever is
correctly clipped shut, and flush with the body surface.
Rear Transom/Bumper Panel
The rear transom panel is screw fixed in the following manner:
At each side, an angle bracket bonded to the underside of the transom top surface is secured by two
screws to the aerofoil mounting strut.
A row of screws secures the lower edge of the panel to the muffler alloy heatshield, which is itself screwed
to the rear subframe.
Page 6
Lotus Service Notes
-
2-Eleven
At each side, two screws pass through the transom end flange into captive nuts in the body side panel.
Rear Scuttle Panel
The rear scuttle panel is fixed at each side by two horizontally disposed M6 screws into bond nuts on the
body side panel, and is bonded along the top edge of the rear bulkhead.
Body Side Panel
The body side panels are secured by screw fasteners for ease of access and replacement. Each panel
is retained as follows:
The top edge of the body outer side panel lips over the body inner side panel, to which it is fixed with four
screws engaging with captive nuts in the inner panel.
A single screw passes from beneath, through the end of the rear bulkhead capping rail into a captive nut
in the side panel.
The lower edge of the body side is secured to four threaded inserts in a chassis extension flange.
At the front of the rear wheelarch, two screws secure the side panel baffle/stiffener to a vertical angle
bracket bolted to the main chassis rail.
At the rear end of the panel, two screws pass from beneath, through the rear transom flange into captive
nuts in the body side.
At the front of the body side, two screws pass upwards into captive nuts in the rear end of the front body
panel.
'A' Panels
At the front of each body side, a separate 'A' panel is used to form a duct for air exhausting from the front
wheelarch. Each panel is secured by four screws at the top (2 into the body side, 2 into the front body panel),
and 2 screws into the body side sill at the bottom.
Front Quarter Panels
A front quarter panel is fitted ahead of each front wheel and forms a mounting and duct for the oil cooler,
as well as tying the front corner of the body to the splitter panel. The quarter panel is fixed by:
2 screws from beneath, through the splitter into captive nuts in the quarter panel lower flange.
2 screws down through the front body flange into captive nuts in the quarter panel upper flange.
Front Wheelarch Shields
A small moulded plastic panel is fitted within each front wheelarch, fixed between the body side and radiator mounting panel, and provides protection for the cooling and brake system components.
Front Undertray
An alloy sheet undertray is fitted beneath the nose, and stabilises the front body, splitter panel, and crash
structure to the front of the chassis. The undertray is secured by:
3 screws into the front edge of the chassis (also slots into the extrusion).
3 screws and nuts at each side into the lower flange of the crash structure.
5 fixings around the front edge, passing through the splitter into captive nuts in the front body flange.
2 screws and nuts to a central support bracket from the crash structure.
1 screw each side to the splitter panel.
Front Splitter Panel
A flat timber composite splitter panel is mounted beneath the nose to cleanly split the airflow above and
below the underside of the car to optimise aerodynamic downforce whilst minimising drag. A road and race
version of the panel are designed to balance the forces produced by the two types of rear aerofoil. Note that
the front splitter panel is constructed from timber composite, sealed by a layer of resin, and that the occasional
grounding of this panel, which is a normal occurrence under track conditions, will cause erosion of the outer
layer, requiring periodic repair or replacement.
The panel is secured by:
Undertray fixings as listed above.
2 screws at each side to the front quarter panel.
Page 7
Lotus Service Notes
2-Eleven
Front Body Panel
To remove the front body panel for access to the radiator, front suspension, brake control system and other
front chassis components, proceed as follows:
Release each of the two oil coolers from the front body by removing the two securing screws.
Remove the aero screen to prevent damage, or at least release the two rearmost fixings at each side
securing the screen to the body sides.
Remove the single screw each side from within the front corner of the cockpit into a captive nut in the
body.
Remove the two screws each side from within the 'A' panel duct into captive nuts in the body.
Remove the two screws each side fixing to the top of the front quarter panels.
Remove the single screw each side from beneath, fixing the splitter panel to the body inboard of the oil
coolers.
From beneath the nose, remove the 5 screws securing the splitter panel to the body flange.
Carefully lift the front body from the car, disconnecting the wiring harness if applicable.
Note that the front turn lamps (if fitted) are bonded into the front body using Betaseal products.
Rear Aerofoil
Two types of rear aerofoil are available. For road going cars, a fixed angle GFRP composite curved blade
with integral end plates is used, whereas the track optimised aerofoil is made using carbon fibre with alloy end
plates, and has provision for adjusting the angle of incidence. Each type should only be used with the corresponding front splitter panel in order to maintain the correct aerodynamic balance.
Both aerofoil types are mounted via machined alloy support plates to the top surface of the rear subframe.
Each plate uses an angle bracket at its base to secure to the subframe, and two of the same angle bracket to
brace the plate to the rear clamshell through which the plate penetrates. A further angle bracket secures the
blade to the top of the support plate.
The track type aerofoil angle of attack
may be adjusted by loosening the rear pivot
screw on each support plinth, and removing
the front fixing screw. Tilt the blade to the
desired angle, and refit the screw in the most
appropriate fixing hole. Tighten all fixings
securely.
Slots are also provided on the endplates
to allow correct horizontal alignment to be
maintained after adjustment of blade angle.
Pivot screw
Alternative
fixing hole
positions
ohs166
Exterior
The Launch Edition of the 2-Eleven is finished in a two tone combination of B111 Lotus Sport Black and
B115 Arctic Silver, with yellow/black/silver styling decals. A '2 Eleven' decal is applied to the rear transom panel,
with optional larger decals on each body side. Stone chip film is fitted to vulnerable areas.
Mirrors
A central rear view mirror is mounted
on the top of the cabin front scuttle, with an
additional mirror on both the driver's and passenger's body sides. Each of the convex glass
mirrors may be adjusted after slackening (turn
anticlockwise from above) the knurled clamp
nut below the mirror.
Tighten
to fix
Slacken
to adjust
ohs164B
Page 8
Lotus Service Notes
2-Eleven
2-ELEVEN.C - FRONT SUSPENSION
The front suspension is based on standard Elise/Exige componentry, but the angle of the top wishbone
ball joint housing differs to better suit the lowered ride height. For the same reason, re-configured steering
arms are fitted, being machined from solid EN16 steel billets, and heat treated.
On cars with the optional 'Sports Pack', revised road springs front and rear are fitted on Ohlins dampers
featuring remote gas reservoirs, adjustable spring platforms and separate adjustments for compression and
rebound damping. The 22 compression and 60 rebound damper settings allow the characteristics to be fine
tuned to individual requirements, whilst the threaded spring platforms allow adjustment of ride height and corner
weighting. Recommended front/rear mid-laden ride height for both road and track use is 100/110mm. Front
height should always lie within the range 95 - 110mm, with a corresponding rear setting 5 - 10mm higher.
Each gas reservoir is mounted on the side of the crash structure, and is connected to its damper body
by a steel braided hose. Compression (bump) damping is adjusted by turning the knob on the end of the gas
reservoir canister: Turn clockwise to increase damping, and counterclockwise to decrease. Recommended
settings are as follows:
Road use: 11 clicks from full hard
Track use: 11 clicks from full hard
Rebound damping is adjusted via a
ribbed collar below the bottom spring seat:
Turn clockwise (as viewed from below) to
increase damping, and counterclockwise to
decrease. Recommended settings are as
follows:
Road use: 8 clicks from full hard
Track use: 8 clicks from full hard
The motorsport stiffened and 5-position
adjustable front anti-roll bar (included as part
of the Sport Pack) provides further opportunity
for fine tuning. To stiffen the bar, use a more
forward hole, and to soften, use a more rearward hole. Recommended setting:
Road use:
Central hole
Track use:
Central hole
c47B
Lower wishbone
Drop link
Anti-roll bar
Stiff
Soft
Note that the hard Nylon type chassis mountings used with this 'bar require periodic lubrication with MoS2
grease at least every 3,000m (5,000km). For suspension geometry refer to Section 2-ELEVEN.TD - TECHNICAL DATA.
2-ELEVEN.D - REAR SUSPENSION
On cars with the optional 'Sports Pack', revised road springs front and rear are fitted on Ohlins dampers
featuring remote gas reservoirs, adjustable spring platforms and separate adjustments for compression and rebound damping. Recommended front/rear mid-laden ride height for both road and track use is 100/110mm. Front
height should always lie within the range 95 - 110mm, with a corresponding rear setting 5 - 10mm higher.
The 22 compression and 60 rebound damper settings allow the characteristics to be fine tuned to individual
requirements. Each gas reservoir is mounted on the rear subframe and is connected to its damper body by a
steel braided hose.
Page 9
Lotus Service Notes
Compression (bump) damping is adjusted by turning the knob on the end of the gas
reservoir canister: Turn clockwise to increase
damping, and couterclockwise to decrease.
Recommended settings are as follows:
Road use: 15 clicks from full hard
Track use: 10 clicks from full hard
Rebound damping is adjusted via a
ribbed collar below the bottom spring seat:
Turn clockwise (as viewed from below) to
increase damping, and counterclockwise to
decrease. Recommended settings are as
follows:
Road use: 15 clicks from full hard
Track use: 12 clicks from full hard
2-Eleven
Rebound
adjustment
collar
d50aB
All cars are equipped with through bolted spherical joints on the inboard ends of the rear toe-links, allied
to a tubular steel crossbrace connecting the rear sides of these joints to provide 'double shear' support. For
suspension geometry refer to Section 2-ELEVEN.TD - TECHNICAL DATA.
Page 10
Lotus Service Notes
2-Eleven
2-ELEVEN.E - ENGINE
The 1.8 litre 2ZZ-GE engine with VVTL-i (Variable Valve Timing and Lift - intelligent) as used in other
Elise/Exige models, is fitted with a low pressure Roots type Magnuson MP62 supercharger to provide up to 0.5
bar (7 psi) of boost pressure. The supercharger is mounted on the left hand side of the block and driven by a
lengthened version of the multirib auxiliary belt. The unit is self contained and features helix twisted rotors to
minimise output pressure variations, and maintenance free gearing and bearings, requiring no externally sourced
lubrication. An integral by pass valve under ECU control, operates to recirculate air from the compressor outlet
back to the inlet under conditions of idle and part throttle to the benefit of economy and quiet operation.
The supercharger is hung off the new intake manifold by two bolts in conjunction with eccentric sleeves in
order to ensure stress free alignment. An alloy bracket supports the nose of the unit to the RH engine mounting
plinth, and a tubular strut braces the intake end of the unit to the clutch slave cylinder mounting point.
Air is drawn from an enlarged air cleaner through the throttle body and adaptor and into the supercharger
axial intake port. From the outlet port on the compressor top surface, the air is directed through a stainless
steel duct to the LH end of an air/air chargecooler mounted behind the engine, where airflow gathered from
an intake duct in each of the body sides aft of the cockpit, is directed by convoluted ducting to a chargecooler
shroud and through the radiator finning to cool the compressed intake charge. The cooled air exiting from
the RH end of the chargecooler flows via another stainless duct into a cast alloy intake plenum/manifold. The
whole intake tract uses large diameter ducting and generously radiused bends to optimise airflow and intake
efficiency and minimise any potential throttle lag. A charge air temperature sensor is mounted in the outlet
tank of the chargecooler.
Each end of the chargecooler is mounted by two alloy spacers to a fabricated steel mounting bracket secured to the engine crankcase by a single fixing bolt. A bonded rubber bush at this position supresses vibration
effects, and in conjunction with the rubber hose connections to the inlet and outlet ducts, provides an isolated
mounting of the chargecooler.
A re-shaped breather pipe is used to connect the crankcase breather spigot to the cam cover and circumnavigate the supercharger.
Road going cars use the standard catalytic converter, which is substituted by a plain pipe on track cars,
but all versions are fitted with a unique exhaust muffler, featuring a double pass design, with single RH tailpipe
exiting through the rear transom panel.
Four special high-flow port fuel injectors are used (common with Cup cars and USA Exige S) in conjuction
with unique engine programming, which incorporates control of the supercharger by-pass valve. The boost
characteristics have allowed the switching point from low to high lift cam profile to be varied between 4,500
and 6,200 rpm dependent on engine load (at normal running temperature). Twin front mounted oil/air coolers
are fitted one each side, ahead of the front wheels.
Accusump
To provide protection against the possibility of oil starvation caused by the extreme g-forces possible with
track use on slick tyres, the 2-Eleven is fitted with an Accusump oil storage system.
A 2-litre Accusump reservoir is mounted
behind the engine on the left hand side of the
rear subframe, and is plumbed into the LH oil
cooler return hose at the front of the engine
bay. The device comprises an alloy cylinder
divided by a sliding piston, one side of which
is connected to the engine oil supply, with
the other containing pressurised air. With
the engine running, the cylinder is charged
with oil provided by the engine oil pump, but
if the pressure should drop for a short period
due to oil pump pick up pipe exposure during
extreme braking or cornering events, the accumulator air pressure forces the stored oil
into the engine lubrication system to maintain
continuity of oil supply until normal conditions
are resumed.
Pressure
gauge
Accusump
reservoir
e234
Page 11
Lotus Service Notes
Connection to chargecooler
outlet & inlet
2-Eleven
Chargecooler inlet duct
New inlet
manifold
Supercharger
outlet connector
Supercharger
outlet elbow
Mounting lug
for supercharger
Chargecooler
outlet duct
Supercharger
outlet adaptor
Swan neck
adaptor
fixings
(s/c inlet)
Fixing point
to manifold
By-pass valve
capsule
Fixed to engine
mounting plinth
Front
Support strut to clutch
slave cylinder mounting
Alternator anchor
e235
Cooling air intake duct
Chargecooler
Collector
Outlet to engine
Charge air
temperature
sensor
Cooling air
trunking to
chargecooler
Rear
Fixing bracket to
clutch housing
Alloy
spacer
Inlet
from s/c
Fixing bracket to
to crankcase
Spacers
pl4610cca
Page 12
Lotus Service Notes
2-Eleven
A one-way valve at the oil cooler connection of the 'T'- piece ensures that the oil discharged from the
Accusump is directed into the oil pump and not the cooler. An Electric Pressure Control (EPC) valve fitted at
the connection to the Accusump cylinder, allows cylinder charging when oil pressure is above 35 - 40 psi, and
cylinder discharging at engine oil pressures below 35 - 40 psi. The EPC is also linked to the ignition switch
such that with the ignition switched on the valve is open to allow oil flow, and with ignition off the valve is closed
to retain oil within the reservoir.
Normal Operation
When the ignition is turned on, the EPC valve on the Accusump is opened, allowing the pressurised oil
stored in the reservoir to flow out into the engine and prime the oil galleries and bearings ready for start up.
When the reservoir has been emptied, the pressure gauge on the end of the reservoir will indicate the precharge pressure which should be 7 - 15 psi.
When the engine is started, engine oil pressure will force the reservoir piston back, such that the reservoir
air pressure gauge will indicate engine oil pressure, with the quantity of stored oil dependent on this pressure
at any one time. With cold oil, 80 psi may be seen, but idling at normal running temperature should produce
around 30 - 40 psi. Note that the pressure reading on the reservoir gauge is damped and will lag behind the
actual instantaneous pressure. A pressure relief valve in the end of the reservoir protects the equipment from
over-pressure damage. If oil is seen to escape from this valve, a fault in the lubrication system is indicated, or
excessive rpm have been used with cold oil.
When the engine is stopped, the EPC valve closes and a quantity of oil pertaining to the oil pressure at
that time, will be retained in the Accusump ready for re-starting.
Routine Checks
Be aware that the indicated oil level on the dipstick will depend on the amount of oil stored in the Accusump, which itself is dependent on the both the Accusump pre-charge air pressure and the engine oil pressure
when the ignition was switched off.
Before checking the oil level, the Accusump pre-charge pressure should first be checked; turn on the
ignition to open the EPC valve and allow the stored oil to be discharged from the Accusump. The pressure
gauge reading will drop during this discharge, but should then register 7 - 15 psi representing the pre-charge.
If necessary, adjust the air pressure using tyre inflator equipment on the Schraeder valve adjacent to the gauge
and set to 15 psi. Allow adequate time for the gauge reading to stabilise.
The oil level should now be above the top
OIL FILLER CAP
mark on the dipstick. To check for correct oil
level, the engine should be started to charge
the Accusump, and run to normal operating
temperature until the Accusump pressure
gauge registers 40 psi. If the engine is already
hot, idle oil pressure may not be sufficient to
open the Accusump valve, and the pressure
gauge will continue to show 15 psi pre-charge.
Increase engine rpm to open the valve. With
the gauge showing 40 psi, turn off the engine.
The EPC valve will then close and trap the
DIPSTICK
normal hot idle quantity of oil in the Accusump
cylinder.
After a suitable oil drainback pause, the sump oil level may then be inspected on the disptick, and the
level corrected to the top mark. It is important to maintain oil at this level to accommodate the oil transfer into
the Accusump at pressures greater than 40 psi. Be aware that checking the oil level under any conditions other
than 15 psi pre-charge and 40 psi oil pressure will produce inconsistent results.
ohs131aB
ohs149aB
Oil Changing
Before draining the sump, the ignition should first be switched on to open the EPC valve and allow the
Accusump to discharge the stored oil into the sump. Check that a pressure of 7 - 15 psi remains in the Accusump at the end of this process, and if necessary top up the pressure using tyre inflating equipment on the
Schraeder valve next to the gauge and set to 15 psi.
Page 13
Lotus Service Notes
2-Eleven
The oil can then be drained in the usual way, with the quantity contained in the oil cooler lines disregarded
for the purposes of routine maintenance. If an engine failure has occurred, with possible debris contamination
of oil hoses and coolers, it is recommended to replace both oil coolers, and to replace or thoroughly flush the
feed and return hoses. At each service interval the in-line filter gauze in the hose between the Accusump and
'T'- piece, and located in the RH rear wheelarch, should be renewed.
SUMP DRAIN PLUG
ohs135
OIL FILTER
ohs129
After renewing and pre-filling the engine oil filter, refill the sump to about 10mm above the top mark on the
dipstick. Start the engine and allow to idle. Do NOT rev the engine or drive the car. The Accusump will take
up to 2 litres of oil from the sump to store within the cylinder. Continue to idle the engine until the Accusump
pressure gauge drops to 40 psi (as the oil warms) and then switch off the engine. Top up the oil to the top
mark on the dipstick.
Supercharger Remove/Refit
To remove:
1. Remove the chargecooler inlet and outlet ducting.
2.
Remove the throttle body and vacuum/breather hose plumbing.
3.
Using a 6-point socket, relieve auxiliary belt tension and remove the auxiliary belt. Remove the alternator
top mounting bolt, slacken the lower, and swing down the alternator. Release the dipstick tube from the
supercharger.
4.
Using a strap wrench, remove the supercharger pulley retaining nut, and slide off the pulley.
5.
Remove the support strut between the throttle body adaptor and the clutch slave cylinder. Slacken the
pinch bolt securing the supercharger to the nose bracket. Remove the two bolts supporting the supercharger to the inlet manifold and withdraw the supercharger.
To refit:
1. With the supercharger nose bracket bolted to the engine mounting plinth, fit the upper fixing on the alternator to the nose bracket outer end (with 13.5mm spacer). This defines the position of the nose bracket.
Tighten bracket to engine mounting plinth to 50 Nm. Remove alternator top bolt and swing down to allow
supercharger to be fitted.
2.
Prepare supercharger: Clean mating faces of supercharger and outlet adaptor using Betaclean 3900. Fit
'O' ring into groove in outlet adaptor and fit to supercharger using 6 off M8 x 25 setscrews with Permabond
A130. On the fixing located inside the adaptor, Permabond should be applied over the entire thread length.
Orientate the adaptor with the outlet towards the rear of the car when fitted. Torque tighten all fixings to
25 Nm.
Clean mating faces of outlet adaptor and outlet elbow using Betaclean 3900. Fit 'O' ring into groove in
outlet adaptor face. Fit outlet elbow to point to LH side of car using 4 off M8 x 25 setscrews with a pipe
clip bracket secured by both rearmost fixings. Tighten to 25 Nm.
Page 14
Lotus Service Notes
2-Eleven
3.
Fit M8 stud B111E6081S into RH top (as viewed on face) fixing position in supercharger inlet flange. Clean
mating face on supercharger and inlet adaptor using Betaclean 3900. Fit 'O' ring into groove in adaptor
face and fit adaptor to supercharger using 2 off M8 x 30 flange head bolts in top positions and M8 flange
nut on stud - all 25 Nm. Disregard 4th position at this stage.
4.
Mount supercharger: With the pulley removed from the supercharger, slide the nose into the nose bracket
until hard against the machined step. Support to the inlet manifold sliding bushes using M10 x 50 flange
head bolts and Permabond A130, but do not tighten. Tighten the nose bracket socket head pinch bolt to
25 Nm.
5.
Loosley fit the supercharger support strut between the inlet adaptor (M8 x 55 bolt with A130) and the clutch
slave cylinder fixings (M8 x 25 with A130). Tighten the three support strut bolts to 25 Nm. Carefully tighten
the two M10 x 50 flange head bolts to pull in the two spacers evenly to clamp against the supercharger.
6.
Refit the alternator upper bolt and spacer and tighten to 25 Nm. Tighten the lower bolt to 25 Nm.
7.
Fit the pulley to the supercharger with the longer boss towards the 'charger. Fit the nut onto the shaft, and
use a strap wrench to hold the pulley whilst the nut is tightened to 61 Nm.
8.
Use a 6-point socket on the tensioner arm to allow fitment of the multirib accessory drive belt around the
pulleys as shown, ensuring that the belt is correctly seated in all the ribbed pulleys.
Belt tensioner
spring/damper
Water pump
Slave pulley
Belt tensioner
Supercharger
Alternator
Crankshaft pulley
pl4103cc
9.
Refit other components in reverse order to removal.
#
#
#
Note areas of change compared with standard models;
Engine dipstick tube altered to avoid supercharger.
Crankcase breather pipe altered to avoid supercharger.
Relays on engine bulkhead move to avoid supercharger by-pass capsule
Page 15
Lotus Service Notes
2-Eleven
Supercharger Nose Assembly
If the supercharger input shaft oil seal should be damaged or found to leak, the complete nose assembly including the nose housing, shaft, bearings and seals should be replaced as a unit by the following procedure:
Parts Required
Supercharger Nose Assembly
A128E6020S 1 off
Oil Fill Kit
A128E6014S 1 off
1.
Remove the complete supercharger assembly from the engine (see above).
2.
Use a strap wrench to hold the pulley, and remove the pulley nut. Use a three leg puller to withdraw the
pulley from the shaft. Apply forces only to the pulley and shaft end. Other techniques may damage the
housing or internal components.
3.
Provision for collecting the contained oil before removing the 8 bolts securing the nose housing to the
main supercharger body. To separate the nose from the body, expanding jaw pliers should be used in the
recesses provided around the flange. Do not pry between the mating faces, or damage will be caused
and oil leaks result. Drain all the old lubricant from the gearcase and discard appropriately.
4.
Stand the supercharger body on end with the gearcase uppermost. Discard the old synthetic drive coupling, and fit the new part supplied in the oil fill kit onto the three pegs on the rotor drive gear. Check that
the two alignment dowels are fitted in the supercharger body flange.
5.
Fill the gear case with 120 ml of Magnuson Products Supercharger oil as supplied in the oil fill kit.
6.
Clean the mating face on the supercharger body and on the new nose housing, and apply a bead of Loctite Eliminator Sealant, supplied in the oil fill kit, around the whole of the joint face on the nose housing,
looping around each of the fixing holes.
7.
Before attempting to fit the nose housing, first align the three pins on the input shaft with the vacant holes
in the drive coupling. Place the nose housing into postition, and ensure that the two alignment dowels
engage with their corresponding holes. It may be necessary for the casing bolts to be used to pull the two
housings together.
8.
If re-using the casing joint bolts, the threads should be thoroughly cleaned before applying Loctite 242 or
equivalent medium strength threadlocking compound. New casing bolts are pre-treated. Fit the eight bolts
and tighten progressively to pull the joint evenly together. Finally torque tighten to 27 Nm in the pattern
shown.
1
Tightening sequence
5
7
6
8
2
9.
4
3
Fit and secure the oil service plug, and position mark. Refit the supercharger.
Page 16
e233
Lotus Service Notes
2-Eleven
2-ELEVEN.F - TRANSMISSION
Clutch
The 2-Eleven is fitted with an uprated clutch cover assembly rated for a maximum torque of 362 Nm, and
which enjoys a mass reduction of 0.6 Kg over the regular cover. Also fitted is an uprated friction plate which
uses 4 steel compression springs in the cush drive hub, in place of the regular item's 4 rubber blocks.
Differential
The 2-Eleven is fitted as standard with an 'open' bevel gear differential, supplemented by switchable Lotus
Traction Control (LTC), with an option package of variable LTC with Launch Control. For full details of these
electronic systems, refer to Section 2-Eleven.M
Two types of optional Limited Slip Differential (LSD) are also available.
Torsen Type: A Torsen (TORque SENsing) gear type LSD limits the speed differential between the two rear
wheels by mechanically distributing the applied torque in accordance with the available grip at each tyre. The
LSD uses worm wheels to interconnect the two output shafts and uses the poor torque reversal efficiency
of this type of gearing to ensure that both wheels are always supplied with driving torque. This feature can
enhance vehicle performance in some competition events, and help maintain mobility in some types of soft
ground condition.
Apart from the taper roller bearings supporting the differential in the transmission case, the LSD is not
serviceable. For details of bearing preload adjustment, refer to Service Notes sub-section FJ.6. There is no
special oil requirement for the Torsen LSD. All factory supplied transmission assemblies originally built with
Torsen LSD are identified on the bar code label applied to the top surface of the transmission case; The 3rd
character of the 7 digit code is 'O' for open differential, and 'L' for limited slip.
Plate Type: A competition type friction plate LSD made by TRD is available in both '2 way' and '1.5 way' variants.
This type of LSD uses a pack of friction clutch plates between each differential output gear and the differential
carrier. The load applied to the clutch pack is proportional to the input torque via a cam and ramp angle design
incorportated between the 4-pinion spider (driven by the crownwheel) and the two clutch pack assemblies. The
'stiffness' of the LSD operation is dependent on the ramp angle which may be specified on ordering. A '2 way'
LSD uses the same ramp angles for drive and overrun to provide similar slip control in both conditions. A '1.5
way' LSD uses different ramp angles for drive and overrun to reduce the clutch pack load on braking. There is
no special oil requirement for the plate type LSD, but to maintain design performance, inspection and cleaning
of the plates should be carried out every 15,000 miles (25,000 km) by a competent agent.
2-ELEVEN.G - WHEELS & TYRES
Optional on the 2-Eleven are 240R type lightweight forged alloy 5-spoke roadwheels, which at 7x16 and
8x17, are ½ inch wider, front and rear, than the standard Exige wheels, but retain the standard insets of + 31.3 mm
and + 38.0 mm. The wheels are finished in either Satin Black or High Power Silver, with 'Lotus Sport' moulded
into one of the spokes of each wheel. The Lotus specific, regular Exige Yokohama A048 tyres, identified by
'LTS', are fitted as standard. Each wheel is retained by four standard Elise/Exige spline head 60 degree taper
seat bolts, for which a splined adaptor tool is stowed in the vertical tube of one of the roll-over bar backstays.
No security coded wheel bolts are used.
Note that these forged alloy wheels incorporate a steel centralising sleeve to locate onto the hub spigot,
and is normally retained in the wheel. A smear of copper grease on the spigot will help prevent corrosion between the hub and sleeve causing the insert to become separated from the wheel.
2-ELEVEN.J - BRAKES
-
The anti-lock braking system is uprated in the following respects:
Motorsport brake pads (Pagid RS14) are fitted front and rear together with cross-drilled brake discs;
Steel braided brake hoses fitted all round;
Optional Castrol 'SRF' synthetic racing brake fluid. Over 500°F boiling point. Dot 4.
Brake callipers painted yellow.
Page 17
Lotus Service Notes
2-Eleven
Access to the brake master cylinder reservoir is available via a small panel in the driver's side front body;
release the screw fastener using the tool provided in the roll over bar backstay, and withdraw the panel. To
refit, engage the tongue beneath the front end of the aperture, and secure the rear end with the fastener. Note
that to avoid erroneous low fluid tell tale activation under extreme track use, it may be necessary to fill the fluid
reservoir to the base of the neck.
Option
An optional brake upgrade comprises larger front discs (308mm vs. 288mm) mounted on alloy centres
and clasped by A.P. Racing 4- pot callipers.
Brake Pad Bedding
If new brake pads and/or discs are to be fitted, a bedding-in procedure should be followed:
WARNING; This procedure should be carried out only on a closed track, paying appropriate regard to
any other track users. Do not attempt on the public highway.
The purpose of brake pad bedding is to:
Transfer a layer of friction material onto the disc faces to achieve maximum performance;
Stabilise compressible materials to avoid a spongy pedal;
Boil off volatile elements in the friction compound;
Align the pad and brake disc surfaces for full contact.
If the pads are not bedded in correctly, or are used aggressively straight after fitting, pad glazing may occur. This condition results from resins in the pad material crystallising on both the pad friction surface and the
brake disc surface, producing brake judder and vibration. Also, rapidly escaping volatile elements and moisture
from the resin, in seeking an immediate escape route out of the friction compound, can create small fissures
that can lead to cracking and chunking of the material.
-
Bedding Procedure;
To generate some heat in the discs and pads, perform 4 to 6 stops with medium brake pressure from
around 70 mph (110 km/h) to 40 mph (60 km/h), allowing around 30 seconds between stops. The pad
temperature should not exceed 400 degrees C.
Immediately after this procedure, carry out one high speed stop with medium to heavy brake pressure,
without activating the ABS, from around 80 mph (130 km/h) to 40 mph (60 km/h).
Perform 3 or 4 recovery stops to clean the discs and pads, using light pedal pressure from around 70 mph
(110 km/h) to 40 mph (60 km/h).
Repeat the high speed stops, including the recovery stops, a further 2 or 3 times. The brakes may now
be considered fully bedded.
New Pads on Used Discs
If new brake pads are to be fitted on used discs, it is recommened to chamfer the edges of the pad to
allow optimum bedding.
Parking Brake
Immediately after track use or hard brake usage when the discs are still hot, if possible, avoid using the
parking brake (chock wheels) to prevent heat transfer into the pads and brake fluild.
2-ELEVEN.K - COOLING
The 2-Eleven uses the standard horizontally mounted radiator, with twin cooling fans on its underside.
The fans are switched individually by the engine ECM in conjunction with a fan control module mounted in
the chassis front well, behind the radiator. One fan is switched on at 98°C on rise, off at 93°C on fall, with the
second fan motor run in parallel, and switched on at 103°C on rise, off at 98°C on fall.
Twin front mounted oil/air coolers (std. Exige hot climate spec.) are fitted, one ahead of each front wheel.
An engine intake air chargecooler radiator is rubber mounted behind the engine, with cooling airflow gathered
by body apertures alongside the rear of the cabin, and fed via convoluted ducting to a collector on the forward
side of the chargecooler. Air exhausting from the chargecooler radiator escapes via a rear transom aperture.
Page 18
Lotus Service Notes
Engine Bay Ventilation
The body of the 2-Eleven incorporates
four air intake ducts;
Grilled air intakes at each side of the front
scuttle, feed air via ducting formed within
the body sides to the engine bay; the left
hand duct feeds a cool air supply with a
small 'ram'effect to the engine air cleaner;
the right hand duct feeds cooling air to
the front of the engine bay.
Two grilled air intakes at the rear of the
cockpit sides supply a plenum on the
front of the chargecooler radiator.
Hot air exhausts from the engine bay via
an aperture in the rear body.
2-Eleven
Engine bay cooling
Chargecooler airflow
ohs161B
Engine intake airflow
2-ELEVEN.L - FUEL SYSTEM
In order to meet the fuelling requirements of the 255 PS engine specification, a high output fuel pump is
fitted in the otherwise unchanged tank. This pump is slightly longer than the standard item and requires a new
alloy cap (replaces original plastic cap) to retain the pump in the plastic housing inside the tank.
Page 19
Lotus Service Notes
2-Eleven
2-ELEVEN.M - ELECTRICAL
-
The 2-Eleven is available with three levels of lighting equipment:
Track; with no lighting equipment.
Race; with rear turn lamps, brake lamps and rear fog lamps.
Road; with full lighting set, but no CHMSL.
Lighting Switches (if fitted)
Principal lighting functions are controlled by a row of three push button switches
mounted in a nacelle below the scuttle top
edge; for the rear fog switch (if fitted) see
later. Each switch is pressed once to switch
on, and pressed a second time to switch off.
A symbol accompanies each switch to indicate
its function.
Headlamp switch
Hazard switch
RHD shown
Sidelamp switch
ohs163B
Sidelamp Switch
Positioned in the right hand end of the panel, this switch functions with or without the ignition, and switches
on the sidelamps and instrument/switch illumination. A tell tale in the switch button lights up green to indicate
when the circuit is active.
Press the switch a second time to switch off the sidelamps, but note that the headlamps must first be off
(see below).
Headlamp Switch
Centremost of the three switches, that for the headlamps functions with or without ignition, and switches
on the headlamps together with the sidelamps and instrument/switch illumination. A tell tale in the switch button lights up green to indicate when the circuit is active. The steering column lever switch (see later) is used
to select main or dip beam.
Pressing the switch a second time will switch off the headlamps, but leave on the sidelamps (see
above).
Hazard Warning Lamps Switch
The hazard warning switch is located at the left hand end of the panel and has an icon in the switch button which is back lit when the ignition is switched on. The switch is operative at all times, and when pressed,
causes all the turn indicator lamps to flash in unison. The turn lamps tell tale and the hazard switch icon will
also flash. Press a second time to switch off.
This facility should be used when the car is stopped on the highway in circumstances where a warning
to other traffic would be judicious. Use of the hazard warning lamps may be subject to local traffic laws, with
which drivers should familiarise themselves.
Instrument Illumination
A small button is provided on the steering column shroud ahead of the ignition switch, by which the brightness of the electroluminescent instrument illumination may be adjusted. To cycle through the range of brightness, first switch on the lights, and then press and hold the button before releasing at the desired setting.
Note that this dual function button also resets the trip distance recorder if pressed only briefly.
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Lotus Service Notes
SIDE PANEL SWITCHES
Situated at the end of the fascia, outboard
of the steering column is a switch panel providing various functions dependent on vehicle
specification.
Engine Start Button
Fitted on all cars, at the bottom of this
panel is a red button to activate the engine
starter motor. This circuit is operative only
when the ignition is switched on. Care should
be taken not to press the button when the
engine is running, as damage to the starter
mechanism is likely to be caused.
For correct operation of this function see ‘Starting Procedure’.
2-Eleven
Variable traction control
Traction control 'off' switch
Rear fog/rain light switch
Engine start button
ohs162
Rear Fog/Rain Light Switch (if fitted)
On cars fitted with full road lighting, the switch above the starter button controls the two rear fog lamps,
which operate only in conjunction with the ignition and headlamps. Tell tales in the switch button and instrument
pack light up amber to indicate when the circuit is active. Press a second time to switch off the lamps.
Note that whenever the headlamps and/or ignition are switched off, the fog lamps will also switch off. On
re-instatement of ignition and headlamps, the fog lamps will remain off until requested again by pressing the
switch.
For track cars fitted with rear warning ‘rain’ lamps, these may be activated any time the ignition is on, by
pressing this button. Tell tales in the switch button and instrument pack light up amber to indicate when the
circuit is active. Press a second time to switch off the rain lamps.
Lotus Traction Control
All cars are equipped with Lotus Traction Control (LTC), whether or not the optional Limited Slip Differential
(LSD) is specified.
Lotus Traction Control (LTC) is a software programme within the engine electronic control unit (ECU) which
uses inputs from the wheel speed sensors to determine the degree of wheelspin occurring, and when necessary,
modulate fuel injector delivery to control engine power output until grip is restored. This feature, which operates
at all speeds above 6 mph, can improve vehicle stability in some extreme conditions of use, especially where
variable surface grip prevails, or when maximum vehicle performance is being exploited.
The optional Torsen type Limited Slip Differential (LSD) is a mechanical gear system incorporated into the
final drive unit, and limits the speed differential between the two rear wheels by distributing the applied torque
in accordance with the available grip at each tyre. This feature can enhance vehicle performance in certain
types of off-road or closed venue competition, and help maintain mobility in mud, snow or sand. LTC then acts
electronically to stabilise high speed vehicle behaviour under high cornering loads or extreme manoeuvres.
If the LTC tell tale in the instrument panel is seen to flicker, this is an indication that the tractive limit has
been reached, and traction control activated.
Lotus Traction Control ‘Off’ Button:
In certain circumstances, such as loose or soft surfaces, it may be desirable temporarily to switch off the
traction control, for which purpose an LTC ‘off’ button is provided on the switch panel outboard of the steering
column. To switch off the LTC; with the ignition switched on, hold the button pressed for 2 seconds. The button
tell tale together with the instrument panel tell tale will light up amber to confirm system de-activation.
WARNING:
•
LTC should always be active when driving on the public highway.
•
If the system is switched off when driving off-highway, be aware of the consequent change in
vehicle behaviour and modify driving style accordingly.
To re-activate LTC, press (momentarily) the button a second time and check that the button and instrument
panel tell tales go out. Note that the button tell tale will flicker in conjunction with the instrument panel tell tale
if traction control is triggered. Irrespective of the system status at the time of ignition switch off, LTC will default
to ‘on’ next time the ignition is switched on.
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Lotus Service Notes
2-Eleven
Variable Traction & Launch Control (if fitted)
Cars equipped with the optional variable traction and lauch control, have a rotary control knob mounted
above the LTC ‘off’ button on the switch panel.
Variable Traction Control
Each time the ignition is turned on, normal full LTC is activated. To enable variable traction control, turn
on the ignition and hold the LTC ‘off’ button pressed for 2 seconds. Do not touch the throttle pedal. Check that
the tell tale in the switch button is lit. Start the engine. Note that if the ignition is switched off (e.g. prior to a
second start attempt), the above procedure must be repeated in sequence.
With the switch button tell tale lit and the engine running, the rotary knob may then be used to select the
degree of traction control desired:
•
For maximum traction control (0% slip) turn the knob fully counterclockwise.
•
To reduce traction control (to allow up to 12% slip), turn the knob progressively clockwise.
•
Fully clockwise, traction control is disabled, as indicated by the lighting of the instrument panel tell tale.
Variable Launch Control
This feature allows the engine rpm to be limited during a competition start in order to balance engine power
against available grip and provide a controlled degree of wheelspin for the first moment of acceleration, until
superseded by the traction control system at around 6 mph.
To enable this feature, turn on the ignition and hold the LTC ‘off’ button pressed for 2 seconds. Check that
the tell tale in the switch button is lit. Then;
•
With ignition on, engine stopped, fully depress the throttle pedal for 5 seconds.
•
Tacho will now show launch rpm. Turn the rotary knob as necessary to select any desired launch rpm
between 2000 and 8000.
•
Release throttle and start engine.
•
Turn the rotary knob to select the desired level of traction control (see above), noting that the launch control
setting will not be affected.
•
Engage first gear, apply full throttle (ECU limits engine speed to selected launch rpm), and rapidly ‘drop’
clutch.
•
Maintain full throttle throughout the transition from launch to traction control (at around 6 mph) until the
first gear change is required.
•
To disable launch control when variable traction control is still required, reset launch rpm to 8,000.
NOTE
•
Do not attempt to slip the clutch during this process, as overheating or damage to the clutch mechanism
may occur. An instant clutch engagement is required to ‘break’ rear tyre traction and initiate wheelspin.
•
Do not attempt LC starts in any gear other than first.
•
Do not hold the engine at or near maximum rpm for more than a few seconds.
•
Under no circumstances should this track feature be employed on the public road.
•
Use of Launch Control is an ultimate technique designed to produce the fastest possible race start.
Always allow the clutch to cool and recover before repeating a launch controlled start. The extreme
loads associated with such starts will result in reduced transmission component life cycles.
•
At the next key-on, the system will default to full LTC and Launch Control off. Turning on the ignition and
holding the LTC 'off' button pressed for 2 seconds will restore the previous traction and launch settings.
Adjustment Tips
Note that the optimum settings for variable traction and launch control will differ for each set of track surface, tyre and ambient conditions. A suggested adjustment logic follows:
•
Set the traction control to a mid position.
•
Start with a low launch rpm e.g. 4,000 rpm.
•
Trial launch and assess initial wheelspin control and transition into traction control.
•
If launch control is set too low, the engine may ‘bog down’ and fall out of the power band. If set too high,
too much initial wheelspin may result, with poor step off from the line.
•
Similar logic applies to traction control adjustment when this system takes over above about 6 mph.
Page 22
Lotus Service Notes
2-Eleven
Battery Access
The lightweight 'Odyssey' battery uses absorbed glass mat, dry cell technology to provide high electrical
performance with minimum weight and size. The battery is located centrally in the cabin rear bulkhead, protected
by a composite cover. No routine inspection or topping up of the electrolyte is required, but at every service interval, the battery terminals should be checked for security and condition, and protected with petroleum jelly.
For access to the terminals, the bulkhead cover must first be removed. Use the 3mm hexagonal key to
remove the four fixings securing the battery cover to the chassis and bulkhead, and disconnect the auxiliary
power socket lead (if applicable).
BATTERY ACCESS
OFF
ccbatteryB
m264G
BATTERY ISOLATOR
Battery Isolator Switch
A battery master switch is mounted on the left hand side of the rear scuttle, and is provided as a safety
feature to allow a third party, from outside the vehicle, to turn off the engine and islolate all battery power.
This facility should be used only when necessary for safety reasons, or prior to removing the battery from
the car. If possible, do not operate the swtich until at least 10 seconds after switching off the ignition, in order
to allow the engine management system to adjust the setting of some components ready for re-starting, and
to avoid the loss of adaptive learn memory in the ECU.
To turn off battery power, turn the red key (knurled alloy knob on road cars) a quarter turn counterclockwise
until aligned fore/aft. Remove the key to prevent loss and fit the rubber cap to protect from rain ingress. To
turn on, insert the key, press down and turn a quarter clockwise. The key is now captive.
Battery Charging
The Odyssey PC680 battery fitted to the 2-Eleven uses aborbed glass mat (AGM) technology to provide
the virtues of both deep cycling ability and high cranking power. Thus low rate long duration drains and short
duration high amperage pulses are accommodated. The battery is fully sealed, recycling all gases internally
and using no external vent. There is also no electrolytic corrosion of the positive terminal, or corrosion to the
surrounding area. Never attempt to remove the top decal cover, or failure of the battery will ensue.
The state of charge in the battery can be determined from the following table:
Voltmeter reading
State of charge
12.84 V
100%
12.50 V
75%
12.18 V
50%
11.88 V
25%
The battery does not lose its charged energy during cold storage temperatures, so there should be no
need to trickle or float charge during the winter months. To store off season, measure the battery voltage to
ensure it is fully charged; 12.8 volts or greater, and recharge if necessary. Turn off the battery isolator switch, or
disonnect the negative battery cable to prevent any applied electrical load during storage. The battery should
not freeze in temperatures down to - 40°C, so can be left in the vehicle except in the most extreme climates.
The battery can be stored for 2 years or more at temperatures below 25°C.
Under conditions of normal daily use, it should not be necessary to use external battery charging equipment. If the battery becomes discharged to the extent that the car cannot be started, the recommended course
of action is to fit a substitute battery whilst the original battery is trickle charged. If, in an emergency, the car has
Page 23
Lotus Service Notes
2-Eleven
to be ‘jump’ started, the subsequent conditions of vehicle use may not allow for sufficient alternator charging
of the battery to achieve a fully charged state. The battery should be trickle charged by external means until
12.8 volts is recorded.
The battery manufacturer recommends an Odyssey EPS 8A charger, which would require around 2½
hours to re-charge a fully discharged battery. Note that a trickle charger will not be capable of re-charging a
fully discharged Odyssey battery. Putting the battery into service at a less than fully charged state will reduce
the time period for which the car can be parked without subsequent starting difficulties. A battery left in a fully
discharged state for a prolonged period, may not be recoverable to its original condition. Allow several hours
after disconnecting a charger before measuring the battery voltage.
WARNING:
•
Hydrogen gas generated by the battery could cause an explosion, resulting in severe personal
injuries.
•
Charge battery in a well ventilated area.
•
Never charge a frozen battery. It may explode because of gas trapped in the ice. Allow a frozen
battery to thaw out first.
•
If you get electrolyte, which is an acid, in your eyes or on your skin, immediately rinse with cold
water for several minutes and call a doctor.
Auxiliary Power Socket
An auxiliary power socket is fitted in the right hand side of the battery cover. The socket is operative at
all times, and is provided with a protective hinged flap.
The format of the socket allows a standard cigarette lighter element to be used, or other electrical accessories requiring this type of fitting. Maximum current draw should not exceed 15 amps.
Page 24
Lotus Service Notes
2-Eleven
Fuses
Two 4-slot fuseboxes are mounted on the rear bulkhead and control the principal engine circuits. Track cars
fitted with rear lamps, use a third 4-slot fusebox, located within the battery compartment for the lighting circuits.
Cars with full lighting sets replace this 4-slot box with a 22-slot fusebox within the battery compartment.
The ‘Littel’ type fuses are numbered and coloured according to their amperage rating, and may be removed
by withdrawing from their slots.
ENGINE BAY FUSES
Engine Bay Fuses
Slot Rate Circuit
E1 7.5A Engine control
relay
E2 15A Cooling fan 1
E3 15A Cooling fan 2
E4 Not used
Slot
F1
F2
F3
F4
Rate
15A
15A
20A
10A
Circuit
Batt. services
Ign. services
Fuel pump
Main relay
Track Lights Fusebox
Slot Rate Circuit
R1 5A Turn lamps
R2 5A Rain lamp
Slot Rate Circuit
R3 5A Rvrs. lamps
R4 5A Stop lamps
m265
F4
F3
F2
F1
E4
E3
E2
E1
Full Lighting Set Fusebox
Slot
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
Rate
7.5A
5A
7.5A
10A
7.5A
20A
Circuit
Not used
Not used
Reverse lamps
Not used
Brake lamps
Turn lamps
Not used
Not used
Hazard
Horn
Not used
Aux power socket
Slot
A13
A14
A15
Rate
15A
A16 10A
A17
A18
A19
A20
A21
A22
10A
10A
10A
10A
-
Circuit
Not used
Not used
Switch pack &
dipswitch
Sidelamps, rear
fog
Dip beam LH
Dip beam RH
Not used
Main beam LH
Main beam RH
Not used
Fuse 1
Fuse 11
LHD front
RHD front


Fuse 12
Fuse 22
m255
ABS Fuse: A 60A Maxi fuse protecting the ABS circuits is located within the battery box.
Fuse colours:
2A - Black;
3A - Violet;
4A - Pink;
5A - Orange;
7.5A - Brown;
10A - Red;
15A - Light Blue;
20A - Yellow;
25A - Clear.
Page 25
Lotus Service Notes
2-Eleven
2-ELEVEN.O - MAINTENANCE & LUBRICATION
A Maintenance Schedule for the 2-Eleven is available under part number LSL519, and a Pre Track Session Check List, which should be completed before each and every track driving session, under part number
LSL520.
Recommended lubricants are unchanged apart from the option of Castrol SRF brake fluid. Spark plugs
are part number ALS3E6015F (NGK PFR7G) with 0.8mm (- 0.1, + 0) gap.
Vehicle Recovery
No towing eye is fitted on the 2-Eleven. If the car has to be recovered by towing either forwards or backwards, a fabric towing strap should be secured to the passenger side of the roll over bar. In operation, care
should be taken to prevent damage to the aeroscreen or rear aerofoil.
2-ELEVEN.Z - MISCELLANEOUS
Warranty
‘Track Use’ Cars
The Lotus 2-Eleven is designed and supplied into markets other than the U.K. only as a track use vehicle,
as defined by character 12 of the V.I.N. being ‘H’ or ‘J’. This specification is also available as an option in the
U.K., identified in the same manner. All such cars are not eligible for European type approval, or Australian
Compliance Plate Approval, or equivalent regulations in other countries. The Lotus 2-Eleven is supplied with
no specific type approval paperwork or certification information and Lotus Cars will not provide any assistance
to any person or company seeking to register a 2-Eleven model for road use outside of the U.K.
Lotus offers no warranty other than that required by law, on any ‘track use’ car in any territory.
U.K. Road Use Cars
The following Warranty applies only to cars built by Lotus for road use in the U.K., as identified by V.I.N.
character 12 being ‘F’ or ‘G’, and only whilst being used in the U.K. It is permissible for the car to be driven on
closed circuits or private test tracks, but using the car in a competitive manner, including timed runs or laps,
will invalidate the Lotus Vehicle Warranty.
Warranty Periods
Warranty period for vehicle; 12 months/12,000 miles.
Warranty period for replacement parts; 12 months/12,000 miles.
Corrosion perforation warranty; 2 years unlimited mileage.
Exclusions From Warranty Coverage
The 2-Eleven features an open cockpit such that all issues relating to water ingress, including damage
to trim and upholstery, staining or discoloration of the chassis, and damage to electrical equipment within
the cabin, are not covered by this warranty; use a suitable outdoor car cover when necessary to protect
against weather damage.
Adjustments to screw fixed body panels and components, glass and trim should be considered as routine
maintenance and may periodically be required, especially when subjected to high forces by repeated track
use.
Internal and external mirrors are vulnerable to damage from driver/passenger ingress/egress as well as
from external strikes, and are excluded from warranty coverage.
All composite panels on the 2-Eleven are designed for light weight consistent with aerodynamic function,
and may be damaged by inappropriate application of bodyweight or other injudicious treatment. The
durability and standard of the paint finish may not match that of more conventionally constructed cars.
There is no body or paint warranty on the Lotus 2-Eleven.
If the car has ever been used on road or track with ‘slick’ or equivalent racing tyres, warranty is void.
Clutch and brake discs are excluded.
For full details of the 2-Eleven warranty and its restrictions and limitations, refer to the Owner's
Handbook, or 2-Eleven specific Warranty Certificate LSL521
Page 26
Lotus Service Notes
2-Eleven
Circuit Diagrams
Start, Alternator & Ignition
Sheet 1
Page 28
Fuel Pump & Engine Management
Sheet 2
Page 29
Engine Management
Sheet 3
Page 30
Tail, Stop, Reverse & Fog Lamp
Sheet 4
Page 31
Turn Indicators, Side & Hazard Warning Lamps
Sheet 5
Page 32
Switch Pack & Headlamps
Sheet 6
Page 33
Instruments
Sheet 7
Page 34
Engine Cooling Fan
Sheet 8
Page 35
Horn & Rain Lamp Relay (track option)
Sheet 9
Page 36
ABS & Traction Control
Sheet 10
Page 37
Harness Ground Splices
Sheet 11
Page 38
Fuse Layout (base & SVA cars)
Sheet 12
Page 39
Power & Ground Structure
Sheet 13
Page 40
Fuse Layout (base & track cars)
Sheet 14
Page 41
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