FUEL CELL Lotus Sport – Fitting Instructions 70ltr `FIA
Contents
1. Caned by s negoan Part Number ALS3T0009F PROCESS Version 1 FUEL CELL SHEET 4 lh Terere a ep Mg E e Bg Fg a dg o ge eal Sy A oe Part Number ALS3T0009F PROCESS Version 1 FUEL CELL SHEET 2 F TOOLS REQUIRED BOILING WATER TO SOFTEN HOSE ENDS e CLEAN WORKING BENCH AND AREA SOCKETS ASSORTED e TORQUE WRENCH CRAFT KNIFE e EXTENSION BARS CIRCLIP PLIERS MASKING TAPE WD40 DUCT TAPE MALLETS HACKSAW OR SUITABLE CUTTING TOOL PAINT PEN LOTUS SERVICE MANUAL A120T0327J TOYOTA SERVICE MANUAL RM733E TOYOTA SERVICE MANUAL RM929E VEHICLE SUPPORT RAMP FUEL DRAIN CAN RATCHETS SPANNERS ASSORTED ALLEN KEYS ASSORTED PHILLIPS HEAD SCREWDRIVER FLAT BLADED SCREWDRIVER INSTRUCTIONS NOTE 1 ALL BOLTS SHOULD BE TORQUED CORRECTLY SEE LOTUS SERVICE MANUAL FOR STANDARD PART OR TORQUE REFERENCE IN THIS DOCUMENT NOTE 2 ALL BOLTS TORQUED SHOULD BE PAINT MARKED NOTE 3 ENSURE ALL NESSECARY SAFETY PRODECURES ARE FOLLOWED WARNING DO NOT ATTEMPT TO DO THIS MODIFICATION WITH THE ENGINE RUNNING OR WHEN THE ENGINE IS HOT TAKE ALL NECESSARY PRECAUTIONS TO GUARD AGAINST FIRE AND EXPLOSION RISK WHEN DEALING WITH FUEL AND FUEL VAPOUR READ ALL INSTRUCTIONS THOROUGHLY BEFORE COMMENCING WORK AND ENSURE ALL COMPONENTS ARE PRESENT IF IN ANY DOUBT CONSULT A LOTUS DEALER BEFORE UNDERTAKING THE WORK ACTIVITY REMOVE EXISITINGTANK constancia 8 ACTIVITY RELOCATE LA TCHS CABLE se2. 10 10 Part Number ALS3T0009F PROCESS Version 1 FUEL CELL SHEET d _ E de ACTIVITY PREPARE AREA Cover or remove all obtrusions from fuel cell area Duct tape over all sharp edges corners and joints 10 Remove approximately 5 10mm of materials from the inboard side of the fuel hose aperture on the chassis 20 Clean all internal surfaces make sure free from dirt or deposition inboard side only indicated 30 REMOVE ALL BOLTS NUTS AND PROTRUSIONS INTO THE FUEL CELL AREA red 40 PLACE DUCT TAPE OVER ALL OBTRUSIONS ALL a 7 y A E SHARP EDGES AND CORNERS h Ky f E A i Epon ME ey Mr e Dr Ji 5 Increase the size of the fuel hose aperture by 5mm dr O 06 E a CAREPOINT 20 IT IS IMPERATIVE THAT THE AREA WHERE THE NEW FUEL CELL WILL BE INSTALLED IS FREE OF ANY OBSTRUCTIONS SHARP EDGES POINTS BOLT HEADS AND THREADS THE COMPLETE INNER AREA SHOULD BE SMOOTH WHEN YOUR HAND IS RUN ACROSS THE SURFACE ANY OBTRUSION ONTO THE FUEL CELL WILL DAMAGE THE FUEL CELL 30 Take care to cover all sharp edges corners and obtrusions with tape 20 If absolutely necessary replace with button type head bolts on the inner surface SEQ PART NUMBER PART DESCRIPTION QTY F C TORQUE TOOLING 10 Part Number ALS3T0009F PROCESS Version 1 FUEL CELL SHEET SEQ Key Es EM ACTIVITY FUEL PUMP INSTALLATION Way EM 10 Place the f
3. Part Number ALS3T0009F PROCESS Version 1 FUEL CELL SHEET DN ed ed L OS TO S SFP OOF T Ln Lotus Sport Fitting Instructions 70ltr FIA Approved FT3 FUEL CELL TRACK USE ONLY Application Specific to Lotus Sport S2 Exige Cup Vehicles with Toyota 2ZZ GE Engines oo T the equipment on pubhc roads may consbtute a cnminal offence Accordingly the purchaser of the equipment and all persons who w use the equipment must ensure that the equipment is not used inv public road Lotus Motorsport Limited cannot and does not pt any hability ansina directly or ndirectly out of the use of apment other than in respect of death or personal injury caused by its negligence tatutory nghts when dealing as a consumer are not affected Difficult Part Number ALS3T0009F PROCESS Version 1 FUEL CELL SHEET DN ed ed OVERVIEW This fuel cell sits in the same location as the standard tank uses the carry over fittings and standard fuel pump It holds 70 litres nominally Internally it has three baffles running to 80 of the height of the tank each with two fuel apertures at the bottom between chambers The fuel pump chamber additionally has 2 x TF331 trapdoors to hold fuel close to the pump The fuel pump operates as normal with the level float giving correct indication you will find that the fuel level gauge will not move for a period on a full tank of fuel this is normal as a proportion of
4. at if the vehicle is fitted with a Lotus Sport chassis plate that it is fixed in the same region Must be clearly visible 10 Label only refers to specific serial number and as such must never be removed as long as the vehicle is fitted with the corresponding fuel cell PART NUMBER PART DESCRIPTION TORQUE TOOLING 10 10 Part Number ALS3T0009F PROCESS Version 1 FUEL CELL SHEET SAO TF Disclaimer Lotus accepts no liability for any direct indirect or consequential damage or loss including as a result of negligence arising from the application of these fitting instructions by any person For the avoidance of doubt this does not affect your statutory rights and Lotus does not exclude liability if any to you for death or personal injury arising out of Lotus negligence Please note that the fitting of any Lotus approved part s by anyone other than a Lotus approved engineer may invalidate the vehicle warranty
5. el cell is designed for the use of hydrocarbon gasoline only The fuel cell may experience minor swelling when subjected to fuel Due to the elastomeric nature of fuel bladders a certain amount of vapour permeation or diffusion will occur Always allow generous ventilation around the cell vehicle so as to preclude the accumulation of fuel vapours Water vapour and direct sunlight UV exposure can adversely affect fuel bladders Keep the system externally and internally free of water and water vapour When storing a fuel cell drain the bladder completely drained dried out close off all ports and keep it in a dark dry cool environment Fuel cell capacities are expressed herein as nominal values Please be sure to study ATL s Product Safety Bulletin DS 381 before installing or using any ATL product Remember improper selection installation or use can cause personal injury property damage or death Don t take unnecessary risks Your fuel cell should be serviced at least once a year Most importantly the bladder should be inspected for any fuel leaks or blistering Any damage or broken components should be repaired or replaced before use All fuel cells should be static ground during refuelling and during use on a track Never use a PVC tube for refuelling lt will create enough static build up causing a spark Check specific series regulations to confirm that installation of fuel cell meets requirements although that fuel ce
6. ll is FIA approved the installation may have to vary between regulations Do not over fill or top off your vehicle tank which can cause gasoline spillage Avoid prolonged breathing of fuel vapours Use fuel only in open areas that get plenty of fresh air Keep your face away from the nozzle or container opening Never siphon fuel by mouth nor put fuel in your mouth for any reason Fuel can be harmful or fatal if swallowed If someone swallows gasoline do not induce vomiting Contact a doctor or and emergency medical service provider immediately Keep fuel away from your eyes and skin it may cause irritation Remove fuel soaked clothing immediately ram a Part Number ALS3T0009F F U E L C E LL PROCESS 2 74 7 Version 1 SHEET KIT CONTENTS 1 x 74ltr Fuel Cell 1 x Product Safety Bulletin 1 x Warning Documentation 1 x Product Warranty Card 1 x Certificate of Compliance 1 x Chassis Sticker tamper proof RACING FUF CELLS FIA Standtara Z LYS F Y K Hamologatiarn baar Z Fl 1 L _ 1 3 MY Manutecturer Auto Tec Laboratories Ltd O Serial Numba Note Additional parts may be included or required dependant upon condition of existing fuel tank and fuel pump i e Fuel Pipe Clip A120L60125 A Part Number ALS3T0009F FUEL CELL LESS EA Version 1 aa aprendo rocr ansu ne esis o any pul road ca Mago Limted cannot N pit any habdity drecty reed by out ot he uwo rot om vo omer than msg death or personal wy i
7. n Keep braided earth strap as this will be used later Polypropyiene saddles Fuei tank Foam sponge Rubber wedge Earth braid cradie CAREPOINT QUALITY STANDARD 20 Be careful to take the necessary precautions when handling fuel and fuel vapours Do not take any risks 30 Any damage or broken components should be repaired or replaced before use SEQ PART NUMBER PART DESCRIPTION QTY F C TORQUE TOOLING 10 A120T0327J Lotus Service Manual 10 RM733E Toyota Service Manual 10 RM929E Toyota Service Manual Part Number ALS3T0009F PRES Part FUEL CELL LOL EA Version 1 SHEET ACTIVITY RELOCATE LATCH amp CABLE 10 Remove cockpit tailgate operations latch and bracket 20 Disconnect the cable from the latch and remove the cable from the fuel cell area vicinity as indicated 30 The cable should be moved so that it runs over the top of the chassis through the plastic bulkhead and to the latch handle A L Remove tailgate latch operation cable running through fuel cell area as CAREPOINT QUALITY STANDARD 10 It is the general recommendation for road based track use only vehicles to relocate the latch and cable mechanism However an alternative is to remove the mechanism completely from the vehicle and fit bonnet style pins to secure the tailgate engine cover SEQ PART NUMBER PART DESCRIPTION QTY Fc TORQUE TOOLING 10
8. nd that no damage has occurred during the installation 40 Check all fuel lines for leaks 50 Check all fuel lines for fouling rubbing or any interference 60 If satisfactory and correct add 1Olitres of fuel to the fuel cell via the normal filling method 70 Turn on engine and idle for 5mins checking for any fuel leaks fuel pickup issues and other abnormalities Rectify any Issues 80 If satisfactory and correct refit all the ancillary components removed initially shear panel handbrake cable gear selector and cross gate cables under tray 90 Safety check the vehicle before allowing out of the workshop 4 A e A Hole for earth strap Through aperture plates check all pipes are secure and correctly routed Check fuel filler and breather connections Check pipes for routing and foul conditions CAREPOINT QUALITY STANDARD 50 YOU will be able to hear the fuel pump running and picking up the fuel 60 Never drive the vehicle without the shear panel and under tray in position PART NUMBER PART DESCRIPTION TORQUE TOOLING 10 10 10 Part Number ALS3T0009F PROCESS Version 1 FUEL CELL SHEET ACTIVITY CHASSIS STICKER 10 20 Clean surface area as indicated with suitable fluid 30 Remove backing of tamper proof chassis sticker 40 Adhere to chassis making sure that no bubbles are underneath press firmly to the corners CAREPOINT QUALITY STANDARD 10 It is recommended th
9. ns casdisessbidesuecestussssetesssdieescbbceseieaesbausseuadedoadssed easdussdeekecssbluastusdesaec cacti eescbbcesekeacsbidsssnacedonecsselesscbsessebesssbhessieaseteisetds 9 ACTIVIPY PREPARE AREA cion iii 10 ACTIVITY BURL PUMP INSTALLA TION oscila dana 11 LR NAE N FUELCELC INS TALCA TION uranio 12 ACTIVITY BUNA LS ivan ie 13 ACTHTIY CHASSIS Sy FIC IRE cons n 14 Part Number ALS3T0009F PROCESS Version 1 FUEL CELL SHEET DN ed ed ACTIVITY REMOVE EXISITING TANK 10 Read all fuel cell literature supplied with the cell 20 Following instructions in Lotus Service Manual A120T0327J Toyota Service Manual RM733E and Toyota Service Manual RM929E 30 Drain fuel from vehicle or run down the fuel to minimum levels 40 Remove fuel tank filler hose and breather clips on the upper side of the tank 50 From the fuel pump access aperture disconnect the quick connect fuel pipe the fuel feed pipe and the pump electrical connector 60 Place the car a two post vehicle lift and secure 70 Remove vehicle under tray and diffuser 80 Disconnect handbrake cable from the callipers 90 Disconnect cross gate and selector cables from gearbox 100 Remove shear panel from vehicle and the ground wire 120 Remove the fuel tank from the vehicle and place on suitable work surface 130 Remove the fuel pump from the fuel tank and set aside This will be used in the new fuel cell Please check fuel and parts for conditio
10. the fuel will be above the pump The fuel cell is made from ATL 810 C material in accordance with FT3 1999 specification and includes yellow foam in all chambers except in fuel pump chamber 4x6 top plate with filler neck and vent As manufactured itis FIA Approved Fuel Cell Full tank running times full throttle track only dependant upon ambient conditions driver track amp vehicle Exige S2 Cup 240 70ltr fuel cell 80 minutes Exige S2 Cup 240 standard tank 45 minutes Fuel Cell Weights 7Oltr fuel cell 5 6 Kg Standard production steel tank 12 8 kg S A o e LNT TE Serraria TE CHASSIS SIDE VIEW CHASSIS UNDERSIDE VIEW Part Number ALS3T0009F PROCESS Version 1 FUEL CELL SHEET E ee gt gt WARNING NOTES THIS FUEL CELL IS FOR TRACK USE ONLY MAJOR SANCTIONING BODIES SUCH AS FIA HAVE RECOGNISED THAT FUEL CELLS ARE AFFECTED BY OZONE ULTRAVIOLET AGEING AND THE CHEMICAL ACTION OF GASOLINE AND RACING FUELS HENCE A FIVE YEAR LEGAL LIFE SPAN HAS BEEN SET ON ALL FUEL CELLS THE RUBBER BLADDER PORTION OF YOUR FUEL CELL SYSTEM MUST BE REPLACED WITHIN 5 YEARS OF ITS MANUFACTURE DATE Gasoline as well as other flammable materials and liquids adhesives solvents etc and the vapours they produce are extremely dangerous Be sure to read and follow the instructions Failure to do so can result in property damage bodily injury or death Take all reasonable precautions to guard against safety This fu
11. uel pump into the fuel cell top plate with the orientation shown nozzle should be 20degrees from pictorial horizontal 20 Place the plastic over ring on top A 30 Then the metal nut ring ensuring that the key locks into ti place on the fuel pump indicated 40 Insert the 8off fixings and loosely hand tightening in the torque tightening sequence shown inserting the earth strap to 4 as indicated 50 Follow the torque tightening sequence shown and paint mark when correct torque has been reached See torque tightening instructions on tank Making sure that the earth strap is Remove 8 off inner fixings attached previously removed from existing fuel tank from top plate of cell CAREPOINT QUALITY STANDARD SEQ PART NUMBER REED PART DESCRIPTION PART DESCRIPTION a F C TORQUE TOOLING Po TOOLING Torque Tooling Reference 3 5Nm Torque wrench HE Part Number ALS3T0009F FUEL CELL PROCESS SHEET 924 38 gt Version 1 ACTIVITY FUEL CELL INSTALLATION 10 Offer the fuel cell up towards the chassis 20 Connect the quick connect to tank pipe confirm that it has clicked home and is secure 30 Connect the fuel feed pipe confirm that it has click home and is secure 40 Connect the fuel pump electrical connector and confirm that it has click home and is secure 50 Begin to insert the pump side of the fuel cell first pressing it e z E into the upper corners and o
12. ver the chassis lower rail lips i a front and rear 60 Offer the ffiller side up and press into the corners and again over the chassis lower rail lips front and rear 70 Reconnect Fuel filler hose and fuel breather hose fitting new It may be the case that the fuel cell appears retaining clips creased at the indicated corner s This should 80 naturally fill out when fuel is added to the cell k 120 CAREPOINT QUALITY STANDARD 10 The intricate design of the bag tank means that the physical installation of the fuel cell can be a delicate operation generally necessary to be completed by two people 20 If necessary lubricate the inner surface of the chassis area to ease installation 50 The tank when seated corrected will appear into pop into position 60 Please ensure that the fuel cell does not curl up on itself as it progresses over the chassis rail lips SEQ PART NUMBER PART DESCRIPTION QTY F C TORQUE TOOLING 10 Part Number ALS3T0009F PROCESS Version 1 FUEL CELL SHEET ACTIVITY FINALS 10 Drill a hole in the access aperture to feed the earth strap through insert a rubber grommet to seal 20 Feed the earth braid strap up through the hole in access aperture and secure to the main roll hoop via a suitable fixing ensuring that the connection is secure and earthed 30 Check that all hoses clips connectors and fixings have been correctly installed a
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